Professional DPF Cleaning for Trucks & Commercial Fleets

Modern diesel trucks, vans and HGVs rely on their Diesel Particulate Filter (DPF) to control emissions, protect the engine and stay compliant with UK road laws. When that filter becomes blocked, a fleet can quickly face downtime, rising fuel costs, limp mode and avoidable repair bills. Professional cleaning offers a practical and cost-effective way to restore performance without replacing expensive components.

This guide explains why commercial vehicles suffer DPF issues more often than cars, what symptoms fleet managers should watch for, and how proper on-car or off-car cleaning saves money compared with doing nothing. You’ll also see how the right service provider keeps trucks on the road with clear testing, reliable results and minimal disruption.

Why Truck and HGV DPFs Block Faster Than Car DPFs

Heavy Loads Mean Higher Soot Output

A truck pulling weight day after day produces more combustion soot than a private car. Even with modern SCR and AdBlue systems, the DPF works much harder under load. Long climbs, low-speed site driving and urban delivery routes all contribute to soot buildup that accumulates faster than the vehicle can regenerate.

Stop–Start Urban Routes Slow Down Regeneration

Many fleet vehicles operate in cities, doing short journeys or idling at depots. This prevents the exhaust reaching the temperatures required for passive or active regeneration. When the DPF fails to burn off soot regularly, the filter fills rapidly.

High Mileage Increases Ash Load

Even when regeneration succeeds, ash remains inside the DPF. High-mileage trucks and vans build up ash over time, gradually reducing the filter’s capacity. This is one of the most common reasons fleets book periodic off-car refurbishment cleaning.

Mixed Driving Conditions Across Drivers

Fleet drivers vary in driving style, payloads and routes. One truck might spend its life on the motorway. Another may spend most of its time in towns or sites. This inconsistency often leads to one or two vehicles in the fleet suffering far more DPF issues than others.

Typical Symptoms of a Blocked DPF on Trucks and Vans

Fleet managers often recognise the early signs long before the warning light appears. A commercial vehicle with a restricted DPF may show:

• Loss of power under load
• Poor acceleration on hills
• Increased fuel consumption
• Frequent active regenerations
• Exhaust temperature warnings
• DPF warning lights or messages
• Strong diesel smell due to over-fuelling
• Limp mode triggered at motorway speeds

If the blockage continues, the ECU may disable regeneration entirely. This often results in a no-start countdown, forcing the vehicle off the road. For more background on the consequences of blocked filters, see our guide on blocked DPF & turbo problems.

Cost Breakdown: DPF Cleaning vs Doing Nothing vs Replacement

Commercial vehicle operators face several choices when symptoms appear. The financial difference between taking action early and delaying repairs can be significant.

Professional Cleaning Cost (On-Car or Off-Car)

Truck and van DPF cleaning usually falls within these UK ranges:

• On-car DPF cleaning: typically £180–£300
• Off-car DPF refurbishment cleaning: typically £250–£600 depending on size and condition

Important: these figures are not fixed. Costs vary based on vehicle type, DPF condition, access and diagnostic work required. For an accurate quote, call us on 07827533529 or message our team. You can also see general pricing trends in our DPF cleaning cost guide.

Cost of Doing Nothing

Allowing trucks or vans to run with a blocked DPF leads to several escalating expenses:

• Higher fuel consumption: often 10–20% above normal
• Limp mode downtime: missed jobs, delayed deliveries, and a vehicle sitting idle
• Engine stress: high exhaust temperatures and back-pressure can damage turbos, sensors and EGR systems
• Recovery costs: vehicles that reach no-start conditions must be recovered to the workshop

For fleets running tight schedules, downtime alone can overshadow the cost of a full refurbishment clean.

DPF Replacement Cost

OEM truck and LCV DPFs vary widely in price.

• Small vans: £700–£1,800
• Large vans / 3.5t vehicles: £1,200–£2,800+
• Heavy trucks / HGVs: £2,500–£6,000+ in many cases

Replacement is rarely required unless the core is physically damaged, melted or cracked. This is why off-car refurbishment cleaning remains the preferred option for fleet managers.

Downtime and Fuel Cost Implications for Fleets

Every Hour Off the Road Has a Cost

For trades, couriers, logistics companies and HGV operators, a blocked DPF doesn’t just affect the vehicle – it affects customers, delivery slots and contract obligations. A van or truck losing a day can cause knock-on delays across the entire operation.

Blocked DPF = Higher Fuel Use

Restricted exhaust flow forces the engine to work harder. Fuel consumption rises as regeneration attempts become more frequent. This can add thousands per year to operating costs across a fleet.

Driver Complaints and Lost Efficiency

A sluggish vehicle slows down site work, loading, and delivery turnaround times. Many drivers report needing more throttle input, which uses even more fuel and accelerates wear.

On-Car vs Off-Car DPF Cleaning for Trucks and Vans

On-Car DPF Cleaning

On-car cleaning is carried out while the filter remains fitted to the vehicle. It suits vehicles where the DPF is accessible and the blockage is mostly soot rather than heavy ash.

Advantages include:

• Lower upfront cost
• Same-day service for many vans and light trucks
• Ideal for vehicles with early to moderate blockage

This is our most popular fleet service due to its quick turnaround. You can see how this compares to other options in our postal DPF cleaning service overview.

