MILLING MEA MAGAZINE ISSUE 15

MIDDLE EAST & AFRICA

EVENT REVIEW

Buhler Networking Days 2025

TECHNOLOGY FOCUS Dust & Explosion Control

BAKING TECH

Sustainable Packaging in Baking

INGREDIENTS STERN

MIDDLE EAST & AFRICA

Year 3 | Issue No.15 | July - Aug 2025

FOUNDER & PUBLISHER

Francis Juma

SENIOR EDITOR

Martha Kuria

EDITOR

Wangari Kamau

Stephen Kibe

EXTERNAL CONTRIBUTORS

Martin Mucha

Kipng'etich Yegon

BUSINESS DEVELOPMENT

DIRECTOR

Virginia Nyoro

BUSINESS DEVELOPMENT

ASSOCIATE

Johna Sambai

HEAD OF DESIGN

Clare Ngode

ASSOCIATE DESIGNER

Emmaculate Ouma

ACCOUNTS

Anita Kinyua

Published By: FW Africa

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Milling Middle East & Africa is published 6 times a year by FW Africa. Reproduction of the whole or any part of the contents without written permission from the editor is prohibited. All information is published in good faith. While care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of any action taken on the basis of information published.

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FEE BUSINESS

www.feedbusinessmea.com

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www.sustainabilitymea.com

www.hpcmagmea.com

Perfecting Your Flour Quality Through Innovation and Expertise

With over 50 years of experience, Pakmaya stands by your side from diagnosis to solution. We offer practical and expert approaches tailored to your needs.

The Focus of Our Business

Securing tomorrow’s Food through Today’s Innovations

In this issue, we shine a spotlight on industry leaders driving solutions that are shaping the future of Africa’s food and agriculture sector. These giants are not only addressing current challenges but are also laying the foundations for a sustainable and prosperous tomorrow.

Stern Ingredients East Africa exemplifies innovation through its MC Mühlenchemie Technology Center in Kenya. Their “Understanding Flour” strategy is redefining baking across the region. “We’re particularly proud of our cake mix solutions,” says Nolte, pointing to their flexibility, which has become a game-changer for local markets. In addition, their fortification solutions for maize and wheat flour are enhancing nutritional outcomes, proving that innovation and impact can go hand in hand.

Meanwhile, Bühler, a global leader in milling equipment, continues to set the benchmark for sustainability. At their Fourth Networking Days, the message was clear: sustainability is no longer optional; it is essential for long-term business success. By integrating eco-conscious practices into cuttingedge technologies, Bühler is shaping a future where efficiency and environmental responsibility are inseparable.

This issue also sheds light on why dust control and explosion prevention remain paramount in the milling industry. Fine organic dust generated during grinding, handling, and storage is highly combustible. When suspended in the air, even the smallest spark—from static electricity, machinery, or friction, can trigger a devastating explosion. Beyond the immediate risk to workers’ safety, such events can damage equipment, halt production, and cause lasting reputational harm.

On the commodity front, Tanzania’s “Grain Drive” is positioning the country as a potential breadbasket of the region. Through strategic commitments and partnerships with private investors, the government is expanding grain production, particularly maize, rice, and wheat, which are staples in East Africa. These efforts are designed not only to meet domestic demand but also to strengthen Tanzania’s role as a reliable supplier to food-deficient neighboring countries.

Consumer preferences are also reshaping the grains industry. Whole and specialty grains are gaining ground globally, driven by growing health awareness and the demand for fiber-rich, nutritious foods. Their strong association with reducing chronic diseases, including obesity, cardiovascular conditions, diabetes, and certain cancers, continues to fuel this momentum. For millers and processors, however, working with whole and specialty grains presents unique challenges. These require specialized equipment and techniques, making their processing a call for innovation for the industry. In this issue, we share expert insights into how the industry is adapting to these demands.

Finally, we bring you a comprehensive roundup of the latest developments in the baking, milling, grains, and cereals sectors as well as the most relevant news shaping our industry.

Enjoy your read!

Martha Kuria, Senior Editor, FW Africa.

Grain & Milling Expo (GME)

October 8–9, 2025

Casablanca, Morocco

https://expo.grainmillingexpo.ma/en/

Grain Industry Expo

October 10–12, 2025

Bikaner, Rajasthan, India

https://www.grainindustryexpo.com/bikaner/

11th MAGROTEX 2025

October 23, 2025 - October 26, 2025

Mardin, Turkey

https://shorturl.at/ZtjoF

AgroFood Summit 2025

November 5-7, 2025

Mersin, Türkiye

https://agrofoodsummit.com/

VIV MEA

November 25-27, 2025

Abu Dhabi, UAE

https://www.vivmea.nl/

IAOM MEA Conference & Expo

December 1-4, 2025

Jeddah, Saudi Arabia

https://iaom-mea.com/Jeddah-2025/

Africa Dairy Innovations Summit

February 25-27, 2026

Nairobi, Kenya

http://www.africadairysummit.com/

Africa Food Manufacturing Nigeria & Western Africa

April 14-16, 2026

Lagos, Nigeria

http://www.afmass.com/

Africa Food Manufacturing Kenya & EA

July 15-17, 2026

Nairobi, Kenya http://www.afmass.com/

IDMA Istanbul 2026

June 25- 27, 2026

Turkiye

https://www.idma.com.tr/

INVESTMENTS

Saudi Arabia’s First Mills acquires Al-Manar Feed Company in US$20.5M deal

SAUDI ARABIA - Saudi Arabia’s First Milling Company (First Mills), a producer of flour, bran, animal feed, and wheat derivatives, has completed the acquisition of Al-Manar Feed Company Ltd., a leading feed manufacturer in the Kingdom.

The deal, valued at SAR 77 million (US$20.52 million), was announced on August 12 and involves the purchase of 100% of Al-Manar’s shares. First Mills said the acquisition will be financed through Sharia-compliant bank facilities, available cash, and other financing options. Its financial impact will appear in the company’s third-quarter 2025 consolidated statements. Al-Manar, headquartered in Makkah, is known for producing high-quality animal feed for ruminants, poultry, and horses. Its integration into First Mills’ operations follows earlier board approval, conditional on successful operational testing to confirm quality, quantity, and efficiency standards.

Vice Chairman Abdullah Ahmed Al-Shehri described the acquisition as a milestone in First Mills’ strategy to grow its footprint in the feed sector. “We continue to pursue highvalue opportunities for sustainable growth in support of the objectives of Saudi Vision 2030 and to enhance the contribution of local production to achieving food security, while serving our customers across all regions of the kingdom,” he said.

COMMODITY UPDATE

The deal adds 420 tonnes per day of feed output to First Mills’ operations, lifting total daily production to 1,320 tonnes. The company noted the added capacity will help meet rising demand, broaden its geographic reach, and diversify revenue sources.

Chief Executive Officer Abdullah Abdulaziz Ababtain added that the move would strengthen competitiveness. “The acquisition will enable us to deliver a more comprehensive range of products and services, better meet the needs of the local market and reinforce the company’s long-term competitive position,” he said.

Morocco to import 7.5 million tonnes of wheat in 2025/26: USDA

MOROCCO – Morocco is expected to import 7.5 million tonnes of wheat in the 2025/26 marketing year, according to the latest global supply and demand outlook from the U.S. Department of Agriculture’s Foreign Agricultural Service (USDA). This forecast, highlighted in an August report and cited by UkrAgroConsult, signals the country’s deepening reliance on external markets to meet over half of its wheat demand, driven by persistent droughts and escalating global grain prices.

Global wheat production is estimated at 789.8 million tons, down 2.1 million tons from July, while consumption remains

steady at 801.6 million tons, creating a supply-demand gap that is pushing prices higher. For Morocco, where wheat accounts for over half of cereal consumption and bread is a dietary staple, this global shortfall is particularly concerning.

The USDA projects global wheat reserves at 256.2 million tons for the 2025/26 season, the lowest since 2016/17, due to poor harvests in key producing regions like Europe, Russia, and Ukraine. The USDA FAS reported that the 2024/25 marketing year saw total wheat and barley production drop to 3.12 million metric tons, a 43% decline from the previous year. For 2025/26, production is expected to recover slightly but remain below the 10-year average, with forecasts of 1.7 million metric tons for common wheat, 1.1 million metric tons for durum wheat, and 0.7 million metric tons for barley.

According to a report by Interfax, Morocco imported more than 1.1 million metric tons of wheat from Russia by the end of June 2025, marking a 2.3-fold increase compared to the previous agricultural season. This sharp rise in wheat imports signals a notable expansion in Morocco’s grain import capacity and reflects broader shifts in global grain flows, especially as countries reassess their supply strategies amid mounting geopolitical and climate pressures.

INVESTMENTS

Cadyst Group finalizes acquisition of two subsidiaries of Somdia Group

CAMEROON - Cadyst Group, a leading agro-industrial and food processing player in Central Africa, has finalized the acquisition of the Grands Moulins du Cameroun (SGMC) and the Grands Moulins du Phare du Congo (SGMP), subsidiaries of the Somdia Group after a lengthy regulatory process. The transaction was officially concluded on August 6, 2025, with both companies’ boards of directors approving the change in shareholding and governance.

As part of the new leadership structure, Mr. Célestin Tawamba, President of Cadyst Group, was appointed Chairman of the Board of Directors of SGMC and SGMP. He will be supported by new directors, including Mrs. Elizabeth Gouater, Director and Chief Executive Officer of Cadyst Group. With this acquisition, Cadyst strengthens its leading position in Cameroon and extends its operations into the Republic of Congo, marking a significant step toward consolidating its status as a pan-African agro-industrial group.

Established by Mr. Tawamba with La Pasta, a small unit producing just 25 tons per day of pasta and flour, Cadyst has grown into a diversified conglomerate.

Its portfolio today includes flour production (Cadyst Grain), pasta and biscuits under the PANZANI brand, local distribution (Cadyst Retail), healthcare (Cadyst Health Care), and poultry farming (Cadyst Farming), which specializes in day-old chicks.

In his statement, Mr. Tawamba emphasized the human dimension of the deal. “It is with great joy and deep emotion that we welcome SGMC and SGMP to Cadyst. August 6, 2025 marks much more than an acquisition, it is the starting point of a new chapter, bringing new opportunities for our teams, our partners and our markets,” he said. According to him, beyond the assets and figures, it is women and men who join the adventure with their experience, their culture and their know-how.

ANNIVERSARY

Azam celebrates 50 years of excellence with special Golden Jubilee wheat flour pack

TANZANIA - Azam, the flagship brand of Bakhresa Group, has marked its Golden Jubilee, celebrating 50 years of quality, affordability, and innovation across Eastern and Southern Africa. The milestone was commemorated on August 8 at the Super Dome, where Tanzania’s leading conglomerate gathered in a colorful ceremony. Founded in 1975 by entrepreneur Said Salim Awadh Bakhresa, Azam began as a small restaurant before growing into one of Africa’s most recognized brands. Over the decades, it has become a symbol of trust and value for households across the region.

To honor the anniversary, Said Salim Bakhresa & Co. Ltd. unveiled a Special Golden Jubilee pack of Azam Ngano Bora Wheat Flour, a staple in Tanzanian homes. The refreshed packaging reflects both legacy and consumer loyalty. “This Golden Jubilee is not just a celebration of our history, but a reaffirmation of the values that define who we are,” said Ali Asgar Mukadam, CEO of Said Salim Bakhresa & Co. Ltd. He emphasized the company’s commitment to uncompromising quality, affordability, and community upliftment.

From its Tanzanian base, Azam has expanded into Uganda, Rwanda, Burundi, Malawi, Mozambique, South Africa, Zimbabwe, and Zanzibar, contributing to regional industrial growth, job creation, and economic development. Its diverse portfolio spans food and beverages—including wheat flour, biscuits, ice creams, juices, and soft drinks—transport services such as Azam Marine and Azam Transport, and digital broadcasting through Azam TV.

The group also invests in agriculture and manufacturing, operating Bagamoyo Sugar, Azam Edible Oil, Azam Poly Sacs, and expanding into household products like soaps and detergents. Its energy and hospitality ventures include United Petroleum and the eco-friendly Hotel Verde Zanzibar. Looking ahead, Azam is extending its carbonated soft drinks operations into Uganda, reinforcing its ambition to reach new markets while upholding its core promise of quality and affordability.

Alapala commissions 300 tpd wheat flour mill for Aruana LLP in Kazakhstan (Investments)

KAZAKHSTAN – Alapala has commissioned a new 300-tonnes-per-day wheat flour mill for Aruana LLP, one of Kazakhstan’s leading food producers, further strengthening the company’s role in the country’s milling sector.The project marks Aruana’s second major investment in milling capacity as it seeks to meet rising demand for flour both in Kazakhstan and in surrounding export markets. Kazakhstan remains one of the top wheat producers in the world, with the milling sector playing a crucial role in its economy and export earnings.

Founded in 2010, Aruana is recognized for its “Patsha” brand flour, produced from high-protein wheat grown in Kazakhstan, a country long regarded as Central Asia’s breadbasket. The company operates its own grain storage facilities, allowing for precise grain blending and strict quality control throughout the production process. By supplying bakeries, food manufacturers, and retail distributors at home and abroad, Aruana has positioned itself as a trusted supplier of premium flour.

The newly commissioned mill is fitted with state-of-theart cleaning, grinding, and sifting equipment, alongside fully automated process control systems designed to optimize energy use and reduce operational costs. This integration of technology ensures high milling efficiency and also guarantees consistent output and premium flour quality, helping the company to compete in regional markets where demand for quality wheat products continues to grow.

Commenting on the partnership, Görkem Alapala, chief executive officer of Alapala, said that Kazakhstan is a strategic market for Alapala, and they are proud to support Aruana’s growth with a tailor-made milling solution that delivers efficiency, quality and reliability. “Our collaboration with Aruana is a great example of how we can combine advanced milling technology with a client’s strong market vision,” he said.

INVESTMENTS

AGI Milltec commissions 6 TPH Hanuman Rice Mill in India

INDIA – AGI Milltec, a leading manufacturer of grain processing solutions and a division of Ag Growth International (AGI), has announced the successful commissioning of the Hanuman Rice Mill in Karnataka. The newly completed facility is a fully integrated, state-of-the-art rice milling plant with a processing capacity of 6 tonnes per hour (TPH). The plant was officially inaugurated by Shrimad Samyamindra Thirtha Swamiji, head of the Kashi Math Samsthan. His presence lent a spiritual and cultural significance to the event, underlining the mill’s importance to the local community.

