Flour Milling and Blending Systems for Wheat, Sorghum and Millet

Produce a premium wheat, sorghum and millet flour close to production areas

Flour milling and blending systems are small-to large-sized milling and blending systems, available from local and international manufacturers that allow production of premium wheat flour close to production areas. Small-scale equipment is relatively simple to install but require reliable sources of electricity. Solar power is an option as this technology is particularly advantageous in more remote locations.

This technology is TAAT1 validated.

7•7

Scaling readiness: idea maturity 7/9; level of use 7/9

Cost: $$$ 3,500 USD

For small flour mill machine with a capacity of 300 - 500 kg flour per hour

ROI: $$$ 12—15 %

increase in milling yield

38,000 USD

Base price for a fully automatic flour mill with a capacity of 30 ton flour per day

80—82 %

maximal recovery of flour

18—20 %

maximal recovery of bran

IP

Open source / open access

Problem

The problems addressed by the technology of Flour Milling and Blending Systems, include:

Quality and Market Accessibility: Manual techniques for producing wheat flour used in many Sub-Saharan African communities do not meet quality standards preferred by consumers, thereby limiting market opportunities.
Transport Costs and Shelf Life: There is a challenge regarding the costs associated with transporting wheat from farms to factories. Additionally, the limited shelf life affects access and supply to markets, food processors, and manufacturers on local and national scales.
Competitiveness and Self-Sufficiency: African wheat farmers face challenges in competing with imported products due to the limitations of manual techniques and the quality of flour produced. There's a need to enhance their competitiveness and achieve self-sufficiency in wheat-related products.

Solution

The technology of Flour Milling and Blending Systems offers several solutions to these challenges:

Improved Flour Production: It allows for the production of premium wheat flour using milling and blending systems of various sizes, ensuring quality that meets consumer standards.
Reduction in Transport Costs: By allowing the processing of wheat into flour close to production areas, it reduces transportation costs from farms to factories.
Longer Shelf Life: Flour milling and blending enable longer shelf life for the produced flour, facilitating better access and supply to markets and various food manufacturers.
Boosting Local Competitiveness: Building capacity in rural communities to mill and blend wheat flour boosts local output, adds value, and improves the competitiveness of local producers, enabling them to rival imported products.
Enhanced Business Development: Flour milling and blending technologies promote business development in rural communities by allowing for better supply chain management and trade opportunities.
Improved Equipment and Self-Sufficiency: Flour milling technologies offer a wide range of equipment suitable for different wheat processing stages, fostering self-sufficiency in food production.
Adaptability and Widespread Deployment: The technology's simple equipment setups, adaptable power sources (electricity, diesel generators, solar panels), and ease of installation allow for widespread deployment, especially in areas with limited storage facilities, poor infrastructure, and weak market links.

Key points to design your business plan

This technology is beneficial for users (Processors):

Using the Milling and blending systems provides convenience, time, energy, labor, and nutritional benefits, along with reducing transport costs and contributing to food security.

For cost considerations:

A small manual flour mill (300-500 kg flour per hour) costs approximately 3,500 USD,
A fully automatic mill with a 30-ton daily capacity is around 38,000 USD.

Training operators and ensuring safety and quality in the manufacturing process are crucial.

Key partners include agro dealers or manufacturers, and estimating profit is essential.

Adults 18 and over: Positive high

Adults, especially in agriculture, benefit significantly from value addition, reduced labor, and new market opportunities. The technology boosts income, productivity, and entrepreneurial potential, enhancing livelihoods in rural areas.

The poor: Positive low

The poor may struggle to invest in milling equipment initially, but they benefit from access to cheaper, nutritious flour. Over time, the technology can create jobs and enhance food security, though the immediate impact is lower.

Under 18: Positive low

This group benefits indirectly through improved nutrition from millet and sorghum-based foods. They aren't involved in milling or economic activities but gain from healthier, affordable meals due to increased local flour availability.

Women: Positive high

Women, being key in food processing, benefit from reduced manual labor and time savings. It also creates business opportunities in food production, helping improve their income and reducing household burdens.

Farmer climate change readiness: Significant improvement

The technology helps farmers adapt to climate change by enabling them to add value to crops, store processed flour, and reduce crop loss, making them more resilient to climate variability.

Carbon footprint: Same amount of carbon released

The carbon emissions are similar to traditional methods due to energy requirements for milling and blending, with no significant reduction unless renewable energy sources are used.

Water use: A bit less water used

The technology uses less water compared to traditional grain preparation methods, as flour processing and cooking require less water than whole grain washing and boiling.

Countries with a green colour: Tested & adopted
Countries with a bright green colour: Adopted
Countries with a yellow colour: Tested
Countries with a blue colour: Testing ongoing

Countries where the technology is being tested or has been tested and adopted
Country	Testing ongoing	Tested	Adopted
Ethiopia	–No ongoing testing	Tested	Adopted
Kenya	–No ongoing testing	Tested	Adopted
Mali	–No ongoing testing	Tested	Adopted
Niger	–No ongoing testing	Tested	Adopted
Nigeria	–No ongoing testing	Tested	Adopted
Senegal	–No ongoing testing	Tested	Adopted
Sudan	–No ongoing testing	Tested	Adopted
Tanzania	–No ongoing testing	Tested	Adopted
Zimbabwe	–No ongoing testing	Tested	Adopted

This technology can be used in the colored agro-ecological zones. Any zones shown in white are not suitable for this technology.

Agro-ecological zones where this technology can be used
AEZ	Subtropic - warm	Subtropic - cool	Tropic - warm	Tropic - cool
Arid
Semiarid
Subhumid
Humid	–	–	–	–

Source: HarvestChoice/IFPRI 2009

The United Nations Sustainable Development Goals that are applicable to this technology.

Goal 2: zero hunger

Goal 8: decent work and economic growth

Conduct Market Research: Conduct thorough market research to understand the market needs and identify viable business models.
Consult Experts for Location: If uncertain about the location, seek advice from experts to avoid investing in the wrong place.
Analyze Investment Requirements: Perform a comprehensive analysis of investment needs, considering capital equipment, staff wages, and other fixed and variable costs.
Identify Financing Strategies: Based on the analysis, identify financing options, including loans, personal funds, or investors.
Secure Funding: Once financing is secured, proceed to purchase the necessary machines for cleaning, annealing, and milling.
Construct the Processing Line: Build the flour processing line based on professional advice for optimal installation.
Optimize Electricity Costs: Minimize electricity costs to ensure profitability and maximize net margins during operations.
Implement Quality Assurance: Ensure continuous quality assurance at the flour mill to meet market standards regarding gluten content, sedimentation, and index values of the product.