As the vehicle parc accelerates toward greater efficiency, lower emissions and increasingly complex powertrain technologies, the science underpinning lubricant performance has never been more critical. Additive packages, the precisely engineered blends of chemical components, play a central role in enabling lubricants to meet the rising demands of Original Equipment Manufacturers (OEMs), regulators and end users.

Complexity in Modern Lubricant Formulation

The lubricant formulation landscape has transformed dramatically over the past two decades. What was once a relatively stable landscape, now requires continued adaptation to keep up with rapidly evolving OEM specifications. These specifications are driven by stringent environmental legislation, and an OEM focus on extracting the maximum performance from the powertrain. The number of unique engine tests required for a single top tier 5W-30 passenger car lubricant profile has expanded from 25 in 2005 to around 60 today. Each test evaluates a specific performance scenario, such as biodiesel compatibility, protection against low-speed pre-ignition (LSPI), wear protection, sludge control and many more.

Formulators must account for other considerations such as REACh regulations, material compatibility, the performance implications of base oils and formulation competitiveness. Formulating an additive package requires not only chemical expertise, but a broader market understanding.

The Process; focused on Lubrizol® CV9660 heavy duty engine oil additive package

Lubrizol's formulation development path is broken into four key stages which are pre-platform, platform development, platform extension and platform prolongation. This is underpinned by Lubrizol's extensive technology capabilities, with laboratories in Europe, Asia, India and the Americas. These capabilities specialise in the areas of chemical synthesis, formulation blending, application testing, mechanical testing and real-world testing. The constant evolution of products ensures the process is circular with the formulation being continually reviewed and developed against the vehicle parc, regulations and OEM requirements.

The heavy duty engine oil additive package Lubrizol® CV9660, followed this development pathway from its conception through to commercial deployment. This article will use Lubrizol® CV9660 as an example to walk through this development path.

The pre-platform phase begins with the foundational research. The fundamental building blocks of technical knowledge, identifying candidates for testing and engaging with OEMs to align on performance needs and potential future technology direction. For Lubrizol® CV9660, the testing at this stage focused on evaluating performance in areas such as detergency, oxidation control, corrosion protection, diesel soot dispersancy, and durability. While the product's end performance targets might be clear from the outset, the main objective at this stage is to map out the component behaviours. This provides clear direction for prototype formulations, setting the base level of knowledge for the remainder of the project.

Once the baseline knowledge was established, Lubrizol® CV9660 moved into formulation development - the main product defining phase. Here the formulation was put to the test, undertaking required OEM engine and laboratory tests to gain approvals. For Lubrizol® CV9660, the overall testing included more than 22,000 laboratory tests, over 200 engine tests and field trials covering more than 7 million kilometres.

At Lubrizol, achieving the industry credentials and OEM approvals is critical. Not only does it provide the data and evidence to support the product's performance, but it also demonstrates that it meets the high standards required. In the absence of rigorous industry testing and OEM approvals, there is a real risk to engine hardware and ultimately to the consumer. Diligent performance testing is vital to ensure the product will protect the engine even in the most extreme of drive cycles. The importance of rigorous and accredited testing which underpins industry and OEM approvals is not to be underestimated.

Once the development of the additive system and full market launch of the product is completed, the focus shifts to expanding the product market through extension of the product's capabilities. Here, Lubrizol supports industry partners to gain additional approvals, ensuring the formulation is credible, validated and suitable for diverse applications. The expansion of the product base oil coverage is also considered, opening up different regional markets. Collaboration is key, enabling broader use across varying engine platforms and operating conditions. For Lubrizol® CV9660, this included receiving additional key OEM approvals via extensive field trials.

A long time into the future for Lubrizol® CV9660, the eventual stage before the process restarts is product line prolongation - maintaining a product's relevance. This requires continued work with OEMs, renewal and extension of approvals and ongoing base oil compatibility programs. It also takes into account any landscape changes around specifications, vehicle parc requirements or legislation developments.

Meeting Leading Market Requirements

Lubrizol® CV9660 followed the development process outlined above, and was engineered to satisfy wide ranging global needs by providing:

Broad viscosity and base oil coverage
Strong performance in areas such as wear protection, engine durability and deposit control
Close collaboration with partners to optimise deployment

The formulation path has enabled Lubrizol® CV9660 to deliver a high performance, high value and flexible product offering across multiple viscosity grades. Significant consideration of the foundational aspects of product development have allowed Lubrizol® CV9660 to build into the market leading formulation it is today.

With the ability to serve all the key viscosity profiles from a single additive package and viscosity modifier combination, Lubrizol® CV9660 embodies the strength of Lubrizol’s formulation development process; efficient, technically robust and built for evolving market needs.

Looking Ahead: The Future of Additive Science

Additive development will continue to intensify as the industry confronts new challenges: electrification-derived hardware changes, higher thermal loads, expanded use of re-refined base oils, next generation proposed categories such as PC-12 and GF-8 and increased sustainability expectations.

A successful additive package development will increasingly depend on:

Integrated digital and AI driven decision making
Modular, flexible component design
Ensured compatibility with electrified powertrains
Optimised formulations for low viscosity, enabling higher fuel efficiency
Circular economy approaches to raw materials and supply chains

In this future landscape, the technical expertise applied in additive development become not only a differentiator, but a necessity for ensuring lubricant performance keeps pace with the evolution of mobility.

The Development Lifecycle of a Lubricant: The Technical Expertise Behind Modern Additive Development