Pipeline pigging is a specialized tool used to clean and inspect industrial pipelines. The process helps prevent debris accumulation, grease, corrosion, and fractures to provide optimal flow assurance. Pigging is crucial for maintaining flow integrity and preventing accidents, especially in the food, beverage, and dairy/cheese industries.
Understanding Pipeline Pigging
Pipeline pigs (sometimes known as pipeline intervention gadgets or pipeline inspection gauges) are tools used for pipeline cleaning and inspection. The purpose of pigging is to remove debris, scale, and contaminants from pipeline walls, assess internal conditions, and optimize efficiency by reducing friction and energy required for material transportation. This pipeline cleaning process is very beneficial to the food, beverage, and dairy/cheese industries. However, due to the risky nature of the procedure, it is only performed by experienced and skilled personnel.
How Pipeline Pigging Works
Pigs function similarly to a pipe-cleaning squeegee, but instead of being pushed through the pipe on a wire, the projectile and product are pushed through the pipework using pressured air, nitrogen, or water. The product can be forced out of the line or, if necessary, returned to the holding tank.
LIAG® DMV Pigging System
Ideal for pasty media and low-germ processes, DMV pigging systems are designed with CIP/SIP LIAG® free flow arc- and pigging valves and pig launching and receiving stations without dead pockets. These systems simplify modular components, minimizing hygienic risk areas. DMV lip pigs are homogeneous, hygienic, and offer excellent cleaning effects. They are FDA-rated, flexible, and suitable for tight radii. The dynamic lips form a reliable seal and can be equipped with a magnet for location and control. The optimum pigging procedure is tailored to each project, ensuring diverse requirements are met.
Benefits of Pipeline Pigging
Pipeline pigging provides several advantages to a variety of industries. These benefits include:
Pipeline Pigging in the Food, Beverage, and Dairy/Cheese Industries
Pipeline pigging systems are beneficial for producers running sticky, thick, or viscous products regularly. This is especially true for the food, beverage, and dairy/cheese industries. Their higher product viscosity leads to more residue, and pigging systems maximize the recovery of leftover products. This makes cleaning their pipes more efficient after production, ensuring product quality and safety while minimizing waste.
In one case study, The Center Fresh Egg Company saved $46,000 annually through product recovery, but yield losses were a concern. They repeatedly processed liquid eggs, breaking five million eggs daily. The standard air-blow technique failed to recover significant amounts of product, as air blast systems traveled through the product rather than retrieving it.
Product recovery, also called pigging solutions, was added to their existing pipeline processes as well as in new plants, depending on existing configurations. The egg-breaking plant has successfully maintained product and profits by implementing a safer work environment, improved productivity, insect control, and faster cleanup, resulting in a return on investment in six months and a consistent recovery of lost dollars annually.
Reusable Pig Systems for Food, Beverage, and Dairy/Cheese Industries
A recovery CIP system with reusable pigs has a high capital cost, requires a larger space, increases the contamination risk, lowers ownership costs, has a shorter time/delay, and ensures proper flow rates. When selecting a pigging system, take into account the support and experience of the vendor, your unique application requirements, safety features, customizable options, and seamless integration. Select a system that meets your needs and has a definite return on investment.
Key Considerations When Implementing a Pigging System
Future Trends in Pipeline Pigging
Industry 4.0 technologies are being integrated with enhanced liquid product recovery in process industries, enhancing efficiency, resource optimization, and continuous development through data analytics, automation, and Internet of Things sensors. This integration helps businesses maintain competitiveness and achieve maximum productivity, efficiency, and performance in their manufacturing processes, thereby enhancing their overall performance.
Future developments that are being predicted include an increase in sensor accuracy, better data processing, and a wider adaptation to various pipeline conditions. These advancements should strengthen the case for pigging as an increasingly vital part of pipeline upkeep and inspection.
Conclusion
Reusable pipeline pigging is an essential tool that helps you optimize efficiency and product quality in the food, beverage, and dairy/cheese industries. With over 80 years of engineering and design experience, R-Cap offers innovative problem-solving solutions for processing applications. Our team is dedicated to understanding your pipe-pigging needs by identifying the solution, performing proper installation, and setting you up for successful operation.
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