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Product Recovery Systems Special Tees Pig Driving Valves Pig Stopper

Pig Catching Pipe Cleaning Station Pig Design Layouts

VARICOVER® Product Recovery Systems (Sanitary Pipe Pigging Systems)
Gea Tuchenhagen

[GEA Tuchenhagen Pigging Systems]

VARICOVER® Product Recovery Systems can achieve up to 99% recovery of your valuable product!

GEA Tuchenhagen Product Recovery Systems recover valuable finished product from process pipe lines. The systems are available fully automated, semi-automated or with manual operation.

All systems leave a thin film of residual product that is easily removed by CIP. This technique also substantially reduces consumption of effluents traditionally used for push out.

Advantages of Using Product Recovery Systems:
• Reduced product loss
• Reduced production down times
• Reduced consumption of water for rinsing and push out
• Reduced effluent disposal costs
• Reduced consumption of CIP

Pre-conditions for Product Recovery:
• Fluid product must be suitable for pumping
• No sedimentary products
• Consistent tube ID throughout the pipe system to recovered
• Pipe sections and bends with circular cross sections
• Flat and smooth weld seams inside the pipe
• Connection fittings (valves, instruments etc) suitable for pigging

Features of the GEA Tuchenhagen Product Recovery System: Safe operation Automated process Pig position monitored by proximity switches Fully drainable and pocket free Fully CIP or SIP of the entire system including driving medium valves Driving medium options in water, air, CO2, or N2 Temperature resistant to 266° F Product pressure 150 PSI.g Sanitary VARIVENT® flange connections AISI 316 L material all wetted parts

Applicable for the following products: Shampoo, lotions, creams, toothpaste Pharmaceutical liquid products Washing agents, cleaning agents Yogurt, quark, cheese Fruit pulp, syrup, concentrates Dough vegetable oil Personal products Internal medicines & more

Sizes
• OD 1", 1.5", 2", 2.5", 3", 4"

View VARICOVER® Product Recovery Systems Brochure (PDF)

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Special Tees

Special Tees are used for product inlet and outlet purposes. The branch line has a reduced diameter allowing the pig to pass the opening.

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Pig Driving Valves

These valves are close couple to either an In-Line Access Unit or the catching pipe. Arranged in a traditional block and bleed arrangement, the valves allow the transfer of driving media (water or gas) or CIP into the system.

The valves are sized to the requirements of the system.

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Pig Stopper

A pig stopper is pneumatically actuated to position a rod across the housing to prevent movement of the pig. The pig stopper has two functions dependent on the system design:

• If the catching pipe (see illustration on right) is used as a pig launching station then the pig stopper prevents the pig from moving from the catching pipe under vacuum. See diagram EMII/1.
• Pig stoppers allow the positioning of pigs before and after tee pieces.

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Pig Catching Pipe

The catching pipe mechanically prevents further movement of the pig in the pipe. In some system designs, such as EMI/1, the pig must be returned form the catching pipe (which would be designated the catching station) to the launching station before the pipe is cleaned.

The catching pipe can be supplied with integrated driving valves (see design layouts) and proximity switch for confirmation of pig position.

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Cleaning Station

The cleaning station is integrated into the product process path and its design ensures that flow is not restricted when the pig is docked in the receiving station.

It is fully cleanable and can be used either as a launching or receiving station. Product or CIP can pass through the station in either direction.

Verification that the pig is in place is provided by proximity switches.

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Pig

Shaped to easily negotiate small bend radii and tees, the pig contours also ensure cleanability of the entire surface. Position is detected with encapsulated magnets that can be provided shrouded in stainless seel in event of breakage.

Pigs are available in inert material such as silicone or FKM.

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Type EMI/1

Production
The pig is retained in the launch station while product flows from the receiving station.

Product Push Out
Valves V4.1 and V4.2 (see diagram for EMI/1) are retracted and the V3 pushes the pig into the pipe. Valves V1 and V2 are activated to allow the push out media to drive the pig and residue product to the receiving station.

Pig Return
When the pig is stopped at the catching pipe, valves V6 and V7 are activated to immediately return the pig to the launching station.

Cleaning
The pig is cleaned inside the launching station at the same time as the rest of the station is cleaned.

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Type EMII/1

Production
The pig is retained in the catching pipe and retained in place by activated pig stopper V5 (see diagram for EMII/1). Product enters the system via the special Tee.

Product Push Out
Pig stopper V5 is retracted and valves V6 and V7 activated to push the pig and residual product towards the receiving station.

Pig Return
The pig is returned to the launching station propelled by gas and pushes out residual post rinse water. Note: pigs cannot be run through dry pipes.

Cleaning
The pig is cleaned inside the receiving station at the same time the rest of the system is cleaned.

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Type DM/1

This system offers a number of advantages for specific process conditions.

Multi-Directional
Pigs S1 or S2 (see diagram for DM/1) may push the residual product in the desired diretion while the other pig is held in its station.

Anti-Foaming
For product that reacts with air and creates unwanted foam, pigs S1 and S2 are driven at the same time. When returning, one pig provides phase separation of air from the product.

Single Pig
It if is not desirable to use a special Tee as in system EMII/1, then system DM/1 with single pig can be used.

Other Systems
GEA Tuchenhagen also offers variations that allow semi-automatic or manual operation of the system. Please contact GEA Tuchenhagen.

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