I thought this would be enough to avoid DPF problems, but it looks like I need a new one.
Who is telling you that you need a new DPF? Like Videodoctor, I had an 08 Mondeo IV 2.0TDCI which never had a DPF problem in the 3.5 years I owned it from new.
My daily commute is 3.5 miles to work, 3.5 miles home again. I would often go for a couple of weeks of never doing more than 10 miles at a time.
Videodoctor's summary of how the engine feels when regenerating, and the 500-mile regeneration intervals, maps closely to my experience with the car.
Skidpan is also correct that you don't need to rev the engine hard to start a regeneration: simply keep the revs around the peak torque range (1750 - 2250rpm) in 4th / 5th / 6th gear is fine.
However you DO need to be at a road speed of higher than 38mph for regeneration to start (so that the airflow through the engine bay will dissipate the heat around the DPF canister, it really does get very hot). Once the regeneration has started, it will continue even at idle, as the engine cooling fan runs while the DPF regenerates. When the fan switches off, the regeneration has stopped.
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