Selecting the Finest Punjab Wheat

We begin with contract-grown, high-protein wheat sourced from select Punjab farms under multiyear agreements.

• Field Protocols: Growers follow our seed-variety and fertilizer guidelines to achieve ≥12 % protein and <13.5 % moisture at harvest.
  
  
• Inbound Sampling: A probe extracts core samples from every truck; labs run rapid NIR scans for moisture, protein, and starch damage, plus strip tests for pesticide residue.
  
  
• Visual & Odor Check: Inspectors look for pink kernels (fusarium) and off-odors that indicate spoilage.
  
  
• Barcode Traceability: Accepted loads receive a GS1-128 barcode linking farm, field, and test data to a lot number that follows the wheat through packaging.

Triple-Stage Cleaning & Destoning

Wheat passes through three fully enclosed circuits to reach 99.9 % foreign-material removal.

1. Vibratory Screens – Two decks (4 mm and 2 mm) shake out straw, sticks, and oversized clumps at up to 20 t/h.
   
   
2. Aspiration Channels – Variable-speed blowers pull away husk, dust, and shrivelled kernels; air velocity auto-adjusts via differential-pressure sensors.
   
   
3. Magnet & Destoner – Neodymium magnets capture ferrous metal; a pressure-fluidized destoner ejects quartz, glass, and embedded stones heavier than 0.3 g.
   
   
4. Optical Sorter (bonus pass) – RGB + NIR cameras reject moldy or insect-damaged kernels for premium-grade flour.

Tempering & Conditioning -  – Gentle Moisture, Optimal Milling

Raising kernel moisture to a precise 15 – 16.5 % is the bridge between cleaning and flawless milling. Controlled hydration relaxes the bran layer, keeps endosperm firm, and ultimately boosts extraction efficiency while safeguarding vitamins and enzymes.

• Inline Moisture Meter — A PLC-driven dosing system atomizes filtered water through precision spray bars; closed-loop sensors fine-tune additions in real time until the target is reached within ± 0.2 %, eliminating over- or under-tempering.
  
  
• Stainless Steel Silos — Hydrated wheat rests for 8–12 hours in food-grade silos where slow-turning augers gently tumble kernels, equalizing moisture and maintaining a uniform grain temperature below 25 °C to prevent premature germination or microbial growth.
  
  
• Quality Verification — Operators perform a kernel bite-test alongside random moisture probes; once the grain cracks cleanly without chalking and lab readings confirm spec, the batch is cleared for precision milling.

Where Heritage Stones Meet CNC-Controlled Rollers

Our hybrid milling line combines the authentic flavor of stone-ground chakki flour with the pinpoint uniformity of digitally controlled rollers, delivering both heritage taste and modern performance in every batch.

• Stone Chakki Unit – Massive 24-inch granite stones rotate at a steady 230 rpm, gently crushing wheat to preserve its natural oils, aroma, and rich, nutty character prized in traditional roti.
  
  
• CNC-Controlled Roller Mills – Five break and eight reduction passages use servo-driven rollers that maintain a ±0.01 mm gap and keep roll-surface temperatures below 45 °C, preventing starch damage while producing ultra-fine Maida, Suji, and Fine Atta.
  
  
• Real-Time Sensor Network – Vibration, load, and temperature probes stream data to a central SCADA dashboard; any deviation triggers automatic roll-gap adjustments within two seconds, safeguarding consistency and maximizing yield.
  
  
• Integrated Airflow & Sifter Feedback – Smart dampers balance air pressure across plan-sifters, ensuring uniform particle distribution and minimizing bran specks in finished flour.
  
  
• Predictive Maintenance Analytics – Sensor trends flag bearing wear or roll misalignment days in advance, reducing unplanned downtime and extending equipment life.

By fusing heritage stones with digital intelligence, our Precision Milling section guarantees flour that feels traditional on the palate yet meets the strictest modern specifications for texture, nutrition, and baking performance.

Separating Perfection

After the wheat is reduced in the break and reduction passages, the mixed meal enters a multi-stage sifting and grading carousel that refines each particle into its destined SKU.

• Plan-Sifters (12 sections, 60–180 µm mesh)
  Draft-controlled sifters vibrate at 210 rpm, guiding the material through progressively finer screens. Larger bran flakes move to the outer exits, while finer endosperm particles travel inward—cleanly separating Chakki Atta from semolina in a single pass.
  
  
• Turbo Sieves & Air-Lift Purifiers
  High-speed rotary sieves break agglomerates and discharge overs. An upward air stream in the purifier deck gently floats light specks and fibre to dedicated chutes, polishing Suji grains and Maida streams to bakery-grade whiteness. All purge rates and mesh-pressure differentials are logged to the ERP for Overall Equipment Effectiveness (OEE) analysis.
  
