Effective resource management and efficient energy consumption makes business sense to companies of all sizes and sectors.

As an unavoidable running cost, resources like electricity, gas, and water are the most consistent expense that companies pay for. However, just because these resources are unavoidable, that doesn’t mean that they can’t be efficiently managed.

Monitoring and managing energy usage is encouraged throughout the manufacturing sector, and most companies will already have energy management plans in place. Certain aspects of improving energy efficiency are relatively easy – turning off light switches in rooms, not leaving computers on standby, and having HVAC systems on a timer.

Other aspects, particularly those that take place during operational processes, may pose a challenge to manufacturers.

In this article, we will be looking at the key reasons for energy management and efficiency, ways to measure energy efficiency, and how companies that process liquids improve energy efficiency during operations with HPS Advanced Liquid Product Recovery (Pigging) Technology.

Key Reasons for Energy Management and Efficiency

There are three key benefits associated with energy management and efficiency in manufacturing:

  1. Financial savings
  2. Operational efficiency
  3. Environmental sustainability

Financial Benefits of Energy Management

Most companies that actively focus on improving their energy efficiency will do so for financial reasons.

Although energy management has been encouraged for many years, the significant rise in the price of electricity and gas since 2020 has seen interest increase. Companies are looking for ways to reduce their expenditure and investing in energy management is a beneficial way to do so.

Companies that practice traditional energy management techniques can expect to save an average of 15% on their energy bills (according to SensorFact).

For manufacturers of liquid products looking to save more, thinking outside the box and investing in a long-term solution, such as advanced pigging technology, is beneficial. High quality pigging systems are known to last for over 30 years with regular maintenance and operator training.

Operational Efficiency

Businesses and manufacturers will also look towards energy management programs as a tool for improving operational efficiency. Environmental management programs frequently include a review of existing procedures and operations, which highlight steps in procedures that may be unnecessary or not as efficient as they could be.

By reviewing processes and considering the impact of policy and procedure on energy consumption, companies can make changes that positively impact operations.

HPS’s pigging technology benefits companies who are looking to improve their operational efficiency by speeding up changeovers and CIP processes, reducing downtime, and increasing capacity and flexibility.

For example, pigging technology is helping DCS Group speed up their sanitisation process by 91% and has reduced their washout times by 83%. You can read the full case study on how HPS pigging systems improve personal care production.

Environmental Sustainability

Although the financial benefits are the primary reasons that companies invest in managing their energy, the growing need for sustainable actions has also seen companies turn to energy management programs.

Manufacturers keen on improving their energy consumption not only optimise resource usage but also reduce reliance on fossil fuels. Additionally, adopting smarter energy practices enables manufacturers to reduce their carbon footprint and enhance their compliance with sustainability regulations.

Pigging technology has been proven to help companies reduce their energy consumption and improve their carbon footprint through an independent study performed by Carbon-Zero. The report shows that HPS pigging technology helps manufacturers of liquid products to lower their carbon emissions by up to 99.3% per changeover.

By increasing the efficiency of changeovers and CIP processes, pigging technology also helps manufacturers reduce their electricity and/or gas consumption. Manufacturers who use heated water in their CIP processes also benefit from having to heat significantly less water, saving time and money.

Ways to Measure Energy Efficiency

For many manufacturers, the hardest part of energy management is knowing where to begin.

A good starting point is to research energy management programs and energy management systems, such as those provided by your electricity and gas suppliers.
Other options include researching energy efficient appliances and technology that can be implemented into offices and factories.

How To Improve Energy Efficiency

Energy management systems and programs help companies to highlight ways to increase energy efficiency. Even if manufacturers opt not to take part in a formalised energy management program, there are still ways that energy efficiency can be improved.

Energy Conscious Plant Design

Building and renovating manufacturing facilities can be a daunting task. However, the design and furnishing of factories can play a massive role in improving energy efficiency.

When planning and fitting factories, it is important for companies to consider the environmental impact of building on a site, the general layout and the impact on people and processes, the sustainability and energy efficiency of equipment, and the inclusion of facilities that enable closed-loop operations.

Manufacturers building new sites should also research their suppliers to ensure that they are contracting work from environmentally friendly and eco-considerate companies. This is particularly important as regulations come in that will require companies to keep a close eye on their scope 3 carbon emissions, as well as their scope 1 and scope 2 emissions.

Find out how pigging helps companies reduce their carbon footprints.

Investment in Energy Efficient Technologies

Energy efficient technologies are varied. From simple, everyday things, such as sensor activated lighting, to complex, specialist equipment, there is opportunity for improved efficiency in almost every aspect of factory processing.

