Fava future: Beneo invests €50M in German pulse-processing plant

28 Apr 2022 --- Beneo is making a €50 million (US$52.6 million) investment in a pulse processing site based in Offstein, Germany, strengthening its plant-based portfolio. The site will produce protein-rich pulse ingredients. Initially, it will focus on protein concentrate, starch rich flour and hulls from fava beans, with the option to process other pulses in the future.

The first quantities of Beneo’s fava bean ingredients will be available in June.

Construction is underway, and the plant is expected to be fully operational within the second half of 2024. Beneo will process the raw ingredients in intermediate production facilities until the new plant is fully operational. 

Protein-rich attributes
Beneo’s fava bean protein concentrate and starch rich flour will be used for protein-enrichment and texture improvement in meat and dairy alternatives and bakery, cereals, and gluten-free products.

The investment is being touted as an essential milestone for Beneo, extending its footprint into the market for sustainably produced plant-based protein ingredients.“The recent investment by Beneo into a new pulse production site is only the starting point,” reveals Christoph Boettger, executive board member at Beneo. 

Speaking to FoodIngredientsFirst, he says that the company has already received “very positive” feedback regarding fava bean ingredients. 

“When it comes to pulse-based protein ingredients, customers consider different elements such as their protein level, taste and technical performance and whether they are allergen-free.”

The growing interest in products that support a flexitarian, or even vegetarian or vegan diet mean that Beneo’s fava bean ingredients are an appealing solution, he notes. 

Moreover, fava bean ingredients are gluten- and soy-free. 

“They have a mild taste and a creamy, light yellow color. Being natural, they support the development of clean(er) label products and are also suitable for vegan, vegetarian and flexitarian diets. Fava bean protein concentrate is a vegetal protein that in certain applications could replace animal protein as well as soy proteins. It has shown high solubility and very good emulsifying properties,” explains Boettger.

“We strongly believe in plant-based ingredients and therefore see the new plant as an important first step in enlarging our protein offering. This will enable us to produce a wider variety of sustainable plant-based protein ingredients over the coming years.”

Sustainability wins
The company asserts that throughout Beneo’s entire supply chain, environmental sustainability is top of mind. Pulses help to reduce greenhouse gas emissions at the farm level. For example, fava beans provide nitrogen for themselves and subsequent plants, so nitrogen fertilization is unnecessary. 

The first quantities of Beneo’s fava bean ingredients will be available from June 2022.

The fava beans will be locally sourced from farmers certified by the Sustainable Agriculture Initiative (SAI) and thus follow sustainability standards. As Beneo manufactures fava bean protein, starch-rich flour and hulls, the crop will be fully used and valorized for functional ingredients. 

Furthermore, the production process has been chosen for its low energy consumption compared to alternative methods, contributing to Beneo’s carbon neutrality and sustainability targets.

“Green electrical power will supply the new factory and the highly efficient, sustainable plant is being built with the aim of zero Scope 1 and 2 CO2 emissions to meet the the level of the company’s sustainability goals,” continues Boettger. “As a result, the production process will require less energy than competitive products.”

Earlier this year, Beneo’s executive board member Dominique Speleers hinted to The World of Food Ingredients that the company would be investing in a plant-based protein crop. See the exclusive interview on page 74. 

By Elizabeth Green

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