Pigging technology from HPS helps recover up to 99.5% of valuable product, cutting rework and optimising efficiency in chocolate production lines
With cocoa prices at historic highs and cost pressures mounting across the supply chain, chocolate producers are under more pressure than ever to protect their margins and reduce losses.
From cocoa liquor and butter to finished chocolate, the cost of inefficient processing has never been higher – or more avoidable.
Every Kilogram Counts
In today’s climate, even small losses can be expensive. Whether you’re transferring cocoa liquor in bulk or blending milk chocolate on the line, the cost of residual product left in pipelines adds up fast. Wasted chocolate isn’t just a hit to the bottom line; it’s lost revenue, wasted energy, and time spent on unnecessary rework.
HPS technology ensures more of what you produce makes it to packaging, and not to rework or the drain.
Invisible Losses, Real Costs
Changeovers and flushing often lead to significant product loss, especially where viscosity and temperature sensitivity pose additional challenges. HPS technology helps mitigate these losses by:
- Preventing solidification and degradation
- Reducing changeover and flush times
- Lowering cross-contamination risks
- Protecting product integrity
How Pigging Works
HPS technology uses a specialist hygienic projectile (the “pig”) to recover residual product left in pipelines after transfer. The pig is propelled through the line, usually by filtered compressed air, and pushes the remaining product to the next stage – leaving the pipeline virtually clear.
For temperature-sensitive products, HPS systems integrate with water-jacketed pipework, ensuring fast and efficient product recovery without any disruption to quality.
Real Results in the Real World
Across the industry, chocolate producers are saving valuable product, saving time, and protecting margins with HPS technology. For example:
- A UK-based chocolate manufacturer reduced product rework from 15% to under 1%, saving £2 million annually in recovered product.
- In the U.S., Log House Foods installed five automatic HPS pigging systems. They now recover up to 2,500 lbs of coating, with waste typically just a few pounds. This has improved lot control, eliminated unnecessary flushing, and helped prevent downtime caused by product settling or freeze-ups.
Is Your Process Losing Product?
With cocoa prices soaring and efficiency under the spotlight, many chocolate manufacturers are reassessing their production methods to reduce losses and improve yield. HPS has been providing proven and innovative pigging solutions for decades. It’s delivering results for the world’s leading producers, including Barry Callebaut, Mondelez, Lindt, Ghirardelli and others – helping them recover product, minimise waste, and optimise changeovers.
Tailored to the unique requirements of chocolate processing, HPS systems handle products efficiently, while supporting sustainability and operational goals – helping manufacturers remain competitive.
Batch after batch, bar after bar.
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Media contact
Joseph Clarke
Editor, International Confectionery
Tel: +44 (0) 1622 823 920
Email: [email protected]
