Calcium carbonate: Consistency is the key
to success – Hosokawa Alpine and ACCM
in the spotlight

As part of a farewell tour marking 40 years of technical and application-specific expertise, Dietmar Alber, accompanied by AT MINERAL PROCESSING editor Lukas Höpfner, travelled on to Cairo following a visit to Jordan Minerals in Amman (see AT MINERAL PROCESSING issue 02/2026): to ASCOM Carbonate and Chemicals Manufacturing (ACCM), one of the region’s leading manufacturers of calcium carbonate.

Once there, it quickly became clear that ACCM in Egypt is far more than just a production site: the company exemplifies an enduring international partnership. In particular, the long-standing collaboration with Hosokawa Alpine – significantly shaped by Dietmar Alber, who has been involved in this partnership since its inception – runs like a thread through the company’s development.

In conversation with Ahmed Niazy, Managing Director of ACCM, the focus was on the key success factors in the demanding market for mineral fillers. Product consistency was particularly highlighted as a decisive competitive advantage. In addition, ACCM’s sustainability strategy was discussed, as well as the question of whether and how viable long-term sales markets can be developed for ultra-fine products. The discussion was complemented by Khaled Khattab, Projects Manager at ACCM, and Suleiman Smadi, MENA Sales Director at Hosokawa Alpine, who provided further in-depth insights into technical and sales perspectives.

ACCM is part of the ASCOM Group, a diversified group of companies with activities in the fields of industrial minerals and mining. In 2008, the strategic decision was taken to launch a greenfield project with ASCOM Carbonate and Chemicals Manufacturing (ACCM) – a step whose significance could scarcely have been foreseen in this form at the time. The initial search was for the best strategic and technical partner to implement the project, which, after extensive research and discussions, was ultimately found in Hosokawa Alpine. 

Today, the potential of this important decision is clear to see. ACCM combines a decisive locational advantage: both the quarries and the production facilities are located in Egypt – and are only around 20 minutes apart. This close integration of raw material extraction and processing forms the backbone of the company’s efficiency.

However, the road to get there was anything but easy. Setting up a company of this scale presented the team with considerable challenges – particularly in the early years. In addition to the technical commissioning, the main focus was on establishing stable processes, tapping into markets and winning the trust of customers.

“In the mineral raw materials and fillers industry in particular, it takes time for a new supplier to establish itself,” explains Niazy. “Customers test and compare intensively – that can take up to a year.” Because in a highly competitive market, quality is not just an advantage, but a prerequisite for success.

Furthermore, the start-up phase coincided with one of the most turbulent periods in recent Egyptian history: the 2011 Egyptian Revolution. Whilst the country was gripped by uncertainty, the team worked in parallel to build up ACCM step by step. Looking back, Niazy particularly highlights the dedication and resilience of the team at the time, who laid the foundations for today’s success despite adverse circumstances.

When Niazy himself joined the company in 2017, exports stood at around 300 containers per month, supplemented by sales on the local market. Today, this volume has multiplied to around 1500 containers – an impressive growth rate that underscores ACCM’s consistent focus on international markets.

Business development and international expansion 

AT MINERAL PROCESSING: What has changed since 2017?

Ahmed Niazy: We initially focused on fundamentals that appeared simple but were in fact crucial. A key point was to give the company a clear commercial profile in the first place – because that was precisely what had been missing before. We developed a professional company profile, created technical data sheets and began to make the actual quality of our products visible.

At the same time, we systematically expanded our sales team, recruited new staff and significantly strengthened our presence at international trade fairs. Above all, however, we have learnt to actively position our products in the market. That may sound obvious, but it is the key to building trust and winning new customers. On this basis, we have been able to tap into new markets step by step.

Another crucial factor in our success lies in the entrepreneurial mindset of the owners. Decisions are made quickly, and opportunities are consistently seized. This has significantly accelerated our growth. Whenever we have expanded our capacity, the demand was already there – often even greater than the additional supply.

When I joined the company in 2017, we carried out intensive calculations, analyses and ran through various scenarios: What volumes can realistically be sold? At what prices? And with what plant configuration do we achieve the best economic efficiency? On this basis, we carried out targeted optimisation. As soon as growth took hold, a noticeable momentum developed – a veritable snowball effect that continues to drive us forward to this day.

Product consistency and brand development

AT MINERAL PROCESSING: What would you say is the most distinctive feature of ACCM products?

Dietmar Alber: What has particularly stuck in my mind from the early years of working with ACCM is the exceptional product consistency – and in my view, this is precisely one of the key factors for success in the GCC filler industry.

