Interview: Namık Kemal Parlak

Fluctuating wheat origins, quality concerns, market volatility, and margin pressures demand smarter tools in the grain milling industry. Fabien Varagnac—a respected milling consultant with nearly two decades of hands-on experience—explains how digitalization and AI are reshaping every dimension of flour production, from sourcing and quality control to operational agility and risk management. In this exclusive interview, he offers a forward-looking vision of the mill of the future—where strategic thinking, data-driven insight, and technological adaptability are key to thriving in an increasingly complex and competitive landscape.

Fabien Varagnac
Independent Milling Sector Consultant

Behind every loaf of bread lies a complex global system and at its center is a milling industry undergoing a transformation. Few understand this better than Fabien Varagnac, an independent milling consultant whose journey from a trained miller to strategic advisor spans nearly 20 years and countless flour mills worldwide. In this exclusive interview with Miller Magazine, Varagnac shares powerful insights into the evolving world of grain processing. From the rise of digital technologies and the growing emphasis on wheat quality to Africa’s surging demand and the mounting pressures of supply chain volatility, he paints a vivid picture of an industry in transition.

Varagnac calls for smarter, more flexible mills and smarter, more empowered millers to manage today’s volatile grain markets. With deep knowledge and clear conviction, he outlines a forward-looking vision for the ‘mill of the future’: data-driven, digitally connected, and strategically embedded in the global food value chain.

Fabien, your journey from a trained miller to a strategic consultant is remarkable, with nearly two decades of experience and visits to flour mills around the world. In your view, what is the biggest misconception the public has about the milling industry today?

That’s a very good question. I believe the biggest misconception is that most people simply have no conception of what milling actually is. When you mention flour milling, many immediately think of an old-fashioned windmill or a traditional stone mill. There’s very little awareness of what the modern milling industry looks like today. And that’s a real shame, because this is a sophisticated, high-tech, and constantly evolving industry. It plays a crucial role in the global food system by ensuring food security and putting bread on the table for people all around the world. Yet, the industry remains largely invisible to the general public.

Another issue is the poor public image of wheat flour, particularly in developed economies, where it’s often criticized in the context of gluten, carbohydrates, and certain diet trends. Flour suffers from this negative perception, despite being a foundational component of the global food system. Globally, wheat accounts for roughly 20% of caloric intake and about the same share—around 20%—of global protein intake. That’s significant, especially considering how difficult and costly it is to access protein, whether animal- or plant-based.

In regions such as North Africa and Central Asia, wheat can make up as much as 40% of total protein intake. That highlights just how critical flour is to food security and nutrition, particularly in areas where alternative protein sources are limited.

So, in short, the milling industry is modern, essential, and deeply tied to global nutrition. It may not be the most nutrient-dense food, but flour remains one of the most accessible and affordable sources of nutrition today and that deserves recognition.

A SHIFTING WHEAT MAP

Reflecting on your career in the milling industry, what major shifts have you witnessed, and how have they influenced your perspective on the sector?

Over the past 20 years, I’ve seen a number of major trends reshape the milling industry. One of the biggest has been consolidation and growing competition across global markets. There are no “virgin” or untapped flour markets left—everywhere you look, from Europe and the U.S. to Russia, Turkey, Africa, Latin America, and Asia, the milling sector has become highly competitive.

Another key trend is product diversification. As competition increases, millers are seeking ways to differentiate themselves. In developed markets, this has taken the form of specialized flours—organic, whole grain, ancient grain, and so on. Even in emerging economies, where a single type of flour used to dominate, we’re now seeing a shift toward more tailored flours for different applications—bread, pastries, croissants, and more. This evolution is driven by the need to meet growing consumer expectations and to carve out a margin in competitive environments.

On the supply side, we’ve also seen a massive change in wheat sourcing. Back in the 1990s, about 80% of global wheat exports came from just five countries. Today, the export landscape is much broader, with many more origins involved—and with that comes increased variability in both quality and quantity.

