Milling Industry: Key Processes and Technologies

Experts for Milling

Malcolm has an extensive background as a Mechanical Engineer in Material Handling and Sieving Technology and has been working on Vibratory Sifter Technology for well over 40 years, with the last 21 years at Kason Europe. Malcolm currently holds the role of Technical Sales Engineer. He handles all the technical aspects of providing the Regional Sales Managers with the quotations they require to sell the AMP/AHS range of equipment globally. He also assists the RSM’S with customer queries and final deal negotiations as well as liaising with the Engineering team to ensure a smooth transition between sales and GA approval. His vast knowledge means that he also offers and provides training where required on the AMP product range of equipment across the European Sales group.

George Bougioukas, Plant Manager of Acmon systems has over a 20 years of experience in plant process design for both mechanical and automation engineering in a wide range of industrial sectors. He has gained a unique knowhow of cross-cutting technologies and applications bringing the organization to reach a new industrial value chain era. George’s expertise includes applications ranging from reception and storage of raw materials, pneumatic and mechanical conveying, sieving, weighing and dosing, mixing, up to bagging and final product dispatch. Behind George there is a dedicated team of engineers who like him are constantly striving to improve design and performance of all plants Acmon systems has been delivering all around the globe for the last 30years on a turnkey basis.

Alex McCans is National Sales Manager for HammerTek Corporation, manufacturer of the innovative Smart Elbow Deflection Elbow. With over 10 years of experience in mechanical and pneumatic conveying of bulk solids, Alex leads the HammerTek sales team to solve conveying challenges for customers around the world. His expertise and dedication have helped establish HammerTek as a trusted leader in the industry.

David Hyer has led Thayer Scale as President and General Manager since 2016, overseeing all aspects of daily operations and long-term strategic direction. He originally joined the company in 1985 as a college student writing machine-level code for the PI-164 instrument, returning in 2013 after a successful career in senior leadership at Teradyne and two venture-backed technology ventures. Prior to rejoining Thayer Scale, David served as Division Manager for Teradyne’s circuit-board test and inspection business, where he was responsible for P&L and led global sales, engineering, and service teams. His broader background includes senior roles in sales, business development, and product strategy across high-growth technology companies. David brings deep expertise in the design and manufacture of precision conveyor belt scales and gravimetric feeders. Under his leadership, Thayer Scale has strengthened its focus on product specialization, engineering excellence, and rigorous quality, delivering solutions tailored to the demanding needs of the Food, Energy & Building Products, and Chemical & Industrial markets. He holds a Bachelor of Science in Electrical Engineering from Tufts University. David and his wife have three children, and he enjoys tennis, golf, and spending time on the water.

John has been working as a Mechanical Engineer in Mixing & Sieving Technology for over 47 years, the last 6 at Kason and is currently in the role of Technical Sales Engineer. He handles all the technical aspects of providing the Regional Sales Managers with the quotations they require to sell the AMP/AHS range of equipment globally. He also assists the RSM’S with customer queries and final deal negotiations as well as liaising with the Engineering team to ensure a smooth transition between sales and GA approval. His vast knowledge means that he also offers and provides training where required on the AMP product range of equipment across the European Sales group.

Russell Grotto serves as the Director of Operations for the Toll Processing sector of Elcan Industries’ sieving business. He graduated from Union College with a BA in Managerial Economics. His father, Bob Grotto, is the founder of Elcan Industries and served on the board of PEMA for over a decade. Russ works closely with customers to help them develop catered sieving solutions to their specific products and needs. Before becoming the Director of Operations, Russ served as an operator in the toll processing plant and has hands on experience running screening machines. Russ also works closely with the manufacturers of the sieving equipment Elcan sells and was an integral part in bringing their newest line of equipment, the Hi-Sifter, to the US market place.

Adrian is currently the President of MoistTech Corp and has been with MoistTech Corp. since 2010 starting as the Sales Manager. Bringing to the company many years of experience and expertise in multiple industrial moisture applications, Mr. Fordham has vast knowledge in Near-Infrared moisture sensing and detection technology.

Robert brings over 25 years of experience for bulk material handling and material processing equipment to Material Transfer. At MTS, he is responsible to fostering new business opportunities while nurturing account relationships. His depth of experience and industry knowledge allows our Team to meet the growing needs of our customers as we continue to provide the highest quality systems to the marketplace.

Nathan Grube is BinMaster’s Regional Vice President of Sales, covering 11 states across the central United States. Grube joined the BinMaster team in 2001 and has since built the company’s reputation for reliable sales and customer support. Working with users, distributors, and OEMs from North Dakota to Texas, Grube possesses bulk solid inventory sales experience in agriculture, aggregates, cement, plastics, and mining, among other industries.

