Synthetic vs Mineral Lubricants: The Optimal Choice for Modern Engines

Firoz Musthafa, Founder and R&D Engineer, Armorol Nano Ultra Lube, in an interaction with Industry Outlook, discusses how evolving engine efficiency standards and stringent emission norms are reshaping lubricant preferences in India. With a detailed understanding of synthetic and mineral oil dynamics, he sheds light on regulatory, technical, and market challenges faced by lubricant producers and highlights innovative solutions to navigate this rapidly changing landscape.

Given the rapidly evolving engine efficiency standards in India that are prompting manufacturers to rethink lubricant choices, what key factors influence the preference for synthetic versus mineral oils?

Several key factors influence the preference for synthetic versus mineral oils. When deciding between synthetic and mineral oils due to new efficiency standards in India, many aspects such as laws, technical concerns, costs, and how engines operate are involved.

It is very important to follow the regulations and environmental laws when choosing a company for outsourcing. Since India must now use Bharat Stage VI (BS-VI) emission norms, vehicles need cleaner and better engines that rely on superior lubricants. Because of aims to be carbon neutral and improved fuel requirements, more drivers rely on engine oils that have low viscosity and better performance; these are strengths of synthetic oils.

Improving the efficiency and design of engines is making people lean toward using synthetic oils. Nowadays, the tight tolerances and blocked space of downsized, turbocharged engines ask for lubricants that have great thermal stability, lower volatility, high oxidative and shear stability, and low HTHS (High temperature high shear) properties found only in synthetic oils. Synthetic oils also make it possible to go longer without changing the oil, in line with what the manufacturers want to save on both costs and delays.

Advantages of synthetic oils can be seen in how they work over mineral oils. Rising temperatures and stress make natural oils less suitable, but synthetic oils are not affected as much and do a better job at preventing friction, lowering engine wear, and deposit buildup.

Cost and market economics represent a complex consideration in the synthetic versus mineral oil debate. Mineral oils are significantly cheaper and still dominate in cost-conscious segments, particularly in rural or two-wheeler markets due to their price sensitivity. However, while synthetic oils have higher upfront costs, they offer longer service life and better protection, lowering the total cost of ownership (TCO) over time, which is especially important for fleets and heavy-duty vehicles.

OEM recommendations and aftermarket trends are increasingly favoring synthetic oils. Many newer vehicle models come with factory-fill synthetics or explicitly recommend synthetic oils for warranty compliance. As awareness and trust in synthetics grow, along with marketing from OEMs and oil companies, consumer shift is expected, particularly in urban and premium vehicle segments through aftermarket education and adoption.

Finally, availability and supply chain considerations impact the practical implementation of synthetic oil preferences. India's capacity to produce Group III/IV base stocks used in synthetics influences availability and pricing within the domestic market. The import dependency for synthetic base oils often impacts pricing and supply, especially under volatile forex or geopolitical conditions, which can affect the overall economics of choosing synthetic over mineral oils.

Summary

India's evolving engine efficiency and emission standards are tilting the lubricant preference toward synthetic oils, especially for newer vehicle segments, commercial fleets, and urban consumers. However, price sensitivity, legacy vehicle population, and infrastructure limitations will keep mineral oils relevant in the short to medium term.

What challenges do lubricant producers face in tailoring synthetic formulations to meet diverse engine types and driving conditions prevalent in India?

Lubricant producers in India face a complex set of challenges when formulating synthetic lubricants that meet the diverse engine types, vehicle usage patterns, and environmental conditions across the country. Such difficulties impact different aspects of building products, manufacturing them, and setting their edge in the market.

Ensuring the reliability of the fuel mixture is very challenging due to so many types of engines. Countless types of engines are available in India, like two-stroke and four-stroke, carburetted and fuel-injected, normally aspirated and turbocharged, diesel and petrol, CNG and hybrid types. Because every engine requires something different from lubrication, synthetic motor oils are made to cover these individual needs. Moving from BS-IV to BS-VI brings additional challenges, since current cars drive on special types of engine oil, while older ones are sensitive to these new products. Apart from that, producers of lubricants need to address different OEM requirements, especially when there is a conflict between lowering volatility and raising detergency, which makes the mixing process more difficult.

