Custom Dual-Pig System For Oxidation Prevention & Viscous Products

Custom Dual-Pig System For Oxidation Prevention & Viscous Products

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How Does a Dual-Pig System Prevent Oxidation?

Prevent product contact with air

The dual-pig pigging system is specially designed for the processes that the liquid products are oxygen-sensitive. As exposure to the air may lead to much dissolved oxygen content and potential spoilage.

During the initial operation, the first pig is driven by product to the automatic stopper to evacuate the air and water in the pipeline. The pig works as a seal to block the outlet of the stopper, and prevent the product behind it from oxidizing due to air contact. Once product transfer is concluded, the clean compressed air starts to propel the second pig to push the residue product inside the pipeline into the storage tank below the stopper, and this marks the conclusion of the first pigging cycle. The procedure is similar for pigging operations directed to the receiving station.

Summary: How does it work?

  • Phase 1: First pig removes air or water to prevent contact.
  • Phase 2: Product transfer in an oxygen-free pipeline.
  • Phase 3: Second pig recovers over 99% of the residue product.
Dual-pig system workflow diagram for oxidation prevention
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Dual-Pig System: Technical Details & Components

Custom Dual-Pig System For Oxidation Prevention & Viscous Products
dual-pig system

Applications:

The dual pig system is suited to a diverse range of industries, including: paints, coatings, wine, foam gel, cosmetics.

Features:

  • Sanitary design: meeting strict sanitary standards
  • Propellant: clean compressed air, water and products
  • Control mode: Fully automated controlled

Benefits:

  • Oxidation prevention and foam reduction
  • Efficient pipe cleaning and product recovey for viscous products
  • Reduction of cleaning agents, water and operation downtime
  • Minimizing operating errors, and labor costs
  • Lowering sewage treatment fees

Specifications

ItemParameter
DIN11850 PipingDN25, DN40, DN50, DN65, DN80, DN100, DN125, DN150
ISO Piping1″, 1.25″, 1.5″, 2”, 2.5”, 3”, 3.5”, 4”, 5”, 6”
MaterialSS304/SS316L ( for product- contact surfaces)
Pressure≤ 0.8MPa
PolishingRa≤0.8
Temperature≤100°C
SealingEPDM,FKM,VMQ, other materials upon request
Sanitary dual-pig launcher for automated pigging systems
Sanitary dual-pig launcher for automated pigging systems

Features

  • The dual-pig launcher serves as the housing, designed to accommodate both pigs side by side
  • Sanitary design, no cleaning dead corner
  • CIP & SIP compliant
  • Automated operation
  • SS304/ SS316L (for product-contact surfaces)
  • Connection type: flange, clamp, welding
  • Piping sizes: ISO1″-ISO6″, DN25- DN150

Technical data

  • Featured hygienic profile
  • Placed side by side in dual-pig launcher
  • The pig can be launched into the pipe by sequence
  • Locatability: containing embedded magnetic cores for precise detection via Hyperfore pig detection unit.
  • 3D/5D bends compatible
  • Materials: available in VMQ, other materials upon request
  • Piping size range: DN25-DN150, ISO1″-ISO6″
Hygienic dual pigs with magnetic cores for pipeline detection
Hygienic dual pigs with magnetic cores for pipeline detection
automatic pig stopper

Introduction

This automatic stopper is a critical component in pigging systems, the automatic stopper is primarily used to intercept the pig, leading it to stop at a specific location within the pipeline, and to recover product to a target tank near that location. It is designed to meet the needs for segmented product recovery and cleaning of certain pipeline sections.

Technical data

  • Working pressure range: 0 ‐ 10 bar
  • Temperature range: 0°C ‐ 100°C
  • Main body material: SS316L(for product-contact surfaces)
  • Sealing material: EPDM by default; Optional: VMQ, FKM, FFKM, NBR
  • Surface roughness: Ra≤0.8μm (for product-contact surfaces)
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What Products Is This For?

Dual-pig system for cosmetic lotion and cream processing

Cosmetics

Protect product quality and maximized yields

Oxygen-free wine transfer solution using dual-pigging system

Wine

Prevent air contact and preserve aromas

Dual-pig system for chemical liquid recovery

Chemicals

Safe production of hazardous products

Automated dual-pig system for paint and coating production lines

Paints

Eliminate cross-contaminiaton and pipe skinning

Fruit Purée

Prevent browning in juice concentrates

Hygienic dual-pigging for biopharmaceuticals products

Biopharmaceutical

High-hygiene recovery to secure product integrity

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Everything You Need to Know About Dual-Pigging
Dual- pig system is pigging system with 2 pigs. The launcher is designed to accommodate 2 pigs side by side. Dual- pig system solution is utilized to oxygen-sensitive or highly viscous product transfer. Step 1 Oxygen Removal: The function of the first pig is to evacuate air from the pipe, ensure the product quality and integrity, and prevent product oxidation.

Step 2 Solvent Cleaning: Some special solvent or cleaning agents is captured between the two pigs.

Step 3 Product Recovery: This pigging solution can be applied to paint, coating, chemicals to remove the viscous product adhered to the pipe inner wall.

Yes, the Hyperfore dual-pig system is fully automated. It is seamlessly integrated with PLC or Scada network.

Key automation benefits:

  • Operators can monitor and manage the pigging cycle via HMI in real time.
  • Pigging Automation ensures efficiency by optimizing pigging frequency.
  • Automation significantly reduces human errors.

Selecting an ideal pigging system depends on the product chemical properties and specific hygiene requirements of the pipeline.

  • Oxygen-sensitive products: If the product is easy to be jeopardized by oxygen exposure, a dual-pig system is the right choice. The first pig is utilized to evacuate the air inside the pipe, and protect the product from oxidation.
  • Solvent-Assisted Cleaning: For special paints and highly visous fluids, a single-pig system can’t achieve a thorough pipe cleaning. In a dual-pig configuation, some solvents could be captured between the two pigs to facilitate a deep pipe cleaning procedure.
  • Eliminating Cross-Contamination: For a shared pipeline that requires frequent changeover, the solvent-assistant cleaning provided by a dual-pig system is much safer and cleaner than a single-pig system, eliminating the risk of residue contamination.

It uses the first pig to evacuate air from the pipe and create a oxygen-free environment for product transfer.

  • Phase 1: First pig removes air or water to prevent contact.
  • Phase 2: Product transfer in an oxygen-free pipeline.
  • Phase 3: Second pig recovers over 99% of the residue product.

Related Pigging Products

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