Consistency means far more than just consistent quality. It begins right at the quarry, for example with a consistently high whiteness of the raw material, and continues consistently through all stages of the process. The result is products with stable particle size distributions, an upper particle size range that is absolutely free of spatter particles and – in the case of coated grades – an excellent and consistent coating quality. This is extremely important for all end-users in the polymer and paint industries, as their formulations do not allow for fluctuating quality.

Added to this is another, often underestimated aspect: reliability. By this we mean the ability to deliver consistently across the entire GCC product range. It is the combination of consistent product quality and reliable availability that builds trust and thus lays the foundation for a strong reputation in the market, particularly when competing with established global players. 

Ahmed Niazy: Yes, absolutely.  This consistency is no accident, but the result of several interlinked factors.

Firstly, we benefit from the exceptionally high quality of Egyptian raw materials. The geological conditions and the properties of our deposits form an extremely stable foundation.

Secondly, from the very beginning we have consistently relied on the technology we considered to be the best, and we have remained true to this approach to this day. In our view, the long-term partnership with Hosokawa Alpine confirms the wisdom of this decision. The process equipment we use enables us to meet all our key requirements and ensures a high level of process reliability.  At the same time, the various dry and wet processing technologies allow us to offer a broad product range – from superfine and medium-fine to surface-coated calcium carbonate powders.

The third key factor is the operation itself: proximity to our processes, consistent control and monitoring of the equipment, and the high priority given to quality assurance in day-to-day operations.

Product consistency is therefore not achieved through a single aspect, but through the precise interplay of raw materials, technology and operational excellence.

Exports, logistics and international competition

AT MINERAL PROCESSING: What is your current export share?

Ahmed Niazy: Exports are our mainstay: our current share stands at around 80 %, which corresponds to approximately 1500 containers – with the clear aim of doubling this volume in the coming years.

India is a key market in this regard. The country offers enormous potential: a rapidly growing plastics industry with high demand for high-quality GCC fillers, as well as an increasingly demanding paints and coatings industry, where a high whiteness of the fillers is crucial – not least to partially reduce the use of the cost-intensive white pigment titanium dioxide. Despite the country’s size, the availability of high-quality calcium carbonate deposits in India is limited. Locally available fillers often have a higher quartz content and a lower whiteness than industry requirements demand. This is precisely where we can play to our strengths.

The second major growth driver is Africa. We are now active in several regions – from North to West and South Africa – and are seeing dynamic growth there. Markets such as Algeria, Morocco and South Africa are particularly important to us.

Furthermore, we have significantly expanded our presence in Saudi Arabia and are continuously exploring further growth opportunities, for example in Brazil, Venezuela, Turkey and parts of Europe, such as Poland.

Many are surprised that a low-cost raw material such as calcium carbonate can be transported economically over such distances. Yet this is precisely where the importance of efficient logistics and clear market positioning becomes apparent: if quality, price and delivery reliability are right, global markets can also be successfully served.

AT MINERAL PROCESSING: So could Europe even be a market?

Ahmed Niazy: Yes, absolutely – and we are seeing increasing success there, primarily due to our high and consistent product quality. However, entering the market is challenging: the logistics are complex and transport costs are correspondingly high.

Nevertheless, there are applications where exporting to Europe can be economically viable – particularly when the quality of locally available raw materials does not meet the requirements. In such cases, we can offer clear advantages with our products.

Ultimately, however, it always comes down to cost-effectiveness. We are working hard to secure competitive freight rates and maintain close relationships with shipping companies. The basic principle remains the same: product costs and logistics must, when added together, match the respective market price.

AT MINERAL PROCESSING: Is the high quality you produce equally in demand across all markets?

Dietmar Alber: What is the situation in Africa, for example? In the past, there was certainly great interest there in high-quality production plants for GCC, but at the same time, quality requirements were often still comparatively low.

Ahmed Niazy: The picture is changing significantly: Africa is developing dynamically. In the past, locally available material produced using simple plant technology for basic applications, such as base colours, was often sufficient.

Today, however, we are seeing a clear trend towards higher-quality products. Particularly in the plastics industry and in the sector of high-quality paints, demand is rising for consistent, high-quality mineral fillers – and these are increasingly being imported.

As the population and industries grow, so do expectations regarding product quality. This is precisely where significant potential opens up for us.

AT MINERAL PROCESSING: What is the situation regarding local competition, for example in Algeria?

Ahmed Niazy: There is certainly movement in the market: some projects have already been implemented, and others have been announced. However, developments in Algeria often proceed at a comparatively slow pace, which is primarily due to complex and, in some cases, frequently changing regulatory frameworks. Whilst investment in modern, high-quality production facilities is on the rise, one decisive factor remains: the availability of suitable raw materials. High-quality deposits, which serve as the basis for first-class GCC fillers, are limited – and this remains a key challenge for local competitors in Algeria.

