In the metal forming industry, the role of forming oil is becoming increasingly important. At the same time, tightening environmental regulations and growing pressure for sustainability have made the development of eco-friendly forming oils a key industry trend. This article explores the latest technological and research trends, focusing on keywords such as chlorine-free, sulfur-free, and non-volatile, while also considering both the potential and the limitations of eco-friendly forming oils.

Why Eco-Friendly Forming Oil?

• Traditional mineral oil-based forming oils often contain chlorine, sulfur, and other additives that may cause environmental pollution, residual toxicity, and higher waste treatment costs.
• Concerns are rising over greenhouse gas emissions, ecological damage, and workplace safety (human health risks).
• Both international and domestic regulations on chemical usage, waste management, and air/water pollution are becoming stricter and directly impacting the industry.

Against this backdrop, demand is growing for forming oil products that can minimize environmental impact while still delivering processing efficiency, die protection, and product quality.

Recent Research and Technology Trends

Here are some key findings from recent studies and developments:

Category	Key Developments
Vegetable Oils + Eco-Friendly Additives	Example: Sheet metal forming experiments using vegetable oil-based lubricants with boric acid additives showed lower friction coefficients and reduced die wear and galling compared to mineral oil-based lubricants.
Bio-Based / Biodegradable Oils	Products are being developed using vegetable esters, biodiesel-derived oils, or non-edible plant oils that offer biodegradability and reduced ecotoxicity.
Chlorine-Free / Sulfur-Free Additives	Research is focusing on replacing conventional chlorine- and sulfur-based extreme-pressure additives, since chlorine and sulfur compounds are major sources of harmful emissions and pollutants.
Non-Volatile Formulations	Developing oils with reduced VOC emissions, higher flash points, and lower risks of smoke, odor, or ignition. Vegetable-based oils often outperform mineral oils in this area.
Solid Lubricants / Nano-Additives	Use of graphite, molybdenum disulfide (MoS₂), boric acid, or nano-silica as solid or nano-particle additives to reduce friction and strengthen protective films. These materials are also explored as alternatives to chlorine- and sulfur-based additives.

Benefits of Eco-Friendly Forming Oil

When commercialized, these technologies are expected to bring several benefits to manufacturing sites:

1. Compliance with Environmental Regulations
   Chlorine- and sulfur-free formulations help meet chemical regulations and reduce environmental risks.
2. Improved Worker Health and Safety
   Reduced emissions of harmful volatiles, odors, and toxic gases lead to a safer and cleaner workplace.
3. Lower Waste Disposal and Maintenance Costs
   Biodegradable oils reduce waste disposal and cleaning costs, while decreased die wear leads to lower die replacement expenses.
4. Better Product Quality and Extended Die Life
   Lower friction and improved protection minimize defects such as galling, scratches, and scoring, while higher thermal stability prevents deformation and cracking.
5. Enhanced Corporate Image and Sustainability Value
   Aligns with ESG (Environmental, Social, and Governance) initiatives, supports eco-certifications, and improves customer/consumer perception.

Challenges and Limitations

There are still technical and practical hurdles to overcome:

• Vegetable oils may suffer from low oxidative stability, degrading quickly when exposed to heat and oxygen.
• Poor low-temperature fluidity (high pour point) can limit applications.
• Some chlorine-free and sulfur-free additives may have lower extreme-pressure performance than conventional ones.
• Higher costs due to bio-based or nano-material ingredients.
• Limited testing and field validation of alternative additives.

Future Outlook and Development Directions

Eco-friendly forming oil development is likely to focus on:

• Utilizing non-edible vegetable oils and renewable raw materials.
• Combining solid lubricants and nano-additives for durability under extreme conditions.
• Non-volatile, low-VOC formulations with high flash points.
• Eco-friendly additive packages, such as chlorine- and sulfur-free EP agents, as well as green antioxidants and corrosion inhibitors.
• Advanced lubrication channel management for longevity, filtration, and recyclability.
• Meeting international certifications and regulatory standards (e.g., OECD biodegradability, EU REACH, U.S. EPA).

Strategies for Dyna

For a company like Dyna, strategies to respond to this trend and lead in product development may include:

• Developing a dedicated eco-friendly product line: chlorine-free, sulfur-free, low VOC, biodegradable.
• Strengthening performance testing to benchmark against conventional products in terms of friction, thermal stability, and die protection.
• Monitoring domestic and global environmental regulations continuously.
• Sharing customer case studies from automotive, aerospace, and electronics industries to showcase productivity and cost-saving benefits.
• Acquiring sustainability certifications, such as biodegradability tests, eco-labels, and environmental agency approvals, to reinforce trust.

Conclusion

Eco-friendly forming oil is no longer a passing trend — it has become a necessary direction for the manufacturing industry. While technologies such as chlorine-free, sulfur-free, and non-volatile formulations present early challenges in terms of cost and performance, in the long run, they offer the triple advantage of cost reduction, environmental protection, and enhanced brand value.

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Dyna Co., Ltd.
Industrial Lubricant Solution
E-Mail : dyna@dynachem.co.kr
Web : dyna.co.kr/en/