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Chocolate is loved worldwide, but making it is expensive. In recent years, higher raw material costs, unpredictable cocoa prices, and the push for sustainable manufacturing have challenged chocolate makers. Any product lost during processing means higher costs and lower profits.

Pigging technology is useful in this situation. Pigging has revolutionised the chocolate industry by assisting producers in recovering nearly all of the product that is left inside pipelines during production and changeovers. Manufacturers may satisfy sustainability targets while reducing waste, increasing efficiency, improving hygiene, and reducing losses with sophisticated pigging systems.

The Challenge of Chocolate Processing

The process of making chocolate is delicate and intricate. Whether making coatings, syrups, fillings, or liquid chocolate, producers encounter a number of difficulties:

• Expensive raw materials: Every gram of chocolate is valuable due to the spike in cocoa costs.
• ​Products that are viscous: Because chocolate is thick and sticky, it might be challenging to completely clear pipes.
• ​Changing recipes: Frequent changes in recipes results in increased product loss and cleaning needs. Examples of these include milk, dark, white, and flavoured variants.
• ​Problems with waste disposal: Lost chocolate frequently ends up in the trash, which raises disposal expenses and environmental difficulties.
• ​Requirements for quality and hygiene: To avoid contamination, chocolate must be handled in a hygienic setting.

Without an efficient recovery solution, chocolate manufacturers lose significant amounts of finished product during changeovers and cleaning cycles.

What is Pigging Technology?

Pigging technique uses a specialised tool known as a “pig” to recover and remove leftover product from pipelines. The pig is a sanitary, flexible projectile that fits tightly into pipelines. The residual product is forced into the line by the pig, which is driven by compressed air, gas, or liquid, leaving the pipe essentially clean.

Pigging was first created for the oil and gas industry, but it has since been modified for the food and beverage sectors using hygienic designs. Modern pigging techniques in chocolate production guarantee reduced product waste, quicker switchovers, and improved hygiene.

Pig launchers and receivers for safe pig introduction and removal are components of a standard pigging system.

• ​A clean pipeline design that works with items of food quality.
• ​Controls and automation for smooth interaction with current procedures.
• ​Specialised pigs constructed from flexible, FDA-approved materials that are safe to come into contact with food.
• ​Pigging makes sure that what would otherwise be wasted is put back into the production process by recovering up to 99.5% of the product from pipelines.

Why Chocolate Manufacturers Need Pigging Technology?

For chocolate manufacturers, using pigging technology is becoming essential rather than optional. Here’s why:

1. Optimising Product Recuperation

Revenue is lost for each kilogram of chocolate that is lost in the pipeline. Manufacturers may recover almost all of the product thanks to pigging technology, which drastically lowers losses during cleaning and changeovers.

2. Cutting Expenses and Waste

Reduced chocolate waste results in decreased raw material and disposal costs. Saving goods increases profitability because the price of sugar and cocoa is rising.

3. Quicker Transitions

Processing chocolate frequently involves a variety of flavours. Conventional flushing requires water, cleaning agents, and time. Pigging increases production uptime by reducing the time required for changeovers.

4. Better Safety and Hygiene

Pigging systems are made to be hygienic for food. They aid in upholding high standards of quality and reducing the possibility of cross-contamination between batches.

5. Advantages of Sustainability

Reducing wastewater and product loss is consistent with the objectives of global sustainability. Manufacturers of chocolate can lessen their environmental impact by using pigging technology.

6. ROI, or return on investment

After using pigging, the majority of manufacturers experience a quick return on investment because the savings from recovered chocolate soon exceed the cost of installation.

Real-World Example: Pigging in Chocolate Manufacturing

Consider a chocolate company that produces milk chocolate, dark chocolate, and hazelnut filling under different product lines. Traditionally, multiple litres of product are wasted on each changeover because it gets stuck in the pipeline. This results in tonnes of chocolate being lost over the course of a year, as well as large financial losses.

Almost all of that product is recovered and put back into the production tank or packed as sellable goods when using a pigging technique. It creates income rather than being swept away as waste. Production capacity is freed up as cleaning gets quicker and uses fewer resources.

Pigging Technology Beyond Chocolate

Although the processing of chocolate is the subject of this article, pigging is employed extensively in the food and beverage sector:

• Drinks: dairy products, soft drinks, and juices.
• Mayonnaise, mustard, and ketchup are examples of sauces and condiments.
• ​Cosmetics and personal care: lotions, gels, and creams.

​This adaptability shows how pigging is revolutionising sectors where efficiency, hygiene, and product recovery are crucial.

Key Considerations for Implementing Pigging Technology

Prior to spending money on pigging technology, chocolate producers had to think about:

Not every pipeline is built with pigging in mind from the start. The key is compatibility.​

• Integration of automation: To minimise manual involvement, modern systems can be completely automated.
• ​Design of the pig: Select food-grade pigs that are safe and long-lasting for viscous goods like chocolate.
• ​Maintenance: Even though systems are reliable, frequent inspections guarantee sustained effectiveness.
• ​Collaborate with professionals: A customised solution is guaranteed when working with experts like IUS Pigging Systems.

Why Choose IUS Pigging Systems?

Designing, supplying, and implementing cutting-edge pigging systems for businesses across the globe is our area of expertise at IUS Pigging Systems. Our technologies are designed to maximise product recovery, efficiency, and hygiene while catering to the particular requirements of chocolate manufacturers.

Chocolate manufacturers gain from working with IUS because of their demonstrated proficiency with liquid product recovery solutions.

• ​Technology for pigging viscous materials that is specially designed.
• ​Dependable, long-lasting designs made of food-grade materials.
• ​A dedication to cost reduction and sustainability.

Final Thoughts

The rising cost of raw materials and the growing need for efficiency are putting pressure on the chocolate business. Conventional processing techniques can result in increased waste, higher operational costs, and large output losses.

It’s time to reconsider using pigging technology in chocolate production. Manufacturers may decrease losses, expedite switchovers, enhance hygiene, and run their businesses more sustainably by putting innovative pigging systems into place. Pigging technology is not merely an innovation; it is a necessity for businesses who are serious about remaining competitive in the modern market.

IUS Pigging Systems is prepared to assist chocolate producers in moving forward with more intelligent, effective, and environmentally friendly manufacturing.