Jakarta, Indonesia – The challenge began three years ago in the headquarters of PT ISM Bogasari Flour Mills, one of the world’s largest flour milling facility. The challenge regarded the realization of a complete retrofit of three milling lines without interrupting production. With a highly innovative design, technical and technological strategy, Ocrim won the challenge and completed the complex upgrading intervention with great satisfaction.
Ocrim-PT ISM Bogasari Flour Mills: Together For 50 Years
The first milling plant built by Ocrim for Bogasari Flour Mills dates back to 1971. Since then, the partnership has intensified more and more, based on common values and objectives. In these 50 years of activity Bogasari Flour Mills, which is a business unit of the PT Indofood Sukses Makmur Tbk group, has grown to become the main producer of wheat flour in Indonesia and one of the world’s largest milling facility. The largest production site is in Jakarta with a production of around 11,650 tons per day; the other site is located in Surabaya (East Java), with around 6000 tons per day.
The last project that committed Ocrim for three years concerns the Jakarta plant which has 15 milling lines – which the company identifies from letter A to letter O -, all equipped with Ocrim machines. The recent intervention had as its object the update of the H-I-J lines of the mammoth plant, but it was not a question of replacing only the 40-year-old machines with the latest technology. The work that Ocrim had to face was much more complex and required a highly innovative design, technical and technological strategy that would guarantee production without interruption and respond to new consumption trends. Therefore, the three milling lines, on customer’s request, have been updated one at a time, allowing production to continue uninterruptedly for 3 years necessary to make the update. An important challenge that Ocrim has brilliantly overcome by using new and patented programming and installation methods, increasing the production capacity of each milling line by 50% (from 800 to 1,200 tonnes per day).
From left: Mr. Alberto Antolini, CEO Ocrim, and Mr. Franciscus Welirang, CEO Bogasari Flour Mills
The Retrofit Process
To meet customer requests and achieve agreed aims, Ocrim has put in place technological solutions for layout, plant design and cutting-edge automation. Concerning the layout, it was necessary to reinforce the civil structure of the building by integrating the building with an additional floor to exploit as much as possible the concept of energy savings applied to the entire plant. Furthermore, with a very innovative and efficient diagram, it has been possible to implement Ocrim last generation double deck roller mills – used in an optimal way to obtain an excellent final product – and to apply modular plansifters with 10 channels also for a concrete space optimization.
The Modular Technology Concept has been introduced, a system that allows you to stop only a part of the mill and to allow maintenance only on the affected machines without stopping the entire line. Concerning the automation, Ocrim has equipped the three lines the innovative @rollermills software that allows the operator to control the mills remotely via tablet and then to program them with a single operation carried out at any point of the mill. This system allows to intervene promptly in case of adjustments, and production optimization, since the operator is no longer required to act on the roller mill on-board control, it almost completely cuts down the setting time of the entire line and is also innovative for safety purposes, because, despite running on wi-fi, it guarantees a secure protection from external agents. Other key improvements include the Ocrim latest RMX roller mills, characterized by the presence of which stainless steel material for food grade surfaces; the automatic sieves tensioning devices on plansifters to drastically reduce downtime for maintenance; the optimization of the automatic adjustment of pneumatic system by inverter to optimize consumption.
The results obtained got above the customer expectations who, as you can imagine, expressed great appreciation and satisfaction for the work done. Yet another challenge experienced with the professionalism and passion typical of the Ocrim team, which confirm its role as an attentive, reliable and innovative partner.
