HPS custom pigging systems for process industries

Advanced Liquid Product Recovery (‘Pigging’) Technology offers a versatile solution for various liquid processing applications. From food, beverages, and cosmetics, to paint, coatings and lubricants, pigging systems recover valuable residual product from pipelines that would otherwise be discarded as waste.

As global leaders in hygienic and sanitary liquid product recovery, HPS designs our solutions around the unique production needs and requirements of each customer.

In this article, we explore why custom pigging systems are important and the key factors to consider when designing one.

Why Custom Pigging Systems Matter

Not all companies offer bespoke pigging systems, as some opt for off-the-shelf solutions. However, custom pigging systems stand out for several reasons:

Every Plant is Unique

Just about every plant or factory layout is different. Unique factors such as pipeline configurations, product viscosities, production volumes, hygiene and sanitary requirements and operational goals all influence the optimal design of a pigging system.

That’s why at HPS, there’s no such thing as an off-the-shelf pigging system. Our experts work closely with each customer to understand their specific needs, challenges, and goals.

From there, we design custom pigging systems precisely tailored to address their unique requirements. Our focus on customisation ensures that our solutions not only deliver tangible benefits but also offer a high return on investment (ROI) and rapid payback.

reduce cross-contamination risks during product changeovers in liquid processing

Optimised Performance

Custom pigging systems are designed and engineered to match the unique characteristics of the products being processed.
This optimisation not only ensures efficient operations but also minimises waste and maximises operational efficiency and productivity.

Enhanced Reliability

Tailored to the specific operating conditions and challenges of your application, custom-designed systems are inherently more reliable, leading to reduced downtime and maintenance costs.

Flexibility and Adaptability

Liquid processing operations are constantly changing – whether due to new product formulations, changing production processes, or shifting industry standards.

Customised pigging systems designed around the precise needs and requirements of each customer offer greater flexibility to accommodate these ongoing changes.

As operational requirements evolve over time, bespoke pigging systems have remarkable versatility, seamlessly adjusting to meet the evolving demands of the industry.

HPS advanced liquid product recovery systems custom designed

Product Integrity and Quality

Maintaining product integrity and quality is crucial, especially in hygiene critical industries. Custom-designed systems can incorporate features to prevent contamination or product degradation, ensuring consistent quality and consumer safety.

For instance, in chocolate applications, this may involveusing jacketed pipework to maintain and regulate heat levels, ensuring the product’s integrity and preventing degradation.


Custom pigging systems deliver long-term cost-effectiveness by optimising performance, increasing yields, decreasing downtime, and cutting waste.

Calculate your estimated Pigging System Savings.

Export Support and Service

When opting for a custom pigging solution from HPS, customers benefit from the expertise and support of experienced engineers throughout the whole process, from your initial enquiry to post commissioning needs.

This ensures seamless integration, optimised performance, and ongoing reliability of the equipment.

HPS pigging system recovering product

Factors to Consider in Designing a Custom Pigging System

Product Characteristics

It’s important to understand the specific characteristics of the product being processed, such as viscosity, temperature sensitivity, abrasiveness, and chemical aggressiveness.

Depending on the specific characteristics of your product, HPS offer a range of pigging systems tailored to suit your needs.

In addition, the product characteristics will greatly influence the design and material composition of the pig (the specialist device that recovers product from the pipe). For example, FDA approved food grade silicone polymer materials are commonly used in hygiene/sanitary applications to ensure compliance with food safety standards and prevent contamination.

Likewise, solvent-based products need to be pigged using solvent-resistant pigs. Additionally, when dealing with more aggressive chemicals, it may be necessary to utilise a different model of pig that offers enhanced resistance and durability.

Pipeline Design and System Integration

The layout and configuration of the process pipelines play a critical role in determining the design of the pigging system.

Factors such as pipeline diameter, length, bends, material, and the condition of the existing infrastructure must be carefully evaluated.

The pigging system should be seamlessly integrated with the existing equipment, infrastructure, and automation systems to optimise performance and minimise disruptions to production.

beverage sector pigging systems

Operating Environment

It’s important to consider factors like operating temperature, pumping pressures, sanitation requirements, and potential hazards in the operating environment.

By evaluating and addressing these factors within the operating environment, designers can develop pigging systems that are robust, reliable, and tailored to meet the unique challenges of each application.


Automation plays a key role in improving the efficiency, productivity, speed, and safety of liquid product recovery systems.

During the initial stages of planning a pigging system, you’ll need to determine the desired level of automation based on operational requirements and objectives.

Automatic pigging systems are proven to streamline product recovery processes and improve safety by decreasing the risks of human error.

Either standalone or integrated automated pigging process control systems will need to be carefully considered when designing a custom pigging system. Standalone systems feature a separate panel from the existing setup and automatically control all aspects of the pigging operation.

Integrated systems seamlessly merge into existing process control systems, allowing for comprehensive control throughout the plant and enhancing the overall manufacturing process efficiency.

Scalability and Future Expansion

Anticipating future growth and changes in production requirements is essential to design a pigging system that is scalable and adaptable.

Pigging systems that are flexible and designed around the precise requirements of the plant and process enable easy expansion and modifications to accommodate ever-changing business needs and technological advancements.

Find Out More

By carefully considering these factors and partnering with a trusted provider like HPS, companies can ensure the successful implementation of custom pigging systems that enhances efficiency, increases yields, cut wastes, and drives overall operational excellence.

For further insights and comprehensive information, explore our whitepapers and resources via the Pigging System Resources section of our website.

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To learn more about HPS custom product recovery technology, please get in touch. We look forward to hearing from you!

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