Valvoline FlexFill Gear Oil Squeezes Innovation Into Every Drop

Thanks to a new squeezable design, the Valvoline FlexFill pouch makes quick and clean work of routine gear oil changes. Learn more about the people behind the packaging, and what it takes to bring an innovation like this to market.

Much like oil changes and tire inspections, differential service is a critical part of a vehicle’s regular maintenance needs. Neglected differential fluid can lose integrity, causing a subsequent decrease in performance and component life.

While changing out the gear oil is a pretty simple job, it is undoubtedly messy.

Because the differential lives under the car, there’s rarely enough clearance to easily pour in fresh fluid. Oil must be pumped up and in, usually via an extension hose or pump device. This can be cumbersome and, well, since you can’t beat gravity, it can also be a great way to ruin a perfectly good shirt.

“There must be an easier way.”

Peruse enough automotive forums and you’ll find a variety of sworn-by homemade “solutions,” from super syringes to garden sprayers. No disrespect to plucky ingenuity, but none of these hacks solves the underlying problem.

“Traditional gear oil packaging was making a very easy task pretty difficult to complete,” says Tracie Mayo, Senior Brand Manager at Valvoline. “It was really just a no-brainer for us to innovate in this space and make it easier for end-users.”

Along with a talented group of packaging designers and marketing professionals, Mayo helped develop FlexFill. This clever, squeezable pouch makes quick and easy work of applying gear oil – even in tight spaces. The result is less waste, less headache, and a job well done.

Valvoline FlexFill Full Synthetic Gear Oil

Formulated for ultimate protection and performance, FlexFill comes in two full synthetic grades for exceptional wear and high/low temperature protection: 75W – 90 and 75W – 140.

The all-in-one solution helps provide outstanding thermal stability for cleanliness and longer service life.

• Extreme Pressure Additive ensures better load carrying capacity and wear protection.
• Excellent Thermal Stability protects oil from high-temperature breakdown.
• Anti-Foam Agent helps prevent foaming of fluid for continued lubrication.
• Contains Limited Slip Additive to protect and enable clutches in such drivelines.

More Than Meets the Eye

Ever since Capri Sun introduced us to the pure joy of jabbing an orange straw through a foil squeeze pouch, this style of packaging has proven its endurance in the consumer marketplace. Easy to handle and intuitive to use, it’s a wonder it took so long for these innovative squeeze bags to enter the automotive sphere.

Despite its straightforward design though, Mayo says a lot of blueprinting went into FlexFill’s development – not to mention what sounds like some seriously fun stress tests. Valvoline packaging engineers had to consider everything from the bag’s structure and material, to its seal and tip, to how the product lays in a box, sits on a shelf, and ultimately, performs when squeezed into service.

The process is just that – a process.

“There really is quite a bit of engineering that needs to take place,” Mayo says. “When you’re moving to this type of packaging, there are a few priorities to consider.”

Put Through Its Paces

A top concern for Valvoline was how FlexFill performed during drop testing. Whether the bag was sitting in a retail store, warehouse, or service bay, the company needed to be sure if it accidentally fell to the floor, it wouldn’t explode. Mayo says engineers performed a variety of vigorous tests where they dropped both individual bags and entire cases of product from designated feet to ensure the package could withstand the fall.

Another concern was puncture resistance. Often, during shipping, a variety of items end up in the same box. A FlexFill bag (or two) could share space with heavy pieces of machinery or a sharp-edged product. “We wanted to make sure that, again, there’s no oil on the floor,” Mayo says. (That said, you should put down the utility knife if you know a box contains FlexFill.)

Engineers also needed the bag to maintain the exact same retail footprint as its predecessor. Basically, FlexFill had to sit comfortably in the same shelf space as the older cone-topped bottle designs. This challenging parameter dictated much of the bag’s structure, encouraging packaging experts to think creatively.

“They really leaned into how the top seals with the bag,” Mayo says. “There are actually 2-3 layers to the bag itself – like a film that layers together with nylon and other pieces – and that ensures the seal at the neck (which is where we would typically see leakage occur) will not leak.”

A Note on Recycling

While Valvoline’s FlexFill uses less plastic than traditional cone-top bottles, the package itself is not recyclable because it contains oil. “But we’re working on that!” says Mayo excitedly.

She points out the National Lubricant Container Recycling Coalition or NLCRC, which is actively exploring ways to recycle motor oil bottles, gear oil bottles, and other traditionally non-recyclable containers. “Valvoline is a member of the coalition and has a few different tests going on in different markets, so we hope to find sustainable solutions sooner than later,” she says.

Click here to learn more about some of the cool pilot programs the NLCRC has in motion, and what it – and its partners – are doing to cut down on automotive waste.

Fresh New Look

After myriad tests and multiple prototypes, Valvoline’s new squeeze pouch was ready for branding. Mayo and her team settled on the name “FlexFill” because they felt it gave the clearest indication of what the bag does. They then determined what the benefits of the bag would be – Easy to Use, Less Waste, Works in Tight Spaces – as well as the benefits of the oil in the package.

“I think it works really well. Consumers have been very responsive,” she says.

Looking ahead, Mayo encourages automotive enthusiasts and professionals alike to keep an eye out for Valvoline’s new Extended Protection Full Synthetic Motor Oil. With 10x stronger thermal resistance and 50% better wear protection, the formulation provides the necessary extra protection demanded by modern engines.

“We’re also working on motor oils specially formulated for hybrid engines,” Mayo says. “So, expect to see us launch that new product in the next 3-4 months.”

Interested in learning more about how Valvoline’s gear oil formulations keep transmissions and differentials operating smoothly? Not too long ago, we sat down with some very smart folks at the company to talk all things gear oil – namely, what it is, why it’s important, and how it’s evolved. You can check out that article HERE. Find the right Valvoline product for your vehicle by visiting https://www.valvoline.com.