AGI Milltec is part of Canada-based Ag Growth International, which acquired the Bengaluru-headquartered company in 2019. Since then, the firm has extended its presence across Southeast Asia, Africa, and Latin America, focusing on grain handling, storage, and processing innovations tailored to local market needs. The company described the Karnataka project as a reflection of its ongoing commitment to empowering the rice milling sector with innovative, reliable, and performancedriven technologies. The new plant features a complete turnkey configuration, from pre-cleaning and de-stoning to whitening, polishing, grading, and packaging, designed to enhance product quality and operational efficiency.

“This milestone reflects our commitment to empowering the grain processing industry with advanced, reliable, and high-performance milling solutions. We are proud to be part of Hanuman Rice Mill’s growth journey and look forward to continued success together,” the company stated following the commissioning. The 6 TPH plant forms part of AGI Milltec’s broader strategy to provide end-to-end grain processing solutions across India and other major rice-producing regions. The company, which has delivered more than 15,000 installations in India, offers customized milling lines ranging from 2 TPH to 20 TPH capacities.

Bunge Global SA strikes strategic

deal to acquire

plant-based ingredient business from IFF

USA – Bunge Global SA, a leading agribusiness and food ingredient company, has entered into a purchase agreement with Solae to acquire substantially all the assets related to the lecithin, soy protein concentrate, and crush businesses of International Flavors & Fragrances, Inc. (IFF).The deal, announced in early August 2025, allows IFF to sharpen its focus on higher-margin, innovation-driven segments like its isolated soy protein business. The transaction is expected to close by the end of 2025, pending regulatory approvals and customary closing conditions.

The acquisition includes IFF’s commodity-focused operations, which employ approximately 250 workers globally, which generated approximately US$240 million in revenue for IFF in 2024. While financial terms were not disclosed, the acquisition aligns with Bunge’s strategy to deepen its presence in the food, feed, and biofuel sectors. Speaking during a conference call with analysts following IFF’s August 6 earnings report, J. Erik Fyrwald, chief executive officer and director, described the soy crush, soy protein concentrate and lecithin products being divested as a “better fit with Bunge.”

For IFF, the divestiture reflects a broader portfolio

PARTNERSHIPS

optimisation strategy. CEO J. Erik Fyrwald described the assets as “commoditised” and better suited to Bunge’s operational model. “They were low single-digit EBITDA margins for us and were distracting from our very differentiated isolated soy protein business,” emphasised Fyrwald, adding that the sale will allow IFF to focus on innovation and application development in its core food ingredients segment. With a strong presence in the world’s top three soybean oilseedproducing countries, Brazil, the United States, and Argentina, Bunge is well-positioned to integrate and optimise the acquired operations.

Ocrim, Grespan Impianti forge strategic alliance to deliver turnkey feed production solutions

ITALY – Italian milling technology specialist Ocrim has entered into a strategic partnership with Grespan Impianti, a longestablished designer and builder of turnkey feed production plants. The alliance aims to offer high-tech, flexible, and efficient solutions to the global feed and agri-food industry, the companies announced.

Founded in 1961 and headquartered in Castrette di Villorba, Italy, Grespan Impianti brings more than six decades of experience in developing systems tailored for the livestock, food, and agri-food sectors. Over the years, Grespan has evolved from serving Italy’s livestock industry to delivering

custom-engineered solutions for feed manufacturing, food premix production, and bulk material handling, including storage, dosing, and mixing systems used in food, paint, and construction industries.

“Together, the two companies offer integrated, high-tech, flexible solutions geared toward maximum efficiency. Our alliance is rooted in shared Italian manufacturing values, a commitment to innovation, and an ability to deliver on diverse customer needs,” the companies said in a joint statement. Ocrim, based in Cremona, Italy, is a global leader in the design and manufacture of milling equipment for wheat, maize, and other grains. It has completed high-profile flour and feed mill installations in more than 150 countries. On the other hand, Grespan has a notable international presence, having installed facilities in countries across North Africa and the Middle East, including Tunisia, Morocco, Algeria, and Saudi Arabia, as well as in Eastern Europe—Ukraine, Hungary, and Russia.

By combining their know-how, the partnership positions itself to meet growing global demand for advanced feed solutions, driven by the expanding livestock and poultry sectors and the need for food security through localized feed production.

Cimbria installs largest bucket elevator in Romania

ROMANIA – Cimbria, a global leader in grain and seed processing, has successfully installed its largest bucket elevator to date, the EH 64, at the UMEX SA Constanta Port Terminal in Romania. Standing an impressive 49 meters tall, this engineering marvel is designed to handle a staggering 1,500 tons of wheat per hour, setting a new standard for high-capacity vertical conveying in port terminals. The EH 64, with a belt speed of 3.60 m/sec, is engineered for efficiency, durability, and reliability in demanding industrial environments. It features a galvanized finish, pedestal bearings, and HARDOX wear plates, ensuring long-term performance under rigorous conditions.

As part of the same project, Cimbria also supplied a 1,500-ton-per-hour belt conveyor, creating an integrated solution that supports the growing logistical demands of Romania’s busiest port. The installation forms part of a comprehensive expansion at UMEX, which covers new terminals for both grain and fertilizer handling.

Cimbria first shipped the elevator top of the EH 64 to Romania in March 2024, working with VIGAN Engineering to ensure precise integration into UMEX’s ship-loader system. The nearly 10-ton elevator top was built with reinforced wear plates and corrosion-resistant finishes to endure the harsh conditions of continuous grain handling.

By September 2024, the EH 64 was fully operational, delivering the promised capacity of 1,500 tons per hour, confirming its status as Cimbria’s most advanced bucket elevator to date.

The UMEX terminal expansion also includes grain storage silos with a combined capacity of 100,000 tons and fully automated intake and loading systems. Backed by EU funding under Romania’s Transport Programme 2021-2027, the project is expected to raise the port’s annual handling capacity by close to one million tons.

ANNIVERSARY

SIMEZA celebrates 50 years of grain storage innovation, global

growth

SPAIN – SIMEZA, the Spanish grain storage specialist is celebrating its 50th anniversary this year, marking a halfcentury of providing engineered steel silos to agricultural and industrial clients worldwide. Established in 1975 as Silos Metálicos de Zaragoza, the Zaragoza-based company has evolved into one of Europe’s leading manufacturers of modular silo systems, offering solutions with storage capacities ranging from 8 to 25,000 cubic meters.

The company now serves a wide range of clients across the agricultural, industrial, and farm sectors in Europe, the Middle East, Africa, and Latin America. “We have spent five decades focused on one thing, helping our customers store grain safely. Reliability, innovation and a renowned engineering expertise have been the keystones of our success. That’s what matters,” said Alberto Baena, chief executive officer of SIMEZA.

SIMEZA’s silo systems are designed with modularity in mind, allowing for efficient on-site assembly. The use of high-grade steel enables the structures to withstand extreme weather conditions, while integrated aeration systems help preserve grain quality by maintaining proper ventilation. These features have made the silos a preferred choice for clients looking for durability, ease of installation, and grain preservation performance.

The company operates under strict European Union quality and safety guidelines and holds the UNE-EN 10901:2011+A1:2012 certification, which governs the manufacturing of structural steel components. In addition, SIMEZA enforces rigorous standards for its suppliers, ensuring that every component used in its silos meets its quality benchmarks. Grain storage is becoming increasingly critical in global food supply chains. As climate variability, post-harvest losses, and rising demand for traceability put pressure on grain management systems, companies are investing in more reliable and efficient infrastructure.

Stern

East Africa Ingredients

Customer

BY STERN INGREDIENTS EAST AFRICA

The MC Mühlenchemie Technology Center in Kenya is a prime example of the “Understanding Flour” strategy in Africa

The MC Mühlenchemie Technology Center in Nairobi –operating as Stern Ingredients East Africa Ltd. (SIEA) – is the third of its kind on the African continent and a central element in the com-pany’s global strategy. Alongside locations in Nigeria and South Africa, this East African center – serving a region that extends as far as Angola – shows the commitment of the world market lead-er in flour treatment to be as close as possible to its customers – a sign of its special involvement in a region with enormous po-tential.

LOCAL PRESENCE AS A SUCCESS MODEL

“Understanding Flour” is more than a motto – it is the foundation of MC Mühlenchemie’s philosophy. The company delivers customized solu-tions for the standardization, improvement, and enrichment of flour, a vital staple. True understanding requires deep knowledge of local con-ditions and challenges, something made possible by the presence of the Technology Center in Kenya. This close proximity to customers in the region enables finely tuned solutions that would be difficult to de-velop from afar.

The heart of the facility is a 400 square metre baking application tech-nology, development and consulting laboratory. It offers comprehensive possibilities for flour and grain analyses, and includes a trial bak-ery with the latest equipment, from spiral kneaders and sheeters to deck and convection ovens. Here, expert staff can simulate baking processes, test the effects of enzymes and other ingredients, and im-plement the results directly in local mills. This local research and de-velopment facility is part of MC Mühlenchemie’s global network of 12 Technology Centers and 7

production locations on 4 continents.

David Nolte, since August 2021 Head of Operations and R&D for Stern Ingredients East Africa, is a highly qualified miller with over two dec-ades of experience , giving him deep specialist knowledge which he brings to MC Mühlenchemie. “From the start, I focused on our African customers and developed a strong connection to the continent and its people,” Nolte notes. This connection is evidenced by the appreciation the company shows for the region.

The fact that in 2023 MC Müh-lenchemie held its centennial celebration for all of Africa in Nairobi underlines the special importance of this location and the strategic posi-tion of the East African market.

LOCAL DIVERSITY REQUIRES SPECIFIC SOLUTIONS

East Africa is a burgeoning region marked by impressive cultural di-versity. This melting pot of countless ethnic groups with their own traditions and languages has given rise to very specific product require-ments, especially in foods. This diversity is directly reflected in the ex-pectations placed on local solutions.

The team in Nairobi addresses this diversity

and can also serve the neighbouring countries of Tanzania, Uganda, Ethiopia and Rwanda from this central location in East Africa. It works on products like “Baker’s Flour” for sandwich bread, and – especially important for the local market –“Homebaking Flour” for regional specialities like chapati and mandazi. They meet not just technical standards, but also cul-tural preferences that would be next to impossible to understand without a local presence.

“We’re particularly proud of our cake mix solutions,” says Nolte. “They offer customers a flexibility that makes the difference in this region – a real milestone for us.” At the same time the team supports with fortification solutions for maize and wheat flour. These flours are enriched with important vitamins and nutrients like iron, zinc and folic acid, to combat malnourishment and “hidden hunger” – problems that remain acute in many parts of Africa.

This tremendous dynamic, with constantly changing challenges in daily life, demands flexibility and a deep understanding of local realities. But implementation is frequently “pole pole” – step by step, with delibera-tion. “In East Africa personal relationships and community are every-thing,” Nolte explains. “Social interaction

WE MEET NOT JUST TECHNICAL STANDARDS, BUT ALSO CULTURAL PREFERENCES THAT WOULD BE NEXT TO IMPOSSIBLE TO UNDERSTAND WITHOUT A LOCAL PRESENCE

beyond working hours is es-sential.” The Swahili saying “Haraka haraka haina baraka” (“Haste has no blessing”) encapsulates this approach, and underscores the need for the virtues of calm, patience and deliberation in East Africa, including in business life.

PROMPT ANSWERS TO URGENT CHALLENGES

One of the most pressing issues for East African millers is "grist change" – fluctuating grain quality and a volatile global wheat market, strained further by geopolitical tensions. Rising costs, increasing infla-tion and higher fees are impacting manufacturers and customers alike, and leading to rising food prices – a development that has noticeable social effects, especially in developing countries. As a company that processes over 150 million tonnes of wheat each year, MC Müh-lenchemie has the necessary expertise to master these challenges.

Since the region is heavily agricultural, much of the raw materials like wheat and corn are locally sourced. With its analysis capacity in Nairo-bi, Mühlenchemie can develop solutions for individual needs and make them available to mills much faster. Personal communication between customer and consultant, from field to final product, is also much more direct.

the team also offers training, seminars and workshops. These services are critical for strengthening local know-how and building up sustained capacity and are further evi-dence of LOCAL APPLICATION TECHNOLOGY FACILITY HELPS TO DEVELOP TAILOR-MADE SOLUTIONS

In addition to analyses of grain and flour,

MC Mühlenchemie’s long-term commitment to the region.

development of our services in other parts of the world.”

IN NUMBERS

NUMBER

The benefit of having an own local laboratory and application technolo-gy facility lies in the ability to develop tailor-made solutions in direct customer proximity. This enables fast reactions to inquiries and changes, as well as the development of locally adapted solutions de-signed especially for the challenges faced by African millers. “It is es-sential to build trust and long-term connections to local partners and decision-makers,” says Nolte of the challenges in working in Kenya. “Patience, sensitivity and the ability to deepen relationships are key in moving projects forward here.” In part thanks to this approach, today MC Mühlenchemie counts more than 2000 mills in over 150 countries among its customers.

GLOBAL KNOWLEDGE MEETS LOCAL EXPERTISE

The East African facility is part of a global ecosystem. Norman Loop, Regional Director for Europe, the Middle East, and Africa, explains: “With the Nairobi location, we are expanding our global network and adapting our services to local markets. In doing so, we can build on our global expertise. Meanwhile, the knowledge we gain on the African market contributes to the further

This dovetailing of global knowledge and local expertise is what makes MC Mühlenchemie strong. At the central “Future Makers” SternTechnology Center in Ahrensburg, Germany, over 100 scientists and applications technologists work on tailor-made solutions to the requirements of the worldwide milling industry. From there, knowledge is transferred to all regions and adapted to local conditions.

MC Mühlenchemie serves over 2000 mills in more than 150 countries. Today, the team of experts in the 12 Technology Centers around the world assists mills locally with individual solutions for optimum flour quality. The close collaboration among these worldwide centres makes it possible to share knowledge and best practices across regions, for the benefit of all customers.

