How the DCS Group Are Significantly Increasing Yields while Reducing Waste and Production Downtime
We recently issued our latest case study on pigging for personal care processing. The case study shows how a well-known British manufacturer, the DCS Group, is using eight HPS pigging systems to improve their processes.
The DCS Group is using their pigging systems to reduce waste, create less effluent, optimise changeovers, reduce production downtime, and increase yields at its new plant in Redditch, UK.
ABOUT THE DCS GROUP
DCS Manufacturing is a modern private-label health and beauty product manufacturer that specialises in liquid-fill products.
DCS make a wide range of products for many of the world’s best-known and well-recognised brands. The products include shampoos, conditioners, gels, lotions, creams, body sprays, and natural silicone oil-based products, as well as sanitisers.
Importantly, DCS also produce the Enliven range of products, which is their own brand.
The Enliven brand delivers quality personal care and grooming products of exceptional value. These range from everyday essentials to a select range of luxury items.
In 2020, the DCS Group relocated their manufacturing facilities to a larger, state-of-the-art factory in Redditch, England. They took the opportunity to review the whole factory layout and processes.
HPS PIGGING SOLUTIONS FOR PERSONAL CARE PRODUCTS
Case Study – HPS Pigging and DCS When moving into the new facility, DCS recognised that the manual cleaning and CIP procedures they had formerly had in place were unsuitable for their new facility.
They wanted to ensure that they created as little liquid waste and effluent as possible during changeovers whilst also optimising their changeover times and CIP routines.
HPS designed, supplied, and implemented eight fully automatic, single-pig pigging systems for the DCS Group.
Like other pigging systems for personal care manufacturers, the HPS equipment is sanitary, preventing batch cross-contamination and increasing product quality.
HOW IS THE DCS GROUP BENEFITTING FROM HPS PIGGING TECHNOLOGY?
Since the final commissioning of the HPS pigging systems took place, the DCS Group have recorded:
- A 91% decrease in sanitisation time, from 3 hours to 15 minutes.
- An 83% reduction in washout times.
- A 93% reduction in waste, compared to when using IBCs.
- Very little effluent to dispose of.
- Fast, reliable changeovers and transfers.
Although these are the most notable benefits of pigging for the DCS Group, we’re sure that there are many more for them to discover!
FIND OUT MORE
Alternatively, you can find more case studies on pigging in the Resources section of our website, covering industries such as food, beverages, chocolate, homecare and household, and paints and coatings.
To discover more about how HPS Advanced Liquid Product Recovery (Pigging) Technology can help you improve your processes and increase yields, please get in touch today!