Running leaner and greener – the importance of HGV emissions system maintenance

Anthony Greatwood, Director of Sales and Marketing at DPF cleaning and remanufacturing specialist, Ceramex, examines the role of emissions system maintenance in reducing HGV operating costs

As HGV operational costs continue to escalate for transport operators, the need to mitigate this financial impact in terms of minimising fuel consumption and unscheduled maintenance remains a major priority, alongside the requirement to ensure ongoing compliance with Euro VI emissions regulations.

All Euro VI trucks are fitted with diesel particulate filters (DPFs) as part of the vehicle’s exhaust after treatment system (EATS), which prevents noxious particulate matter, such as soot and ash, from entering the atmosphere.  Although soot deposits are largely removed automatically by a continuous regeneration process, non-combustible ash also accumulates in the DPF over time.  This substance needs to be removed from the DPF ‘off-vehicle’ at regular intervals, using a specialist procedure such as Ceramex’s patented Xpurge^® cleaning process to avoid the unit becoming blocked.  A saturated DPF quickly loses its effectiveness and immediately causes a reduction in engine performance.  In-depth research by Ceramex has found that a saturated filter is likely to result in a minimum 2% increase in fuel consumption, compared to the operation of a clean filter.

When the volume of soot and ash inside a DPF increases, the back pressure rises, which produces a higher load on the engine to force the exhaust gases through the DPF.  This uses more fuel and can also cause excessive stress to the engine and emissions system, increasing the potential for a breakdown, subsequent downtime and the need for expensive component replacement.

In the event that 20% of a DPF becomes blocked by soot and ash, for example, the remaining 80% of a filter’s capacity works harder to remove these noxious exhaust contaminants.  This causes the DPF to be placed under greater pressure with the increased possibility of the unit failing.

Processing some 2,000 HGV DPF units per week from its 67,000 square-foot facility in Reading, Ceramex provides HGV fleets with an exchange-based service, where batches of dirty DPFs are collected from customers in the UK and overseas and replaced with fully cleaned and remanufactured ‘truck ready’ units, on a scheduled basis.  This fast turnaround, contract-based approach, minimises vehicle downtime and offers customers value through economies of scale and a planned approach to DPF cleaning, which ensures vehicles run efficiently.

Ceramex’s Xpurge^® cleaning process, which uses an innovative combination of de-ionised water and compressed air, removes accumulated soot and ash deposits within the DPF.  Xpurge^® collects the particulate matter in aqueous suspension, which eliminates any risk of noxious particulates entering the atmosphere.  This process is unique to Ceramex across the world.  After cleaning, Ceramex’s patented Veritex^® technology provides a detailed internal inspection of the DPF, to prove the results of the cleaning process and give customers reassurance as to the quality of the returned filter.

Taking an environmentally responsible approach to waste removal and disposal, Ceramex is also the only specialist HGV DPF cleaning provider which has an onsite treatment plant that safely removes the particulate matter from the water.  The solid matter is safely disposed of by a government licensed third party, in accordance with environmental regulations.

Ceramex DPF cleaning provides HGV operators with a cost-effective and sustainable solution to keeping their trucks operating efficiently throughout their service life.  To find out more, please get in touch