“The combination of global R&D, regional understanding, and the ability to turn both into customer-specific solutions is what makes our ‘Under-standing Flour’ concept so effective,” says Khalif Steinbrich, Area Sales Manager East Africa. “The Nairobi center stands as a beacon for this approach and a strategic hub for the future of milling in one of Afri-ca’s most dynamic regions.”

AFRICA FOOD MANUFACTURING EXPO

Event Highlights

Did you miss the Africa Food Manufacturing Expo - Kenya & Eastern Africa edition 2025, Africa's No.1 Food & Beverage Manufacturing and Milling Industry Trade Shows and Conferences? Here is a glimpse of what you missed, but dont worry, we have you covered in 2026!!

Held from July 2–4, 2025 at the Sarit Expo Centre in Nairobi, the event was more than just an exhibition, it was a story of how Africa is reimagining the way it feeds, serves, and manufactures for itself and the world.

For the first time, Africa Manufacturing Week and Africa Food & Hospitality Week came together, uniting industries that are often treated separately, food processing, hospitality, packaging, logistics, animal feed, and personal care. The result was a vibrant showcase of innovation and collaboration, with over 80 exhibitors presenting cuttingedge machinery, sustainable packaging solutions, plant-based ingredients, and

KENYA & EASTERN AFRICA EDITION 2025

digital logistics platforms.

The 13-session conference program, powered by leading sponsors such as Kerry, Bühler, IFF, AGF, and Dohler, explored urgent themes including food security, circular economy strategies, protein alternatives, and digitization. Conversations underscored a shared mission: growth that is both profitable and sustainable.

Beyond the Expo hall, the Africa TasteMasters Culinary Festival captured hearts with flavors that told stories of culture and creativity.

From West, South and Eastern Africa, 2026 got you covered!! You can never miss

•AFMASS Zambia & Southern Africa Edition - March 25-27, 2026 | Lusaka, Zambia - 3rd edition

•AFMASS Nigeria & Western Africa Edition - June 2-4, 2026 | Lagos, Nigeria - 1st edition

•AFMASS Kenya & Eastern Africa Edition - July 15-17, 2026 | Sarit Expo Centre, Nairobi, Kenya - 11th edition

AFRICA FOOD MANUFACTURING EXPO

KENYA & EASTERN AFRICA EDITION 2025

AFRICA FOOD MANUFACTURING EXPO

KENYA & EASTERN AFRICA EDITION 2025

Ancient Crops

Modern Solutions

Collaborative Pathways to Revitalize Africa’s Milling Sector

BY MARTHA KURIA

From July 2 to 4, 2025, the Sarit Expo Centre in Nairobi, Kenya, hosted the Africa Future Food Summit alongside the Africa Food Manufacturing Expo 2025, creating a dynamic platform for industry leaders, technology providers, and academic experts to converge. This three-day event catalyzed discussions on leveraging Africa's ancient crops such as millet, sorghum, teff, fonio, cassava, and sweet potatoes, to address the continent's evolving food security and market demands. Through shared expertise and innovative solutions, the summit illuminated a path to transform the grains, milling, and baking sectors.

ADVANCED MILLING, PROCESSING, AND STORAGE SOLUTIONS

The Africa Food Manufacturing Expo 2025 showcased stateof-the-art technologies designed to enhance efficiency and scalability in the milling, feed and food processing. Here is a highlight of milling equipment giants that graced the expo.

Bühler, a global leader in food processing equipment, presented its integrated solutions, bolstered by the Bühler Insights platform for real-time operational analytics, enabling data-driven decision-making. Italian firm OCRIM demonstrated its turnkey milling plants, optimized for wheat, corn, and other cereals, offering precision and reliability for large-scale operations.

Cimbria highlighted its engineered systems for grain, seed, and food handling and storage, ensuring quality preservation across the supply chain. Myande Group, with a portfolio of over 1,200 plants worldwide, showcased expertise in oils and fats processing, starch derivatives, fermentation, and smart factory technologies, blending innovation with operational

scale.

Grain storage and feed milling systems were represented by Turkish manufacturers Altınbilek, with over 200 turnkey facilities in more than 110 countries, and ÇSİ, which produces ISO 9001:2008-certified silos, handling equipment, and concrete floor systems. Depart, part of the Alapala Group, presented its range of spare parts, after-sales services, telescopic conveying systems, color sorters, rice machinery, and packaging solutions to support milling and pasta operations.

SHOWCASING KENYA'S THRIVING FMCG INDUSTRY

In the Fast-Moving Consumer Goods (FMCG) space, Capwell Industries Limited, a prominent sponsor of the event, stood out with its versatile portfolio, including flour, rice, pulses, confectionery, and beverages under trusted brands like Soko, Amaize, and Pearl, demonstrating their ability to meet varied consumer preferences. Bakex, a stalwart in wheat flour production, highlighted its role as a reliable supplier in Kenya’s market, showcasing its high-quality flour products to industry stakeholders. Spice World Ltd, operating under the “Butterfly” brand, presented its ISO 9001:2015-certified spices and food products, emphasizing rigorous quality standards and compliance to deliver consistent, flavorful offerings that

resonated with expo attendees.

In the bakery industry, Skypex Supplies Ltd played a pivotal role by exhibiting high-quality bakery ingredients and equipment tailored for industrial, artisanal, and hospitality applications. Their focus on precision, underscored the importance of consistent, high-quality baked goods. Broadway Bakery, recognized for its widely consumed bread varieties, and DPL Festive, which operates East Africa’s largest fully automated bakery facility, impressed attendees with their broad portfolio of products through live demonstrations and product displays.

Adding to the sector’s dynamism, Ndivisi showcased its soybean processing capabilities, presenting meals for human and animal nutrition alongside crude soya oil.

REVITALIZING FORGOTTEN CROPS: INDUSTRY INSIGHTS

Africa’s ancient crops such as millet, sorghum, teff, and fonio, form the backbone of food security in semi-arid regions. The continent accounts for 60% of global millet production

and nearly 30 million tonnes of sorghum annually, led by Nigeria, Sudan, and Ethiopia. Rural consumption of sorghum often exceeds 50 kg per capita yearly, yet urban markets lean heavily on maize. These resilient crops thrive in challenging conditions, requiring minimal water and poor soils, but laborintensive processing limits their commercial potential. Current applications, such as milling into flour or brewing into beer, represent only a fraction of their possibilities, with untapped opportunities in value-added products, industrial applications, and exports. In a panel discussion featuring Austin Kearby, Managing Director of Anchor Foods, Francis Mbaki, Head of Service Sales for East Africa at Bühler, Peter Muni, a seasoned milling industry consultant, and Prof. Catherine Kunyanga, Associate Dean at the University of Nairobi’s Faculty of Agriculture, these crops, long overshadowed by maize and wheat, can be processed, marketed, and embraced by modern consumption patterns.

EXPANDING THE SCOPE: FROM GRAINS TO CROPS

Francis Mbaki, Bühler’s Head of Service Sales for East Africa, reframed the discussion, urging a shift from "ancient grains" to "ancient crops" to include root staples like cassava and sweet potatoes. “A tuber is not a grain,” Mbaki noted. “Its higher moisture content and irregular sizes demand specialized equipment. Collaboration is key, we can’t solve these challenges in isolation.” This broader perspective underscores the need for tailored processing technologies to unlock the potential of diverse crops.

Austin Kearby, Managing Director of Anchor Foods and a small-scale sweet potato flour producer, shared insights into market challenges and opportunities. “Consumers often ask, What do I do with sweet potato flour?” he explained. By blending it with millet for nutrient-rich porridge, his team has created products that resonate with consumers for their sweetness, smoothness, and nutritional value. However, energy-intensive

drying processes remain a significant barrier, particularly for small-scale producers in East Africa.

Mbaki proposed innovative solutions, such as compact milling plants and “milling as a service” models, where farmers pay for processing without owning equipment. This approach, already successful in other regions, could democratize access to advanced technology for diverse crops like millet, sorghum, and cassava.

ADDRESSING SUPPLY CHAIN CHALLENGES

Peter Muni, a seasoned milling consultant, identified inconsistent supply as a critical obstacle. “Most millers aren’t familiar with millet or sorghum,” he said. “When they consider processing them, the first question is supply reliability.” In East Africa, these crops are rarely grown at commercial scale, leading to variability that complicates cleaning and grinding. Muni referenced past projects where equipment adaptation and collaboration with traditional users were essential to progress.

Regulatory compliance adds another layer of complexity. Muni advocated for early engagement with bodies like the Kenya Bureau of Standards, noting their openness to new product standards. Kearby highlighted the costbenefit dilemma for small and medium enterprises (SMEs): “Certification builds trust, especially for aflatoxin control, but the upfront investment can deter young entrepreneurs.” He acknowledged the value of standards in fostering consumer confidence, yet stressed the need for accessible pathways to compliance.

BRIDGING ACADEMIA AND INDUSTRY

Prof. Catherine Kunyanga, Associate Dean at the University of Nairobi’s Faculty of Agriculture, addressed the disconnect

"CERTIFICATION BUILDS TRUST, ESPECIALLY FOR AFLATOXIN CONTROL, BUT THE UPFRONT INVESTMENT CAN DETER YOUNG ENTREPRENEURS.''

between academic innovation and market adoption. “We have countless innovations—ready-to-eat products like sorghum crackers, millet pasta, and amaranth cereals that appeal to modern consumers,” she said. Yet, these remain confined to university labs due to weak industry linkages. To address this, the university is developing one of Africa’s largest extrusion units for training and small-scale production, aiming to empower graduates as entrepreneurs.

“The gap is in connection,” Kunyanga emphasized. “Students have patented innovations; companies seek new products. We need stronger partnerships to bridge this divide.”

COLLABORATION AS A CATALYST

Collaboration emerged as the cornerstone of progress. Mbaki underscored its role in overcoming technical challenges, from optimizing enzyme performance to reducing energy costs in milling. “No single company has all the answers,” he said, highlighting partnerships with research institutions and technology providers. Muni stressed supply chain resilience, noting that joint training and knowledge-sharing platforms could streamline operations and mitigate risks like supply delays or contamination.

Kunyanga advocated for formalized partnerships, such as memoranda of understanding, to protect intellectual property and foster trust. “Clear terms create a safe environment for testing and scaling innovations,” she explained, emphasizing the need for legal and technical clarity to drive commercialization.

A PAN-AFRICAN VISION

Bühler’s new Grain Application and Training Centre in Nigeria reflects the importance of regional customization. “Cassava and yam dominate in West Africa, while maize leads in East Africa,” Mbaki noted. “But diversification is gaining traction.” Bühler’s “Africa Grains Online” program aligns farmer capabilities with processor needs, fostering a cohesive supply chain.

Kunyanga captured the summit’s ethos: “These crops are our heritage, healthier, resilient, and ready to meet modern demands for safety, quality, and convenience.” Mbaki concluded with a call to action: “Challenges are opportunities. By working together, industry, academia, regulators, and farmers, we can unlock new markets and transform Africa’s food landscape.”

Bühler’s

Fourth Networking Days

Scaling Sustainable Innovation

BY MARTHA KURIA

Over 1,200 leaders from the food, feed, and sustainable mobility sectors gathered at Bühler Group’s headquarters in Uzwil, Switzerland, for the fourth Networking Days, a triennial event focused on scaling innovative solutions to address the needs of a growing global population and a warming planet. Held on June 23–24, 2025, and themed “Multiplying Impact Together,” the summit emphasized collaborative leadership, circular business models, and bold innovation as critical drivers for transforming industries and achieving sustainability at scale.

The event welcomed participants from over 90 countries across six continents, including representatives from global food manufacturers, technology innovators, academia, and public institutions. Bühler’s leadership stressed that the era of experimentation has ended, urging the rapid scaling of proven solutions to sustainably feed and mobilize 10 billion people by 2050. “The true power of innovation lies in its multiplier effect. When breakthroughs connect across businesses and industries, they create waves of change,” said Bühler CEO Stefan Scheiber.

DRIVING SUSTAINABLE BUSINESS THROUGH ACTION

A key message throughout the event was that sustainability is no longer optional, it is integral to long-term business success.

Bühler CTO Ian Roberts highlighted the company’s progress on its 2019 pledge to develop technologies that reduce energy, waste, and

water use by 50% across 15 key value chains. With nearly CHF 500 million (US$624 million) invested in R&D since then, Bühler’s technologies have achieved up to 80% savings in processes such as aluminum processing and chocolate production.

Johan Rockström, Director of the Potsdam Institute and creator of the Planetary Boundaries framework, urged business leaders to view sustainability as a competitive advantage. “Sustainability enhances competitiveness, resilience, and access to new markets. Communicate that clearly and consistently,” he said.

Leaders from Mars, Cargill, Nestlé, and AAK shared practical examples of sustainable transitions. AAK CEO Johan Westman explained how transforming its palm oil supply chain to achieve 91% deforestation-free sources by 2024 delivered both environmental benefits and increased profitability. “Palm oil has the highest yield per hectare of any oil crop,” he noted, underscoring its vital role in future food systems.

INNOVATION ANCHORED IN CIRCULARITY

Circular economy principles were a central theme. Michele Andriani of Andriani S.p.A. described how the company transformed production byproducts into new revenue streams, such as pet food and bioenergy, through partnerships with Bühler. Similarly, Illycaffè’s Andrea Illy outlined how coffee waste is repurposed for cosmetics and how regenerative farming is promoted among its growers. “Circularity isn’t just a sustainability concept, it’s a growth engine,” said Julia Binder, Professor at IMD, encouraging businesses to envision transformative innovations and map the steps to achieve them.

DATA, DIGITALIZATION, AND RESILIENT FOOD SYSTEMS

The second day expanded the discussion to trade flows, supply chain resilience, and food affordability. Rabobank’s Vito Martielli highlighted the growing grain trade driven by demand in Africa and China, while PTC’s Neil Barua emphasized digital tools like AI and predictive analytics to minimize disruptions. Panelists also addressed the challenge of delivering safe, affordable, and nutritious food amid rising global pressures. “Taste, nutrition, cost, and sustainability must all be achieved simultaneously, with taste remaining paramount,” said Cargill CTO Florian Schattenmann.

