EP2 grease — lithium 12-hydroxystearate soap thickener at NLGI 2 consistency with sulphur-phosphorus extreme-pressure additive package — is the most-used industrial and automotive grease in India by volume. Sold across PSU and private-label brands (Servo Gem EP2, Mak EP2, HP Lal Mohor EP2, Castrol LMX, Gulf 600 EP2, Shell Gadus), it covers roller bearings, plain bearings, chassis lube, agricultural machinery, light industrial gear and many automotive applications. This guide gives the complete recommended formulation (BOM), manufacturing process, BIS IS 7623 spec, and India pricing.
| Component | Function | % (m/m) | Indian Supplier |
|---|---|---|---|
| Group I SN500 base oil | Carrier base oil, viscosity 130-150 cSt @ 40 °C | 75.5% | IOCL / HPCL / IOCL Group I bright |
| 12-Hydroxystearic acid (12-HSA) | Fatty acid for soap formation | 9.0% | Croda / Godrej / Wilmar India |
| Lithium hydroxide monohydrate | Alkali for saponification | 1.5% | FMC / Albemarle / SQM Indian distributors |
| Sulphurised olefin EP (5-10% active S) | Extreme-pressure 4-ball weld additive | 3.5% | Lubrizol Anglamol 99 / Lubechem LC-EP-SULF-OLF |
| Mixed Pri/Sec ZDDP | Anti-wear, secondary AO | 1.5% | Lubrizol / Afton / Lubechem LC-AW-ZDDP-PCM |
| 2,6-DTBP hindered phenol AO | Primary oxidation inhibitor | 0.4% | BASF Irganox L57 / Songwon SongNox 1076 |
| Alkylated DPA aminic AO | Secondary AO synergist | 0.4% | LANXESS Naugalube 438L |
| Alkenyl-succinic acid (ASA) | Ferrous rust inhibitor | 0.5% | King Industries K-Corr 200 / LC-CI-ASA |
| Tolutriazole (TTA) | Yellow-metal CI | 0.05% | PMC Ouvry Cobratec TT-100 |
| Polyisobutylene tackifier (Mn 1300) | Adhesion + cohesion | 0.8% | BASF Glissopal / INEOS Indopol |
| Calcium nitrite | Vapour-phase rust inhibitor | 0.5% | Indian inorganic suppliers |
| Yellow dye | Visual identification | 100 ppm | BASF / Clariant pigments |
| TOTAL | 100.0% | — | |
Process notes: saponification at 195-205 °C, dehydration vacuum 130-140 °C, finishing additives below 110 °C, milling to NLGI 2. Final QC: dropping point 188-194 °C, working penetration 265-295, 4-ball weld 250-315 kgf, copper-strip D4048 1B. Ex-works cost ₹125-170 / kg at 5 MT batch.
| Property | Test Method | IS 7623 EP2 Spec | Lubechem LC-GR-LI-EP2 Target |
|---|---|---|---|
| Worked Penetration (60 stroke) | ASTM D217 / IS 1448 P-99 | 265-295 | 270-285 |
| Dropping Point | ASTM D2265 / IS 1448 P-65 | 180 °C min | 188-194 °C |
| 4-Ball Weld Load | ASTM D2596 | 250 kgf min | 250-315 kgf |
| 4-Ball Wear Scar (40 kgf, 1 hr) | ASTM D2266 | <0.60 mm | 0.40-0.50 mm |
| Timken OK Load | ASTM D2509 | Report | 40-50 lbf |
| Copper Strip Corrosion @ 100 °C / 24 hr | ASTM D4048 | 1B max | 1A-1B |
| Water Washout @ 79 °C | ASTM D1264 | 15% max | 5-10% |
| Oxidation Stability (100 hr @ 99 °C, O2 bomb) | ASTM D942 | 40 kPa drop max | 20-30 kPa |
| Roll Stability Change | ASTM D1831 | Report | <15% |
| Base Oil Viscosity @ 40 °C | ASTM D445 | Report | 130-180 cSt |
EP2 grease is the most-used industrial and automotive grease in India — lithium 12-hydroxystearate soap thickener at NLGI 2 consistency (working penetration 265-295) with sulphur-phosphorus extreme-pressure additive package. Dropping point 185-195 °C, base oil viscosity 130-180 cSt at 40 °C.