Weather plays a huge role here. Last year, for example, France had a disastrous harvest in terms of quality. That limited export opportunities significantly. This year looks more promising, but the fluctuation from one season to the next can be dramatic. As a result, it’s no longer realistic for millers to rely on a single wheat origin for an entire year. I have clients in Africa who had to switch between eight different wheat origins in the past 12 months. Each origin change means adjusting the grinding, milling parameters, additives—everything. It’s incredibly complex.

Geopolitical factors are another source of disruption—conflicts, trade barriers, and logistical bottlenecks in critical areas like the Suez Canal or the Gulf of Aden can all impact wheat availability and prices.

Millers must constantly adapt—not only to shifting market demands but also to unpredictable supply chains and global events. You can’t just be a good miller anymore. You need to be a weather analyst, a financial strategist, and a geopolitical observer. Simply knowing how to grind wheat isn’t enough in today’s world.

WHAT MILLERS ASK MOST

You work closely with millers across diverse regions. What are the most frequent challenges or requests they share with you? Have you observed any trends in their priorities?

Yes, absolutely. One of the most common and recurring questions millers ask me is related to wheat quality—what is the current quality, what will it be in the next harvest, and whether they should source from one origin or another. This topic comes up in nearly every conversation I have with millers.

This strong focus on wheat quality reflects just how critical it has become in today’s competitive environment. Consistent and stable quality is no longer optional—if a miller fails to maintain high standards, the competition is ready to step in and take market share. Every market I work in, regardless of the region, is increasingly prioritizing quality.

As a result, we rarely see a mill operating without a proper laboratory or analytical setup anymore. In the past, quality control was often visual—millers would inspect the flour, make a basic judgment like “this is a bit whiter or darker,” and release it to the market. That’s no longer acceptable. Today, quality must be measurable, traceable, and managed with precision.

Closely linked to this focus on quality is the growing importance of traceability. This is increasingly becoming a core demand—especially in more mature markets where traceability is required for certifications such as organic, or simply for maintaining consistency. Whether it’s understanding the origin of a batch of wheat or managing internal quality systems, traceability enables millers to identify what wheat went into which flour, and which processing parameters were applied at each stage.

Ultimately, quality and traceability go hand in hand. You can’t deliver reliable quality without knowing exactly what’s happening in your supply chain—from wheat sourcing to processing. That’s why these two topics have become central priorities for millers around the world.

Another key topic is energy efficiency. It is becoming increasingly important for millers to improve their efficiency. Whether driven by sustainability or simply by the need to manage energy consumption and ultimately energy costs, millers are monitoring their efficiency more precisely than ever before. This monitoring leads to a lower environmental impact and better margin management. It is a global trend, everyone is impacted by energy challenges. Whether due to the war in Ukraine or poor infrastructure, almost every mill globally has faced energy challenges in recent years. This is one of the reasons why equipment manufacturers are focusing so much on this topic, and as a mass industry, the milling sector needs to be as efficient as possible. New equipment and technologies are helping in this respect, with new mills consuming less energy and the widespread use of sensors and smart dashboards enabling millers to accurately track and monitor their energy consumption.

As you pointed out, the increasing volatility in global grain markets and the diversification of wheat origins have made it more challenging to maintain consistent flour quality. How can millers ensure consistency despite such raw material variability? 

To maintain flour consistency in the face of variable wheat quality, the first step is having the right analytical equipment—especially for rheology. You need to thoroughly evaluate the quality of incoming raw materials. Once you have that data, you can begin adjusting your process accordingly. There’s actually a lot of flexibility within the milling process—you can modify your diagram or tweak machine settings to influence the final flour quality.

Wheat blending is another crucial lever. But to blend effectively, you must fully understand the quality of each wheat origin—both what you have in storage and what you can access in the market. This allows you to blend more precisely and achieve a more stable end product.

Flour treatment is also a key factor. Enzymes, ascorbic acid, and other treatment technologies are now essential tools that help millers fine-tune the functional performance of their flour. These treatments can compensate for quality gaps in the raw material and ensure the flour meets customer expectations.

Beyond tools and technologies, what really makes a difference is knowledge and data. Millers need a strong internal database of historical performance, as well as access to external insights. This is where I often support my clients—helping them interpret data, apply accumulated knowledge, and develop new flour formulations or process settings tailored to current wheat conditions and market demands.