Off-Car DPF Refurbishment Cleaning

Off-car cleaning involves removing the DPF and flushing it with specialist equipment. This is the most thorough method and removes both soot and ash.

Benefits include:

• Full restoration of flow rates
• Ideal for high-mileage or severely blocked vehicles
• Essential for trucks with recurring limp mode issues

Most fleets schedule this during planned downtime or servicing intervals to minimise disruption.

How Often Should Fleets Schedule Preventative DPF Cleaning?

Every fleet is different, but general guidance is as follows:

• Fleet vans: every 60,000–80,000 miles
• 3.5t trucks: every 70,000–100,000 miles
• HGVs: every 100,000–150,000 miles

Fleets running urban delivery routes may need more frequent cleaning. Vehicles doing long motorway runs often regenerate successfully and require cleaning less often.

Signs You Need Preventative Cleaning

• Regeneration messages appearing more often
• Drivers reporting sluggish performance
• Rising fuel usage across similar routes
• DPF pressure sensor readings trending higher

For van fleets in particular, our guide on DPF cleaning for taxis and vans explains the patterns seen in stop–start driving.

Checklist for Choosing a Professional Truck DPF Cleaning Service

1. Do They Provide Before and After Data?

A credible provider should supply flow readings, pressure data or video evidence showing the condition of the filter before and after cleaning.

2. Do They Diagnose the Underlying Cause?

Cleaning the DPF won’t help if injectors, sensors or the EGR system are faulty. Diagnostics must be part of the process.

3. Do They Offer On-Car and Off-Car Options?

Fleets need flexibility. Some vehicles need fast turnaround on-car cleaning, while others require full refurbishment.

4. Are Cleaning Chemicals and Equipment Designed for Heavy Commercial Filters?

Truck and HGV DPFs are larger, more complex and more expensive. Appropriate equipment is essential.

5. Is There a Clear Process for Fleet Bookings?

Look for providers who offer predictable scheduling, same-day turnaround where possible and multi-vehicle support.

6. Do They Avoid Shortcuts Like Drill-Through “Cleaning”?

Any company offering to “punch” or damage the DPF should be avoided immediately. This is illegal, voids MOT compliance and can cause serious engine damage.

7. Is the Company Experienced With HGVs, Cranes, Tippers, Refrigerated Trucks and Mixed Fleets?

Commercial vehicles vary significantly. Your provider should be familiar with all major manufacturers and Euro standards.

8. Do They Offer Transparent, Flexible Pricing?

A reputable company will explain that pricing depends on access, blockage level and the vehicle type. They should provide an exact quote once diagnostics are complete.

Call to Book Professional Fleet DPF Cleaning

If your trucks or vans are showing DPF warnings, rising fuel usage or sluggish performance under load, book a professional clean at our workshop:

DPF Cleaner UK
Unit 2, 2 Cutts Street, Wood Terrace, Hanley, ST1 4LX
Phone: 07827533529

We clean DPFs for all commercial vehicle types, from small fleet vans to full HGVs.

FAQ: DPF Cleaning for Trucks & Commercial Fleets

How long does truck DPF cleaning take?

On-car cleaning usually takes 1–2 hours. Off-car cleaning ranges from 24–48 hours depending on workload and removal time.

Will DPF cleaning remove both soot and ash?

On-car cleaning mainly targets soot. Off-car cleaning removes soot and ash, restoring full flow. For high-mileage trucks, refurbishment is often the best choice.

Can a blocked DPF put a truck into limp mode?

Yes. High back-pressure leads to reduced power, regeneration failure and eventually limp mode. Professional cleaning resolves this once the underlying issue is diagnosed.

Is DPF cleaning cheaper than replacement?

Almost always. Replacement DPFs for trucks can reach several thousand pounds. Cleaning is a fraction of the cost. Always remember that prices vary depending on vehicle type and condition, so call for an accurate quote.

Will cleaning prevent future blockages?

Cleaning restores flow but won’t prevent blockages caused by faults such as injector issues or sensor failures. Diagnostics are essential.

Do fleet vehicles need periodic DPF cleaning?

Yes. Ash accumulates over time, even when regeneration works. Preventative cleaning helps avoid breakdowns and fuel waste.

Can you clean DPFs for refrigerated trucks and Euro VI HGVs?

Yes. We regularly handle large commercial filters, including Euro VI systems, temperature-controlled vehicles and long-haul trucks.

What happens if the DPF keeps blocking after cleaning?

The underlying problem must be found. Common reasons include EGR faults, failing sensors, split hoses or injector imbalance.

Do you offer fleet discounts?

Contact us directly for multi-vehicle bookings. Pricing depends on the number of vehicles and the cleaning method required.

Book Your Fleet Into Our Workshop Today

Whether you run delivery vans, builder’s trucks, refrigerated fleet vehicles or heavy HGVs, a professional DPF clean keeps your business moving.

DPF Cleaner UK
Unit 2, 2 Cutts Street, Wood Terrace, Hanley, ST1 4LX
Phone: 07827533529

Send us a message or call to get an exact quote based on your vehicle type and DPF condition.