By Alapala

 

2020 was most certainly an extraordinary year in all aspects. In the face of challenges brought about by the global Covid-19 pandemic, businesses and economies struggled hard to maintain their operations.

By prioritising adding value and competitive edge to its customers' businesses since 1954, Alapala is one of the leading machinery suppliers and turnkey solution providers in the grain milling industry. Thanks to its wide range of activities, services and their wide global distribution network, Alapala has been able to successfully continue its operations worldwide during this global crisis of an unprecedented scale.

Alapala builds and services turnkey plants of any desired capacity worldwide with world class engineering solutions. Operating on the basis of a 'customer- and-solution oriented' approach, Alapala has built more than 650 turnkey projects so far, whilst their equipment operates in 5,000 factories in over 120 countries across four continents.

In addition to all of this, in 2019 The Association of Machinery Exporters also listed Alapala as the top exporter in the food machinery industry. Exporting 95 percent of its production, Alapala is also featured on the 2019 Top 1000 Exporters list of the Turkish Exporters Assembly.

The company has been able to successfully complete various greenfield and turnkey modernisation projects across the globe in 2020, despite the severe effects of the pandemic.

Surely, under these challenging conditions, business expertise and manufacturing excellence alone were not sufficient. In the words of Alapala Group CEO Görkem Alapala, 'our management priority is always the health and safety of our employees and their families.'

Projects Commissioned in 2020

Operating in the fields of grain and feed milling technologies, grain handling and storage systems, professional support services and industrial construction, Alapala successfully commissioned eight turnkey and three modernisation projects in different parts of the world in 2020, including Europe, Africa, Asia, Canada, and the Middle East, placing substantial importance on the safety and health of its employees and partners.

Harinera Roca S.A, Spain

Established in Agramunt, Spain in 1939, Harinera Roca S.A. decided to pursue a new investment in an additional unit to be built next to the existing 120 TPD plant, as a result of the rising demand for flour in the region.

Commissioned by Alapala in January 2020, their new mill with a 100 ton per day capacity processes local wheat and other types of grains to produce various different types of organic and traditional flour for bakeries.

The flourmill has a special diagram that allows for the processing of different kinds of cereals such as wheat, spelt and rye at different shifts upon requirement. This technology is called 'Swing Milling' and is one of Alapala's latest processing solutions.

Alapala Construction also supplies the steel building structure of flourmill, with this detail evident in the specialised nature of the design, supply, and construction of the industrial buildings.

Alapala completed its 650th reference project worldwide for Harinera Roca Company, Spain. This is also one of the numerous Alapala references all over Europe that all have been completed in the last three years including France, Belgium, the Netherlands, Hungary, Bulgaria, and Serbia.

Mazagan Flour Mills Company, Morocco

In January 2020, Alapala completed the installation of its newest flourmill reference in Africa for Mazagan Flour Mills Company. Mazagan Flour Mills is a family-owned company and a long-term business partner of Alapala, currently operating with a total wheat processing capacity of 900 tons in two locations in the El Jadida region.

The plant has a 300 TPD capacity and produces three different types of bakery flour, mainly for domestic consumption. The mill was installed in a newly built six-floor concrete building, designed and constructed in full conformity with high sanitation standards.

Equipped with the latest Alapala technology consisting of Similago II roller mills (DAVG), Quadro Plansifters with larger sieve boxes (GPAK) and control sifters (RKEM), the plant also uses an optical sorter for very fine cleaning of wheat prior to milling, to ensure the highest level of food safety.

The plant operates efficiently with an advanced automation system, which enables centralised monitoring and management of cleaning, milling, and packaging processes. The system enables the generation of detailed production reports, with real-time error diagnosis and long-distance connection features.

The first flourmill of Somalia

Alapala is very active in the African market with its local presence assured via its various branches, country offices and a wide representative network. This presence is further bolstered by numerous flour, semolina and maize mill references across the entire region which includes Senegal, Zambia, Angola, Kenya, Tanzania, Mozambique, and Ghana.

National Flour Mills Company (NFMC)'s new plant, the first flourmill in Somalia, was commissioned by Alapala in April 2020. With the completion of the project, NFMC started its operations at Berbera Port Region in Somalia to distribute the flour it produces all over the country.

