CAF Rail, a global leader in comprehensive transportation systems, has always been at the forefront of innovation, ensuring its fleet is ready to meet the demands of modern rail transportation. With over 180 carriages in operation, each with its own engine, maintaining optimal performance is essential. However, the company faced a significant challenge: the need to clean the Diesel Particulate Filters (DPFs) of its fleet.
The DPF Cleaning Challenge
The engines in CAF Rail’s fleet are equipped with DPFs, crucial components that capture harmful particles from diesel exhaust, helping to reduce pollution. These filters need to be cleaned regularly to ensure they continue to function efficiently. For CAF Rail’s Chester depot, this meant cleaning 360 DPFs each year in Chester alone—one for every carriage, cleaned at least twice annually.
Outsourcing the DPF cleaning process was both costly and inefficient. At a rate of over €1,000 per clean, the company was facing an annual expense of over €400,000 just for DPF maintenance. Alongside the financial burden, there was the issue of excessive vehicle downtime. Each time a DPF was sent off-site for cleaning, valuable operational hours were lost, which led to decreased availability of trains for service.
Perhaps most concerning, however, was the loss of control over their fleet. Relying on third-party services for DPF cleaning meant that CAF Rail had to deal with unpredictable turnaround times and the challenge of managing a fleet without direct oversight on maintenance schedules.
The Solution: Carbon Clean’s DCS-25 Commercial DPF Cleaning Machine
Enter Carbon Clean, a leader in DPF technology. Our DCS-25 Commercial DPF Cleaning Machine provides an efficient, in-house solution for cleaning DPFs, and CAF Rail’s Chester division has now made the strategic decision to install one of these advanced machines in their facility. The DCS-25 utilises state-of-the-art technology to clean DPFs quickly and effectively, returning them to near-new condition without the need for costly and time-consuming manual labour. With this machine, CAF Rail can now take control of their DPF cleaning process, eliminating the need to outsource this critical task.
The Benefits: Reduced Costs and Improved Efficiency
By adopting the DCS-25, CAF Rail stands to save millions of pounds over time. No longer needing to outsource cleaning, they will avoid the excessive-per-clean charge. With over 360 cleans each year, this translates into significant savings, ensuring that their maintenance budget goes further. Moreover, by performing DPF cleaning in-house, CAF Rail will dramatically reduce vehicle downtime. The DCS-25 machine is designed for fast, efficient cleaning, allowing the team to turn around each filter in just a few hours. This increased efficiency means that trains spend less time off the tracks and more time in service, which helps keep the fleet operating at maximum capacity.
Taking control of the cleaning process also means CAF Rail can better manage its fleet maintenance schedule. No more relying on third parties to set turnaround times—CAF Rail now has complete oversight of when and how the cleaning is done, ensuring that DPF maintenance doesn’t interfere with their operational needs.
Training for Success
To ensure CAF Rail’s team would get the most out of their new machine, Carbon Clean’s experts
went on-site to provide comprehensive training. Our team worked closely with George, Continuous
Improvements Manager, and the rest of the Chester facility staff, ensuring they understood how to
operate the DCS-25 to its full potential. From setup and maintenance to best practices for achieving
optimal results, our hands-on training empowered CAF Rail’s team to integrate the DCS-25 into their
daily operations seamlessly.
With our support, CAF Rail’s staff is now equipped with the skills and knowledge to maintain their DPFs in-house efficiently, without the need for external intervention. This independence is a game-changer, giving CAF Rail greater flexibility and control over their fleet maintenance.
Looking Ahead: A Cleaner, More Efficient Future
By investing in the DCS-25 Commercial DPF Cleaning Machine, CAF Rail has taken a major step toward transforming its fleet management practices. With the ability to clean DPFs in-house, they can lower operating costs, improve fleet uptime, and regain control over their maintenance schedules.
In the years ahead, CAF Rail will continue to lead the way in rail innovation, and Carbon Clean will
remain proud to be their partner in maintaining the highest standards of fleet performance.
Together, we’re making rail transportation more efficient, cost-effective, and environmentally
friendly—one clean DPF at a time.
