Whether fresh or dried, processed to syrup or fermented to alcoholic drinks: the fruit of the carob tree, also known as locust bean pods, are cultivated above all in the Mediterranean region and have been popular as a versatile foodstuff for centuries. Today, the foodstuffs industry attaches increasing importance to the positive and functional properties of the nutritious legume.

Carob is highly valued in any field of nutrition due to its nutritional properties and new market trends. It is a natural ingredient being highly energetic, rich in bioactive compounds and fibre, and a source of minerals and vitamins, containing 0% fat. Its caramel taste makes ‘carob powder’ a healthy substitute for cacao to be used in sweet spreads for breads or bakery with no need to add sugar or other sweeteners.

"We were searching for a grinding system which was laid out for maximum end-product fineness values at simultaneously high throughputs", says CEO Enrique Pérez Martínez to explain the background.

And this is why a Hosokawa Alpine Zirkoplex ZPS 630 has been in operation at Pedro Pérez since early 2019. The numerous advantages of the Alpine classifier mill such as the steplessly adjustable fineness or the cool grinding thanks to the high air flow rate convinced the Spanish comminution specialists. "What tipped the scales in favour of the mill was the possibility of performing trials on a production scale in Hosokawa Alpine's own application testing centre", says Enrique Pérez Martínez in explanation of his reasons for purchasing the system.

"The highest quality is the only way to total satisfaction". According to this guiding principle from Pedro Pérez, the production process of the ultrafine ground carob powder starts with the quality control of its raw material, the carob pod. These carefully selected carob pods are pre-milled, sieved by size, cleaned of foreign materials and transported pneumatically to the classifier mill. The next step, the micronisation to the desired end-product fineness of 97% < 75µm, is performed by the Hosokawa Alpine ZPS classifier mill.

Design tests in the Alpine application testing centre, coordination by the agent, commissioning in Spain – the cooperation between Hosokawa Alpine and Pedro Pérez was characterised by international processes: "A well-coordinated and clear communication was vitally important for this project. Only in this way was it possible to find the best solution for this special application. We are happy to say that the project management between the German manufacturer Hosokawa Alpine and the Spanish commercial agents Clave XXI, S.L. functioned perfectly“, summarises Jürgen Zeller, Sales Manager at Hosokawa Alpine.

From cultivation of the carob trees to grinding the pods, Pedro Pérez – as a certified organic company – sets great store by a sustainable production process. The Hosokawa Alpine Zirkoplex ZPS ensures this and guarantees the production of high-grade and environmentally friendly products. "The gentle comminution performed by the ZPS classifier mill in combination with our dehydrogenation process makes it possible for us to retain in a natural way all the nutritious and functional properties of the carob pod in the ultrafine 'demicrocarob' powder", says Enrique Pérez Martínez.

More than pleased with the results of the new system, Pedro Pérez has discovered even more advantages of the classifier mill from Hosokawa Alpine. "The mill is extremely energy-efficient and because of its flexibility, is universal in use", says Enrique Pérez Martínez. Thanks to the Hosokawa Alpine mill, it has been possible for Pedro Pérez to consolidate the innovative edge over the competition even more and to stabilise the requisite economic foundations.

As a result of this project the company has developed a new innovative product: BEFLESH Mediterranean carob (this project has received the funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 829699). This product is 100% pure raw carob powder, produced with a very innovative technology which respects the original beneficial properties of the carob fruit, and has an exclusive particle size suitable to be used as a functional ingredient in a wide range of food products. BEFLESH is the best ‘healthy’ substitute for cocoa powder - free from caffeine and theobromine and low in fat - as well as a ‘natural’ sweetener or a ‘beneficial’ flour, to be used in our daily food, increasing significantly its dietary fibre and polyphenol content.