Reduce Product Waste
Throw less of your product to drain with a world leading product recovery solution
High ROI
Discover tangible returns with more product going to your customers
Lower Carbon Footprint
Reduce waste, water, and harmful CIP chemicals with Pigging technology

Discover Pigging

World Leading Technology

Streamline Your Process

Welcome to blucorcontrol

blucorcontrol are proud to be working with the world leaders in liquid product recovery, transfer, and hygienic pigging systems, HPS – Product Recovery Solutions.

These systems are used to help organisations increase the profitability and efficiency of their processes as well improving their carbon footprint. For more information on blucorcontrol and how these systems can help you and your operation, please click on the tabs below.

What “Pigging” Means

Simply, “Pigging” is the process of forcing a solid projectile through a pipeline to recover product. It was initially used in the oil and gas industry, but more recently has been adapted and scaled down for many liquid process industries.

In these applications the “Pig” has a slightly larger diameter than the pipeline that is being pigged. The propellant used to push the Pig can vary from compressed air, carbon dioxide, nitrogen, water, or the next product. These systems are most often used to recover product to a destination such as a storage tank or a filling machine. A simple pigging system example can be seen below:

How are the systems used?

The most basic and typical example of a pigging system can be explained using the video above as a template.

Pigging can be used with a wide variety of liquid products, but in this case we’ll use sauces as an example.

A manufacturer of sauces uses the same line to run different products on a daily basis. After each run of product the pipeline will still be full of sauce, meaning that this must be removed before they can run another product through the same line. The most usual way of overcoming this problem is to run water or cleaning fluid through the line. This is costly, time consuming, and also means that the line may still hold pockets of water or cleaning fluid.

In the video above the manufacturer is running a sauce into their filler for bottling. Once the storage tank has emptied the pigging sequence is started. A launch housing introduces the pig into the line via a piggable diverter valve and starts to empty the line of sauce to the filler (notice how the pig stops depending on the demand from the filler). If it’s a high-performance Pig such as those from HPS, it will recover up to 99.5% of product from the piggable line. After the pigging sequence has finished, and the pig has automatically returned to it’s housing, then either the next product can be run, or a less intensive CIP sequence can be run. The pigging sequence can also be used to recover the CIP fluid.

Is Pigging used in your industry?

Pigging is currently used in many process industries, including the following: Beer, Wine, & Spirits, Soft Drinks, Confectionery, Chocolate, Food, Paint, Pet Food, Homecare, Beauty, Cosmentics, Personal Care – and many others!

Benefits of Pigging

There’s a lot to gain from Pigging. Benefits include:

  • Increased Profits, Productivity and Efficiency

Other than increasing product yield by recovering product that would otherwise have gone to waste, Pigging can help reduce cleaning and changeover times between production runs. The reduction in changeover and cleaning times also reduces labour costs and downtime of the line.

  • Increased Product Yields

After a transfer, even if the line is gravity fed, there will be residual product within the line, especially if it is a high viscosity. A properly designed Pigging system that uses a high-performance pig will recover up to 99.5% of product from the piggable line.  The recovered product will be in the same condition as the rest of the product and therefore you can use this product as normal.

If your product has foaming or aeration issues then usually the line will be purged with water or even the product itself. The initial run of product will be wasted because it mixes with the water or it is ran until it no longer foams. A pigging system can remove the need for this step altogether and therefore increases yields in this case. (Please see “System Types” tab for more information on how Double Pigging Systems can help with aeration and foaming issues)

  • High Return on Investment (ROI)

The culmination of reduced waste and increased product yields provides a high ROI, typically customers will see an ROI within 1 year. If you have a high value product and a large line that has a lot of residual product after a product run, then your ROI will be significantly high with a Pigging system.

  • Reduced Water Usage

Water reduction can come in many ways, the most obvious way is because of shorter cleaning times. The less residual product left in the line requires less water to remove it. Also, if you are purging a line with water then this step can also be completely removed with a properly designed Pigging system.

  • Positive Environmental Impact, Lower Carbon Footprint, Better Sustainability

Simply, the less residual product left in your lines means that less product has gone to waste and your lines require less cleaning chemicals and less water. Therefore your waste management or waste removal is reduced (as well as associated costs with this). More companies are turning to pigging systems to help them reach their environmental sustainability goals, especially concerning water use. A Pigging system can achieve these goals as well as many other benefits!

System Design

 

So that we can understand what will be the most efficient and effective way to implement the technology, before we design your Pigging system we will perform a comprehensive survey of your process. None of the systems are off the shelf and most often they are retro fitted around your existing process, so expert care and consideration should be taken.

 

 

 

Our systems can be designed around bend panels, pasteurisers, tank farms, heat exchangers, level and pressure equipment and many other standard pieces of process equipment.

To do this effectively we use industry leading designs and technology. These integral parts of each pigging system are listed below.

 

 

The Pig & the Pig Detector

The HPS Pig has a market leading design. It is made entirely of silicone and is fully flexible, this allows it to safely navigate your line at high speeds and pressures as well as travel through 1.5D 90° bends.

The inner core of the HPS Pig is made of a magnetic silicone, this compound is magnetised by HPS at their headquarters in Nottingham, UK.
This allows the pig to be detected by the HPS Pig Detector – a non-intrusive detector calibrated to detected the HPS Pig which is mounted on the outside of the pipeline.

