Bio-based anti-wear additives for sustainable lubricant systems

Lubricants are indispensable in almost all industrial applications – but most still contain fossil additives that harm the environment and deplete resources. This is where the WearAble research project comes in: its goal is to develop a new generation of bio-based anti-wear and extreme pressure additives that can completely replace fossil substances.

To achieve this, we use plant-based residues and by-products from food processing. From these raw materials, we extract functional molecules with anti-wear properties. This creates a sustainable raw material base that does not compete with food production and conserves resources at the same time.

Innovative molecular modification for stable high-performance additives

Our research focuses on the targeted chemical-enzymatic modification of plant molecules. This adaptation improves their oil compatibility, stability, and tribological effectiveness. The optimized molecules can be integrated into oil-based lubricants and form a protective, friction-reducing layer on metal surfaces.

This combined approach is considered a technological breakthrough: for the first time, a completely bio-based and at the same time high-performance additive class is feasible that is functionally equivalent to fossil alternatives – with significantly lower environmental impact.

From laboratory to industrial processes – the contribution of Fraunhofer IVV

Together with our project partners from Belgium, we at Fraunhofer IVV are developing the central processes for obtaining and modifying biogenic molecules. These include:

• Stabilization and purification of plant waste streams
• Enzymatic and chemical modification
• Scaling up to pilot plant scale

The focus is on developing efficient, sustainable, and transferable processes that can be implemented on an industrial scale. Our researchers combine bio-based chemistry, reaction engineering, and process development to establish stable and reproducible process chains.

At Fraunhofer IVV, we are thus laying the foundation for making bio-based additives from waste materials economically viable – a key step toward industrial transformation in line with the bioeconomy.

Sustainable lubricants with market relevance

WearAble is creating a new class of bio-based additives that combine environmental responsibility with industrial performance. The molecules we have developed meet the high requirements of modern lubricants and can be integrated into existing systems without technical restrictions.

The project is thus making an important contribution to the transformation of the lubricant industry toward sustainable, circular production systems and strengthening the competitiveness of bio-based solutions in the European market.