With 30 years' expertise, VP designs Automatic pigging system for hygienic & industrial pipeline
At the end of a product transfer, some material inevitably remains in the pipeline, causing waste and economic loss. Traditional methods, such as flushing with water or cleaning agents, are inefficient, incomplete, time- and labor-intensive, and generate large volumes of wastewater and pollutants.
A pigging system is designed for pipeline cleaning, maintenance, and product recovery. It works by propelling a pig — slightly larger than the pipeline’s inner diameter — through the line with compressed air, nitrogen or cleaning liquids. The pig scrapes inner pipe walls, pushing residual product into a recovery container for thorough cleaning, higher product recovery and reduced waste. The pig’s outer layer features elastic, wear-resistant materials like polyurethane or special rubber, with built-in magnets for position tracking by magnetic sensors.
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Achieves up to 99.5% recovery (depending on pipe size, media viscosity, and system design), significantly reducing pipeline residue and improving material utilization.
Cuts production changeover time dramatically, boosting efficiency by over 80% compared to traditional cleaning methods.
Minimizes mixing risks between batches and formulations, ensuring process safety and product quality, while cutting rework and scrap losses.
Removes over 99% of pipeline deposits without damaging pipe walls, reducing blockages and chemical cleaning needs, and extending equipment service life.
Typical payback period is 3–8 months, delivering long-term economic benefits.
Reduces pipeline length and equipment footprint by up to 40%, optimizing overall plant layout.
Reduces water consumption by over 95%, significantly lowering chemical usage, wastewater discharge, and disposal costs for greener production.
Pigging systems are Widely used in a variety of industries such as:
Recover product, efficiently remove residue, and withstand demanding conditions including high temperatures, high pressure, corrosive media, and frequent operations. Pipelines typically utilize welded or flanged connections for sealing performance, primarily serving the petrochemical, lubricating oils industry.
Prioritize thorough cleaning, zero residue, and contamination-free processes. After pigging, pipelines are flushed with water or cleaning agents. For rapid disassembly and sanitation, hygienic tri-clamp (Tri-Clover) connections are used, making them ideal for food, pharmaceutical, and cosmetic industries.
Main Equipment in Pigging System Includes: Launching/Receiving Stations(Core Components), Intermediate Pigging Stations, Cleaning Pigs (various materials, Such as Foam Pigs), Piggable Pipeline Sections, Reinforced Pipe Sleeves, Pig Tracking Sensors, Industrial-Grade Communication Cabling, PLC-Based Control System, Pig Loader/Unloader(Optional) and Control Systems.
Pig launcher & receiver for efficient, safe pipeline cleaning & product recovery
The PLC system provides centralized monitoring of the pigging station, including: 1. Product valve actuation status (open/closed); 2. Pneumatic control valve positions; 3. Real-time pig tracking through the pipeline. Pigging Station Utility Parameters Valve & Cylinder: 304SS, Power Supply: 24V DC, IP Rating: IP65, Design Pressure: 20 bar, Temperature Range: -30°C to 120°C, Average Ball Speed: 1.0-1.5 m/s, Actuation Pressure: 5-8 bar.
The pigging system middle station is a critical facility in pipeline pigging operations, designed as a fast pig launcher and receiver at designated intermediate...
In pigging systems, the Pig Launcher (Launcher Station) plays the critical role of the “starting point” and “control hub”. It is far mor...
In pigging systems, the Pig Receiver (Receiver Station) plays a critical end-point role, serving as core equipment that ensures pipeline cleanliness, operationa...
The 3-Way Distribution Valve is specifically designed for complex pigging systems. It allows pig passage and enables pipeline switching, overcoming the limitati...
The Piggable Valve (Full Bore Ball Valve for Pigging) is specifically designed for pipeline pigging systems. To ensure pigs pass smoothly without jamming or dam...
The Piggable Tee is a specialized pipeline component designed for Pipeline Pigging systems. Its primary function is to provide a horizontal, obstruction-free pa...
Made of elastic material, good sealing and wear resistance
A pigging pig is an elastic projectile with a diameter slightly larger than the pipeline’s inner diameter, made of elastic materials (such as rubber or polyurethane). Driven by the medium inside the pipeline (gas or liquid), it performs cleaning tasks. Typically cylindrical with conical ends for smooth passage through bends. Advanced sensors and control systems can be embedded to monitor position and speed in real time, enabling precise control and automation.
