Tiny component. Massive effect.

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​​​​​​​Functional integration is a top priority with this innovation from POLYTEC: With a higher degree of cleaning and lower costs, we are setting new standards in the powertrain.


​​​​​​​The differential pressure regulated oil separator, or DDG separator for short, combines two essential basic functions in one combined module with "cleaning" and "venting" of the crankcase. Microscopically small oil particles are filtered out of the crankcase ventilation gases during cleaning, which would otherwise enter the combustion chamber and worsen the exhaust gas values.

At the same time, the DDG oil separator keeps the pressure in the crankcase at a constant negative pressure level - even under extremely fluctuating engine operating conditions. This venting of the crankcase ensures that no gases or oil particles can escape from the crankcase into the environment, even in the event of minor leaks.

In combination with our multi-level suction jet pumps, the DDG separator can be expanded into an active oil separation system with significantly higher filter efficiency. Already today, this system can meet the expected future regulatory requirements such as EU7 or CARB.

FEW PARTS, BUT A LOT OF FUNCTION

in the smallest installation space

POLYTEC's in-house development also excels beyond legal requirements: The DDG separator is a fault-tolerant, universal "plug & play" separator, which means it can be used in any combustion or hybrid engine and does not require any customer-specific modifications. An extended service life of the turbocharger, longer service intervals and low costs are further advantages.

The new type of separator is expected to be used for the first time in 2025, when it will go into series production with the first EU7 engines. Our preparations are already in full swing and we are currently working in parallel on several development, prototype and small series orders for diesel, petrol and hybrid engines.


​​​​​​​​​​​​​​PICTURE:
Interior view of a DDG oil separator: few parts, but a lot of function in the smallest installation space
​​​​​​​Copyright: POLYTEC GROUP


​​​​​​​"It has been a long journey from the initial idea to a product mature enough for serial manufacture. However, this process was always characterised by an openness to new ideas and trust in the skills of the team members.” 

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Tobias Burkert
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Innovation Engineer and mastermind of this project for the future