The demands from OEMs regarding decarbonization and compliance with regulations like CSRD are not future trends; they are current business requirements.
In this context, innovation is not about finding mere substitutes but about identifying engineering solutions that offer a tangible competitive advantage. Today, I want to analyze a specific business case that illustrates how a strategic decision in formulation can have a radical impact on profitability, performance, and market positioning.
Let’s consider a brake pad production plant, a familiar scenario for many of us. This plant consumes 300 tons of steel fiber per year for its “Low Steel” formulations. In these formulations, steel fiber typically accounts for about 10% by weight and 25% by volume of the friction material.
The engineering proposal is as follows: replace 50% of the volume of that steel fiber with r0_vein C, a high-performance functional additive derived from the circular economy.
The key here is the replacement by volume, a technical decision based on the different densities of the materials:
By making this change, we are not just swapping one material for another; we are redesigning the pad’s composition to unlock a series of competitive advantages.
From the manufacturer’s perspective, this substitution translates into three pillars of value that directly impact the business, starting with raw material management.
From a raw materials perspective, the economic benefit is immediate. By replacing 50% of the steel fiber’s volume, the lower density of r0_vein C results in a significant reduction in the total mass of the fibrous component needed.
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The substitution of 150 tons of virgin steel with a second-life material like r0_vein C has a massive environmental impact.
By adopting materials from the circular economy, the company not only responds to current demands but also anticipates future regulations (ESPR, DPP), ensuring the product’s long-term competitiveness.
While the savings on raw materials are compelling, the true engineering value is realized in the final product. In a standard friction material (puck) where steel fiber accounts for about 10% of the weight, this reformulation delivers significant improvements.
By substituting half of the steel fiber’s volume, we achieve a notable 18% weight reduction in the fibrous component of each pad. This directly translates into a lighter end product, making the friction material itself nearly 2% lighter.
This consistent weight reduction, while seemingly small per unit, represents a substantial cumulative impact across a production line manufacturing millions of pads annually. It’s a direct and efficient contribution to the automotive industry’s critical goal of vehicle lightweighting, essential for improving overall efficiency and range.
“For years, we’ve treated formulation changes as incremental adjustments. What this data shows is a paradigm shift. By strategically replacing steel fiber with a functional additive like r0_vein C, we’re not just tweaking a formula; we’re fundamentally upgrading the final product. We’re delivering a lighter, more sustainable, and cost-effective brake pad without compromising performance. This is the kind of multi-faceted innovation the market is demanding.”
As the data shows, the integration of r0_vein C is not a simple raw material change. It is a comprehensive technological upgrade of the product.
From a business perspective, the result is a superior brake pad that can be manufactured at a lower cost (thanks to savings in the fibrous component), with an unparalleled sustainability value proposition and improved technical performance through weight reduction. This is the most efficient and strategic path for any manufacturer looking not just to compete, but to lead in the new era of the friction industry
