Daimler Truck case study

Magcat reduced scale build-up in Daimler’s test facility, cutting downtime and protecting critical cooling equipment.

Client: Daimler Truck
Region: Germany
Application: Engine testing cooling system
Sector: Automotive
Product: Magcat water conditioner

Daimler Truck operates extensive engine testing facilities, where multiple engines run continuously under controlled conditions. Cooling water is circulated through charge air coolers (CACs) and other components, with heat ultimately rejected via a cooling tower. Persistent scale formation in the system was reducing efficiency and causing frequent cleaning shutdowns.

The challenge

Severe scaling across the cooling system, with certain sections identified as the “worst of the worst” (WOW)

Stand 12’s charge air cooler typically required descaling every 1,500 operating hours (around two months at 24/7 running)

Scale accumulation was disrupting Daimler’s essential engine testing programme, leading to many hundreds of hours lost annually

A chemical control programme using sulphuric acid dosing and LSI adjustment helped but did not prevent scaling

The solution

After consultation with Fluid Dynamics and review of system data, a 3” Magcat unit was specified for the WOW stand, sized to treat a design flow of 118 gallons per minute. The dual-treatment Magcat system was installed in March 2016.