How One Engine Workshop Reduced Downtime with Ultrasonic Cleaning

In this case study we examine how a mid-sized engine repair workshop adopted a stainless steel ultrasonic engine cleaner / DPF filter cleaning machine with pump and achieved real results in terms of downtime reduction, cost savings and improved quality.

The workshop serviced engine rebuilds and DPF filter refurbishments. Previously they relied on manual cleaning combined with chemical soak tanks. Cleaning a batch of engine blocks or DPF cartridges took several hours, labor was high, and sometimes parts were returned with residual soot, causing re-work.

After investing in an industrial ultrasonic cleaner with a 360-L tank, stainless steel 304 build, 3600 W ultrasonic power at 40 kHz (with option for 28 kHz) and an integrated pump/filtration system, the workshop changed their workflow.

Results observed:

• Cleaning time for engine blocks dropped by 40%. The ultrasonic cycle completed in less than half the time previously required.

• Labour hours per job dropped significantly: fewer manual scrubbing hours meant technicians could focus on inspection and assembly rather than cleaning.

• Quality improved: cleaned parts showed consistent cleanliness, fewer rejects in assembly or failure in testing. Customer feedback improved.

• Bath life extended: With the pump/filtration system the cleaning fluid was kept clean longer, so fewer bath changes were required. Disposal and chemical costs went down.

• Additional service offering: The workshop began to offer dedicated DPF filter cleaning/refurbishment as a stand-alone service, creating a new revenue stream.

• Competitive advantage: Marketing the workshop as having advanced ultrasonic cleaning capabilities helped win new contracts from fleet operators seeking higher quality and faster turnaround.

Key take-aways from the workshop’s experience:

• Invest in appropriate tank size so parts can be processed in batch, not one at a time.

• Use the correct ultrasonic frequency and power for your part types. For heavy carbon and soot removal 28 kHz was especially effective.

• Ensure your machine has a strong pump and filter system to maintain bath clarity.

• Train staff in loading/unloading, pre-soak (if required), temperature control and cycle timing to maximise efficiency.

• Monitor bath life, chemical concentration, temperature and parts cleanliness as part of your workflow.

• Use the improved cleaning capability as a marketing point: faster service, higher quality, green credentials (less chemical waste).

In conclusion, the workshop’s adoption of an industrial ultrasonic engine and DPF filter cleaning machine delivered quantifiable benefits: faster turnaround, lower costs, higher quality and new business opportunities. This case study shows that the right equipment, when integrated into workflow, can transform a repair facility.