Optimization Starts with Emissions Best Practices

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Optimization Starts with Emissions Best Practices
By Ceramex North America LLC. | May 1^st, 2025 | 6-min read

The aftertreatment system is essential for helping heavy-duty diesel engines meet emissions regulations. Diesel Particulate Filters (DPFs) and Diesel Oxidation Catalysts (DOCs) are critical components—and if neglected, they can lead to costly repairs, increased fuel consumption, and regulatory issues.

At Ceramex North America, we specialize in professional restoration of DPFs and aftertreatment components to help fleets maximize uptime and minimize operating costs. Below are five best practices for maintaining these vital components.

1. Application Affects Your Service Interval

Fleets operate under different conditions. Terrain, idle time, payload, and driving style all affect how quickly soot and ash build up.

• Severe-duty applications, such as refuse, delivery, or construction vehicles, typically require more frequent cleanings.
• Over-the-road fleets benefit from steadier operation and may have longer intervals between services.

What to do:
Establish a customized maintenance schedule based on real-world operating conditions—not the OEM guidelines. Use diagnostic tools to monitor soot load, backpressure, and regeneration frequency to fine-tune service timing.

Learn more about application-specific service planning by contacting one of our emissions experts.

2. Understand Your Emissions Components

Today’s emissions systems are complex and include multiple components. A single ongoing component failure can impact the entire system.

• Misdiagnosing a sensor failure as a clogged DPF can lead to unnecessary repairs.
• For example, a malfunctioning DOC can prevent proper DPF regeneration and cause additional failures.

What to do:
Ensure technicians and drivers understand how each component works and how they interact.

For more training resources, visit our Emissions Education section.

3. Minimize Downtime with Swing Units

Downtime for DPF cleaning can disrupt operations. Many fleets can mitigate this by utilizing swing units—formally restored, validated filters that are ready for immediate installation.

• Supports preventative maintenance rather than reactive repairs
• Keeps trucks on the road while the original unit is restored

What to do:
Work with a restoration provider like Ceramex to keep a rotating inventory of validated swing units. While one filter is out for service, another is ready to install—reducing downtime and improving fleet efficiency.

Learn more about swing unit programs.

4. Always Replace Clamps and Gaskets

Aftertreatment systems face extreme heat and vibration. Worn clamps and gaskets can compromise the seal of the system.

• Reusing worn clamps may lead to exhaust leaks and backpressure issues
• Damaged gaskets can cause soot leaks or sensor malfunctions

What to do:
Always replace clamps and gaskets when reinstalling aftertreatment components. Use OEM-quality or high-grade aftermarket parts to ensure a tight seal and prevent future failures.

Visit our Products page for OEM-quality clamps and gaskets at approximately 60 percent of the cost.

5. Understand Your Total Cost of Ownership (TCO)

Proper aftertreatment maintenance affects more than just parts cost. It impacts fuel efficiency, labor, downtime, and long-term reliability.

• Delayed service can result in voided warranties, fines, or unplanned breakdowns
• Low-quality parts often require more frequent replacement and repairs

What to do:
Track data such as fuel efficiency, regen rates, and repair history. Plan proactively, and work with trusted partners to avoid repeat issues.

Final Thoughts

Maintaining your emission system is critical to fleet reliability, emissions compliance, and controlling operational costs. Implementing the right best practices ensures that your aftertreatment components operate effectively for the long haul.

Ceramex North America offers industry-leading DPF cleaning and restoration using our patented Xpurge™ technology, restoring filters to like-new performance and minimizing downtime.

For professional service, visit www.ceramexna.com or contact our team to learn how we can help your fleet stay efficient and compliant.