TLT: How long have you worked in a lubrication-related field, and how did you decide to pursue a career in the lubricants industry?
Harrington: I have worked in the lubrication-related field for 36 years. My career began in 1989 at D.A. Stuart in Canada, where I started as a quality control technician. In that role, I tested all incoming raw materials and outgoing finished goods, and when products were out of specification, I would adjust them to meet requirements. The constant need for adjustments was frustrating, so with guidance from R&D, I began reformulating products to improve their consistency—whether it meant adjusting the ratio of base oils for viscosity or tweaking soluble oils for better emulsion stability. I became fascinated by how these products were put together.
In the early 1990s, when Shell discontinued production of natural sulphonate—a primary emulsifier for many of our water-soluble products—D.A. Stuart had to rapidly reformulate its product line. I was assigned several products to reformulate, which deepened my interest in formulation. I constantly asked the chemists why each raw material was included in the formula (I am sure I drove them crazy with my constant questions!). When a position opened in R&D, I was invited to join the R&D team. I focused mainly on water-soluble metal removal and forming fluids, but also worked on cleaners, corrosion inhibitors and industrial oils.
My decision to pursue a career in the lubricants industry was driven by my background in chemistry and a strong interest in applied science. Early on, I was drawn to the technical challenges and opportunities for innovation in metalworking fluid (MWF) formulation. The ability to develop products that directly impact manufacturing efficiency and equipment longevity has kept me engaged and passionate about this field throughout my career.
TLT: What are some of the trends you have seen in metalworking formulation over the course of your career?
Harrington: Over the course of nearly 40 years, I have seen many trends. Most notable are:
1.
Sustainability and green chemistry
•
Biobased and renewable additives. Since the early 2000s, there has been a strong shift toward biobased and renewable raw materials in MWFs. Innovations include multifunctional additives with high renewable content. These additives improve sustainability profiles by enhancing fluid and tool life while reducing the environmental impact.
•
Boron-free and low VOC formulations. Recent product launches focus on boron-free and zero-VOC formulations to meet increasingly stringent environmental regulations and customer demands for safer, greener products.
2.
Regulatory compliance and health and safety
•
Global regulation of biocides and hazardous substances. The industry responded to tighter regulations on biocides, triethanolamine (TEA), monoethanolamine (MIPA) and other hazardous substances by developing compliant alternatives and reformulation legacy products.
•
ISO/IATF Certification. The adoption of ISO 9001:2015 and IATF 16949:2016 standards have driven improvements in product quality, traceability and safety.
3.
Performance enhancement and multifunctionality
•
Formulators have developed additives that provide superior acid-neutralizing, buffering and multi-metal compatibility, as well as improved lubricity, corrosion protection and emulsification.
•
High-performance fluids for aerospace and automotive. MWFs are now engineered for demanding applications, such as aerospace (aluminum, titanium, nickel alloys) and automotive, with enhanced stability at high and low temperature and tailored viscosity profiles.
4.
Digitalization
•
Sensor integration. The use of real-time sensors for monitoring fluid condition (pH, density, conductivity, biological oxygen) has enabled predictive maintenance and optimized additive dosing, reduced downtime and maximizing lubrication.
5.
Globalization and market shifts
•
Regional product localization. Companies have localized formulations to meet regional requirements, such as cleaners, safety data sheet (SDS) profiles and adaptation to local regulations and customer needs.
•
Growth in Asia-Pacific. Asia has become the largest consumer of MWFs, with significant growth in both volume and market share since the 1990s.
6.
Recent and emerging trends
•
Artificial intelligence (AI) and automation. Integration of AI and machine learning for process optimization and predictive maintenance is transforming smart factories and metalworking operations.
•
Ecofriendly processing. Waste reduction, alternative energy use and sustainable manufacturing practices are now central to new product development.
•
Advanced materials. The emergence of lightweight and challenging to machine materials and composites has intensified the demand for fluids that offer enhanced wear resistance, precise coolant delivery and superior foam control.
TLT: How do you feel about regulations driving how we formulate products?