With the full surface area of the pig touching the walls of the pipe it creates a better seal (especially through bends and uneven surfaces such as welds) and therefore much more efficient recovery capabilities compared to other pig designs. This is how the HPS design of pig is able to create up to 99.5% recovery through piggable pipe. The pigs are suitable for recovering chemicals, paints, concrete, oils, food, beverages, pastes, gels, homecare and personal care products.

– Sizes range from 1inch to 8 inch
– Bi-directional
– Works in temperatures up to 250°c
– Gauranteed to work up to 30km
– FDA Approval spec 177.2600

 

The Launch & Receive Stations

Each pigging system needs a way of introducing the pig into the line, and also a way of receiving the pig once it has finished recovering the product. The pig is introduced into the line with the launch station but during a transfer the pig stays inside the launch housing as there is a piggable launch valve that keeps the launch housing locked off from the main line.

The receive station is where the pig is sent to when recovering the product, once the pig is detected at the receive station then the system valves are opened and closed to allow the pig to return to the launch housing.

There are many arrangements and potentially more than one of each station per line depending on the design of the system.

 

 

HPS ISBV

The HPS Inflatable Seal Ball Valve is a hygienic ball valve that is both piggable and has a fully CIP-able cavity. Most balls valves have a small cavity and a constant seal against the ball, this makes cleaning the cavity almost impossible.

The ISBV has an inflatable seal, so when inflated it creates a strong seal against the ball, when it is deflated it allows for the ball to move and/or the cavity to be fully cleaned during a CIP. Arrangements come in both 2-port and 3-port, and are also used on launch stations or as diverter valves.

 

Custom Design and Custom Built

Most pigging systems are retro-fitted, and therefore the design must be specific to the existing equipment as to not disrupt the existing efficiency of the line and also the consistency of the quality of the product. Systems can have multiple drop offs to different destinations on the same line, or be diverted to different fillers or destinations from a single launch housing. This is done with the HPS Piggable diverter valve. This valve is also used to divert around heat exchangers and other pieces of non-piggable equipment.

 

Safety

Safety is intrinsic to many aspects of our systems, for example, the lack of a solid magnet within the pig makes the HPS pig the safest on the market. But one of the most important aspects, which has been achieved through constant improvement over 20 years, is the software. The Functional Design Specification (FDS) is written so that the software for the pigging system has many fail safes relating to potential faults during the sequence (such as valves failing to open etc). This keeps both the pigging system and your existing equipment safe.

Also, the launch stations are designed so that if there is an unexpected fault during a sequence, such as a power failure or even a software fault, that the system depressurises itself without any need for physical interference.

System Types

Pigging systems can come in many arrangements and configurations to achieve different goals within your existing lines. The most basic systems are listed below.

Single-Pig System

This is the most common type of system which usually consists of 1 launch station and 1 receive station. This system is often not suitable for products with foaming or aeration issues, but any other product that you are pumping from A to B can have a single pig system integrated with it. After transferring your product to your destination the launch station will introduce the pig into the line and the pigging sequence will recover the product to the receive station. Once the pig has been received it will return to the launch housing and the sequence will be complete.

Double-Pig System

This system incorporates two pigs in the system. It is most often used to stop aeration and foaming and is the most appropriate system for beer and wine producers. A single pig system only starts its sequence after the transfer of product has been completed, with a double pig system the system initially sends a pig to the outlet of the transfer pump, the pump then starts to transfer product which pushes the pig to the destination and into a receive housing, when the pig is received in the housing the product is diverted as normal to the destination. Once the transfer is finished then the second pig recovers the product from the line as a normal single pig system would do.

The pig on the outlet of the pump creates a barrier between the product and the air within the line, this stops any aeration or foaming if it is implemented correctly.

Tank Drop Off System

A drop off system is the same in principle as a single-pig system, but between the launch and the receive there are multiple drop-offs that the pig can recover product to. The drop-off system can also be used with a double pig system too.

HPS Rotomatrix

The HPS rotomatrix offers fully flexible product distribution much like traditional flow-plates and bend panels, but is fully piggable. It can come with 8 arms and up-to 20 destinations.
The arms are easily manoeuvrable due to the swivel joints which makes it easy for operators to select new destinations.

  • Pipe diameters from 1½ to 4 inch.
  • Safety feedback with path selection integrated into PLC.
  • Expansion can be accommodated into the design for future lines or destinations.

 

 

HPS Automatrix

This Fully-Automatic Product Distribution System allows full path selection & product recovery from any product source to any destination. They can be mounted vertically or horizontally or as a skid with all wiring and I/O completed. The system is fully automated which can reduce labour costs and user error. The system can be fully integrated with pigging and CIP.

  • Massively Speeds Up Changeover and Selection Times
  • Easy to Operate and Control
  • Improves Safety by Reducing Manual Changeovers
  • Saves Resources and Labour
  • Lowers Chances of Human Error
  • Horizontal, Vertical or Portable (‘Skid’) Mounting Options
  • Enables Pigging for Full Product Recovery

Contact

Ben Molineux
Sales Director
Mobile: +44 (0) 7789 816479
Email: ben@blucorcontrol.eu

blucorcontrol are a registered UK company, any enquiries from the UK will be passed onto the Head Office in Nottingham, UK at HPS – Product Recovery Solutions www.hps-pigging.com