Many different climates and roads in India make the job of making synthetic lubricants challenging. They should be able to handle the extreme heat and your car’s required functions in crowded city areas, on long highways, and dusty areas. Because the climate in India varies from cold in the north to hot in the south, lubricants need to maintain their thickness and work well in many temperature conditions. This difficulty worsens since many commercial fleet vehicles run at high loads and are filled with fuel that varies a lot in quality, therefore requiring a strong, reliable lubricant.

Ensuring good pricing and quality together is a big challenge for the Indian market. Superior performance being the plus point of synthetic formulations, they do cost much more than traditional formulas, which isn’t suitable for typical Indian buyers, as they are very price-conscious in these sectors. As a result, additive packages are made cost-effective while the base oils are top quality. Consequently, lubricant producers often need to offer multiple grades and performance tiers, which complicates both manufacturing processes and logistics operations.

Infrastructure and supply chain constraints pose significant operational challenges. India lacks sufficient domestic production of high-quality synthetic base oils such as Group III+ and Group IV PAOs, leading to import reliance and exposure to global supply chain disruptions. Ensuring consistent quality across decentralized blending plants and regional warehouses becomes particularly challenging for high-precision synthetic formulations that require stringent quality control measures.

Regulatory and environmental pressures add another dimension of complexity to synthetic lubricant development. Keeping up with frequently updated BIS (Bureau of Indian Standards) specifications, as well as API and ACEA standards, requires constant research and development investment. There is also a growing demand for eco-friendly lubricants with biodegradable additives and low carbon footprints, adding further complexity to synthetic formulation requirements.

Consumer awareness and market education challenges significantly impact the adoption of synthetic lubricants. Many vehicle owners remain unaware of the benefits of synthetic lubricants or mistrust their compatibility with older engines, leading to low synthetic adoption in the mass market. The prevalence of counterfeit or mislabelled lubricants undermines consumer trust and impacts brand positioning, making market education efforts more difficult and expensive.

Finally, field testing and validation present ongoing challenges for lubricant producers. Laboratory testing doesn't always replicate real-world Indian driving conditions such as potholes, dust ingress, and temperature spikes, requiring producers to invest in extensive field trials across different regions and vehicle types. Achieving endorsement and validation from OEMs requires long test cycles and extensive technical collaboration, which can significantly delay product launches and increase development costs. This comprehensive validation process is essential but adds considerable time and expense to bringing new synthetic formulations to market.

Summary of Key Challenges

Lubricant producers in India must navigate technical, economic, and logistical complexities when tailoring synthetic formulations for a highly heterogeneous and price-sensitive market. The key to success lies in adaptive R&D, localized testing, cost optimization, and strategic partnerships with OEMs.

Also Read: Harmonic Filters: Essential Tools for Power Quality Enhancement in Indian Industries

How do environmental regulations and emission norms in India influence the choice between synthetic and mineral lubricants for vehicle fleets?

Environmental regulations and emission norms in India, especially the implementation of BS-VI (Bharat Stage VI) standards, have significantly influenced the choice between synthetic and mineral lubricants, particularly for vehicle fleets. The new rules about these regulations have an impact on choosing lubricants for many fleet activities and environmental purposes.

Stiffer emissions rules require that cars use cleaner fuel, and BS-VI norms that follow Euro 6 have extra restrictions on PM, NOx, and HC. As a result, DPFs and SCRs are required for after-treatment, and they are very affected by changes in lubricant. As they are low-SAPS, synthetic lubricants are perfect for engines that have to meet BS-VI standards. On the other hand, unless modified mineral oils are used, they tend to leave more ash and contamination that obstructs the work of after-treatment devices and contributes to extra costs and emissions for truck operators.

Picking a lubricant also relies on supporting good engine performance and saving fuel. Because emissions and fuel-efficiency norms relate to each other, OEMs have been encouraged to fit smaller engines that are more accurate and have less tolerance. Synthetic lubricants lessen friction inside the engine, so that the engine’s fuel efficiency and reduction of carbon emissions are improved. Synthetic oil use in transportation can help save fuel, leading to a benefit for the environment and for the company’s money matters.

