The Science of True Filter Restoration
DPF360’s Restore™ process is not conventional cleaning—it is a full-system restoration protocol engineered to recover catalyst function beyond the limits of standard methods. While typical processes remove surface-level soot, Restore™ utilizes a proprietary multi-stage chemical extraction designed to penetrate deep into the substrate, targeting phosphate buildup, oil ash, and other catalyst-poisoning compounds that basic cleaning cannot address. Precious metal content lost during service life is replenished, returning catalyst coatings toward original OE specifications and restoring up to 90% of original performance. This distinction defines the difference between a component that has been cleaned and one that has been fully restored.
Following the Restore™ process, Diesel Oxidation Catalysts (DOCs) demonstrate significantly improved functional performance. Embedded contamination is removed, and controlled heat treatment reactivates catalyst activity to as much as 90% of original efficiency, resulting in measurable operational improvements:
- More consistent and reliable DPF regeneration
- Reduced emissions and cleaner combustion conditions
- Decreased frequency of active regeneration events
- Extended DOC and DPF service life
- Lower overall maintenance demand and operating costs
Comprehensive before-and-after testing validates restoration results against original equipment performance benchmarks, confirming catalyst activity and airflow characteristics consistent with OE specifications.
Multi-Step Chemical Extraction
The Restore Process selectively removes phosphate deposits, sooty oils, and deactivating poisons, all without harming the original active catalyst materials.
Precious Metal Restoration
During the process, any precious metals lost in previous service are replaced, restoring the catalyst coatings to original OE metal levels.
Performance Heat Boost
Finally, multiple heat treatments are applied, resulting in up to 90% greater performance and ensuring the DOC runs like new.
The Restore™ Process
The Restore™ Process is a multi-stage chemical extraction system engineered to selectively remove phosphates and other catalyst-poisoning deposits while preserving the integrity of the original active catalyst materials. During restoration, any precious metals diminished through service are replenished, recharging the catalyst coating toward original OE metal loading and restoring full catalytic potential. A final high-temperature treatment completes the process, stabilizing the catalyst and securing long-term performance.
Effects of Restore™ on DOC Components
Once the catalyst wash coat is fully re-exposed and precious metal content is returned to OE levels, exhaust gas can again make full contact with a clean, highly active catalytic surface.
The result: Unrestricted flow and renewed catalytic interaction throughout the component.
DOC Performance After the Restore™ Process
After phosphate contamination is removed and precious metals are restored, DOC performance typically increases by over 90%.
In short: The DOC performs like new.
Phosphates Contamination & Catalyst Poisons Are The Main Cause of DOC Deterioration and Deactivation
Phosphate Contamination: The Primary Cause of DOC Deactivation
Phosphate contamination gradually deactivates Diesel Oxidation Catalysts by coating and fouling the active surface, blocking exhaust gas from reaching the catalyst. Over time, these contaminants penetrate deeper, reducing DOC efficiency and impairing its ability to support reliable particulate filter regeneration. Frequent incomplete or forced regenerations and filter plugging are key signs of a deteriorated DOC. Phosphate, a combination of materials including phosphorus, zinc, sulfur, magnesium, calcium, silicone, iron, nickel, copper, and chrome from engine oil and wear, forms a glassy coating that masks the active washcoat. Without intervention, a deactivated DOC can cause the entire DPF system to clog and fail, compromising engine performance and reliability. Fortunately, phosphate deposits can be removed, restoring catalyst activity.
Diesel Oxidation Catalyst (DOC): Key to Filter Regeneration
The DOC is a critical component in controlled particulate filter regeneration. Poor DOC performance can lead to incomplete regenerations, ultimately causing particulate filter failure. Its role is to scrub exhaust emissions, raise exhaust gas temperature, and increase nitrogen dioxide concentration—all essential for reliable filter performance and regeneration. Typically, regeneration begins with the engine’s electronic fuel control system, which injects fuel into the exhaust stream. This reacts within the catalyst, generating substantial heat and increasing nitrogen dioxide levels to support regeneration. Frequent incomplete regenerations, forced regenerations, or filter plugging are clear signs of a deteriorated or nonfunctioning DOC. Restore™ returns DOC performance to factory standards, restoring reliability and efficiency.
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Frequently asked questions
Signs of any deteriorated or non-functioning DOC
Phosphate materials and other catalyst poisons latch onto the catalyst surface, gradually masking the active layer and reducing its ability to interact with exhaust gases. Over time, these contaminants migrate deeper into the coating, further deactivating the catalyst.
As the buildup grows, the DOC can begin to clog and restrict exhaust flow. Once performance drops below its operating threshold, it can no longer keep itself clean or support reliable DPF regeneration—leading to higher backpressure, poor efficiency, and avoidable downtime.
What is The Critical Role of the Diesel Oxidation Catalyst (DOC) in Reliable Particulate Filter Regeneration
The Diesel Oxidation Catalyst (DOC) is a core emissions-control component—and a major driver behind consistent, reliable particulate filter regeneration.
When DOC performance begins to drop, emissions rise, regenerations become incomplete, and the particulate filter is pushed toward premature failure.
A properly functioning DOC performs two essential jobs. First, it oxidizes and “scrubs” harmful diesel exhaust emissions. Second, in systems equipped with a Particulate Filter, the DOC elevates exhaust gas temperatures and increases nitrogen dioxide (NO₂) concentration. These two outcomes are vital for dependable filter regeneration.
Regeneration typically begins when the engine’s electronic fuel system introduces additional fuel downstream. That unburned fuel reacts aggressively across the catalyst surface, generating the heat and NO₂ needed to burn off accumulated soot inside the filter.
However, when the DOC is underperforming, it cannot generate the required heat. Without sufficient exhaust temperature—and without the proper NO₂ balance—the Particulate Filter simply cannot regenerate. Left unaddressed, the filter loads with soot, plugs, and ultimately fails.
How Does Phosphate Contamination Affect DOC Performance?
Phosphate contamination is the leading cause of DOC deterioration and loss of activity. These deposits bond tightly to the catalyst surface, gradually covering the active sites and preventing proper interaction with exhaust gases. Over time, contaminants and catalyst poisons penetrate deeper into the coating, further deactivating the catalyst and, in severe cases, clogging the substrate and restricting exhaust flow. Once DOC performance drops below critical operating levels, it can no longer sustain its own reactions or generate the heat and NO₂ required for reliable particulate filter regeneration.
Why Is DOC Restoration Critical for Particulate Filter Performance?
The Diesel Oxidation Catalyst (DOC) is vital for particulate filter regeneration. It raises exhaust gas temperatures and boosts nitrogen dioxide (NO₂) levels, both of which are critical for burning off accumulated soot during regeneration cycles. When the engine injects extra fuel for regeneration, the catalyst must generate sufficient heat to complete the process. A low-performing DOC cannot reach these temperatures, leading to incomplete regenerations and eventual filter failure. Our restoration process restores DOC efficiency, ensuring consistent heat generation, reliable filter regeneration, and long-term system performance.
Maximize Fleet Efficiency with DPF360 Restore™
DPF360’s Restore™ technology gives fleet operators a cost-effective alternative to costly DOC replacement while ensuring peak emission system performance. By restoring DOCs to near-new condition, our process extends component life, reduces downtime, and keeps fleets EPA-compliant. Fleets benefit from fewer regeneration issues, lower fuel consumption during regen cycles, and significant savings compared to buying new components. This proven technology keeps trucks running efficiently while supporting environmental compliance.
