Miller Magazine Issue: 142 October 2021

77 COVER STORY MILLER / OCTOber 2021 • Availability of historical data, as well as real-time operational data. In many countries around the globe, medium and small- scale facilities continue to operate manually, each and ev- ery plant is suitable for automation. In my view, developing countries where labor costs are low, automation is needed to increase safety, improve production, and achieve plant optimization. However, the level of automation could differ. In developed countries, we have achieved a “lights out” fully automated operations that only require a minimum amount of maintenance personnel. The cost for automa- tion control systems varies from 16-25% of the total budget based on size and sophistication of the plant. In today’s connected world, with VNP, one can control and support the plant from anywhere, anytime 24/7. The innovations and solutions brought to the milling industry are: • Ethernet-enabled (smart) MCC’s, which enables operator to clear faults and monitor statuses without going into the MCC room. • More diagnostic and performance data is available. • Reduced downtime with replacing units. • Enhanced production reporting and data to measure plant performance quickly and precisely. • Tracking of products throughout the process. • Migration of legacy automation systems to the newer and up- dated control systems. The convergence of IT (Information technology) and OT (Operational technology) opens a great opportunity for ev- eryone involved. The convergence of business systems with plant-wide / site-wide automation systems provides for more tracking of key performance indicators (KPIs), regulatory compliance (genealogy, track and trace), as well as supply chain management if needed. The industrial automation and IT groups, who previously had little interaction, are now col- laborating to share standards, best practices, innovations, security policies, procedures and technology. The milling industry will have to embrace IoT, or they will be left behind. Regulatory compliance, recall procedures, food security and innovations will force them to stay current. Plant optimization, cost competitiveness, and productivity gains are the benefits of a digital small mill. Further, smart mills work within a secure wireless network, and they will be supporting a highly automated process, linked seam- lessly with enterprise software working through the cloud. Oper- ators are controlling the mills from their tablets, with all the facility data at the fingertips, including the equipment manuals. As we know, Industry 4.0 refers to the fourth industry revolution, it’s the way we produce product due to digital transformation. IoT makes 4.0 possible and smart mill a re- ality. Equipment in our process industry are getting smart- er, and they are producing critical data that are essential to increase productivity. These machines are connected with one another and create and share information. In our milling industry, we have smarter roller mills, scaling sys- tems, moisture controller that are communicating with the plant master controller, and some are communicating with each other producing better results. In our industry, I see the adaptation of Industry 4.0 to be slow due to its cost, but it will happen. Millennials are the driving force behind this requirement, and we better adapt. This technology revolution, though very slow to adapt in the milling and grains industry, is here to stay. In conclusion, I can maintain that if we are talking about a forward-looking system like automation in milling, smart mills, and Industry 4.0, we cannot ignore this system. What we are supposed to do is to optimize the infrastructure of our busi- nesses and energy distribution systems to make Industry 4.0 available and to benefit from the facilities and advantages offered by the system. About Author Karan Singhal, Milling Technologist Professional with ac- complished 12.5 years of experience providing proficient, cost-effective, innovative solutions for increasing oper- ational efficiency, improving product quality, maximizing yields, and achieving production goals. Possesses techni- cal and mechanical knowledge of milling equipment, sys- tems, processes, and methods. Refined operations man- agement expert within large-scale multifaceted production environments. With both tertiary and extensive practical experience within the FMCG, wheat flour milling, maize milling, oat milling, legume and pulses milling including related grain processing thermal applications, combined with the relevant, proven expertise, in GMP, OHS, JIT, MRP, Food-Processing, Quality-Assurance, Food-Safety, Product Traceability, Production Scheduling, Process Enhancement, Raw Material Purchasing, Packaging Operational Coordina- tion within related in-house external service industries. He has Postgraduate Diploma Course in flour milling from International Association of Operative Millers (IAOM), Lenexa, Kansas, USA (2021) and Postgraduate Diplo- ma Course in Flour Milling Technology from International School of Milling Technology, CSIR - Central Food Tech- nological Research Institute (CFTRI), Ministry of Science & Technology, Government of India, Mysuru, Karnataka, India (2011-2012). He is the author of many professional editori- als in renowned milling industry magazines and an active member of IAOM. E-Mail: karansinghal.miller@gmail.com