4. Page 4 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom Why CP Kelco Chose HPS as their Pigging Systems Provider HPS has a solid reputation as the world’s leading hygienic and sanitary pigging systems specialists . That ’s because HPS has a proven track record of successful projects which deliver high return on investment (ROI), rapid payback, and that exceed client’s expectations. In addition, HPS has specialised in process pigging since 1995 and has worked with a wide variety of companies t hat manufacture food ingredients, beverages, chemicals, and so on. Asked why CP Kelco chose HPS, Tyson commented, “HPS ha d expertise in our product segment and demonstrated an understanding of what design elements were required for cGMP facilities. They were able to demonstrate their equipment to our technical team by facilitating a site visit with a customer with similar req uirements to ours.” The Solution Working closely with CP Kelco, HPS designed, supplied, implemented, and commissioned a single - pig pigging system. The bespoke pigging solution recovers up to 99.5% of product from the pipeline. If it wasn’t for pigging, th is usable product would be discarded as waste. Like most HPS pigging solutions, the system is fully automatic, meaning the HPS pig is sent and returned using PLC control. Special HPS pig - detection technology ensures accurate and reliable pig location and subsequent control by the HMI/PLC. The pigging system is fully compliant with cGMP.
3. Page 3 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom Project Background The CP Kelco team reached out to HPS because they were reinstating an existing pipeline for transfer between different processing areas at their facility in San Diego, California, USA . They wanted to incorporate liquid product recovery (pigging) in to their process. The length between the processing areas is 900 feet . Therefore, the company estimated that if they didn’t have a pigging system , they would lose roughly 1200 gallons of useable product each cycle . CP Kelco had used pigging before, but not a system provided by HPS, and the system had been demolished over 10 years ago due to changing business conditions. The previous system was a manual one - way system, where operat ors would have to remove the pig from the receiver and bring it back to the launcher. The footprints of the launch and receive stations were also q uite large, taking up valuable workspace. So , Tyson Richart, Engineering Manager at CP Kelco , approached HPS to discuss using process pigging to recover usable product, instead of sending it to waste. They also wanted to use pigging t o improve their manufacturing and production processes. It was critical that the pigging system was fully compliant with c urrent Good Manufacturing Practices or “cGMP” . Tyson explained , “The previous pig system was a one - way system with a city water propelled launcher an d a receiver at the other processing area. At the conclusion of the pig transfer, operators would have to remove the pig from the receiver and bring it back to the launcher”. “The length between the processing areas is 900 feet and it was estimated that ab out 1200 gallons of product would be lost without a pigging system.” CP Kelco, San Diego, California, USA
6. Page 6 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom Because the customer chose an automatic pigging system, this enhances safety and minimises the risks of human error by reducing manual intervention. S ummariz ing the project , Tyson said : “Overall, the project was a success. The lead time of HPS was about half of their competitors which allowed us to get the system up and operational to meet our business needs. HPS provided technical support in a timely fashion to help ensure issues were resolved quickly and that the system had flexibility for future potential changes.” When asked if he would recommend HPS to other companies, Tyson replied : “Yes. HPS was able to help us customize our design based upon our processes. They worked hand in hand with us to help us understand the trade - offs of the different design elements.”
1. Product Recovery (Pigging) Case Study: CP Kelco San Diego, California, USA How an HPS Pigging System Increases Yields and Reduces Product Losses in Food Ingredients Manufacture HPS Product Recovery Solutions www.HPS - Pigging.com
5. Page 5 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom As well as pig detection technology, the pigging equipment uses a bi - directional pig, various specialist valves, plus full engineering drawings, electrical c onnection diagrams , functional design specification plus more. HPS provided a full service – from design and supply of a system to implementation, commissioning, and customer support. When commissioning was complete, HPS engineers ensured employees under stood how the system worked and were fully aware on how to operate and maintain the equipment properly and safely . The Results The primary aims of the project were to increase product yields and reduce product losses. The pigging system recovers up to 99.5% of product from the pipeline. If it wasn’t for pigging, this product would be wasted. Because the HPS system is bi - directional, it enables CP Kelco to experiment with different cleaning techniques of the pipeline , since they have different utilities present in each of the processing areas. Tyson commented, “We have been able to recover all the product from the pipeline as we had anticipated. The bi - directional system has allowed us to experiment with different cleaning techniques of the pipeline since we have different utilities present in each of the processing areas.” In addition to recovering massive amounts of product, the HPS solution is flexible, and extremely space efficient. Tyson explained, “Our previous experience was with pig systems that had launchers and receivers with large footprints. The HPS system is compact and lightweight which allows us to consider this system in areas where we previously did not have space.”
2. Page 2 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom About the Customer CP Kelco , a division of J .M. Huber Corporation , is a nature - base d ingredient solutions company. It produces a wide range of products including gellan gum, pectin, xanthan , carrageenan and other hydrocolloids for the food, beverage and consumer products industries. With more than 200 years of experience in manufacturing, manipulation and application of multiple hydrocolloids , the company’s goal is to be the preferred partner for providing innovative products and solutions through the use of nature - based chemistry. Headquartered in Atlanta, Georgia, USA, CP Kelco has manufacturing , R&D facilities and offices throughout the gl obe . This enables the company to exceed the global and requirements of their customers. Summary • HPS designed, supplied, and implemented one fully automatic single - pig pigging system at a CP Kelco plant in San Diego, California, USA . • CP Kelco is a nature - based ingredient solutions company with manufacturing, R&D facilities, and offices throughout the world. • CP Kelco approached HPS to incorporate liquid product recovery (pigging) technology to recover product, instead of sending it to waste. • If the company wasn’t pigging, they would lose roughly 1200 gallons of usable product each cycle. • As well as recovering massive amounts of product, the HPS solution is flexible and space efficient. • The system is fully automated which means it increases operational efficiency, enhances safety, and minimises the risks of human error by reducing manual intervention .
7. Page 7 © Hygienic Pigging Systems Ltd 2015 - 2017 HPS Product Recovery Solutions | www.hps - pigging.com | +44 (0)115 925 4700 | info@hps - pigging.com Hygienic Pigging Systems Ltd, 46 Evelyn Street, Beeston, Nottingham NG9 2EU, United Kingdom Contact HPS To improve the efficiency and effectiveness of your liquid processing, contact your nearest HPS Office : United Kingdom ( Head Office ) : HPS Product Recovery Solutions 46 Evelyn Street Beeston Nottingham, NG9 2EU United Kingdom T: +44 (0) 115 925 4700 E: info@HPS - Pigging.com USA and Canada: HPS LLC T: +1 908 858 5225 E: usa@hps - pigging.com Australasia: HPS Australasia T: +61 (0)8 8278 1009 E : australia@hps - pigging.com All other countries: We have agents throughout the world. Please contact the HPS head office and we will put you in touch with your local HPS representative: T: +44 (0) 115 925 4700 E: info@HPS - Pigging.com You can also find us on:
