Production & Process Management System

End-to-End Digital Control of Flour Production, Quality, and Distribution

THE BRIEF

The client required a fully integrated production management system to control and monitor the entire flour milling lifecycle. This included managing works instructions, optimising wheat allocation through gristing, recording production data, integrating laboratory testing, and coordinating downstream processes such as silo storage and final packing into bulk or bagged products.

Introduction

Flour milling is a complex, multi-stage process where raw materials must be carefully blended, processed, tested, and distributed. The client’s existing processes relied heavily on manual coordination and disconnected systems, limiting visibility and efficiency across production.

To support scalability and improve operational control, the client required a centralised digital solution capable of managing the entire production workflow from raw wheat allocation through to finished product dispatch.

The Client

E.B. Bradshaw & Sons is a UK-based flour milling company producing high-quality flour for a wide range of commercial customers. Their operations require precision, consistency, and full traceability across the production process to maintain product standards and meet regulatory requirements.

Solution

Axisware developed a comprehensive production management system tailored to the specific requirements of a modern flour mill.

At the core of the system is the management of works instructions, which define each production run, including product specifications, required quantities, and processing parameters.

A key component of the system is gristing.
In flour milling, a grist is the precise blend of different wheat types used to achieve a specific flour quality. Different wheat varieties have varying protein levels, moisture content, and baking characteristics. The system enables controlled allocation of wheat batches into a grist mix, ensuring consistency and adherence to product specifications.

The system then tracks the production lifecycle, including:

  • Allocation of wheat stock to production runs via gristing
  • Recording of milling output and process data
  • Integration with laboratory testing for quality assurance (e.g. protein levels, moisture, ash content)
  • Automated movement of finished flour into silo storage
  • Management of downstream processes including bagging, bulk loading, or hybrid fulfilment

Seamless integration between production, laboratory, and storage ensures full traceability and real-time visibility across operations.

Benefits

  • Complete Production Traceability from raw wheat intake to finished product
  • Consistent Product Quality through controlled gristing and integrated lab testing
  • Improved Operational Efficiency via automation of production workflows
  • Real-Time Visibility of production status, stock levels, and outputs
  • Flexible Fulfilment Options supporting both bulk and bagged distribution
  • Reduced Manual Intervention and minimised risk of human error

Conclusion

The implementation of a fully integrated flour production management system has enabled E.B. Bradshaw & Sons to modernise their milling operations. By digitising and connecting each stage of the process, the business benefits from improved control, enhanced quality assurance, and greater efficiency across the entire production lifecycle.

Project Details

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