In today’s competitive manufacturing landscape, businesses are constantly seeking ways to improve efficiency and increase profit margins. One powerful solution, though still unfamiliar to many, is Advanced Liquid Product Recovery Technology — commonly known as pigging.
Whether you process liquids such as food, beverages, paint, lubricants, chemicals, personal care products, or other liquid-based products, HPS pigging systems can enhance your production processes, drastically reducing waste while maximising profits.
What is Liquid Product Recovery?
Liquid product recovery, commonly referred to as pigging, is a process used in industries that handle liquids, such as food, beverages, cosmetics, chemicals, paint, and lubricants.
Pigging systems work by using a specially designed projectile, known as a “pig,” alongside other specialist equipment to recover valuable product left in pipelines after a production run. This recovered product is then reused, minimising waste and maximising yield.
To better understand how pigging works, explore the key components of a pigging system and how they contribute to more efficient liquid recovery.
Why Consider Advanced Product Recovery Technology?
Many manufacturers are fully aware of the product losses that occur during production.
Even small amounts of leftover product can add up over time, leading to significant losses. Advanced production technology, such as pigging systems, offers a solution to this problem.
By reclaiming valuable product left in pipelines and reintroducing it to production, pigging systems dramatically reduce waste and significantly enhance overall operational efficiency.
This translates directly to increased profitability by maximising your product yield, reducing cleaning costs, and increasing production uptime.
How HPS Pigging Technology Boost Profits
HPS is a global leader in designing and implementing pigging systems. Here’s how our solutions can directly increase your profit margins:
Minimising Waste
Every drop of product matters. By using HPS pigging systems, you can recover nearly all the product left in your pipelines, reducing waste to almost zero.
This not only saves money but aligns with sustainability goals by reducing the need for raw materials and lowering the volume of wastewater generated. Less waste means more product to sell or reprocess — directly increasing profits.
Increasing Product Yields
The more product you recover, the more you can package, sell, or use in subsequent production runs. This increases your yields and maximises the value of your raw materials, all of which directly contribute to higher profit margins.
HPS pigging technology has been proven to recover up to 99.5% of residual products from pipelines, providing the best recovery rate available on the international market.
Reducing Changeover Times
Transitioning between products is often time-consuming and costly, especially if cleaning is required.
HPS pigging systems make these transitions faster and more efficient by removing residual product from pipelines before cleaning. This reduces downtime, saves labour costs, and increases production capacity, leading to enhanced profitability.
Lowering Cleaning Costs
By removing most of the product from your pipelines before cleaning, pigging systems reduce the amount of water, cleaning chemicals, and energy needed. This not only saves money but also reduces your environmental impact.
Enhancing Quality Control
Cross-contamination due to leftover product in pipelines can lead to costly recalls or rejected batches.
Pigging ensures that your pipelines are thoroughly cleared, reducing the risk of contamination and maintaining high-quality production standards. This leads to fewer rejects, fewer recalls, and improved customer satisfaction — all of which improve profit margins.
Reducing Equipment Downtime
Frequent downtime for cleaning or product changeovers can significantly impact productivity.
Pigging systems minimise these interruptions, ensuring that equipment is operational for longer periods, which translates to higher efficiency and profitability.
High Return on Investment and Payback
HPS pigging systems deliver a high return on investment (ROI) in a remarkably short time. Many manufacturers recover their investment nearly always in less than 12 months.
By reducing waste, improving yield, and cutting down on cleaning and downtime, companies can realise substantial savings — often hundreds of thousands of dollars annually.
Who Can Benefit from HPS Pigging Technology?
HPS systems are designed for manufacturers in industries that process liquids, including:
- Food and Beverages: Recover sauces, dips, oils, soft drinks, spirits, sugar syrups, and other liquids efficiently and with minimal waste.
- Cosmetics and Personal Care: Reclaim lotions, creams, shampoos, and other high-value products.
- Paint, Coatings and Chemicals: Recover water-based paints, solvent-based paints, varnishes, pigments, coatings, and a wide range of chemicals, reducing waste and saving costs.
- Pet Food: Increase yields and cut waste of products such as pet food meat emulsions, slurries, animal feed, pet snacks, treats, and other wet pet foods.
- Chocolate and Confectionery: Recover chocolate, coatings, syrups, and other liquid confectionery products to improve yields.
- Household Liquids: Recover detergents, cleaners, bleaching agents, and other household liquids efficiently to lower operational costs.
- Lubricants: Increase profitability by recovering products such as motor oil, gearbox oil, hydraulic oils, and greases plus many more.
Real-World Results
Manufacturers using HPS Advanced Liquid Product Recovery Technology report remarkable cost savings and efficiency gains. For instance:
- A food producer achieved a high return on investment (ROI) within 6 months by recovering significant amounts of product.
- A beverage company reduced cleaning times by 50%, enabling increased production capacity.
- A pet food manufacturer estimates annual savings of approximately $540,000 CAD by implementing HPS pigging systems.
- A chemical manufacturer eliminated product losses of up to 60 gallons per changeover, avoiding annual waste valued at $1.4 million.
- A lubricant producer now saves up to 50,000 litres of product daily and has improved loading times by as much as 50% thanks to a streamlined process.
These are just a few examples of how HPS pigging systems deliver substantial savings and efficiency improvements across industries.
Find more real world examples by reading our pigging system case studies.
Take the Next Step
If you’re interested in reducing waste, increasing efficiency, and boosting profits, HPS can help. Our experienced pigging design team will work with you to create and implement a pigging system tailored to your specific needs and production environment.
We recognise that every manufacturing process is different. That’s why we create bespoke solutions designed specifically to meet your requirements, infrastructure, and operational goals.
Find Out More
Recovering residual product from process pipelines through pigging is a simple yet transformative way to enhance your production processes.
Whether you’re new to pigging or looking to upgrade an existing system, HPS Product Recovery Solutions offers the expertise and technology to deliver measurable results.
Ready to learn more? Contact HPS today and start maximising your profits with smarter, more efficient production.