Synthetic Motor Oils: Innovations Enhancing Engine Performance

In an exclusive interaction with Industry Outlook, Thahir Ibramshah, Business Head–India of  ziel lubricants, discusses the critical role of synthetic engine oils in enhancing fuel efficiency, reducing emissions, and supporting BS6-compliant engines amid India’s gradual shift to EVs. He emphasizes how advanced additives and OEM collaboration are shaping the future of sustainable automotive lubrication.

How do the latest innovations in synthetic motor oils improve fuel efficiency and reduce engine wear compared to traditional mineral oils?

When discussing the fuel efficiency of synthetic oil, it’s important to understand the role of base oils. Base oils are the foundation of engine and gear oils, and they are categorized into five different groups, depending on the application and formulation.

Group I consists of mineral base oils, which are considered conventional. In contrast, synthetic base oils fall under Group III, Group IV, and Group V. These are typically used in modern, high-performance lubricants.

New-generation engines are designed to meet higher performance standards and deliver improved fuel economy, and typically require Group III or higher synthetic base stocks. This is because conventional mineral base oils, such as those in Group I, generally have lower viscosity indices and less stable properties under varying temperature conditions.

For example, the viscosity index of typical mineral base oil is around 90–93. In comparison, Group III synthetic base oils have viscosity indices of 130 and above, making them approximately 30–35 percent higher in this aspect.

This higher viscosity index directly influences friction reduction within the engine. Lower friction leads to less energy loss, which in turn improves engine power output. As a result, the oil lasts longer, performs better under stress, and contributes to enhanced fuel economy. In essence, the superior molecular structure and thermal stability of synthetic base oils make them ideal for supporting modern engines that demand higher efficiency and performance.

What role do advanced additive technologies play in enhancing the thermal stability and longevity of synthetic motor oils?

From a manufacturing perspective, when formulating lubricant using Group III synthetic base oil, it is important to recognize that additives contribute nearly 50 percent of the product's overall performance. The selection and blending of these additives are just as critical as the choice of base oil.

In accordance with current standards set by the American Petroleum Institute  and various European regulatory bodies, manufacturers must carefully select base oils and pair them with a precise additive package to meet the required performance levels. Leading additive suppliers provide a range of components, including antioxidants, dispersants, nitrogen-based additives, and friction modifiers. Each of these components is engineered to support key aspects of engine protection and performance.

For example, oxidation stability is essential to maintain oil integrity, especially under high engine temperatures and varying ambient conditions. Without proper oxidation control, oil degradation occurs more rapidly, leading to reduced oil levels and compromised protection. Manufacturers incorporate antioxidants to mitigate this risk.

Nitrogen-based additives are specifically used to control carbon deposits.  During combustion, around 70 percent of the fuel is expelled through the exhaust system, but the remaining 30 percent can result in unburnt residues, which adhere to engine components. These deposits, if not controlled, can reduce both engine efficiency and oil service life. Therefore, dispersants and detergents are carefully blended to manage cleanliness throughout the engine. Friction modifiers are also a critical component in modern formulations. These additives reduce metal-to-metal contact, thus minimizing wear and improving fuel efficiency. From the manufacturing standpoint, incorporating the right balance of friction modifiers ensures smooth engine operation and supports extended oil drain intervals.

Previously, engine oil change intervals were typically around 5,000 kilometers, but with advancements in synthetic base oils and additive technologies, manufacturers now formulate oils that can last 10,000 to 15,000 kilometers or more, depending on OEM requirements. Premium vehicle manufacturers, such as those in Germany, often specify even longer intervals. In conclusion, from the perspective of lubricant manufacturers, the combined performance of synthetic base oils and carefully engineered additive packages is essential in meeting the demands of modern engines. This synergy ensures high performance, improved fuel economy, extended drain intervals, and overall engine protection.

How are synthetic motor oils engineered to meet the performance demands of modern engines, including turbocharged and hybrid powertrains?

Generally, the role of a turbocharger is to increase engine power output without changing the engine's displacement.  A turbocharger operates at extremely high speeds, typically around 130,000 RPM. Due to such high rotational speeds and extreme operating conditions, turbocharged engines require high-performance engine oils. Conventional mineral oils are generally not sufficient to provide the necessary protection under these conditions.