In Africa, companies like Naval Group and Partners in Food Solutions are establishing regional food production hubs and fostering cross-border expertise. “Let’s create an opportunity superhighway to transform Africa’s food systems, one factory at a time,” said Mandla Nkomo, CEO of Partners in Food Solutions.

The event concluded with an inspiring keynote from Francois Pienaar, former South African rugby captain, who spoke on integrity, courage, and leadership under pressure. Bühler’s Scheiber echoed this in his closing remarks: “Courageous leadership is essential to accelerate business transformation. Together, we can shape a better, more

sustainable future.”

WORLD-CLASS MILLING ACADEMY TO ADDRESS INDUSTRY SKILLS GAP

Building on the momentum of the 2025 Networking Days, where global leaders united to scale sustainable solutions for food security and industry transformation, Bühler Group launched a state-of-the-art Milling Academy at its Uzwil headquarters. This 1,800-square-meter facility is designed to empower food and feed millers with advanced training, equipping them to tackle the evolving challenges highlighted during the summit, such as stricter food safety regulations, sustainability targets, climate impacts, labor shortages, and supply chain instability.

The Milling Academy directly supports Bühler’s commitment to multiplying impact through innovation and collaboration. CEO Stefan Scheiber emphasized that by providing hands-on training and access to cutting-edge technologies, the academy ensures millers can implement sustainable practices and optimize processes, aligning with the event’s focus on scaling solutions to feed 10 billion people by 2050. “With the opening of our state-of-the-art Milling Academy, we are empowering the next generation of milling

professionals to drive continuous improvement across the food and feed sectors,” said Stefan Birrer, Head of Business Area Milling Solutions at Bühler.

The facility integrates seamlessly with Bühler’s innovation ecosystem, offering access to the Grain Innovation Center, an arena within the machine park, three high-tech classrooms, two laboratories focused on analytics and electronics, and a fully automated school mill with a 24-tonne-per-day capacity. These resources provide an immersive learning experience, enabling participants to master both modern and legacy machinery while adopting the circular economy principles and digital tools championed at Networking Days.

Dario Grossmann, Head of the Milling Academy, emphasized its learner-centric approach. “Participants tell us the Milling Academy sets a new standard for quality, reflecting the collaborative and innovative spirit of our global network. We’re ready to meet the growing demand for training as our customers strive to achieve sustainability and resilience.”

Offering over 100 courses annually in seven languages and the capacity to train more than 750 professionals, the academy also houses the School of Feed Technology (SFT), expanding its impact across food and feed sectors. Courses are modular and flexible, supporting on-site learning in Uzwil or at customer facilities worldwide.

BÜHLER’S GLOBAL LEARNING ECOSYSTEM

The Milling Academy complements Bühler’s global education network, which includes partnerships with Kansas State University in the U.S., the African Milling School in Nairobi, Kenya, and training mills in Wuxi and Changzhou, China. Participants can also engage with Bühler’s innovation infrastructure, including the Grain Processing Innovation Center in Nigeria, the Cocoa Competence Center in Côte d’Ivoire, and the International Rice Milling Academy in India.

Early trainees have praised the academy’s modern facilities, collaborative environment, and practical approach. “The infrastructure and concept are outstanding,” said Oliver Efrain Romero Lucero of CMI Alimentos, Guatemala. “The instructors are highly skilled, and the training materials are exceptionally well-prepared.” Jan Tuborg Pedersen from Denmark highlighted the integrated showroom and innovation center, describing the hands-on experience as “incredibly valuable.”

BÜHLER’S EXTRUSION WORKSHOP IN NAIROBI, KENYA

Reinforcing its commitment to advancing milling expertise in Africa, Bühler hosted its inaugural Food Extrusion Workshop from July 15–18, 2025, at the African Milling School in Nairobi. This first-of-its-kind workshop in Africa focused on enhancing skills in advanced extrusion processes critical to food production, including vacuum degassing, co-extrusion, remote-cut technology, and product coloring.

Participants explored the fundamentals of extrusion and how ingredients influence expansion, texture, color, and flavor through a blend of theory and hands-on learning. Sessions covered innovations like modified flours, breadcrumbs, reconstituted rice, and fortified blended foods such as super cereals. The Bühler twin-screw extruder facilitated practical training, allowing participants to evaluate samples and create products like breadcrumbs and dry textured protein flakes.

The workshop also featured live demonstrations at Proctor & Allan (EA) Ltd., showcasing modified flours, super cereals, breadcrumbs, breakfast cereals, and snacks. Participants delved into the science of puffing and drying, as well as the sensory aspects of cereals, snacks, and puffed products, gaining insights into how extrusion shapes consumer products and market trends. MMEA

Buhler Extrusion workshop attendees at Proctor & Allan

Dust Control Explosion Prevention and

Safeguarding Grain Milling and Processing Facilities

BY STEPHEN KIBE

Grain milling and processing facilities are vital to the global food supply chain, yet they operate under constant threat from one of the most underestimated hazards in industrial environments: combustible dust. Fine particles generated during milling, conveying, and storage can accumulate in the air and on surfaces, creating a volatile atmosphere where a single spark may trigger a catastrophic explosion. To mitigate these risks, facilities must implement comprehensive dust control and explosion prevention systems tailored to the unique challenges of grain handling operations.

THE NATURE OF THE RISK

Grain dust, when suspended in air at the right concentration, is not just combustible; it's a potential catalyst for a deflagration or even a secondary explosion, often more destructive than the initial blast. Common ignition sources include overheated bearings, static electricity, friction from moving parts, and electrical faults. Equipment such as bucket elevators, hammer mills, and dust collectors are particularly vulnerable due to their enclosed design and high particle throughput.

The consequences of dust explosions are severe: loss of life, structural damage, regulatory penalties, and long-term reputational harm.

PROACTIVE RISK MANAGEMENT IS NOT JUST A REGULATORY REQUIREMENT;

IT'S A MORAL AND OPERATIONAL IMPERATIVE

Therefore, proactive risk management is not just a regulatory requirement; it's a moral and operational imperative. Some of the examples of the case studies from Africa include the Quantum Foods Feed Mill Explosion that occurred in June 2024 in Malmesbury, South Africa, resulting in the death of one worker and serious injuries to two others. The incident triggered automated emergency protocols, including fire suppression systems, which helped contain the damage. The cause is still under investigation, but dust accumulation and ignition sources are suspected. In April 2022, the Spenza Maize Milling Factory Explosion in Kirinyaga County, Kenya, left a worker seriously injured. The incident led to disputes over compensation and raised concerns about safety protocols. Investigations pointed out possible dust ignition due to inadequate ventilation and dust accumulation.

A Kenyan study found that long-term exposure to grain dust in animal feed mills leads to reduced lung function in workers. This highlights serious health risks tied to inadequate dust control. Grain dust contains fine particles that, when inhaled over time, can impair respiratory health, causing conditions like chronic bronchitis or occupational asthma. The study emphasises the urgent need for protective measures such as proper ventilation systems and personal protective equipment (PPE) to safeguard workers in these environments.

DUST CONTROL SYSTEMS: THE FIRST LINE OF DEFENSE

BLT WORLD, working closely with the international ScrapeTec team, is a key partner across Africa, helping businesses optimise their conveyor systems by controlling dust emissions and preventing material spillage. ScrapeTec Systems, distributed by BLT WORLD, are advanced German-engineered solutions designed to tackle dust and material spillage in bulk conveyor operations. These systems, like AirScrape and DustScrape, float just above the conveyor belt, avoiding direct contact and thereby reducing wear and damage. Instead of relying on traditional friction-based skirting, ScrapeTec uses a clever combination of airflow and angled steel blades to redirect particles inward and trap fine dust. This not only improves material flow but also drastically cuts down on airborne dust, minimising health risks and explosion hazards at transfer points.

GENERAL STRATEGIES IN AFRICAN GRAIN FACILITIES

Effective dust control in grain handling facilities relies on a combination of engineering solutions and operational practices designed to minimise airborne particles and reduce explosion risks. Transitioning from open conveyors to enclosed systems, such as screw conveyors or pneumatic transport, greatly limits dust emissions during material movement and reduces worker exposure. Industrial dust collectors, including baghouse filters, cartridge collectors, and cyclone separators, capture fine particles at critical source points. Advanced models like the Donaldson Torit PowerCore CP Series offer compact, highefficiency filtration tailored to the demands of grain processing environments. Local exhaust ventilation (LEV) systems further enhance control by extracting dust directly from machinery through strategically placed hoods and ducts, maintaining airflow velocity to prevent settling and clogging.

Complementing these mechanical systems is rigorous housekeeping protocols. Facilities implement routine cleaning using explosion-proof vacuums and anti-static tools to prevent dust accumulation on surfaces such as floors, beams, and equipment. Scheduled cleaning and visual inspections ensure ongoing compliance and safety. Additionally, dust suppression technologies, such as fogging systems or chemical agents, are deployed at high-risk areas like transfer points and unloading zones to bind particles and reduce airborne concentrations. Together, these measures form a comprehensive approach to dust management, safeguarding both personnel and infrastructure.

CONTAINING THE THREAT: EXPLOSION PREVENTION SYSTEMS

While dust control reduces the likelihood of ignition, explosion prevention systems are designed to detect, isolate, and suppress combustion events before they escalate. Grain handling facilities employ a range of advanced safety technologies to mitigate the risks of fire and explosion caused by combustible dust. Spark detection and extinguishing systems use infrared sensors to monitor ducts and chutes for sparks or hot particles continuously. When a threat is detected, extinguishing mechanisms, often water mist or chemical agents, activate within milliseconds to neutralise the hazard without disrupting operations. Complementing this are explosion venting systems, which feature engineered panels designed to rupture at specific pressure thresholds, safely releasing combustion gases. For indoor environments where

SOURCE: SCRAPTEC

external venting isn't feasible, flameless venting options provide a contained solution that prevents flame discharge while relieving pressure.

To further enhance protection, explosion suppression systems are installed on high-risk equipment such as silos, mills, and dust collectors. These systems detect rapid pressure increases and deploy suppressant chemicals to extinguish the flame front before it can spread. Isolation devices play a critical role in containing explosions within specific zones of the facility. Equipment such as isolation valves, abort gates, and rotary airlocks are strategically placed to seal off interconnected machinery during an event, preventing flame propagation and minimising damage. Together, these technologies form a layered defence strategy that prioritises both operational continuity and worker safety.

HOW TECHNOLOGIES ARE REVOLUTIONISING DUST CONTROL

Emerging technologies are revolutionising dust control in grain handling and processing facilities, offering smarter, safer, and more efficient solutions. One major advancement is the use of automated dust monitoring systems, which rely on sensors to track airborne particle levels in real time. When dust concentrations exceed safe thresholds, these systems can trigger alarms or activate suppression mechanisms, allowing for immediate intervention and reducing the risk of ignition. Another innovation is the deployment of robotic cleaning units equipped with vacuum systems and brushes. These robots are particularly effective in confined or hazardous spaces such as silos and ducts, minimising the need for manual cleaning and significantly improving worker safety and operational efficiency.

Additionally, digital twins and simulation tools are being

used to create virtual models of grain handling environments. These models enable operators to simulate dust generation scenarios, identify problem areas, and optimise the placement of dust control equipment. Together, these technologies represent a proactive shift toward precision safety management in facilities where dust-related hazards are a constant concern.

REGULATORY COMPLIANCE AND BEST PRACTICES

In the United States, OSHA's Grain Handling Standard (29 CFR 1910.272) mandates dust control, ignition source management, and employee training. The National Fire Protection Association (NFPA) provides additional guidance through standards such as NFPA 61 (Agricultural and Food Processing Facilities), NFPA 68 (Explosion Venting), and NFPA 69 (Explosion Prevention Systems).

THE FUTURE OF SAFETY IN GRAIN MILLING OPERATIONS

Facilities must conduct a Dust Hazard Analysis (DHA) to identify potential ignition sources, vulnerable equipment, and mitigation strategies. This analysis should be updated regularly and integrated into operational protocols. Training employees to understand the risks, recognise early warning signs, and follow safety procedures, including lockout/tagout, confined space entry, and personal protective equipment (PPE) usage. Grain milling and processing facilities operate in a highrisk environment where dust control and explosion prevention are non-negotiable. By investing in tailored systems, ranging from advanced filtration and spark detection to explosion suppression and venting, operators can protect their workforce, preserve infrastructure, and ensure regulatory compliance. Safety is not a one-time investment but an ongoing commitment to vigilance, innovation, and responsibility. MMEA

Bridging Tradition & Convenience

Ryan’s Instant Porridge

BY MARTHA KURIA

In Kenya’s evolving food industry, convenience is increasingly shaping consumer choices, yet cultural heritage remains central to dietary preferences. James and Ben Enterprises, a Nairobibased startup, is bridging that gap with Ryan’s Instant Porridge, a product designed to combine traditional porridge with modern processing technologies for safety, nutrition, and ease of preparation. In an interview, Milling Middle East & Africa speaks with CEO and co-founder Kagwima Benson, who shares the journey from university-level product development to market launch, and the company’s ambitions to be “the king of the market.”

MMEA: Please introduce yourself and tell us about James and Ben Enterprises.

KAGWIMA: My name is Kagwima Benson, the CEO and co founder of James and Ben Enterprises. I hold a BSc in Food Science and Technology and have served in quality assurance, compliance, and food safety and quality management system development, including consulting for major companies in the Kenya. James and Ben Enterprises is a startup company based in Nairobi, Kenya, incubated at the Kenya Industrial Research and Development Institute (KIRDI). Here, my role is to provide an environment that creates potential for every employee that works with us so that we consistently meet customer satisfaction targets and achieve sustainable financial performance.

MMEA: What inspired you to start this venture in convenience foods?

KAGWIMA: The inspiration was to deliver

Benson Kagwima, CEO, Ryan Instant Porridge Products

“health and nutrition in a convenient and easy to prepare way that will save on time, while serving vulnerable groups such as weaning babies and busy urban and peri urban households. During our feasibility study, we recognized that imported convenience cereals like cornflakes and puffs are often unavailable or unaffordable, and many consumers don’t associate with it. Porridge, by contrast, resonates deeply with local traditions. With our flagship brand Ryan’s Instant Porridge, it was designed to deliver modern convenience without compromising nutrition or cultural familiarity.

