Brake Fluid Manufacturing Plant
High-Precision Brake Fluid Plants for Automotive & Industrial Use
Brake fluids are the lifeblood of every modern vehicle’s hydraulic braking system. They transmit force from the brake pedal to the wheel cylinder, enabling effective braking under high temperatures and pressures. The manufacturing of high-quality brake fluid requires precision in blending, strict moisture control, and advanced formulation technology to meet international standards such as DOT 3, DOT 4, DOT 5, and DOT 5.1.
Liuminex Projects and Equipments Pvt. Ltd. designs and supplies complete Brake Fluid Production Plants — from raw material handling to final packaging. Our turnkey systems ensure high product purity, consistent viscosity, and compliance with SAE J1703, ISO 4925, and other automotive-grade quality standards.
With decades of chemical process experience, Liuminex plants are engineered for energy efficiency, automation, and scalability, catering to both small-batch and large-scale brake fluid producers worldwide.
Types of Brake Fluids Produced
Liuminex plants are capable of producing all major categories of brake fluids used across automotive and industrial applications:
DOT 3 Brake Fluid (Glycol-based)
Widely used in passenger cars and light commercial vehicles.
Made primarily from glycol ethers and polyglycols.
Offers reliable performance under moderate temperatures.
DOT 4 Brake Fluid
Enhanced with borate esters for improved thermal stability.
Suitable for high-performance and heavy-duty vehicles.
Higher boiling point and lower moisture absorption.
DOT 5 Brake Fluid (Silicone-based)
Non-hygroscopic (does not absorb water).
Used in specialty and military vehicles.
Compatible with rubber and metal components, but not with glycol-based systems.
DOT 5.1 Brake Fluid (Advanced Glycol Blend)
Combines high boiling point with glycol-based compatibility.
Used in performance vehicles and ABS-equipped systems.
Each fluid type demands precise blending ratios, moisture control, and filtration to achieve the required boiling point, viscosity, and chemical stability — areas where Liuminex engineering ensures absolute precision.
Raw Materials Used in Brake Fluid Production
Brake fluid manufacturing involves the careful selection and handling of the following raw materials:
Glycol Ethers (e.g., Triethylene Glycol Monomethyl Ether)
Polyglycols and Polyalkylene Glycols
Borate Esters (for DOT 4 fluids)
Silicone Oils (for DOT 5 fluids)
Corrosion Inhibitors and Stabilizers
pH Modifiers and Antioxidants
Deionized Water (strictly controlled to avoid contamination)
All raw materials are metered precisely using load cells, dosing pumps, and automated valves to ensure consistent blending and repeatable batch quality.
Brake Fluid Production Process
The manufacturing process in a Liuminex Brake Fluid Production Plant follows a sequence of controlled chemical blending and purification steps designed to maintain high product integrity.
1. Raw Material Preparation and Storage
Raw materials are stored in stainless-steel or FRP tanks equipped with nitrogen blanketing to prevent oxidation and moisture ingress.
The materials are pre-filtered to remove impurities.
2. Precise Metering and Charging
Each ingredient is charged into the blending vessel through automated dosing systems.
Load cell feedback ensures accurate measurement as per recipe data.
3. Blending Process
The core operation involves homogeneous mixing of glycols, borate esters, and additives under controlled temperature and agitation.
Liuminex reactors feature variable-speed agitators, jacketed vessels, and PLC control for temperature, time, and torque.
4. Dehydration and Vacuum Treatment
Brake fluid is highly sensitive to moisture.
The mixture undergoes vacuum dehydration at controlled temperatures to remove dissolved water vapor.
This step ensures low water content (<0.05%), critical for maintaining high boiling points.
5. Filtration and Polishing
Fine filtration (typically 1–5 micron) removes particulates and ensures optical clarity.
Liuminex offers multi-stage filtration systems with stainless steel filter housings.
6. Quality Testing and Analysis
Every batch is tested in the in-house lab for:
Boiling point (dry and wet)
Viscosity at various temperatures
pH value
Corrosion resistance
Compatibility with rubber and metal parts
7. Storage and Packaging
The finished fluid is stored in inerted holding tanks.
Automatic filling machines package the product into bottles, cans, or drums under nitrogen-purged conditions to prevent contamination.
Labeling and coding systems ensure full traceability.
