HPS high performance pigging system

Energy costs are rising, and companies are having to think of ways to lower their consumption and decrease their bills. For companies that manufacture or process liquids, HPS hygienic and sanitary pipeline product recovery systems are an efficient and economical way of saving energy and cutting costs.


Here’s a detailed explanation of ‘what is pigging‘. But to put it briefly, pigging, also known as liquid product recovery, is a technology that recovers product from pipelines using a specialist projectile (the pig).

Pigging originated in the oil and gas industry as a way of clearing debris from pipelines. In 1995, HPS was founded with a pipeline pig and a pigging system based on the same concept but designed specifically for use in the hygienic and process industries.


In the process industries, pigging refers to technology that uses specialist projectiles to recover, rather than waste, residual liquid in pipelines. Pigging technology has developed from manual systems to semi-automated or fully automated pigging systems that require minimal human intervention.

HPS pigging systems are typically fully automated, and they make processes easier and faster. The pigging sequence is programmed into the PLC and/or HMI system and begins running after the transfer sequence.

During the pigging sequence the pig is released from the pig housing station into the line. It is then propelled through the pipeline using either a gas or a liquid as the propellant. The product is pushed to the end of the line and deposited into its destination.

The pig, without being removed due to its bi-directional design, is returned to the pig housing, where it can be cleaned as part of CIP procedures. Having a closed-loop systems means that there is no manual intervention, which increases safety and hygiene.


HPS pigging systems and pigging products are economical and efficient in how they use energy sources, such as gas and electricity. By using pigging systems in processes, companies will reduce their energy consumption and energy bills will decrease.

In a traditional changeover, energy is used to power pumps, heat water (if applicable), and, if the pipelines are jacketed, maintain pipeline temperature. In addition to regular running costs like having the lights on, these can add up to a considerable amount of money.

The primary energy source of a pigging system is electricity, which is required to power the compressor. Although the total consumption of electricity will depend on the frequency of pigging runs, savings will be made when comparisons are made between traditional changeovers and changeovers that include an HPS pigging system. This is because changeovers are much quicker.


The actual amount that pigging systems will cut your costs will depend on the different variables that make up your processes and your existing changeover and CIP procedures.

When you contact HPS, our pigging system consultants will ask you to explain your current processes and will be able to give you estimates on how much faster your changeovers will be. Using this information, you’ll be able to calculate how much money you’ll save on energy bills by using HPS pigging systems.


HPS pigging systems cut energy costs, and companies also benefit from reduced waste, carbon output, and, in processes where water is used, water usage. Therefore, the benefits of pigging and product recovery systems are significant.


HPS pigging systems reduce waste by recovering up to 99.5% of product from full pipelines. This recovered product is pushed to the line’s destination and can be processed further or sent on for packaging and sale.

For example, KIK Custom Products, having implemented an HPS pigging system, are now saving 160 gallons of product per run, which equates to a revenue increase of $2735 per run – read the pigging system case study on homecare production.

By reducing the amount of waste that is produced, companies can decrease the amount of money that they spend on waste storage, transport, treatment, and disposal. Companies have even approached HPS with the goal of reducing waste and associated costs as their primary reason for pigging.


HPS pigging systems can also reduce CO2 emissions by up to 99.3% per changeover. In 2022, we commissioned an independent report from Carbon-Zero UK. They reported decreased carbon emissions using HPS pigging technology when compared to a traditional changeover – here’s an interesting report on carbon footprint reduction and HPS pigging technology.


Finally, because HPS pigging systems remove product from the line before CIP processes begin, the quantity of water that is required to clean the lines decreases. Although water is not used in all industries as part of CIP processes, for those that do use water this can be highly beneficial.

Reducing water usage decreases overheads and increases environmental sustainability. Some manufacturers are now able to measure the exact quantity of water that is required for CIP procedure, optimising their water usage and reducing energy use even further.


HPS Product Recovery Solutions have been in business since 1995. With over 800 customers and over 2,000 systems in place, we’re the product recovery experts that you need.

Our pigging systems are helping manufacturers throughout the world save energy and cut their costs. For more information on the benefits and return on investment a product recovery or pigging system could bring to your organisation, including detailed pigging system payback and ROI calculations, contact HPS today!

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