3D twinRoller flour mills · atta, maida, suji, besan
One live 3D model of your mill: trucks at the gate, wheat cover by variety, tempering bins, roller floors, flour bins, packers and the godown. Each problem reaches the person who fixes it on WhatsApp, before the shift ends.
01Live 3D twin
Pick a view along the top: gate, silos, cleaning, the five-floor mill, bins, packing, dispatch, food safety or one traced order. Click any silo, roller mill or packer to open its record and alert.
Operational AIFictional roller flour mill and besan unit with sample data — your twin is drawn from your own site and systems.
02Definition
Each area below matches a view in the 3D model, with the records it reads and what it flags.
A flour mill digital twin is a live model of a flour mill that stays in step with the real plant through the records it already keeps: weighbridge slips, silo levels, tempering logs, mill PLC readings, packer counts, lab results and dispatch orders. It shows where wheat and flour are now, what is behind plan and what will run short, so the head miller and plant team act before output, quality or delivery slips.
03Measures
The measures a head miller and plant head review every shift, each calculated one way from the named system, so teams argue about the action, not the number.
| Measure | What it tells you | Where it comes from |
|---|---|---|
| Flour extraction | Flour produced as a share of wheat milled; the number that decides margin. | Mill product scales and the B1 feed scale |
| Bran and by-product % | Bran as a share of wheat; a rise usually means roll gaps or sieves have drifted. | Bran scale, lab ash results |
| Tempered moisture | Moisture after tempering against target, with rest hours per bin. | Moisture meter readings, dampener logs |
| Milling rate vs plan | Tonnes milled this shift against the planned rate. | B1 feed scale, production plan |
| Power per tonne | kWh per tonne of wheat milled, by section and shift. | Energy meters on the mill and pneumatics |
| Packed vs plan | Bags or pouches packed by SKU against the packing plan. | Packer counters |
| Check-weigher rejects | Share of bags rejected for weight; also shows giveaway. | Check-weigher logs |
| Wheat cover by variety | Days each variety lasts at the planned grist. | Silo levels, grist plan, open purchase orders |
| Gate waiting time | Minutes from a truck's arrival to unloading, by stage. | Gate register, weighbridge, grading reports |
| Food safety checks done | Scheduled checks completed on time against due. | Check schedule, photo logs, lab register |
| Finished goods cover | Days of stock per SKU against open dealer orders. | Godown stock, sales orders |
| Dispatch on time | Dealer orders delivered by the promised date, last 30 days. | Invoices, gate-out and delivery records |
04Problems it removes
Most mill losses are small, slow and sitting in a record nobody is watching. The twin watches them together.
The twin shows each truck's wait by stage and flags lots stuck behind the lab. With GrainGrade photo grading at the bay, only borderline lots go to the lab.
Extraction and bran are tracked against plan every shift, next to roll changes and lab ash. Drift on one passage shows up the day it starts.
Bin levels and packer rates give the hour each bin will be full. The twin tells the packing in-charge and head miller which SKU to move to which packer before the mill has to slow down.
Magnet, sieve, metal detector and lab checks are scheduled, chased on WhatsApp and logged with a photo. When a buyer or an FSSAI audit asks, the evidence is already filed by date and lot.
05A shift on the twin
Three moments from one shift at the sample mill. Times, tonnages and figures are illustrative.
T-4 read 15.2% moisture against a 16.0% target after dampener flow fell 9%. The twin warned the head miller four hours before T-4 was due at the mill: clean the dampener nozzle and add 0.8% water as the bin is drawn.
Its 220 bags of maida 50 kg were planned straight off P-3, which was stopped. The twin found 220 bags of an older lot in the godown, so dispatch loaded those first and the delivery held.
A bag clamp jammed and the maida bin was rising four points an hour. The twin set the hour it would be full, sent the fitter, and told the packing in-charge to move maida 50 kg to P-4 if P-3 was still down at 15:00.
06How it is built
A flour mill digital twin is built from a site drawing and the records the mill already keeps. New sensors are added only where a missing reading costs money.
We trace your site plan to scale, from the gate and silos to the packing hall and docks.
Weighbridge, mill PLC or SCADA, packers, lab register and ERP are read, never written to.
