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Efficiency through automation

At our state-of-the-art flour milling plant, efficiency is not just an aspiration—it is our benchmark. By leveraging cutting-edge Bühler machinery and fully automated systems, we achieve unparalleled precision, consistency, and sustainability throughout the milling process. This commitment to innovation ensures enhanced production efficiency, superior product quality, and reduced energy consumption.

Enhanced Efficiency and Superior Quality

Automated Excellence

Our milling process is fully automated, reducing the need for human intervention while maintaining exceptional accuracy. The programmable logic control units integrated into the plant allow real-time monitoring and provide actionable feedback for optimizing every stage of production.

Key benefits

Unlike normal plants, where operations often rely on manual adjustments and monitoring, Buhler’s automated plant achieves a production increase of up to 20% by minimizing downtime through real-time controls and predictive maintenance systems. This results inconsistently higher throughput and smoother operations.

Traditional plants often face quality variations due to inconsistent grinding or manual handling. Buhler’s automated systems, featuring precision digital controls and hygienic designs like swing-out feed modules, improve product quality by 15% through uniform particle sizes and contamination-free processes.

Conventional plants may consume more energy due to outdated machinery. Buhler’s energy-efficient equipment, such as the air-recycling aspiration channel, reduces power usage by up to 15%, saving approximately 1,200 kWh per ton of processed grain annually.

Non-automated plants often experience raw material losses of up to 8%. Buhler’s advanced separation systems reduce waste to less than 2% by integrating real-time monitoring and feedback loops that optimize raw material use.

Unmatched Product Purity and Safety

At the start of our process, the Bühler Destoner ensures that only the finest raw materials proceed to production. By efficiently separating stones, glass, and other impurities, it safeguards product purity and adheres to the most rigorous food safety standards. Its adjustable settings and automatic feedback loops allow it to adapt to different grain types, delivering consistently superior results with minimal manual input.

The precision continues with our Roller Mill Dolomit, a machine engineered for high-capacity, consistent grinding. The mill features intelligent monitoring systems to ensure a uniform feed rate, automatic roll adjustments, and hygienic operation. Built with user-friendly interfaces, it provides real-time data to optimize performance while minimizing contamination risks.

Automation That Redefines Efficiency

At the heart of our operations is the Programmable Logical Control Unit (PLC), an intelligent control system that drives efficiency and consistency. Intuitive interfaces, real-time monitoring, and remote accessibility allow for smooth, automated processes that adapt dynamically to changing product characteristics. Features like integrated recipe assistants and automated adjustments ensure minimal downtime and optimal resource utilization.

Comprehensive Milling Process Flow

Cleaning and Preparation

The journey begins with a thorough cleaning to remove impurities such as stones, metal, and lighter particles. This step is crucial for ensuring the quality of the final product and protecting downstream machinery.
Destoner (MTSD)
This machine sets itself apart with its high separating efficiency, capable of handling up to 22 tons of wheat per hour.It effectively removes stones, glass, and dense impurities using automated controls and a customizable airflow system.

Equipped with contamination sensors, it dynamically adjusts its settings to optimize performance while requiring minimal manual intervention. Its durable design ensures reliable operation, even in high-throughput scenarios.
Destoner Machine
Rotary Separator (Ultratrieur)
Featuring precision-engineered pockets, the Ultratrieur ensures a highly accurate classification of grains by size and shape. Its modular design allows it to process up to 48 tons per hour, depending on grain type.

Automated adjustments and optional digital monitoring tools streamline operations, providing unparalleled adaptability and efficiency compared to standard separators.
Destoner Machine
Air-Recycling Aspiration Channel (MVSS)
This system revolutionizes impurity removal by recycling air, cutting energy consumption by 15%. It handles capacities of up to 30 tons per hour for cleaning and uses electronic controls for precise airflow adjustments.

Inspection windows with integrated LED lighting simplify monitoring and maintenance, making it an eco-friendly and user-focused alternative to conventional aspiration systems.
Destoner Machine
Cleaning and Preparation

Key Machines

conditioning

Conditioning prepares the cleaned wheat for grinding by adding moisture to achieve optimal pliability. Automated moisture control systems ensure precise conditioning tailored to each grain type. These systems continuously monitor and adjust humidity levels, guaranteeing perfect preparation for grinding and maximizing flour yield.
Conditioning

Timeline Item 1

Grinding

Grinding is the heart of the milling process, where conditioned grains are transformed into fine flour. Precision is paramount, and our advanced roller mill ensures exceptional results.
Roller Mill (Dolomit MDDP/MDDQ)
Known for its robustness and reliability, the Dolomit Roller Mill uses self-contained forces for precise and stable grinding. With a grinding capacity of up to 8 tons per hour per roller set, this system outperforms traditional manual mills, which typically operate at lower capacities and require frequent manual adjustments.

