TLT: How long have you worked in a lubrication-related field, and how did you decide to pursue a career in the lubricants industry?
Dura: Over the past 11 years, I have dedicated my career to the lubricants industry, transitioning from pharmaceutical manufacturing, which represents a significant departure from lubrication manufacture. My passion for organic chemistry and small molecule synthesis has always driven me, and while pharmaceutical research presents numerous challenges, I discovered that the lubricants industry offers even greater complexity and challenges. The end-use applications involve machinery and equipment of considerable scale, far exceeding the scope of a protein binding site, receptor, etc.
The myriad of known and unknown variables in an end-use scenario demands specific chemical interactions to ensure optimal performance and prolong the lifespan of essential equipment—equipment that constructs our homes, roads, vehicles and more. Determining suitable lubricants involves far more intricate chemistry than merely developing a single active ingredient. Each lubricant type—engine oils, driveline fluids, gear oils, greases and others—requires distinct chemical properties and interactions.
My mental toolbox in the pharmaceutical industry necessitated a set of chemical reactions to synthesize small molecules. However, in the lubricants industry, that toolbox must now encompass not only those reactions but also an understanding of how these chemistries work synergistically and interface on surfaces to deliver desired performance attributes.
TLT: What is interesting and different about grease that has kept you interested versus the other areas you have supported?
Dura: My interest in grease formulation arises from a perspective frequently articulated by STLE Fellow Dr. Gareth Fish. Traditional lubricants typically encompass two dimensions: base oil and additives. While viscosity modifiers might be considered an additional dimension, for the purposes of this commentary, they are included within additives. Grease, on the other hand, encompasses four dimensions: base oil, additives, thickener and process. This introduces a significant increase in compositional and manufacturing complexity when compared to homogeneous lubricants such as engine oils or transmission fluids.
It is important to acknowledge the challenges encountered by formulators of homogeneous lubricants; however, the two additional dimensions involved in grease formulation render it both captivating and challenging. The interplay between base oil viscosity, additives, the selected thickener and the manufacturing process generates an almost infinite array of finished lubricants/products. This variability is influenced globally by diverse stocks, chemical compositions, thickener preferences and manufacturing capabilities. Throughout my career, I have encountered numerous challenges, and I am consistently faced with new obstacles to overcome in this field.
TLT: What is the No. 1 piece of advice you would give to a person who might be interested in starting a career in the lubricants industry?
Dura: That is an intriguing question, as my entry into the lubricants industry marked a significant pivot in my career. I was advised early on that proficiency in any discipline within this industry would take several years due to its diversity and complexity. Reflecting on my career trajectory, I realize that my most notable misstep post-graduation was not initially considering the lubricants industry over others, such as pharmaceuticals. This industry presents extensive opportunities and challenges that I was not fully aware of until I transitioned into it.
For individuals contemplating a career in lubricants, I strongly recommend engaging with organizations responsible for maintaining its technical standards, such as STLE, NLGI and ASTM International. In my view, this industry underpins many activities we often take for granted—roads, buildings, automobiles and more. Identify an area that piques your interest, delve deeply into its nuances and pursue it with vigor.
TLT: What has been the biggest challenge for you in the grease industry over the last five years?
Dura: The most significant challenge I have encountered in the grease industry over the past five years has been the demand for higher performing lubricants and more stringent specifications to ensure product quality. Working primarily in additive manufacture and package creation, these elevated performance requirements necessitate the development of new chemistries or combinations thereof to be more effective and meet updated specifications. This, however, is the exciting part of the role—identifying solutions to increasingly complex chemical problems.
The introduction of the high-performance multiuse (HPM) core and tags has provided a superior and more distinguishing method to classify grease, necessitating different combinations of polymers and chemistry to meet the specifications and testing criteria associated with each tag. An additional challenge has been the increased necessity to collaborate with end-users to understand how these specifications translate to the “real-life” needs of the lubricant. One crucial correlation that I overlooked earlier in my career in lubricants was recognizing that bench testing does not always accurately predict product performance in the field. Understanding the testing requirements to develop a robust and high-performing lubricant for real-world applications remains an ongoing challenge.
TLT: What do you see as the “next big thing” in the grease space?
Dura: I believe the next significant development in the grease industry will be the identification and utilization of alternative thickener options to lithium-based grease products. While lithium-based greases have long been established as highly effective and robust thickeners with excellent properties, their reliance on lithium hydroxide monohydrate poses potential challenges for the market moving forward. As the electric vehicle industry continues to expand and automotive regulations increasingly favor this direction, alongside the regulatory hurdles faced by lithium hydroxide monohydrate, it is imperative for our industry to explore additional options to mitigate our dependency on this material. It is important to note that I am advocating for alternatives rather than a direct replacement at this time. The next significant advancement would be the development of a grease akin to conventional lithium or lithium complex greases, without the dependency on lithium hydroxide monohydrate as a raw material.
You can reach Robert Dura at robert.dura@nch.com.