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.