Innovative Bar Processing Methods

Highlights:

• Slab forming and extrusion are two common bar processing methods.
• Bars made with simple, clean ingredients are gaining popularity in the market.

Most Common Bar Processing Methods

Global growth in nutrition bars has made the nutrition bar category increasingly competitive but also full of opportunity. Nutrition bars not only address consumers’ interests in healthy snacking but can also meet a wide range of needs. While there are variety of ingredients from which to choose (including macronutrients, micronutrients, and functional ingredients), most manufacturers are using one of two common bar processing methods.

The first method is known as slab forming. After the wet and dry ingredients are mixed together, they’re run through a slab former—a machine that uniformly deposits the mixture onto a conveyor to create a long slab. At this point layers and toppings can be added. Next, the sheeted mixture passes under a roller which compresses the slab. After this, the slab is cut twice—once by the slitter into several long strips and then again with a perpendicular cut by the guillotine.

The other common method for producing bars is extrusion. After the ingredients are mixed together, they’re passed through an extruder (rather than a slab former), which forms the mixture into the shape of a bar. Again a guillotine is used to cut it to the desired bar length. Depending on the type of bar, the next steps might include enrobing or baking (followed by a cooling step), or simply packaging.

Clean Label Trending in Nutrition Bars

Using simple ingredients is one approach to making clean label bars. RXBar set the standard with its front-of-package labeling of its simple ingredients (like egg whites, almonds, and dates), with brands IQ Bar, And Nothing Else, and VOW Bars soon following suit. RXBar and IQ Bar also quantify the ingredients on the front of the package for additional transparency.

Clean energy, such as the use of coffee and coffee fruit (as in Regrained Coffee Chocolate Supergrain+ Energy Bar), is also ramping up in bars. So too is the idea of sustained energy, particularly from protein. Protein is perceived as a clean label ingredient that provides a slow-release energy boost compared to bars high in sugar. To communicate this benefit, Trailnuggets Pro Chocolate Peanut Energy and Protein Bar, for example, claims its 10 grams of protein can “fuel adventurous consumers anytime and anywhere.”¹

Raising the Bar

While innovative processing and labeling approaches are sure to resonate with today’s bar consumers, producing clean label bars always starts with clean label ingredients. Glanbia Nutritionals’ Bar Solutions include everything brands need to get started—from dairy- and plant-based proteins to custom nutrient premixes to trending flavors for bars. Contact us to learn more.

References

1. Mintel, A year of innovation in snack bars, 2020, May 2020.