Aseptic Pigging System
The award-winning APV Aseptic Pigging System (ARRS) efficiently recovers product from process pipes requiring stringent hygiene and sterile conditions, ensuring high food integrity. The system provides a sustainable solution that increases productivity, reduces waste, and enhances product yields. It is widely used in manufacturing lines for extended-shelf-life (ESL) products and long shelf-life products, such as yogurts and desserts, as well as plant-based alternatives, ice cream and some types of personal care products.
FEATURES
High-Performance Sterile Product Recovery
The award-winning APV Aseptic Pigging System is engineered for exceptional product recovery in extended shelf life (ESL) and long shelf-life product lines. This advanced system ensures minimal product loss, superior hygiene, and efficient cleaning-in-place (CIP), making it ideal for sensitive and high-value products.
This system minimizes product loss and enhances cleaning-in-place (CIP) processes, leading to improved production efficiency and sustainability. It complies with the highest hygienic standards, ensuring high food integrity. The APV Aseptic Pigging System can be fitted or retrofitted to any system and saves more high-value product than ever through a quicker cleaning process, leading to more up-time with less CIP. This also reduces chemical and water usage.
Highest Hygienic Standards, High Food Integrity
Aseptic pigging is performed with steam barriers at required interceptions in launching and receiving stations. It produces a sterile process while providing control of the sanitary state by returning the pig in aseptic conditions for multiple uses.
Key Features:
- High Product Recovery: Provides up to a 70%* reduction in product loss compared to hygienic cleaning systems without the APV pigging system and optimizes recovery before Cleaning-in-Place (CIP), resulting in more uptime with less CIP.
- Superior Hygiene: Maintains sterile conditions to ensure product safety. No product bypass, electropolished housings for better cleanability, and precise pressure control.
- Sterile Operations: Uses steam barriers and positive pressure to maintain aseptic conditions.
- Increased uptime: Due to faster cleaning methods, it provides more runtime compared to food processing plants without the APV pigging system.
- Certified Materials: CE marked, FDA, and EU food contact certified materials.
- Sustainable Design: Minimizes water and CIP chemical usage by up to 70%* due to less product soil to be washed out of the pipes.
- Easy to use and maintain: It can be retrofitted into existing systems and is optimized for maintenance using SPX FLOW spare parts, simplifying maintenance and operation.
*Figures are contingent on actual running conditions within the plant.
Why Choose APV Aseptic Pigging System?
- By Design: Ensures no product bypass and precise pressure control.
- By Construction: Electropolished housings for easy cleanability.
- By Material: Certified for FDA and EU food contact.
- Functionality: Optimized for high-efficiency product recovery and minimal waste. Uses steam barriers and positive pressure for aseptic conditions throughout the production run.
Applications
- Any liquid and viscous products
- Chocolate
- Cosmetics
- Cream with 40% fat and higher
- ESL and Long-life products, such as yogurt, cheese and other fermented products
- Desserts
- Ice cream
- Milk concentrates
- Nutraceuticals
- Neutral pH products
- Plant based applications
The APV Aseptic Pigging System uses a projectile, commonly called a “pig” or “scraper,” made of silicone or EPDM rubber, to push the product through the pipe. Instead of using water to clean the product from pipes at the end of a production run, the pig clears all product remnants pushed by water or compressed air or inert gas. This saves valuable product from being flushed away while also reducing water usage as there is no direct contact of product with water. There is always a scraper between water and product giving a clean-cut during change overs.
- Pre-Production Setup: The entire product line is sterilized, maintaining a clean and dry process line.
- Product Priming: Product is initially primed from the valve manifold through the launching station to the receiving station.
- Production Cycle: Continues production of ESL and long shelf-life products under sterile conditions.
- End of Production: Water, sterile air or inert gas flushes through the pipeline, releasing the pig to clear the line of all the product.
- Product Recovery: Most of the product is recovered, minimizing losses.
- Cleaning-in-Place (CIP): The pig sits in the receiving station while cleaning-in-place (CIP) is performed. Because there is less product in the pipes, CIP is quicker and minimizes chemical usage. After CIP, the pig is sent back to the launching station using compressed air or inert gas instead of water. This results in a clean, empty pipe ready for the next production run.
- Sterilization: The seal chamber of the two stations and drain valves are equipped with steam barriers. The temperature of the steam barriers and the air pressure in the product line are maintained to ensure aseptic conditions. As such, the entire product line is sterilized.
The APV Aseptic Pigging System recovers more product, reduces waste, and saves water, making your production processes more efficient and sustainable.
DIMENSIONS & SPECIFICATIONS
The APV Aseptic Pigging System is available in various connection diameters and in SMS and DIN piping.
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