In the end, consistency comes from the intelligent use of equipment, treatment options, and informed decision-making backed by data and experience.

THE FLOUR BOOM IN AFRICA

Africa is increasingly seen as a future demand hub for grains and flour-based products. Based on your close experience with this market, how would you describe the current state of the African milling sector? What key opportunities and challenges do millers face across the continent? 

Yes, that’s absolutely true. Africa is really booming. The demographic trends alone make this evident. The population is growing rapidly and is far from plateauing. Combined with accelerating economic development across many regions, the continent presents a very dynamic and promising environment.

When it comes to the milling sector in Africa, it’s incredibly diverse. You already have some large international players established in the market — while not dominant, some have been present and investing for quite a long time. Alongside them, we see the emergence of strong local companies, some of which are becoming significant players with solid financial backing and the ability to invest in robust, professional operations.

At the same time, there are still many small-scale players scattered across the continent. However, we’re beginning to observe trends of consolidation — a sign that the sector is maturing. Milling capacity is clearly increasing, with new projects constantly emerging, whether through new market entrants or existing players expanding, acquiring competitors, or venturing into other countries.

The growing demand for flour and flour-based products is a major opportunity. Over the last decade, wheat consumption in Africa has grown at a rate of around 2.5% annually — that’s roughly a 30% increase in ten years, which is substantial. We’re also witnessing diversification in flour types. In many countries where there used to be just one standard type of flour, there are now three, four, or even more varieties, reflecting a shift toward more mature and differentiated consumer preferences.

Another key trend is vertical integration. Many millers are now investing in pasta, biscuit, and industrial bakery production, depending on the country. Some major traders have even started acquiring milling groups in Africa — something that was rare in the past due to economic and political risks. But now, with the improving investment climate in many regions, more players are establishing a physical presence on the ground.

That said, significant challenges remain. The economic environment, while improving in many countries, is still very tough in others. Bureaucracy, complicated administrative systems, and tax regimes that do not always support business development pose major hurdles.

Another critical bottleneck is logistics — especially related to infrastructure like roads, ports, and silos. Many countries have invested in milling capacity and even retail distribution is improving — flour now reaches remote villages more easily than before. However, the inbound logistics remain a serious issue, particularly since most wheat is imported. Many ports lack sufficient unloading capacity, leading to congestion. Ships often have to wait one, two, or even three weeks before they can discharge. Dedicated grain docks are rare, discharge rates are low, and silo capacity at ports is often lacking. As a result, millers need a constant fleet of trucks operating 24/7 to transport the wheat — despite poor road infrastructure. This is becoming an increasingly urgent issue as economic growth continues. While there have been some infrastructure investments here and there, a much more substantial and coordinated effort is needed to match the region’s milling and consumption potential.

WHY AI IS THE FUTURE OF FLOUR MILLING

AI and smart technologies are gaining traction in the grain processing industry. What concrete benefits can millers expect from embracing digital transformation? Are your clients generally open to these innovations, or do many still prefer traditional approaches?

This is a very important topic—not just in our industry, but across all sectors today. AI is now part of everyday conversations, not only among professionals but even in the broader public.  I believe it’s the next crucial step in the industry’s evolution.

So what can mills expect from adopting digital technologies? First and foremost: efficiency—across the board. From procurement to processing to quality control, every aspect of the operation can be optimized. Milling is a high-volume, low-margin industry. That means every cent matters—every 0.1% gain in yield or efficiency is vital. At the same time, there are so many variables and pieces of equipment affecting performance that it becomes very difficult for a human team to track and optimize everything manually.

This is where smart technologies and AI can make a real difference. They help connect the dots across your operation—making sense of complex data to identify where you can boost efficiency or improve quality. That’s the first major benefit.

The second is flexibility and adaptability. With greater wheat origin variability, grist changes, and product diversification, mills need to be able to react quickly. Digital tools help monitor and understand raw materials, processes, and final products in real time. This responsiveness is becoming essential—not only to maintain product quality but also to stay competitive in a fast-moving market. So yes, efficiency and flexibility are the two key drivers of digitalization in milling.

