Our Roller Milling Process

The various processes employed during the conversion of grain to flour have become many and varied, and keep evolving.

To produce the highest quality flour, it is necessary to utilise modern milling methods which effectively provide the Miller more tools and choices as to what may be performed so as to process the various components of the grain.

Now, our Millers preferentially use Metal Rollers so as to be able to properly control the grinding of the grain and the progressive grinding steps that are required to separate as much good quality flour as possible from the grain without damaging the components of the grain.

The use of metal rollers to grind the grain allows greater grinding precision and more uniformity, uses less energy and, counter-intuitively, causes less heat-degradation of the components of the grain and allows better health and nutrition outcomes.

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  GRAIN SOURCING

  Grain is a Variety-based crop that is seasonally grown and harvested annually, and which varies in quality according to the genetically conferred attributes of the grain Variety, the intrinsic nature of the soil and region, and the seasonal effects on the growing environment. Each parcel of grain is unique, and has the potential to confer unique characteristics to the Flour created from it.

  All our farmer partners employ farming methods that seek to preserve and improve the integrity and fertility of their soils and the local environment for themselves and their future generations, where such practices are commonly referred to with Organic, Sustainable and Regenerative Agriculture Systems. This close partnership and our quality control systems allow us to be able to trace the content of every batch of flour back to the grain grown and sourced from every farm.

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  GRAIN CLEANING & CONDITIONING

  Farmers clean the grain as they reap it. Millers clean the grain as they receive it and again clean the grain before they mill it. Mill Cleaning is an intensive and multi-step process, intended to remove any foreign or unsuitable seeds, un-millable material; and any biological and physical contaminants.

  Water is utilised to progressively Condition and Temper the grain in multiple steps over several days. With grain Conditioning, we seek to make the Branny outer layers of the grain more flexible and readily separable from the endosperm. With grain Tempering, we seek to modify the crystalline matrix that binds the endosperm such that, when ground, the complex carbohydrate provides the intended rate of water absorption and rate of fermentation when utilised as flour within a dough.

  
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  FLUTED BREAK ROLLERS

  So as to be able to efficiently and effectively remove the bran from within the crease of the wheat grain, and to be able to best separate the bran as flakes; cleaned and conditioned grain is progressively passed through a series of individually-crafted metal Break Roller Mills with different fluting and grinding gaps, where the grain is firstly sliced open to release the endosperm without damaging the germ or creating heat. Then, progressively over subsequent Break Roller grinding passages, adhering endosperm is judiciously scraped off the flakes of bran with minimal damage to either, and the largest lumps of endosperm are reduced in a very controlled manner to more manageable particle sizes (semolina).”

  
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  SIFTING & PURIFYING - ROLLER

  Grain is progressively Coarsely and Finely ground, and each outcome is then Sifted; and this creates multiple streams containing various proportions of the various components of the grain. Careful sifting and sorting of ground grain allows the various components of the ground grain to be separated by particle size, shape, and density. Our Plansifters have multiple sieves for every stream and sort all ground product, separating semolina, flour, bran and wheat germ. Our Purifiers utilise air flotation to sift, sort and clean semolinas of similar particle size by shape and density, where purified semolina can then be sent for Fine grinding.

  More streams are created for further grinding, where, after every grinding passage, and consequent to sifting, some “flour” is released and other components are streamed for further grinding and sifting.

  Purified semolina, when ground and sifted to a fine-enough particle size which will absorb water as appropriate and be able to create the intended dough or batter, is called “flour”.

  Using Fluted Break Rollers and smooth Reduction Rollers, grain is progressively ground much more precisely and only according to specific need. With minimal disruption to the germ and bran, semolina is more precisely ground and sifted, creating more semolina and better quality flour with minimal energy input and less generated heat.

  
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  SMOOTH REDUCTION ROLLERS

  Purified semolina is progressively finely ground and Sifted to reduce particle size. With each grinding and sifting of the semolina, as it is progressively reduced in particle size, some small Bran flakes and Germ and final Flour are sifted off. Finally, when the Miller judges that only poor quality flour is remaining, that stream becomes Pollard.

  The adjustments of the machines that grind Finely and the setup of the Plansifters and Purifiers are critical to creating flours that have the intended dough and baking characteristics.

  Using Smooth Reduction Rollers, semolina is progressively ground according to specific intention; creating more specific grades of smaller semolina with minimal energy input and less generated heat. With minimal disruption to the germ and bran, larger particles of semolina are more precisely ground and sifted, and germ is readily flattened and separated without damage to nutrition and flavour. Then, with more uniform smaller particle size and minimal contamination, further smooth reduction rollers can precisely grind the endosperm to create better quality flour that has much more predictable dough water absorption and complex carbohydrate with intended fermentation characteristics.

  
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  STREAMING OF PRODUCT & PACKING

  After “enough” Grinding and Sifting, multiple streams of the various components of the grain are created. Selected streams of like product are combined, such that individual streams of Semolina, and Flour, and Germ, and Bran, and Pollard can all flow out of the Mill and be stored and then packed in to suitable containers for provision to customers.