Reducing the frequency of oil changes and the amount used has grown as vital for organizations that want to manage their monthly readjustment and budget for fuel and parts. Heavy-duty vehicles can go as far as 40,000–60,000 km on synthetic oil before it has to be changed, and they are less likely to break down or oxidize when working hard. Since less frequent oil changes keep oil out of the environment, this helps reach the goals and aims of the circular economy and sustainability.

Compatibility with emissions-control hardware is crucial for BS-VI vehicles that use sensitive components like Diesel Particulate Filters (DPFs), Selective Catalytic Reduction (SCR), and EGR systems. Synthetic oils have better volatility control, reducing oil burn-off and particulate emissions, while containing additives compatible with modern emission systems that minimize hardware fouling and failure. Mineral oils may be unsuitable or even harmful for these components, potentially increasing the total cost of ownership for fleets through more frequent maintenance and component replacement.

The government push for green logistics and fleet electrification also influences lubricant choices. While EVs are growing, internal combustion engine (ICE) fleets, especially in logistics, still dominate the market. Government programs like FAME-II, vehicle scrappage policies, and clean fuel incentives push for modern, efficient fleets, which inherently favor synthetic lubricants due to their compatibility with advanced engine platforms and superior performance characteristics that support environmental objectives.

Finally, lubricant labeling and regulation compliance requirements have created additional pressure toward synthetic options. New lubricant standards, such as IS 13656:2021 aligned with API SN/CK-4, require compliance with emissions and performance benchmarks. Synthetic oils are better positioned to meet or exceed these standards, while mineral oils need enhanced additive packages to achieve compliance, raising costs without achieving the full benefits that synthetic formulations can provide. This regulatory framework effectively creates a competitive advantage for synthetic lubricants in the fleet market, where compliance with environmental standards is not just preferred but mandatory.

Summary: Impact of Regulations on Lubricant Choice for Fleets

Conclusion

In the context of tightening environmental regulations, synthetic lubricants are increasingly preferred by Indian vehicle fleets because they enhance engine efficiency, protect emissions-control systems, and help fleets comply with regulations while improving operational cost-efficiency. This regulatory pressure is accelerating a market shift from mineral to synthetic lubricants, especially in BS-VI commercial and high-performance fleet segments.

In what ways does lubricant type affect engine wear, fuel efficiency, and maintenance intervals in India’s growing electric and hybrid vehicle segment?

In India's expanding electric and hybrid vehicle (EV/HEV) segment, the type of lubricant used—synthetic versus mineral or specialized e-fluids—plays a critical role in influencing engine wear (where applicable), fuel efficiency, and maintenance intervals. While traditional internal combustion engine (ICE) concerns are less prominent in EVs, hybrids and certain EV components still require lubrication, and the right fluid can significantly impact performance and longevity.

Engine wear remains relevant in hybrid vehicles (HEVs, PHEVs) that still use combustion engines, though typically in start-stop cycles and short bursts. These operating modes increase thermal stress and component wear, especially during cold starts, demanding lubricants with excellent film strength, low-temperature fluidity, and high shear stability—attributes best delivered by synthetic oils. Mineral oils, especially at lower viscosities, degrade faster under start-stop and thermal cycling conditions, increasing wear risks in hybrid powertrains. Consequently, synthetic oils reduce wear and protect engine components better in hybrids under India's high-traffic, high-temperature conditions.

Fuel efficiency and energy efficiency considerations vary between hybrid and electric vehicles. In hybrids, where both electric motors and ICEs share propulsion duties, synthetic engine oils with lower viscosity and better friction modifiers improve ICE fuel efficiency, contributing to better overall vehicle mileage.Since there isn’t any fuel in EVs, fluids such as coolants and transmission oil still have an impact on their energy use. Using synthetic e-fluids in the EV’s gears along with its bearings improves efficiency and lengthens range. Proper management of heat in a vehicle’s battery and motor largely depends on synthetic thermal management fluids in Indian weather, which, in turn, boosts efficiency. Therefore, motor oil specially for EVs improves its operation by reducing the amount of power it wastes on friction and overheating.

