Process Oils Market, Global, 2024-2031

Circular Economy, Electrification, and the Need for Biodegradable, Non-Toxic Products are Driving Transformational Growth

Process oils are specialized natural or synthetic lubricants used in the chemical and technical industries. They serve either as key ingredients in finished products or as processing aids for raw materials.

Process oils offer several advantages over unprocessed oils, including enhanced stability, improved performance, and better compatibility with other materials. They are also more efficient in their applications, minimizing the need for frequent replacements. For example, rubber process oils enhance the processability and quality of rubber products, while green rubber process oils provide environmentally friendly alternatives to conventional rubber process oils.

This report focuses on trends and disruptions and analyzes new and upcoming trends in industries that are expected to drive demand for process oils. The study will complement our recent market forecast report on the global lubricants market.

The study period is 2022-2031, with 2024 as the base year and 2025-2031 as the forecast period. The process oils examined are white oils, transformer oils (electrical oils), and rubber process oils, each segmented by application and product type.

The Impact of the Top 3 Strategic Imperatives on the Process Oil Industry

Transformative Megatrends

• Why:
• Circular economy trends are massively transforming the process oils industry and many other areas of the chemical industry.
• Vegetable-based oils such as soybean, palm, rapeseed, and sunflower oils are gaining popularity due to biodegradability and low toxicity.
• Soy-based process oils increasingly find applications in tire and polymer processing.
• Frost Perspective:
• Investing in the development of process oils with a lower carbon footprint and improved sustainability is imperative to remain significant in the market. In the past, banning distillate aromatic extract (DAE) in Europe forced the manufacturers worldwide to shift away from DAE. Similar regulations, driven by environmental impact, will shape the industry in the future.
• Tire and rubber manufacturers are leading the transition toward eco-friendly process oils.
• While the growth in end applications, especially in industrial and automotive applications, during the forecast period, will impact process oil demand, it will also transform into a more sustainable industry.

Geopolitical Chaos

• Why:
• The process oils market is susceptible to geopolitical instability, which affects raw material availability, pricing, trade policies, and supply chain efficiency.
• Sanctions on Russian crude oil and petrochemicals have caused shortages in crucial feedstocks for process oils, especially in Europe, which is home to leading manufacturers.
• In addition, US-China tensions and policies of the new US government could result in uncertain tariffs and trade restrictions affecting the import/export of feedstock and end products, such as tires.
• Frost Perspective:
• Heavy reliance on Middle Eastern or Russian crude oil makes companies vulnerable to sanctions, OPEC decisions, and regional conflicts. To avoid this, diversifying feedstock sources and local supply can be advantageous.
• Companies like ExxonMobil, Chevron, and TotalEnergies are increasing sourcing from the Americas and APAC.
• Efficient inventory management will also be essential, allowing manufacturers to adjust strategies to secure feedstock availability.

Competitive Intensity

• Why:
• The process oils market is experiencing increasing competition from both established players and new entrants focusing on sustainability, innovation, and regional expansion.
• New players such as Novvi LLC, Biosynthetic Technologies, and Kraton are disrupting the market with biobased, food-grade, and non-toxic products.
• Simultaneously, Asian players such as Petronas (Malaysia) and SK Lubricants (South Korea) have penetrated the specialty process oils market.
• Frost Perspective:
• New competition and aggressive expansion of Asian players pose challenges for traditional oil manufacturers by potentially making the market highly competitive. APAC, especially China and India, is a high-growth market, intensifying competition.
• As a result, oil majors such as ExxonMobil, Shell, Chevron, TotalEnergies, and Nynas are shifting toward low-aromatic, high-performance, and bio-based process oils.
• Innovation, investment in sustainable products, and a strengthened supply chain, and presence in high-growth regions are essential considerations for market participants.

Scope of Analysis

• Process oils are specialized natural or synthetic lubricants used in the chemical and technical industries. They serve either as key ingredients in finished products or as processing aids for raw materials.
• Process oils offer several advantages over unprocessed oils, including enhanced stability, improved performance, and better compatibility with other materials. They are also more efficient in their applications, minimizing the need for frequent replacements. For example, rubber process oils enhance the processability and quality of rubber products, while green rubber process oils provide environmentally friendly alternatives to conventional rubber process oils.
• This report will focus on trends and disruptions and analyze new and upcoming trends in industries that are expected to drive demand for process oils.
• The study will complement Frost & Sullivan's recent market forecast report on the global lubricants market, which can be accessed through this

Competitive Environment

Number of Competitors

• 50+

Competitive Factors

• Customer sales support; proximity and/or consistency in supply; consistency in specifications; adherence to quality tests specified by end users, including quality tests for aromatic content and viscosity

Key End-user Industry Verticals

• Rubber processors and tire manufacturers, plastic manufacturers, pharmaceutical manufacturers, personal and home care producers, power companies, distributors

Leading Competitors

• H&R, Ergon, Nynas, Shell, Sinopec, Calumet, ExxonMobil

Revenue Share of Top 5 Competitors (2024)

• 25%

Other Notable Competitors

• IRPC, NX Nippon, Repsol, Gandhar Oil, IOCL, HPCL, Apar, Chevron, Phillips66, HollyFrontier (HF Sinclair)

Distribution Structure

• Direct sales and distributors

Key Competitors

White Oils

• Nynas
• Shell
• H&R Group
• ExxonMobil
• Chevron Corporation
• Calumet
• Apar Industries
• Gandhar Oil
• Raj Petro
• PetroChina
• Sinopec
• Petro Canada
• Sasol
• BP
• BPCL
• Sonnenborn

Savita Oil

• HollyFrontier (HF Sinclair)
• Rubber Process Oils
• H&R Group
• Nynas
• Shell
• Ergon
• ExxonMobil
• TotalEnergies
• Calumet
• Chevron Corporation
• Repsol
• PetroChina
• IOCL
• HPCL
• ENEOS Xplora Inc.
• HollyFrontier (HF Sinclair)

Transformer Oils

• Nynas
• Shell
• Ergon
• ExxonMobil
• Calumet
• Cargill
• Apar Industries
• Gandhar Oil
• PetroChina
• Valvoline Inc
• Sinopec
• San Joaquin Refining Co. Inc.
• IOCL
• Engen Petroleum

Growth Drivers

• The expansion of electrical grids will drive the power sector and, thus, transformer oil demand.
• The process oil market is gradually moving toward consolidation, with larger players expanding and acquiring niche companies.
• The global plastic market is forecast to record a 5.2% CAGR between 2021 and 2026 to reach $753.1 billion by 2026.
• Lithium-ion battery separators are expected to be the fastest-growing application for white oils.
• Developments in the tire industry, driven by high-performance tires and new materials, including natural rubber (latex) in tires, along with lower rolling resistance silica fillers, are a growth driver.

Growth Restraints

• Regulatory pressure and adherence to norms across end industries restrain the market.
• High investment costs, including product approval costs, for new entrants restrain the market.
• Technological advancements hamper the demand for conventional grades, especially for transformer oils.
• Rising focus on renewable power generation across regions, especially in Europe and North America, restrains the process oil market.