Case Study

Veedol is a company specializing in the production and distribution of high-quality lubricants and oils. The brand has a long-standing reputation in the industry, known for its innovative products and commitment to performance. Veedol's product range includes motor oils, gear oils, hydraulic fluids, and specialty lubricants, all designed to meet the demanding needs of various engines and machinery. With a global presence, Veedol serves a wide range of markets, including both consumer and commercial sectors.

1. Recover remaining oil in pipeline
2. Cleaning pipeline internally
3. Remove chances for cross contamination
4. Minimize changeover time between batches
5. Minimize overall downtime to increase productivity
6. Multi product transfer

The company experienced substantial product wastage during product change overs due to the absence of a pigging system in their manufacturing process. The objective was to reduce pipeline losses, optimize product transfer, and improve overall productivity.

At IUS we are constantly working to provide smarter solutions and systems that energize the transformation of the industry to achieve a more productive, and sustainable future.

Recovery of product from a pipe line is as important as cleaning pipe internally & reduce cross contamination. Pigging system is an ideal solution to achieve such objectives because a pigging system can recover product and clean pipeline at same time in a single operation.

In this case, M/S IUS strategically re-designed key components of system e.g. Launcher, Receiver, Piggable cladded TEE and Elbows, Manual pig detecting sensor etc. With the help of in-house R&D department we fine-tuned the components. IUS will install 2 piggable pipeline which will be connected to all the blenders and both the filling machines. In simple words since there are 2 filling machines, maximum of 2 simultaneous fillings will take place. Once the filling is completed, the line will be pigged, ensuring the entire pipeline hold up to be recovered in the filling machine hopped. This will empty the entire pipeline which will allow the client to use the same pipeline for next transfer.

By using this pigging system, the client could now make transfers without the hassle of complicated manifolds, lesser manpower, faster changeovers, up to 99% product recovery, extremely low contamination and almost zero waste oil generation.

Following the installation of the pigging system, ALPLA conducted trials and observed significant improvements, including:

– Almost complete product recovery, minimizing wastage during changeovers.

– Time savings and increased productivity due to efficient transfer and pigging process.

– Reduced contamination.

– Cost savings by eliminating product losses and optimizing CIP solutions.

– Reduced waste generation, contributing to sustainability goals.

ALPLA is an Austrian firm. Their plant located in Silvassa, Gujarat, provides contract manufacturing services to Hindustan Unilever Ltd., producing various products such as toothpaste, hair gels, and creams. ALPLA faced significant pipeline losses during product changeovers in the manufacturing process of these high-viscosity products. Although aware of the pigging system and its advantages, they did not incorporate it earlier due to process and commercial constraints. This case study highlights how IUS successfully implemented a pigging system to minimize pipeline losses and enhance operational efficiency.

ALPLA experienced substantial product wastage during product changeovers due to the absence of a pigging system in their manufacturing process. The objective was to reduce pipeline losses, optimize product transfer, and improve overall productivity.

IUS experts visited ALPLA’s plant to understand the existing process and develop a suitable pigging system. The proposed solution included the installation of 3 portable launchers and 13 receivers for the filling machines. The user could detach and attach the launcher at different locations as required, ensuring flexibility and ease of use. To meet budgetary constraints, a manual system with manual ball valves, pressure gauge, and PRV was designed. The only electrical component was the pig detecting sensor, indicating the pig’s position in the launcher and receiver.

The implementation process involved the following steps:

– Product transfer: The operator would transfer the product using the existing process.

– Launcher installation: After completing the transfer, the pump would be turned off, and a blind was placed to seal the location. The launcher was then attached, and the existing destination auto valve and air inlet valve were opened.

– Pig movement control: The pig movement was controlled automatically by the hopper’s level sensor. When the hopper level was high, the pig would stop, and when the level dropped, it would resume, recovering the product.

– Pig retrieval and cleaning: Once the pig reached the receiver, the pig detecting sensor indicated its position. The pig was then sent back to the launcher, and the launcher was detached for cleaning. The pig and launcher were cleaned in a dedicated area.

– CIP and blind placement: After cleaning, the blind was placed, and the Clean-in-Place (CIP) process was performed to ensure system cleanliness.

Following the installation of the pigging system, ALPLA conducted trials and observed significant improvements, including:

– Almost complete product recovery, minimizing wastage during changeovers.

– Time savings and increased productivity due to efficient transfer and pigging process.

– Reduced contamination.

– Cost savings by eliminating product losses and optimizing CIP solutions.

– Reduced waste generation, contributing to sustainability goals.

ALPLA was impressed by the speed at which the pigging system was incorporated, taking only 3 days. They began reaping the benefits of the system from the first transfer after installation, endorsing its effectiveness and efficiency.

The successful implementation of a pigging system in ALPLA’s Silvassa plant resulted in significant improvements, solving the problem of pipeline losses during product changeovers. The solution provided cost savings, minimized waste generation, improved cleanliness, and increased productivity. IUS’s expertise and the collaborative approach played a crucial role in delivering a tailored pigging system that met ALPLA’s requirements and exceeded their expectations.

