DIY pigging system

At first glance, designing a pigging system might seem simple—simply push a pig through a pipeline to recover leftover product.

It’s a common misconception that leads to some companies or individuals trying to create their own pigging systems – and they can end up paying for it dearly.

Yes, the principle of pigging is pretty straightforward.

But be careful – that doesn’t mean it’s easy – or worth it.

Pigging systems (also known as liquid product recovery technology) involve much more than just the pig itself.

They are sophisticated, integrated solutions made up of specialist components such as pig launch and receive stations, pig detectors, valves, pipework, and automation software. Each of these elements must be carefully designed and configured to work seamlessly together for optimal performance.

Without the necessary technical expertise, companies that try to design pigging systems themselves (we call them “DIY” pigging systems) often fall short.

Far too often, the results are systems that don’t work very well (or at all!), causing in inefficiencies, safety hazards, regulatory non-compliance, and significantly higher costs in the long run – literally money down the drain.

In this article, we’ll look at the risks associated with DIY pigging systems and highlight the importance of using modern, automated pigging solutions from a specialist provider, to ensure reliability, safety, and maximum operational efficiency and performance.

HPS pigging system
                            Expert-Designed Advanced HPS Pigging System

 

Common Challenges with DIY Pigging Systems

Here are some of the most significant challenges businesses face when attempting to create a pigging system themselves:

1. lack of technical expertise

Designing an effective pigging system demands extensive knowledge in several critical areas:

Pipeline Design: Pipelines must be smooth, undamaged, and correctly sized to ensure efficient pigging and prevent operational issues.

Fluid Dynamics: A thorough understanding of how liquids and gases interact with the pig is essential for achieving effective propulsion and maximum product recovery.

Product Requirements: Different products have unique requirements, including specific materials and system designs, to prevent contamination and inefficiencies.

Interference Fit: The precise fit, dimensions and tolerances of the pig related to the pipeline, valves and other specifications is essential.

And much more! Without expertise in these specialised areas, DIY pigging systems are likely to underperform, fail prematurely, or pose safety risks.

2. Poor Component Selection

Selecting the wrong materials, components, or system configuration can have serious consequences, including:

Product contamination: Some materials aren’t compatible with food, beverage, or pharmaceutical products.

Pipeline damage: As well as performance issues, an improperly sized pig or unsuitable pipe material can cause wear or damage over time.

System inefficiencies: DIY systems often result in poor product recovery rates or slower processing speeds.

The success of a pigging system depends on the correct selection of materials and components tailored to the specific application. This level of customisation requires expertise and a deep understanding (and experience) of the operational environment.

3. Safety Concerns

DIY pigging systems can pose significant safety risks, including:

Overpressure: Incorrect pressure settings can lead to equipment damage, pipeline failure, and much more.

Pigging failure: An incorrectly designed system is more likely to cause a stuck or damaged pig, which can block the pipeline, halting production and potentially causing costly downtime or damage.

Operator injury: Without proper safeguards, manual handling of pigs can be hazardous. Pigs are heavier than many realise—for instance, a 4-inch pig weighs approximately 1.4 kilograms. When propelled at high speeds, any solid projectile of this weight poses a serious safety risk. If dislodged or released, the consequences can be severe.

We cannot overstress safety: HPS engineers have witnessed DIY systems causing pipelines to blow apart, pigs to break out of the system and fly, at high speed, across a factory, high pressure air escapes, pigs breaking in the line – the list goes on.

Inadequate Pig Detection: DIY systems often lack advanced pig detection technology, leaving operators unaware of the pig’s exact location. This can result in production delays, system malfunctions, and safety hazards, especially if the pig becomes stuck or malfunctions during operation.

safety first HPS

 

4. Regulatory Non-Compliance

Many industries, such as food and beverages, must adhere to strict hygiene and safety standards. DIY systems often fail to meet these regulations, resulting in:

Fines or penalties: Non-compliance can lead to costly legal repercussions.

Product recalls: Contaminated or compromised products can harm your brand and bottom line.

Damaged reputation: Failing to meet standards can have a negative impact on customer trust and confidence.

5. Long-Term Costs

While DIY systems might seem like a cost-effective option initially, they often lead to higher expenses in the long run due to:

  • Frequent breakdowns and repairs.
  • Inefficiencies in product recovery.
  • Increased downtime during maintenance or troubleshooting

Why Professional Expertise and Experience Matters

At HPS, our advanced pigging systems are the result of decades of innovation and hands-on experience.

While the principle of pigging—propelling a projectile through a pipeline to recover residual liquid—may seem straightforward, creating a safe, efficient, and reliable solution requires deep technical expertise.

Designing, manufacturing, and implementing a successful product recovery solution—especially one that recovers up to 99.5% of product and delivers a rapid return on investment—requires expert help. You need a team that truly knows what they’re doing. That’s where HPS comes in.

pigging system training

1. Tailored Design

Every HPS pigging system is unique, just like every production facility. HPS designs systems that align with your exact requirements, including pipeline layout, product type, and operational goals.

2. High-Performance Technology

From our high-performing pigs to advanced, non-intrusive pig detectors, every component in an HPS automated pigging system is specially designed for reliability, efficiency and durability.

3. Focused on Safety

Safety is a core feature of every HPS pigging system, which incorporates mechanical, electrical, and software-controlled measures to minimise risks.

These include interlocking devices, physical barriers, accurate pig detection systems, advanced software routines, system time-outs, and automatic venting to maintain safe pressure levels.

Additionally, the HPS pig is designed without solid magnets that can shatter or complex fins that risk tearing or pressure loss, ensuring reliable and safe operation at every stage.

4. Automation and Integration

HPS systems integrate seamlessly with your existing setup, offering semi or full automation for greater efficiency and safety. Our systems are compatible with PLCs, HMI screens, and SCADA software, providing precise control and monitoring.

hps pigging automation

5. Compliance Assurance

HPS systems are designed to meet or exceed industry standards for hygiene, safety, and sustainability. This ensures you remain compliant with regulations while delivering high-quality products to your customers.

6. Ongoing Support

We don’t just install your system and leave. HPS offers full support, including installation, training, maintenance, and upgrades, to keep your pigging system running smoothly. If you have a question, we have a dedicated customer care team at your service!

Case Study: The DIY Pigging System That Didn’t Work

At HPS, we often hear from companies that tried to build their own pigging systems but faced significant challenges. One such case involved a food manufacturer looking to cut costs by designing a DIY system.

Unfortunately, the system recovered very little product, leaving substantial waste in the pipeline. Within six months, frequent failures rendered it completely unusable, forcing the company to abandon the system.

When they turned to HPS, we installed a tailored, automated pigging system. The manufacturer is now benefiting from enhanced efficiency, minimal waste, and a reliable system that meets their operational needs.

DIY vs. Professional Pigging Systems: The Bottom Line

While it might be tempting to create a pigging system yourself, the risks far outweigh the benefits. A DIY system can lead to inefficiencies, safety concerns, and high costs, while an expert designed system like those supplied by HPS ensure reliability, efficiency, and long-term value.

Let’s put it this way – there are very few people who could buy a selection of components, then design and build a fully functional, safe and modern automobile.

It’s much the same with pigging systems!

Contact HPS

If your facility is still relying on outdated pigging technology, the time to upgrade is now. HPS Advanced Pigging Technology is designed to deliver superior safety, productivity, efficiency, and cost savings, ensuring your plant stays ahead in a competitive and fast-changing market.

Start maximising your yield, reducing waste, and improving your bottom line with a solution you can trust—contact HPS now!

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