Aseptic Pigging: How It Works

Urs Hofer, CEO, and Matthias Stettler, financial adviser to Uresh, have developed a financial model for their new aseptic pig and explain it in more detail to PROCESS.

Uresh offers for its aseptic pig a financial model in which operator and provider share the savings. What data do you take as the basis for calculating the savings?

Hofer: In pigging technology we can draw on many years of experience, which allows us to calculate potential savings with a little central data from the customer. For the calculation, we need only the following parameters: the volumes of the process pipe connections, the number of cleaning operations for the period in question, and the raw product costs. On top of this there are the savings for the caustic solution and its disposal, as required in a conventional cleaning without pigging. In this we are of course dependent on good cooperation with the customer.

Stettler: In this partnership-based approach we have the main motive for a Shared Savings financing agreement. Savings can be offset as “negative costs” in an investment calculation. Our offer to the customer is to outsource, wholly or partially, his investment costs. In return for our participation in the costs, we want to share in the savings. If the customer considers the savings, less the rent, for the system, he has in the end a positive nett effect. What more does one want?

According to what paradigms do you calculate the shares and how flexible are these paradigms?

Stettler: This question can only be answered with regard to individual customers. But: both sides have a positive return. With our paradigms, we try to find a balance with which all parties are satisfied. The way we reach that is a matter for negotiation. We offset the credit risk with minimum contract durations and part payments on the initial investment costs. Whatever the case, he is left with a positive return, which in turn depends on how high the potential savings are. Regardless of the distribution paradigm, the customer makes additional savings in further areas which cannot be considered in their entirety in our calculation, such as logistics. And, of course, more flexible production is possible with the pigging system. On top of that come benefits for the environment.

How do you guarantee the asepticity of the pig during production operations?

Hofer: The pig is kept in an aseptic pig-catcher station which is completely sealed off from its surroundings. The pig is CIP-cleaned and disinfected in this station or steamed with sterile steam. There are no cylinder rods leading outwards to position the pig. It is therefore impossible for bacteria to be drawn in from outside.

Have you already had experience of validation and approval practices with the authorities?

Hofer: All pig installations can be validated, i.e. every ejection of products follows exactly the same course. The customer validates the complete process himself, which is why we do not have this data available.