In the global flour milling industry, there has always been a certain mystique about P.T. Bogasari Flour Mills' mammoth mill in Jakarta, Indonesia. Recognized as the world's largest flour milling facility for many years in terms of both milling capacity and physical size, it stands as a monument to the growing importance of flour-based products in that heavily populated country as well as the greater Asia region.
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This recent surge in popularity of wheat flour-based products prompted Bogasari officials to authorize yet another expansion of the plant.
The mill, which has 15 milling lines (yes, 15), recently expanded its 'I' and 'J' milling lines, with production capacity in each line increasing from 800 tonnes (wheat equivalent) per day to 1,200 tonnes per day. Capacity in the 'H' mill is in the process of being expanded from 800 to 1,200 tonnes, with the expansion expected to be completed in the third quarter of . When the final piece of equipment is installed, the plant's daily capacity will reach 11,650 tonnes and its yearly production capacity will be more than 4 million tonnes.
The world's largest flour mill needed to get bigger to meet consumer demand, said Franciscus 'Franky' Welirang, director of PT Indofood Sukses Makmur, with responsibility for Bogasari's milling division, in an interview with World Grain.
'Indonesia's flour market is growing,' Welirang said. 'The average 10-years growth is 5% per annum, mostly due to population growth, changes in eating habits and the growth of the middle-income class.'
According to a recent Global Agricultural Information Network report from the U.S. Department of Agriculture, relatively stable macro-economic conditions in Indonesia have allowed middle and upper-middle income consumers to diversify their diets to include more western-style foods like bread and pasta.
'Rather than eating rice three times daily, many Indonesians have switched to eating bread or noodles for breakfast,' the USDA said. 'Restaurants are also driving demand for wheat-based food products. The number of high-end bakeries is also growing, mainly in major cities, including Jakarta, Surabaya, Medan, and Bandung.'
Welirang, who is also president of APTINDO, the Indonesian flour milling association, said wheat consumption in Indonesia is currently 8.5 million tonnes but is expected to jump to 11 million tonnes annually by . While rice still dominates as a staple food in Indonesia with annual consumption at more than 100 kilograms per capita, wheat flour consumption has risen to 23 kilograms per capita.
Keeping pace with demand
To keep pace, the company's flour production capacity also has grown 5% in the last 10 years, Welirang said. In addition to the Jakarta expansion, Bogasari is building a new mill in Cibitung, which will include two existing and two new milling lines with total capacity of 2,600 tonnes per day. It also has a mill in Surabaya with eight lines totaling 6,150 tonnes of daily capacity and a mill in Tangerang with two lines and 200 tonnes per day capacity.
Bogasari became part of the Indofood group in and produces a range of flour products sold under brands such as Cakra Kembar, Segitiga Biru, Kunci Biru, and Lencana Merah. The company also produces pasta for both domestic and export markets under the La Fonte brand.
'There are five main flours produced with a total of more than 50 SKUs, differentiated by protein, ash and specialized flour,' Welirang said.
Bogasari's primary flour customers are the Small Medium Enterprises (SMEs), which comprise about 66% of the Indonesian market, Welirang said. The list of larger customers includes Indofood, which acquires its flour (22% of Bogasari's total flour production) from its subsidiary, as well as Mayora, Nippon Indosari, Nabisco, Monde and others. The export market accounts for less than 5% of the company's flour output, Welirang said.
'Based on the volume, both (large and small flour end users) are growing,' Welirang said.
Bogasari, which employs 2,300 workers at its milling plants, is by far the biggest flour miller in Indonesia and has a market share of 50%, according to Welirang. While it is still dominant, its market share has dropped a bit since , when it was reported at nearly 70%.
Indonesia has 28 flour milling companies that have a production capacity of 11.8 million tonnes of flour (grain equivalent), Welirang said, noting that actual flour production in is expected to be around 6.4 million tonnes.
'The total capacity nowadays is more than the market needs,' Welirang said. 'The national average utilization is 70%.'
He noted that the country's milling market has become far more competitive since deregulation in , when the country had just five flour mills, but that the competition is good for Bogasari and the country's milling industry in general.
'Bogasari differentiates its products by having consistent quality, natural, pure wheat flour and also with availability by having a strong distribution network and services,' Welirang said. 'The brand of Bogasari flour is very strong.'
The mill in Jakarta, as well as Bogasari's other milling plants, typically receives wheat imports from three countries: Australia ' its primary supplier ' as well as the United States and Canada. However, the recent drought in Australia has forced Bogasari to also bring in wheat from the Black Sea region, Welirang said.
Bogasari's operations are supported by a maritime unit of five post panamax and five handy/supramax vessels, which are used to transport wheat from those countries.
Retrofitting the mill
For the expansion of the Jakarta facility, Bogasari turned to Ocrim SpA, the Cremona, Italy, milling equipment manufacturer that has been involved in various expansions of the Jakarta mill since it opened more than 40 years ago.
One of the challenges was increasing capacity without expanding the physical size of the mill. To do this. the wheat cleaning and milling sections of the milling lines were retrofitted with latest-generation equipment from Ocrim.