The periodic maintenance schedules used by these vehicles should also affect your decision about lubricant selection. Though EVs have less noise and fewer components, maintenance must be done on some important parts such as the reduction gearbox, thermal systems, and at times the e-axles. The life of a vehicle is lengthened since synthetic e-fluids quality is better, resisting oxidation and degradation. Using synthetic lubricants in hybrids, owners can drive further without changing the oil, especially necessary for cities and users who travel large distances on a regular basis. Trying to provide longer service intervals, lubricants make a big difference, synthetics being the best choice for both.

Since they are used in Indian weather, lubricants for electric cars face a new set of difficulties. The hot weather, crowded cities, dust, and a lot of idling while waiting increase the temperature and pressure inside a vehicle’s various parts. Thanks to their chemical makeup, synthetic oils give better results in extreme conditions by not breaking down and continuously protecting the engine. Managing the heat in EV batteries is very important, so using synthetic dielectric coolants is more reliable and effective in India. In India's challenging operating environment, synthetic fluids provide better protection, longevity, and stability—critical attributes for the newer, more sensitive EV/HEV platforms that require reliable performance under diverse and often extreme conditions.

Summary of Lubricant Effects in EV/Hybrid Context

Conclusion

In India's growing EV and hybrid segment, synthetic lubricants and e-fluids are essential for ensuring low wear, high efficiency, and extended maintenance intervals. Mineral oils are largely unsuitable for this segment due to their limited thermal stability, shorter life, and incompatibility with advanced components. As India ramps up EV adoption, the lubricant industry is evolving toward tailored synthetic formulations for e-mobility, focusing on range optimization, safety, and sustainability.

How are Indian lubricant companies leveraging R&D to innovate additives that enhance synthetic lubricants’ advantages over traditional mineral oils?

Indian lubricant companies are increasingly investing in R&D to develop next-generation additives that unlock the full potential of synthetic lubricants, positioning them as superior alternatives to traditional mineral oils. To meet stricter standards, make cars more fuel efficient, and provide better life for engines, the industry is working on these innovations, coping with the nation’s special demands and conditions.

Indian experts are creating additives for India’s needs because of the country’s high temperatures, dust, unusual traffic, and fuel quality problems in various regions. The use of these formulations in synthetic lubricants makes sludge and soot control easier, enhances friction reduction, boosts anti-wear properties especially when the engine is turning slowly or under high pressure, and helps save fuel. So, synthetic oils help keep engines more clean, offer better protection, and perform better when stress is applied than mineral oil.

Based on BS-VI rules, companies in India are adding low sulphur/phosphorus/ash additives to engine oils so they emit less Sulphated Ash, Phosphorus, and Sulphur, which avoids fowling emission systems and maintaining low volatility to keep engine oil consumption down. They are making special additives for synthetic oils that meet the strict guidelines and support the use of oils in highly pressurized turbocharged engines for a long time. Bound by the rules on emissions, mineral oils often need expensive and complicated additives to meet the standards.

With improved antioxidants made by Indian R&D laboratories, the oil in commercial vehicles can be used longer even in hot climates and crowded cities, which is very beneficial for fleet owners. The preservation of proper thickness, smoothing abilities, and protection in synthetic oils is thanks to such additives. Synthetic oils with advanced oxidation inhibitors last longer and reduce engine deposits compared to mineral oils.

With India's electric mobility transition, R&D is also focused on innovating additives for EVs and hybrids, including dielectric fluids for EV batteries and motors, low-viscosity high-performance e-transmission fluids, and additives for hybrid engines which operate under unusual thermal cycles with frequent start-stop conditions. Indian lubricant firms are developing thermally stable, electrically insulating fluids to cool electric components and additive packages that prevent copper corrosion, a major concern in EV drive units. These innovations expand the role of synthetic lubricants into future-ready applications where mineral oils are not viable.

To align with India's environmental and circular economy goals, lubricant R&D is focusing on sustainability and green chemistry by exploring bio-based or biodegradable additives, reducing heavy metal content such as zinc and molybdenum, and adopting ashless anti-wear additives that offer similar protection but lower environmental impact. These sustainable additives complement the longer life and higher efficiency of synthetic lubricants, making them more attractive than mineral oil alternatives.

