EXECUTIVE INTERVIEW: Don’t Rush the Process

Don’t Rush the Process: Why Discipline Still Defines Great Milling Technologists

Across Africa, flour millers are navigating a complex operating environment shaped by high energy costs, volatile wheat import prices, infrastructure constraints, and growing regulatory and consumer expectations around food safety and sustainability.

In this executive interview, Milling Middle East & Africa Magazine speaks with Michael Ndukwe, Shift Head Miller at Niger Mills Company, a division of Flour Mills of Nigeria, who shares a comprehensive perspective on the flour milling industry across Africa.

With more than 12 years of professional experience, Ndukwe gives a grounded, operations-driven account of the realities of modern milling, offering insights into plant efficiency, food safety systems, workforce development, and the technological and sustainability shifts reshaping the sector.

MMEA: Can you briefly introduce yourself and provide an overview of your experience in the flour milling industry?

I am Ndukwe Michael Scott, a Shift Head Miller at Niger Mills Company, a division of Flour Mills of Nigeria. I am a seasoned professional miller with over 12 years of experience in the industry, and I have developed the skills and expertise necessary to contribute meaningfully to team and organizational success. 

Throughout my career, I have gained extensive experience across all aspects of the flour milling industry, including automation, food safety systems, hygiene practices, and process control. My responsibilities have covered staff supervision, inventory management, cost analysis, and customer service. I am a strong communicator and leader with a proven ability to motivate teams to achieve both departmental and organizational goals. I also have a solid track record of improving profitability through effective cost management and reduced downtime, while remaining committed to delivering high professional milling standards.

MMEA: What initially drew you to the field of flour milling, and how did you develop your expertise?

I started my career in Engineering Department, initially I never intended nor imagined to be a Flour Miller, nor do I know what it takes to be a Miller, but I was involved in the Erection and Installation of Our C-Mill year 2007 – 2008. (500 metric tons per 24 hours Mill) from the installation of Steel Silos and Cat-Walks to installation of Building Structures, Steel Columns, Concrete of the floors and finally the installation of All Buhler Milling machines. In the Technical Department as a Mechanical Fitter, during the installation work, I wanted to know more how those machines works, I later developed passion and interest to be a professional miller, oppourtunity now presented itself while i was still in the technical department, an opening to be trained as a qualified personnel in the art-of-flour-milling, the trade. (the magic of processing raw wheat into good consumable flour used for various purposes such as Bread, Biscuit, Noodles etc.) Examination and interviews was set, I passed internal prerequisite examinations that qualified me to work as a Mill Assistant. From there, I pursued further professional studies and advanced training, including programmes such as NABIM, which enabled me to progress to Assistant Miller and subsequently to Shift Miller. 

MMEA:What would you consider the most significant achievement of your career in flour milling?

My most significant achievement is the daily responsibility of ensuring the production of safe wheat flour, semolina, and whole wheat meal that consistently meet statutory, regulatory, and mutually agreed customer food safety requirements. This includes implementing and continuously improving an effective quality and food safety management system that supports a long-term food safety culture across operations.

MMEA: In your current role, how do you ensure smooth and efficient milling operations?

Efficient operations begin with disciplined execution across the entire production chain, including wheat intake operations, correct storage practices, raw material cleaning, gristing, tempering and conditioning, milling, finished product storage, and product blending to meet customer specifications. I also validate the effectiveness of the food safety management system through internal and external audits and inspections. Any deficiencies identified are addressed promptly, with lessons applied to improve processes and strengthen food safety competencies. Risk-based controls aligned with our operating context are applied to achieve food safety objectives and drive continuous improvement.

MMEA: How do you motivate and equip your production team to achieve operational excellence?

I prioritize regular communication with every team member to effectively manage food safety risks associated with changes in products, processes, and technologies. This approach promotes continuous improvement, accountability, and alignment with operational objectives.

MMEA: You recently graduated from the African Milling School. What does that training mean for your career?

The programme provided hands-on exposure within milling facilities alongside structured classroom discussions, helping me develop a deeper conceptual understanding of the milling process. The training focused on mill balance, identification of critical control points, and the milling of different wheat classes. It enhanced my understanding of how raw materials and milling systems influence cleaning, conditioning, milling, and finished product quality, while reinforcing the critical role employees play in controlling and optimizing the process.

MMEA: What is the biggest challenge facing the flour milling industry in Nigeria and Africa today, and how is it being addressed?

One of the most significant challenges is the high cost of energy and operations. Consistent energy supply is essential for continuous milling operations, yet high electricity costs place heavy pressure on manufacturers, particularly in the milling and baking sectors. Currency fluctuations and foreign exchange scarcity also significantly impact the cost of importing wheat, which remains the primary raw material for most African millers. In addition, infrastructure and logistics challenges, especially poor road networks around major ports such as Apapa in Nigeria, increase transportation costs and disrupt supply chains.
To address these challenges, companies are pursuing mergers and acquisitions to streamline operations and improve efficiency, such as Flour Mills of Nigeria’s acquisition of Honeywell. Others are diversifying wheat import origins to more cost-effective markets and investing in local wheat value chain development. Increased private-sector investment in logistics and vertical integration into farming is also gaining momentum. A notable example is the Grain Processing and Innovation Center launched in Kano in July 2024 through collaboration between Bühler and Flour Mills of Nigeria.

