Bühler India is revolutionising the grain and food processing industry with cutting-edge innovations and strategic partnerships. Their SuperHusk huller and TopHusk Hull Separator, among other advancements, are setting new standards in efficiency and sustainability. The Smart Rice Mill project exemplifies their commitment to smart, eco-friendly technology. Local production at their Bengaluru facility enhances supply chain efficiency, while collaborations with institutions like AIET and CFTRI are shaping future industry leaders. Favorable government policies like ‘Make in India‘ have spurred growth, driving local manufacturing and boosting export capabilities. In an exclusive interview with ET Manufacturing, P Chandrasekharan, Head of Manufacturing, Logistics & Supply Chain, Middle East, Africa and India & Southeast Asia. Bühler (India) details the company’s proactive approach towards transforming India’s food processing landscape, aligning with global sustainability goals.

Q. Can you elaborate on some of the most significant innovations Bühler India has introduced in the grain and food processing industry, and how they contribute to sustainability?

Ans. Bühler India’s innovations in grain and food processing emphasise efficiency, sustainability, and food safety, reducing environmental impact and conserving resources. Some key advancements include:Sustainability: Reduction of broken rice and waste: key process developments in Paddy value chain- efficient hullers, whiteners, and polishers. Some of the key innovation include:

a) SuperHusk huller: Delivers efficient hulling, taking the next step towards the future of rice milling, with 8-10 % of power savings, automatic switching between rollers with improved rubber roller consumption of 15-20% and overall lower power consumption of 8-10%
b) TopHusk Hull Seperator: Delivers optimized flow of grains in a closed air circuit to accurately separate the husk from the brown rice, generating two clean fractions rice-husk to the mixture is below 0.5%, resulting in reducing food wastage of 0.5-1 %
c) Rice Conditioner: The Rice conditioner is the ideal solution for wet milling that enables excellent hygiene & sanitation.
d) Automatic Series TopWhite: Advanced technology for higher efficiency resulting in less Broken generation in process: 1-2 % and low power consumption of 10-15%
e) HighPoly Polisher: HighPoly processed rice which, with its high gloss and pearly lustre makes it a highly visible and attractive product on market shelves with less Broken generation in process of 1-2 % and low power consumption of 10-15%

Quality and Product consistency: Digitalisation in rice processing through the introduction of first of its kind inline sensors in the rice industry. Quality control of rice real-time is a great value add for the rice processors. The cooking quality of rice and market acceptance is closely linked to the shine, smoothness, and whiteness. R&D teams at Bühler India developed the first of its kind online sensors that could give real time information about these critical quality parameters. This would be critical for making our rice mills smart.

Food safety: Stones> Rolls: Development of industrial solutions for Atta. The modification of the starch structure in wheat during the grinding process in an important parameter in determining the softness and sensory properties of roti/chapathi. Traditionally atta produced from chakki mills alone could produce these properties. However, chakki atta has the risk of stone shavings getting worn off and mixing with the product. R&D teams at Bühler India with the support of a global cross functional team, innovated the concept of “PESA”. This patented solution creates the atta properties of chakki grinding without the use of stones.

Quality: consistency in product granulation: Development of industrial solutions for Besan. Besan production typically happens in small mills with rotary sifters. A traditional mill has a battery of these sifters for granulation control. Besan being hygroscopic, easily soaks in moisture from the atmosphere making the granulation control through the traditional methods of rotary sifters difficult. Bühler’s innovative air classification milling system was the first of its kind mill for Besan milling in India. We achieve consistent yield and granulation at high throughputs.

Optimisation: For Indian market and supply chain: Development of Direct Gas Fired Oven in India (this is currently being tested)

Q. The R&D wing of Bühler India is specialised in rice solutions. Could you discuss some of the key research projects currently underway and how they are expected to impact the grain processing sector?

Ans. The Research and Development (R&D) wing at Bühler India is making significant strides in innovation, with its latest project focusing on the concept of a “Smart Rice Mill.” This advanced initiative aims to revolutionize rice processing by incorporating a suite of intelligent machines and sophisticated automation systems designed to meet the evolving demands of the global market.

