We understand the importance of machine availability. Your KPIs suffer from unplanned downtime, early component failure, and restricted parts availability. As a result, Aletek has developed specialised OEM replacement products to resolve these problems.
Tailor-made Upgrades
Let us help you reduce downtime
Installation assistance
Expert technical support
Testing and reports
Exhaust-related fleet audits
Design criteria
- Ensure maximum worker safety with superior DPM filtration
- Eliminate performance issues and reactive maintenance
- Tailor DPFs to suit a specific asset and engine configuration
- Simplify installation with a preference for direct-fit integration
- Select materials and high-grade steels to enhance durability
- Maximise ROI by extending OEM reliability and lifecycle
- Availability of spare parts for critical assets
Material selection
To ensure consistent quality and best-in-class DPFs, we’re intentional about our supplier partnership selections.
- Steel pipes & sheets – We use high-quality steel from an Australian supplier for our DPF housings, pipes, rotable frames and rock covers. For precise pipe bends, we procure steel donuts.
- Substrates – A leading filter provider has exclusively partnered with us. These substrates feature a high-grade regenerative catalyst coating.
- Surface finishing – To prevent corrosion, we use stainless steel pickling. Other surface finishes are available, including powder coating and ceramic coating.
- DPF fittings – We source premium components such as wiring harnesses, V-band clamps and installation hardware.
- Data loggers – Data logger enclosures are IP66-rated with 316-grade stainless steel. Fire-rated sleeves protect cables, and hoses are high-temperature rated.
Product design
R&D improvements
- Before design begins, define a concise project outline
- Backpressure testing and engine data collection
- Input from clients, including service intervals
- Consider an OEM engineering analysis including FEA and CFD
Design Team process
- Designs led by 3D scans, onsite measurements, and OEM DPFs
- 3D printing, CAD design, and prototyping managed in-house
- Conduct field trials when necessary to collect data
- Physical pipe jigs built to match OEM pipes as required
- Emission Control Product Manager approves designs
Project management and onsite support
- Custom project management and implementation options
- Site-specific parts catalogues, training and user guides available
- Onsite support services, emission testing, and DPF fleet audits
- Remote and onsite data monitoring
DPF system manufacturing
Lean manufacturing and quality assurance ensure accurate and exceptional fabrication. We use the latest technology in our modern workshop.
- Raw components collected from the warehouse
- Preparation stage with laser cutting, punching, and folding conducted in-house
- Processing stage includes rolling laser-cut sheets, cutting pipe lengths, and shaping donuts to specific angles
- Welding preparation involves drilling, pressing, and expanding
- Templates, pipe jigs, and multiple QA checks assist fabrication
- Welding and cleanup activities commence, and filter substrates added
- The last QA stage inspects fabrication, welds, and fit-out for accuracy
- Surface pickling removes imperfections from DPF enclosures
The same process applies to rock covers and rotable frames, except for a powder-coated finish.
Continuous improvement loop
- We resolve technical issues, including installation problems
- Long-term solutions over short-term fixes (e.g. root cause analysis)
- Use customer feedback to help refine product designs
