10th International Meeting of the European Union of Independent Lubricants Companies (UEIL)

Citation

Margaroni, D. (1999), "10th International Meeting of the European Union of Independent Lubricants Companies (UEIL)", Industrial Lubrication and Tribology, Vol. 51 No. 2. https://doi.org/10.1108/ilt.1999.01851bab.011

10th International Meeting of the European Union of Independent Lubricants Companies (UEIL)

10th International Meeting of the European Union of Independent Lubricants Companies (UEIL)

Keywords Conference, Lubricants, UEIL

30 October 1998Sheraton Hotel, Brussels, 30 October 1998

This event, held every three years, is the most important event in the calendar of the UEIL and was attended by some 160 delegates representing 12 member states, the largest contingent being from the UK with some 30 delegates. The UEIL, membership of which excludes the major oil companies, is nevertheless a powerful voice in Europe, with direct access to the various Directorate-General groups in Brussels. This point was emphasised in that two of the presenters were from the European Commission.

The majority of the presentations were in English, but simultaneous translation facilities were provided which covered the major European languages. The theme of the Conference, as indicated by the title "Towards the Millennium" was very much looking to the future of the industry in Europe.

Review of the global lubricants market ­ threats and opportunities for the European independents

D. Arnaud, Petro Finance Downstream Services

The speaker first dealt with the base oil supply situation, which has increased by 14 per cent in two years in North America, mainly on account of capacity increases from Conoco/Pennzoil in Louisiana and PetroCanada in Toronto. During 1995 to 1997, capacity marginally declined by 1.9 per cent in Western Europe, mainly on account of the BP Llandarcy closure in the UK. In Asia, capacity rose by over 17 per cent during the same period.

In the subcontinent, capacity rose by 1.3 per cent and in the OECD Pacific by 1.7 per cent . In China and ASEAN, however, capacity has increased by a very substantial 82 per cent , mainly in Singapore and Thailand.

Taking into account the Middle East and other regions, the overall world-wide increase in base oil capacity is about 6.5 per cent .

Although the overall market for lubricants has been fairly stagnant over the last two years, many individual operators have seen good profitability owing to the opening up of many markets to international competition. Petro Finance predicted that 95 per cent of the world market will be open to international competition by 2005, compared with 89 per cent in 1995.

However, the Asian crisis has significantly upset the supply/demand balance, with Asian demand predicted to fall by 4.5 per cent in 1998, followed by moderate growth of 0.5 per cent in 1999, and a firmer growth of 1.5 per cent in 2000. The overall predicted demand of 10.8mmt by 2005 is considerably less than the forecasts of some months ago.

The following three key events took place in 1997-98, with significant consequences for competitors in markets all over the world.

• •

  the North American surplus has now become larger than the Western European surplus;

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  Northeast and Southeast Asia have now become surplus regions;

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  the Middle East deficit declined by 40 per cent.

As a result, significant differences to the future trade flows of lubricants are predicted, where the current flow is from Western Europe and North America into deficit regions such Asia, Africa, Latin America and the Middle East. Changes are already being seen in that base oil exports to Southeast Asia declined by 11 per cent in 1997, and by 24 per cent to Northeast Asia. In contrast, exports to the Middle East rose by 20 per cent during the same period. However, it is anticipated that as new plants in Singapore and Saudi Arabia become operational, European suppliers to these areas will be forced to look for alternative markets.

US exports go mainly to Mexico and Canada, have increased by 55 per cent in 1997 with the commissioning of the Excel Paralube plant in Lakes Charles, Louisiana. At the same time exports to Canada rose by 12 per cent and to the rest of the hemisphere by 54 per cent . At the same time, US exports to West Africa, the Middle East, ASEAN, North Asia and China decreased, and it remains to be seen how strongly the USA will compete with Europe to attract other African customers, in which case a damaging price spiral could ensue.

In 1997, trade into Asian markets has been affected mainly by the expanding capacity in the region rather than currency changes, the latter favouring local suppliers in situations involving dollar-priced base oils. Trade in finished products will be more susceptible to currency changes, since the base oil contribution to the cost of a finished product already puts importers at a disdavantage, as do the lower local blending costs.

