UZWIL, SWITZERLAND — Bühler developed and recently launched the AIPesa MDGM, a compact and space-saving milling system that is based on the technology of the company’s PesaMill.

The PesaMill, which was specially developed for the industrial production of Atta flour, is available in two models with capacities of 75 or 150 tonnes. There are many PesaMill plants being used in India and neighboring countries.

However, the majority of Atta flour is still being produced on chakki stone mills with daily capacities of up to 10 tonnes. To offer an alternative to the hundreds of small chakki mills, Bühler designed the AIPesa, a compact and space-saving milling system with an hourly capacity of 700 kg.

It includes a high-compression mill, a plansifter and a bagging station, a switch cabinet with control system, and it has the same hygienic and operating technical properties as the PesaMill. AlPesa can be operated stand-alone and with manual bagging, or it can be integrated into an existing mill. The AlPesa milling system is a cost-effective, easy-to-operate compact milling system for producing authentic Atta flours, Bühler said.

Atta flour, produced from a variety of wheat, is used in making flat breads like chapti, roti and puri, staple foods in India, Pakistan and Bangladesh.

The new AIPesa milling system is not limited to India and its neighboring countries. More than 40 million people of Indian, Pakistani or Bangladeshi origin live elsewhere in the rest of the world. In order to produce their familiar flat bread, they have had to rely on importing the traditional Atta flour from their former homeland.

Bühler now offers a global version of the AIPesa milling system. It also may be used for processing other special whole grain foods, such as sorghum and millet. AIPesa is a plug-and-play concept that offers the perfect solution for integrating it into existing mills. Installation and commissioning can take place within two weeks.

Bühler worked closely with specialists for Atta flour to develop a new process for the industrial manufacture of whole grain Atta flour. The Bühler Atta process is the first industrial process technology for manufacturing hygienic, faultless and authentic tasting Atta flour. The core of the Atta process, which offers a modern alternative to the common chakki mills, is the high-compression mill, PesaMill MDGA, with grinding rolls.

The high-compression mill was developed for the particular requirements of Atta production. It ensures a high throughput while maintaining top food safety. The machine can be easily cleaned and requires less maintenance than a chakki mill, which needs to have its stones redressed every month. In addition, producers can customize their product thanks to the innovative milling system. The PesaMill can produce flour according to specific values for water absorption, starch damage and granulation in order to adapt to regional market preferences. After milling, a plansifter makes efficient sifting and sorting possible. Furthermore, Bühler’s ZZ sifter offers a compact solution for separating bran particles and semolina. The result is an Atta flour with optimal color.

A single PesaMill can replace up to 20 traditional stone mills with its completely integrated process — and there are innumerable other advantages such as higher yields, reduced energy consumption and the possibility to produce multiple flour qualities on the same machine.