In developed countries like the USA, approximately 80% of households own a spray lubricant. The products are ubiqutious and versatile, however their performance relies on petroleum-derived solvents that contribute to volatile organic compound (VOC) emissions, environmental persistence, and potential human health hazards. This project challenged the team to explore safer, bio-based alternatives to the hydrocarbon solvents that power WD-40’s signature functions—lubrication, penetration, moisture displacement, and corrosion protection.
Using a green chemistry framework, the team worked with WD-40 to evaluate candidate solvents for technical performance, environmental fate, and human health hazards. Compatibility with existing lubricants was assessed using Hansen Solubility Parameters and Flory-Huggins modeling, while hazard profiles
The analysis identified three pathways for reformulation. Strategy 1 explores bio-derived “drop-in” hydrocarbons produced through fermentation that could replace petroleum feedstocks with minimal reformulation. Strategy 2 introduces moderately polar solvents—such as β-farnesene and ethyl acetate—that biodegrade more readily and reduce persistence and carcinogenic risk. Strategy 3 proposes a deeper redesign, pairing highly biodegradable solvents like ethanol or ethyl lactate with plant-derived lubricants and emulsifiers to create a fully bio-based formulation.
Together, these findings show that safer, renewable solvent systems could replace petroleum-based chemistry in multi-use lubricants, though the greatest environmental benefits come from approaches that move beyond simple drop-in replacements toward full formulation redesign.