Pigging systems are a proven way for manufacturers to cut waste, improve yield, shorten changeovers, and reduce their environmental footprint.
For those new to the concept, pigging involves using a specially designed projectile (the “pig”) to recover residual product from pipelines that would otherwise be lost. The results are higher efficiency, less waste, and significant cost savings. Learn more about pigging and product recovery systems.
But for project and process engineers, the key question isn’t whether or not to use pigging – it’s how to implement it most effectively in their plant. Broadly, there are two scenarios:
- Retrofitting pigging into an existing line
- Designing pigging into a new installation
Both approaches deliver strong ROI. The right choice depends on where your plant is in its lifecycle, how much disruption you can tolerate, and your strategic priorities around cost, sustainability, and growth.
1. Retrofitting Pigging Into Existing Lines
Retrofitting is often the go-to choice when plants already have a well-established production line but want to improve efficiency, reduce waste, or respond to new sustainability targets.
Typical triggers for retrofits include:
- Rising ingredient costs or frequent product loss
- Pressure to reduce waste or improve sustainability metrics
- The need for faster product changeovers without major downtime
- Existing CIP (clean-in-place) cycles that are too long or costly (here’s the difference between CIP and pigging.)
- Nearing capacity and needing to create more, without adding more lines
Advantages of retrofitting:
- Fast ROI: Expert designed pigging solutions often pay for themselves quickly due to immediate reductions in product loss.
- Targeted upgrades: you don’t need to overhaul your entire line; pigging can be added to specific transfer routes where savings are greatest.
- Minimal new equipment: retrofitting typically involves modifying existing pipework and installing pig launch/receive stations, valves, and controls.
Considerations for engineers:
- Downtime and disruption: retrofitting may require temporary shutdowns; careful planning is key.
- Pipework condition: make sure there are no dents or damage along the pipe length you intend to pig. Welds should be smooth, clean, and have minimal intrusion into the internal bore to avoid obstructing pig travel.
- Pipework internal diameter: must be consistent throughout, with no obstructions which could hinder the pig (note bends are usually fine – the HPS pig can negotiate 1.5D 90 degree bends)
- System complexity: older plants may have layouts that require additional engineering work to integrate pigging smoothly.
In summary, retrofitting is often a low-risk, convenient and high-reward option for facilities looking to achieve quick gains without committing to a full redesign.
2. Designing Pigging Into New Installs
For new plants, expansions, or full line replacements, pigging can be designed into the system from day one. This gives engineers the chance to build an optimised solution that maximises efficiency across the line.
Another benefit of new builds is the chance to integrate pigging system design into wider project goals such as sustainability and compliance.
Advantages of adding pigging at the start include:
- Optimised layout: new systems can be engineered with pigging in mind, ensuring smooth pig travel and maximum product recovery
- Future-proofing: plants can be built to meet evolving sustainability and efficiency requirements.
- Cost efficiency: while retrofits can save money, adding pigging at the design stage often proves more cost-effective long-term, avoiding later modifications
- Integration with automation: pigging can be seamlessly incorporated into wider control systems, CIP (clean-in-place), and other automated processes.
Considerations for engineers:
- Capital investment: upfront costs may be higher than a retrofit, but lifecycle ROI is often stronger.
- Design flexibility: engineers can tailor the system to handle multiple product types, longer transfer lines, or complex routing.
- Project timeline: to ensure a smooth project, it’s best to factor pigging into project planning as early as possible. For new installations, incorporating pigging from the start sets the foundation for long-term efficiency, flexibility, and sustainability.
3. Which Option is right for you?
It’s not really retrofit versus new install – it’s about matching pigging to the right situation:
- If you’re running an established line that’s otherwise performing well but maybe nearing capacity or needs efficiency improvements, retrofitting is usually the quickest, most cost-effective route.
- If you’re building new facilities or replacing major lines, then designing pigging in from the start ensures you’ll maximise recovery, minimise operating costs, and avoid expensive modifications later.
Key factors to weigh:
- Product value and pipeline length (the higher the value of the product and the longer the pipeline runs, the greater the potential savings from pigging)
- Line age and condition (older lines or lines in poor condition may not justify a retrofit if replacement is imminent)
- Expansion plans (pigging is easier and cheaper to design in than add later)
- Budget and payback expectations (retrofit for speed, design-in for scale)
4. Real Customer ExAMPLES
Retrofit: An ingredients manufacturer integrated a pigging system into a reinstated 6-inch line. This prevented the loss of approximately 1,200 gallons of usable product during each cycle, delivering a rapid return on investment.
New Install: A leading personal care manufacturer relocated production to a new site and made the strategic decision to integrate HPS pigging technology during the design phase. This proactive approach has delivered major benefits, including faster and more consistent changeovers, a 93% reduction in product waste, and substantial cost savings through higher yields and lower effluent handling costs
See more real-world pigging results.
5. Final Thoughts
Both retrofit and new install approaches deliver strong business cases for pigging. The decision comes down to timing:
- Retrofit: When you want quick ROI, minimal disruption, and better performance from existing infrastructure.
- Design-in: The ideal option when you’re building new lines or redesigning existing ones. Incorporating pigging from the outset makes it easier to optimise layouts, maximise efficiency, and ensure long-term scalability and growth.
In either scenario, pigging technology helps protect margins, reduce waste, and deliver cleaner, more sustainable production – backed by long-term support and service.
Next Steps
Not sure which path is right for your plant? Request a Free Pigging Consultation from HPS. Our engineers will review your pipeline, model potential savings, and recommend the most cost-effective pigging solution for your needs.