AUTONEWS

Brembo invents less polluting brake disc

Brembo, a specialist in braking systems, does not limit itself to equipping all F1 World Cup cars, as it also produces discs and brake pads for most sports cars on the market. However, this Italian company is also concerned about the dust caused by the friction of the pads on the discs, which is why it has invented a system it calls Greentell, which reduces brake dust by 90%, the black dust that dirties the wheels and also affects the lungs.

If combustion engines produce polluting emissions, some of which are carcinogenic, they are not the only part of a car that poses a risk to public health. Tires break down due to friction on the asphalt, releasing millions of microplastic particles that end up being ingested by the animals we eat and then ending up in the bodies of human beings. Brake dust is even more harmful to health, as its very small particles penetrate deep into the lungs, causing more harm to health than the particles released by combustion engines.

Until now, the only pollutant emissions that were limited were those caused by engines that burn fossil fuels, but the reality will change with the introduction of the Euro 7 standard, which will also limit brake emissions. Originally, Euro 7 was scheduled to be implemented in mid-2025, but at the request of car manufacturers competing for the European market, it was delayed until November 29, 2026, prohibiting vehicles from producing more than 7 mg per kilometer, a figure that will drop to just 3 mg/km from 2035.

Brembo's Greentell system aims to reduce the production of very fine particles resulting from the wear of the brake discs, but especially of the brake pads, from the friction needed to stop the car. The advantage of Brembo's solution is the disc, or more precisely, the treatment of its friction surface, which the Italian manufacturer achieves using Laser Metal Deposition, a method that consists of depositing powdered metals on the surface of the disc, heated brutally by a laser beam. To make this work perfectly, the Italian technicians say they have developed a double layer of coating for the disc, which includes a “secret” alloy developed by Brembo.

According to the WLTP method, which we already use to determine the consumption and emissions of modern vehicles and which will soon be used to assess emissions of toxic brake dust, brakes release 20% of all finer particles into the air, substantially more than the 7% emitted by combustion engines. Brembo confirms that Greentell reduces brake dust emissions by 90%, which is good for health. At the same time, the innovative system increases the lifespan of the brake discs by 80%, which in turn are thinner (and lighter) than traditional cast iron discs, with the Italian brake specialist estimating that they can last 20% to 30% longer than conventional systems, which also includes the pads.

A logo engraved on the disc is a simple, easy-to-use wear indicator and proof of early replacement suggestions (Photo: Brembo)

One of the merits of the project is the synergy between the disc and the pad. The disc, which is nickel-free and has a double coating applied using laser deposition technology (Laser Metal Deposition), is much more resistant to corrosion. It can be used in a variety of configurations: integral, floating, double cast and lightweight discs. The system works in conjunction with a dedicated pad, developed to make the most of the surface's durability and preserve braking performance. According to Brembo's own bench tests, wear is significantly lower compared to traditional cast iron discs. This is good, as it will require fewer replacements.

Another detail that I found interesting is the visual Easy Check system, a practical solution that indicates, by the disappearance of the logo engraved on the disc's braking track, when it is time to replace it. It is the kind of detail that makes sense: simple, functional and visible, without electronics, without complications. Furthermore, Brembo has already approved the system as Original Equipment (OE) for a wide range of vehicles.

All of this was validated by a Life Cycle Assessment study, audited by third parties, which indicates a reduction in environmental impact of up to 85% compared to traditional systems. In a sector increasingly pressured by responsibility and efficiency, this is no small statistic. And without the need for many sacrifices from consumers, except for a slight impact on costs and consequently on prices.

With the Greentell Set, Brembo has managed to show that it continues to be a reference.

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