The Smart Rice Mill is a testament to our commitment to integrating state-of-the-art technologies. It features an array of advanced equipment, including intelligent hullers, whiteners, and polishers, alongside AI-powered sorters and eco-intelligent dryers. These components work in tandem with the latest plant automation systems, such as Mercury and the Azure-based IoT platform, Bühler Insights.

A key highlight of the Smart Rice Mill is its deployment of innovative machine controls, branded as PADA, which optimises various processing requirements and enable predictive maintenance. By leveraging cutting-edge technologies like machine learning, deep learning algorithms, big data analytics, and AI tools, we ensure that the mill operates at peak efficiency.

In addition to its technological advancements, the Smart Rice Mill also boasts significant operational improvements. It incorporates self-cleaning mechanisms to maintain hygiene standards and includes the X-tend portfolio, which offers highly reliable, long-life spare parts that reduce downtime and maintenance costs.

These developments are in line with Bühler Group’s broader sustainability goals, which aim to minimize waste, water usage, and energy consumption. The company is committed to maintaining the smallest possible environmental footprint while fulfilling customer needs with precision and efficiency.

As Bühler continues to innovate, the Smart Rice Mill stands out as a pioneering effort to transform the rice milling Industry.

Q. With a state-of-the-art production facility in Bengaluru, Bühler India has set high standards in sustainable manufacturing. What specific practices and technologies have been implemented to achieve LEAN manufacturing and ISO certifications for quality and environmental management?

Ans. Bühler India has set high standards in sustainable manufacturing with adoption of solar power and PNG in day-to-day operations. In addition, mentioned below are few of the specific practices and technologies supporting Lean manufacturing.

BPS+ (Bühler Production System) is an encyclopaedia of various tools and techniques based on Lean principles. It’s the basis for a uniform language to guide our progression towards operations excellence in Manufacturing. BPS+ drives us to improve efficiencies, effectiveness, and profitability of our operations. Through continual elimination of waste, we optimize lead-time, reduce costs, reduce operational risks, and create value for customers.

Collaborative Robots (Cobot) welding in combination with fixtures and effectors achieve high-quality welds on a variety of our jobs. Cobots are instrumental in catering all sizes of operations as it provides higher throughput, increased repeatability, and without compromising on quality.

Artificial Intelligence (AI) can help us better understand the business problems. Bühler with a history of 164 years in business has immense data. We in manufacturing find use of AI in Quality Assurance which brings to us predictive analytics to the forefront. We can predict potential defects by analysing historical data and patterns, enabling early defect identification to improve quality.

Q. With 75% of Bühler machines sold in India being manufactured at the Bengaluru facility, how has this local production influenced supply chain efficiency, delivery times, and overall customer satisfaction in both the domestic and global markets?

Ans. Local production at Bühler’s Bengaluru facility has had a significant positive impact on several key aspects:

Supply Chain Efficiency
Reduced Lead Times: By manufacturing machines locally in India, we have minimized the dependency on international shipping and customs procedures, which can be time-consuming and complex. This results in a more streamlined supply chain with fewer delays.

Localised Sourcing: Sourcing raw materials and components locally helps cut down on the complexities associated with global sourcing. This not only reduces lead times but also minimises risks related to geopolitical issues and international trade policies.

Delivery Times
Faster Turnaround: Local manufacturing facilitates quicker production cycles, allowing us to respond rapidly to customer orders. This is crucial for meeting tight project timelines and staying competitive in the market.

Proximity to Market: Being closer to our primary market (India), we have significantly reduced transportation time, ensuring that machines reach domestic customers faster than if they were shipped internationally.

Overall Customer Satisfaction
Improved Responsiveness: The ability to manufacture locally enables us to be more responsive to customer needs, including quicker modifications, maintenance, and servicing.

Cost-Effective Solutions: Reduced shipping and import costs translate into more competitive pricing for customers, enhancing their overall satisfaction.

