The Future of Hydraulic Fluids: How Bio-Based Alternatives Are Powering Sustainable Industry

As global attention shifts toward environmental sustainability, industries are re-evaluating the materials and systems that drive their operations. One key area undergoing transformation is the use of hydraulic fluids — essential for energy transmission, lubrication, and cooling in countless applications, from small machines to heavy-duty industrial equipment.

Traditionally, these fluids have been mineral-oil based, but increasing concern about environmental safety, oil spill risks, and resource scarcity has created momentum for bio-based hydraulic fluids derived from renewable vegetable oils. A recent comprehensive study by researchers published in Biomass and Bioenergy [2024] offers an in-depth exploration of the current state, performance, and future of bio-based hydraulic lubricants.

What Are Bio-Based Hydraulic Fluids (BHFs)?

Bio-based hydraulic fluids (BHFs) are lubricants derived from renewable biological sources, primarily vegetable oils (e.g., rapeseed, sunflower, corn, soybean, canola, coconut, etc.) instead of conventional petroleum-based oils. They serve the same functional purposes as traditional hydraulic fluids: transmitting power, lubricating components, reducing wear, and managing heat in hydraulic systems.

Why Bio-Based Hydraulic Fluids?

Vegetable oil-based hydraulic fluids have several advantages:

• Biodegradability and non-toxicity

• High flash points and lubricity

• Low volatility

• Safer for the environment in case of leaks or disposal

  
  

These properties make them attractive for use in industrial applications, especially where environmental impact is a major concern such as agriculture, construction, marine systems, and forestry equipment.

In addition, global demand for eco-friendly lubricants is rising. The hydraulic fluid market, valued at over $20 billion in 2022, is projected to reach $25.93 billion by 2030, driven in part by increased interest in sustainable alternatives. Manufacturers like Mobil, Shell, and Chevron Texaco, traditionally leaders in petroleum lubricants, are now among the key players investing in bio-based alternatives. Not just out of obligation, but because the market, regulations, and public expectations are evolving.

Source: Market Research Future

Challenges in Widespread Adoption

Despite their clear environmental benefits, bio-based hydraulic fluids face critical hurdles:

1. Higher Costs

   
   

   Bio-lubricants are typically 30–40% more expensive than mineral-based alternatives, making them less attractive for cost-sensitive markets.

   
   

2. Feedstock Competition

   
   

   Using edible oils (e.g., rapeseed, soybean) for fluid production competes with food supply. Non-edible options are under-explored and underutilised due to lack of data and infrastructure.

   
   

3. Performance Limitations

   
   

   Bio-based fluids often suffer from oxidative and thermal instability, poor cold-temperature performance, and shorter service life, especially in demanding applications.

   
   

4. Compatibility Issues

   
   

   Many BHFs are not fully compatible with existing hydraulic systems, seals, and components raising adoption barriers.

   
   

5. Lack of Biodegradable Additives

   
   

   Most available additives for anti-wear, anti-oxidation, and rust protection are still petroleum-derived.

Innovations and Research Directions

The article highlights a range of ongoing R&D efforts to address these issues:

• Chemical modification of vegetable oils (e.g., esterification, epoxidation) to enhance performance

• Use of oleic acid-rich oils from hybrid or genetically modified plants for better oxidative stability

• Development of fire-resistant bio-based hydraulic fluids for high-risk industrial environments

• Exploration of biodegradable additives and new base stocks from non-edible oils like moringa or rubber seed oil

Toward a Circular Hydraulic Future

As environmental regulations tighten and sustainability standards rise, the shift toward bio-based high-performance hydraulic fluids is not just a trend—it’s an industrial necessity. Government policy support, cost-reduction strategies, and expanded standardisation are key to scaling adoption.

Furthermore, innovations in formulation and additive technology are rapidly closing the performance gap between bio-based hydraulic fluids and petroleum-based fluids. In time, bio-based hydraulic fluids could outperform conventional lubricants in both performance and ecological safety, making them the new gold standard in hydraulic system maintenance and design.

Final Thought

The transition to bio-based hydraulic fluids offers a critical opportunity to reduce environmental impact without compromising industrial performance—but only if innovation, policy, and market forces work in concert. Manufacturers, researchers, and regulators all have a role to play in making BHFs not only greener, but also more accessible and reliable for the industries that rely on them.

Citation: This article is based on insights from:

Rogoš, A., Kamalakar, G., Bahadi, M. A., et al. (2024). Recent advances and challenges in bio-based high-performance hydraulic fluids: A review. Biomass and Bioenergy, 183, 107160.https://doi.org/10.1016/j.biombioe.2024.107160