Lubricant production is a tough and competitive market.
That’s a key reason why an increasing number of lubricant manufacturers worldwide are turning to HPS technology.
Our latest case study describes how HPS Product Recovery Solutions helped Exol Lubricants, the UK’s largest independent lubricants manufacturer, achieve significant improvements in production efficiency, waste reduction, and sustainability.
Interested?
Learn how our Advanced Liquid Product Recovery (Pigging) Technology enabled Exol to recover high-value lubricants that would have otherwise been lost, helping them boost yields and reduce environmental impact.
Read the full case study here >> Pigging System Case Study on Lubricants.
About Exol Lubricants
Exol Lubricants, a leading manufacturer in the lubricants industry, produces an extensive range of high-quality oils for sectors like automotive, agriculture, and transport.
Operating out of their two UK sites—Birmingham and Rotherham—Exol is known for delivering top-tier products and exceptional customer service, solidifying their position as an industry leader.
The Challenge: Overcoming Operational Inefficiencies
Faced with rising production costs and industry-wide supply chain challenges, Exol sought a solution to reduce product losses and improve operational efficiency.
Their existing pipeline system resulted in substantial waste and contamination risks during the transfer of oils and additives.
These inefficiencies hindered their ability to meet sustainability goals and contributed to unnecessary costs.
Exol needed a reliable solution to boost product recovery, enhance safety, and streamline operations.
The HPS Pigging Solution: Custom, Efficient, and Sustainable
HPS designed a custom pigging system for Exol’s Rotherham site, installing three specialised pigging lines that ensured maximum product recovery and operational efficiency:
Line 1 (2-inch): Transfers oil from storage to tankers for bulk transport to the Birmingham site.
Line 2 (3-inch): Equipped with a piggable diverter valve for seamless oil transfer between tankers and storage tanks.
Line 3 (3-inch): A versatile line with dual launch points to support flexible and efficient oil transfers from storage to tankers.
With full automation and centralised control, the pigging system allows Exol to monitor and manage the entire operation remotely, ensuring optimal performance and minimal downtime.
Key Benefits and Results: Efficiency, Sustainability, and Cost Savings
Exol’s deployment of HPS pigging technology has delivered impressive results across multiple areas:
- High Product Recovery Rates: Up to 99.5% of residual oil is recovered, significantly reducing waste and increasing yields.
- Operational Efficiency: Faster product transfers and changeovers have led to better throughput, less downtime, and greater capacity.
- Enhanced Operational Safety: The automation and remote control features have decreased manual intervention, lowering safety risks and improving efficiency.
- Reduced Environmental Impact: By minimizing waste and optimizing resource usage, Exol has made significant strides toward meeting their sustainability targets.
Simon Matthews, Exol’s Product Development Manager, highlighted the impact of the new system:
“Since the initial commissioning, we’ve managed to recover process losses of up to 50,000 litres per day, with the streamlined process speeding up loading times by as much as 50%.”
Why Exol Chose HPS for Pigging Systems
Exol partnered with HPS because of our proven expertise in the lubricants sector and our ability to deliver customized, scalable pigging solutions.
As Simon Matthews noted, “HPS had expertise in pigging systems for lubricants and other associated industries for the transfer of fluids efficiently between blending vessels, storage tanks and road tankers.”
Looking Ahead: A Future of Growth and Sustainability
With their new pigging systems in place, Exol is not only reaping immediate efficiency and sustainability benefits but is also well-positioned for future growth.
The SCADA system integration and potential for site expansion provide Exol with the tools they need to scale their operations while maintaining high levels of product quality and environmental responsibility.
Boost the Efficiency of Your Liquid Processing – Contact HPS Pigging Experts Today!
Ready to enhance your liquid processing operations? Get in touch with our team of pigging experts today and discover how our customised solutions can optimise your production, reduce waste, and enhance overall efficiency.
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