Mandi Steffey
Sales Marketing Manager
Laidig Systems

One of the most critical aspects of milling is the storage and handling of byproducts. These materials are valuable for animal feed production, but they present storage challenges due to their tendency to compact and bridge in poorly designed silos, leading to erratic flow, reduced material quality, and potential production downtime.

As Africa’s population and grain milling industries continue to expand, operators are facing a range of silo unloading challenges that require innovative solutions. From increasing automation to improving material storage, industry professionals may be wondering about the best practices that can streamline operations, enhance product quality, and ensure long-term efficiency.

ADAPTING TO A GROWING MARKET

Grain and flour mills across Africa vary widely in size and sophistication, depending on their location. North Africa, West Africa, East Africa, and South Africa all have unique market dynamics, but one common trend is the push for modernization. As wages rise and consumer demand for high-quality food and animal feed products increase, mills are investing in larger, more efficient operations.

In the past, smaller mills have traditionally relied on bagging or flat storage methods for milling byproducts like soybean meal wheat bran, which can be labor-intensive and difficult to manage. However, many are now considering transitioning to automated storage and reclaim systems, paired with vertical silos, to improve cleanliness, reduce labor costs, and ensure consistent material flow.

“Automation drives quality,” said John Koorn, international sales manager at Laidig Systems, Inc. “With a growing population, mills need to focus on efficiency while maintaining the high standards that consumers expect.”

ADDRESSING STORAGE CHALLENGES

One of the most critical aspects of milling is the storage and handling of byproducts. These materials are valuable for animal feed production, but they present storage challenges due to their tendency to compact and bridge in poorly designed silos, leading to erratic flow, reduced material quality, and potential production downtime.

To prevent these issues, experts recommend using first-in, first-out (FIFO) storage methods to maintain quality. Ensuring that the oldest material is unloaded and used first helps preserve the nutritional value of the product and prevents spoilage.

High humidity is another factor that can affect material flow. In regions with extreme moisture levels, like parts of Africa—whether from the climate or the product itself—mills must consider specialized silo designs that enable consistent discharge patterns. This may involve silo bottom reclaimers or other in-silo mechanical systems designed to extract material regardless of its moisture content.

“A well-designed system provides flexibility,” Koorn said. “You have to have a device to dig that material out,” Koorn noted. “That’s what Laidig Systems does.”

A COMMITMENT TO LONG-TERM SOLUTIONS

Laidig engineers, manufactures, installs, and services specialized, automated, industrial silo reclaim equipment for thousands of customers around the world who are handling hundreds of different materials. A Laidig reclaim system consists of a large, heavy-duty auger that is designed to rotate on its own axis while simultaneously advancing around a silo’s perimeter, creating a first-in, first-out material distribution. The equipment reclaims the material and unloads it into the next step of the customer’s process, which may involve truck or train loadout, or a bagging system. All of the reclaim systems Laidig makes are customized for those types of specific application needs and process goals.

Koorn stresses the importance of a thorough planning process tailored to each client’s needs. “We always ask questions,” he said. “How much do you want to store? How many days do you want to store? What’s your reclaim rate? Are we feeding a bagging system, loading trucks, or recycling?”

These factors help design a system that meets immediate needs while accounting for future growth. “We do a very thorough study before we offer solutions, and they’re designed to their goals,” he said.

CONTINUED TRAINING AND SUPPORT

Another factor in long-term success is making sure any new advanced equipment can be serviced and supported over time. Emerging technologies like preventative and predictive maintenance tools can help minimize any potential downtime. Laidig utilizes remote monitoring technology that allows mills to track equipment performance and detect potential issues before they become critical. Some customers even integrate their systems with Laidig’s expert team of engineers, enabling diagnostics and adjustments to be made from thousands of miles away.

“That is a very big asset,” Koorn said. “We can monitor a site and help them determine their maintenance schedules.”

PLANNING FOR LONG-TERM EFFICIENCY

When designing a storage and handling system, mills must consider both immediate needs and future growth. While it may be tempting to focus solely on current production demands, experts advise taking a long-term approach.

Key factors to assess include:

• Storage Capacity: How much material needs to be stored, and for how long?
• Material Flow Requirements: Will the system feed a bagging line, load trucks, or support a recycling process?
• Scalability: Can the system accommodate future expansion?

“I was told many times that the first dollar is the cheapest dollar,” Koorn said. “When you invest, let’s invest in something that’ll work for a 20, 30, or 40-year lifespan.”

LOOKING AHEAD

Africa’s flour milling industry is at a pivotal moment, with increasing demand for automation, efficiency, and quality control. As the industry evolves, mills that embrace best practices in bulk material handling will be better positioned for long-term success.

By focusing on optimized storage, training, predictive maintenance, and forward-thinking system design, mill operators can improve operational efficiency while meeting the needs of a rapidly growing market.