NOTE: This case study is based on the provided information and is intended for illustrative purposes only.

M/S Marico Limited is one of India’s leading consumer goods companies operating in the global beauty and wellness categories. Company plant is based in Sanand, Gujarat and has a tremendous production capability of moisturizer/ hair oil/ gel etc. (product). The company wanted to further improve their production capability by introducing the pigging system.

Recovery of product from 6 No’s of pipe line is as important as cleaning the pipe internally with a cost-efficient solution.

Pigging system is ideal to reduce the pipeline cost drastically but as M/S Marico Limited was dealing with Total 6 No’s of pipeline with separate product & destination. M/s IUS suggested a unique solution to keep the cost down.

To achieve all objectives M/S IUS suggested Mobile launching station with single pig Hygienic Pigging System instead of typical 6 separate Launching stations.

With this unique approach, the system is capable to perform pigging in all 6 lines with only a single launcher which helps to reduces the cost.

1. Recover moisturizer remaining in pipeline.
2. Cleaning pipeline internally.
3. Use same mobile skid based launcher system to all 6 pipe lines.
4. Make launcher plug & play for automation in all 6 pipe lines.
5. Minimize overall downtime to increase productivity while keeping the cost down.

Hygienic pigging system with mobile launcher and a single pig.

At IUS we are constantly working to provide smarter solutions and systems that energize the transformation of the industry to achieve a more productive, and sustainable future.

Recovery of product from a pipe line is as important as cleaning pipe internally & reduce cross contamination. Pigging system is an ideal solution for to achieve such objectives because a pigging system can recover product and clean pipeline at same time in a single operation.

In this case, with an innovative approach M/S IUS was able to re-invented key components of system i.e. the Launcher, utility connections, isolation valves, instrument and panel. With the help of the in-house R&D department we fine-tuned the components.

While re-designing the launcher, M/S IUS faced a big problem as all six inlet/ starting points of the pipeline were not aligned & were on a different height from the floor. Thus creating a challenge where a fix mounted launcher on the mobile trolley could not be attached with every pipe. To resolve this issue variable height mobile skid mounted assembly was done which means that the launcher could now pivot in the same plane as the piping which elegantly resolved the height issue.

Another challenge faced was that all 6 pipe lines were automated systems & had their individual control panel which are further controlled by a single SCADA system. It means that M/S IUS had implement a solution for incorporating same mobile launcher system with all 6 pipe lines control panel individually, so M/S IUS provided a special connector to the launcher system skid mounted panel which could easily connect to the control panel of any one of 6 pipe lines in succession & a hassle-free pigging could be done.

With this solution M/S IUS re-invented the launcher system which was a plug & play, mobile, flexible, modular & cost effective.

With this innovative approach toward the process IUS is able to achieve:

1. Recovery of more than 99%-line volume, which leads to approximately 40 to 45 Litres of recovered product per pigging cycle.
2. Cleaning pipeline internally with pigging cycle.
3. Remove chances for cross contamination by strategically arrangement of components.
4. Minimized overall cost significantly by reducing 5 numbers of launcher.
5. Minimize overall downtime per cycle which leads helped M/S MARICO to increase its productivity significantly

Before installation of pigging system average cleaning of pipe requires more than 20 min. since it involves immense labor work and wastage of material.

After installation of hygienic pigging system with variable height mobile skid mounted, the cleaning time is dramatically reduced to 3-5 mins.

Thus a Pigging System provided 45% of improvement in change over time over old system, with product recovery.

M/S JSW Paint Pvt. Ltd., is a water-based paint manufacturing company based in Torangallu. With new setup in mind they wanted to overcome some problems with water based paint product with innovative design and unique solution.

Recovery of product from a long pipe line is as important as cleaning pipe internally to reduce cross contamination.

Pigging system is ideal to reduce the pipeline cost dramatically because same line can be used for multi-product transfer by connecting different sources to different destinations with same pigging pipeline.

To achieve all objectives M/S IUS suggested dual pig system with water column and pig washing cycle.

M/S JSW PAINT offer us –
Total 5 No’s of pipeline (2 no’s od 4” line & 3 no’s of 6” line).
In an average more than 100 mtr length with average 4 no’s of sources and 12 no’s of destination

1. Recover paint remaining in pipeline
2. Cleaning pipeline internally with water
3. Remove chances for cross contamination
4. Multi product transfer from source to destination

DUAL PIG SYSTEM WITH WATER COLUMN AND PIG WASHING CYCLE
WASHING MEDIUM – WATER

IUS is constantly working to provide smarter solutions, systems that energize the transformation of the industry to achieve a more productive, and sustainable future.

In this case, M/S IUS strategically re-designed key components of system e.g. Launcher,
Receiver, Valves etc. With the help of in-house R&D department we fine-tuned the components.