Product development began in 2018 at university level. We subsequently incubated at KIRDI and secured certification to launch in August 2024. The company marks one year in market as of August 2025.

MMEA: Why the brand name ‘Ryan’s’?

KAGWIMA: Brand strategy was deliberate: a name that communicates the unique selling proposition and long term vision, to make Ryan’s synonymous with “ready to eat porridge. Ryan comes from a Greek origin, meaning that it’s kingly, signalling the intent to be the king of the market. Interestingly, some consumers purchase simply because a child or grandchild is named Ryan, proof the name connects with families.

MMEA: Please take us through the production process of Ryan’s Instant Porridge

Ryan’s Instant Porridge is made from a carefully curated blend of sorghum, soya, maize, and sweet potatoes. This combination was perfected through extensive trials to balance nutrition, functionality, and consumer appeal. Understanding ingredient chemistry was critical such as starch characteristics (amylose/ amylopectin ratios) affect hydration and lumping. The team chose raw materials they understand and the chemical composition behind, so the product disperses smoothly and delivers the intended mouthfeel while providing essential nutrition.

The production process is a blend of precision and innovation. Using conventional milling followed by extrusion cooking, we transform raw ingredients into an instant flour. “It’s like bringing your home kitchen to an industrial scale.” Ground ingredients are extruded at around 140 °C, where shear and friction cook the product, drive off moisture, and provide a sterilizing effect. The cooked extrudate is then milled to specification.

The result is a fine flour that reconstitutes in hot water within seconds, ready to serve.

MMEA: How do you ensure product safety and consistency?

KAGWIMA: Food safety starts with raw material reception. We source directly from farmers and aggregators, with supplier approval audits in place. Extrusion technology ensures microbial safety, while protective packaging, using resealable pouches maintains quality. We are KEBS certified, which validates our compliance with food safety and labeling requirements.

Processing follows KEBS standards, with strict operating procedures, sensory evaluations, and staff training. “A cooked product should not be grainy, should not have a rough texture, and it should have a mouth feel that is very soft.” Batches are also checked against packaging recipes for functional consistency. Staff and visitors must wear PPE; “there is no direct contact between the personnel and the product process.”

MMEA: How has the market responded so far?

KAGWIMA: The response has been very positive. Monthly output has grown from about 250 kg when we started to 1.5–2.0 tonnes We are already in more than 30 supermarket outlets within Nairobi, working to introduce our products in other major urban centers. We also offer home deliveries.

Demand sometimes outstrips supply, which has pushed us to improve our inventory management. Customers appreciate the convenience, safety of the product. We have ensured customers can effectively use the product by providing preparation guidance printed on the park and reinforced through social media demos and seasonal recipe cards during our campaigns. In addition, packaging is segmented by market. We have 250 g and 500 g pouches for household customers in resealable, water resistant pouches, and bulk packaging for institutional buyers. A cup per pack promotion reinforces “porridge on the move.”

Beyond retail, Ryan’s collaborates with NGOs such as Tabasamu Alliance, private institutions, and universities particularly Egerton University to run awareness and access programs. Tabasamu Alliance subsidizes porridge for children in daycare programs so “every kid should have a cup of porridge whenever they want at any time.” Making bulk cooked porridge is impractical and unsafe to hold at day care

level, because children arrive at intervals unlike schools where children follow a strict meal time. With instant porridge, a caregiver makes a fresh serving per child, cutting waste, reheating cycles and contamination risk while saving time and energy. The campaign aligns with the brand promise: nutrition, convenience, dignity.

MMEA: What challenges have you faced in sourcing raw materials and processing?

KAGWIMA: Two stand out: aflatoxin risk in maize and price volatility driven by seasonality. “By mid year, there is no maize again,” pushing prices up. The company cushions shocks through inventory management, buying in bulk when feasible, while keeping consumer purchasing power in view. For sweet potatoes, sun drying caused discoloration and long cycle times, so the team has partnered with a company that does good drying with a dryer. However, because extrusion can accept higher pre extrusion moisture (≈25–30%), we don’t have to dry the sweet potatoes to a lower moisture because the operation blends efficiently and targets a final flour moisture ≤13% for shelf stability. This is an advantage to us in cost reduction. Technology constrains is another challenge. Extrusion capacity and service support are scarce. “If your extruder fails, you find that you are the only player in the market. James and Ben mitigates risk through its KIRDI production contract, but sector wide, more accessible extrusion services would accelerate SME innovation.

MMEA: Who are your main competitors, and how do you differentiate?

KAGWIMA: We compete with both imported brands and local instant flour producers. Our edge lies in using natural, locally sourced ingredients and maintaining strong customer engagement. Unlike imported brands that may not understand local preferences, we listen to feedback and adapt our products

to community needs.

MMEA: Do you plan to diversify beyond porridge?

KAGWIMA: Yes. While Ryan’s Instant Porridge is our flagship product, we are already developing other instant flours, including millet-based varieties. A millet-based instant flour has already been certified, though the team is addressing processing challenges related to millet’s unique chemical composition. Our long-term goal is to become the go-to brand for convenient, nutritious meals in Kenya and beyond.

MMEA: How does your work support Kenya’s food and nutrition security initiatives?

KAGWIMA: We address food security through accessibility, affordability, stability, and utilization. By sourcing locally, we support farmers and reduce food loss. By sourcing locally and supporting contract farming, the company reduces postharvest losses and strengthens farmer livelihoods, contributing to a more resilient food system.

MMEA: What advice would you give to young entrepreneurs in the food industry?

KAGWIMA: Entrepreneurship can be lonely and challenging, but surrounding yourself with the right team makes all the difference. Build resilience, stay close to your customers, and never compromise on quality. Technology and innovation should be embraced as tools to solve challenges in nutrition and food security.

MMEA: Finally, what legacy do you hope to leave with this venture?

KAGWIMA: I want James and Ben Enterprises to be remembered as a champion of food security, using technology and innovation to deliver nutritious, culturally relevant, and convenient meals. Our vision is to set a standard for local enterprises proving that Kenya can produce safe, high-quality convenience foods that compete with global brands. MMEA

Grain Drive Tanzania's

BY MARTHA KURIA

Tanzania, an East African country situated just south of the Equator, was formed as a sovereign state in 1964 through the union of the theretofore separate states of Tanganyika and Zanzibar. With a population exceeding 65 million as of 2025, the country relies heavily on agriculture as the backbone of its economy. The country boasts 44 million hectares of arable land, of which about 29.4 million hectares are suitable for irrigation, though only a fraction is currently utilized. The sector contributes nearly 30% to the country's Gross Domestic Product (GDP) and employs about three-quarters of the workforce. Among agricultural commodities, grains play a

pivotal role in ensuring food security, providing livelihoods, and driving economic activities. Major grains in Tanzania include maize (corn), rice, wheat, sorghum, and millet, which together form the staple diet for the majority of the population. Per capita grain intake is estimated at 150-200 kg/year. Maize alone accounts for over 80% of dietary calories, with a per capita consumption estimated at 100 kg/person.

MAIZE: RISING TO AFRICA’S NO. 2 PRODUCER

Maize is the dominant grain in Tanzania, serving as a staple crop and accounting for a significant portion of the country’s export revenue. Key

production regions include the Southern Highlands and the Lake Zone, where soil and climate conditions are suitable. Yields typically average 1-2 tons per hectare (t/ha), which is well below potential levels due to limited access to improved seeds, irrigation, and mechanization.

For MY 2023/24, estimates from the United States Department of Agriculture (USDA) anticipated harvests at 6.1 MMT. However, recently, the Ministry of Agriculture revealed that the country harvested an impressive 11.7 million tonnes in the 2023/24 season, surpassing Nigeria to claim the title of Africa’s second-largest maize producer.

According to the April 2025 USDA report, maize production in Tanzania is forecast at 6.8 million metric tons (MMT) in 2025/26, a 3% decline (200,000 metric tons (MT)) from the prior year, and area harvested to decrease by 2.44 percent to four million hectares. Post attributes the decline primarily to below-average short rains (“Vuli”) in late 2024, input distribution delays, and pest pressure from

fall armyworm. The decline is also driven by farmers shifting to alternative crops due to low maize prices, which ranged from US$0.59 to US$1.41 per kilogram. Maize consumption was forecasted at 6.08 MMT in MY 2024/25, a decrease from 6.3 MMT the prior year, due to high prices and substitution with other staples.

Tanzania remains a net exporter of maize to neighboring countries, especially Kenya, Uganda, Rwanda, the Democratic Republic of the Congo, and Malawi, becoming a crucial part of the regional food supply chain. In 2023, Tanzania exported US$71.7M of Corn, making it the 36th largest exporter of Corn (out of 158) in the world. For 2025/26, the USDA projects corn exports to decrease by 10 per cent year-over-year, reaching approximately 900,000 metric tons. Post attributes the decline to the fact that traders are facing significant challenges in obtaining export permits through official channels, as the procedures have become increasingly stringent and bureaucratic.

MAIZE PRODUCTION IN TANZANIA MY 2015/16-MY2025/26

RICE: STAPLES UNDER PRESSURE FROM URBAN DEMAND SHIFTS

Tanzania is the largest rice producer in East Africa, producing nearly twice the combined output of other East African countries like Kenya, Uganda, and the Democratic Republic of Congo. The crop is Tanzania’s second most important grain, and the government has identified it as a strategic crop. The strong output is driven by initiatives like the National Rice Development Strategy (NRDS), which aims for even greater output, targeting 8.8 million tonnes by 2030.

Primary production areas are Morogoro and Mbeya in the Southern Highlands, where water availability supports paddy cultivation. In 2015/16, rice was cultivated on 1.15 million hectares, producing about 2.94 million tonnes of paddy (rough rice) at an average yield of 2.54 tonnes per hectare. By 2019/20, yields had improved significantly to 3.30 tonnes per hectare, pushing rough production to 3.48 million tonnes even though the cultivated area slightly declined to 1.05 million hectares. Current yields range from 2-3 t/ha, reflecting progress but still below global benchmarks due to inconsistent access to quality inputs and infrastructure.

Production for 2025/26 is projected at 2.51 MMT (milled basis), slightly below the previous year due to delayed planting and disease pressure, particularly bacterial leaf blight. However, the country remains a net exporter of rice to neighboring countries, with the USDA projecting rice exports to decline significantly by 50 percent to 50,000 metric tons year-

RICE PRODUCTION IN TANZANIA

MY 2015/16-MY2025/26

on-year, down from 100,000 metric tons in the previous marketing year 2024/25 on stringent bureaucratic export procedures implemented by the Government of Tanzania since 2023.

WHEAT

Wheat production in Tanzania is relatively minor compared to other grains, with the country heavily reliant on imports to meet demand. According to USDA data, the five-year average (2020/21–2024/25) for wheat production stands at 77,000 metric tons (MT), harvested from an average area of 61,000 hectares (ha), with an average yield of 1.27 MT/ha. The USDA forecasts a 10% year-onyear increase in 2025/26, reaching 80,000 MT, driven by government initiatives to boost output. Annual demand is around 1 million MT, with consumption projected to rise by 4% to 1.175 million MT in 2023/24, fueled by population growth, urbanization, and tourism. In 2023, Tanzania imported US$466 million worth of wheat, ranking as the 38th largest importer globally. Import volumes are estimated at 800,000–1 million MT annually, with a bill of about US$221 million. USDA projects a 15.4 percent increase in wheat imports for MY 2025/26, reaching 1.5 million MT to meet rising domestic demand.

TANZANIA IS A NET EXPORTER OF MAIZE BECOMING, A CRUCIAL PART OF THE REGIONAL FOOD

SUPPLY CHAIN.

The Tanzanian government, however, has set ambitious plans to scale up production to 1 million tons by 2025 through the adoption of improved seeds and enhanced agricultural practices.

SORGHUM

Sorghum is a drought-resistant grain well-suited to Tanzania's arid and semi-arid regions, providing a reliable food source in areas with unreliable rainfall. Over 70% of production is used domestically for human consumption (as flour for porridge or ugali) and animal feed, with the remainder for brewing and minor industrial uses.

Annual production hovers around 0.8-1 MMT,

TANZANIA EXPORT SHARE OF RICE TO THE NEIGHBORING COUNTRIES

forming part of the combined sorghum and millet output of 1.5-2 MMT. Key regions include central Tanzania, such as Dodoma and Singida, where it thrives on marginal lands. According to FAOSTAT data, sorghum production in Tanzania has shown fluctuations but remained relatively stable in recent years. In 2023, production reached 737,800 metric tons from an area of 683,900 hectares, yielding about 1.08 metric tons per hectare. This represents a slight decline from earlier estimates, such as around 1 million metric tons in 2020, partly due to erratic rainfall and pest pressures. The Tanzania Ministry of Agriculture's Annual Report for 2023/2024 reports sorghum production at 821,922.9 tons, aligning closely with FAOSTAT figures and reflecting a broader increase in cereal output from 11.42 million tons in 2022/2023 to 18.94 million tons in 2023/2024, a 65.9% rise attributed to adequate rainfall, enhanced extension services, and greater input use.

MILLET

Millet production in Tanzania is concentrated in the central and northern regions, with Dodoma accounting for 18% of the total output, Tabora for 12%, and Shinyanga for 11%. According to USDA FAS estimates, Tanzania's millet production has

averaged approximately 326,000 metric tons (MT) over the past decade, with recent figures indicating 282,000 MT in 2023/24 and a projected increase to 325,000 MT in 2024/25, representing a 15% year-on-year growth. The five-year average (2020-2024) stands at 320,000 MT, with projections for 2025/26 at 330,000 MT, a 3% increase. Production is expected to remain stable, but it faces challenges from climate change. The Ministry of Agriculture is focusing its efforts on improving seeds and irrigation to boost yields.

CHALLENGES FACING TANZANIA’S GRAIN SECTOR

The industry grapples with low mechanization, high energy costs, and post-harvest losses (up to 40%). Food safety and fortification compliance also remain inconsistent. Aflatoxin contamination and inadequate storage affect quality. However, the Tanzanian Initiative for Preventing Aflatoxin Contamination (TANIPAC), launched five years ago, is on the brink of completion, offering renewed hope for safer grains in Tanzania and the broader East African region. This comprehensive project, part of Tanzania’s Development Vision 2025 (TDV 2025), was initiated to address the persistent issue of aflatoxin contamination,

IN NUMBERS 50%

DECLINE IN RICE EXPORT IN 2025/26

SOURCE: FAOSTAT, 2021

which has plagued Tanzania’s maize and other key crops, affecting both local consumption and exports.