A further factor to be considered is the quality mismatch between developed and developing countries, with synthetic and XHVI oils becoming more and more dominant in the former regions, although it is anticipated that the more competitively-priced XHVI-based products will appeal more to customers in developing areas. This could mean that less sophisticated suppliers could achieve some sort of respite when dealing with customers more concerned with price than with quality. This will in turn hit the marketing budgets of the suppliers of high-quality products.

Petro Finance predicts that the role of the small operator, whose volumes are too low to contemplate local manufacture, will become increasingly more difficult in Asia. This will especially be the case where commodity-type motor oils are concerned, since currency movements have pressurised margins.

In Europe, however, independent manufacturers have not been involved in the current round of mergers and joint ventures, which have generally only involved majors with large supply problems. However, the prospect of a single currency raises questions over the continued viability of local margins, which are higher in, e.g. Germany compared with the rest of Europe. There will undoubtedly be some pressure towards a convergence of prices.

The surplus capacity in the USA has resulted in wafer-thin margins owing to intense competition, and further mergers and plant closures are anticipated.

Mergers and acquistions ­ how they are considered by the European Commission

Dr K. Mehta, European Commission DG IV/Competition

The definition of a merger, or "concentration", was "a merger between previously independent undertakings".

Acquisition of control could be by:

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  acquisition of shares;

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  acquisition of assets;

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  creation of joint venture;

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  change in structure of control.

The criteria for assessment by DG IV had changed in March 1998, with the earlier set of rules being replaced by a more complex set of conditions, i.e. the threshold criteria now being:

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  2.5 billion ECU combined world-wide turnover;

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  100 million ECU EU-wide turnover of at least two parties;

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  100 million ECU combined turnover in at least three member states;

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  25 million ECU turnover of at least two parties in the three member states;

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  two thirds rule.

The concept of the affected market was:

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  Horizontal. Two or more parties have a combined market share of 15 per cent or more in the same product market.

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  Vertical. One or more parties are active in a product market which is upstream or downstream of a product market in which another party is active and their combined market share is at least 25 per cent .

The definition of a relevant product market was one where the products/services are regarded as being interchangeable with regard to characteristics, price, and intended use.

Organisations undertaking any of the above operations had a statutory duty to notify DG IV within seven days of agreement or public bid using a standard procedure, any merger activities being suspended during the period of review. The majority of submissions (in practice some 85-90 per cent) were not opposed; if there was a potential problem the DG was under an obligation to notify the respective organisations within 30 days. Decisions by the DG to oppose the merger were subject to a longer period of consideration and could also be challenged in court.

The lubricants market in the USA ­ ILMA overview ­ structure and initiatives towards the Millennium

I.Tripp, Etna Products Inc. (Past President of ILMA)

ILMA (Independent Lubricant Manufacturers Association) in America, which is currently celebrating 50 years of existence, in many ways parallels UEIL as representing the independents but excluding the majors. The two organisations were working together in areas of common interest, e.g. in health, safety and environmental issues.

The Association is currently comprised of 139 Regular member companies, 150 Associate member companies and 11 international member companies.

ILMA Regular members are largely small businesses ranging in size from fewer than ten to more than 200 employees. ILMA regular members are by definition, neither owned nor controlled by companies that explore for or refine crude oil to produce lubricant base-stocks. Base oils are purchased from refiners which are also competitors in the sale of finished lubricant products. Independent lubricant manufacturers succeed by manufacturing and marketing high quality, often highly specialised lubricants. Their success in this competitive market also is directly attributable to their tradition of providing a more bespoke service to their customers compared with the majors. As a group, ILMA member companies blend, compound and sell approximately 25 per cent of the USA's lubricant needs covering the full range of lubricant products. In particular, they supply over 75 per cent of the metalworking fluids utilised in the country.

ILMA Associate members are the suppliers which provide the Regular members with base-stocks, additives and other goods and services.

In recent years, ILMA added an international membership category and currently has member companies from six foreign countries, with the intention to expand the scope to cover issues common to international compounders and blenders.

ILMA is served by a 15-member Board of Directors elected to staggered three-year terms, with the terms of five members expiring each year. Board members may be re-elected to additional terms without limit. In addition, the Board meets four times per year and, as needed, through the year via conference calls.