M/S IUS developed proper automation sequence to achieve the necessary results. IUS developed a pig washing cycle at launcher and tested the same at factory to minimize the chances of failure at site.

Recovery of product from a long pipe line is as important as cleaning pipe internally to reduce cross contamination and pigging system is ideal solution for this application as dual pig system can recover product and clean pipeline at same time in single operation.

By using this pigging system client can not only able to recover the product in pipeline but also able to use same line for multi-product transfer. E.g. – Two different products can be transfer from two different sources to two different destinations by using same pipeline.

With newly developed automation cycle and fine-tuned design of key components IUS can predict the positive results.

Pigging Cycle Description:

1. Product Transfer
To transfer the product from source to destination with two pigs (Launcher side & Receiver side).

2. Product Recovery
To recover the product at destination by moving launcher side pig.

3. Pig at receiver
Both pig received at receiver.

4. Water Column Cycle
Creation of Water column in between two Pigs.

5. Pig at Launcher
Both pig travel at launcher and drain the water column.

6. Pig Washing Cycle
Pig get wash at launcher.

7. Pig at home
Sending both pigs back to its home position.

With this innovative approach toward the process IUS is able to achieve:

1. Recovery of more than 99% line volume. Which leads to approximately 900 to 1000 ltr of recovered product per pigging cycle.
2. Cleaning pipeline internally with water column cycle
3. Remove chances for cross contamination by strategically arrangement of components.
4. Reduced overall cost dramatically by sung same pipeline for transfer from number of sources to number of destination.

With this redesigned process IUS was able to achieve low contamination no more than 100 PPM

To confirm the result of contamination one product is passed through the pigging line, followed by a pigging sequence which is followed by the second product.
Sample of second product is examined by spectrometric analysis to check the content & traces of
first product.

M/S Ruparel foods Pvt. Ltd., is one of the India’s biggest a peanut butter manufacturing & exporter company based in Mahuva. With existing setup they wanted to overcome some problems with product with innovative design and unique solution.

Recovery of product from a pipe line is as important as cleaning pipe internally to reduce cross contamination.

Pigging system is ideal to reduce the pipeline cost dramatically because same line can be used for multi-product transfer by connecting different sources to different destinations with same pigging pipeline.

In this case most suitable advantage according to product is less cleaning time. As peanut butter is very difficult to clean at room temperature and doing it manually is a time consuming task which leads to overall less productivity.

To achieve all objectives M/S IUS suggested Hygienic Pigging System.

M/S RUPARAEL FOODS offer us –
Total 3 No’s of pipeline.
One of which consist two sources and one destination.

1. Recover Peanut butter remaining in pipeline
2. Cleaning pipeline internally
3. Remove chances for cross contamination
4. Minimize changeover time between batches
5. Minimize overall downtime to increase productivity

Hygienic pigging system with heat tracer for multiple source and single destination

IUS is constantly working to provide smarter solutions, systems that energize the transformation of the industry to achieve a more productive, and sustainable future.

In this case, M/S IUS strategically re-designed key components of system e.g. Launcher, Receiver, Valves etc. With the help of in-house R&D department we fine-tuned the components.

Recovery of product from a pipe line is as important as cleaning pipe internally to reduce cross contamination and pigging system is ideal solution for this application as pigging system can recover product and clean pipeline at same time in single operation.

By using this pigging system client can not only able to recover the product in pipeline but also able to use same line for multi-product transfer. E.g. – Two different products can be transfer from two different sources to two different destinations by using same pipeline.

To keep peanut butter viscous for easy transfer we integrated heating system to our pigging system which also dramatically reduces pigging time.

To tackle the problem of two sources and one destination we introduced a elegant solution by developing a manifold which solves the issue. Our newly developed manifold allowed us to perform all necessary transfer and pigging cycle with ease.

With newly developed automation cycle and fine-tuned design of key components IUS can predict the positive results.

Pigging Cycle Description:

1. Product Transfer
To transfer the product from source to destination with two pigs (Launcher side & Receiver side).

2. Product Recovery
To recover the product at destination by moving launcher side pig.

3. Pig at receiver
Both pig received at receiver.

4. Pig at home
Sending both pigs back to its home position.

With this innovative approach toward the process IUS is able to achieve:

1. Recovery of more than 99% line volume. Which leads to approximately 20 to 25 ltr of recovered product per pigging cycle.
2. Cleaning pipeline internally with pigging cycle
3. Remove chances for cross contamination by strategically arrangement of components.
4. Minimized changeover time dramatically as no manual cleaning is needed.
5. Minimize overall downtime by 30 minutes per cycle which leads to increase productivity Which help M/S RUPAREL to increase its productivity by 15%.

Before installation of pigging system average cleaning of pipe requires more 30 min. which involves removing piping from its location and cleaning it with the help of cloth stick and immense labor work.

After installation of hygienic pigging system with heat tracer cleaning time is dramatically reduced to only 3 min.

Pigging system provided 90% of improvement in change over time over old system, with product recovery.