pigging system industry applications

Pigging and Liquid Transfer Solutions in Wide Use

HPS pigging and liquid transfer technology is in use by a wide variety of sectors, industries and applications.

These include food, beverages, chemicals, paints and coatings, pet food, lubricating oils, homecare products, personal care liquids, cosmetics and many others.

Regardless of the application, HPS hygienic product recovery (‘pigging’) systems and liquid transfer solutions will improve your processing operations. This is through increased product yields, improved efficiency, waste reduction, less downtime, minimised contamination risks plus much more. Here’s more about the benefits of HPS pigging systems.

Different Solutions for Different Goals

So, which HPS solution is most suitable for your application?

There is no one-size-fits-all solution when it comes to HPS technology and all systems are custom designed to the individual process.

However, there are a variety of different types and configurations of pigging and liquid transfer systems to achieve different goals within your processing operations. They tend to fall into the following categories:

In this blog, we take you through the different types of HPS systems, to help you find the most suitable solution for your specific application.

Pigging Systems

The Single-Pig Pigging System

Suitable for:

  • Simple processes
  • Processes that pump a product from source to destination
  • Any type of product (except products with aeration and foaming issues)
  • Manual, semi or fully automated operation

The Single-Pig Pigging System is the most common type of product recovery system. As the name implies, the pig is usually sent from single source to single destination. The destination is typically either a filling machine or another storage vessel for the product.

Single-pig solutions tend to be most suitable for simple processes and typically consist of one launch and one receive station. They can be used for a wide variety of applications in different industries including food, beverage, confectionery, personal care plus many more.

Generally, if you pump a product from source to destination, then it’s highly likely you’ll be able to incorporate a single pig system into your processes. However, there are some exceptions as single pig systems may not be suitable for products susceptible to foaming or aeration issues.

So, how do they work?

Following the product being transferred to its destination, the pig is then introduced into the line via the launch station. The HPS pipeline pig recovers the product from the line and forces it to its destination. Once there, propellant is introduced at the Receive station to return the pig to the launch housing. Following that, the pigging sequence is complete.

single pig pigging system

The Double-Pig Pigging System

Suitable for:

  • Products that cannot come into contact with air
  • Beer, wine and foam gel products
  • Products susceptible to aeration and foaming
  • Semi or fully automated operation (although nearly always fully automated)

The Double-Pig Pigging System is often (but not exclusively) used with products that cannot come into contact with air during processing. This is because exposure to air may degrade the products, for example increasing the dissolved oxygen content in wine or because the products are susceptible to aeration or foaming. Therefore, this system is most suitable for beer, wine and foam gel products.

Double-pig systems are advantageous in these applications because they use two separate pigs. The first pig precedes the flow of product being recovered, typically to avoid air contact and minimise foaming or oxidative degradation. The purpose of the second pig is to clear the line, recover the residual product and transfer product efficiently.

With single pig systems, the pigging sequence begins only after the transfer of product has been completed. However, double pig systems differ as before the product is transferred, a pig is sent to the outlet of the pump to reduce the air in the line. The pig acts as an interface between the product and air within the line. This prevents air from coming into contact with the product and so eliminates any aeration and foaming issues.

Product is then transferred into the line behind the pig. The product then pushes the pig to its destination where the pig re-enters its housing. Once the transfer is complete, the second pig then recovers the product from the line as if it were a single-pig pigging system.

double pig pigging system

The Dual Pigging System

Suitable for:

  • Processes with a cleaning solution in between the pigs
  • Predominately paint and coatings applications but works with other products too
  • More complex processes
  • Semi or fully automated operation (although nearly always fully automated)

The Dual Pigging System like the Double-Pig System also uses two separate pigs. This system was originally designed for paint and coatings applications. However, if your application requires you to have a cleaning solution combination between the pigs, then the dual-pig system is for you.

The two pipeline pigs are introduced into the line with a measured amount of either solvent or water between the two pigs. The product-pig-cleaning solution-pig combination is propelled to the destination, recovering the product and flushing the line with the water/solvent product that is between the two pigs.

dual pig pigging system

The Tank Drop Off Pigging System

Suitable for:

  • Processes with multiple product destinations
  • More complex processes
  • Can be used for a variety of applications and industries
  • Semi or fully automated operation (although nearly always fully automated)

The Tank Drop Off Pigging System is relatively similar to a single-pig pigging system. However, it incorporates multiple destinations on the same line that the pig can recover product to, rather than a single destination. It can be used with a wide variety of products including chocolate, personal care, chemicals, plus lots more. What’s more, there is no limit on the number of tank drop-offs that can be used.

So, how do they work?

After product has been transferred to a tank, a pig will be automatically injected into the line to the blocking valve for that tank. Any blocking valves between the destination and the pig are opened up to allow for a clear route. As the pig is propelled through the pipeline, it pushes all product residue into the tank. The pig is then returned with the same receive-return pigging station used on a single-pig pigging system.

tank drop off pigging system

Liquid Product Distribution and Transfer Systems

The HPS Piggable Rotomatrix System

Suitable for:

  • Processes with multiple sources and multiple destinations
  • Used with a wide variety of products
  • Manual operation
  • Common with cosmetics, personal care, paints, wineries and bottling plants
  • Ideal replacement for traditional flow plates or bend panels
  • Companies looking for a cost-effective solution

If you have a need to quickly and reliably connect pipelines from multiple sources to multiple destinations, then the Rotomatrix system is for you. The HPS Piggable Rotomatrix System is a cost-effective, manual piggable manifold that uses a compact set of rotating arms.

It can be used with a wide range of products; however, it’s commonly associated with cosmetics, paints, pet food, wineries and bottling plants. The Rotomatrix offers fully flexible product distribution and product recovery from any source to any destination. Like the Automatrix below, it’s great for getting rid of ‘snake pits’ of hoses and flexible pipes.

Each arm contains a pig launcher directly after the pump and each destination has a pig receive station and return station. This enables a pig to be sent to and returned from any destination. So, for example, if you have multiple storage tanks, the Rotomatrix enables any of these storage tanks to transfer product to any of the process lines effectively and efficiently.

rotomatrix liquid transfer

The HPS Piggable Automatrix System

Suitable for:

  • Processes that transfer liquids from multiple sources to multiple destinations
  • Fully automated operation
  • Companies that have a need to improve safety and reduce connection errors
  • Industrial and hygienic processes
  • Common with paints, coatings, wine transfer and bottling

If you have a need to improve safety, reduce connection errors, limit hoses, and cut out nearly all manual selection procedures, then the HPS Piggable Automatrix System will meet your needs.

The HPS Automatrix is a fully automatic piggable valve manifold that enables full path selection. As the name implies, the Automatrix consists of valves that easily allow product to be automatically routed from multiple sources to multiple destinations safely, reliably, quickly, hygienically and efficiently. And because it’s fully piggable, it saves product, time, resources, water, CIP chemicals and labour. In this way, the benefits of HPS Automatrix liquid transfer technology are substantial.

There is no limit on the number of sources and destinations, therefore the Automatrix can be easily expanded in sources and destinations to meet future production needs. It is available in many different sizes and different mounting formats. These include horizontal, vertical, portable or as skid configurations.

automatrix liquid transfer

Contact HPS – The Pigging and Liquid Transfer Experts

Regardless of the solution you choose, if you choose HPS as your pigging and liquid transfer provider we can confidently say that our technology will transform your processing operations and deliver a high return on investment.

If you would like any more information about any of the pigging and liquid transfer systems listed above, then please do not hesitate to get in touch.

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