Enhanced Customer Support: Local production facilities have allowed us to provide better customer service and support, including quicker resolution of issues and more effective communication.

Global Impact
Scalability: With a significant portion of its production based in India, we can better manage and scale its operations to meet global demands.

Flexibility in global markets: The Bengaluru facility not only serves the domestic market but also supports global distribution. This geographic diversification in production helps us buffer against regional market fluctuations and disruptions.

Local production at the Bengaluru facility has allowed us to enhance our supply chain efficiency, reduce delivery times, and improve overall customer satisfaction in both the domestic and global markets. Which in turn has helped us remain competitive and responsive to the evolving needs of our customers while maintaining high standards of quality and service.

Q. Bühler India collaborates with several academic institutions to enhance industry-academic ties. Can you provide examples of successful partnerships or projects with these institutions, and how they have benefited both the industry and academia?

Ans. Bühler India has established several fruitful partnerships with academic institutions that significantly strengthen the synergy between industry and academia.

• We have entered a Memorandum of Understanding (MoU) with Alva’s Institute of Engineering & Technology (AIET) to introduce a specialized Rice Milling curriculum within the agriculture branch of their Bachelor of Engineering program. This initiative provides academia with a deeper understanding of technology, market trends and attracts students.

• Our MoU with the Central Food Technological Research Institute (CFTRI) for student exchange programs in grain milling technology has greatly enhanced the knowledge base of both students and employees, fostering a robust environment for innovation.

• Our collaboration with Ramaiah University of Applied Sciences offers a Bachelor’s in Vocational – Post-Harvest Technology, ensuring that the curriculum aligns with business needs.

• Our association with Dayananda Sagar University focuses on training and CAD skill development.

These collaborations bring significant benefits to all involved. For academia, they provide practical exposure and create opportunities for cutting-edge research, which in turn attract students and funding.

For us, these partnerships are invaluable as they offer access to a pool of talented students and foster innovation through collaborative research projects. For the students, the benefits are immense-they gain real-time industry experience, bridging the gap between their theoretical knowledge and practical application, and develop essential skills such as problem-solving, networking, and communication.

Overall, these partnerships ensure that students are well-prepared to meet the demands of the industry, while academia and the industry co-evolve to drive technological advancements and growth.

Q. How have favourable government initiatives like “Make in India” and the Agri-Export Policy impacted Bühler India’s growth and operations, particularly in the production of rice milling solutions, coffee machinery, and biscuit/wafer ovens? Can you share specific examples of how these policies have supported your manufacturing expansion?

Ans. The “Make in India” initiative, along with the Production Linked Incentive (PLI) Scheme for the food processing sector, has been pivotal in driving Bühler India’s growth and operational expansion. These policies, aimed at bolstering self-sufficiency and enhancing local manufacturing, have provided a fertile ground for our business.

For instance, in August 2022, Bühler India expanded its local production by manufacturing Sortex color sorters, which are crucial in ensuring food quality and safety within the grains and food industries. This move not only supports local manufacturing but also aligns with the national objective of enhancing food processing capabilities.

Additionally, government subsidies, tax breaks, and infrastructure development initiatives have improved our production processes and facilitated easier market entry for our innovative rice milling solutions, coffee machinery, and biscuit/wafer ovens.

As India’s focus on becoming self-reliant through the ‘Atmanirbhar Bharat’ initiative gains momentum, we have found ample opportunities to grow our local production facilities. We have begun the production of our Plansifter and Purifier-core machines in the flour production process-and have plans to commence production of Roller mills by 2025.

This local manufacturing drive not only meets the domestic demand but also strengthens our export capabilities under the Agri-Export Policy. These policies and schemes have effectively shaped our business prospects by emphasizing food security and safety, providing financial incentives, and fostering a robust infrastructural framework.

Looking ahead, we aim to continue expanding its core product portfolios to include the feed and advanced materials industries, further contributing to both national and global food processing needs.