Automation features such as digital roll-gap monitoring ensure accuracy within microns, while auto-balancing mechanisms and real-time adjustments maintain consistent performance even during continuous operation. The integrated control panel provides real-time visualization of operational parameters and remote troubleshooting capabilities, reducing downtime by up to 25% compared to non-automated systems. Its ergonomic and hygienic design also ensures compliance with international food safety standards, making it a cornerstone of modern milling efficiency.
Destoner Machine
Grinding

Key Machine

Sifting and Purification

Once grinding is complete, the flour undergoes meticulous sifting and purification to ensure only the finest particles make it to the final product.
Plan Sifter (SuperSift DRAA)
Equipped with multiple sieve layers, the Plan Sifter ensures high throughput with a total sifting area of 8 m2, and handling capacities between 5 to 7 tons per hour. It uses automated vibration control and adjustable sieves to achieve precise separations and grading.

Real-time diagnostics provide continuous monitoring, reducing downtime and ensuring operational efficiency. The compact and modular design simplifies maintenance while supporting scalability, making it a reliable choice for high-demand production needs.
Destoner Machine
Purifier (Norit MQRH)
The Norit Purifier delivers high yields of semolina and flour with a performance of up to 1.5 tons per hour per half-machine. It features three sieve decks equipped with NovaPrime mesh for precise separation and grading.

Automated airflow adjustments enhance separation efficiency, while the intuitive design allows tool-free adjustments and easy maintenance. The robust construction reduces downtime and meets stringent international food safety standards, making it a critical asset for achieving consistent, high-quality outputs.
Destoner Machine
Sifting and Purification

Key Machine

Final Processing and Blending

In this stage, automated blending systems ensure precise mixing of the flour to meet specific customer requirements. These systems achieve a uniformity rate of over 98% across batches, supported by advanced real-time analytics. By analyzing ingredient properties such as moisture content and particle size, the system dynamically adjusts blending parameters to accommodate fluctuations. With a throughput capacity of up to 15 tons per hour, this process minimizes inconsistencies and ensures the highest quality standards for end products. Automated alerts further enhance efficiency by detecting and correcting deviations instantly, reducing waste by up to 10% compared to traditional methods.

Packaging

The final step is fully automated packaging, a process that guarantees precision, hygiene, and product integrity. With a capacity to handle up to 10 tons of flour per hour, these systems utilize advanced weight calibration sensors to ensure accurate portioning and prevent overfilling. Features like automated tamper-proof sealing safeguard product quality during transportation and storage. Additionally, integrated traceability systems record batch information, enabling comprehensive tracking from production to delivery. By minimizing human contact and automating quality checks, these systems reduce contamination risks and ensure that every package meets the highest industry standards.
Final Processing and Blending

In this stage, automated blending systems ensure precise mixing of the flour to meet specific customer requirements. These systems achieve a uniformity rate of over 98% across batches, supported by advanced real-time analytics. By analyzing ingredient properties such as moisture content and particle size, the system dynamically adjusts blending parameters to accommodate fluctuations. With a throughput capacity of up to 15 tons per hour, this process minimizes inconsistencies and ensures the highest quality standards for end products. Automated alerts further enhance efficiency by detecting and correcting deviations instantly, reducing waste by up to 10% compared to traditional methods.

Packaging

The final step is fully automated packaging, a process that guarantees precision, hygiene, and product integrity. With a capacity to handle up to 10 tons of flour per hour, these systems utilize advanced weight calibration sensors to ensure accurate portioning and prevent overfilling. Features like automated tamper-proof sealing safeguard product quality during transportation and storage. Additionally, integrated traceability systems record batch information, enabling comprehensive tracking from production to delivery. By minimizing human contact and automating quality checks, these systems reduce contamination risks and ensure that every package meets the highest industry standards.

The Impact of Automation

By integrating advanced systems, our milling process delivers unmatched results in both efficiency and quality. Buhler’s Premium Plus solution enables downtime reduction by up to 25%, significantly enhancing continuous operation and ensuring higher throughput compared to traditional plants.

Manual intervention is minimized through predictive maintenance, which extends equipment lifespan by 20% and reduces unexpected failures by analyzing and ranking potential issues in real-time. Remote monitoring capabilities via Bühler’s digital services allow operators to detect and resolve issues 30% faster, further reducing delays.

Comprehensive data management systems, which store data from up to 200 past jobs, ensure traceability across the production cycle. These systems also analyze performance metrics to identify optimization opportunities, boosting overall productivity by 15% and ensuring consistent product quality.

This harmonious blend of automation and data-driven strategies not only saves time and energy but also revolutionizes every stage of production, setting a new benchmark for industry excellence.

Delivering Excellence Every Day

Together, our Buhler machines form an ecosystem of innovation that optimizes productivity, conserves energy, and elevates the quality of our flour.

From the first grain to the final product, our fully automated plant ensures precision, reliability, and a commitment to sustainability.

With “Efficiency Through Automation,” Powered by cutting-edge technologies such as the Destoner, Roller Mill Dolomit, and Plan Sifter, we deliver unparalleled product purity, uniform grinding, and exacting blending precision.

Real-time monitoring, predictive maintenance, and energy-saving innovations keep our plant running at peak performance, ensuring higher throughput, minimized downtime, and a future-focused approach to sustainability.

we’re not just milling grains—we’re crafting possibilities, raising industry standards, and delivering value to our customers with every batch of flour we produce.

This is the future of milling, and we’re proud to lead the way.