'To achieve the desired results it was necessary to reinforce the civil structure of the building due to additional loads, integrating the building with an additional floor to exploit as much as possible the concept of energy savings applied to the entire plant,' Ocrim said. 'Moreover, with a very innovative and efficient diagram, it has been possible to implement Ocrim's latest-generation double-deck roller mills, used in an optimal way to obtain an excellent final product, and to apply a modular plansifter with 10 channels also for a concrete optimization of the space.'
The sifters feature an automatic sieve press to guarantee ease of operation and reduced maintenance times. Ocrim's automation department equipped the three lines with @rollermills software that allows mill operators to control the mills remotely via tablet and then to program them with a single operation carried out any place in the mill.
'Since the operator is no longer required to act on the roller mill onboard control, it almost completely cuts down the setting time of the entire line and is also innovative for safety purposes, because, despite running on Wi-Fi, it guarantees a secure protection from external agents,' Ocrim said.
The new equipment is made of stainless steel to guarantee the best product quality and safety, Welirang said.
'The new milling lines are equipped with the latest state-of-the-art technology, ready for implementation of 4.0 (a term that refers to the fourth industrial revolution in engineering and manufacturing that is being implemented in Indonesia) with all the important features of product safety and energy savings,' Welirang said.
He noted that having both state-of-the-art equipment and knowledgeable millers are essential to run a mill the size of the Jakarta plant.
'The most important factor is having good millers,' he said. 'And for sure, the automation system, the smart sensors, online control and all the IOT (Internet of Things) will help the millers operate the mill in a good and efficient manner.'
The company operates an in-house packaging unit that produces degradable polypropylene bags to support its packaging requirements.
About 85% of the flour produced at the Jakarta mill is packed in 0.5-kg, 1-kg, 2-kg and 5-kg packs, 25-kg bags and 750-kg jumbo bags, which are then transported by trucks and railcars. The remaining 15% of the flour is transported in bulk, Welirang said.
For exported flour, Bogasari uses the Jakarta and Surabaya state port facilities, but it does have its own ports for exporting wheat bran pellets in bulk, he said.
Welirang noted that as part of the expansion at the Jakarta plant, Bogasari plans to install an additional 36,000 tonnes of wheat storage capacity to cover the mill's needs for high, medium and low-protein wheat.
Potential for more expansion
Welirang said among the biggest challenges facing milling companies in Indonesia is transporting finished products as the country is composed of five large islands and more than 15,000 smaller ones.
'Bogasari has 26 warehouses to cover the distribution in all of Indonesia,' he said. 'Close collaboration with shipping companies is very important.'
The company is strategizing about how to expand its output, specifically in Eastern Indonesia, where economic development is less advanced and transporting product to that area is difficult due to its remoteness.
In a interview with World Grain, Welirang discussed potential strategies for this market.
'One option is to build a new mill for Eastern Indonesia,' he said. 'That would be a challenge, and it depends on economic development, but this could be located somewhere in Papua. It's a possibility. We would then use the international port in Sorong. From a mill there, we would import wheat in bulk and ship out in containers.'
Depending on market growth in that region, Welirang said such a development could occur in the next 10 years.
In that same interview, Welirang noted that greater opportunities also exist in the Southeast Asia export markets where the milling industries were not as strong asIndonesia.
'We need better port facilities so we can export processed flour-based products to Southeast Asia,' Welirang said. 'We, as an industry, are doing that already and total exports of wheat flour, byproducts and wheat flour-based products have grown in value to $755 million, and in the next few years this will reach $1 billion. So we are a very important industry for the economy, and exports will play a growing role in this in the future.'
Product Description
The multi-story flour milling plant is famous for its advanced processing technique, complete machine assembly, low power consumption as well as convenient operation and maintenance.
The maize processing line includes four main sections:
1) Cleaning Section: (separation, aspiration, destoning and dampening);
2) Degermination Section: (polishing, crushing and grading);
3) Milling Section: (grinding and sifting);
4) Packing Section: 25KG/Bag flour auto-packing; 50KG/Bag bran auto-packing;
Features of Wheat Milling Plant
1.wheat flour milling Machine With a magnificent look, the building helps to improve the brand awareness, and it is a permanent building with long life.
2.The manufacturing workshops of wheat flour milling Machine are bright and spacious, while the equipped machines allow simple disassembly and maintenance. Moreover, there is little dust inside the workshops.
3.A hanging bin could be built to realize wheat batching or flour batching. The finished wheat flour can be discharged from the second floor for convenient loading onto trucks.
4.Our wheat flour milling plant has storage bins for original wheat and cleaned wheat respectively. Their large storage capacities fully meet the requirements for continuous batch production.
5.The material distribution floor smooths and perfects the entire processing flow.
6.The materials are fed in a ladder-typed manner, so, fewer elevating and conveying devices are needed, resulting lowered power consumption.
7.The multi-story layout reduces noise level, and this structure provides extra convenience when some changes are needed to upgrade the existing production flow.
