Next-Generation Technologies: Pioneering solutions poised to shape the flour milling landscape in Africa
Africa’s flour milling industry is undergoing a remarkable transformation, fueled by technological advancements, sustainability demands, and evolving market preferences. With the continent’s population expected to exceed 2.5 billion by 2050, demand for staple foods such as bread, pasta, and other flour-based products is on the rise. One of the significant trends shaping the MEA milling industry is the shift toward processing local grains such as sorghum, millet, and teff. These grains are resilient to harsh climatic conditions, making them vital for food security in arid regions.
The introduction of next-generation milling technologies is poised to meet this growing demand while improving production processes and supporting food security. Companies like Bühler, Alapala, and Ocrim are at the forefront of this shift, offering state-of-the-art equipment and tailored services to meet the unique challenges of this diverse market. “Our approach is to understand the specific needs of each client and provide solutions that maximize their potential,” says Ocrim’s Technical Director, Marco Galli.
A recent report by the International Grains Council highlighted that the integration of data analytics has led to a 20% increase in milling efficiency for some companies in Africa. According to the report, one notable example is a partnership between a leading Egyptian miller and Bühler, which resulted in a 30% increase in production efficiency and a significant reduction in energy consumption.
Alapala, another leading player, has been instrumental in delivering tailor-made milling solutions for various grains, including wheat, corn, and pulses. Alapala’s CEO, Görkem Alapala, highlights the importance of innovation: “The future of the milling industry lies in our ability to adapt and integrate technological advancements to meet the ever-evolving needs of our customers.”
The Rapid Evolution of the Flour Milling Machinery Market
To meet the demand for next generation milling, the flour milling machinery market is rapidly evolving. According to Future Market Insights, the global wheat milling machine market is projected to grow at a compound annual growth rate (CAGR) of 3.9%, with its value expected to rise from USD 1,232.2 million in 2023 to USD 1,806.5 million by 2033. In 2022, the market was valued at USD 1,185.9 million, growing at a CAGR of 3.5%. This growth is driven by rising demand for high-quality flour, automated milling systems, and the popularity of specialty and organic flours.
Similarly, the maize flour and grits processing market is forecast to reach USD 83.1 billion by 2026, expanding at a CAGR of 4.2% from 2021 to 2026. This growth is largely fueled by increased consumption of maize-based products, such as breakfast cereals, snacks, and convenience foods.
Overall, according to Cognitive Market Research, The Global Flour Milling Machines market size will grow at a compound annual growth rate (CAGR) of 5.30% from 2023 to 2030. Although North America dominates the flour milling machines market, other regions, including Middle East and Africa are poised to experience increase, driven by demand for bakery goods like bread, pasta, pizza, other flour-based products and high urban residence.
Source: Cognitive market research
Game-Changing Milling Technologies
According to Thomas Zehnder, Head of Digital Solutions at Bühler, “Data-driven insights are transforming the way we operate. Our clients can now make informed decisions that not only improve efficiency but also reduce their environmental footprint.” New milling technologies prioritize precision and sustainability. High-tech roller mills, automated sifters, and optical sorters now produce flour with consistent particle size and purity, thanks to Industry 4.0 technologies. Smart sensors, IoT devices, and artificial intelligence (AI) are increasingly integrated into milling operations to enable real-time monitoring and control.
Automated systems adjust parameters such as moisture levels, temperature, and grinding pressure to maintain consistent flour quality. Bühler’s Insights platform, for instance, uses AI to provide real-time analytics on milling operations, reducing energy consumption by 10% and minimizing waste. IoT-enabled grain sorting systems, such as SORTEX by Bühler, ensure unmatched accuracy in removing damaged or contaminated grains.
African milling companies are increasingly adopting these technologies to stay competitive. In East Africa, Ethiopia leads the region’s milling sector, processing approximately 17.5 million metric tons of corn, wheat, and rice annually, according to Rabobank. Despite this impressive capacity, the wheat milling industry remains fragmented and underutilized, presenting investment opportunities. Countries like Kenya and Uganda, however, are leading the charge in adopting modern milling technologies. The region’s strategic location and access to regional trade blocs such as the East African Community (EAC) make it a hub for grain processing and distribution.
Meanwhile, West Africa’s flour milling sector continues to thrive, driven by demand for staple foods such as bread and noodles. Nigeria remains a key market, with large-scale millers investing in both capacity expansion and technological upgrades. For example, Flour Mills of Nigeria Plc has integrated digital monitoring systems that allow for predictive maintenance and optimized production cycles. “Data is revolutionizing how we manage our facilities. It ensures we meet the highest quality standards while reducing waste,” said John Oluwaseyi, Technical Director at Flour Mills of Nigeria. In Cameroon, CESCO advanced the construction of a grain storage and steel mill facility with a capacity of 20,000 tonnes, featuring 15 corrugated steel silos to strengthen the region’s agricultural infrastructure.
Meanwhile, Saudi Arabia recently saw CESCO complete the Factory Acceptance Test (FAT) for a high-capacity bagging line system for United Feed Company (UFC). In South Sudan, Tanis Milling Technologies recently, executed a turnkey project that includes a 500 tonnes-per-day (TPD) maize mill and a 100 TPD wheat mill with advanced automation systems for real-time monitoring.
As Görkem Alapala aptly puts it, “The future is bright for the milling industry in the MEA region. By embracing technology, sustainability, and collaboration, we can unlock the full potential of this dynamic market.” Moreover, Bühler has launched the next generation of its TAS grain cleaning system, the TAS LAAC. The system’s remote control feature and ultra-reliable sensors allow operators to make quick adjustments and maximize uptime. Bühler Insights integration enables advanced trend analysis for improved yields.
Sustainability at the Core of Innovation
Sustainability is a driving force behind the technological advancements in the grains and milling sector. The milling process accounts for around three-quarters of the energy used in a flour mill, hence, manufacturers are responding by introducing energy-efficient equipment. With the MEA region facing challenges such as water scarcity and climate change, companies are prioritizing eco-friendly solutions.
Bühler’s energy-efficient equipment and Alapala’s waste-reduction technologies are just a few examples of how the industry is embracing sustainability. The use of renewable energy sources and the development of circular economy models are also gaining traction.
One inspiring story comes from a miller in Kenya who transitioned from traditional milling to modern energy-efficient systems powered by solar energy. “We used to struggle with high energy costs and inconsistent power supply,” says the mill owner, Jane Njoroge. “Switching to solar-powered milling has transformed our business, making us more resilient and environmentally responsible.”
Stefan Scheiber, CEO of Bühler, emphasizes the company’s commitment to sustainability and innovation: “Our solutions are designed not only to optimize production efficiency but also to ensure that we are contributing to a more sustainable food system. We believe the MEA region has immense potential, and we’re here to support that growth.”
The Future of Flour Milling in Africa
Looking ahead, the future of flour milling in Africa is bright. The industry is expected to benefit from continued technological advancements, increased focus on food security, and a growing consumer base. Another revolutionary development is the move toward electric milling in Sub-Saharan Africa (SSA).With around 500,000 to 750,000 maize mills traditionally powered by diesel, International Grains Council predicts that this transition could significantly reduce environmental impact. Diesel consumption in the region is nearly 900 million liters annually, contributing approximately 2.3 million tonnes of carbon dioxide emissions. Switching to electric milling, and adopting digital milling solutions could add an estimated US$ 2.5 billion in value across SSA by 2030 and reduce carbon emissions by 5 million tonnes per year. “The milling industry is at a turning point. Innovation and collaboration will be the key drivers of future success,” said Dr. Schlauri of Bühler Group.
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