MMEA:What emerging trends or innovations are shaping the flour milling industry?

Key innovations include the integration of artificial intelligence and the Internet of Things for predictive maintenance, which plays a critical role in reducing operational costs. There is also a strong focus on energy efficiency to support net-zero goals, alongside product diversification into alternative grains, specialty flours, and fortified flour products.

MMEA: How does Africa compare with the rest of the world in terms of industry advancement?

In contrast to developed markets such as Europe and North America, which focus on incremental efficiency gains, Africa is expanding production capacity rapidly to meet growing demand for staple foods. The continent is also experiencing accelerated modernization, with increased investment in industrial milling and the adoption of modern, high-capacity machinery supplied by international manufacturers.

MMEA: How do you envision the future of flour milling amid technological and consumer changes?

Food safety and sustainability will become core competencies for the industry. Mills are increasingly adopting renewable energy solutions such as solar power and investing in compact, high-efficiency machinery capable of reducing energy consumption by up to 30%. Circular economy practices will expand, with by-products such as bran repurposed for bioenergy or high-value food ingredients. Traceability will also become more critical, as consumers demand transparency regarding food origins, supported by blockchain technology and advanced data management systems. The future belongs to producers who combine high-capacity automated production with flexibility to meet niche and health-focused consumer demands.

MMEA: How can the industry contribute to addressing climate change?

The industry can significantly reduce its environmental impact by transitioning to renewable energy sources, adopting electric vehicle fleets, and implementing closed-loop systems to minimize waste. Increased use of recyclable and biodegradable materials and extended product life cycles will further reduce environmental pressure and emissions.

MMEA:Have you experienced setbacks that provided valuable lessons?

Yes, as a professional, I have encountered situations where flour did not meet customer specifications, such as incorrect ash content, poor granulation, or unacceptable color, resulting in rejected loads. These experiences highlighted the importance of strict raw material intake controls, proper wheat tempering, and frequent monitoring of roller mills. Addressing such challenges reinforces the value of robust quality control systems and often leads to stronger, more automated quality assurance processes.

MMEA: How do you envision the future of your career, and what challenges do you foresee?

As the industry evolves, several structural and operational challenges are likely to shape both my career path and the broader flour milling landscape. One of the most pressing issues is the skilled labour gap. There is a growing shortage of qualified professionals capable of operating, maintaining, and troubleshooting advanced, automated milling machinery. As mills increasingly adopt digital and high-capacity systems, the demand for technically competent personnel continues to outpace supply.

Another major challenge is energy and raw material volatility. Rising energy costs, where milling activities account for approximately 75% of a mill’s total energy consumption, combined with volatile wheat prices driven by climate change, place sustained pressure on operational profitability and cost management.

Cybersecurity risks are also emerging as a critical concern. As mills become more connected and increasingly reliant on remote monitoring, automation, and data-driven decision-making, they face heightened exposure to cyberattacks. This shift requires not only technological investment but also knowledge and awareness of industrial data security and system protection.

Finally, there remains resistance to technological change in many regions. A significant portion of the industry still operates with traditional, aging machinery. Transitioning to digital and automated systems demands substantial capital investment, as well as a shift in mindset, particularly among long-serving workers accustomed to conventional milling methods.

MMEA: What advice would you give aspiring flour milling professionals?

My advice is to have role models. You will always learn something valuable from people who have walked the path before you. In my own journey, I have been influenced by professionals such as Engr. Chris Leicester, Mr. Edgar Stewart, my General Manager Mr. Gregory Ehimen, Mr. Samuel Olisa, Mr. Sudhakar Padmaraju, and Dr. Osy Michael. These individuals have helped shape my focus, resilience, dedication, and professional principles. In many ways, their guidance serves as a reference guide, though it is important to remember that no one is perfect, as we all have individual strengths and weaknesses.

Milling, much like the transformation of raw wheat into quality flour, happens in stages. Do not rush the process, and do not take shortcuts, shortcuts will always show, somewhere and somehow. Respect the process. Follow established protocols, continuously improve your knowledge and skills, and remain adaptable. Ask questions and ensure you receive satisfactory answers. If you do not, ask someone else. Growth in milling is built on patience, discipline, and continuous learning.

MMEA: Do you have any final insights on animal feed milling?

Animal feed milling places strong emphasis on safety and quality control, with digital traceability and rapid mycotoxin testing increasingly replacing long laboratory turnaround times. Operational challenges include steam and moisture management, pellet quality control, and raw material volatility, particularly in markets such as Nigeria. Energy consumption remains a major concern, with pellet mills accounting for about 50% of total feed mill energy use, driving demand for energy-efficient equipment. There is also growing interest in alternative protein sources, including insect protein, microbial proteins, and upcycled food waste, as the industry seeks sustainable solutions.

By Martha Kuria, Food Scientist and Product Innovation Specialist.

This feature appeared in ISSUE 18 of MILLING MIDDLE EAST & AFRICA MAGAZINE. You can read this and the entire magazine HERE.