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New hybrid vehicle White Paper released as part of NEXCEL’s CO2-reducing technology drive

October 4, 2018


  • New White Paper outlines hybrid development opportunities using Nexcel technology

  • Testing of conventional powertrains demonstrates Nexcel potential to reduce CO2 emissions by 2 g/km

  • 2018 Toyota Prius development vehicle demonstrates Nexcel packaging flexibility

Castrol’s innovation business, Nexcel has released its new white paper on hybrid development. ‘Challenges and Opportunities for the Development of Hybrid Electric Vehicles: a Unique Perspective from Nexcel’ outlines the future landscape for CO2-reducing technologies and systems integration and provides insights into how Nexcel technology can add value to future hybrid designs. At the recent Cenex-LCV event 2018, the company displayed its 2018 Toyota Prius plug-in, which is fitted with a Nexcel oil cell and dock to showcase the modular packaging benefits of its innovative active oil management system, which during recent testing demonstrated its potential to reduce CO2 emissions by 2 g/km, for a wide range of conventional powertrain configurations.


“Nexcel is committed to reducing vehicle emissions, for which hybrid technology is a crucial enabler,” says Nexcel sustainability director, John Ward-Zinski. “Our 2018 Toyota Prius demonstration vehicle is the first hybrid to be adapted for use with our active oil management system, demonstrating that even the most restrictive packaging limitations are not a barrier to adoption of this technology. The benefits offered by Nexcel perfectly complement the environmental performance of existing and emerging powertrain technologies, and there was a great deal of interest shown in what we are doing at Cenex-LCV. The Nexcel stand was constantly busy”.


Tests of Nexcel’s proprietary technology, which were conducted across three different conventional engine types, demonstrated the system’s potential to reduce CO2 emissions by 2 g/km. This is delivered by ensuring precise oil-engine match, accelerating the engine warm-up procedure and promoting enhanced efficiency of the engine’s inherent design.

The anticipated cost for each gram of CO2 saved with Nexcel is around €42(1), similar to the cost per gram of CO2 for a micro hybrid (stop-start plus regenerative braking) and approximately half the cost per gram for one of the most popular new technology strategies, a mild hybrid system(2).


“Using data from the European Commission’s 2017 Impact Assessment of Upcoming CO2 Regulations,(2) we have established that Nexcel is one of the most affordable routes to CO2 reduction which will help passenger cars meet the Commission’s demanding 2021 European fleet average target of 95 grams of CO2 per kilometre,” states Nexcel business development director, Ben Russell. “Nexcel will be able to offer significant CO2 reduction at a price that is broadly equivalent to the adoption of electric power assisted steering (EPAS), which a few years ago was considered a radical evolution of the proven system, yet today it is almost ubiquitous.”


“Challenges and Opportunities for the Development of Hybrid Electric Vehicles: A Unique Perspective from Nexcel” is available on request from Nexcel’s website (



1€42/g is Nexcel’s estimate for an initial high-volume application based on a combination of bill of materials and manufacturing costs. €21/g is Nexcel’s indicative target for a high-volume application with further economies achieved through increased levels of integration with the vehicle early in the design.

2The European Commission’s 2017 impact assessment of upcoming CO2 regulations is available here, with the data referred to on page 30.

Discover more about the NEXCEL active oil management system in these press releases



Richard Gotch
+44 (0)1295 277050 (office)  /   +44 (0)7831 569 732 (mobile)


Nevil Hall

44 (0)1295 277050 (office)   /    +44 (0)7711 861662 (mobile)

NEXCEL Background Information

NEXCEL automotive application is a self-contained, sealed cell that contains the correct grade of oil and specification of filter. Designed for flexible installation anywhere in the engine bay via a docking station, it is managed by a dedicated electronic control unit that communicates with the vehicle via the standard databus. An electric pump controls the flow of oil between the engine sump and the remote cell and an oil analysis capability can be integrated. By reducing the volume of oil in the engine, the NEXCEL system has been developed to allow faster warm-up of the engine oil, which can reduce tailpipe CO2 emissions.


Containing the oil within a sealed cell also makes recycling of old oil a much more practical option because it eliminates contamination by other fluids during the drain and recovery operation. NEXCEL units can remain sealed up to the point of re-refining, allowing the oil to be returned to its original specification. Changing the cell takes just minutes. For garages, the benefits also include the elimination of spills and greatly simplified oil recovery. NEXCEL’s closed ecosystem could help to eliminate some of the one third of drained engine oil (worldwide) that currently disappears into the environment.


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