ILMA headquarters staff consist of six paid individuals, i.e. the Executive Director, Director of Publications, Advertising Manager, Manager Member Services, Associate Editor and Co-ordinator of Support Services.

Committees are divided into two categories; Industry Committees (Automotive Lubricants, Metalworking Lubricants,Industrial Lubricants, Technology, and Operations and Administration), and Association Committees (Ethics, Education, Finance, Government Affairs, Long Range Planning, Membership, Nominations, Programme Planning, Site and Meeting Review, and Statistics). ILMA also recognised the significance of the Associate members by establishing, in 1997, an Associate Member Advisory Panel, comprising of three base oil producers, three additive manufacturers and threeothers.

ILMA has been active in a wide range of issues, including:

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  Government Affairs (clean air, stormwater, environmental, health and safety legislation, and industry coalition building).

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  Automotive (API categories CH-4, PC-7.5 and PC-8, PC-9, and GF-3).

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  Health and Safety (Metalworking Fluids Standard Advisory Committee, Material Safety Data Sheets submissions, Voluntary Guideline on Management of Metalworking Fluids, Review of NIOSH criteria for exposure to metalworking fluids, AAMA draft specification for metalworking fluids). Metalworking Fluid Stewardship Group (Publications on voluntary guidelines for management of metalworking fluids, product stewardship, data collection, and support of the Metalworking Fluids Standard Advisory Committee).

Recent developments and advances in metalworking fluids including chemical management

M.R. Burdett, Houghton Vaughan plc

The main drivers for developments and advances have been as follows.

Health and safety of manufacturers and users

Elimination of, e.g. high aromatic mineral oils, secondary amines, chlorinated hydrocarbons, phenols, nitrited corrosion inhibitors.

Environmental effects in their manufacture, use, regeneration/recycling and disposal

Elimination of, e.g. chlorinated hydrocarbons, hindered phenols, nonyl phenyl ethoxylates. Certification of plants to ISO 14000.

Legislation both national and EEC

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  Environmental Protection Regulations 1996;

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  Control of Pollution Regulations 1996;

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  Special Waste Regulations 1996;

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  Land Fill Tax Regulations 1996;

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  Air Quality Standards 1995;

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  Environmental Labelling Directive 91/325/EEC (2);

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  Health and Safety at Work Act 1974;

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  Protection of Workers from Risk 80/1107/EEC & 89/391/EEC;

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  Dangerous Preparations Directive 88/379/EEC;

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  Transportation Labelling;

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  W.G.K Classification (Germany only at present).

Influence of and resistance to contamination

Three main areas of contamination are tramp oils, micro-organisms and water salt ions.

Fluids are designed to minimise emulsification of tramp oil. Contamination by micro-organisms by bacteria, yeasts and fungi is inevitable and the cessation of use of phenolic ingredients has exacerbated the problems. Other biocides have a finite shelf-life which depletes biocide potency during storage and use, as does the subsequent interaction of the biocide with micro-organisms. The incorporation of chelating agents and careful selection of emulsifier can at least in part overcome problems arising from the presence of water salts ions, although high concentrations of chloride and sulphate ions can eventually become the limiting factor in emulsion life.

Chemical (raw material) availability

During the past 15 years the development of alternative base oils, emulsifiers, lubricity and load carrying additives, corrosion inhibitors and biocides, etc. has meant that the formulator has a wider range of choices in many respects, albeit the use of a number of the more traditional type of ingredient has been curtailed owing to health, safety or environmental reasons.

Fluid life and user cost perception

Although fluid life expectancy has increased markedly in recent years, with some systems operating satisfactorily after as much as five years with the same fluid, the initial purchase price of the fluid is still mistakenly perceived by some buyers as being the prime issue, rather than the overall operating costs over a period. The metalworking fluid industry still needs to get the message across to such customers.

Machining developments

The high costs of new machinery, i.e. £250,000 and upwards, demands 24 hr per day and six days per week operation in order to ensure adequate payback.

