One of the most common questions raised during the early stages of discussions about implementing HPS Advanced Liquid Product Recovery technology (which is a type of ‘pigging’ technology) in process pipelines, is about pipeline geometry.
Specifically, about implementing pigging technology in pipework which has bends. The questions are usually along the lines of “What happens when a pig gets to a bend?”.
Most factory pipelines, used to transfer product, have several bends in them.
This article addresses that question comprehensively and clarifies a frequent misconception about pigging system limitations.
Do Pigging Systems In Process Industries Need Straight Pipelines?
Firstly, in this context, a Pig is a specialist device, and a key component of product recovery or pigging systems, used by companies that manufacture or liquids, or transfer liquids through pipelines as part of the manufacturing process.
The pig travels through process pipelines, recovering product as it goes.
Pigging operations are usually performed automatically during batch changeovers, or at the end of a product run or shift.
The recovered product, which is perfectly usable once ‘pigged’, can continue to be processed, packed or stored, instead of being downgraded or sent to waste.
Most facilities have pipeline layouts which include bends, vertical segments, and varying inclines.
Recently, one prospective client summarized the issue as follows:
“We can’t use pigging because not all our lines are straight – we have many bends in our pipework. What would you do about that?”
The prospective client assumed, incorrectly, that pigging systems for process industries require straight lines.
Understanding Pigging for Product Recovery
Pigging systems deliver substantial benefits, including:
- Significant reductions in product loss
- Majorly increased yields and capacity
- Decreased cleaning time and water usage
- Lower energy and labour costs
- Reducing contamination and cross-contamination risks
- Enhanced environmental sustainability and operational efficiency
Here’s a more detailed overview of the Benefits of Pigging
A common assumption, however, is that pigging systems only function effectively in straight pipeline runs.
While this may have been a limitation in some early-generation systems or rigid pig designs, modern pigging technology has evolved significantly.
While there are still some pig designs available that require either straight lines or wide sweeps, HPS Product Recovery Solutions pigs are engineered to operate in non-linear, multi-directional pipeline systems, no matter how complex the layout is.
Specifically, HPS pigs are capable of:
- Navigating 1.5D , 90 degree bends (bends with a radius 1.5 times the pipe diameter)
- Maintaining full-body contact and henvce full product recovery level, with the internal surface of the pipe throughout the pipeline geometry
- Achieving recovery rates exceeding 99.5%
- Operating in both directions (bi-directional travel)
Fully Detectable Pigs That Can Navigate Bends
Importantly, HPS pig do NOT contain any solid magnets or magnetic powders. Instead, they have a unique, flexible magnetic core.
This enables full pig detection (essential for automation and control), while also allowing the pig to navigate bends.
Pigs which do contain solid magnets or magnetic powders should generally be avoided in process systems. This is because, if something goes wrong, a solid magnet is likely to break or shatter, and contaminate the line, leading to serious problems.
Similarly, is a magnetic powder escapes from the pig, it will cause major contamination problems which can be time-consuming and expensive to rectify.
The design of the specialist flexible core inside HPS pigs the risks of shattering and the associated serious line contamination risks.
Considerations When Pigging
While the ability of HPS pigs to handle bends is well-established, successful implementation still depends on good engineering practices. This is principally good pigging system design, but also ensuring pipework is in good mechanical condition (which includes a consistent internal diameter free of dents, intrusions, or misalignment)
Pigging is widely adopted in industries that process liquids.
HPS Advanced Liquid Product Recovery (ALPR) technology has been continuously developed over the years, ensuring it meets the rigorous demands of modern hygienic, industrial, and process-critical environments. Our systems are proven in applications across:
- Food and beverage production
- Chocolate and confectionery
- Paints and coatings
- Personal care and cosmetics manufacturing
- Household and homecare liquids
- Pet foods
- Industrial lubricants
- Battery fluids
- Sealants and adhesives
- Speciality and fine chemicals
- And many others!
These environments often involve complex pipeline networks – but our pigging solutions continue to deliver reliable, repeatable product recovery with exceptional performance.
Pipeline bends are not a barrier to effective pigging, as long as you select the right pigging technology.
HPS pigs operate efficiently in systems with bends, elevation changes, regardless of pipeline length – while maintaining high recovery rates and product integrity.
If your facility is currently experiencing high levels of product loss, long changeover times, excessive water or CiP chemical usage, or you would like to investigate innovative yet proven ways to improve your general operational inefficiency, it may be time to evaluate the benefits of integrating HPS pigging technology into your process.
Contact HPS Today
In these uncertain economic times, it’s more important than ever that companies that manufacture or process liquids operate at maximum efficiency.
So to discuss your pipeline configuration and how advanced pigging solutions can optimize your production, reduce waste, and improve overall environmental sustainability, please get in touch:
Our friendly, knowledgable team will be more than happy to have a open, no-obligation conversation with you about pigging technology, and whether it is right for your business.
Similar Articles about Pipeline Pigging and Bends:
Here’s another article about this subject that you might find interesting:
Advanced Pigging Technology: Navigating Bends and Enhancing Flexibility in Production Lines