VP adopts advanced global polyurethane manufacturing technology and has developed solutions with different materials for various operating conditions, ensuring excellent elasticity, sealing, and wear resistance. Common materials include: Composite PU, Fluoroelastomer, Silicon Rubber, and Steel Brush.
Industrial-grade pigging pigs feature a modular, detachable structure (large-diameter body and lips) for easy maintenance and cost reduction.
Sanitary-grade pigging pigs use a seamless one-piece design to eliminate dead zones and prevent residue buildup.
A pigging system uses pigging pigs to efficiently recover products, clean, or separate media inside pipelines. The operation steps are as follows:
1. Launch Preparation: Insert the pigging pig into the launching station and close the inlet valve.
2. Pig Propulsion: Use a driving medium (air, nitrogen, or cleaning liquid) to push the pig into the pipeline, where it scrapes the pipe wall and moves forward.
3. Product Recovery: The pig pushes residual liquid to the receiving station for recovery.
4. Pig Retrieval: After completing the task, the pig enters the receiving station and is collected through valve switching.
5. System Reset: The pig returns to the launching station, ready for the next operation.
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Smart Pigging Control: Automated, Safe & Efficient Operations
Pipeline Pigging Control System is an automated or semi-automated system designed to manage and control pipeline pigging operations. It ensures the safe and efficient operation of Pigs within pipelines, enabling them to perform tasks such as cleaning, inspection, isolation, or media transfer.
BJVP control center is equipped with a comprehensive set of software and hardware for DCS control, where control systems are tested before shipment, Remote Control service and support is available to the customers, Compliant with Industrial Automation Safety Standards (IEC 61131-3).
Central control room master control (on-site monitoring).
On site control (central control room monitoring).
The system enforces a single control right through a permission interlock protocol to avoid signal conflicts and security risks caused by dual control operations.
Minimize resistance and wear for smooth pigging
Long Radius Elbows are necessary to ensure Pig move through smoothly in a pipping system. BJVP designs and manufactures long radius elbows in various types of materials.
1. The straight pipe segment between two elbows shall not be less than 10D;
2. Elbows must be equipped with straight pipe segments at both ends, with a length not less than 1.5D;
3. Elbows shall not connect directly to the pigging station; a straight pipe of ≥6D is required;
4. Standard angles of 45°, 60°, and 90° are recommended for elbows; non-standard angle elbows should not be used;
5. Elbows must have a bending radius of 5D or larger;
6. Each pigging station requires independent support, with supports every 4–6 m along the pipeline.
| Pipe Size | Outer Diameter | Inner Diameter | Roundness Deviation | Surface Finish |
|---|---|---|---|---|
| 1.5"-DN40 | 34.7mm | 38mm | ±0.15mm | <0.8µm |
| 2"-DN50 | 60.3mm | 52.5mm | ±0.2mm | <0.8µm |
| 3"-DN80 | 88.9mm | 77.9mm | ±0.3mm | <0.8µm |
| 4"-DN100 | 114.3mm | 102.3mm | ±0.4mm | <0.8µm |
| 6"-DN150 | 168.3mm | 154mm | ±0.6mm | <0.8µm |
Reliable Pigging System China Manufacturer
Professional R&D, Design, Manufacturing, Installation and After-Sales
The customized service provided by the company can fully meet the individual needs of customers and ensure that the pigging system is perfectly matched to the customer's production process.
Professional technical support and after-sales service team to provide customers with a full range of protection, to ensure that customers have no worries in the process of use, high customer satisfaction.
Professional R&D, Design, Manufacturing, Installation and After-Sales Servic
High brand reputation and industry recognition
BJVP's pigging system adopts advanced technology and design concept, and the product performance is in a leading position in the industry. VP - Your Reliable Pigging System China Manufacturer.
About Us
We provide customized pigging system solutions tailored to customers' piping systems, product characteristics and production needs. From pig design to drive system configuration and recovery unit selection, the actual needs of the customer are fully considered to ensure that the system is perfectly matched with the customer's requirements.
Our professional team provides customers with a full range of technical support from system design, installation and commissioning to operation training. Provide timely after-sales service, including equipment maintenance, troubleshooting, and spare parts supply, to ensure the long-term stable operation of the pigging system.
We focus on long-term partnerships, and provide customers with continuous improvement solutions through continuous technological innovation and optimization. Regularly visit customers to understand the operation of the system and customer feedback, adjust and optimize the service content in a timely manner, ensuring satisfaction.
Our pigging experts will reply to you. We sincerely look forward to cooperating with you