Manufacturers of liquid products may struggle to find ways that they can improve their energy efficiency within the manufacturing process itself. The technologies that do exist are relatively niche or little known, however the demand for energy efficiency and energy efficient technology is raising their profile within the manufacturing industry.

For the remainder of this article, we’ll explore liquid product recovery, commonly known as pigging technology, uncovering its functionality and its pivotal role in aiding manufacturers to decrease their energy consumption.

How HPS Pigging Technology Helps Companies Improve Their Energy Efficiency

Pigging: What Is It?

Originally developed for use in the food and beverage industry, HPS pigging technology has been specially developed for use in other process and hygienic industries. The purpose of pigging in liquid processing is the recovery of product from pipelines and tubing.

How Does Pigging Work?

Pigging works by sending a specialist projectile, known as the pig, through pipelines. HPS pigs have an interference fit that minimises the quantity of product that bypasses the pig, creating a high recovery rate of up to 99.5% from full pipelines.

The pig is introduced to the pipeline via a pig launcher. Most modern solutions use automated pigging technology controlled by a PLC to do this as this enables easy and safe operation.

After travelling the length of the line, the pig enters the pig receiver. The bi-directional design of the pig removes the need for return loops or removal, allowing the pig to be sent back to the start of the line quickly where it re-enters the off-line pig housing.

HPS Advanced Liquid Product Recovery Technology is designed to accommodate CIP processes. The pig housing is designed to allow turbulent flow around the pig, ensuring the pig is thoroughly cleaned and reducing cross-contamination risks.

Who Can Use Pigging Technology?

HPS works with manufacturers in numerous liquid processing industries. We have extensive experience with companies who manufacture beverages, food, chocolate, confectionery, pet food, personal care products, cosmetics, homecare products, chemicals, lubricants, greases, paints, coatings, and more.

We also work with engineering companies and purchasing firms looking to provide high-performance liquid product recovery technology for their clients.

Find out more about the key industries benefiting from HPS pigging technology.

How Does Pigging Help Companies Improve Energy Efficiency?

Implementing pigging technology into operations allows companies to improve their energy efficiency in a variety of ways. It is worth nothing that some of the benefits of pigging are dependent on the specific processes performed by a manufacturer.

Pigging technology is used before or as part of changeover sequences, which can be highly energy intensive. Changeover processes can involve using high-powered pumps, heating water, or maintaining product liquidity using pipeline jacketing (this is particularly relevant to manufacturers of products like chocolate, confectionery, and edible oils).

Pumps, heating, and jacketed systems require significant quantities of energy to function.

Pigging speeds up changeover sequences, reducing the amount of time that pumps need to run and jacketing needs to be heated. Depending on the product and any changeover requirements, the length of time that production is down during traditional changeovers can vary from a few hours to days.

With pigging technology, the extensive process of clearing product from the lines is reduced. The HPS pig is capable of moving at extremely high speeds – testing indicates that the HPS pipeline pig can travel at speeds of 18.14 m/s. HPS clients have been known to decrease their washout times from three hours to 15 minutes (a reduction of 91%) due to the speed and efficiency of pigging systems.

Additionally, by recovering up to 99.5% of product from full pipelines, the quantity of water that needs to be heated for flushing purposes is reduced and, in some cases, removed all together. Heating water is time-consuming and energy-intensive, therefore removing the need for large quantities of hot water also speeds up changeovers and reduces energy consumption.

How Do We Go About Getting a Pigging System?

The best and easiest way to begin the process of investing in hygienic and sanitary pipeline liquid product recovery technology is to contact a reputable provider, such as HPS.

Reputable providers will offer:

  • Custom-designed solutions.
  • A thorough investigation into current processes.
  • Fast and reliable communication.
  • Lifetime Customer Care.
  • High-quality, high-performance equipment.
  • Training and maintenance plans to ensure safe operation.

Pigging technology providers should also have extensive, dedicated experience, working with a range of products in a variety of industry sectors. This will enable them to draw upon their knowledge to provide the best solution.

HPS Product Recovery Solutions

HPS Product Recovery Solutions have been in business for over 29 years. With numerous Advanced Liquid Product Recovery Systems commissioned and active, our systems are long-lasting and effective.

We work with many companies, ranging from SMEs to MNCs, including Croda, Mondelez, Coca-Cola, Sherwin-Williams, and Barbot Paints.

Find out how we can help you by getting in touch with us today.

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