For companies that process liquids or wet products, efficiency and cost-effectiveness are important.
However, many companies overlook one of the most effective ways to enhance both: Advanced Liquid Product Recovery (Pigging) Technology.
Also known as “pigging”, the technology is designed to recover product from pipelines, reducing waste and improving overall process efficiency.
Failing to implement technologies such as pigging can lead to a range of hidden costs that may not be immediately obvious but can significantly impact a company’s bottom line, operations, and environmental footprint.
1. Financial Costs
Product Waste
One of the most immediate and tangible financial costs of not using pigging technology is product waste.
Without pigging, a significant amount of product is left behind in process pipelines during each batch change or cleaning cycle. Over time, this accumulated waste represents a substantial loss in potential revenue.
For companies dealing with high-value ingredients, such as cosmetics, lubricants, or premium beverages —and even for manufacturers facing volatile raw material costs – the financial impact can be particularly severe.
The cost of lost product directly affects profitability and can add up to thousands, if not millions, of dollars annually.
High Cleaning Costs
In systems without a pigging process, cleaning pipelines between product batches or after production runs requires extensive use of cleaning chemicals, water, and manual labour.
These additional resources increase operational costs. The longer cleaning times also lead to more downtime, further reducing production efficiency and output.
In contrast, automated pigging systems can recover most of the product from the pipelines, reducing the need for extensive cleaning and the associated costs. In some cases, the need for flushing can be eliminated completely, due to the recovery efficiency of the HPS pipeline pig.
Energy Consumption
The energy required to pump, heat, or cool cleaning agents and to drive additional cleaning processes can be substantial. Without pigging, energy consumption increases, leading to higher utility bills. Over time, these additional energy costs can represent a significant financial burden, especially in large-scale operations.
As energy costs continue to rise, the impact on operating expenses only increases, making energy efficiency more crucial than ever for companies that process liquids such as food, beverages, confectionery, paint, personal care products, lubricants or any other liquids.
Here’s an article about how pigging systems save energy.
2. Operational Costs
Extended Downtime
Every time a production line needs to be cleaned or changed over to a new product; it must be shut down. These shutdowns are costly because they represent periods of lost production, directly impacting profitability. The longer the downtime, the greater the financial loss due to halted output and missed opportunities for generating revenue.
Without a pigging system, the cleaning process is longer and more labour-intensive, resulting in extended periods of downtime.
This not only reduces overall productivity but also limits the flexibility of the production schedule, making it harder to respond to ever-changing market demands or urgent orders.
Inconsistent Product Quality
Residual product left in pipelines between batches can lead to contamination, resulting in inconsistent product quality. Products left in the line may also deteriorate or solidify. This can lead to costly product recalls, rework, wasted product or even damage to the brand’s reputation.
Ensuring consistent quality requires additional measures, which can increase operational complexity and costs.
3. Environmental Costs
Higher Water and Chemical Usage
Traditional cleaning processes without pigging require large amounts of water and chemicals to flush out the remaining product from pipelines. This excessive use of resources not only increases operational costs but also contributes to environmental degradation.
Companies face increasing pressure to reduce water usage and minimise the environmental impact of their operations, and failing to adopt sustainable technologies and practises makes it harder to meet these goals.
Waste Disposal Challenges
The waste product, combined with the cleaning agents used in processing equipment, must be disposed of properly, often as hazardous waste.
Disposal can be expensive and subject to stringent environmental regulations. Non-compliance with these regulations can lead to fines, legal action, and damage to the company’s reputation.
Furthermore, the environmental impact of disposing of large quantities of waste is significant, contributing to pollution and the depletion of natural resources.
However, manufacturers with a pigging system can significantly reduce waste generation, mitigating these disposal challenges. By minimising the amount of waste being sent to waste, pigging has a positive impact on both operational costs and environmental sustainability.
Discover how pigging improves environmental sustainability.
Carbon Footprint
The energy-intensive processes required to clean pipelines without pigging also contribute to a larger carbon footprint.
As companies worldwide work to reduce their carbon emissions, the inefficiencies of conventional flushing become a significant drawback. Implementing pigging can reduce energy consumption, thereby helping companies to lower their overall carbon footprint and move towards more sustainable operations.
An independent report by Carbon-Zero highlights that pigging systems can reduce carbon emissions by over 2 tonnes each time a manufacturer switches from one product to another. The report specifically examines water-based and solvent-based paint production as examples.
Read the full Carbon-Zero report on how pigging reduces carbon emissions.
Time to Implement Pigging?
The decision not to use pigging technology in liquid processing carries hidden costs that can significantly impact a company’s bottom line, operational efficiency, and environmental responsibility.
By understanding and addressing these hidden costs, companies can make more informed decisions about their liquid processing systems.
Implementing HPS pigging technology not only helps to recover lost product and reduce waste but also enhances overall efficiency, leading to substantial long-term savings and a more sustainable operation. The return on investment of a pigging system is nearly always significant.
For companies looking to improve their bottom line, reduce environmental impact, and stay competitive in today’s market, pigging is not just an option—it’s a necessity.
Find Out More
If you are interested in learning more about pigging’s benefits specifically for your liquid processes, please get in touch.