Aseptic Pigging Systems | Product Recovery

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Aseptic Pigging Systems

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.

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.

Optimized Efficiency and Sustainability

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 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.

Hygienic Standards and System Integrity

Highest Hygienic Standards and Food Safety

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.

Design Principles and Operational Excellence

Why Choose APV Aseptic Pigging Systems?

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.

Key Applications

Diverse Product Capability

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

PIGGING SYSTEM

Material in Contact with Product: SS316L
Internal Launching and Receiving Station: Electro-polished
External Surface: Glass-blasted
Compatibility: Compatible with existing SPX FLOW pig; suitable for new or existing lines
Maximum Production Temperature: 90°C
CIP Temperature: Maximum 90°C

PIG

Design: SPX FLOW
Product Recovery: Maximum product recovery, up to 70%* of the line volume
Materials: Made of 1935/2004/EC food contact-compliant silicone or EPDM
Certifications: CE-marked and constructed with both FDA and EU food contact-certified materials
Traceability: Material part and batch numbers engraved on the pig for full material traceability

*Figures are contingent on actual running conditions within the plant.

COMPLIANCE

CE Marking for Machine: (MD 2004/62/EC)
Food Contact Material: 1935/2004/EU & FDA 21 CFR 177.2600 compliant/US

PIGGING SYSTEM

Material in Contact with Product: SS316L
Internal Launching and Receiving Station: Electro-polished
External Surface: Glass-blasted
Compatibility: Compatible with existing SPX FLOW pig; suitable for new or existing lines
Maximum Production Temperature: 90°C
CIP Temperature: Maximum 90°C

PIG

Design: SPX FLOW
Product Recovery: Maximum product recovery, up to 70%* of the line volume
Materials: Made of 1935/2004/EC food contact-compliant silicone or EPDM
Certifications: CE-marked and constructed with both FDA and EU food contact-certified materials
Traceability: Material part and batch numbers engraved on the pig for full material traceability

*Figures are contingent on actual running conditions within the plant.

COMPLIANCE

CE Marking for Machine: (MD 2004/62/EC)
Food Contact Material: 1935/2004/EU & FDA 21 CFR 177.2600 compliant/US

The Aseptic Pigging System is available in various connection diameters and in SMS and DIN piping.

PIPE STANDARD

ISO (SMS): Available from 1.5" to 4
DIN: Available from 40 to 100

Our pigging systems are identified by an order code and a serial number. The order code is constructed according to selected options and follows this pattern:

TYPE	DIAMETER	CONTROL UNIT	SEALS	PIG	PUSH CONFIGURATION
SSAS-	038	ASI (A)	EPDM (E)	SILICONE (S)	Drain only (A)
	051	DIRECT CONNECT (D)	HNBR (H)	EPDM (E)	Push by air (B)
	063		FPM (F)
	076
	101
	040
	050
	065
	080
	100

For example, this would result in SSAS-038AESA.

The order code, along with the serial number and year of fabrication, is engraved on the launching station body. Only the serial number is engraved on the receiving station and draining T bodies.