Digitalization is one of the biggest changes most industries have seen in a lifetime and has the potential to revolutionize almost every aspect of the food and feed sectors. 

From mechanical improvements to automation, the world is in an era of connected devices with smart analytics powered by artificial intelligence and machine learning. Bühler, based in Uzwil, Switzerland, has been at the forefront of this technological innovation. 

With services that range from online ordering of spare parts and process optimization to full production automation, Bühler’s digital services are designed to help customers more efficiently address issues such as food safety, transparency along the value chain, energy conservation and waste reduction. 

World Grain recently talked with Alexis Nöel, Bühler’s digital program manager, about new innovations, challenges and the future of digital solutions for the company’s milling solutions. 

Since October 2022, NÖel has led the digital transformation of the group’s largest business unit and driven alignment of its cloud business across all functions, including R&D, project execution, technology, platform development and regional organization. 

WG: What are some of the latest digital transformations that Bühler is working on?

Nöel: At Bühler, our latest digital transformations in milling solutions are centered on advancing the grinding process and wheat tempering in the cleaning phase. We are moving beyond basic process monitoring to provide actionable recommendations that directly enhance operational efficiency for our customers. 

The grinding process, which is crucial to flour milling and currently largely manual, stands to gain substantial benefits from these innovations. Similarly, our focus on wheat tempering has revealed significant potential for improvements, positively impacting the subsequent milling stages. By integrating these advanced digital solutions, Bühler aims to optimize both the precision and effectiveness of these critical processes.

WG: How will that improve the milling process for customers?

Nöel: Improving the milling process for customers involves optimizing the grinding and wheat tempering stages. For grinding, precise adjustment of the grinding rolls ensures the entire roll length is used efficiently, achieving the desired product granulometry with minimal energy expenditure. Our data indicates that, in practice, roll adjustments are often suboptimal due to limitations in current tools. By offering accurate roll adjustment recommendations, we aim to address this issue and enhance efficiency. In wheat tempering, our research has identified key factors affecting flour moisture, allowing us to help customers meet their target moisture levels more reliably and without the guesswork that is typically involved.

WG: What are some challenges that customers are asking for solutions to? 

Nöel: In the flour milling industry, customers seek digitalization solutions primarily for process optimization, quality control and resource management. For process optimization, real-time monitoring and predictive maintenance are crucial to ensure consistent quality and minimize downtime. In terms of quality control, automated systems for testing and ensuring flour quality, along with enhanced traceability using digital records, are in demand to meet stringent standards. For resource management, customers look for energy-efficient solutions to monitor and optimize energy consumption, aiming to reduce costs and environmental impact, and digital tools to manage byproducts and reduce waste. These digital advancements help improve operational efficiency, maintain high-quality standards and promote sustainable practices.

WG: What are some of the challenges in transitioning and familiarizing customers with new digital solutions? 

Nöel: Transitioning and familiarizing customers with new digital solutions in the flour milling industry faces several challenges. Resistance to change is significant. The high initial costs and uncertainty about the return on investment (ROI) complicate the transition. Technical complexity, such as integrating new digital tools with existing systems and effectively managing large volumes of data, poses some obstacles. Additionally, employees often lack the necessary technical skills to operate and maintain these new systems, making comprehensive training programs essential but time-consuming and costly. Overcoming these challenges requires strategic planning, clear communication about the benefits, and investment in training and support to ensure a smooth transition to digital solutions.

WG: Digital solutions collect a lot of data. How is Bühler using this data to improve its technology and also the milling process for customers? 

Nöel: Data collected from digital solutions helps us drive continuous improvement and innovation in flour milling by uncovering trends and patterns that guide strategic decisions and process optimizations. Advanced analytics, including machine learning and AI, predict outcomes and tailor solutions to specific operational needs. Additionally, data on customer interactions and feedback allows for the identification of needs and preferences, enabling the development of customized solutions and services. This customer-centric approach enhances our machines development, service enhancements, and overall customer satisfaction, leading to more personalized and efficient milling operations.

WG: What methods has Bühler used to address this? 

Nöel: The extensive and diverse data collected is crucial for the success of advanced AI features. Bühler is uniquely positioned to excel in this area due to its internally developed platforms and software. Bühler machines generate in-depth process data, which is enhanced by the Mercury Manufacturing Execution System (MES). Maintenance data from the Computerized Maintenance Management System (CMMS) ProPlant also contributes valuable insights.Additionally, the broad customer base using these digital platforms accelerates data accumulation. Early in this journey, Bühler established data scientist teams to develop proprietary models. These teams collaborate with experienced milling technologists to address the industry’s most pressing challenges.

WG: What are the potential benefits and drawbacks to the use of AI? 

Nöel: The use of AI in various industries offers significant benefits, such as enhanced efficiency and cost savings. AI can optimize production processes, reducing waste and improving yield, while predictive maintenance minimizes downtime and maintenance costs. Additionally, AI helps optimize resource use, such as energy and raw materials, leading to significant cost savings and labor efficiency by automating repetitive tasks. However, there are notable drawbacks, including technical challenges and dependence issues. AI systems require high-quality data to function effectively, and poor data quality can lead to erroneous conclusions. Integrating AI with existing systems can be complex. Furthermore, over-reliance on AI systems can be problematic if they fail or produce incorrect results, and AI should complement human decision-making to ensure balanced and efficient outcomes. Balancing these benefits and drawbacks is crucial for successful AI implementation.

WG: What are some of the areas where digital solutions/AI will be able to assist in the future?

Nöel: In the future, digital solutions and AI will increasingly enhance flour milling through advanced process and machine adjustments, quality control and production planning. AI algorithms will enable real-time adjustments to milling processes and machinery, optimizing operational parameters for improved efficiency and product quality. By analyzing continuous data streams, AI will predict equipment wear and automatically adjust settings to maintain peak performance. In quality control, AI will provide precise monitoring and analysis of flour characteristics, ensuring consistent quality and rapid detection of deviations. For production planning, AI will facilitate more accurate forecasting and scheduling by analyzing historical data, market trends, and demand patterns. This will enable mills to optimize inventory levels, streamline operations, and respond more swiftly to market changes, ultimately enhancing overall productivity and competitiveness.