Plant equipment manufacturer Bühler is driving the digital transformation of milling operations through real-time data insights, predictive maintenance and AI-driven optimisation.

With the milling industry under pressure to increase output while minimising resource waste, the company is delivering solutions that balance performance with sustainability to enhance long-term profitability.

“By investing in smarter solutions today, we’re building a stronger, more resilient food system for tomorrow,” says Bühler MD Marco Sutter.

Ranging from high-efficiency roller mills and energy recovery systems to smart automation and digital monitoring tools, the company’s solutions assist mills in reducing energy and water consumption, operational costs and environmental impact. The solutions also assist in minimising product loss and improving process efficiency.

“We’re committed to making milling smarter, cleaner and more sustainable, without compromising on performance,” says Sutter.

He adds that digitalisation is “a game-changer for milling”, as it provides millers with real-time operational visibility and allows for data-driven decision-making.

Bühler’s digital tools monitor equipment performance, process parameters and energy use, consequently allowing for predictive maintenance that helps to reduce unplanned downtime. This results in higher efficiencies, less waste and better product consistency.

Through platforms such as Bühler Insights, customers can access real-time performance data across a plant. Subsequently, AI algorithms analyse this data to detect inefficiencies and optimise process parameters.

Further, the company’s temperature and vibration monitoring systems detect inefficiencies early, allowing for proactive interventions while digital services, such as yield management and energy monitoring, optimise the entire production process.

Integrating smart sensors, automation and advanced software into process lines can help mills achieve energy savings of up to 15% and waste reductions of up to 30%, depending on site conditions, Sutter says.

Its optical sorters and cleaning systems ensure that only safe, high-quality grains are processed, significantly reducing food loss.

These technologies also enable millers to recover usable product from material that would otherwise be rejected, which, in turn, supports food security by increasing available supply.

Bühler’s roller mills include the Arrius and Arrakis series, which offer integrated drive systems, improved grinding performance and minimal heat generation, all of which contribute to energy savings while delivering “consistent, high-quality” output.