AT MINERAL PROCESSING: Do you see any specific challenges or requirements when working with customers in different countries?

Ahmed Niazy: Yes, the requirements are extremely diverse and vary considerably depending on the market and application. Often, the challenges begin with logistics. In Saudi Arabia, for example, some customers expect delivery in silos. However, if we export our products in jumbo bags or 25 kg bags, additional interim storage and handling solutions are required.

Furthermore, packaging concepts, specific product properties and application-related requirements also play a decisive role. Ultimately, no two orders are alike: every market, every product and every customer brings its own expectations – and it is precisely this flexibility that is crucial to international success.

GCC quality, process engineering and the trend towards finer powders

AT MINERAL PROCESSING: ACCM is experiencing strong growth in volume. Would it make sense to switch to larger systems?

Ahmed Niazy: This is indeed an issue we are looking at very closely. If we want to double our volume in the medium term, it makes sense to opt for larger capacities in new systems – ideally doubling the output per line. This brings clear advantages: less floor space required whilst achieving higher output, as well as lower investment costs per tonne produced.

We have already acquired additional land to specifically prepare for this expansion. At the same time, we are not solely focused on growth. It is crucial that every investment strategically aligns with our international orientation and sustainably strengthens our market position.

Dietmar Alber: Hosokawa Alpine already has a concept for an even larger fine classifier. The design is complete, so implementation can take place at short notice if required.

AT MINERAL PROCESSING: You mentioned the quality of Egyptian limestone earlier. What makes it special?

Ahmed Niazy: A key advantage of our limestone lies in the combination of large deposits and a very high, consistent quality.  These characteristics form the basis of our current model of success.

The key factor here is the interplay between easily grindable raw material and the process technology used – in particular Hosokawa Alpine’s ball mill and TTD classifier concept. With this configuration, we achieve both high throughput and very fine particle sizes.

At the same time, we are constantly asking ourselves how we can further improve our products. We are currently already achieving fineness values of around 70 to 80 % below 2 µm – but we aim to increase these figures even further in the future.

Our focus here is clearly on dry processing. It enables us to avoid additional complexity and remain economically efficient. Wet processing not only entails higher investment costs but also significant energy requirements for drying – a factor that is becoming increasingly important in view of rising gas prices.

Dietmar Alber: What developments do you see in the coatings industry? In many markets, we are seeing dry GCC powder increasingly being replaced by GCC slurries. These offer several advantages: more cost-effective production, the inclusion of water and dispersants, and overall economically attractive terms of use for the customer. And what is the situation in the Egyptian paper industry in this context?

Ahmed Niazy: The paint industry in Egypt has been one of our most important markets from the outset – and we have successfully established ourselves here. Our customers include, amongst others, two of the country’s largest paint manufacturers. The paper industry in Egypt, by contrast, is less developed compared to other regions, which currently limits the market potential. Nevertheless, we are monitoring developments very closely.

The topic of GCC slurry is certainly of interest to us. We are actively assessing the extent to which additional potential can be tapped here and whether corresponding business models can also be implemented locally. Should there be specific requirements, we are always ready to develop appropriate solutions together with our customers.

Demand for ultra-fine products

AT MINERAL PROCESSING: What about applications that require a D90 value of less than 2 µm? Is there a market for this?

Ahmed Niazy: Yes, this market exists – and it clearly belongs to the premium segment. Only a few manufacturers are capable of producing such fine products reliably and reproducibly.  Those who overcome this hurdle find themselves in a competitive environment with few suppliers. Relevant applications can be found, amongst other things, in paper, plastics, films and, in particular, in so-called breathable films.

Dietmar Alber: GCC for breathable films, in particular, is a highly demanding speciality product. It is not enough simply to achieve a high degree of fineness. What is required is a very steep particle size distribution, a high degree of whiteness, minimal coarse particles above 10 µm, a precisely tailored surface treatment and the highest possible level of purity.

These requirements make the manufacturing process correspondingly complex – but at the same time open up attractive margins.

Ahmed Niazy: That is precisely where the challenge lies. We know in principle how such products can be manufactured, and the demand is there. However, this is not a traditional high-volume business, but a demanding specialist segment.

Complete process control along the entire value chain is crucial – from grinding, dispersing, drying and coating right through to the processing behaviour in the end product. Even the slightest deviations, for example in the coating process, can lead to defects in the film application such as pores, colour variations or structural weaknesses.