Used in roller bearings, plain bearings, chassis lube points, agricultural machinery, light industrial gear and many automotive applications. Sold by IOCL Servo (Servo Gem EP2), BPCL Mak (Mak EP2), HPCL (HP Lal Mohor EP2), Castrol (LMX EP2), Gulf, Shell and 100+ private-label brands. BIS IS 7623 covers the spec.
NLGI 2 lithium 12-OH EP grease recommended BOM (% by weight): Group I SN500 base oil 75.5%, 12-hydroxystearic acid 9.0%, lithium hydroxide monohydrate 1.5%, sulphurised olefin EP (5-10% active S) 3.5%, ZDDP AW 1.5%, phenolic antioxidant 2,6-DTBP 0.4%, aminic antioxidant alkylated DPA 0.4%, alkenyl-succinic-acid corrosion inhibitor 0.5%, tolutriazole 0.05%, PIB tackifier Mn 1300 0.8%, calcium nitrite 0.5%, yellow dye 100 ppm.
Saponification temperature 195-205 °C; dehydration 130-140 °C; finishing 110 °C. Working penetration 265-295, dropping point 188-194 °C, 4-ball weld 250-315 kgf, copper strip 1B.
NLGI grade is the consistency (working penetration). EP000 is liquid-like (445-475 penetration) — used in centralised lubrication systems and as gear lube. EP00 is semi-fluid (400-430) — also centralised systems and worm gear. EP0 (355-385) — soft grease for low-temperature start. EP1 (310-340) — softer general-purpose. EP2 (265-295) — the standard industrial grease. EP3 (220-250) — stiffer, for high-speed bearings.
Same lithium 12-OH soap + EP chemistry, just different soap percentage to give different consistency. EP2 uses ~9-12% soap; EP000 uses ~5-7% soap.
BIS IS 7623 specifies 4-ball weld load (ASTM D2596) ≥ 250 kgf for EP2 grease. Premium industrial EP2 targets 315-400 kgf. Achieved by sulphurised olefin EP additive (3-5% in finished grease, giving 1.5-2.5% active sulphur), often co-formulated with phosphate ester or Mo-DTC for additional EP synergy. 4-ball wear (D2266) target wear scar < 0.55 mm. Timken OK Load (D2509) target 40+ lbf for premium EP2.
Lithium 12-hydroxystearate soap melts around 190-200 °C — dropping point (ASTM D2265) is the temperature at which the grease structure breaks down and oil drops. Lithium 12-OH is intrinsically a 200 °C-grade thickener. Operating temperature recommendation is dropping point minus 30 °C — so EP2 lithium grease is good for continuous service up to 130 °C, with brief excursions to 160 °C.
For higher operating temperature, lithium complex (drop >260 °C, service to 150-180 °C continuous) or calcium sulfonate complex (drop >300 °C, service to 180-200 °C continuous) is used.
Branded EP2 grease retail (Castrol LMX, Shell Gadus, Gulf 600 EP2) ₹220-340 / kg in 18 kg pail or 180 kg drum. PSU brands (IOCL Servo Gem EP2, BPCL Mak EP2, HPCL Lal Mohor EP2) ₹180-250 / kg. Regional private-label and aftermarket ₹140-200 / kg.
Lubechem custom EP2 (LC-GR-LI-EP2) ex-works ₹125-170 / kg for 5+ MT batches — depending on base oil grade and EP package selection. Margins typically ₹40-80 / kg between blender ex-works and aftermarket retail.
IS 7623:1993 (reaffirmed) is the Indian Standard for 'Industrial Multipurpose Grease' covering NLGI 1, 2, 3 lithium grease (with and without EP additive). Specifies dropping point (180 °C min for non-EP, 180 °C for EP), worked penetration range, 4-ball weld load (250 kgf for EP2), copper strip corrosion (1B), water washout (D1264) <15%, oxidation stability D942 pressure drop <40 kPa.
BIS certification mandatory for selling under BIS-registered channels; testing at BIS-listed labs (IIP Dehradun, CPCL, IOCL R&D Faridabad, HPCL Bangalore). Cost ~₹5-12 lakh per grade test.
Share your target volume (MT/year), brand positioning (PSU-equivalent / private-label / premium), and BIS IS 7623 requirement. We respond within one business day with the BOM, process SOP and indicative cost.