GRAIN STORAGE CAPACITY: SCALING UP FOR SURPLUS MANAGEMENT

Tanzania's current grain storage infrastructure is managed primarily by the National Food Reserve Agency (NFRA), which operates 30 facilities with a total capacity of approximately 286,000 metric tons (MT) as of 2024. This represents an increase from 246,000 MT in 2023, reflecting incremental improvements but still falling short of national needs. The country plans to reach 3 million tons storage capacity by 2030.

The government has prioritised expansion through a US$450 million investment to boost NFRA's capacity to 1.1 million tons by mid-2025. In August 2024, the National Food Reserve Agency (NFRA) of Tanzania inaugurated a stateof-the-art silo complex in Babati District, Manyara Region, marking a significant milestone in the country’s efforts to enhance crop processing and storage capabilities. Valued at TZS 18 billion (US$7.2 million), this ultramodern facility is designed to handle various crops, including maize, sunflower, barley, soybeans, and sorghum, aiming to increase storage to between 700,000 and 1,000,000 MT by June 2025.

The government, through Big Results Now (BRN is working on decentralized warehouses, each averaging 300 MT, with 275 maize-specific facilities built across eight districts. The Warehouse Receipt System (WRS) links these to credit access, benefiting over 165,000 households and reducing losses through better handling.

BALANCING TRADITIONAL MILLS AND INDUSTRIAL GROWTH

Tanzania's maize milling is fragmented and less industrialized compared to Kenya's concentrated model. The industry is overwhelmingly represented by small “posho” and micro-mills, processing staples, primarily maize, wheat, and rice. A 2022 census reported 33,721 mills nationwide, primarily small-tomedium-scale, producing 95% of maize flour.

Wheat milling capacity has grown to 10,000 metric tons (MT) daily by 2022, though reliance on imports. Rice milling is thriving, with Tanzania leading East Africa in production (2.4 million MT in 2023/24), exporting to Uganda and Kenya.

Key players include Bakhresa Grain Milling, with its Azam brand and 120,000 MT storage capacity, and Mohammed Enterprises (MeTL), which processes 300 tons of maize and 500 tons of wheat daily. Camel Flour Mills (650 MT/day) and Marenga Millers (50 MT maize flour, 75 MT feed) are also significant, alongside the government’s Cereals and Other Products Board, investing US$8.7 million in new processing plants.

The feed industry, fueled by maize and sunflower, supports Tanzania’s expanding poultry, livestock, and aquaculture sectors. Feed demand is projected to reach 9 million MT by 2035, driven by tourism recovery and policy changes like the 2017 removal of an 18% feed tax.

ADVERTISE IN MILLING MIDDLE EAST & AFRICA - NO.1 GRAINS INDUSTRY MAGAZINE & WEBSITE

Top 10 Global Gluten-Free Grains and Pseudocereals

1 Rice

Rice remains the world’s most widely used gluten-free flour base. With 2024/2025 global production estimated at 540.83 million metric tons, rice is unmatched in availability and versatility. Its neutral flavour and fine texture make it a natural choice for baked goods, noodles, and blended flours.

2

Maize

Maize is another cornerstone of gluten-free blending. Global production for 2024/2025 is projected by the USDA to be 1.23 billion metric tons. Its flour adds structure, colour, and a mild sweetness in flatbreads, tortillas, and baked goods. In Africa, where maize is already a dietary staple, it is a natural fit for composite flour applications.

3

Sorghum

Sorghum has carved out a strong role in gluten-free formulations, thanks to its resilience in arid regions. Production for 2024/2025 is estimated at 62.37 million metric tons by the USDA, with Africa, India, and the United States as leading producers. Rich in antioxidants and dietary fibre, sorghum is a great choice for gluten-free bakery products

4

Millet

Millets are experiencing a resurgence in global recognition. Once considered underutilised, these drought-tolerant grains are celebrated for their adaptability and nutritional value. Global production for 2024/2025 is forecast at 29.17 million metric tons. Long a staple in Africa and Asia, millets are now gaining traction in modern diets driven by the popularity of ancient grains.

Oats

5 (Certified Gluten-Free)

Although naturally gluten-free, oats have historically faced risks of cross-contamination. Certified gluten-free oats are increasingly used in bakery products, snack bars, and cereals. Global oat production for 2024/2025 is projected at 22.59 million metric tons, while the gluten-free oat market alone was valued at more than US$250 million in 2024.

6

Buckwheat

Despite its name, buckwheat is a pseudocereal prized for its high-quality protein and compounds such as rutin. Global production reached about 2.2 million tons in 2023, led by Russia, China, and Ukraine. Buckwheat is used in soba noodles and gluten-free blends, and its earthy flavour and nutrient density secure its place among the top glutenfree ingredients.

7

Teff

Native to Ethiopia and Eritrea, teff has long been the primary ingredient in injera bread. Recent production figures indicate Ethiopia grows around 0.5 million tons annually on more than 2.4 million hectares. Rich in iron, calcium, and fibre, teff is drawing global attention for gluten-free baking and sports nutrition.

8

Fonio

Fonio, a heritage grain from West Africa, is rapidly gaining prominence on the global stage. Regional production ranges from 600,000 to 700,000 tons annually, with Guinea, Nigeria, and Mali as leading producers. Known for its nutty flavour, quick cooking time, and high micronutrient content, fonio thrives in poor soils with minimal inputs

Amaranth

Another ancient pseudocereal, amaranth is valued for its resilience and nutrient richness. It is particularly high in lysine, an essential amino acid often lacking in cereals, making it an ideal complement in composite flours. Amaranth is used in porridges, snack bars, and gluten-free baked goods, and is increasingly cultivated in regions prone to drought.

Quinoa

Quinoa has evolved from an Andean staple to a global superfood. While Bolivia and Peru remain leading producers, cultivation now extends to North America, Europe, and parts of Africa. With its balanced amino acid profile, high protein content, and versatility, quinoa continues to drive demand in baked goods, snacks, and blended flours.

Alternative Grains & Buckwheat’s place

The Rise of in the Spotlight

BY WANGARI KAMAU

In recent years, the global demand for alternative grains has increased rapidly, driven by shifting dietary preferences, the rise of plant-based diets, and growing awareness of gluten-related health issues. According to Global Market Insights, the global gluten-free food market was valued at US$12.9 billion in 2024 and is projected to climb to US$33 billion by 2034, growing at a CAGR of 9.9%. While gluten-free products were once a niche offering for people with celiac disease, they now appeal to a far broader audience, including those with non-celiac gluten sensitivity and health-conscious consumers seeking perceived digestive, cardiovascular, or energy benefits. This evolving demand is creating space for a diverse range of crops, from quinoa and teff to one of the lesser-known but nutritionally powerful options: buckwheat.

Buckwheat (Fagopyrum esculentum) is not a true cereal but a pseudocereal, produced for food much like grains, but botanically unrelated to the grass family. First cultivated in China over 5,000 years ago, buckwheat is today grown most extensively in Russia and China. Its agronomic appeal is significant as it thrives on marginal soils, requires low inputs, and matures in as little as 30 days, making it an ideal emergency or rotational crop. Its dense canopy suppresses weeds, and it needs fewer pesticides, herbicides, and nitrogen than many other grain crops, making it a natural fit for organic systems.

BUCKWHEAT PRODUCTION AND MARKET TRENDS IN AFRICA

While Europe and Asia dominate global buckwheat production, together accounting for over 90% of the world’s supply, Africa’s footprint, though modest, is showing steady growth. Tanzania is by far the continent’s powerhouse, producing approximately 95% of Africa’s buckwheat, with an estimated 22–23K tons annually, representing less than 1% of global output. This dwarfs output from the second-largest producer, Egypt, which yields under 800 tons per year.

According to data from IndexBox, production levels across the continent have remained relatively stable in recent years, with average yields of 1.1 tons per hectare and a harvested area holding steady at 22K hectares. The most notable expansion occurred in 2015, when production volumes saw a near 5% spike, but since then, growth has been modest.

Africa’s buckwheat output was worth around US$7.9 million in 2024, representing a gradual increase over the past decade (+2.5% CAGR since 2013). However, market volatility has been evident, with peaks in 2015 and 2019 followed by periods of stagnation.

Consumption tells a similar story of concentration and cautious optimism. Tanzania again leads the way, accounting for roughly 85% of total buckwheat consumption, equivalent to 313 kg per 1,000 people, far above the global average. Ethiopia follows distantly but with remarkable momentum, growing at +18% annually over the last decade, while Nigeria, Egypt, and a handful of North African countries maintain smaller but stable consumption bases.

Trade flows reveal Africa as a net importer, with Ethiopia dominating import volumes at over 1.8K tons (71% of total imports), followed by Nigeria and Morocco. Interestingly, Morocco’s imports have surged at an eye-catching +71% CAGR between 2013 and 2024. On the export side, Tanzania remains the principal supplier, although volumes have been declining, while Uganda has emerged as a small but fast-growing player.

Looking ahead, market forecasts suggest that Africa’s buckwheat sector could grow at a +0.8% CAGR in volume and +1.5% in value through 2035, potentially reaching US$15 million. While this growth is modest compared to other regions, rising health awareness, changing diets, and increased availability through e-commerce could gradually position buckwheat as a more significant staple in niche African markets.

NUTRITIONAL PROFILE OF BUCKWHEAT: A POWERHOUSE PSEUDOCEREAl

Buckwheat’s nutritional value sets it apart from many other gluten-free grains and pseudocereals. Its dehulled seeds, or groats, contain around 12% protein with a high biological value, offering all essential amino acids, including lysine, leucine, valine, methionine, and tryptophan, making it a rare complete plant-based protein source. The most valuable protein fractions, albumins and globulins, account for up to 65% of its protein content, while its low prolamin levels make it suitable for those with celiac disease.

RISING HEALTH AWARENESS, CHANGING DIETS, AND INCREASED AVAILABILITY THROUGH E-COMMERCE COULD POSITION BUCKWHEAT AS A MORE SIGNIFICANT STAPLE IN NICHE AFRICAN MARKETS.

Carbohydrates in buckwheat seeds are primarily starch, comprising 58–70% of the seed, with a notable proportion of resistant starch that supports colon health, improves glucose metabolism, and contributes to a low glycaemic index. Dietary fibre makes up 5–11% of the seeds, with both soluble fractions (pectin, gums) that help lower cholesterol and regulate blood sugar, and insoluble fractions (cellulose, lignin) that aid digestion and bind bile acids.

Though modest in fat content, generally 3–4%, buckwheat delivers beneficial fatty acids, with oleic and linoleic acids as the dominant unsaturated fats, and palmitic acid as the primary saturated fat. Its mineral profile is equally impressive, providing magnesium, zinc, potassium, phosphorus, iron, copper, and manganese in quantities that compare favourably to common cereals.

Adding to its appeal, buckwheat contains rutin, a potent flavonoid known to strengthen blood vessels and support cardiovascular health. These attributes, combined with its versatility in products ranging from soba noodles to glutenfree breads, position buckwheat as a valuable ingredient in modern, health-conscious, and functional food applications.

BIOLOGICALLY ACTIVE COMPOUNDS IN BUCKWHEAT

Beyond its impressive macronutrient and mineral profile, buckwheat offers an array of biologically active substances that enhance its value as a functional food ingredient. Rich in B-group vitamins, including thiamine, riboflavin, niacin, pantothenic acid, and pyridoxine, it supports energy metabolism and nervous system health. Sprouted buckwheat also provides vitamin C, while its seeds contain vitamin E (tocopherols) and choline, an essential nutrient involved in liver function and neurotransmitter synthesis.

One of buckwheat’s most celebrated bioactives is rutin, a flavonoid with antioxidant and anti-inflammatory properties that help reduce blood pressure, strengthen capillaries, and lower the risk of arteriosclerosis. Alongside rutin, buckwheat contains quercetin, orientin, vitexin, and other phenolic compounds, with concentrations varying across the plant’s flowers, leaves, and seeds. These flavonoids act as natural antioxidants, protecting cells from oxidative damage and

IN NUMBERS

potentially reducing the risk of chronic diseases.

Polyphenol content in buckwheat is influenced by cultivar, growing conditions, and plant maturity, with leaves often holding the highest levels. However, rutin is concentrated mainly in the hulls, meaning milling processes can significantly affect the final flavonoid content of groats and flours.

While buckwheat’s health-promoting compounds are a strong advantage, awareness of potential sensitivities is important. Allergic reactions, though relatively rare outside Asia, can be severe, and the leaves contain phototoxic fagopyrins, which are not typically present in groats or flour. Nevertheless, when processed appropriately, buckwheat remains a nutrientdense, antioxidant-rich crop with significant potential in health-oriented food product development.

BUCKWHEAT IN FOOD PROCESSING AND MILLING

For millers and food processors, buckwheat offers both technical and market advantages. As a pseudocereal with naturally gluten-free properties, it can be positioned in high-value product lines targeting consumers with celiac disease, gluten sensitivity, or those following gluten-free diets for lifestyle reasons. With the global gluten-free food market projected to more than double in size by 2034, buckwheat represents an ingredient that can diversify a mill’s portfolio beyond conventional wheat or maize

According to a 2021 book on pseudocereals by Tatiana Bojňanská et al., buckwheat milling typically involves hulling the triangular seeds to remove the fibrous outer layer, followed by grinding into flour.

The flour

has a distinct, earthy, nutty flavour and a darker colour, which can be used to differentiate premium product lines. In composite flours, buckwheat blends well with rice, millet, or maize flour to improve protein quality, amino acid balance, and micronutrient density. This makes it ideal for producing gluten-free bread, biscuits, pasta, and noodles. In particular, the grain’s gelatinisation characteristics give it good binding and moisture-retention qualities, useful in maintaining structure in gluten-free baked goods that often suffer from crumbling or dryness.

Beyond bakery applications, buckwheat groats can be processed into breakfast cereals, granolas, and snack products. Roasted groats, known as kasha, retain their shape and provide a chewy texture, making them suitable for readyto-eat grain salads and meal kits. Extrusion technology enables processors to transform buckwheat into puffed snacks or instant porridge flakes, which have a longer shelf life and quick rehydration properties, making them attractive to both domestic and export markets.

