How to Produce Bars
How it is made

How to Produce Bars

Process principle for soft cereal bars and dough bars with or without coatings.

How to produce soft cereals and dough bars with or without coating.

20 March 2023

Speakers

Bars can be found in different formats: plain or with cereal, with or without chocolate coating.

In the segment of specialized nutrition, the market is driven by high-protein formula and meal replacers providing an enjoyable sensorial experience.

In response to those drivers, Roquette offers a wide range of solutions with NUTRALYS® for plant-based protein enrichments, NUTRIOSE® for fiber enrichment, polyols as humectants, pea starch for low GI carbohydrates, and GLUCIDEX® maltodextrin and dried glucose syrup as binders. 

These bars are usually deposited, made from a blend of syrup and dry product (powders or cereals). A chocolate coating can be added or not.

The first driver of the promulgation is the nutritional profile of the final product, the aim being to bring the right nutrition to the targeted population.

Regarding the dough bar: 

On the dry part, NUTRALYS® pea protein will bring powerful nutrition and, thanks to our formulation, a stable texture over time.

PEA STARCH LN 30 as a slowly digested carbohydrate will bring longlasting energy.

For the syrup, NUTRIOSE® FM 06 soluble fiber, will bring sugar-free fiber enrichment with an outstanding digestive tolerance.

LYCASIN® 85/55 maltitol syrup  and NEOSORB® 70/70 sorbitol syrup will be humectants for bar texture stability.

GLUCIDEX® 21 dried glucose syrup will provide sweetness and some texture to the bar and will also play an anticrystallizing role.

Here is a typical process for dough bars

 

             
Blend of dryingredients as proteins, fibers, starch. Blend of syrups as fibers, polyols, maltodextrins, syrups around 20°C. Blend syrups and dry ingredients, reaching the right cohesiveness for an easy lamination. Lamination of the dough through your specific die.  Bands are cooled in a tunnel to be cut at the right size.  Bars are cut, and stickiness will be a key parameter. A chocolate coating can be applied after.  Bars go through a colling system to ensure chocolate tempering before packing.

 

Regarding the cereal bars:

NUTRIOSE® FM 06 soluble fiber will bring sugar-free fiber enrichment with an outstanding digestive tolerance.

NUTRALYS® T65M textured pea protein will contribute to the chewiness and to the plant protein content.

LYCASIN® maltitol syrup, SweetPearl® P200 maltitol, NEOSORB® 70/70 sorbitol syrup are good binder humectants.

Here is a typical process for cereal bars:  

             
Blend of the syrups made from fibers, polyols, maltodextrins around 60°C.   Blend of dry ingredients: cereals, crisps. Blend syrups and dry ingredients in a blender or by continuous process to feed the line controlling the temperature. Lamination of the cake through your specific die.
Control of the temperature for an easy lamination. 
The bands or cake go in a colling tunnel before cutting.  Sizing of the bar, where texture will be key for a smooth cutting.
A chocolate coating could be applied.
 
Bars go through a cooling bar for tempering finalization before packing.
 

 

Request a Document

Entering your details below will send your query to the relevant team for a swift and helpful response. We will not use your details for anything other than replying to your query.

Product Details

Your Details

* Required fields

Request A Document

{Market}

Submit > {Product} > {Usage Country}

Make An Inquiry

Entering your details below will send your query to the relevant team for a swift and helpful response. We will not use your details for anything other than replying to your query.

Product Details

Your Details

* Required fields

Make an Inquiry

{Market}

Submit > {Product} > {Usage Country}