Indian companies are pursuing strategic collaborations and test programs by partnering with global additive giants like Lubrizol, Afton, and Infineum for technology transfer, working with automotive OEMs for co-developing and field-testing new additive technologies, and collaborating with academic and research institutions for materials science and fluid dynamics insights. These partnerships accelerate product validation under real-world Indian driving conditions and faster adaptation of synthetic oils in mass-market and fleet segments.

Summary of Additive Innovation Enhancing Synthetic Lubricants

Conclusion

Indian lubricant companies are aggressively leveraging R&D to push synthetic lubricants ahead of mineral oils, focusing on performance, durability, environmental compliance, and future vehicle readiness. This R&D momentum is positioning Indian players not just as suppliers but as innovation leaders in the global lubrication industry.

Looking ahead, how will advances in bio-based and synthetic lubricants reshape India’s lubricant market and engine performance standards over the next decade?

Over the next decade, advances in bio-based and synthetic lubricants are set to dramatically reshape India's lubricant market and influence engine performance standards, driven by emission norms, sustainability goals, and technological innovation. This transformation is expected to unfold across multiple dimensions of the industry.

The shift toward high-performance, low-emission lubricants will significantly impact engine performance standards. Tighter emission norms (BS-VI+ and beyond) will demand lubricants that support low-SAPS formulations, high-temperature stability, and improved fuel efficiency. Synthetic and bio-based lubricants will help reduce engine wear and oil degradation while supporting turbocharged, high-efficiency engines with longer service life. This will lead OEMs and regulators to raise baseline performance requirements for factory-fill and aftermarket lubricants. The outcome will be that mineral oils are phased out in most high-performance applications, with synthetic and bio-based oils becoming the new standard.

The acceleration of sustainable and circular economy goals will drive the rise of bio-based lubricants derived from vegetable oils or renewable esters. These bio-lubricants will gain traction due to their biodegradability, lower toxicity, and reduced carbon footprint. Sectors like agriculture, marine, and off-road equipment, where environmental leakage risks are high, will lead in adoption. Government mandates or incentives could further accelerate adoption in public and industrial fleets. India's lubricant market will see a parallel track developing, with synthetic oils serving high-performance engines while bio-based oils cater to eco-sensitive sectors.

Market evolution will be characterized by premiumization and differentiation, shifting from volume to value. The market will transition from a high-volume, low-margin mineral oil focus to a premium, technology-driven synthetic and bio-lubricant ecosystem. Growth is expected in low-viscosity synthetics (0W-16, 0W-20) for fuel efficiency, long-drain synthetic oils for commercial vehicles and fleets, and smart lubricants with sensors and monitoring capabilities. Lubricant companies will compete more on innovation, OEM partnerships, and environmental compliance than on price alone.

Support for EVs and hybrid vehicles will require specialty synthetic fluids for electric mobility. As EVs and hybrids gain market share, demand will rise for synthetic dielectric coolants for batteries, e-gear fluids for electric drivetrains, and lubricants with thermal and electrical stability. Indian lubricant R&D will focus on developing low-viscosity, high-efficiency fluids to extend EV range and component life. Synthetic and bio-lubricants will evolve from supporting ICEs to becoming integral to next-generation vehicle platforms.

The regulatory push and R&D transformation will tighten performance standards. New BIS and API standards in India will increasingly require environmentally safe and longer-lasting lubricants while promoting bio-based content and sustainability certifications. Lubricant R&D will pivot from basic formulation to molecular-level customization, green chemistry, and life-cycle optimization. Government and industry collaboration will institutionalize the shift from traditional oils to advanced formulations, fundamentally changing how lubricants are developed, manufactured, and marketed in the Indian market.

Summary of Key Trends Over the Next Decade

Conclusion

By 2035, India's lubricant industry will undergo a profound transformation characterized by a decade of reinvention. Synthetic and bio-based lubricants will gradually eclipse mineral oils in volume and value, fundamentally altering the market landscape. Engine performance standards will evolve to accommodate next-generation vehicles, tighter emissions, and sustainability benchmarks. Companies that invest in R&D, green chemistry, and OEM alliances will lead the market, positioning themselves at the forefront of this industry transformation.