Tim Llewellyn is the Global Director of Sales at Flexicon Corporation, a world leader in the design and manufacture of bulk handling equipment and custom-engineered systems. He has over 20 years of experience managing and delivering complex global projects within the bulk material handling industry, including expertise across multiple sectors, including food, chemical, pharmaceutical, nutraceutical, and plastics. Tim has a proven track record of building and managing teams focused on helping clients solve their powder handling challenges. Tim holds a Bachelor of Science degree in Mechanical Engineering from Lehigh University.

Paul Malcolm, General Manager of Engineering at Pneuvay Engineering, has been with the company since 2008. He is a highly experienced and qualified engineer, holding both advanced and associate diplomas. Paul is an expert in designing lean and dense phase pneumatic conveying systems and works by the motto, “Excellence is not a skill, it is an attitude”. Outside of work, he enjoys fishing with his son and playing with his daughter.

Chuck Johnson is the director of sales at National Bulk Equipment, located in Holland, Michigan. His professional experience includes over 25 years in the design, engineering, & sales of bulk material handling equipment & systems. Johnson holds a BS in mechanical engineering from Michigan State University.

Gareth Meese works as Regional Sales Director – EMEA (Europe, the Middle East, India, and Northern Africa) for Eriez-Europe, a global leader in several key technology areas, including magnetic separation, metal detection, and material handling equipment. With nearly 20 years of experience in continuously-evolving positions, Gareth is well versed in bulk material handling applications. When Gareth joined Eriez as an Export Sales Engineer, he led several Eriez teams tasked with expanding business throughout Scandinavia, the Baltic States, and the Czech Republic. Later, as Export Sales Manager, he concentrated on growing Eriez-Europe in Russia, Europe and Northern Africa. His recent promotion expands his geographic responsibilities further with the addition of the Middle East and India. Gareth has been instrumental in pursuing Eriez’ vision and holds a Bachelor of Science in Physics from Cardiff University. Gareth is more than prepared to discuss and recommend a tailored solution for any unique bulk material handling application.

Carrie Hartford is the Director of Business Development and Senior Project Engineer in Jenike & Johanson’s office in California. For nearly 2 decades, she has been solving challenging bulk material flow related problems around the world. Typical projects include the analysis and design of bins, hoppers, feeders, and transfer chutes. Previously, she opened and established an engineering office and laboratory facilities in Perth, Western Australia. Internationally she publishes and presents technical papers, participates in conferences, and presents numerous short courses in the field of bulk solids flow. Carrie has a Mechanical Engineering degree from the University of California, Santa Barbara and an MBA from Azusa Pacific University in California. She is a licensed Professional Mechanical Engineer in the State of California.

Emre Ergun is the Head of Sales of IEP Technologies Europe. He brings over 24 years of experience in the industrial explosion protection and prevention field, specializing in explosion suppression & isolation systems, venting (including flameless venting), and spark detection & extinguishment solutions. He is also experienced on dust explosibility testing methods, applications and relevant standards. He holds BS Chemical Engineering from Middle East Technical University, Ankara, MS Engineering Management from Northeastern University Graduate School of Engineering, Boston MA and MBA from Babson College, F.W. Olin Graduate School of Business, Wellesley MA USA. Mr. Ergun is a certified safety auditor (CSA) by the National Association of Safety Professionals, NASP.

Gerard van Schoten is Managing Director at HETHON, a globally active specialist in powder dosing systems. With a strong technical background and hands-on experience throughout the company, Gerard combines strategic leadership with deep process knowledge in dry bulk handling. He is widely regarded for his expertise in handling and dosing poorly flowing powders, particularly in industries requiring high precision and reliability under challenging conditions such as ATEX environments. Gerard works closely with international customers, engineers, and agents to translate complex process challenges into custom-engineered, long-term solutions. Having grown within the company from a technical role into leadership, Gerard brings a unique combination of technical credibility and commercial insight. He remains actively involved in advising on system configurations, control integration, and customer-specific adaptations—ensuring that every solution HETHON delivers is both technically sound and practically applicable. Gerard regularly supports agents and customers worldwide and is a trusted point of contact for clients seeking high-performance dosing technology for demanding industrial applications.

Chris has been working at Spiroflow for over 10 years and is currently in the role of technical sales manager. He handles all the technical drawings and specifications during the sale and aides our drawing office while the equipment is designed, he also assists the manufacturing department with the build. His vast knowledge of powder handling and mechanical design is why he is involved in every aspect of designing our powder handling solutions.

Sylvain Bellamy is currently the Commercial Director for Powder Process and Technology at Tetra Pak, based in France. With over 25 years of specialized experience in powder processing, handling, and packing, Sylvain has held various roles across the Americas and Europe, providing him with a comprehensive understanding of the global market. Sylvain's robust background in the food processing industry has sharpened his powder expertise during his years at Tetra Pak, where he contributed to developing innovative powder processing solutions. He leverages his extensive experience to drive strategic growth and operational excellence, always ensuring the delivery of cutting-edge technology and solutions that bring innovations to the market. Contact: Sylvain.Bellamy@tetrapak.com

Matthew is a mechanical engineer holding an honours degree from the Auckland University of Technology and has been responsible for BFM® Global’s product development, testing and compliance programme for over 7 years. Matt’s experience is centred on the powder handling industry with a specific focus on flexible connectors, and all the compliance requirements around them. From food to pharmaceutical and all industries in between, Matt works with our Distributor partners, end users and OEMs from Europe, Asia and the Americas to solve application challenges. He regularly attends industry tradeshows around the world and understands the complex requirements of each different market.