Harrington: Regulations have become a major consideration in how we formulate products in the lubrication industry. I view this as both a challenge and an opportunity. On the one hand, changing regulations, for example the restrictions on certain biocides, VOCs and hazardous substances, require us to continually adapt our formulations to ensure compliance and safety. This could mean reformulating legacy products, sourcing alternative raw materials and investing in new testing protocols. While these changes are demanding they also push us to innovate and improve our products’ environmental profiles and performance. On the other hand, regulatory requirements have led to significant advancements in sustainability, health and safety. For example, the move toward biobased and renewable additives, boron-free and low-VOC formulations and ISO/IATF certification has resulted in fluids that are safer for workers and better for the environment. Regulations have also encouraged the adoption of new technologies, such as real-time sensor integration and digital analytics, which help us optimize formulations and ensure ongoing compliance. Ultimately, while regulations can be challenging, they have helped elevate the standards of our industry and inspired continuous improvement. I believe that embracing regulatory change is essential for driving innovation and delivering products that meet the needs of our customers and society. While regulations can present significant challenges, especially in terms of reformulation, cost and complexity, they also create powerful incentives for innovation, sustainability and continuous improvement. Embracing these changes can help companies lead the industry in both compliance and product performance.
TLT: Do you think that regulations are a threat to the water-based metalworking formulations, pushing a move toward oil-based products, more like the EU formulations?
Harrington: This is a timely and important question. Regulatory developments pose substantial challenges for water-based MWF formulations. However, whether these regulations constitute a “threat” that could drive a shift toward oil-based alternatives, as observed in certain European markets, depends on several key factors:
1.
Regulatory pressure. Increasing restrictions on certain biocides, boron compounds, amines and other commonly used additives in water-based fluids can make it difficult to maintain performance, stability and microbial control.
2.
Raw material availability. When key ingredients are banned or reclassified, formulators must rapidly find alternatives. This can be costly and time-consuming.
3.
Performance trade-offs. Reformulating to comply with regulations may compromise lubricity, corrosion protection and emulsion stability, potentially making oil-based products more attractive for certain applications.
Despite these challenges, many companies view this regulatory landscape as an opportunity. The industry has responded with innovative water-based fluids that are biocide free, boron-free and low in VOCs, leveraging advanced emulsifiers, renewable additives and improved microbial control techniques. Many customers and regions (particularly in North America) continue to prefer water-based fluids for their lower environmental impact, easier disposal and worker safety benefits. There are regional differences; the EU does have stricter regulations, and this has led to a higher proportion of oil-based formulations in some segments. However, innovation in water-based fluids continues globally, and many companies are committed to maintaining and improving these products rather than abandoning them.
Yes, regulations do create pressure and complexity for water-based MWFs, but this also drives innovation. While some markets (EU) have seen shifts toward oil-based products the overall trend is toward safer, more sustainable water-based formulations that meet evolving regulatory requirements. The key is ongoing R&D investment and collaboration across the industry to ensure water-based fluids remain viable and competitive.
TLT: A concern in the industry is bringing in young people to be the next generation of MWF specialists; how do you think companies and STLE are doing regarding attracting new talent?
Harrington: Many companies recognize the demographic challenge facing the industry and are making efforts to attract and retain young talent. Strategies include offering internships, co-op programs and entry level positions that provide hands-on experience in labs and manufacturing environments. Several organizations also collaborate with universities to sponsor research initiatives, deliver guest lectures and participate in career fairs focused on tribology, lubrication and chemical engineering.
STLE has adopted a very proactive approach by expanding student outreach and scholarship programs. This includes supporting university-based student sections and encouraging participation at national meetings. STLE also offers a variety of certification programs such as CMFS and STLE Certified Lubrication Specialist™ (CLS) as well as other specialized training designed to help emerging professionals build credentials and confidence. Furthermore, STLE offers networking events where students and young professionals can interact with industry veterans. There are also many volunteer opportunities within STLE where younger people can get involved.
Despite these efforts there are still challenges attracting and retaining the younger generation. Young engineers and scientists are not aware of opportunities in MWF and tribology. Some don’t even know what it is. The industry is often perceived as “old-fashioned” compared to newer, high-tech industries. This is where companies need to embrace opportunities to use AI and other digital methods such as machine learning to engage the younger generation. Additionally, over the next five to 10 years, there will be new machining approaches, surface finishing technologies and possibly new metallurgies, all of which can lead to newer, more advanced fluid technologies. These advancements will not only enhance manufacturing efficiency but can also open new avenues for innovation and technical contributions. By highlighting these future trends and the potential for significant impact, we can inspire and attract young talent to the field.
Personally, when I entered the field in 1989, I had no idea what an MWF was. But I was given the opportunity and freedom to explore, and I was quickly hooked.
You can reach Karen Harrington at karen.harrington@fuchs.com.