Real improvements are happening on production lines around the world.
Lubricant manufacturers are recovering hundreds of litres of oil that would otherwise be lost or downgraded.
They’re also preventing product cross-contamination.
A major honey facility has solved long-standing batch processing issues that were slowing down production.
To show what this looks like in practice, we’ve added three new case studies to our website. Each one highlights the measurable, long-term benefits HPS liquid product recovery (a type of pigging) technology is delivery across different liquid processing applications.
Lucas Oil Products: Eliminating Product Loss and Improving Tank Farm Efficiency
One of our new case studies features Lucas Oil Products, a global manufacturer of high-performance oils and lubricants.
During a major tank farm upgrade, Lucas Oil identified significant product loss when flushing their transfer lines.
HPS designed and implemented a fully automated pigging matrix system (in other words pigging systems and an automatic valve manifold) that now:
- Recover more than 99.5% of oil from the pipelines
- Stop unnecessary waste during transfers
- Cut down the time and labour spent on cleaning
- Improve throughput across their process
- Reduce effluent and environmental impact
One of the biggest wins came from simplifying their pipework.
What used to be a fairly complicated network has now been reduced to just three piggable lines, making the operation cleaner, easier to run, and much more efficient.
Read the Lucas Oil pigging case study.
Morris Lubricants: Stopping Cross-Contamination and Recovering High-Value Oil
We’ve also published a case study on our work with Morris Lubricants, one of the UK’s longest-standing oil manufacturers.
They needed a system that would stop different blends from contaminating each other and also recover the oil left behind in a 100-metre stainless steel transfer line used for tanker loading.
The 4-inch automated system we designed, supplied and implemented is now helping them:
- Recover the 200–300 litres they were losing each batch
- Prevent cross-contamination between different blends
- Integrate the pigging process into their existing PLC system
- Reduce manual work and speed up cleaning
- Improve site safety and reduce waste
The results have been strong enough that Morris Lubricants are already considering where else pigging could be used across their site.
Read about the Morris Lubricants product recovery project
Major UK Honey Producer: Cutting Waste, Energy Use, and Changeover Times
The third new case study focuses on a well-known UK honey brand that produces more than 26,000 tonnes a year.
They’d been dealing with a mix of challenges from sticky residues in pipelines, slow changeovers, high energy costs from heated lines to the complexity of running multiple products on shared equipment.
Over time, we helped them introduce 20 fully automated pigging systems, which have made a noticeable difference:
- Much higher recovery of honey that would otherwise be lost
- Far quicker changeovers
- The ability to run multiple honey products through the same line safely
- Better traceability
- More production flexibility and capacity
For viscous food products like honey, these improvements can transform the way a facility operates day to day.
Read about the honey processing pigging case study.
A Closer Look at What Pigging Can Deliver
Although these case studies come from different industries, the outcomes are surprisingly consistent. Implementing pigging often leads to:
- Higher yield by recovering product left in pipelines
- Less waste and lower disposal costs
- Faster cleaning and changeovers
- Decreased cross-contamination risks
- Reduced use of water, energy, and CIP chemicals
- More capacity without needing new equipment
Importantly, pigging tends to pay for itself quickly (often measured in weeks) and then continues delivering benefits year after year.
Explore the New Case Studies
If you want to see what these projects looked like in practice, you can read all three case studies on our website.
They give a detailed, behind-the-scenes look at how different companies approached their challenges, why they chose pigging and HPS, and the results they’re seeing now.
- View the new pigging case studies
- Find out how much product and time you could save with a recovery system of your own
If you’d like to discuss your specific application, our team is always happy to help.