HPS pigging system recovering product

Industries involved in liquid processing, from food and beverages to paint, confectionery, and beyond, are constantly looking for ways to stay ahead in the market and keep their products competitive.

Recognising the need for enhanced efficiency and reduced waste, these companies are increasingly turning to HPS Advanced Liquid Product Recovery (Pigging) Technology to optimise their processing operations.

Also known as pigging systems or pigging technology, this fully automated solution reclaims residual liquids from pipelines. This liquid would otherwise be flushed away during the cleaning and changeover process. However, pigging reclaims the product, increasing yields and reducing yields drastically.

In the second edition of our Technology Focus Series, we shift the spotlight to HPS Double-Pig Pigging Systems, focusing on the wide range of benefits they bring to companies that process liquids or wet products.

Exploring Double-Pig Pigging Systems

At HPS, we understand that each company we partner with possesses distinct needs, requirements, and plant layouts. That’s why we customise our pigging systems to seamlessly integrate with your specific operational setup.

In the first edition of the series we focused on one of the most common and popular configurations of pigging system: the single-pig pigging system. If you haven’t already explored it, we encourage you to do so in our Technology Focus Series: Single-Pig Pigging System.

Now, let’s investigate another key configuration of pigging system: the double-pig pigging system. This solution, which we design to align with your precise requirements, uses two pipeline pigs. This setup is commonly (but not exclusively) used with processes where the product must not come into contact with air during processing.

HPS double-pig pigging system

Applications Benefiting from Double-Pig Pigging Systems

Double-pig pigging systems are frequently used in processes where the product cannot come into contact with air, such as in beer, wine, and foam gel products.

This is typically primarily due to the adverse effects of air contact, especially in wine production. When wine is exposed to air, it can increase the dissolve oxygen (DO) content, which is detrimental to its quality. The increased levels of DO can cause the wine to age prematurely, develop off-flavours, and ultimately ruin its taste.

Too much air contact can also lead to foaming or aeration in certain products. If this happens during processing and production, it can result in significant delays and downtime. In some cases, it may even lead to the product being unusable, causing significant losses in resources and productivity.

However, these issues can be easily resolved with the implementation of a HPS Double-Pig Pigging System, which effectively prevents air contact.

Please note, the double-pig system is versatile and can also work with other products. Our team of experts will discuss this with you in the early stages of planning your custom pigging system to ensure it meets your specific requirements and product characteristics.

How the Double-Pig Pigging System Works?

A key feature of the double-pig system is the use of two pipeline pigs. Essentially, the first pig’s role in a double-pig system is to precede the flow of product being recovered, primarily to prevent air contact and minimise foaming or oxidative degradation.

The second pig’s role in the system is to reclaim the residual product from the process pipeline and push it to its destination safely and efficiently.

While the pigging process begins after the transfer sequence has finished in a single-pig pigging system, this isn’t the case for a double-pig system.

Here’s how it works:

In this configuration, before the product transfer sequence, the first pig is automatically sent to the outlet of the pump to reduce the air in the line. Acting as an interface, the HPS pig effectively creates a seal between the product and air, ultimately preventing aeration and foaming.

Following this, product is introduced into the line behind the pig. This pushes the first pig towards its designated destination where it re-enters its housing. Once the product transfer sequence concludes, the second pig then automatically recovers all the residual product from the pipe and forces it to its destination.

To visualise this process in action, we have a useful video that showcases the HPS double-pig system in operation. Enjoy watching!

Key Components of a Double-Pig Pigging System

Other than utilising two pipeline pigs, the double- pig configuration’s other key pigging system components include:

  • Pig launch station.
  • Pig receive/return station.
  • Pig detector.
  • Pig housing.
  • Pipework.
  • Valves and fittings.
  • Automated control system.
HPS pipeline pigs
HPS Double-Pig Pigging Systems use two pipeline pigs


Different Configurations of Double-Pig Systems

Like all HPS pigging equipment, the double-pig system provides flexibility and customisation.