Machine design and system design

Design of coolant systems in new machines is often far from ideal, with coolant tanks of inadequate volumes and unsuitable geometry, leading to high levels of foaming and air entrainment in some cases, and stagnancy leading to anaerobic growths in others. Although these factors apply to individual coolant systems, also too often the design of centralised systems is little better, with large falls, sometimes as much as five metres, again adding to the air entrainment and foaming problem. Coupled with the fact that many machining operations now require filtration to much finer levels than before, e.g. 5µ or less, current fluids need to be inherently low-foaming in nature.

New machining processes

New processes such as CBN Grinding, EDM Contour Milling, EDM Drilling, Deep Hole Drilling and Boring, Profile Grinding and High Speed Machining, together with the use of specialist tooling, coatings, ceramics, and polycrystalline diamond have all necessitated the development of specialised fluids.

Changes in component metal of manufacture

Aluminium has now largely replaced cast iron in many vehicle parts, also sintered components used in, e.g. gears, and spheroidal graphite used in, e.g. suspension components, has meant that the commonly encountered machining operations now involve a very different mix of materials. Thinner sections are used to achieve weight reductions, which has involved the use of higher alloy levels, e.g. 15-17 per cent silicon in aluminium alloys used for cylinder heads. In the aero industry, the increased adoption of fibre-reinforced composites for structural components, together with more complex metallurgy for compressor and turbine blades has again placed new requirements on the metalworking fluids involved in their manufacture.

Control and management of fluids

During the past ten years, the fluid supplier has become increasingly involved in fluid management at customer premises, which has enabled the customer to benefit from specialist expertise in obtaining maximum usability from his fluid. The outcome of this trend has been the development of an entirely new concept known as chemical management. This involves outsourcing of non-productive elements of manufacture to the supplier, who can be contracted to provide not only the fluid, but also the complete control of the machining operation including supply of staff, laboratory facilities, fluid control and regeneration, raw water treatment, swarf treatment, fluid disposal, etc. In this case, the fluid supplier may well provide items of equipment including tanks, mobile bowsers, mixers, pipework, waste treatment, swarf spinners, oil separators, fork lift trucks, etc. The contract can be extended to cover all other fluids and consumables on site, e.g. production fluids, hydraulic oils and lubricants, heat treatment oils and polymers, wash chemicals, corrosion preventives and vapour corrosion inhibitors, proving and calibration fluids, packaging materials, and filtration materials.

Oil instead of emulsion ­ a different approach in metal cutting and machine tool lubrication

A. Kiechle, Daimler Benz AG

Daimler Benz (DB), Stuttgart, have been collaborating with Fuchs Lubricants, Mannheim, in developing a new concept for lubrication in metalworking processes. Although water-mix fluids had the undoubted and important advantage of fire-resistance, the Federal Republic of Germany were now imposing so many restrictions on the use and particularly the disposal of such fluids, that the use of neat oils was becoming more attractive. As a consequence, the development of a suitable low-emission single neat oil was investigated which would encompass all metalcutting processes, including the turning and drilling of both steel and aluminium, and also be appropriate for the associated hydraulic systems. In the event, this ideal was not achieved for a number of reasons, and it was necessary to adopt instead two grades of oil.

Low viscosities of the cutting fluid were required (i.e. 10 mm²/Nat 40°C) to reduce filter sizes to manageable levels. However, since impeller pumps were not satisfactory for oils of such low viscosity, necessitating the use of more expensive reciprocating pumps, it was desirable that the oil for the hydraulic system had an increased viscosity of 46 mm²/Nat 40°C, although containing the same additive package.

Initial experiences of the use of these two fluids were very promising, with economic benefits of low emission losses, increased tool life and oil recovery from swarf of 50-90 per cent by using newly-developed procedures.

Because of the inherent dangers of fire when using neat cutting oils, extensive precautions involving the use of explosion flaps, fire alarms and automatic fire extinguishing devices were all built into the design of the new engine plant.

Because of this development, the current usage of emulsions by DB (7,000mta) was declining, whereas the usage of neat oils (currently 3,000mta) was increasing.

The longer-term priority for DB, after having moved from water-mix fluids to neat oils, is to investigate the use of minimal lubrication, and eventually possibly disposing with lubricants altogether in metalworking operations.