Major Equipment in Brake Fluid Production Plant
Liuminex designs and supplies a full range of process equipment optimized for brake fluid manufacturing:
Stainless Steel Storage Tanks (with heating/cooling jackets)
Precision Dosing Systems
Mixing and Blending Reactors (jacketed, with agitators)
Vacuum Dehydration Units
Heat Exchangers and Condensers
Inline Filtration Systems
Automatic Filling and Packaging Machines
PLC/SCADA Control Panels
Nitrogen Purging and Inerting Systems
Laboratory Testing Units
Each system is built with 316L stainless steel to resist corrosion from glycol-based chemicals and ensure long operational life.
Plant Automation and Control
Liuminex plants feature state-of-the-art PLC and SCADA-based control systems for:
Recipe management and batch tracking
Automatic dosing and mixing
Real-time monitoring of temperature, pressure, and vacuum
Safety interlocks and alarm systems
Data logging for regulatory compliance
This automation ensures uniform product quality, reduces human error, and enables remote monitoring through IoT integration if required.
Plant Equipment & Flow
Equipment | Description |
Base Glycol Tank | Storage of glycol ethers and polyalkylene glycol base |
Additive Dosing System | Accurate addition of corrosion inhibitors and boosters |
Blending Reactor (SS316) | Heated mixing with tight temperature control |
Vacuum Dehydration System | Removes water content to <0.1% (as per standards) |
Filtration Unit | Ensures product purity and prevents particulate ingress |
Cooling & Storage Tanks | Post-blending product stabilization and holding |
Packaging Machine | Bottle, drum, or pouch filling with anti-drip nozzles |
PLC/SCADA Control Panel | Automated batch control, data logging, alarms |
Technical Specifications
Parameter | Specification |
Plant Capacity | 500 Litres/day to 25,000 Litres/day |
Heating Method | Electric or Thermic Fluid |
Moisture Control | ≤ 0.1% (via vacuum dehydration and dry nitrogen blanketing) |
Material of Construction | SS 316 / SS 304 / Non-ferrous contact parts |
Automation | Manual / Semi-auto / Fully automated with SCADA |
Packaging Options | 100 ml to 200 L drums |
Compliance | SAE J1703 / J1704, ISO 4925, FMVSS 116 |
Safety and Environmental Features
Brake fluid contains chemicals that must be handled with care. Liuminex ensures compliance with ISO 14001, OSHA, and ATEX standards through:
Closed system design to prevent vapor emissions
Flameproof motors and control panels in hazardous areas
Nitrogen blanketing in tanks to prevent oxidation
Spill containment and effluent treatment systems
Explosion-proof ventilation and scrubbers
Safe material transfer using diaphragm or magnetic-drive pumps
Environmental safety is built into every stage of plant design — from solvent recovery to wastewater treatment — ensuring minimal ecological footprint.
Quality Assurance and Compliance
Each plant is equipped to produce brake fluid that meets:
SAE J1703 / J1704 standards
ISO 4925 (International Standard for Brake Fluid)
FMVSS No. 116 (Federal Motor Vehicle Safety Standard)
Liuminex also assists in developing SOPs, QC protocols, and operator training to help clients achieve certification and maintain consistent quality.
Key Features
- Ultra-low moisture blending with nitrogen purging
- Closed-loop system to avoid contamination
- Precise heating and agitation for high batch consistency
- Inline quality control sampling & lab interface
- CIP-ready for fast product changeover
- Integrated packaging unit: automatic capping & labeling
- Explosion-proof electrical panels (optional)
Applications
Brake fluid produced in Liuminex plants is widely used in:
Passenger cars and commercial vehicles
Motorcycles and electric vehicles
Heavy trucks and off-road machinery
Military and aviation braking systems
Hydraulic clutch systems
The modular design of our plants allows easy customization for specific formulations or market segments.
Advantages of Liuminex Brake Fluid Production Plant
Turnkey Solutions: From design and engineering to installation and commissioning.
High Purity Output: Achieved through vacuum dehydration and closed-loop filtration.
Automated Operation: PLC-controlled system reduces labor and improves precision.
Custom Capacity: Available from 500 LPH pilot plants to 10,000 LPH industrial lines.
Energy Efficient: Optimized heating, cooling, and mixing systems reduce operational costs.
Compact Footprint: Modular skids designed for easy installation and expansion.
Comprehensive Documentation: Includes P&IDs, 3D models, electrical drawings, and operating manuals.
Global Support: Remote monitoring, after-sales service, and spare parts assistance.
Liuminex stands as a trusted partner to automotive chemical producers worldwide, combining engineering excellence with process reliability.
Optional Add-ons
Automated Filling & Capping Line
Labeling and Barcode Printing Units
Laboratory Setup and Testing Equipment
Data Acquisition and Batch Report Systems
Fire Protection and Emergency Venting Systems