Process Liquids? Here’s How an HPS Pigging Solution Will Help You Cut Waste, Increase Yields and Improve Sustainability in 2022
Key points
Raw material prices are surging. Competition is increasing. Margins are getting tighter. Sustainability targets are becoming ever-more demanding.
As a result, waste reduction and efficiency gains are high on the list of priorities.
For companies that transfer liquids during production, one of the easiest and most effective methods of increasing yields, cutting waste, reducing water and CIP use, and speeding up changeovers, is to use HPS liquid product recovery (pigging) technology.
High Return on Investment
Pigging systems recover residual liquid from pipelines that would otherwise go to waste.
They’re used in everything from food, confectionery and beverage manufacture to cosmetics, household goods, paints and coatings production.
There are major cost savings and efficiency gains from using pigging. That’s because the recovered product can continue to be used, rather than wasted.
For example, a soft drink manufacturer implemented an HPS pigging system and is saving roughly $31,500 US dollars’ worth of product a day.
So, the return on investment from a pigging system is high. Payback is also extremely quick, usually just a few months.
How Pigging Works
Pigging automatically propels a specialist projectile (the “pig”), through a process pipeline.
As the pig travels through the line, very little liquid can get passed it. So, the pig safely reclaims the liquid product.
Increased Yields and Reduced Waste
Because pigging recovers nearly all the residual liquid, it’s an incredibly effective way to increase yields.
These increased yields mean more capacity, more flexibility, more saleable product, better productivity and higher profits.
Faster Changeovers
After pigging, there’s barely anything left in the line (HPS pigging systems typically remove upwards of 99.5% of residual product). As a result, changeovers are much quicker.
And because there’s hardly any product left, the requirement for flush and CIP is greatly reduced.
While pigging will not completely eliminate the need for CIP, it will significantly shorten or remove some stages of the CIP process.
Improved Sustainability
Pigging helps companies improve the environmental sustainability of their operations.
By saving product, reducing water and CIP chemical usage, pigging reduces the financial outlay needed for them. It also reduces the associated transportation, treatment and disposal costs.
For example, using HPS pigging systems, a wine manufacturer estimates savings of 40 million litres of water a year, as well as wine savings of 440,000 litres.
Choosing the Right Pigging System
Getting pigging right isn’t easy. There are a lot of different variables to consider, and there are big differences in the effectiveness and performance of different pigging systems.
If you’re looking to implement pigging in your company, make sure you choose a specialist provider, with proven technology and a strong track record (particularly where safety is concerned).
Choose the Right Pig
One of the most important components of any pigging system is the pig itself.
The highest performing pigs tend to be of one-piece, cylindrical, flexible design. Beware of pigs with fins (fins can break, tear, and product can build up behind them after a while causing hygiene issues).
Importantly, don’t use pigs containing solid magnets. That’s because solid magnets can break, shatter and even escape from the line, which is a serious safety concern.
Instead, use a pig with a flexible magnetic core.
Additional Benefits of Pigging
There are many other reasons pigging systems are in wide use in the process industries.
These vary, but include replacing dedicated lines with shared lines, decreased labour costs, prevention of aeration, and reduced contamination risks.
HPS Product Recovery Solutions are the world’s leading specialists in process pigging and liquid transfer solutions.
So, if you’re looking to cut waste, increase yields and improve sustainability in 2022, contact HPS.
T: +44 (0) 115 925 4700
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
