Lowering Friction: How Advanced Surface Coatings Save Energy, Cut Costs, and Boost Industrial Efficiency

When it comes to friction, Lars Pleth Nielsen is a man of many words.

"Friction depends on the characteristics of the surfaces – how flat, round or rough they are," says Pleth Nielsen, manager of the Tribology Center at the Danish Technological Institute. "Friction is also dependent on the medium the surfaces are in, whether it is wet or dry, or what particles are present. It is a multidisciplinary field that spans mechanics, chemistry, and fluid dynamics, requiring analysis down to the atomic level to fully understand what happens."

The Tribology Center develops surface coatings that reduce friction, corrosion, and wear across a wide range of applications. With a coating facility that operates seven days a week, the Center primarily supports Danish industry with customized solutions.

Pleth Nielsen has spent most of his career studying surfaces. He earned a Ph.D. in surface physics, focusing on the behavior of individual atoms on surfaces. Today, in addition to his work at the Institute, he serves as president of ENIWEP – the European Network for Industrial Wear Prevention.

ENIWEP is a EUREKA umbrella action dedicated to industrial wear prevention. The project enhances collaboration between industry and tribology research and accelerates the transfer of scientific discoveries into industrial technology.

One notable initiative is a joint project funded by Spain, Germany, and Belgium, where the team is developing low‑friction, diamond‑like carbon coatings for vacuum and space applications.

Pleth Nielsen notes that friction and mechanical wear account for an estimated 2–4% of a highly industrialized country’s GDP.

“We see wear, tear, and friction issues in major sectors such as food and automotive manufacturing,” he says. “Friction is a major reason why components have limited lifespans. While applying low‑friction coatings is an upfront cost, the long‑term benefits—higher quality output, extended tool life, and reduced maintenance—more than offset the investment. Many companies initially underestimate the hidden costs of friction until they realize the savings from advanced coatings.”

He cites a Danish tin‑can manufacturer as an example. Without coatings, folding and stamping tools wear out after just 30 minutes of production. With the Institute’s coatings, the tools can operate for several months without lubrication, eliminating the need for chemical lubricants and the water‑ and electricity‑intensive cleaning of the finished cans.

The Necessity of Friction

Friction is the force that opposes motion whenever two surfaces rub against each other. Although it can hinder performance, friction is essential for everyday tasks—walking, sitting, climbing stairs—because it prevents slipping.

Lowering Friction

Reducing friction is a key objective in many of Trelleborg’s solutions. In sealing applications, for instance, the sealing function must be achieved without excessive friction that would degrade system performance. Whether accelerating movement on an escape slide or optimizing tire performance on varied terrains, effective friction management is crucial.

In industrial settings where friction reduction can influence GDP, engineering sealing solutions and hoses focuses on achieving optimal friction characteristics through design and material formulation. Trelleborg has developed Turcon PTFE‑based sealing materials that improve efficiency in dynamic hydraulic applications, while the friction technology used in the Scirocco II hose demonstrably reduces costs in solid‑processing operations.

For more information, contact news@trelleborg.com or visit www.trelleborg.com.