By streamlining liquid processes, HPS systems enhance efficiency, minimise waste, and support long-term sustainability in operations
Are you facing challenges like high waste, rising production and raw material costs, product solidification, or slow, labour-intensive changeovers?
HPS Liquid Product Recovery Technology (also known as ‘pigging systems”) are a proven and highly effective method of tackling these issues head on.
Pigging systems are widely used by chocolate and confectionery manufacturers to recover up to 99.5% of residual product from pipelines, reducing waste and saving costs.
Pigging systems offer a range of benefits:
Increase Product Yields and Cut Waste
Chocolate and confectionery ingredients, such as liquid chocolate, syrups, and fillings, are valuable. Without pigging, large amounts of product remain in pipelines after batch runs or between changeovers. Pigging quickly and efficiently recovers nearly all of this product, ensuring minimal waste and significantly higher yields.
Prevent Product Solidification and Reduce Cleaning Times
Chocolate solidifies quickly, making cleaning pipelines challenging. By using pigging, manufacturers can keep the product moving and remove most of the residual product from the line. It works fine with jacketed pipework and prevents product sitting in the line, reducing the risk of overheating or degradation.
In turn, this cuts down on costly heating and time-consuming cleaning processes.
Improve Efficiency and Reduce Downtime
Traditional cleaning and changeover processes in chocolate production can be slow and labour-intensive.
Pigging speeds up the process by removing product quickly and efficiently, reducing the need for extensive manual labour and cutting changeover times. This means higher production uptime and throughput.
Reduce Production and Raw Material Costs
With ingredient costs rising, reducing waste directly impacts profitability.
By increasing product recovery, manufacturers can produce more with the same raw materials, lowering costs per unit and improving overall margins.
Eliminate Product Cross-Contamination
Pigging systems ensure clear pipelines with virtually no residual product left behind. This minimises the risk of cross-contamination between batches and reduces the need for rework or product waste. By reclaiming nearly all the product from the pipe, manufacturers can achieve consistent, high-quality output every time.
How Pigging Works
Pigging uses a specialist projectile (the “pig”) along with dedicated equipment to recover product from the pipeline—reducing waste and improving efficiency.
Significant Savings: Real-World Pigging Benefits in Chocolate Manufacturing
HPS has successfully installed pigging systems in chocolate and confectionery plants worldwide, helping businesses achieve notable improvements in efficiency and cost savings.
For example, Log House Foods faced the challenge of flushing out 500-600 lbs of product during changeovers, which was causing extended downtime and higher labour costs.
After installing HPS pigging systems, they were able to significantly reduce changeover times and minimise waste to a few lbs per batch.
This not only reduced downtime but also enhanced lot control and traceability, leading to more efficient operations and significant savings.
Maximise Efficiency and Minimise Waste
Inefficiencies and product waste can have a significant impact on your production line. By implementing HPS Pigging Systems, chocolate and confectionery manufacturers can achieve higher product recovery, reduced downtime, and ultimately, better resource utilisation.
By streamlining processes, these systems enhance efficiency, minimise waste, and support long-term sustainability in operations.
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Media contact
Joseph Clarke
Editor, International Confectionery
Tel: +44 (0) 1622 823 920
Email: editor@in-confectionery.com
