For many companies that process liquids or wet products, growth comes with a challenge: how do you increase production without investing in a larger facility or additional equipment?
Expanding production lines, adding tanks, or building new processing areas can be costly, time-consuming, and logistically difficult.
The good news is that you may not need to expand at all. By optimising your existing processes – particularly in how you handle product transfer and cleaning—you can increase output, reduce waste, and maximise efficiency without making major infrastructure changes.
One of the most effective ways to achieve this is through Advanced Liquid Product Recovery (Pigging) – a proven technology that helps liquid processing companies recover product, reduce downtime, and improve yields – all within their current production footprint.
The Challenges of Scaling Without Expanding
Many manufacturers reach a point where they need to produce more but are limited by:
- Pipeline Waste: A surprising amount of product gets left behind in pipes during transfer and changeovers.
- Lengthy Cleaning Processes: Cleaning between batches or flavours takes time and reduces available production hours.
- Production Downtime: Changeovers, flushing and rinsing, and cleaning slow down operations and reduce throughput.
- Space Constraints: Adding new equipment or storage tanks requires more floor space, which may not be an option.
If any of these sound familiar, it may be time to look at ways to optimize your existing processes rather than investing in costly expansion projects.
How Pigging Helps You Do More With Your Existing Production Line
Recover More Product from Your Pipelines
One of the biggest inefficiencies in liquid processing is the residual product left in pipelines after a batch transfer. Whether you’re working with food, beverages, cosmetics, or lubricants, leftover product in pipes is essentially wasted revenue.
Pigging systems rapidly recover up to 99.5% of product from full pipelines, meaning more product is available for packaging or further processing .
For example, a beverage manufacturer losing 10 litres of juice per batch due to pipeline waste could recover almost all of it using pigging, increasing overall output without producing more.
Speed Up Changeovers and Reduce Downtime
If your production line handles multiple products, flavours, or ingredients, you’re likely spending a significant amount of time on cleaning and changeovers.
Traditional methods, like flushing and rinsing with water or using CIP (Clean-in-Place), take time, water, and chemicals. Again these reduce production availability.
Pigging speeds up this process by removing residual product extremely quickly (here’s how quick the pigging process is), reducing the need for extensive flushing and cleaning.
And because the pig reclaims so much product from the pipe, this equates to:
- Faster changeovers
- More production time
- Reduced downtime
For example, a personal care manufacturer that used to spend 2-3 hours cleaning between different batches reduced this to 15 minutes by using a pigging system, allowing for more production runs in the same shift.
Increase Product Yields Without More Raw Materials
Because pigging recovers product that would otherwise be lost, companies can increase their product yields without increasing ingredient usage. This means you get more finished product per batch, leading to higher profitability and efficiency.
Even a small increase in yield can have a major impact on bottom-line profits—without any additional investment in storage or processing capacity.
For example, a beverage manufacturer using pigging recovered an extra 4% of product per batch, leading to an additional 48,000 cans per week of a popular soft drink.
And that’s a fairly average figure!
Reduce Cleaning Costs and Environmental Impact
Flushing pipelines between batches wastes water, cleaning chemicals, and energy. Many manufacturers rely on multiple rinse cycles to clear out product residues, which not only takes time but also increases operating costs.
Pigging minimises the need for excessive flushing by removing the remaining product out of the pipeline, reducing:
- Water and chemical usage
- Waste disposal costs
- Downtime between batches
For example, a beverage manufacturer reduced water usage by 50% per batch changeover after implementing pigging, significantly lowering their environmental impact.
Cost Savings and Return on Investment of Pigging
Pigging not only increases efficiency but also delivers a fast return on investment. The cost savings come from multiple areas, including:
- Higher product yields (less waste, more sellable product)
- Reduced cleaning costs (less water, fewer chemicals, less labour)
- Lower waste disposal fees (minimised product loss)
Increased production capacity (more output, less downtime)
Many companies see a return on their pigging system investment within 6-12 months, depending on their industry and production volume.
How to Implement Pigging in Your Production Line
Getting started with pigging is straightforward. Here’s how it works:
Assess Your Needs – Identify areas where product loss, downtime, or inefficiencies occur.
Consult a Pigging Specialist – Choose a company who offers the latest, advanced technology and bespoke pigging systems. Companies like HPS design customised pigging solutions tailored to your processes.
System Design and Integration – A pigging system is designed to fit seamlessly into your existing pipelines (it can also
Implementation and Training – pigging systems are implemented with minimal disruption, and your staff are trained on its operation.
Ongoing Optimisation – Regular monitoring ensures maximum efficiency and pigging system ROI.
Find Out More
If you process liquids and want to maximize your production efficiency without expanding your facility, pigging can help. Contact our experts today!