Advanced Liquid Product Recovery (Pigging) is a Game-Changer
In today’s rapidly evolving industrial landscape, efficiency and sustainability are paramount. As companies seek innovative solutions to streamline their operations and reduce waste, HPS Advanced Liquid Product Recovery (“Pigging”) Technology has emerged as a game-changer in liquid processing.
Also known as ‘pigging systems‘, this proven automated technology efficiently reclaims residual product remaining in process pipelines, increasing yields and cutting waste.
In the first installation of our Technology Focus Series, we take an in-depth look at pigging systems, specifically single- pig pigging systems, and the impact they are having on companies that process liquids, such as food, beverages, paint, homecare, lubricants, and many other applications.
Exploring Single-Pig Pigging Systems
At HPS, we design every advanced pigging system around the precise needs and requirements of each customer. However, it’s important to recognise that pigging systems come in different types and configurations.
One of the different types of pigging systems is the single-pig pigging system. In this setup, the product source is typically pumped from the source to the destination. The destination could be a filling machine or another storage vessel for the product.
Key Components of A Single-Pig System
Single-pig systems use one key component – the pipeline pig – to recover leftover residual product from pipes. This cylindrical specialist projectile travels along the pipeline, driven by a suitable propellant. Other key pigging system components include:
- Pig launch station
- Pig receive/return station
- Pig detector
- Pig housing
- Valves and fittings
- Automated control system
Simplicity and Cost-Effectiveness
Single-pig systems are renowned for their simplicity and cost-effectiveness.
In most cases, they are best suited for applications with a straightforward process where a liquid or ‘wet’ product is pumped from a single source to a single destination.
HPS has successfully implemented these systems for various processors, including food and beverage manufacturers as well as processors of lubricants, pet food, liquid detergents, beauty products and many more.
Variations and CustomiSations
While inherently straightforward, single-pig systems also offer flexibility and customisation. They can accommodate different launch configurations, from single source to multiple destinations, or multiple sources to a single destination, catering to a wide range of industrial needs and requirements.
Exploring the Cost of Single-Pig Systems
The cost of single-pig automated pigging systems can vary depending on several factors. This includes the size and complexity of the system, specific requirements of the application, and any additional customization requirements. However, single-pig systems are known for their cost-effectiveness compared to more complex pigging systems.
Because all customer processing plants are different, we tailor our solutions to meet the precise needs of each customer.
With HPS, there’s no such thing as a standard pricing model. Each project is assessed, and priced based on specific requirements, ensuring that you receive a solution perfectly aligned to your operation.
By working closely with our system design team, you can discuss your goals, operational challenges, and desired outcomes, allowing us to provide you with a detailed and accurate cost estimate and expected pigging system return on investment (ROI).
Benefits of Single-Pig Systems
Like all HPS systems, single-pig pigging systems deliver a wide range of benefits to companies that process liquids.
By reclaiming residual liquid from pipelines, they significantly increase yields. They also improve product quality by reducing contamination risks, and boost efficiency by speeding up changeover times and decreasing downtime.
Additionally, they lead to significant cost savings through waste reduction and lower operational expenses.
Flexible and user-friendly, single-pig systems can be tailored to various industries and contribute to environmental sustainability by minimizing resource consumption.
Specific achievements delivered to customers include:
- 93% reduction in waste compared to when using IBCs.
- Preventing the loss of 1200 gallons of usable product each cycle.
- More yield improvements –160 gallons of a popular homecare product (dishwasher fluid) per batch.
- Savings of 200 kg of butter oil on each run.
- 68 tonnes CO2e (or 99.3%) per changeover saving when replacing a conventional water flush changeover.
Limitations and Considerations
Despite the wide range of benefits single-pig systems deliver, this type of system does have limitations.
It is not suitable for highly complex processes or products prone to foaming and aeration issues, such as beer and wine. For these types of applications, a double-pig pigging system may be preferable.
Preventative Maintenance and System Reliability
Maintaining the reliability and performance of single-pig pigging systems is essential for uninterrupted operation and long-term problem-free operation of the HPS equipment.
While HPS systems are renowned for their durability and longevity, certain components, such as pigs and seals, will eventually need replacing due to normal wear and tear.
HPS offers comprehensive preventive maintenance packages tailored to the precise needs of each customer, ensuring optimal efficiency and system performance while minimizing downtime.
Regularly inspecting equipment and preventative maintenance helps address potential issues before they escalate, ensuring system reliability and longevity.
Training of How to Use the Single-Pig System
HPS provides extensive pigging system training and support to operators and maintenance personnel, so they have the necessary knowledge and skills needed to effectively operate and maintain single-pig pigging systems.
Unlocking Success: Case Studies on Single-Pig Pigging Systems
HPS have successfully implemented single-pig liquid product recovery solutions for numerous customers, delivering tangible benefits across various industries.
CP Kelco: How Single Pig Systems Maximise Yields and Reduce Losses
As an example, HPS implemented a single-pig automated pigging system for CP Kelco in the USA who manufacture a wide range of products for the food, beverage, and consumer products industries such as gum, pectin, xanthan and more.
The liquid product recovery system is helping the company increase yields and reduce product losses. Without the implementation of this innovative system, CP Kelco would have incurred substantial losses amounting to approximately 1200 gallons of usable product per cycle.
Read the full case study – How HPS Pigging Systems Increases Yields and Reduces Product Losses in Food Ingredients Manufacture.
Another Success Story: Barbot Paints
Another notable success story comes from Barbot Paints, where HPS recently implemented a single-pig pigging solution. Since the system’s implementation, Barbot Paints has experienced a remarkable improvement in product quality.
Bacterial contamination in their paint products has been reduced to almost zero, significantly enhancing overall product quality and customer satisfaction. This achievement underscores the effectiveness of fully automated single-pig pigging systems in not only maximizing efficiency but also improving product quality and safety.
Read the full case study – How HPS Pigging Systems Are Reducing Bacterial Contamination in Water-Based Paint Processing.
For further information on how single-pig pigging systems can revolutionize your liquid processing operations, or to discuss your specific requirements, please contact HPS!
Our dedicated hygienic and sanitary liquid product recovery experts are here to assist you and provide personalized solutions tailored to your needs. Get in touch today to explore how HPS can optimize your liquid processing efficiency.