With the head miller we set grists, tempering targets, extraction plan and check schedules.
Each rule gets an owner, from gate QC to dispatch, reached on WhatsApp.
Shifts are replayed and the plan runs seven days forward.
07Compared
| Registers & spreadsheets | Mill SCADA / ERP | Autowhat flour mill digital twin | |
|---|---|---|---|
| What it covers | Whatever the clerk writes down, a day late | SCADA sees the mill; ERP sees bills and stock | Gate to dealer on one record, in 3D |
| Wheat intake | Paper slips and lab register | Weighbridge weight; quality kept elsewhere | Wait, grade, weight and silo per truck |
| Extraction and yield | Calculated at month end | Live scales, but no plan to compare | Against plan every shift, with the cause |
| Packing and bins | Bag count at shift end | Packer counters on the PLC screen | Hour each bin fills, with a packer fallback |
| Food safety evidence | Signed registers, hard to search | Not covered | Scheduled checks with photos, by lot |
| Wheat and packaging buying | Purchase head's judgement | Stock report, no forward plan | Cover by variety and an order-by date |
| Changes to plant control | None | Controls the machines | None; read-only to plant systems |
MoreProducts behind this twin
FAQQuestions about flour mill digital twins
What the twin is, what it reads, what it costs and how long it takes in an Indian mill.
A flour mill digital twin is a live model of the mill that stays in step with the plant through the records it already keeps. It shows the gate, silos, tempering, roller floors, bins, packers and godown in one 3D view and sends each exception to its owner.
In the food industry, a digital twin is a virtual model of a plant, line or supply chain kept current with live data. Food plants use it to track yield and giveaway, keep food safety records, and plan production against raw material before anything runs short.
It reads the systems the mill already runs, such as the weighbridge, silo probes, mill PLC, packer counters, lab register and ERP, and places each reading on a 3D drawing of the site. Rules agreed with the head miller turn readings into alerts.
No. SCADA and mill automation control and monitor the machines inside the milling building. A digital twin reads from them without changing anything, then adds wheat intake, lab results, packing, stock and dispatch, so the mill from gate to dealer sits on one record.
Flour mill software and ERPs record purchases, production entries, stock and GST invoices after the fact. A digital twin shows the plant now and where it is heading: which bin fills first, which variety runs short. It reads the ERP rather than replacing it.
Usually not at the start. Most mills already have weighbridge records, silo probes or dip readings, packer counters, a lab register and an ERP. The twin begins with those and adds sensors, such as silo temperature cables, only where a missing reading costs money.
Flour extraction rate is flour produced divided by wheat milled, times 100, for the same period. Mills usually take wheat milled from the first break (B1) scale and flour from the product scales. In the sample mill, maida 58.2%, atta 11.6% and suji 6.1% give 75.9% extraction, with bran at 23.6%.
It schedules every magnet, sieve, metal detector and lab check, reminds the owner on WhatsApp and stores each result with a photo and time. When a bakery buyer or an FSSAI inspector asks for records, they are already filed by date and lot.
The twin shares a record with Autowhat Production & Procurement. Dealer orders become a packing plan, the plan becomes a wheat requirement by variety, and the buy list gets an order-by date. The twin then shows plan against actual and runs it seven days forward.
The first site is scoped in a 30-minute working session on your own data. Most deployments go live on one site within weeks: the site drawing and a week of records first, then live feeds, WhatsApp alerts and planning, then more units.
It is priced per deployment after a 30-minute working session; there is no public list price. Cost depends on the number of sites and units, such as a besan or dal unit, the systems to connect, and whether any sensors need to be added.
It runs on managed cloud, in your own VPC on AWS, Azure or GCP, or on-premises with your keys. India data residency is available when required. The data stays yours, and the twin reads plant systems without writing to them.
The owner and plant head use the overview and shift replay. The head miller watches tempering and extraction, the purchase head watches wheat cover and the gate, QC watches checks, and dispatch watches stock and dealer orders. Each gets only their own alerts.
08Briefing
In a working session we draw your site, connect two or three sources such as the weighbridge and packer counts, and write the first alerts with your head miller.