The speaker claimed that the level of oil mists were very low in the plant, but had no knowledge of the measurement technique, since this work had been contracted to an outside academic establishment. (The UK experience has shown that accurate measurement of oil mist levels with fluids of this viscosity is almost impossible owing to evaporative losses during collection ­ Ed.)

Health, safety and environmental issues ­ key aspects

Dr T. Gascard, Petrofer

The speaker emphasised the growing importance of health, safety and environmental issues and considered that an increasing amount of product development was directed at the avoidance of health risks rather than improving product performance. Since the various European countries seemed to be drifting apart in terms of their respective national legislations he called for a need for more harmonisation, together with increased co-operation with ILMA. In the consumer area, there is currently much incorrect labelling, indicating confusion among suppliers.

Carcinogenicity achieved prominence with the International Association of Research of Cancer (IARC) Monograph No. 33 in the 1980s which classified base oils according to their carcinogenicity potential.

Toxicity to reproduction and potential to cause genetic modification are new categories of endangering groups, but there is a current lack of proper statistical data.

Genetically modified soya and rape oils are politically high profile, and such products are likely to be used in certain lubricants, if not already.

There was concern over the need for declaration of product composition in Material Safety Data Sheets (MSDSs) and again the rules seemed to be interpreted in different ways in different countries.

The presence of amines in MWFs was a possible source of nitrosamines. In Germany, diethanolamine can still be used but only on the basis that certain limits of nitrosamines are not exceeded.

Short chain chlorinated paraffins have now been largely voluntarily replaced by the medium chain variety, which do not pose the same marine pollutancy potential.

Aquatoxicity, disposal, emulsion splitting are topics which are likely to achieve greater prominence when the water endangering classification system is introduced.

Endocrine modifiers have the potential to mimic the action of hormones and therefore interfere with the inner metabolism of organisms.

Biocides will be regulated by the Biocide Directive, currently in its sixth draft and likely to be issued soon. One particular concern was the imminent outlawing of hexahydrotriazine (HHT), owing to the need to label fluids containing the standard level of 0.1-0.15 per cent HHT with an R43 label when the 24th amendment (ATP) is issued. This would mean that this low cost and effective biocide would need to be replaced by more costly substitutes.

Since some glycols, e.g. the short chain monoethylene glycol and methylethylene glycol, are now classified as irritants, the glycol market is changing rapidly to move towards those which are not so classified.

Polycyclic aromatics (PCAs) are present in most base oils, albeit at levels of less than 2 per cent , and even lower in the severely hydrotreated or severely solvent refined varieties. There is also increasing use of the tracer molecule benz-a-pyrene as an indicator of potential carcinogenicity, which is present in high quality base oils at levels of only 0.1-1.0 ppm.

Methods for the determination of heavy metals have improved dramatically during the past ten to 15 years, and ingredients previously used which contained cadmium, barium or lead, are now outlawed. However, there are concerns over the accumulation of metals such as nickel (allergen), chromium (allergen, suspected carcinogen), and cobalt (causes respiratory problems and vomiting when inhaled as an aerosol) in MWFs during machining operations of alloys containing these metals. MWFs have now been developed which now minimise the uptake of these metals during machining.

The outlawing of all products containing BSE-endangered materials has caused problems in Germany in particular, where the need for formulators to change to vegetable-based products has caused performance problems in certain lubricants.

The situation with regard to food contact regulations seems to differ from one European state to another, again emphasising the need for more harmonisation.

The Packaging Waste Regulations ­ their implications for lubricant producers

A. Persi, Lubra s.p.a.

The strategy behind the EU Directive 94/62 EC was to:

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  reduce the overall volume of packaging;

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  encourage the recovery and re-use of packaging and the recycling of packaging waste;

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  guarantee the quality of packaging in terms of safety and the protection of health for the persons and the environment.

In practice, the enactment of the requirements of the Directive in the various member states provides yet another example of varying interpretation and the need for greater harmonisation. A number of member states have not yet implemented the requirements of the Directive. Those member states that have implemented the requirements of the Directive have adopted a number of different approaches of varying complexity, these various approaches were described in some detail. In practice, packaging was divided into three categories:

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  primary packaging being the first means of product containment;

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  secondary packaging, normally used to contain several primary packaging units;

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  tertiary packaging used in the handling and transport of multiple primary or secondary packaging (excepting containers).

