Compliance with industry regulations is crucial for maintaining product safety, quality, and environmental standards. For manufacturers of liquid and wet products, such as beverages, food, paints, industrial lubricants, personal care, and household care items, adhering to these regulations can be challenging.

Advanced Liquid Product Recovery (Pigging) Technology offers an effective solution to help businesses meet these stringent requirements. In this article, we’ll explore how pigging technology assists manufacturers in complying with industry regulations.

Understanding Industry Regulations

Manufacturers across various sectors face a myriad of regulations designed to ensure product safety, quality, and environmental responsibility. Key regulatory areas are:

Food and Beverage Industry

  • FDA regulations in the United States.
  • EU food safety regulations in Europe.

Personal Care and Household Products

  • Cosmetic regulations, such as the EU Cosmetics Regulation.
  • REACH (Registration, Evaluation, Authorisation, and Restriction of Chemicals) in Europe.

Paints and Industrial Lubricants

  • Environmental Protection Agency (EPA) regulations.
  • Volatile Organic Compounds (VOC) regulations.

These regulations focus on several critical areas, including product safety and quality, environmental impact, and efficient resource utilisation.

It’s important to note that these are just some of the major regulations, and there may be additional local, national, and international regulations that manufacturers must comply with. Staying informed of all relevant regulations is essential for maintaining compliance and avoiding potential legal and financial repercussions.

Role of Pigging Technology in Ensuring Compliance

Pigging technology, which involves the use of a projectile (the “pig”) to recover product from pipelines, plays a significant role in helping manufacturers meet regulatory standards. Here’s how:

Waste Reduction

Pigging systems minimise product loss by efficiently recovering up to 99.5% of residual product from full pipelines, significantly reducing waste. CP Kelco, a natural ingredients company, is saving 1200 gallons of product every cycle by implementing pigging technology.

By reducing the volume of waste requiring disposal, pigging helps manufacturers comply with waste management regulations. Reducing waste also contributes to decreased storage, treatment, transport, and disposal costs, saving money and carbon emissions.

Product Safety and Quality

Product removal prior to cleaning and clean-in-place (CIP) procedures improves cleaning effectiveness, prevents cross-contamination, and ensures that product safety and quality are maintained.

Environmental Impact

Pigging systems lower environmental footprints by reducing waste and conserving water and cleaning agents. HPS pigging systems also reduce carbon emissions by up to 99.3% per changeover, decreasing a company’s carbon footprint, improving sustainability, and contributing to global carbon reduction efforts.

Case Study: Barbot Paints

Barbot Paints, located in Portugal, made changes to their ingredients list to comply with national and international regulations for the use of biocides in paint.

Consequently, they experienced a significant increase in bacterially contaminated paint, requiring numerous recalls, extensive rework, and disposal of packaging materials. Approximately 20% of Barbot’s output was returned, costing them money and time.

Since implementing HPS pigging technology into their operations, Barbot has experienced a 99% reduction in product recalls due to bacterial contamination. They have also increased their yields and are recycling the water used in pipeline flushes.

Read the full case study on how pigging systems are reducing bacterial contamination in water-based paint production.

Steps to Implement a Pigging System for Compliance

To implement a pigging system and achieve greater regulatory compliance, manufacturers should follow these steps:

Assess Regulatory Requirements

Understanding the specific regulatory requirements relevant to your industry will help you identify areas for improvement.

Evaluate Existing Processes

Identify areas in your current processes that can be improved with pigging technology. If you are designing a new site or expanding an existing one, get your chosen pigging system provider involved early.

Design and Implement Customised Pigging Technology

Work with pigging systems specialists to design a pigging system tailored to your specific needs. Every factory and process are unique, meaning that ‘off-the-shelf’ pigging systems provide subpar recovery rates and component suitability.

Train Employees

Ensure your team is trained on the use and maintenance of the pigging equipment. A high-quality provider will include initial training and refresher training courses for your staff.

Regular Monitoring and Audits

Continuously monitor the system and conduct regular audits to ensure ongoing compliance.

Strategic Investment

Pigging technology offers a proactive approach to meeting industry regulations and ensuring product safety, quality, and environmental sustainability. By reducing waste, preventing cross-contamination, and lowering environmental impacts, pigging systems provide a comprehensive solution for regulatory compliance. Manufacturers looking to enhance their compliance efforts should consider implementing pigging systems as a strategic business investment.

HPS Product Recovery Solutions

HPS Product Recovery Solutions has been helping manufacturers of liquid and wet products improve their operations and compliance for over 29 years. From food, beverage, and pet food to paints, coatings, and industrial lubricants, HPS equipment is suitable for use in a wide variety of industries.

For more information on how Advanced Liquid Product Recovery (Pigging) Technology can help your business stay compliant, contact HPS.

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