They can adapt to various launch configurations, ranging from single source to multiple destinations, or multiple sources to a single destination.

In addition to products that cannot come into air such as beer, wine, foam gel products, and certain products in the dairy industry, they can also cater to a diverse array of additional industrial needs and requirements.

Determining the Cost of Double-Pig Pigging Systems

One of the most common inquiries we receive is about the cost of a double- pig system.

There’s no set answer to this as all HPS pigging system systems are bespoke and designed precisely to match the needs of each client.

That being said, several factors typically influence the cost, including: the size and complexity of system, unique requirements of the application, and any additional customisation needs.

Investment in HPS hygienic and sanitary pipeline product recovery technology represents a strategic decision for your company. While there is an initial cost associated when implementing a double-pig pigging system, the tangible benefits and return on investment (ROI) it yields will quickly outweigh these expenses.

It’s important to note, at HPS we prioritise transparency and accountability in our approach. Rest assured, we won’t recommend or sell a project unless we are confident it will provide significant value and return on your investment.

Benefits of Double-Pig Pigging Systems

Double-pig pigging systems offer substantial advantages to companies that process liquids.

Beyond their primary function of preventing aeration, foaming, and dissolved oxygen (DO) issues, double-pig systems bring about numerous other benefits. They significantly increase yields and production capacity while enhancing the efficiency of operations.

In addition, they also improve product quality by minimising bacterial contamination and the risks of product cross-contamination.

Other key benefits of pigging include reduced waste, faster changeovers, reduced downtime, and streamlined production processes.

Furthermore, they contribute to considerable cost savings by reducing waste and lowering operational expenses such as cleaning and labour costs. Please note, we have a useful tool on our website which you can use as a starting point to estimate your expected pigging system cost savings.

Moreover, double-pig systems have a positive impact on the environment by reducing resource consumption. With their rapid payback and impressive ROI, investing in pigging systems such as the double-pig system proves to be extremely beneficial for companies seeking efficient solutions to solve their most complex liquid processing challenges.

double-pig pigging system used with wide range of products
Double-pig pigging systems help prevent aeration, foaming and dissolved oxygen.


Aftercare, Maintenance and Training of Double-Pig Systems

Ensuring the ongoing performance and longevity of double-pig pigging systems requires comprehensive aftercare, maintenance, and training.

At HPS, we offer tailored maintenance plans to address the specific requirements of each client, optimising system efficiency, and decreasing downtime.

In addition, we also provide pigging system training to equip your staff with the necessary knowledge and skills needed to operate and maintain the double-pig pigging system effectively.

With our commitment to aftercare, support, maintenance, and training, we ensure that your double-pig system continues to deliver maximum value and efficiency for years to come.

Unlocking Success: Case Studies on Double-Pig Pigging Systems

HPS have successfully implemented double-pig pigging systems for many customers, delivering tangible benefits across diverse industries ranging from beverages and dairy to personal care and chemicals.

Croda Singapore: Reaping the Benefits of HPS Double-Pig Systems

As an example, HPS implemented a double-pig system for Croda Singapore who manufacture specialised products for the health and beauty care industries. These products include specialised lanolin-based surfactants, esters, and other chemicals.

In addition to double-pig systems, HPS also implemented a single-pig system and piggable valve matrices.

The liquid product recovery systems are helping Croda increase yields and ensure efficient liquid processing. Moreover, they also reduce product waste and minimise plant downtime.

Read the full case study – How HPS Pigging Systems Improve Chemical Processing and Production.

fully automated double-pig pigging systems

Unlocking Your Succes

For further information on how double-pig pigging systems can greatly enhance your liquid processing operations, please reach out to HPS!

Our dedicated team of experts are here to assist you and provide you with an innovative and bespoke solution designed around your precise needs. Simply send us an email, give us a call, or fill out a form, and we’ll be in touch!

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