The recovery and recycling objectives of the Directive are as follows:

1. 1.

   Between 50 and 65 per cent by weight of packaging waste to be recovered within five years from the adoption of the Directive in national legislation. Between 25 and 45 per cent by weight of all packaging materials to be recycled, with a minimum of 15 per cent per type, within the same time period.

2. 2.

   Following establishment of the actual recovery and recycling rates the European Commission will set new targets for successive five-year periods

3. 3.

   Within two years of the coming into force of the Directive, the European Commission will define marking procedures relating to packaging, which must also indicate the materials of composition of the packaging.

Lubricant marketers were faced with particular problems in that plastic packaging which had originally contained lubricant was not suitable for recycling owing to permeation of the oil into the plastic. Such containers could only be incinerated to recover energy in the form of heat.

A cautionary note was introduced, however, to those supporting the concept of re-use in that it was now proved to be ecologically more acceptable to break and remanufacture glass bottles for mineral water than to clean and re-use.

The UEIL was particularly concerned over certain aspects of the operation of the requirements within the community. Customer requirements for the supplier to collect used packaging could act as a barrier to cross-border trade. Also, the practice of transferring responsibility for packaging obligations to other organisations for a fee has led to the development of a number of such organisations. Problems were encountered in that the possibility of transferring packaging responsibility to such national organisations is only accessible to operators in the same state, which is again a barrier to free trade. There were problems, particularly in the industrial sector, relating to the proper storage and safe keeping of used packaging pending uplift by the supplier. As was too often the case, such empty packaging was not managed in a correct manner. Problems had been experienced with drum reconditioners since it was not always possible to empty the drums to such an extent so as to meet their requirements. Finally, there was a danger that if packaging weight was reduced below a safe level, there was an increased risk of pollution incidents arising from ruptured containers.

General statement

L. Krämer, European Commission DG XI/Environment

The speaker, a lawyer by profession, commenced by stating that it was only of late that increased attention had been paid to health, safety and environmental issues, although in fact the issues were raised some 25 years ago. All 15 member states had in the past 20 years developed Departments of the Environment in order to address these issues. His own particular field of expertise was in waste management, where generation needed to be prevented where possible, and he had been involved in national alignment between the various member states. There was a need to remove hazardous substances from products and out of the waste stream. He considered that endocrine disrupters were a major issue in Europe and that a precautionary principle should be adopted for such hazardous substances, with action where necessary to seriously assess costs vs. risks vs. environmental impact. He considered that the whole science of life cycle analysis for packaging was insufficiently developed to merit serious consideration in that the figures could be used to prove anything. He cited the situation of some 750,000 contaminated sites throughout Europe that were potential time-bombs in terms of pollution. Flora and fauna were still diminishing at a worrying rate. Fish were now being imported into the community owing to the collective irresponsible plundering of local fishing grounds.

His conclusion was to the effect that the progress being made by industry was insufficient to offset ongoing and irrecoverable environmental damage. No acknowledgement whatsoever was made to the very substantial improvements in standards in many areas of the environment through the continuing efforts and massive expenditure from industry.

Needless to say, these comments prompted lively response from those representatives of an industry that was already collectively spending many millions on environmental issues, and, as we have already seen, are now devoting more development expenditure towards the reduction in health safety and environmental risks than on product performance. Indeed, virtually the whole of the automotive crankcase lubricant specification developments are largely driven by environmental issues. The speaker appeared to have under-estimated his audience and was lacking in the specific expertise necessary to comment fairly and objectively on environmental issues with regard to the lubricants industry in particular.

