The biggest drawback to using synthetic base oils is the additional cost associated with them. They may be anywhere from three to 15 times more expensive than mineral oil. If you are considering making a switch from mineral to synthetic oils, you must be sure that the benefits to be realized will make up for the additional front-end cost. There are several ways in which this cost can be recouped, such as extending oil change intervals, employing product consolidation or decreasing machine failures.
Another risk with synthetic fluids is the compatibility issues that come with using these lubricants. Some synthetics have been known to cause seals to swell and reduce lubricant flow, while others can dissolve seal materials, allowing leaks and possibly severely damaging the machine.
Not only do some synthetics have compatibility issues with seals, but most have compatibility issues with other fluids. Polyalkylene glycol (PAG) base oils are notorious for their incompatibility with mineral oils, although oil-soluble PAGs (usually called OSPs) largely remedy this drawback. In the event that mineral oils and PAG oils form an incompatible mix, the result is a gelatinous mass that clogs lines and can lead to lubricant starvation and ultimately machine failure. Other incompatibilities for synthetics include paints, hose materials and some additives.
Synthetic esters such as phosphate esters, polyol esters and di-esters are also at risk for hydrolysis. Hydrolysis is a water-induced chemical reaction that can cause a rise in acid number, loss of viscosity and an increase in varnish potential.
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