Exol Lubricants, the UK’s largest independent lubricants manufacturer, is making significant strides in sustainability and operational efficiency by implementing HPS Advanced Liquid Product Recovery (Pigging) Technology. This innovative solution is enabling Exol to save up to 50,000 litres of valuable lubricant product each day, substantially reducing waste in their production processes.
Located at Exol’s Rotherham blending plant, this advanced pigging technology is a strategic move to enhance both environmental sustainability and operational efficiency. By recovering lubricant oils that would otherwise be discarded during production, Exol is achieving considerable cost savings while aligning with its sustainability objectives.
Understanding Pigging Technology
Pigging is a process widely used across various industries that transport liquids through pipelines, including lubricants, chemicals, and food production. The term “pig” refers to a specialist device that travels through pipelines, propelled by compressed air, gases, or water. This cutting-edge technology recovers up to 99.5% of residual liquid product left in pipelines post-transfer, allowing for its reuse or repackaging instead of disposal during cleaning.
Moreover, HPS pigging technology reduces the necessity for cleaning chemicals and lowers the risks of cross-contamination between products, enhancing overall production safety.
Addressing Challenges in Product Loss and Contamination
Before adopting HPS technology, Exol faced significant challenges with product loss and contamination during the transfer of lubricants between storage, blending, and packaging stages. To combat these issues, Exol collaborated with HPS to implement multiple pigging systems designed to recover nearly all valuable lubricant oils remaining in the pipelines after product transfers.
As a result, Exol has experienced a dramatic reduction in product loss and waste, alongside cleaner and more efficient product changeovers.
Peter Elgar, Executive Chairman at HPS, commented on the impact of the technology: “HPS pigging technology has delivered outstanding results for Exol, enabling the recovery of up to 50,000 litres of product daily. Additionally, loading times have been accelerated by as much as 50%, significantly streamlining their production process.”
Advancing Environmental and Sustainability Goals
The implementation of HPS pigging technology has not only facilitated substantial waste reduction but has also aided Exol in minimising the environmental impact of its production activities. By generating less waste, Exol consumes fewer resources, requires less energy for cleaning, and ultimately lowers its carbon footprint.
Elgar further elaborated on the importance of these advancements: “HPS pigging systems prevent companies from wasting significant amounts of perfectly usable product. Our technology directly supports Exol’s commitment to environmental responsibility. By recovering product from process lines, we contribute to reducing the energy and CO2 emissions linked to replacing these losses, making a significant impact on both operational efficiency and sustainability.”
A Proven Solution for Long-Term Success
With impressive results already achieved, Exol is exploring the potential for expanding pigging technology throughout other operational areas. This commitment to continuous improvement not only demonstrates Exol’s dedication to sustainability but also highlights its proactive approach to enhancing production efficiency.
