Efficient and hygienic liquid transfer is crucial to productivity and product integrity in industries that process liquid or wet products, such as food and beverage, right through to chemicals, cosmetics, and homecare.
Yet, many manufacturers face inefficiencies, bottlenecks, and product losses due to outdated or manual routing systems.
Poor liquid transfer increases operating costs and can lead to cross-contamination, downtime, safety risks, compliance issues, and customer dissatisfaction.
But, there’s a solution – Manual or Automated Liquid Transfer Routing Systems.
The Development of Automated and Manual Valve Matrices
Many manufacturers are investing in advanced liquid routing solutions, specifically automated valve matrices like the Automatrix, and manual alternatives like the Rotomatrix.
These systems offer greater precision, repeatability, and operational control.
While automated valve matrices are ideal for high-throughput operations with frequent changeovers and multiple SKUS, manual systems like the Rotomatrix can be more than sufficient for smaller operations, lower product volumes, or where budgets are tighter.
Many manufacturers successfully use manual piggable manifolds to eliminate hoses, improve safety, and reduce routing errors, without the cost or complexity of full automation.
Whether you’re looking to scale up, improve accuracy, or reduce downtime, automated and manual valve matrices are crucial to improving liquid transfer.
When combined with HPS Advanced Liquid Product Recovery (Pigging) Technology, the benefits multiply – boosting yields, reducing waste, and increasing the efficiency of liquid processing operations.
This article explores some of the most common challenges in liquid transfer and how advanced routing systems help solve them.
Cross-Contamination Risks
In facilities handling multiple products, cross-contamination between batches can compromise product safety and quality.
Even trace amounts of allergens, flavours, or chemicals from a previous batch can render a product unusable.
Some manufacturers rely on flow plates or bend panels to manage product routing.
However, these systems are vulnerable to operator error. An incorrect connection can result in unintended product mixing, leading to costly waste, potential recalls, and reputational damage.
The HPS Solution
HPS offers safer, more reliable alternatives through our Automatrix and Rotomatrix Valve Manifold Systems:
- The Automatrix provides fully automated, recipe-based control with integrated CIP (Clean-in-Place), ensuring repeatable, error-free changeovers and enhanced hygiene.
- The Rotomatrix offers clear visual guidance and mechanical interlocks that physically prevent incorrect connections, significantly reducing the risk of human error.
By implementing HPS matrix technology, companies can achieve greater product integrity, reduce waste, and improve operational reliability.
Manual Errors and Inconsistencies
Traditional manual valve operation and temporary hose connections create what operators often call “snake pits” – tangled, disorganised connection points prone to mistakes.
These error-prone setups increase the risk of routing errors and product misalignment and create serious workplace hazards, including trip risks, potential exposure to chemicals, and ergonomic issues for staff who must repeatedly connect and disconnect cumbersome, heavy hoses.
The HPS Solution
- HPS Automatrix technology eliminates these risks by fully automating source and destination selection via PLCs, ensuring consistent, error-free routing. It can also integrate with CIP systems for automated cleaning between batches.
- Rotomatrix technology, with its compact set of rotating arms, provides mechanical interlocks and path selection feedback, physically preventing incorrect connections. This makes it virtually impossible to send a product to the wrong destination.
Both systems improve safety and operational consistency by significantly reducing the potential for human error.
To see how automated manifolds contribute to safer processing environments, read our article on how they reduce risks in liquid processing.
Downtime During Changeovers
Product changeovers traditionally require significant downtime for cleaning, re-routing, and system flushing and rinsing.
In competitive manufacturing environments, this lost production time directly impacts throughput and profitability.
Manual changeover processes are time-consuming and inconsistent, with variation between operators and shifts leading to quality inconsistencies and compliance concerns.
The HPS Solution
- The Automatrix valve manifold significantly reduces downtime by automating nearly all routing procedures.
- The Rotomatrix enables quick, reliable connections with clear visual confirmation, reducing the time needed to reconfigure lines manually (compared to traditional hose connections or multiple valve arrangements).
When paired with HPS pigging technology, both solutions streamline changeovers further, helping manufacturers increase batch frequency without sacrificing safety or product quality.
Product Loss and Waste
Traditional transfer systems often leave behind large volumes of residual product during changeovers or cleaning. This leads to unnecessary waste, increased costs, and lower yields.
The HPS Solution
By integrating HPS liquid product recovery (pigging) technology with valve matrices, nearly all product is recovered from pipelines.
This reduces waste, increases yield, and improves environmental sustainability by minimising product sent to waste treatment or disposed of entirely.
Complex Flow Paths in Multi-Tank Operations
Facilities with multiple tanks, fillers, and process lines face logistical challenges in managing product flow. The more complex the system, the greater the potential for routing errors and inefficiencies.
The HPS Solution
A centralised routing system (using valve matrices) offers full control and visibility over product flow. While manual systems like the Rotomatrix are effective for straightforward setups, automated solutions such as the Automatrix are significantly more advantageous for operations with higher or increased complexity.
With the Automatrix, automated source-to-destination selection through PLCs, allows seamless product routing between multiple tanks and lines. This not only improves operational agility but also eliminates the need for manual intervention, reducing human error and enabling faster, more flexible production planning.
For facilities managing a wide variety of SKUs, frequent changeovers, or complex flow paths, automation delivers unmatched scalability, efficiency, and control.
Unlock the Full Potential of Your Process Lines
Every liquid processing facility is unique, but the challenges of manual routing, product loss, and downtime are almost universal.
By upgrading to an HPS liquid transfer routing solution, you equip your operation with the tools to overcome these hurdles and operate with confidence, consistency, and control.
If you are looking to optimise your liquid processes, then please do not hesitate to get in touch.