In the functional food sector, buckwheat’s high rutin content provides a marketing advantage. Rutin is a bioactive flavonoid with established benefits for vascular health, antiinflammatory action, and antioxidant capacity. Milling by-products such as hulls can be valorised into nutraceutical powders, tea blends, or even functional beverage ingredients. This aligns with the growing demand for plant-based health solutions in the urban, health-conscious markets of the Middle East and Africa.

Buckwheat also has potential in the plantbased protein segment. Bojňanská et al. provide that buckwheat’s protein digestibility-corrected amino acid score (PDCAAS) is relatively high for a plant source, and it contains all eight essential amino acids. This makes it attractive for fortifying gluten-free pasta, meat analogues, or protein bars. Cold milling and fine micronisation technologies can be used to produce high-protein buckwheat flour for sports nutrition powders or specialised dietary products.

For millers in regions where buckwheat is not yet widely cultivated, such as much of Africa and the Middle East, opportunities lie in importing buckwheat groats or flour for speciality processing. Small-scale processors can target premium niches, such as artisanal bakeries, vegan restaurants, and health-food retailers, while industrial-scale players can explore integrating buckwheat into ready-meal components and snack lines. MMEA

BAKING SNACKS &

MIDDLE EAST & AFRICA

Rising Occasion to the

How the Baking Industry is Embracing Sustainable Packaging

BY MARTIN MUCHA

For time immemorial, baked treats have been a universal comfort, whether it is a delicious doughnut from the local bakery or a batch of chocolate chip cookies from the supermarket. However, behind all this indulgence, lies a hidden menace that if not properly handled, could lead to devastating effects. Traditional packaging for baked goods, often made from plastic or nonrecyclable materials, has long been a problem. Thankfully, the baking industry is stepping up with real-world solutions that help reduce waste and carbon footprint.

WHY PACKAGING MATTERS

Billions of individually wrapped baked goods are sold globally every year. This volume has a significant environmental impact, as traditional wrappers like plastic bags and foil-lined boards take centuries to break down and frequently end up polluting our oceans and landfills.

On the flip side, packaging serves crucial functions to baked goods. Good packaging keeps baked goods fresh, prevents contamination, communicates vital information like nutritional facts and expiry dates, and helps attract customers. Therefore, the challenge becomes finding packaging that performs all these functions and remains environmentally friendly.

SUSTAINABLE PACKAGING AT A GLANCE

Sustainable packaging is any form of packaging designed to reduce or mitigate any negative impacts to the environment, meaning that the packaging is made from recycled or renewable materials, is compostable or biodegradable, or it

can be easily reused or recycled. In some cases, it is a combination of all these.

For the baking industry, sustainable packaging could look like: compostable wrappers for cookies, recyclable cardboard boxes for cakes, biodegradable cellophane bags for bread or reusable tins or glass containers for pastries. According to Cypress Research, 62% of wholesale bakers and 61% of ingredient suppliers are currently engaged in sustainable packaging programs, which is notably higher than the general manufacturing average, that stands at 54%.

The global sustainable packaging market size is accounted at USD 126.50 billion in 2025 and is forecasted to hit around USD 240.52 billion by 2034, representing a compound annual growth rate (CAGR) of 7.42% from 2025 to 2034, according to a recent report released by Precedence Research.

WHY THE SHIFT NOW?

Sustainability has been a growing concern for decades, but several recent factors have pushed the baking industry to act faster.

Companies are increasingly recognizing that they have a role to play in tackling climate change and reducing waste. For many brands, sustainable packaging is more than just a marketing trend; it is a core part of their mission. Big bakers and suppliers like Grupo Bimbo, TC Transcontinental, Amcor, and Bimbo Bakeries USA are embedding sustainability into their core business plans.

Contemporary consumers are increasingly demanding more sustainability from the brands that they love. Today’s shoppers are more

MANY COUNTRIES ARE BANNING SINGLE-USE PLASTICS OR IMPOSING TAXES ON NONRECYCLABLE MATERIALS, FORCING BUSINESSES TO ADAPT ACCORDINGLY

environmentally aware than ever. They are reading labels, asking questions, and choosing brands that align with their values. A Nielsen study found that 73% of global consumers say they would definitely or probably change their consumption habits to reduce environmental impact, including how their food is packaged. Similarly, an EcoFocus study revealed that 68% of shoppers consider responsible packaging highly important.

Laws and regulations around packaging waste are also tightening. Many countries and regions are banning single-use plastics or imposing taxes on non-recyclable materials, forcing businesses to adapt accordingly.

Additionally, thanks to advances in materials science and design, sustainable options are more accessible and effective than ever. Compostable films, edible packaging, and plant-based plastics are no longer futuristic ideas, but real, viable solutions being used today.

EXAMPLES OF SUSTAINABLE PACKAGING PRACTICES

Many companies are ditching traditional plastic and opting for materials that can be recycled or composted. For example, some are using kraft

paper boxes with minimal ink, which can be tossed straight into the recycling bin or compost pile. Eco-friendly cellophane (made from cellulose, a plant-based material) is becoming more common as a clear wrapping for baked goods. It looks and feels like plastic, but it breaks down naturally and safely.

Additionally, brands are adopting minimalist designs that use fewer materials and focus on functionality. For example, using a simple wrap instead of a clamshell box, or combining labeling and sealing into one compostable sticker. Minimalist designs also mean being clever with space and shape, for example, using packaging that stacks neatly, fits efficiently into boxes, or collapses after use, to help minimize shipping emissions and waste.

While less common in large-scale baking, some artisanal and local bakeries are experimenting with reusable containers. Customers can bring their own tins, jars, or cloth bags, or even join a deposit-return program where they borrow and return branded containers. This approach takes a bit more effort, but it’s highly sustainable and helps build strong community connections.

Brands are also becoming more open about their sustainability practices, whereby labels

now explain how to dispose of packaging (e.g., “Compost me!” or “Recycle this tray”), and websites often detail the brand’s environmental goals. This transparency helps customers make informed choices.

INDUSTRY-WIDE ACTIONS

In 2019, Bimbo Bakeries USA—a subsidiary of Grupo Bimbo— pledged that by 2025, all its packaging will be recyclable, reusable, or compostable. They’re already rolling out initiatives like Arnold bread bags containing 30% post-consumer recycled (PCR) content, which reduces carbon footprint by an estimated 10 to 20%. Globally, Grupo Bimbo has 43 plants with zero waste to landfill, 144 with over 80% recycling, and the group has recently introduced Mexico’s first 100% compostable loaf bag (“Vital” line) with TÜV-certified packaging.

Toufayan Bakeries (Ridgefield, CT) revamped its pita and flatbread packaging, switching to 100% recyclable bags with resealable zippers, eliminating inner cellophane, and reducing plastic by over 40 tons annually. VP Karen Toufayan explained that this boosts sustainability without raising prices or compromising quality.

Suppliers of packaging materials for the baking industry have not been left behind. St. Johns Packaging now offers bread bags with 30% PCR content, which maintain performance while reducing emissions. Novolex has launched cake cups, clamshells, and dessert containers made with at least 10% PCR, while Novacart uses FSC-certified paper for ovenable molds (like brownie trays) and has introduced Biopap—a line of compostable oven-safe containers and films.

Coveris has developed ‘HEAT-in-pack’ fibre-composite

trays that are oven-safe to 220 °C, grease-resistant, and fully compostable, while TC Transcontinental offers plant-based bakery packaging that is also fully compostable.

Amcor provides PLA and sugarcane bagasse trays that are fully compostable, and are suitable for clamshells and bakery items. Vegware’s plant-based compostable disposables are sold in over 70 countries, while Israeli startup MadeRight converts organic waste into durable mycelium packaging and recently won the Unilever Sustainable Challenge.

CHALLENGES AND CONSIDERATIONS

Sustainable packaging still faces its fair share of challenges. Eco-friendly materials often cost more than traditional plastic. For small bakeries, that can be a dealbreaker unless customers are willing to pay a little extra. Additionally, sustainable materials may not always offer the same shelf life or protection, which can lead to food waste, further exacerbating environmental pollution.

Moreover, not all areas have composting facilities or recycling programs that can handle biodegradable packaging., impeding the worthy efforts of composting and recycling. Transparent labeling (e.g., “Compost Me!”) and QR codes can help close the loop by educating consumers on best conservation practices.

HOW CONSUMERS CAN SUPPORT THE MOVEMENT

Consumers of baked goods can definitely play a role in supporting sustainable packaging. They may opt to buy local since local bakeries often have more flexibility to try sustainable solutions, such as using reusable packaging, rewarding customers who bring their own containers, or using minimal packaging.

Consumers could also shop mindfully, by opting to purchase goods with packaging that has recyclability and proper disposal messaging. Other noble practices include reusing and recycling boxes, composting where possible, and disposing of waste properly

Consumers should also speak up and let brands know that they care about sustainable packaging. Customer feedback is powerful and often drives change. They can encourage bakeries to adopt proven approaches like PCR bags, compostable trays, or mycelium protective packaging.

THE FUTURE OF SUSTAINABLE PACKAGING

The baking industry is already baking in sustainability, from Bimbo’s global PCR pledges to local bakeries favouring reusable containers. With advances in materials innovation, consumer demand, and supportive infrastructure, the future looks bright and ecofriendly. Therefore, next time one picks up a loaf or indulges in a tasty pastry, it is imperative to look for the subtle green signals such as: PCR content, compostable labels, FSCcertified trays, or even QR codes providing information on how to dispose responsibly. These are not just packaging tweaks, but they are small, meaningful steps toward a circular baking economy. MMEA

Intelligent

Transforming the Bakery Industry Baking Systems

BY KIPNG'ETICH YEGON

According to Statista, the global bread and baked goods market is projected to experience a robust growth rate of 7.59% over the next four years, resulting in an astounding 790 billion kilograms of products produced annually by 2028. This significant market growth highlights the intense competition within the industry, compelling bakeries to continually optimise their production systems to maintain a competitive edge. As consumer preferences evolve and demand increases, implementing advanced technologies and efficient processes will be crucial for bakeries aiming to thrive in this dynamic landscape.

UNDERSTANDING INTELLIGENT BAKING SYSTEMS

Intelligent baking systems represent a significant advancement in the bakery industry. These systems integrate various technologies to enhance production efficiency and product quality. These systems typically consist of sensors, artificial intelligence (AI), automation tools, and data analytics capabilities. By utilising these technologies, bakeries can optimise their processes, reduce waste, and improve the consistency of their baked goods.

At the core of intelligent baking systems is the use of sensors that monitor critical parameters throughout the baking process. These sensors collect data on temperature, humidity, and ingredient proportions. AI algorithms analyse this data in real time, allowing immediate adjustments to the baking environment. For instance, if a sensor detects that the dough rises too slowly due to low temperature, the system can automatically increase the oven temperature to ensure optimal baking conditions. This integration of technology not only streamlines operations but also enhances product quality by ensuring that every batch meets precise specifications.

The operation of these systems relies heavily on data collection and analysis. Sensors continuously gather information during the mixing, proofing, and baking stages. This data is then analysed using AI models to identify patterns and predict outcomes based on historical performance. For

example, a bakery may use machine learning to optimise its recipes based on customer preferences and ingredient availability. As stated in a recent study published in ScienceDirect, "the implementation of intelligent systems enables bakeries to achieve significant improvements in both efficiency and product quality" .

KEY FEATURES OF INTELLIGENT BAKING SYSTEMS

Intelligent baking systems are characterised by several key features that contribute to their effectiveness:

Automated Mixing: These systems often feature automated mixers that adjust speed and mixing time in response to realtime sensor feedback. This ensures consistent dough texture and quality.

Temperature Control: Advanced temperature control mechanisms enable precise regulation of oven temperatures, which is essential for achieving the desired crust and crumb structure in baked goods.

Humidity Regulation: Maintaining optimal humidity levels is essential for certain types of bread and pastries. Intelligent systems can adjust humidity levels automatically based on

real-time data.

Energy Efficiency: Many intelligent baking systems are designed with energy-saving features that reduce consumption while maintaining high production standards. For example, variable speed drives (VSDs) can optimise motor performance to minimise energy usage without compromising output.

BENEFITS AND IMPACT

The benefits of intelligent baking systems extend beyond mere convenience; they have a significant impact on bakery operations and product quality. One of the primary advantages is improved product consistency. By closely monitoring and controlling baking parameters, bakeries can ensure that each batch of products meets high-quality standards. According to research conducted by AMF Bakery Systems, implementing intelligent solutions can reduce product variability by up to 30%.

Another significant benefit is waste reduction. Intelligent systems facilitate more accurate ingredient measurements and process controls, minimising excess material usage. This

reduces costs and promotes more sustainable practices within the industry. For instance, bakeries can track ingredient usage in real time, allowing them to adjust orders based on actual demand rather than estimates.

Energy savings are also a critical aspect of intelligent baking systems. Many bakeries have reported a 20% to 40% reduction in energy consumption after implementing these technologies. This leads to lower operational costs and aligns with growing sustainability initiatives within the food industry.

The impact on product quality cannot be overstated. Precise control over baking parameters enables bakeries to produce higher-quality goods consistently. Factors such as texture, flavour, and appearance can be optimised through real-time adjustments facilitated by intelligent systems.

INDUSTRY TRENDS AND INNOVATIONS

As technology continues to evolve, several trends have emerged within the realm of intelligent baking systems. One notable trend is the integration of AI-driven recipe optimisation tools. These tools analyse customer feedback and sales data to suggest modifications to existing recipes or even create

BAKERIES INCREASINGLY IMPLEMENT AUTOMATED MIXING AND KNEADING SYSTEMS

entirely new ones tailored to market demands.

Predictive maintenance is another innovation gaining traction in the industry. By utilising data analytics, bakeries can predict equipment failures before they occur, thereby minimising downtime and maintenance costs. A report from Baking Business highlights that predictive maintenance can reduce equipment failure rates by up to 50%, significantly enhancing operational efficiency.

Sustainability also plays a crucial role in shaping these technologies. Intelligent baking systems often incorporate features designed to lower waste and energy consumption, aligning with broader environmental goals within the industry. For example, some bakeries are adopting modular equipment that allows for scalability in response to seasonal demand fluctuations.

