Johannesburg (South Africa), 25 March 2026: Digitalisation, automation, and data-driven decision-making are rapidly transforming the global milling industry, with the SmartMill approach emerging as a key pathway to enhanced efficiency, consistency, and competitiveness. These trends were emphasised by Swiss technology company Bühler during its presentation at the 90th congress of the National Chamber of Milling (NCM) in mid-March, in Knysna, Western Cape.
.Speaking at the event, Fabio Curatolo, Senior Customer Relationship Manager at Bühler Southern Africa, emphasised that the SmartMill concept is helping millers manage increasing operational pressures, tighter margins, and rising demands for quality and compliance.
Industry platforms like the NCM congress are highly valuable because they bring together milling leaders and technology partners to exchange real-world experiences and align on the industry's needs,
In fact, SmartMill is not an end product but rather a concept comprising hundreds of complementary innovations developed through close collaboration with industry. According to Curatolo, SmartMill signifies a shift towards more connected, transparent, and automated milling operations. By integrating sensors, digital platforms, and advanced analytics, mills can transition from manual checks and experience-based decisions to real-time, data-driven process control.
“The SmartMill involves using connected equipment, sensors, and software to make milling operations more predictable and responsive,” explains Curatolo. “Operators can rely on real-time data to maintain optimal performance, ensure consistent quality, and respond more quickly to deviations.”
Millers today face a complex operational environment
Unstable raw material quality, rising energy and utility costs, maintenance reliability issues, and skills shortages make maintaining consistent production performance more challenging. At the same time, the market demands tighter margins, greater traceability, and higher standards of food safety and quality.
“In South Africa, these pressures are even more severe due to energy instability and rising operating costs,” notes Curatolo. “SmartMill technologies help millers tackle these issues by enhancing process control, improving traceability, and making operations more resilient.”
Digital monitoring and data collection play a vital role in this transformation. “Data turns milling from a ‘best effort’ operation into a controlled, evidence-based process,” says Curatolo. “By analysing trends and detecting changes early, mills can adjust parameters proactively, prevent downtime, and maintain consistent output.”
Transition to the SmartMill approach
Bühler supports millers in their transition to SmartMill through a comprehensive approach that spans consulting, engineering, digital solutions, and ongoing operational support. “Our goal is to help millers translate data into measurable improvements in yield, energy use, and plant performance,” says Curatolo. Among the technologies helping enable this transformation are advanced automation systems, digital production management platforms, and specialised process optimisation tools. For example, Bühler’s digital platforms, such as Bühler Insights and ProPlant, allow millers to organise and monitor maintenance, production, and process data in real time. Solutions such as temperature and vibration monitoring help optimise grinding performance and reduce energy consumption.
One advantage of the SmartMill approach is that it is an incremental journey rather than a revolutionary moment, allowing customers to join at the point that best suits their business. While the speed and direction of the journey are up to each company, everyone needs to start from the same point.
According to Bühler’s experts, anyone considering being part of the journey in the near future should now be thinking about installing sensor technology and the connectivity it provides, offering the production transparency that informs decision-making, because this is the foundation of the whole SmartMill process.
Milling sector sees increased digitisation
Curatolo expects digitalisation in the milling sector to accelerate significantly over the next decade. “We expect stronger automation, wider use of AI-driven analytics for process optimisation, predictive maintenance, and increasing expectations for full traceability across the value chain,” he says. “Sustainability will also be a major driver, pushing mills to reduce energy use, emissions, and waste, while improving resource efficiency.”
However, Curatolo emphasises that a successful SmartMill journey requires more than simply installing new technologies. “The SmartMill works best when it is implemented as a practical, step-by-step programme,” he says. “Clear performance targets, a reliable data foundation, and strong operator engagement are essential. When those elements come together, the result is more efficient, resilient, and competitive milling operations.”
Innovation remains at the core of Bühler’s long-term competitiveness and its ability to create impact for customers. In 2025, R&D expenditure amounted to 4.8% of turnover, with Bühler successfully launching 60 new products to the market, reinforcing its commitment to purposeful innovation and driving performance and sustainability. Bühler’s innovation capability is supported by Bühler’s global innovation network of 26 research and training centres.
