In a world of automation, the parts and pieces of each machine need to be protected from wear and tear as much as possible, and that’s where the proper use of lubricants and maintenance come into play. Lubrication may be a longtime industrial era necessity, but it remains critical in today’s increasingly automated food and beverage processing plants.

Samuel Cole, director of product certification - Equipment and Chemical Evaluation, Food Retail, for NSF International, says processors may be paying even closer attention to lubrication from a food safety standpoint than they did in the past, with a bigger-picture approach creeping into conversations.

“Countries like Brazil have requirements around lubricants such as ISO 21469, and India put legislation in place more than 10 years ago requiring H1 lubricants in food processing facilities,” he explains. “Companies are opening new plants in new regions and new countries to keep up, and people are having to learn the requirements very quickly.”

Furthermore, global regulations continue to expand with regard to PFAS (per- and polyfluoroalkyl substances) and other chemicals of concern, meaning companies are seeking a reduction of risk from the lubricants they use throughout the supply chain, not simply in the processing plants. This, of course, drives innovation, says Amber Dzikowicz, senior manager at NSF International. Lubricant companies are approaching NSF saying that customers have requested PFAS-free lubricants to meet the requirements.

“So we're really digging into those products and making sure they're formulated without PFAS-containing ingredients,” she says. “We're also testing to make sure there's no cross-contamination or unintentional introduction from manufacturing lines that may have produced other products.”

Cole says some manufacturers began switching to PFAS-free formulations a few years ago, seeing the writing on the walls, and those who are reformulating now are starting to move a little more quickly.

Pioneering innovation

Change takes time, investment in R&D and testing of the final product to reach the end of the journey. And when it comes to lubricants, manufacturers and processors need to keep an eye on balancing performance with regulatory demand.

“There are still high-heat applications where processors need a lubricant to perform under extreme conditions, and that's where the innovation comes in,” Cole adds. “How do you maintain performance while also meeting regulatory requirements or customer specifications?”

Nevertheless, innovation in food manufacturing continues to drive innovation in lubrication methods and substances, due to its proximity to consumable products. Innovators in the equipment space are pushing the envelope, with design and functional influences coming from outside the food industry — robotics, tech and even automotive applications. These engineers are often extremely strong in automation and design, Dzikowicz says, and they quickly learn that their concepts need to be food safe.

“A lot of innovators come from a technology background with really exciting ideas, but they may not fully understand food-safe materials, lubricants or sanitary design requirements,” she says. Fortunately, they quickly sort through that challenge and often solve it between prototype and version 2.0 or 3.0, Cole adds.

Food and beverage processing plants are among the first areas where manufacturers began addressing the concerns around PFAS because of the potential for incidental contact — meanwhile, broader industrial applications, such as high-heat, automotive and wind energy, among others, continue to work through the challenges. Cole still believes suppliers will continue to refine the chemistry needed to meet that performance/regulatory balance.

As lubricants continue to improve, processors cannot lose sight of the need for proper lubrication training. Crucial differences in usage, handling and storage for H1, H2 and H3 lubricants must be clearly communicated to workers and best practices followed.

“In manufacturing facilities, lubricants need to be stored properly to prevent the unintentional use of an incorrect product,” Cole advises. “Risk assessments, GMP audits and training all play a role, but the challenge is maintaining those programs between audits.”

Product changeovers have been a focus of tighter risk mitigation steps. If a processor switches between different production lines or different product categories, adequate cleaning must occur to prevent cross-contamination — which is similar for lubricant manufacturers who have to manage production of PFAS-free lubricants as well as traditional substances.

“Food processors need to apply the same thinking to their own operation,” Cole says. As regulations continue to evolve, companies need to adapt, particularly those who play in a global marketplace. As of now, the states are typically creating their own regulations around lubricants in the U.S., while Europe, the UK and other regions of the world have their own requirements in development.

“It becomes very difficult for global companies to maintain a single policy that works everywhere,” Cole says. “Food processors need to stay aware of all of these factors because there are a lot of layers.”

Additionally, geopolitical shifts, tariffs, supply chain disruptions and raw material shortages can throw various monkeywrenches into the works. Changes in trade policies and trends also factor in.

“As lubricant manufacturers face shortages or disruptions, they may need to substitute ingredients quickly, and that creates questions around validation and performance,” Cole concludes. “When you combine that with the rapid expansion of food processing around the world, the next three to five years will be about staying ahead of these changes rather than reacting to them.”