With Quarter 4 just around the corner, there’s one thing that manufacturers of liquid products should be researching.
That’s the latest advanced liquid product recovery technology.
In other words, pigging!
Q4 is all about taking stock of the previous year and planning for the upcoming year: what went well, what went wrong, what could be improved.
It’s also, importantly, the time for realistic budget planning and proposals.
Examining the wins, losses and draws of the previous year will include looking at how you can improve in the new year and beyond.
When it comes to operational processes, you should be looking at advanced technologies that will minimise efficiency leaks and profit leaks. HPS Advanced Liquid Product Recovery (Pigging) Technology combats both.
How Do Manufacturers Use Pigging Technology?
Pigging is a versatile and innovative process used across various industries to recover residual liquids from pipelines. HPS has systems in numerous sectors. We work with companies who manufacture food, beverages, chocolate and confectionery, paint and coatings, lubricants and greases, personal care and beauty, pet food, homecare and household products, and many more!
But how do these manufacturers from all these different sectors use HPS advanced pigging technology?
Firstly, it’s important to understand what pigging is.
Pigging is a method used to recover residual liquids from pipelines that would otherwise be wasted during the cleaning or batch changeover process. It involves using a specialist projectile, known as the ‘pig’, which is made from product-compatible material with a flexible, magnetised core.
The pig is inserted into a pipeline and propelled through the system using a suitable medium as a propellant. As the pig travels through the pipeline, it pushes product ahead of it, effectively collecting the residual material. Once the pig has completed its journey, up to 99.5% of the residual product will be at its destination, be that a tank, IBC, filler, or the next part of the process.
HPS pigs are suitable for use within hygienic or sanitary applications. They can also be cleaned as part of your standard CIP procedures.
How Does HPS Pigging Technology Work For You?
HPS pigging technology will work for you, not against you. Manufacturers use HPS pigging technology to reduce waste, increase yields, improve efficiency, environmental sustainability and much more.
When researching advanced pigging technology, it’s important to consider the benefits of pigging. These include:
- Increased Product Yields: Pigging significantly reduces product waste, leading to cost savings and increased profitability. Although the exact recovery rate will vary depending on variables such as pipe length, pipe diameter, and product viscosity, HPS systems typically have a recovery rate of 99.5% or sometimes even more.
- Enhanced Efficiency: Pigging streamlines production processes by reducing downtime during changeovers and cleaning. In our most recent case study with the DCS Group, their changeover times dropped from 4 hours to 15 minutes!
- Reduced Contamination Risks: Pigging pipelines before CIP procedures ensures the thorough removal of product before the introduction of new product. This minimizes product cross-contamination, ensuring the highest product quality and compliance with industry regulations.
- Sustainability: By reducing product waste and energy consumption, pigging technology contributes to a more sustainable and environmentally friendly manufacturing process. HPS pigging technology also reduces the carbon emissions produced during changeovers –one study shows that HPS pigging systems reduced carbon output by up to 99.3%.
There are other pros to pigging, including reduced effluent and effluent-related costs, higher profits, increased productivity, and optimised efficiency.
What Equipment Is Required For Pigging?
Pigging technology relies on a few key components. Our system design engineers create bespoke pigging systems that account for each customer’s needs and requirements. No two HPS pigging systems are the same, and each pigging system requires different components.
However, there are a few components that each system will have.
- The Pig: The pig is the central component of the pigging system. It is designed to fit the specific dimensions of the pipeline and effectively recover the product.
- Pig Launchers and Receivers: Pig launchers and receivers are used to introduce and reclaim the pig from the pipeline. They consist of specialist valves, solenoids, pipework, and other components that work together to provide high-performance operations.
- HPS AccuTect Pig Detection System: The magnetised core of the HPS pig and the sensitivity of the HPS AccuTect Pig Detection System provide operators with peace of mind. With quick and reliable detection of the HPS pig, along with fast communication to the PLC, the control system (and operators) will always be able to locate the pig.
The Key Takeaways
Pigging technology has become a cornerstone of modern manufacturing practices across a multitude of industries. Its ability to recover valuable liquids from pipelines, reduce waste, enhance efficiency, and improve product quality makes it an indispensable tool in today’s manufacturing landscape.
As industries continue to seek ways to optimize their processes and reduce environmental impact, pigging technology is set to play an even more significant role in shaping the future of production. No matter what industry you’re in, pigging technology is a game-changer that deserves your attention.
You can also use our Savings Calculator to see how much money and product HPS pigging technology could save you.