Alapala provided the entire line of equipment and installed the flourmill plant with a capacity of 300 TPD on a turnkey basis, including four steel storage silos with a capacity of 30,000 tons. The steel structure of the mill building was also supplied by Alapala Construction.

Having 110,000 MT of annual wheat processing capacity to produce high-quality bakery flour varieties for domestic consumption, the plant has an advanced automation system used in combination with supervisory control and data acquisition (Scada) software.

This technology enables an excellent capacity for process control and traceability through the centralised monitoring of the entire process, from wheat intake to flour packing. This is in addition to the remote connection service for real-time error diagnosis and intervention.

Thanks to the sophisticated yield monitoring system combined with the Scada software, detailed production reports can now be generated based on the weighing data collected from six different sections.

In addition, measures were also implemented to ensure safe and hygienic product transfer within the mill. All pneumatic and mechanic transport equipment were also installed in full conformity with EU standards,

Samarkand, Namangan, and Tashkent Don Maxsulotlari JSC, Uzbekistan

The largest agricultural government organisation in Uzbekistan, O'zdonmahsulot AK Group is active with a total of 58 flourmills, 114 bakery stores, 46 pasta lines, 45 feed mills, and two grain storage complexes that are located throughout the country.

Being three of the flour mills under the umbrella of O'zdonmahsulot Group, Samarkand Don, Namangan Don and Tashkent, Don Maxsulotlari's new milling plants were commissioned by Alapala in 2020. These projects were designed on a turnkey basis which includes project design, manufacturing, and installation services.

Founded as a project developed by Kuibyshev Design Institute in 1963, Samarkand Maxulotlari JSC started its operations in a flourmill with a daily capacity of 240 tons, which was installed and commissioned in 1966.

Today, the company operates in a modern mill equipped with new technologies supplied by Alapala. This equipment is able to consistently deliver benefits such as central process monitoring, detailed reporting, and remote connection for instant error diagnosis.

The flourmill produces bakery flour for the region with a capacity of 200 TPD. The flourmill has been installed in a newly built concrete building that conforms to high sanitation standards.

The newest existing Alapala mill in the country, Namangan Don Maxulotlari JSC was installed in April 2020. Supported by the Ministry of Agriculture, the first flourmill started production with a daily capacity of 240 tons in 1964 and it currently operates in flour and feed milling industries, with their existing flourmill plant renovated by Alapala, utilising the very latest technology.

The mill now operates efficiently with an advanced automation system that enables centralised monitoring of the entire process, from cleaning to milling, and packaging. The system is also supported by Alapala's remote connection services.

A reliable business partner, even in times of crisis

With its wide range of capabilities that range from remote technical support to proven turnkey expertise, Alapala can provide timely services in many different parts of the world, whilst also possessing the ability to respond efficiently to urgent problems with advanced technological tools. Providing value and profit to its customers, Alapala adopts a customer-oriented innovative approach in all its operations worldwide.

Managing a business in the face of extraordinary and unexpected developments requires agility and resilience. Competence and expertise alone are by no means sufficient during such times. With such an approach and a powerful global network, Alapala achieved an extraordinary success by delivering a total of 11 projects in 2020.

At a time when economies shrank and businesses struggled to maintain their operations whilst also doing their best to adapt to new requirements and ways of doing business, Alapala has revealed the extent of its resilience, as well as its agility.

Amidst lockdowns, travel restrictions, and significant health risks worldwide, Alapala not only kept its undergoing projects on track, but also undertook new projects, and ultimately managed to complete them all as promised.

Paying strict attention to the health and safety of its employees, as well as its partners, Alapala took all the necessary measures to provide safe working conditions for everyone. Compliance with requirements such as wearing facemasks and observing social distancing rules, as well as all relevant regulations and legislations was ensured through competent and attentive project management practices adopted by Alapala across the globe.

With its powerful structure, planning, and management competency, Alapala completed many projects with varying capacities in many parts of the world from Europe to Africa, realising firsts along the way.

Thanks to its responsible project management practices under challenging conditions, all 11 projects with a total capacity of 3,270 ton/day were completed with no delays. This is a robust indication that Alapala is determined to meet the challenges of this crisis and move forward in full power.

'It is important for us to maintain strong relationships with our business partners and customers. Developed over many years, these relationships are a crucial asset for us and a key source of our competitiveness and differentiation in the market,' notes Görkem Alapala, Alapala Group CEO.

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