Process Liquids? Here’s How to Lower Costs and Increase Your Company’s Profits
Key points
Liquid product recovery (widely known as “pigging”) systems can be found throughout the world operating in plants and factories that pump liquids.
They’re used in the manufacture of foods, beverages, confectionery, personal care, cosmetics, personal care, lubricants, pet food, homecare, paint, coatings, and many other products.
Pigging systems recover residual liquid product from process pipelines that would otherwise go to waste. Pigging technology is one of the easiest and most effective ways to save money and improve the bottom line in the process industries.
So, how does pigging translate into financial gain for companies that process liquids?
Recovering Product from Process Pipelines
Without a pigging process, pipelines are often flushed out with water or other liquid during product or batch changeovers. This results in saleable product being flushed down the drain to make way for the next product to run through the pipe. This process can be extremely time-consuming, wasteful, and expensive.
Because a pigging system recovers the majority of product from the pipeline during the changeover process, there’s a greater volume of product available for further processing, packaging, or sale. Also, less product will be sent to waste. This decreases waste disposal costs significantly. It’sd also much kinder to the environment.
The amount of product saved can be substantial. For example, a soft drinks manufacturer is saving roughly $31,500 US dollars a day with an HPS pigging system. That’s an extreme example, but typically companies will save the equivalent of thousands, sometimes hundreds of thousands of dollars per year.
Saving Water and Associated Costs
Water is a very important resource to many companies that process liquids. Pigging systems help manufacturers save water by reducing the requirement for long and continuous water flushing.
In certain circumstances, a pigging system can even eliminate the need for flushing completely. Even if water is still required for cleaning the pipeline, the amount needed will be far less with a pigging system.
This reduces water usage significantly, which, in turn, equates to significant savings on water and energy bills.
Less use of CIP Chemicals and Cleaning Agents
Because HPS pigging systems reclaim upwards of 99.5% of product from a full pipeline, there is less need to use sanitation and cleaning agents.
While a pigging system won’t necessarily eliminate the need for clean-in-place (CIP) completely, it will speed up the process, lower the amount of chemicals required, resulting in decreased costs.
Lower Cleaning and Labour Costs
Pigging reduces the effort and resources needed to clean process pipes. Because there’s less product to remove, the cleaning process is quicker and requires less labour. This lowers costs significantly. Semi-automated and fully automated pigging systems can reduce these costs even further.
Increased Uptime of Processing Equipment
With increasing customer demand, changeovers are occurring with greater frequency. However, the more changeovers there are, the more downtime there is which can drive up production costs, hinder the bottom line, and decrease throughput.
Pigging enables the transfer of multiple products through the same pipelines and reduces the number of dedicated lines needed.
Because the changeover process is extremely quick with a pigging system, manufacturers can meet customer demand for greater product variety. It also results in less production downtime, which means improved productivity, increased up-time, and more revenue.
The Bottom Line
For companies that pump liquids through a pipeline, pigging will save money by increasing yields, reducing waste, lowering water and chemical use, and making changeovers much faster.
In this way, pigging improves profitability, enhances competitiveness, and boosts the bottom line.
Importantly, pigging systems pay for themselves extremely quickly, while delivering a high return on investment (ROI) year on year.
HPS Product Recovery Solutions are the world’s leading experts in pigging and liquid product recovery solutions for process industries.
So, if you’re interested in finding out how much your operation could save with an HPS pigging system, contact HPS.
E: info@hps-pigging.com
T: +44 (0) 115 925 4700
W: www.HPS-Pigging.com
HPS Product Recovery Solutions (Hygienic Pigging Systems Ltd)
- +441159254700
- info@hps-pigging.com
- http://www.hps-pigging.com
- 46 Evelyn Street Beeston Nottingham Nottinghamshire NG9 2EU GB
About us
If you pump or process liquid or wet product, HPS proven pigging technology will increase your yields, reduce waste, speed up changeovers, improve your environmental sustainability and save you time and money.
By saving product instead of wasting it, HPS systems give you a high return on investment year on year. You’ll also get further gains from improved operational efficiency, less water and CIP chemical usage, and lower waste disposal costs.
How It Works
HPS pigging systems propel a specially designed projectile (the pig) through your line. This recovers the residual product you would usually flush to waste. This recovered product is perfectly usable, so you can continue to process it, pack it or sell it along with the rest of the batch.
HPS systems typically recover over 99.5% of product in a full pipeline. Exactly how much this is in terms of value depends on several factors (pipe length, diameter, product cost etc) but it’s nearly always significant. Meaning payback on your investment is rapid.
Plus, by pigging your pipeline you’ll make CIP and flushing a lot quicker and easier. So changeovers are faster and you save on cleaning agents, water, flushing, energy and labour.
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Where we supply to
UK Ireland, Europe, Africa, Asia, Australia, South America, North America
Industries we supply to
Automation, Chemicals, Consultants, Food and Beverage, Glass Ceramics Cement, OEM, Paper and Pulp, Pharmaceutical Cosmetics Toiletries