Now, regarding whether my clients are open to these technologies… to be honest, many are still reluctant. They’re aware of the discussions happening in the industry, but change doesn’t come easily—especially in a sector where many businesses have been operated the same way for generations. That kind of experience is valuable, milling is indeed about sensing and feeling the product. But with today’s tools, you can achieve the same or even better results with far greater consistency and efficiency. If you have the right sensors, the right data, and the right AI helping you make decisions at the right time, the potential is enormous.

Ultimately, when millers begin to understand how digital tools can support—not replace—their expertise, they become more open to innovation. But yes, there’s still a long way to go in terms of broader adoption.

What are the key barriers millers face in adopting digital solutions, and how can they be overcome? In this context, how can a consultant like you support their transformation journey?

The most important starting point for any digital transformation journey is data—specifically, data collection and data quality. Without reliable data, digitalization simply cannot work. In many mills, data is scattered across paper logs, spreadsheets, and multiple databases. The first step is to centralize and structure that data—ensuring it is collected consistently, securely, and with sufficient historical depth.

This is critical because digital solutions must be tailor-made for each unique milling operation. There’s no one-size-fits-all. Each application depends heavily on that specific mill’s data, experience, and operating environment. That’s why having clean, standardized data is essential—not just for implementation, but for building effective and relevant digital tools.

Once the data is centralized, the next question is data quality. Are your sensors accurate? Are your evaluation methods current? Are they standardized? For example, when we talk about baking performance, that involves assessing bread quality. But how do we define “good” bread? One person might consider a loaf well-risen, while another might not. These kinds of subjective variations must be addressed through standardization of evaluation methods, which is something I often help mills implement.

Another common misconception is that digitalization requires major upfront investment in sensors, databases, or specialized equipment. That’s not true. You can start small—by working with just a couple of parameters using existing lab data, production logs, and mill performance metrics. Even with basic data, mills can begin developing smart systems and digital tools to optimize yield, quality, and efficiency.

Once you build some initial models and begin to see results, you might then identify specific areas where an additional sensor or hardware upgrade could further enhance your process. But smart milling doesn’t have to start with big infrastructure. It can begin with your existing systems—provided your data is clean and consistent.

This is where my role as a consultant comes in. I help millers identify where to begin, which areas to prioritize, and how to align their digital tools with their operational goals. What’s the key pain point? Do you need to improve yield, quality, consistency, or traceability? Once that’s clear, we can co-develop a roadmap—step by step—to achieve those goals using the right digital tools and strategies.

THE MILLERS OF TOMORROW

You are also training the millers. What skills do you believe the next generation of milling professionals must develop to thrive in a more data-driven, globalized industry?

There’s a lot of fear surrounding ideas like “dark factories” or the belief that millers will be replaced by robots. But I don’t share that view. I believe we will always need millers—what will change is the skillset they must bring to the role.

To succeed in the future, millers will need to become even more specialized experts. They must understand their process at a deeper level than ever before. Smart technologies are not here to replace millers, but to enhance their understanding—to help them see more clearly what’s happening within the system, and how their actions affect the final product. That includes understanding the link between operational decisions and changes in flour quality, yield, or process stability.

If millers simply let the machine run on its own without truly grasping what’s happening, there’s a risk that product quality or yield may start to drift—and they won’t know why. That’s why the next generation of milling professionals must develop a strong grasp of the physics and chemistry at work inside the mill. They need to understand the science behind the process, not just operate the machines.

Second, they must be much more open-minded. It’s no longer enough to focus solely on what goes in and out of the milling system. Today’s smart solutions are inherently holistic—they connect every step of the value chain, from field to fork. That means millers will need to think beyond their immediate responsibilities. They must understand what’s happening with raw materials, storage, market conditions, and even external factors like geopolitics, finance, and weather.

In short, millers must break out of silo thinking. The industry demands professionals who can see the broader picture—who can think systemically, anticipate changes, and contribute to the performance of the entire value chain. If they can do that, they will not only remain relevant, but also help push the milling sector forward into a more sustainable and intelligent future.

A VISION FOR THE NEXT-GENERATION MILL

As someone who bridges science, business, and tradition, what is your vision of the “mill of the future”?