Design Engineer, Project Manager, Territory and Sales Manager with 40+ years of experience in capture at source designs, sales and installation projects for high and low vacuum and dust collection and filtration systems and explosion and fire mitigation in dust collection systems.

The milling industry includes all manufacturers and technologies involved in the size reduction, separation, and classification of bulk materials. These processes play a key role in converting raw materials into powders, granules, or particles with specific and controlled properties. Milling is essential in many industries, including food, chemicals, minerals, and construction materials.

Milling systems break down materials through mechanical forces such as impact, compression, or shear. Depending on the application, processes may also include screening, classification, and separation to achieve the desired particle size distribution. In addition, milling can help remove contaminants or reduce moisture content, producing dry and stable materials that are easier to store, handle, and transport.

Production facilities rely on a range of equipment, including crushers, grinders, mills, classifiers, and drying systems. Efficient material handling and process control are critical to ensure consistent product quality and high throughput. Precise control over particle size and moisture levels directly influences product performance in downstream applications.

As industries demand higher precision and efficiency, milling technologies continue to evolve. Advanced systems improve energy efficiency, reduce waste, and enable better control over final product characteristics, supporting reliable and scalable production across a wide range of bulk material processes.

The industry of Milling

Milling allows you to control the particle size of your product in the manufacturing process. Particle size consistency enhances product flow rate and reduces the size, which can assist in the downstream process, depending on the product goals.

A milling process refers to the complete process of cleaning, grading, breaking down, sizing, separating, or classifying dry bulk materials. The actual milling process involves the mill that is used to break solid bulk materials into smaller pieces by grinding, cutting, or crushing.

Types of mills

There are a variety of mills that can be used to process bulk materials. Specific mills can grind powders and solids as small as single-digit microns to any specification.

There are various types of Mills

Here is a list of the most common types of mills:

Jet mill
Air classifying mill
Hammermill
Ball mill
Impact mill
Pulverizing mill

The grinding of solid materials occurs through mechanical forces that break up the structure.

After the grinding, the state of the solid is changed: the particle size, the particle size disposition, and the particle shape.

Purposes of the milling process in engineering:

Pulping: Converting the bulk materials into pulp
An increase in the surface area of a solid
Manufacturing of a solid with a desired particle size

Dry milling vs wet milling

Dry grinding creates much dust that results in the need for proper filtering systems. This can be of specific importance during the grinding of substances whose dust can result in explosive mixtures when mixed with aerial oxygen. Elaborate technical solutions such as systems for dust removal and inert gas overlay are often necessary to achieve the required level of safety. The cost for these filtration machines often significantly exceeds the actual mill’s.

Wet milling, also called wet media milling, is a process in which particles are dispersed in a liquid by shearing, impact or crushing, or attrition. Wet milling can be more intensive, but it can reduce a bulk product into more components and finer particles in the micron & submicron (or nanometer) particle size range.

The milling process industry comprises all manufacturers involved in process technology that is used for breaking down, separating, sizing, or classifying bulk materials. Milling processes can also remove contamination or water/moisture from bulk materials to produce dry particles prior to transport.

The Milling Process

Corn milling process

Corn wet and dry milling are the most important methods of processing corn, and each method produces distinct co-products. The corn wet-milling process is designed to extract the highest use and value from each component of the corn kernel. Wet milling involves soaking or steeping whole corn to soften the grains, after which further processing separates features used in a variety of products. In general, ethanol is not the primary focus for wet milling processors.

The corn dry-milling process is a less versatile, less capital-intensive process that focuses primarily on grain ethanol production. In this process, the corn kernels are hammer milled into a medium-to-fine grind meal for adding to the ethanol production process.

Wheat milling process

The wheat milling process is how cereal grains are ground into flour.

The overall aims of the miller are to produce:

A consistent product
A range of flours suitable for a variety of functions
Flours with predictable performance

Waste from wheat milling is often used on agricultural land as fertilizer.

Bulk solids milling is applied to improve the flowability, dissolvability, or volume reduction of blocky, abrasive, or hard-to-process bulk materials to the exact desired finished particle size.

It is imperative to understand which performance can be achieved by a particular type of mill and which type of bulk solids. It will allow the process engineer to properly select a mill type for a new process or troubleshoot an existing process.

The global milling industry is driven by responding to customer and consumer trends and needs. It is challenging to find a source covering all aspects of the milling process.

Many milling process innovations and new technologies are available in the global processing industries. Some current small developments in available machine models, some present agricultural innovations, and some present revolutionary technologies.