Demand is particularly evident in Europe, for instance in Greece and Turkey, though it is developing in a stable rather than dynamic manner. Whilst there is significant demand in the film sector in Turkey, the market is largely dominated by established suppliers. China is also working intensively to penetrate this segment – though so far with limited success, particularly when it comes to the required fineness and particle size distribution.

For us, this means: this segment offers clear opportunities – though primarily in terms of margins, rather than volume.

Dietmar Alber: An efficient and practical approach to manufacturing products with around 90 % below 2 µm is the integration of additional ultra-fine classifiers into the existing ball mill classification circuit. Through the targeted separation of the fine fractions, it is possible not only to produce the desired product but also to increase the efficiency of the entire grinding process at the same time.

A common misconception is that all the energy is used to achieve a specific final fineness. In fact, an excessively high proportion of fine particles in the mill has a dampening effect on the grinding process. If this proportion of fine particles is specifically reduced, efficiency improves significantly. In practice, it has been shown that by separating off-streams – such as ultrafine fractions below 2 µm or particles below 45 µm from the coarse material stream of the main classifier – additional products can be obtained with virtually no significant energy expenditure.

ACCM’s strategic goals for the future

AT MINERAL PROCESSING: Looking to the future: your strategy appears to be generating a steadily rising demand for your fillers. What are your expectations regarding processing technology and future collaboration with your preferred equipment supplier?

Ahmed Niazy: Essentially, we are pursuing two strategic directions: Firstly, we want to further refine our products. We are already achieving very good fineness levels today, but we see further potential here. Secondly, we are specifically exploring expansion in the area of speciality products – for example, for breathable films or other high-end applications. However, the prerequisite is always that market volumes and margins remain attractive in the long term.

In parallel, we are deliberately focusing on standardisation for larger production lines. Uniform components, comparable systems and harmonised spare parts structures simplify operations, increase efficiency and significantly reduce day-to-day complexity.

Our goals for 2026 and 2027 are clearly defined: a further increase in fineness, the optimisation of process performance, and even greater line stability. Furthermore, we intend to further develop surface treatment for specialist products in a targeted manner. In this context, we see great potential in continuing our collaboration with Hosokawa Alpine. Both companies have ambitious growth plans, and there are numerous opportunities to drive these forward together.

A key component of our future strategy is also the expansion of our research and development capabilities. We are currently investing in a new laboratory with advanced analytical and testing methods. Of particular importance to us is the ability to simulate real-world applications – especially in the plastics sector. This enables us to test the behaviour of our products directly under realistic conditions and provide targeted support to our customers.

Our aim is to position ACCM not merely as a manufacturer of calcium carbonate, but as a technical partner that actively contributes to the optimisation of applications.

Another key advantage lies in our vertical integration: we operate our own quarries and thus control the entire raw material supply chain. Unlike many market players who rely on external suppliers, this enables us to ensure consistently high quality and long-term raw material availability – an important foundation for sustainable growth.

AT MINERAL PROCESSING: What role does sustainability play in your current and future strategy?

Ahmed Niazy: Sustainability is a central component of our corporate strategy. A few years ago, we acquired around 25 acres of land in the immediate vicinity of our plant and installed a large-scale solar power plant there. Today, we are able to run our production almost entirely on solar energy during the day. This is a significant step – not only from an environmental perspective, but also from an economic one. A project of this scale remains the exception in our industry and region.

Partnership with Hosokawa Alpine and Dietmar Alber

AT MINERAL PROCESSING: We have discussed your company’s development, technology, markets and applications. To conclude: from the first systems to the most recent projects – how has the collaboration with Hosokawa Alpine changed over the years?

Ahmed Niazy: This collaboration has been and remains of central importance to us. It is based on a long-standing, trusting partnership, and I would definitely describe it as a win-win situation. Both sides have benefited from each other and developed further together.

Over the years, we have not only grown closer together technically, but have also become much more closely integrated in our project work. Together, we are constantly working to optimise processes – from plant design through to manufacturing, logistics and commissioning. This always involves speed, efficiency and the development of new ideas. I am convinced that this partnership will continue to deepen – particularly in the areas of research and development, in opening up new markets, and in our joint focus on future requirements.

AT MINERAL PROCESSING: And what does it mean to you personally that Dietmar Alber is now reaching the end of his active career at Hosokawa Alpine?

Ahmed Niazy: Of course, this marks a turning point – but at the same time, it also marks the beginning of a new chapter. I am certain that our personal and professional connection will remain. We would be delighted to continue engaging with Mr Alber in the future and to benefit from his experience.

Dietmar Alber: Thank you very much – that makes me very happy, and I can only return the sentiment.

AT MINERAL PROCESSING: Mr Niazy, thank you very much for the interview and your candid insights.