Naveeth Khandelwal, Executive Director and CEO Continental Petroleums Ltd.
As industrial gear systems push boundaries in speed, load, and precision, lubrication technology is stepping up as a critical enabler. In this exclusive interaction, Neha Basudkar Ghate speaks with Naveeth Khandelwal, Executive Director and CEO of Continental Petroleums Ltd., to unpack how base oils, additive chemistry, and regulatory foresight are evolving to meet these challenges. Drawing from his deep industry experience and environmental engineering background, Mr. Khandelwal provides a nuanced view on enhancing gear system performance, sustainability, and lifecycle reliability.
1. How do lubricant base stocks and additive chemistries need to evolve to meet the increasing torque, load, and thermal demands in high-speed and high-precision gear systems?
To meet the escalating demands of modern gear systems, base stocks and additives must evolve synergistically. Group III+ and synthetic base oils with inherently higher oxidative stability, lower volatility, and superior viscosity-temperature characteristics are now essential. On the additive front, we need advanced anti-wear, extreme pressure, and friction-modifying chemistries that operate reliably under elevated temperatures and loads without causing corrosion. The emphasis is now on tailor-made molecular architectures that provide lubrication in fluctuating operating conditions.
2. In your experience, what are the critical failure modes in industrial gear systems that can be mitigated through advanced lubrication solutions, and how does formulation science address these?
Critical failure modes such as scuffing, wear, pitting, and lubricant degradation can all be significantly mitigated with optimized lubrication. Formulation science addresses these by creating stable oil films that resist rupture, incorporating anti-scuffing agents, and enhancing load-carrying capacity through high-performance Extreme Pressure (EP) additives. Additionally, the inclusion of detergents, dispersants, and oxidation inhibitors ensures long-term cleanliness and thermal resilience, directly impacting gear longevity and reducing unplanned downtimes.
3. With increasing operating speeds and tighter tolerances in gear-driven machinery, how should lubricant formulations adapt to maintain film strength without sacrificing thermal stability?
Maintaining film strength in high-speed, high-precision systems requires lubricants with high VI (viscosity index), shear stability, and excellent thermal conductivity. Advanced esters and PAO-based synthetics, combined with viscosity improvers resistant to mechanical shear, help maintain the correct film thickness under varying pressures and speeds. Simultaneously, modern antioxidant systems prevent thermal breakdown, ensuring the lubricant performs across extended operating ranges.
4. What role do synthetic and semi-synthetic lubricants play in extending maintenance intervals for enclosed gear systems in high-contamination environments such as mining or construction?
In high-contamination environments, synthetic and semi-synthetic lubricants provide unmatched performance. Their low pour points and oxidative resistance allow for extended drain intervals even in temperature-extreme or particulate-heavy conditions. These lubricants have better seal compatibility and demulsifying properties, reducing water ingress impact and wear. As a result, equipment in industries like mining or construction benefits from lower total lubricant consumption and reduced maintenance costs.
5. Do you see the need for more standardization or cross-industry collaboration between lubricant formulators, gear OEMs, and hazardous waste handlers to support circular economy models in manufacturing?
Absolutely. The complexity of modern lubricants and gear systems necessitates deeper collaboration among OEMs, formulators, and waste management stakeholders. Standardization of test methods, compatibility metrics, and re-refining specifications can significantly enhance the viability of circular models. Continental Petroleums supports collaborative platforms where R&D, manufacturing, and sustainability can intersect to build scalable, environmentally responsible systems for lubricant reuse and recovery.
6. How should gear-intensive industries develop safe handling protocols for waste lubricants that
contain metal fines or degraded additives, particularly in jurisdictions with limited hazardous waste infrastructure?
Industries must adopt a proactive approach by implementing closed-loop lubricant management systems, integrating filtration, diagnostics, and safe containment practices at the plant level. Even in jurisdictions with limited infrastructure, decentralised treatment units, proper labelling, and documented handling protocols can ensure safer disposal. Training personnel and working with certified hazardous waste disposal partners—such as those aligned with CPCB guidelines in India—is vital for regulatory compliance and environmental safety.
7. How are OEMs and lubricant formulators addressing the challenges of gear lubrication under mixed lubrication regimes, particularly in variable-load and start-stop applications?
In mixed and boundary regimes, where full film lubrication is inconsistent, the formulation focus is on high-performance friction modifiers and surface-active anti-wear additives like molybdenum compounds or organophosphates. OEMs are increasingly specifying lubricant properties like traction coefficient and film durability for stop-start applications. There’s also a trend towards condition-based monitoring to dynamically assess lubricant health and adapt service intervals accordingly.
8. Given your background in environmental engineering, how should gear oil manufacturers adapt to global shifts in environmental regulations such as REACH or BIS mandates on lubricant toxicity and biodegradability?
Manufacturers must prioritize green chemistry—minimizing the use of SVHCs (substances of very high concern), adopting biodegradable ester bases, and ensuring compliance with local and global standards like REACH, BIS, and Ecolabel. The industry R&D should closely align with such regulations. The goal should be to invest in bio-based alternatives and low-toxicity additive systems that maintain performance while reducing ecological footprint, aiming to future-proof our offerings for an environmentally conscious market.