From a manufacturing perspective, the selection of engine oil is critical for turbocharged engines. Only high-quality synthetic engine oils can provide the required thermal stability, oxidation resistance, and lubrication performance to protect both the turbocharger and the engine components.

In summary, to reduce engine stress and ensure reliable turbocharger performance, it is essential to use high-quality synthetic engine oils that are specifically formulated for high-temperature, high-load conditions. These oils help maintain engine efficiency, extend component life, and support the increased power output made possible by turbo charging.

In what ways do synthetic motor oils contribute to sustainability, particularly in terms of reducing emissions and extending oil change intervals?

In the context of emission standards, India is currently operating under the Bharat Stage VI (BS6) emission norms. The transition was made directly from BS4 to BS6, skipping BS5 entirely. This was due to global trends, where regions such as Europe had already adopted Euro 6 standards, and India, being one of the largest countries with a high vehicle population, was under pressure to align quickly with international benchmarks.

The BS6 standard primarily focuses on controlling nitrogen oxide (NOx) emissions, which are a major byproduct of diesel combustion. In addition to NOx, carbon deposits and particulate matter (visible as exhaust smoke) must also be minimized. To effectively meet these stringent emission norms, the use of high-quality engine oil becomes critical.

From a manufacturing standpoint, engine oils now play a vital role in emission control. The service life of modern engine oils has nearly doubled compared to earlier formulations. This extended life is made possible by the use of synthetic base oils and advanced additive packages, which work together to control excess carbon, soot, and other unwanted combustion by products. By reducing carbon buildup and maintaining engine cleanliness, these oils not only support longer drain intervals but also contribute to better fuel economy and reduced emissions.

Also Read: Sustainable Biofuels Production through Biosolutions with Innovations in Enzymes and Yeast

How are OEMs and lubricant manufacturers collaborating to align synthetic oil formulations with evolving global regulatory and performance standards?

Engine manufacturers are required to design engines in compliance with government regulations, such as the transition from BS4 to BS6 emission standards. These regulations are mandated by the government and enforced across all OEMs (Original Equipment Manufacturers).

As a result, when OEMs design engines to meet these tighter emission norms, the engines experience significantly higher stress. To manage this stress while still complying with the stringent emission standards, the role of lubricant manufacturers becomes extremely important.

From a manufacturing perspective, lubricant companies are responsible for developing advanced engine oils that meet the specific expectations of OEMs. These expectations are guided by global regulatory and certification bodies such as COBRA, APR, APA, ACR, and others, which work to maintain and enforce international standards in lubricant performance and emissions compliance.

One of the key requirements is the control of harmful elements in engine oils, such as sulfated ash, phosphorus, and sulfur. These components, if not properly managed, can negatively impact after-treatment systems like diesel particulate filters (DPFs) and catalytic converters.

What is your take on the future ahead?

Looking ahead to the future, it is evident that fossil fuels are gradually depleting. With global fuel consumption continuing to rise, many countries are now actively transitioning towards alternative energy sources such as electric vehicles (EVs), bio-based fuels, and solar-powered solutions. These are widely recognized as the sustainable energy options of the future.

However, achieving 100 percent implementation, especially in a country like India, presents significant challenges. While EV adoption is increasing, the transition will take time due to factors such as high population density and the complexity of government policy implementation across the entire nation.

Currently, electric two-wheelers and passenger cars are becoming more common, and in some major cities, electric buses are also being introduced. Despite this progress, the infrastructure for EV charging, whether for two-wheelers or cars, is still under development. For widespread adoption to occur, the government must establish a comprehensive and accessible charging infrastructure across urban and rural areas. Only then will the full impact of the EV transition be realized, paving the way for a cleaner and more sustainable future for the next generation.

In the meantime, synthetic engine oils remain essential for modern BS6 engines, which demand higher levels of performance and efficiency. These engines, paired with BS6-compliant fuels provided under improved government fuel standards, are helping bridge the gap between current technologies and future solutions.