RATEC modular pigs are brush pigs built from several individual brush discs on a common main body. The discs can be replaced and combined in different orders, so the cleaning result is precisely matched to your pipeline. Modular pigs are available as standard from DN 32 for pressure and suction conveying lines; ATEX- and FDA-compliant versions are also available on request. RATEC develops and manufactures every modular pig in-house in St. Veit an der Glan.
Table of Contents
How modular pigs are built
The core element is a main body with several brush discs mounted in sequence. Each disc can have different bristles. This results in a simple, effective principle:
- Coarse up front: At the front are brush discs with coarse bristles. They loosen deposits and build-up from the pipe wall.
- Fine at the end: Behind them come discs with fine bristles. They pick up the remaining dust and ensure a clean finish.
- Easy to renew: Worn discs are replaced; the main body remains in service.
This way, a single pig performs two tasks in one run that would otherwise require different pigs.
Combine flexibly, clean precisely
Every conveying line is different. Conveyed material, deposits, pipe material and pipeline routing determine what cleaning is required. With the modular pig, we adapt the combination of brush discs to exactly these conditions: number, order and bristle type of the discs.
If your process changes, for example due to a new product or different deposits, you don’t necessarily need a new pig straight away. Often it is enough to replace individual discs or rearrange them. This makes the modular pig the flexible solution for systems where requirements change over time.
Cost-effective thanks to spare parts
Brushes wear out—this is the case with every pig. With the modular pig, however, you only replace the parts that are actually worn. Worn brush discs are available as spare parts, while the main body remains in use. This lowers ongoing costs and reduces material consumption compared to a pig that has to be replaced as a whole.
Technical specifications
| Feature | RATEC modular pigs |
|---|---|
| Construction | multi-part, replaceable brush discs on a main body |
| Nominal diameter | from DN 32 (standard), other sizes on request |
| Pig speed | 1 to 3 m/s |
| Propellant gas temperature | +5°C to +80°C |
| Bristling | selectable per disc, coarse to fine |
| Conveying type | Pressure and suction conveying |
| Spare parts | brush discs can be replaced individually |
| Versions | ATEX- and FDA-compliant materials on request |
The values stated are our standard version. We manufacture other nominal sizes, materials and versions to your specifications.
Why pig conveying lines?
In pneumatic conveying lines, dust remains on the pipe walls and product residues remain in dead spaces despite blow-out, for example in flange gaps or at diverters. During the next product changeover, this material is carried over into the new batch, and over time the line can become clogged. A pig cleans the line dry from the inside, without disassembly and without chemicals. Flushing granulate often does not clean satisfactorily, and a water-air mixture is complex and requires drying before the next batch changeover.
Modular pig, fixed pig or turbo pig?
- Modular pigs: built from replaceable brush discs—ideal when cleaning needs to be flexibly adapted to the pipeline.
- Fixed pigs: one-piece and robust, the economical solution for clearly defined cleaning tasks.
- Turbo pigs: with counter-rotating turbine wheels for particularly thorough cleaning, from DN 125.
- Special pigs: for drying, polishing, for hoses, detectable, or for high temperatures.
Pig system with launching and receiving station
A modular pig is inserted into the line via a launching station, pushed through the line by the driving gas, and gently received at the end in a receiving station. For a thorough result, we recommend several runs. RATEC supplies the matching launching and receiving stations—manual, semi-automated or fully automated with pig return system. If your existing line is not pig-compatible, for example due to large diameter changes or internals in the pipe, we develop suitable modifications.
What matters during design
- Nominal diameter and line routing: DN, length, bends, diverters, and flange connections.
- Conveying method: pressure or suction conveying.
- Conveyed material and deposits: product, dust, angel hair, adhesions.
- Special requirements: ATEX, FDA, temperature, frequency of product changeovers.
- Degree of automation: manual, semi-automated or fully automated.
Customized by RATEC
RATEC is at home in the bulk materials sector and manufactures components for bulk material systems in its own plant in Carinthia, certified to ISO 9001, EN 1090-1 and ISO 3834-2. RATEC pigs are used primarily in the plastics, building materials, food and pharmaceutical industries. For potentially explosive areas, ATEX-compliant versions are available in accordance with Directive 2014/34/EU; for food applications, FDA-compliant materials. We always define the material to suit your requirements. You can find an overview of all designs under Pigs.
Want to clean your conveying lines precisely?
Briefly describe your line, your conveyed material, and your cleaning task. We will get back to you with a concrete solution proposal.