The processing of Wheat Milling Plant
Specifications
Model
Final Products
Power
Capacity
Workshop Dimension(m)
Requirement(KW)
(Per ton of wheat/24h)
60t
Special purpose
290
60
35*10*12
100t
flour
350
100
35*10*12
120t
Grade I
430
The company is the world’s best Pingle Group Wheat Flour Milling Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
120
43*10*12
140t
Grade II
540
140
47*12*12
150t
Standard
550
150
49*12*12
160t
(Co-production)
610
160
49*12*13
180t
720
180
54*12*13
200t
830
200
57*12*13
Company Profile
Hebei Pingle Flour Machinery Group Co., Ltd., established in , is a group enterprise specialized in grain machinery project manufacturing and installation with diversified business.The Parent Company produces mainly 3- ton complete set of flour milling machine and undertakes turnkey project for 100- ton complete set of steel structure equipment.Professional manufacturer specialized in grain processing project manufacturing
and installation with 30 years experience.Main products includes wheat flour milling machine and maize milling machine. Our products have been exported to 40 countries and regions such as Egypt, Ethiopia, India, Iran, Vietnam, Brazil etc.The international Trade Division sets up sales dep., technical engineer dep., after sales service dep.and documentation and logistical dep., which can manage engineer designing,installation and service with professional staff.
After Sales Service
1. Pre-sale service
Within three days after receiving the notification from the customer, our sales department will arrange meeting on the customer's designated site, and makes the best design plan according to the customer's requirements and the actual situation of the site. According to the specific requirements of customers to design and manufacture products, to provide technical transformation of products.
2. On-site installation and commissioning services
After the equipment arrives at the site, our company sends technicians to the site for guidance and assistance in assembly, installation and commissioning.
3. Personnel training
During the trial operation of the equipment, the technical personnel of our company shall guide and train the technical personnel, operators and maintenance personnel of the buyer in accordance with the instructions for the use of the equipment. The training content includes installation and operation procedures and precautions of equipment, common faults and treatment methods of equipment operation, etc.
4. After sales service
Within the warranty period, after receiving any problems with my products used by your company, our company will ensure that technicians will be assigned to the product use site (except force majeure) within 3-5 days of working time to deal with them. Our company carries out life-long maintenance and supplies spare parts for a long time. When the warranty expires, users at home and abroad can call the 24-hour service hotline of customer service center in time if they have problems that can not be solved in the use of equipment. The engineers and technicians of our company can quickly answer them. If the can not solve the problem, our company will send technicians to the scene within 72 hours to deal with it immediately.
Our engineering and technical department provides free technical guidance, consultation and fast door-to-door service for you all the year round, and also provide periodically inspect the operation of the equipment to eliminate the potential failure.
FAQ
1. Q. Are you a factory or trading company? Where is your factory?
A: We are a professional manufacturer. Our factory is located in Shijiazhuang, Hebei Province. We are warmly welcome clients from worldwide to visit our factory and cooperate with us.
2. Q.What's your advantage? Why do we choose you?
A: 30 Years experience of design and manufacture grain machinery.We have the most professional techniques team and best after-sales services.
3. Q: How about the INSTALLATION?
A: Professional engineers are in charge for installation, commission and training, etc.
4.Q: Do you provide after sale service?
A:We provide 24h after service , our over sea service center available in Zambia, Kenya, India, Brazil and Ethiopia.
Zambia: Plot No., Mungwi Road, Heavy Industrial Area, Lusaka, Zambia
India: C601, Patel Heritage, Sector 7, Kharghar, Navi Mumbai.
Brasil: R.Aleixo Garcia, 442- Oficinas, Ponta Grossa- PR, -060, Brasil
Kenya: K2 Godown, Dul Dul Business Park(Mlolongo/Sabaki Area), Mombasa Road, Nairobi, Kenya
5. Q: How can I know your machine is designed for my product?
A: Pingle has dedicated R&D center to provide you with professional machinery technology consulting, professional design to meet different customer needs.
6.Q: How can I know your machine working well?
A: Before delivery, we will test and adjust the machine working condition for you, then you can use directly when you get it.
7.Q: Do you have a ISO certificate?
A: For every model of machine, it has a ISO certificate.
Q: Warranty period
A:We provide 2 years warranty, while for core components, we have 3 years warranty.
Successful cases
Pakistan BANGLE PINGLE FLOUR MILL200T Milling Project
Egyptian AWLAD ELSHAZLI FLOUR MILL 220T Milling Project
Korean MILDAWON CORPORATION 150T Milling Project
Vietnam THIET LAP CO. LTD. 240T Milling Project
Vietnam CIAY VANG CO. 200T Milling Project
Vietnam TIEN HUNG JSC 200T Milling Project
Iran KARKHANE WALC FAGR CO. 200T Milling Project
Iran ARDE POIENAK-E VARAMIN 170T Milling Project
Iran TAVONI NANVAIAN MASHHAD 350T Milling Project
Bangladesh BEST GOLDEN FLOUR MILLS LTD 200T Milling Project
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