pigging systems save carbon

HPS Technology Has Reduced CO2e By over 27k Tonnes in 2023.

Sustainable manufacturing is a concept that is growing in importance. Manufacturers who are working towards improving company sustainability are emphasising the need for recyclable packaging, minimised wastage, and optimised resource use.

“Sustainable manufacturing is the creation of manufactured products through economically-sound processes that minimise negative environmental impacts while conserving energy and natural resources.” – USEPA

The move towards sustainable manufacturing means that companies are looking for innovative technologies and processes that can help them reduce their environmental impact and carbon emissions.

Companies use a controversial technique called carbon offsetting, which many sustainability gurus see as a ‘last resort’ technique, to minimise the impact of their manufacturing processes. But there are also ways to reduce the amount of carbon produced that businesses should consider.

If you work for a company that manufactures or processes liquids, then HPS Advanced Liquid Product Recovery (Pigging) Technology is one of them.

What Is HPS Advanced Liquid Product Recovery Technology?

There are many reasons that manufacturers use HPS pigging and piggable liquid transfer solutions. A key benefit is the positive impact of pigging on the environment.

Pigging is a versatile process that enables companies to recover residual products from pipelines easily and efficiently.

Using automatic pigging controls, the system can quickly and safely introduce a projectile, known as the pig, to the pipeline from the pig launch station. A suitable propellant sends the pig through the pipeline, pushing the residual product to its destination.

The hygienic nature of the HPS pig means that the recovered product can continue to be processed, packaged, and sold, reducing waste and increasing yields. The unique design of the HPS pig ensures high product recovery rates of up to 99.5% from full pipelines.

Carbon Washing in Manufacturing

Recent studies have shown that a sizeable portion of consumers consider sustainability when they are looking to make a purchase. Although the figures vary according to sector, region, and study, the general range is between 63% and 78%. Consequently, companies are advertising their sustainable actions and their carbon emissions with vigour.

However, the quality of the sustainable actions and the resulting decrease in carbon emissions has been called into question for many companies. Businesses purchase carbon offsets, such as tree planting and carbon capture equipment, that they advertise as sustainable actions but that do little to reduce carbon emissions.

Whilst carbon offsetting is beneficial as a last resort, manufacturers need to look at long-term solutions that verifiably decrease carbon emissions.

How Pigging Reduces Carbon Emissions

Finding technologies that have proven results in terms of reducing carbon can be a challenge for manufacturers. Carbon reduction technology for manufacturing processes is a niche sector that requires extensive research. Initial results focus on optimising the use of digital technology and recycling materials to create closed-loop manufacturing processes. Technologies that are implemented directly into operations are harder to find.

Liquid product recovery solutions directly impact operational procedures. They are beneficial to companies looking to streamline their operations and move closer to their sustainability targets.

The environmental benefits of using high-tech pigging technology include:

  • Reduced chemical, water, and energy consumption
  • Reduced waste and effluent
  • Reduced carbon emissions from effluent-related transport, treatment, and disposal
  • Reduced carbon emissions from changeovers

There are many more benefits of pigging for manufacturers, including financial, operational, and logistical.

Carbon Footprint Reduction and HPS Technology

In 2022, independent consultancy Carbon-Zero assessed and compared the carbon footprint of conventional changeover processes to the HPS hygienic pigging process. Using paint manufacturing as an example, the report proved that HPS Advanced Liquid Product Recovery Technology reduces carbon emissions during changeover procedures.

The report considered both water-based and solvent-based paint manufacturing to calculate how much carbon emissions decreased when using HPS pigging technology.

Report Carbon Footprint Reduction-of-HPS Pigging Technology

You can read the full report to find out how HPS technology is benefitting manufacturers, but here’s a quick summary.

  • 7 tonnes CO2e per paint changeover is associated with a conventional changeover of water-based paint.
  • 6 tonnes CO2e per paint changeover is associated with a conventional changeover of solvent-based paint.
  • 0.02 tonnes CO2e per paint changeover is associated with a changeover of water-based paint using HPS technology. This is a reduction of 99.3% per changeover.
  • 0.24 tonnes CO2e per paint changeover is associated with a changeover of solvent-based paint using HPS technology. This is a reduction of 90.8% per changeover.

Although the report is based on paint manufacturing, the same or comparable results apply to all manufacturers of liquid products who use HPS technology.

We have calculated that for every fifty individual pigging systems commissioned, pigging technology reduces carbon emissions in liquid manufacturing by over 27,375 tonnes this year. This is based on an average reduction of 1.5 tonnes of CO2e per changeover and an average of one changeover per day per line.

The reduction of carbon emissions within a business is beneficial for other reasons as well. Governmental bodies are introducing initiatives that are geared towards the reduction of scope 3 emissions throughout the supply chain, meaning all businesses will have to actively work towards reducing their scope 1 and scope 2 emissions.

Improving Sustainability in Liquid Manufacturing

With government bodies around the world seeking to reduce the quantity of carbon and greenhouse gases produced by their industrial sectors, manufacturers of liquid products need to stay up to date with carbon-reducing technologies.

Implementing technologies like pigging can seem like a daunting task, but it doesn’t have to be. The HPS team are product recovery experts with over 28 years of experience designing and commissioning pigging systems and liquid transfer solutions. This means that we can guide you through the entire process and supply you with the best solution for reducing your carbon footprint.

Every process is unique, which is why we only design bespoke pigging systems for our clients. Tailor-designed pigging systems improve efficiency, both in terms of product recovery and carbon reduction.

Having high-quality, high-performance technology benefits companies looking to improve their sustainability. Not only does it benefit the world, but companies can advertise how their processes and products are becoming greener without risking accusations of carbon washing.

HPS Product Recovery Solutions

HPS Product Recovery Solutions is the world’s leading provider of high-quality Advanced Liquid Product Recovery Technology for manufacturers across the globe. With over 28 years of experience, we provide comprehensive guidance on the perfect system for your processes, as well as unparalleled customer support after commissioning.

We are proud to be a sustainable business having achieved the Investors in the Environment Bronze accreditation and ISO 14001 certification. You can find out more about how HPS is an environmentally friendly company by reading our Environmental Policy.

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