  
• Inline Mass-Flow Scales & Auto Samplers
  Coriolis mass-meters record tonnage for each product—Chakki Atta, Fine Atta, Suji, Maida, and Bran—with ±0.25 % accuracy. Auto samplers take 200 g grabs every 15 minutes; their results feed real-time dashboards, ensuring yield balance and texture targets stay within spec before the flour moves to packaging.

In-House Laboratory Quality Assurance

Our in-house laboratory operates as the mill’s final gatekeeper, verifying that every kilogram of flour meets rigorous safety and performance benchmarks before clearance for packing.

• Rapid Inline Checks (Every 30 Minutes)
  Using near-infrared (NIR) spectroscopy, technologists record gluten index, ash, moisture, and Lab* colour values on a rolling half-hour schedule. Results appear instantly on a central SCADA dashboard; any parameter outside tolerance pauses the line for adjustment.
  
  
• Daily Performance Profiling
  Each shift submits composite samples to extended tests, including Falling-Number (enzyme activity), laser-diffraction particle-size curves, and total plate counts for aerobic bacteria. These deeper analytics confirm baking quality and shelf-life potential.
  
  
• Rapid Microbiological Screening
  Swab samples from critical points—clean wheat, tempered grain, finished flour—undergo 12-hour PCR assays for Salmonella and E. coli. A single positive automatically quarantines the entire lot and triggers Corrective and Preventive Action (CAPA).
  
  
• Long-Term Traceability
  For every production lot, 200 g retention samples are vacuum-sealed, catalogued, and stored under climate control for 12 months. If a downstream query arises, the exact flour can be re-tested within hours, providing indisputable trace-back evidence.

Through this layered testing regime, Kamran Flour Mills guarantees that only flour of verified purity, nutrition, and safety reaches customers’ kitchens and bakeries.

Hygienic Packaging

Once flour passes final lab approval, it travels through sealed, stainless-steel conveyors directly into a climate-controlled, HEPA-filtered packaging hall. This positive-pressure environment prevents airborne dust or insects from entering the line and maintains ISO Class 8 air quality.

• Consumer Packs (1 – 10 kg)
  Our fully automated carousel fills LDPE or laminated pouches, purges them with nitrogen to drive residual O₂ below 1 %, and closes them with twin heat seals. Inline check-weighers verify every pack to a tight ± 10 g tolerance, rejecting any under- or over-weight units to uphold net-content accuracy.
  
  
• Industrial Sacks (25 kg / 50 kg)
  High-barrier woven-PP bags are lined with food-grade PE film for moisture protection and printed with lot-specific QR codes. Scanning the code reveals farm origin, milling batch, and full lab results—giving bakeries and processors instant traceability.
  
  
• Foreign-Matter Safeguards
  Each filled bag passes through a dual-sensor system: a tunnel metal detector (1.5 mm ferrous / 2 mm non-ferrous sensitivity) and an X-ray scanner tuned to spot dense particles like glass or stone. Non-conforming packs are automatically diverted to a quarantine chute for investigation.
  
  
• Shelf-Life Assurance
  Nitrogen flushing and low-oxygen permeation film keep flour fresher for up to six months, while tamper-evident tear strips and holographic “KFM” seals reassure customers that every pack is factory-intact.
  
  
• Palletising & Dispatch
  Finished packs are robotically palletised, stretch-wrapped, and labelled with GS1-128 barcodes before entering temperature-controlled storage—ready for GPS-tracked dispatch to distributors nationwide. (Coming Soon)

Through these layered controls, Kamran Flour Mills ensures that every consumer pouch and industrial sack leaves our facility safe, traceable, and fresh—exactly as promised.

Climate-Controlled Warehousing & Nationwide Delivery

Once each lot clears final QC, it is palletized on heat-treated wooden skids and moved into zoned, climate-controlled warehouses that hold temperatures between 15 – 25 °C and relative humidity below 60 %. Continuous data-logger feeds alert the quality team if any zone drifts outside spec, preventing flour caking, weevil activity, or moisture-driven spoilage.

• Climate Zones: Dedicated cool, ambient, and buffer areas let us stage high-turn consumer packs separately from bulk industrial sacks while preserving ideal storage conditions for both.
• FEFO Rotation: The ERP assigns pick lists by first-expiry/first-out so that the freshest flour always leaves first; barcode scanners at each pallet bay verify the sequence in real time.
• GPS-Tracked Fleet: A mixed fleet—10-ton rigid trucks for city drops and 40-foot reefers for intercity hauls—streams live location and temperature data to our logistics dashboard, giving distributors accurate ETAs and condition reports.
• Regional Depots: Six strategically placed hubs—Lahore, Islamabad, Peshawar, Quetta, Karachi, and Multan—cut transit distances, enabling 24–48 hour delivery to 90 % of Pakistan’s population while reducing fuel consumption and carbon emissions.

Together, these safeguards maintain Kamran flour’s purity and nutrition from the mill gate all the way to your bakery shelf or kitchen pantry.

This expanded workflow details every critical point—From kernel to kitchen—ensuring Kamran Flour Mills delivers flour that is pure, nutritious, and consistently world-class.