That’s a very good question. For me, the mill of the future will be a highly connected processing hub—a vital link in the global food value chain. It will play a central role in bridging the agricultural sector, which produces raw materials, with the growing global demand for food.

This future mill will not just process wheat; it will be a strategic tool for optimizing resource use, ensuring that inputs like water, energy, and grain are used as efficiently and sustainably as possible. It will have a pivotal role in feeding the world—not only efficiently, but also responsibly.

At the same time, the mill of the future will be highly versatile. It will need to adapt to a wide range of variables—from climate fluctuations to innovations in food science and consumer trends. Flexibility will be key. It will be equipped to adjust to raw material variations and evolving market demands, all while maintaining quality and performance.

In short, the mill of the future will be a smart, adaptive, and sustainability-driven system—designed to deliver nutritional, high-quality, and exciting food products to a growing global population. It will stand at the intersection of tradition and innovation, science and food security.

HOW MILLERS CAN SERVE DIVERGING MARKETS

Which consumer trends are currently reshaping global flour consumption, and how can millers best respond to these evolving demands?

That’s a challenging but very relevant question. Let’s break it down by looking at two distinct market types. On one hand, we have mature markets such as Europe and North America. In these regions, two major trends are reshaping flour consumption: a growing demand for sustainability and for healthier diets. What’s particularly important to understand is that what used to be niche markets—organic, whole grain, clean-label, gluten-free, ancient grains—are no longer truly niche. In some countries, they’ve already become mainstream, or at least significant enough to warrant serious strategic attention.

These segments are also high-value markets for millers who can serve them efficiently. To meet these demands, flour producers need smaller, more flexible production lines—capable of handling small batch runs with high traceability and the ability to quickly adapt to market shifts. In these mature markets, we’re essentially seeing the coexistence of two parallel models:

• Large-scale plants producing standardized flour at high volume and speed for the mass market.
• Smaller, more agile mills producing specialized flours tailored to consumer trends, with more sophisticated processes and tighter quality controls.

Now, turning to developing markets, we’re seeing a different trend. There’s a noticeable convergence in dietary habits, influenced by globalization. Fast food is growing. Flatbreads like pita are gaining popularity. Eating habits are becoming more standardized across regions—and this is driving up wheat consumption.

This shift leads to massification and industrialization of flour production in many developing regions, particularly in parts of Africa and Asia. In these environments, we observe increasing consolidation of the milling industry, where fewer but larger and more efficient plants dominate the market. The focus here is on cost efficiency, volume, and consistency—requiring large-scale operations and investment in process optimization.

To stay competitive in these fast-expanding markets, millers must often pursue vertical integration. That could mean:

• Moving upstream by getting closer to grain production—either through direct farming partnerships or tighter relationships with traders (or even mergers, in importing countries).
• Moving downstream into value-added segments such as baking, pasta, or biscuit production, which allows better control of product development and pricing, and improves margins.

Remaining a small or average-sized standalone miller is increasingly difficult in these contexts. So the key to success—whether in a mature or emerging market—depends on strategic positioning:

• Agility and specialization in mature markets
• Scale and integration in emerging ones

Millers who understand and adapt to these evolving trends will be best positioned to grow sustainably and profitably.

MILLING AS A FORCE FOR GLOBAL FOOD SECURITY

Do you have any final message for industry stakeholders? 

Yes. I believe we are working in a very exciting time and in an industry that is both challenging and deeply meaningful. It’s important to remind ourselves that what we do matters—we are feeding people, we are innovating, and we are finding creative solutions to global challenges. That’s something to be proud of.

But we also need to promote our work more actively—not just within the milling community, but to the broader public. To return to your very first question: most people have no idea what milling actually is. That lack of awareness is unfortunate. It also has consequences—for example, when it comes to attracting the next generation of professionals. Few young people aspire to become millers, simply because they don’t know what the job involves or how important it is.

So my message to industry stakeholders is this: let’s stay proud of what we do, and let’s make a stronger effort to communicate the value of our work—to show the world that milling is not just an industrial activity, but a vital part of global food security. We are already making a significant contribution to feeding the world—and we can do even more, and even better, in the future.