Benefits of Pigging

Benefits of Hygienic Pigging

Pipeline Cleaning, Product Recovery and Transfer Systems

Hygienic Pigging and Product Recovery Systems deliver a wide range of benefits. These include:

The objectives of hygienic pigging systems vary between organisations. However, once implemented, a good quality solution will help your business –  often in more ways than you might at first think!

Here’s more detail about some of the benefits hygienic pigging and product recovery systems can deliver to your business:

Increased Profits, Productivity and Efficiency

Put simply, because pigging systems help you recover more useable product from your processes, you have more product to sell. But that’s not the only way they help you increase your profits, productivity and efficiency.

Product recovery and pigging systems streamline processes, reducing effort required and making various operations a lot quicker. They can even eliminate some process stages altogether.

High Return on Investment (ROI)pigging and product recovery savings calculator

Because they massively reduce waste and increase yields along with productivity and efficiency, pigging systems deliver a high return on investment. The payback time is also low. Typically, if you choose an HPS pigging solution, your savings will pay back the initial cost of the system in less than one year. So after the first year, it’s nearly all profit. That makes a great business case for including pigging as part of your liquid processing operation.

Higher Product Yields

Increased product yield is one of the most common reasons organizations use a pigging system.

Whenever a process transfers liquid along a pipe, there’s nearly always a product residue left. Even gravity fed lines don’t evacuate all of the product. The more viscous the product, the more residue there is.

Pigging systems will help you recover nearly all this residue, as useable product.

Lower Labour Costs

Reduced labour costs are direct, quantifiable benefits of pigging and product recovery systems.

Pigging reduces the effort and resources needed to clean pipelines. It also makes cleaning and changeover times quicker.  Semi-automated and fully automated pigging systems reduce labour costs even further.

Less DowntimeHPS pigging systems

In addition, non-pigging cleaning operations are often cumbersome, requiring different tools and processes. Pigging reduces the number of these operations. Because pigging systems make cleaning easier and faster, with more streamlined changeovers, they reduce downtime.

HPS pigging systems themselves are robust and reliable. With a properly implemented preventative maintenance programme, downtime is minimal.

Bring the Benefits of Pigging into Your Organisation

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Reduced Waste Processing and Transport Costs

By increasing product yields through pigging, there’s less product to send to waste. What’s more, the cleaning and changeover processes also use less cleaning fluids and water. In this way hygienic product recovery and pigging systems directly reduce waste processing costs.

Pigging Receive Station

Lower Cleaning Costs

Because HPS pigging systems significantly reduce the amount of residue left in pipes, (our specially designed pigs will typically recover 99.5% of all product), cleaning is a lot easier. Because there’s less product to remove, it is quicker, uses less cleaning fluids and resources, and less labour.

Faster Changeovers

When companies expand product ranges, it’s often desirable to use previously dedicated pipelines. However, change over from one batch to another can account for significant product loss, increased use of water for flush outs and less productive human-resource hours.

Pigging speeds up product change-overs because it reduces the length of the wash. If there is only a slight change in product colour, flavour or perfume it is often possible to follow on immediately with the next product after pigging, eliminating the need for flushing altogether. This is a major advantage of pigging for many processes.

Positive Environmental Impact, Improved Sustainability, Smaller Carbon Footprint

The costs of removal or treatment of waste from plants has become a major expense to many liquid processing companies. Additionally, changes in legislation and restrictions from environmental policies can require extra resources and incur further costs.

environmental sustainabilityAn effective way of reducing these costs while promoting carbon footprint reduction is to pig the product transfer pipelines. This significantly reduces waste and associated costs, and the environmental benefits of pigging are significant.

Liquid manufacturing companies across the world now see Carbon Footprint Reduction as a marketing tool as well as an ethical approach to business. Pigging can significantly reduce your organisations direct and indirect Carbon Footprint, which is a key benefit to many organisations.

For example, the power resources saved by reducing cleaning times and associated waste are often considerable.  Indirectly, the reduction in numbers of tankers or trucks required for removal of waste or delivery of waste treatment chemicals also reduces things like road degradation, exhaust emissions and traffic congestion.

Reduced Water Usage

Normally the first part of any Clean In Place (CIP) cycle is to flush out the product residue with water for a period of time before actually proceeding with the cleaning process. If most of the product has already been removed with a pig, then there’s no requirement for a lengthy flush out. This reduces water usage significantly.

Improved Quality

Because of the high product recovery rates of HPS systems, the chances of product contamination and cross-contamination is greatly reduced. This in turn means more consistent product output, lower rework and better control over raw material and finished product inventory are among the many benefits of pigging systems.

Higher Capacity and Increased Flexibility

Because HPS pigging systems recover nearly all residual product in your pipeline or tubing, you can use the same lines for more than one product and reduce the number of dedicated lines you have. So, you can replace many dedicated lines with a lower number of shared lines. This increases the capacity and flexibility of your operation. It also reduces the costs of new installations

Other Reasons for Pipeline Pigging

From preventing aeration and foaming during liquid processing to avoiding dissolved oxygen (DO) or contact with air, as well as stopping product from setting or hardening in pipelines or tubing, there are a wide range of other reasons why companies use pigging.

Bring the Benefits of Pigging into Your Organisation

To find out more about the benefits of pigging and to discuss a solution designed specifically for the needs of your business, just complete this short form:

  • This field is for validation purposes and should be left unchanged.

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Case Studies

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Croda Singapore
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