3a certified product recovery system for food and pharmaceuticals
Optimize your production line with a system designed to efficiently recover high-value products from pipelines while minimizing waste and reducing environmental impact.
The VARICOVER® 3A Hygienic Pigging and Product Recovery System from GEA is engineered to maximize product yield in food, beverage, pharmaceutical, and personal care industries. Utilizing advanced pigging technology, it efficiently recovers viscous and flowing products from pipelines, minimizing waste and ensuring high-quality output. Rated for applications like yogurt, shampoo, and pharmaceutical liquids, it is adept at managing both liquid and slurry products.
The system’s pigging process features full automation options, allowing seamless integration into existing production lines while maintaining a hygienic operation. A key aspect is its compliance with the stringent 3A standards, ensuring suitability for sensitive applications.
The system includes robust components such as pig cleaning and catching stations, ensuring effective product push-out without media contamination. It accommodates operations at pressures up to 16 bar and temperatures as high as 150° C for short periods, providing flexibility in diverse processing environments.
Material options include FDA-compliant silicones and FKM to withstand various chemical exposures, while the CIP-capable cleaning options facilitate maintenance, reducing downtime. This system is essential for manufacturers seeking to enhance efficiency, optimize yields, and adhere to regulatory requirements in their production processes.
Benefits
- Enhances product yield by minimizing residual waste in pipelines.
- Reduces operational costs through automated pigging and product recovery systems.
- Complies with 3A sanitary standards, ensuring safety for food and pharmaceutical use.
- Simplifies maintenance with CIP-capable components, reducing downtime.
- Supports flexible integration into existing systems with modular design options.
- Applications
- Beverages,Syrup,Dough,Personal care products,Vegetable oil,Cleaning agents,Shampoos,Toothpaste,Cheese,Yoghurt,Washing agents,Fruit pulp,Concentrates,Lotions,Quark,Creams,Pharmaceutical liquid products
- End products
- Fruit juice concentrates,Moisturizing creams,Toothpaste tubes,Surface cleaning sprays,Juice beverages,Body creams,Cough syrups,Bottled syrups,Bottled vegetable oil,Face lotions,Yogurt cups,Cheese blocks,Fruit pulps in jars,Bread dough,Shampoo bottles,Quark packages,Detergent bottles
- Steps before
- Reception to pre-mix,Pre-mix to mixing,Product reception,Mixing,Process tank operations
- Steps after
- Storage,Filling,Filler lines
- Input ingredients
- shampoo,lotions,creams,toothpaste,pharmaceutical liquid products,washing agents,cleaning agents,yoghurt,quark,cheese,fruit pulp,syrup,concentrates,dough,vegetable oil,personal care products
- Output ingredients
- recovered high-quality product,product push-out,gentle filled pipelines
- Operating Temperature
- 135°C
- Sterilizing Temperature
- 150°C (short time)
- Operating Pressure
- max. 16 bar for DN25-DN65
- Max. 10 bar for DN80/100
- Control Air Pressure
- Min. 4.2 bar
- Max. 8 bar
- Sizes
- DN25 - DN100 / 1"OD – 4"OD
- Seals Material
- Standard EPDM (FDA)
- Pigs Material
- Silicone / FKM (FDA,EU Regulation 1935/2004 food compliance)
- Automation level
- Automatic / Semi-automatic / Manual
- Cleaning method
- CIP (Clean-in-Place)
- Product push-out method
- Pipeline ejection without media mixing
- Process compatibility
- Food,Beverage,Pharmaceutical
- Integration capability
- New or existing process systems
- Modular design
- Conforms to 3A Standards
- Variable operation
- Allows gentle filling of pipelines
- Versatile application range
- Reception to pre-mix,mixing to storage,storage to filler
- Density/particle size
- 0.5–2.5 g/cm³ / 50–1000 µm
- Foaming tendency
- High
- Viscosity
- High
- Heat sensitivity
- Moderate to High
- Abrasion resistance
- Required
- Food safety compliance
- Mandatory
- Hygienic design
- 3A Standard
- Pressure tolerance
- Max 16 bar
- Thermal tolerance
- Operating temp. 135° C
- 3A Sanitary Standards
- Yes
- FDA Materials
- Yes
- Compact footprint
- Customizable
- Control panel type
- PLC / Manual
- Discharge method
- Pigging system
- Automation level
- Manual / Semi-automatic / Automatic
- Pigging system type
- Automatic / Semi-automatic / Manual
- Pig material
- Silicone / FKM
- Control air pressure for cleaning station
- 4.8–8 bar
- Control air pressure for stopper
- 4.2–8 bar
- Market info
- GEA is known for its expertise in engineering innovative and sustainable equipment and solutions, focusing on sectors such as food, beverages, pharmaceuticals, and energy, with a reputation for quality, efficiency, and advanced technological applications in industrial processing.