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Smarter DPF Strategy Saves Fleet $420K
Diesel particulate filters (DPFs) are essential—but they’re not cheap. For many fleets, replacements can cost upwards of $1,750 per unit, and when you’re cycling through hundreds every quarter, those costs add up fast. That was the challenge facing a fast-growing regional materials fleet: maintenance budgets were stretched thin, and too many filters were being tossed even though they still had life left in them.
Sound familiar?
Let’s talk about how this fleet turned the tide—saving nearly half a million dollars annually—by rethinking their DPF strategy.
Like many operations, this fleet had no reliable way to evaluate whether a filter could be reused. If a unit looked questionable, it was replaced. Over time, this “better safe than sorry” mindset led to significant waste—not just in money, but in materials and downtime.
They knew there had to be a better way.
Partnering with Ceramex North America, the fleet launched a proactive Filter Restoration Strategy that focused on refurbishing DPFs and Diesel Oxidation Catalysts (DOCs) instead of replacing them outright.
Here’s what made the difference:
Restore & Return (RR) Program
Instead of buying new, compliant filters were restored at a fraction of the cost.
Salvage Evaluation
Filters with minor damage that would’ve previously been scrapped were now getting a second life.
Low-Cost Consumables
Affordable clamps, gaskets, and bung replacements extended filter usability without compromising performance.
Tech Training
Ceramex helped train their technicians to properly inspect, install, and maintain restored filters.
“Even with the shipping time, you are faster than the local guys.”
— Fleet Maintenance Lead
From January through May 2025 alone, the fleet cut costs by 20% compared to the same time period the year before. And that was just the beginning.
$37,000 saved in Q2 by restoring just 25+ salvageable filters
$420,000 projected annual savings by restoring half of all replacement filters
6x cost reduction per RR unit vs. new filters
By this time about 800+ filters have been restored for under $1M (vs. $1.45M in replacement costs)
👉 See the full case study here
Downtime is more than just inconvenient—it’s expensive. With a smarter scheduling system and swing units ready to go, the fleet avoided roadside breakdowns and unplanned service events.
Every truck off the road costs $500–$1,000 per day in lost revenue. With restored filters in play, the fleet saw improved uptime and fewer disruptions.
The fleet didn’t just save money—they gained stability and sustainability. Additional benefits included:
Smarter inventory management
Fewer emergency part purchases
Lower failure rates and filter fallout
Less material waste = better environmental impact
Whether you're managing a regional fleet or running a nationwide operation, Ceramex’s OEM-validated DPF and DOC restoration program helps you:
Cut costs
Boost uptime
Reduce waste
Avoid unnecessary part replacements
Ready to stop throwing away money with every filter?
Let’s talk. We’ll help you build a proactive, data-driven maintenance strategy that keeps your trucks on the road—and your budget in check.
👉 Contact us now to schedule a filter evaluation or consultation.