INTEGRATION IN AFRICA'S BAKING SECTOR

Integrating intelligent baking systems in the African baking sector is gradually transforming traditional practices into more efficient and technologically advanced operations. As bakeries across the continent face increasing demand for quality products, many are adopting intelligent baking control systems that utilise sensors, software, and artificial intelligence to monitor and regulate critical baking parameters such as

temperature and humidity. For instance, these systems enable real-time adjustments during baking, ensuring consistent product quality while minimising waste and energy consumption. According to a report on technology in the bakery industry, these advancements enhance operational efficiency and provide bakers with valuable insights for troubleshooting and improving production processes.

In most advanced countries, bakeries increasingly implement automated mixing and kneading systems that reduce labour costs and improve dough consistency. These systems enable precise control over mixing times and temperatures, resulting in enhanced dough development and higher-quality baked goods. Additionally, high-speed ovens are being introduced to meet the growing consumer demand for quicker production times without compromising quality. Such innovations are crucial for bakeries aiming to remain competitive in a market that is becoming more saturated with artisanal and mass-produced baked goods. Local initiatives aimed at modernising food production processes across the continent also support the shift towards automation.

Moreover, adopting intelligent baking systems aligns with broader sustainability and energy efficiency trends within the African

baking sector. By utilising advanced technologies such as programmable logic controllers (PLCs) and variable speed drives (VSDs), bakeries can achieve significant energy savings, reportedly up to 40% compared to older models. This reduces operational costs and helps bakeries comply with increasingly stringent environmental regulations.

CASE STUDIES AND REAL-WORLD APPLICATIONS

Several bakeries have successfully implemented intelligent baking systems, showcasing their benefits through tangible results. An example of an intelligent baking system that is in practice is The Village Bakery in Wrexham, Wales. As the largest gluten-free bakery in Europe, it produces approximately 250,000 loaves each week. Initially, the bakery utilised two depositing lines, conveyor-based systems designed for dividing dough into the appropriate weights for rolls and loaves. However, operators faced challenges with inconsistent results, which prompted a search for a more reliable solution.

To address these issues, The Village Bakery switched to a motor-driven system that achieved extremely high precision in its operations. This new system enables operators to program four different speeds tailored to various products, resulting in a 25% reduction in line running costs. This upgrade not only enhanced efficiency but also improved product consistency.

Moreover, the bakery has experienced reduced downtime since upgrading its equipment. Staff can now shut down each line independently for cleaning and maintenance, streamlining operations. The operators selected equipment with an IP66 protection class, facilitating simple washdowns and maintaining hygiene standards.

The upgrades also included improvements to the tin greasing system. Previously, the low-precision greasing system wasted the greasing agent by spraying before and after the tin was

positioned. The new system effectively reduces the need for greasing agents, resulting in a 10% materials cost savings.

In addition to these operational efficiencies, the new motor-drive system is significantly more energy-efficient, enabling The Village Bakery to reduce its energy costs by 27%. These changes result in annual savings of around £20,000 (US$26,320), meaning that the investments made in upgrading equipment will quickly pay for themselves.

The Village Bakery's experience exemplifies how intelligent baking systems can enhance productivity while reducing costs and waste. By leveraging advanced technologies such as motor drives and programmable logic controllers (PLCs), bakeries can improve their operational efficiency and ensure higher quality products that meet consumer demands.

FUTURE OUTLOOK

Looking ahead, the future of intelligent baking systems appears promising as advancements continue at a rapid pace. Emerging technologies such as blockchain could significantly enhance traceability within supply chains, ensuring that ingredients meet safety standards from farm to table. Blockchain technology provides a decentralised and tamper-proof record of transactions, allowing all stakeholders in the supply chain, from producers to consumers, to verify the provenance and integrity of products. This capability fosters consumer trust and aids in compliance with regulatory requirements, which is increasingly important in the food industry.

Bakeries should prepare for future technological changes by investing in staff training programs and staying informed about emerging industry trends. This proactive approach will enable them to adapt to new technologies and consumer demands more effectively.

Cruncho becomes first Kuwait company to earn gluten-free certification

KUWAIT – Cruncho, a pioneering snack food manufacturer headquartered in Kuwait, has made history by becoming the first company in the country to earn both NSF Gluten-Free Certification and Non-GMO Project Verification for its flagship Prolife product line. This dual achievement marks a significant milestone for food safety and transparency in the Middle East, aligning with the region’s growing demand for healthconscious, clean-label products.

The NSF Gluten-Free Certification ensures that Cruncho’s Prolife snacks meet the U.S. Food and Drug Administration’s Gluten-Free Labelling Final Rule, which mandates less than 20 parts per million (ppm) of gluten.This is a critical safeguard for individuals with celiac disease or gluten sensitivities. Meanwhile, the Non-GMO Project Verification, recognised as the most trusted third-party standard for GMO avoidance, validates Cruncho’s commitment to responsible ingredient sourcing and rigorous supply chain documentation.

Cruncho’s Prolife range includes high-protein puffs, peabased chips, collagen-infused snacks, and vitamin-enriched options, all tailored to diverse dietary needs. These products are now available at over 1,000 retail points across Kuwait and the GCC, and will proudly display the NSF Certified GlutenFree mark and the Non-GMO Project Verified butterfly seal.

Mohammed Ali Khan, Cruncho’s Quality Assurance Officer, praised NSF’s support throughout the certification process, noting that these milestones reinforce consumer trust and elevate the brand’s credibility.

“Earning both Gluten-Free certification and Non-GMO Project verification marks a pivotal moment for Cruncho. Consumers today are more conscious than ever about what goes into their food, and this certification and verification reinforce our promise to deliver clean-label snacks they can trust,” said Mohammed Ali Khan, Quality Assurance Officer, Cruncho. He added that the milestones demonstrate their commitment to delivering snacks that are not only delicious but also responsibly sourced and transparently labelled.

DPL Festive unveils new ciambella cake at Africa Food Manufacturing Expo

KENYA – DPL Festive has expanded its baked goods portfolio with the launch of a new Ciambella cake and four new flavours of its popular marble cakes during the recently concluded AFMASS Food Manufacturing Expo held from July 2-4 in Sarit Expo Center, Nairobi. The product introductions are part of the company’s ongoing strategy to innovate around consumer snacking and dessert experiences in the Kenyan market.

According to DPL Festive, the word Ciambella is Italian, referring to the cake’s circular shape. The product is designed as an indulgent treat and is best enjoyed paired with a rich custard sauce. To enhance this experience, DPL Festive has partnered with Zesta, a well-known household brand, to supply its custard powder. The custard is used to create a creamy sauce that complements the Ciambella cakes, offering consumers a richer and more satisfying dessert option. “Ciambella means more than just a cake, it’s your favourite slices brought to life in a moist, flavourful form. With the added touch of warm custard, we’re offering consumers a dessert experience that’s both nostalgic and modern,” said a representative from DPL Festive at the launch.

In addition to the Ciambella launch, the company also revealed four new flavours in its established marble cake line, namely Mint Chocolate, Chocolate Vanilla, Orange Chocolate and Vanilla Strawberry. These new variants build on the popularity of the existing marble cake range while introducing bolder, more diverse flavour profiles to meet evolving consumer preferences. The cakes are individually wrapped for freshness and convenience, targeting on-the-go consumers, school tuck shops, modern retail shelves, and institutional buyers. “These flavours are new to the market, and while our marble cakes are already well established, we’re creating awareness about these additions,” said the DPL Festive representative.

INGREDIENTS

Grupo Bimbo commits to removing artificial colors from all products by end of 2026

USA - Grupo Bimbo, the world’s largest baking company, has announced a sweeping commitment to eliminate all artificial colorants from its global product portfolio by the end of 2026. The move, revealed on July 29, 2025, marks a major milestone in the company’s ongoing mission to offer simpler, more natural recipes across its expansive lineup of baked goods and snacks.

Currently, 99% of Bimbo’s daily consumption products, including staples like bread, buns, rolls, tortillas, bagels, and English muffins, are already free from artificial flavors and colors. These categories represent approximately 50% of the company’s global net sales and more than 70% of its U.S. sales, underscoring the scale of the transformation already underway.“We continue making solid progress toward our health and wellness targets,” said Rafael Pamias, CEO of Grupo Bimbo. “By year-end, we expect 100% of our bread, buns, and breakfast portfolio to deliver positive nutrition. Looking ahead, we are expanding our focus with a bold goal: by 2026, all our products will be free from artificial colorants.”

The announcement aligns with broader industry trends, as major food companies respond to consumer demand for cleaner labels and more transparent ingredient sourcing. Grupo Bimbo joins peers like Kraft Heinz and General Mills in pledging to remove synthetic dyes, especially in products served in schools and family households.

This long-term vision includes eliminating artificial preservatives and additives while maintaining affordability, safety, and accessibility for families worldwide. The company’s efforts have earned recognition from the Access to Nutrition Initiative (ATNI), which ranks Bimbo among the top four global food companies for its commitment to improving nutritional quality, promoting responsible marketing, and expanding access to healthier products.

Puratos expands with new centers in Canada and Costa Rica

CANADA/COSTA RICA – Puratos, the global leader in bakery, patisserie, and chocolate innovation, has unveiled two new Innovation Centers in Montreal, Canada and Cartago, Costa Rica, delivering cutting-edge innovations in bakery and patisserie product creation. This expansion marks a strategic expansion of its global network.

Puratos, headquartered in Belgium, operates more than 120 Innovation Centres globally to support local and regional clients. The Montreal Innovation Centre, officially opened on August 20, 2025, becomes Puratos’ third facility in Canada, joining those in Mississauga and Chilliwack. Located in the heart of Quebec, the 3,500-square-foot hub is designed to foster collaboration, creativity, and technical excellence. It offers hands-on support for local businesses, with bilingual service and tailored recipe development. Equipped with advanced tools, including a refrigerated marble table for chocolate work and dual proofers for simultaneous retarding and proofing, the centre is well-positioned to meet the unique needs of Quebec’s bakery and patisserie sector.The Montreal facility also integrates Puratos’ “Taste Tomorrow” program, the world’s largest consumer research ecosystem in the food industry.

In Cartago’s Industrial Park, Costa Rica, Puratos has launched a state-of-the-art Innovation Center focused on cocreation and agile product development for the Latin American market. The facility features an upgraded R&D lab and is designed to support professionals in the bakery, patisserie, and chocolate industries with customized solutions tailored to their specific needs.

Both centers reflect Puratos’ commitment to staying close to customers and delivering regionally relevant solutions. These hubs provide product development, category management, and profiling, enabling businesses to create appealing products, establish profitability goals, and refine existing offerings for market success.

GoodMills Innovation launches High-MAC Brans to elevate fibre-rich baking

GERMANY – GoodMills Innovation, a specialist in clean-label cereal and pulse-based ingredients, has introduced High-MAC brans, a new generation of micronized and thermally stabilized cereal brans aimed at enriching baked goods with fiber while maintaining taste, texture, and volume.

Developed from wheat, rye, and spelt, the brans meet growing demand for high-fiber, clean-label bakery products. A proprietary micronization process reduces more than 90% of bran particles to under 200 microns, allowing smooth integration into dough without affecting processing or sensory qualities. This ensures even distribution throughout the crumb, avoiding the coarse texture linked to conventional bran, while boosting fiber and mineral content.

High-MAC brans can be used in breads, rolls, sandwich loaves, pizza bases, crispbreads, and cookies. Dosage levels can be adjusted to meet nutrition claims such as “source of fiber” or “high in fiber” with minimal impact on dough handling. The ingredient is added directly during mixing, simplifying production for both artisanal and industrial bakers.

Beyond functionality, the innovation contributes to sustainability. The brans are derived from grain fractions usually discarded in the “after-flour” stage of milling, helping reduce waste while enhancing nutritional value. Being solely cereal-based, they align with consumer preferences for clean-label ingredients without additives or non-cereal fibers. Thermal stabilization extends shelf life, making the brans suitable for commercial use.

With High-MAC brans, GoodMills Innovation provides the baking sector with a clean-label solution that improves nutrition without compromising quality or appearance. The launch underscores the company’s role in addressing evolving consumer expectations for fiber-rich products with natural, recognizable ingredients. The development follows GoodMills Innovation’s 2024 introduction of Slow Milling ingredients for artisanal baking, further strengthening its reputation for advancing functional solutions in grain-based foods.

INNOVATION

IFF launches POWERFRESH® ACE 2000 enzyme solution to enhance bread shelf life

USA – International Flavors & Fragrances Inc. (IFF) has unveiled its latest innovation for the baking industry; POWERFRESH® ACE 2000, a next-generation enzyme solution designed to extend the freshness of bread while enhancing texture and operational efficiency. Launched in the U.S. market, this breakthrough product targets industrial bakeries aiming to meet rising consumer expectations for longer-lasting freshness while improving operational efficiency.

Developed by IFF’s biosciences division, POWERFRESH® ACE 2000 delivers improved softness, resilience, and cohesiveness across white and whole-wheat bread applications. In company-led trials, the enzyme consistently maintained structure and visual appeal for up to 34 days, even at lower dosage levels compared to market alternatives. The result: loaves that remain soft, easy to butter, and visually appealing long after purchase.

Emily Wagener, IFF’s North America industry leader for food and beverage enzymes, emphasised the dual value of the solution: “POWERFRESH® ACE 2000 is bakers’ ally to deliver high-quality products with the delicious texture and freshness consumers expect, every time”.

The launch responds to mounting pressure on U.S. bakeries to meet rising consumer demands for longer-lasting freshness without compromising quality. A recent survey cited by IFF revealed that 60% of consumers would choose bread marketed as “fresher for longer,” with more than half expecting at least four days of freshness at the time of purchase.

Beyond consumer satisfaction, the enzyme offers significant operational benefits. By improving product resilience, bakeries can extend distribution reach, reduce returns, and minimise waste, aligning with broader sustainability goals.The solution also simplifies inventory management and supports reformulation efforts for cleaner labels. With POWERFRESH® ACE 2000, IFF continues to lead the charge in food biosciences, offering innovative, scalable solutions that meet the evolving needs of both manufacturers and consumers.

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