Welcome to part three of our series on how to keep your pigging systems up to date! So far, we’ve focused on the technical aspects of pigging system maintenance, including new software, and upgraded systems.
In this article, we’ll look at how investing in employee training helps maintain pigging systems and keeps them running efficiently and effectively.
The Basics of Pigging Technology
To understand the importance of pigging system training, we first need to look at what pigging is, how it works, and why companies use it.
Liquid product recovery (pigging) technology is a method used by manufacturers of liquid products to recover residual product from pipelines between transfer sequences. Pigging involves inserting a specialist device, commonly known as a ‘pig’, into a pipeline and then propelling it through the line using a suitable propellant. The pig pushes the product to its intended destination (for example, a filler tank).
Companies use pigging technology for a variety of reasons. Many companies use pigging technology to increase their yields, decrease waste, and reduce production downtime. Other benefits of pigging systems include a high return on investment (ROI), increased plant capacity, a reduced carbon footprint, decreased changeover times, and minimised contamination risks.
Why Operator Training Matters
Investing in employee training is vital for the ongoing success of your pigging system. Well-trained operators are essential for maximising system efficiency, safety, and longevity. By providing comprehensive training, you can ensure that your team is equipped with the knowledge and skills required to operate and maintain pigging systems effectively.
A 2023 article by The Manufacturer states that 90% of workers in the manufacturing sector are open to the possibility of moving to a new job. Given the high potential turnover rate, it’s important that manufacturers invest in regular training sessions with new and old employees.
Regular training sessions ensure that you always have someone on your team who is HPS certified to operate your pigging systems. This prevents the systems from falling out of use or being misused. Although HPS pigging systems have a rapid payback period and a high ROI, the initial investment can be significant. Making sure that they don’t fall out of use is essential to achieving the goals outlined in your business proposal.
Benefits of Operator Training
Operator training offers numerous benefits for companies that use pigging technology.
Firstly, having operators who have received specialist pigging system training leads to increased efficiency. Well-trained operators can effectively use the pigging systems, resulting in heightened productivity. They develop an understanding of system operations, minimising downtime, and maximising product recovery.
Secondly, operator training enhances safety. Emphasis on safety procedures during training reduces the likelihood of human error. Operators learn to identify potential hazards and respond appropriately, ensuring a secure working environment.
Thirdly, trained operators contribute to the longevity of the system. The majority of pigging systems in use today allow for automated pigging process control through integration with your HMI/SCADA software and PLC panels. By being able to promptly identify and address issues flagged through your automation system, trained operators can extend the life of the pigging system. Maintenance and troubleshooting techniques learned during training prevent minor issues from escalating into major problems.
Finally, operator training yields cost savings. While initial investment is required, it pays off in the long run. Well-trained operators minimise downtime, reduce product loss, and prevent costly repairs. Consequently, the operation’s overall efficiency and profitability improve.
How to Implement Operator Training
By providing comprehensive training to operators, you can maximise the efficiency, safety, and longevity of the system. Here’s how to implement operator training effectively to keep your pigging system running smoothly.
Initial Training
Provide thorough training to operators when the system is commissioned. Operator training is included by HPS during the commissioning period. Operators will learn about the systems’ functions, safety procedures, and troubleshooting techniques.
Regular Refresher Courses
Conducting regular refresher courses with operators keeps them up to date with the latest advancements and best practices. We recommend arranging refresher training on an annual basis. Refresher courses should cover any updates to the system and new safety protocols.
Utilise Resources
Take advantage of the resources and training provided by HPS. You’ll find a range of resources on our website, including more blog articles, how-to videos, industry guides, and case studies.
By providing comprehensive and ongoing training to operators, you can ensure that your pigging system remains up to date and operates at its optimal level. A well-trained team is the key to ensuring that your pigging system keeps running efficiently and effectively.
Training with HPS
HPS offers hands-on training sessions at your location, ensuring operators are fully equipped to operate and maintain your specific pigging system effectively.
At HPS, we understand that there can be difficulties around employee training, including costs, scheduling difficulties, and employee resistance. We’re here to support you in arranging your training sessions to accommodate different shift patterns and employee requirements.
On-site training sessions are tailored to your specific needs, with experienced HPS engineers providing comprehensive and accessible instruction. The hands-on element of HPS training sessions allows operators to gain practical experience under supervision, reinforcing learning and increasing confidence.
To maximise the benefits of pigging systems, it’s important that companies who have integrated HPS systems into their facilities take advantage of the training and refresher training sessions offered.
Find Out More
HPS Product Recovery Solutions has been the world’s leading provider of Advanced Liquid Product Recovery (Pigging) Technology for 29 years. We’ve worked with manufacturers in almost every sector of hygienic and process manufacturing, including food, drinks, homecare products, cosmetics, paints, and chemicals.
To find out how HPS can help you implement pigging into your operations and ensure that you have a fully trained team, get in touch today.
Don’t forget to explore our previous blog articles in this series: