January 24, 2024
HPS Product Recovery Solutions, the leading experts in process and hygienic pigging technology, discuss the evolution of pigging and its growth from a “nice to have” to an essential process technology.
Liquid product recovery (pigging) technology is widely used by food and beverage manufacturers. Modern pigging technology is included in the manufacturing process of everything from sauces, dips, ready meals, chocolate, meat slurries and pet foods to soft drinks, juices, wines, and spirits.
Pigging technology has developed a lot over the years, changing from a basic manual process, to fully automated, integrated high-performance advanced liquid product recovery technology.
Most processes that involve liquid transfer through pipelines reap major benefits when state-of-the-art pigging technology is implemented.
Increasing Use in Food and Beverage Production
The benefits of pigging technology for food and beverage manufacturers are influencing the general sector uptake of pigging systems.
Pigging recovers the product from pipelines during batch changeovers that would otherwise be downgraded or flushed to drain or waste treatment.
Pigging results in reduced changeover waste, increased yields and capacity, reduced energy, water and chemical consumption, improved productivity, and optimised efficiency.
It also makes changeover times much quicker and less resource-intensive, whilst maintaining chemical effectiveness and hygienic requirements.
As well as increasing profits, lowering costs, and delivering a rapid payback and strong ROI, pigging also increases environmental sustainability.
How Do Modern Pigging Systems Work?
Pigging works by propelling a specialist projectile (the ‘pig’) through a pipeline during batch changeovers. The pig has an interference fit with the inside diameter of the pipe, which enables any residual product to be recovered and sent to the destination.
There are multiple propellants that can be used to propel the pig, including filtered compressed air, nitrogen, carbon dioxide, water, the next product, or a combination of propellants.
Without pigging, the remaining product would be flushed to waste as part of the changeover sequence.
The pigging operation itself is extremely quick, and product recovery rates are high. High-end pigging systems will typically recover 99.5% plus of product from full lines.
Pigging systems used in food and beverage production are hygienic, closed systems, using pigs and other components made from FDA-approved materials.
Importantly, modern pigging systems are nearly always fully automated to ensure operational efficiency and safety.
Different Pigging System Types
There are many different types and configurations of pigging systems.
Single-pig pigging systems transfer the product to its destination, and then the pig returns.
Double-pig pigging systems use two pigs as part of the transfer sequence to prevent the product from encountering air. Manufacturers of products that can be spoiled through contact with air, such as wine, benefit from using these system configurations.
A more recent innovation is the dual-pig pigging system, specifically designed to combine product recovery with CIP process optimisation.
Additionally, there are multiple-source, multiple-destination and tank drop-off systems that facilitate more complex infrastructure layouts.
Overcoming Barriers to Adoption
One of the barriers to the adoption of pigging technology is the persistent yet outdated perception that pigging is a basic, manually operated technique that has very benefits.
That may have been true for some systems years ago.
However, pigging technology has advanced significantly. Most pigging systems are fully automated and can completely integrate into new or existing PLC systems to allow for seamless communication and efficient operations.
Another barrier is the high initial investment in pigging technology.
However, the high return on investment and payback calculations usually make a strong business case for pigging technology. Purchasing good quality pigging technology will result in high-performance systems that have a typical payback period of between six to twelve months.
After the initial investment is paid off, it is nearly all profit.
HPS Product Recovery Solutions
Founded in 1995, HPS Product Recovery Solutions increases its customers’ profitability by maximising yields, reducing waste, improving environmental sustainability, and optimising efficiency.
Headquartered in Nottingham, UK, HPS has offices in the US and Australia, and global partners worldwide.