The ATIEL Code ­ its implications for lubricants producers

Y. Mordelet, Elf Lubrifiants (President of L'Association Technique de l'industrie Européenne des Lubrifiants (ATIEL))

The objective of ATIEL (Association Technique de l'Industrie Européenne des Lubrifiants) is to represent the technical interests of the lubricants industry at a European level. The Code of Practice sets out the framework to ensure that all the performance requirements of ACEA (Association des Constructeurs Européen d'Automobiles) engine crankcase oils are met and to structure the progress of the future development of engine lubricants. An essential requirement of the system is that everything must be verifiable and capable of self-certification. When developing an engine oil which is to conform to an ACEA requirement, then the full requirements of the EELQMS (European Engine Lubricant Quality Management System) must be followed. Test conditions must follow the CMA (Chemical Manufacturers Association), ATIEL and ATC (Technical Committee of Petroleum Additive Manufacturers) guidelines which set out the test conditions appropriate to the ASTM (American Society for Testing and Materials) and CEC (Co-ordinating European Council for the Development of Performance Tests for Transport Fuels, Lubricants and other fluids) methods of test which are being used. Only certified test laboratories are to be used and the results are registered with the ERC (European Registration Centre) for passing on to the CEC. Once the programme is established, then the viscosity categories need to be defined, and the base oil interchange and viscosity modifier interchange criteria identified, as well as any required changes to the additive performance package. A confidential dossier is prepared which contains all the relevant information and is available for external audit by ISO (International Standards Organisation) inspectors since it is also a requirement that all blend plants and test houses are accredited to the ISO 9000 Quality ManagementSystem.

During subsequent discussions, it was confirmed that in spite of the mandatory requirements for ISO 9000 accreditation, no approach had been made to involve any of the accreditation bodies in the development of the process. It was suggested from the questioner that the inclusion of the ATIEL and ATC Codes of Practice requirements into a Quality Management System will significantly increase the scope of the accreditation, and the amount of auditable records and procedures. In addition, there are a number of specialist areas (e.g. requirements for base oil and viscosity modifier interchange) which are specific to the lubricants industry and of which a visiting inspector would not be expected to have the required degree of expertise, requiring extra time for familiarisation purposes.

Recent advances and developments in automotive lubricants

Dr G.Wallace, Ethyl Europe (Chairman of the Technical Committee of Petroleum Additive Manufacturers in Europe (ATC))

The need for changes in automotive lubricants has been driven by increased end-user demands for performance, economy and serviceability, coupled with progressively more severe emissions limits for carbon monoxide, hydrocarbon, nitrogen oxides and particulate matter, limits for which commenced in 1993. Subsequent further reductions in the emission limits for diesel engines in particular have led to the introduction of exhaust gas recirculation (EGR). Also, at the recent Environmental World Summits reductions in carbon dioxide emissions will also be a requirement, which has prompted much development into improving the efficiency of the combustion process. Recent developments include the introduction of direct injection for gasoline engines (GDI), with the likelihood that injection pressures will increase and that the general complexity of the injection system for both gasoline and diesel will become more pronounced in the search for higher efficiencies. The tighter emission limits have also focused attention on fuel quality, with sulphur levels in particular being subject to successive reductions, with a requirement of 50ppm max for both gasoline and diesel fuels by 2005. These low sulphur levels will be essential for the proper operation of high efficiency deNOx catalysts which will be required to achieve even lower levels of emissions. In addition to the power units, transmissions are also being re-designed to improve fuel efficiencies. Conventional hub reduction units are being replaced with single hypoid units in trucks and continuously slipping torque converter clutches are being fitted to automatic transmission passenger cars.

Lubricants have showed a trend towards lower viscosities and increased "slipperiness" to improve fuel consumption, as well as a general requirement for more extended drain intervals. Also, lubricants have had to cope with the higher piston temperatures requiring improved deposit control, also the lower nitrogen oxide standards have resulted in engine designs with higher soot loadings. As a result, the intense competition which has developed between lubricant suppliers has forced an "economy of scale" approach which has led to a number of mergers affecting both lubricant blenders and additive manufacturers. Lubricant development costs will be reduced by decreasing the number of tests required at the same time as improving test quality.

Possibilities emerging for the future would include:

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  a "globalisation" of lubricant standards;

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  fill for life lubricants;

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  spiralling test costs will force lubricant suppliers to move from industry standards to self-certification;

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  true minimum quality specifications with tests under full statistical control will allow the development of multiple test acceptance criteria within EELQMS.

David Margaroni