Need help with protein bar recipe for business

Need help with protein bar recipe for business

Hello
Good day

I want to start a protein bar making business
So I need help with designing the perfect recipe for production with little processing as possible (no bake no fridge requires) so it’s just
1 - mixing
2 - extruder (cutting)
3 - packaging

The recipe I have is great but I have a problem with stabilizing the bars so soft and the shelf life of the bars specially in this two factors a long side with cost

The ingredients I use

Oatmeal and oatmeal flour
Whey protein powder
Chocolate chips
Peanut butter

The binding syrup and other ingredients for preserve the product where I have a problem with

Also if any notes and advice on changing the ingredient are welcome

Please advise
Thank you.

Hello,

You need to use sugar syrup to make stabile bars. you should cook syrup and mix wit other ingredients.

please notify that if you use more butter it effects shelf life negatively.

The recipe I have is great but I have a problem with stabilizing the bars so soft

Do you mean you have a problem about make bars soft ? Or ?

Thank you so much for the response
I have a problem with stabilizing the bars and shelf life
About the sugar syrup do you suggest a certain water and sugar ratio? Or what kind of sugar syrup is you suggest?
Do you suggest a certain gum for stability?
And what can I add for shelf life?
Also I can remove the peanut butter completely and stick with only the other ingredients
Thank you

You are welcome.

you can use sucrose + glucose syrup mix to bind other ingredients together. You should not use water for long shelf life.

you do not need use any preservative for this type product. Because this product has very low water content and low aw.

total sucrose+glucose syrup to last product ratio can be about 1/4 or 1/3,5. And it depends on other ingredients.

I suggest you do not use butter because butter effects shelf life negatively and it can make product very soft and maybe you can not create a product that has a stable structure.

Thank you so much

I’m sorry for lot’s of questions but I don’t understand the ratio you mentioned can you please explain little bit

Thank you

mixture 1 : 15 g sucrose + 10 g glucose syrup
mixture 2 : other ingredients 75 g

cook mixture 1 until 160 °C than immediately add mixture 2 in it and stir them until get a homogeneous mixture, it is now mixture 3. mixture 3 is your final product.

Thanks a lot for the help
I will make a sample and report back to you if possible
Thank you again

Hello sir I’m sorry for lot’s of questions

Sucrose comes as syrup or it just a table sugar?
Because I searched as a syrup and all I find Suppliers who provide high fractos corn syrup instead

Use table sugar for sucrose and also you need glucose syrup not fructose.

Thank you so much I’ll report you with feedback

Hello sir food scientist I really appreciate your help
I got glucose syrup and I’m going to use tables sugar just like you mentioned
However about the table sugar should I use it plain without water with the glocuse? or I make sugar syrup with the glucose if so what ratio is the water and sugar?
Thank you again

Hello,

No need water. Only add table sugar and glucose syrup together. Cook theme while string. if you have some trouble you can add a little water to make cooking process easier.

Did you try ?

Hello good day
Yes I tried it but didn’t work
The sugar and glucose burns so quickly and it’s difficult to handle without water
Is there a certain way to cook? Or I can add water to the mix what should I do please help me
Thank you

The other thing is when I use it to the dry ingredients it crystals and become hard like hard candy and also the liquid ratio to dry not enough
I used 30 g sugar 20 g glucose
And 150 g oatmeal and whey protein powder
I believe I made a mistake in some point here

I made another experiment which is
Mixer 1
70 g oatmeal
20 g whey protein powder
Mixer 2
100 g sugar
50 g water
1 table spoon glucose syrup

The result is really hard bar where it’s difficult to eat and handle

Did you cook mixer 2 mixture ? Sugar is so much !

ok. to make it softer, increase glucose syrup and decrease sugar ( 15 glucose + 10 sugar ) and cook at lower temperature.

I just tried
15 g glucose
10 g sugar
The problem I have is the mixture becomes so thick and burn so quickly even on low temperature
I can’t mix the other ingredients with sugar and glucose syrup
However do you suggest another way to make a syrup for binding the bars?
Thank you so much

This is just another recipe I made my own it was bad
However the one you gave me I believe it’s much better but it’s difficult to handle

I’m sorry for lot’s of questions
What you suggest sir?
Thank you

No problem.

this job is not easy but i believe you can.
Can you share photos about your work ?
Do you heat igredients before mix with syrup ?

You should make this job with a helper to be fast.

Yes I have photos but I don’t know how to upload them to the forum I will try
No I don’t heat other ingredients because it has a whey protein powder which the flavor and texture will be bad I only use oatmeal and whey protein powder along with the syrup
Other ingredients I will add later like peanut butter flavor or chocolate chips for decorating
Also the 25 % syrup is not enough to combine ingredients
75 % oatmeal and whey protein powder
25 % sugar and glucose syrup

Do you suggest other form of syrup that will help combine the bars and long shelf life?

hello,

your application style is wrong.

you should mix all ingredients in the pan which you melted sugar + glucose syrup.

and you need to heat other ingredients because if they cold , they cool the sugar + glucose mix so you can not make a dough.

You can input ingredient in a oven to heat them when you started to melting syrup

Thanks so much for the help
I will correct my mistakes

Dear Sir sorry for lot’s of questions
What other options I can do for shelf life and binding the bars
I’m not able to use sugar and glucose syrup this way requires heating the other ingredients which I don’t want to do due to whey protein powder get burned
I’m trying to minimize the process as possible

Do you suggest other syrup like sugar and water and glucose syrup?
Or any other syrup form
Plain sugar + glucose syrup is difficult for me
I really need your help
Again I’m sorry for to much requests

i think long shelf life is second step. firstly you should make the bar.

you can try honey as binding ingredient or a similar syrup. Also you can use them without cooked but this makes your bar so soft.

Very true I will focus on the bars right now then see what you suggest for preservatives
For me cooking the syrup using water or something similar to honey because honey effect cost
I’m planning to similar to the production line in the YouTube link

Note
This man is using date past and cashew butter
I don’t want to use dates to my recipe
I imagine I cook the syrup then add to the mixer to make a dough then I move to trays to make decorations and set it to cool
Then move it to cutting and Packaging
What do you think?

Also I tried honey but I cooked honey first didn’t measure what C degree but it took around 5 minutes then I added the dry ingredients to it
And form the bar and let it cool on room temperature
The bar texture is good but little bit hard
I used
50 g dry ingredients
40 g cooked honey
So the syrup is 90% to the Dry ingredients

true process.

90% ?. it should be 40/90 . also do not forget water content of honey which evaporated.

Hey @1992.tariq ,
While it is great that you are working on the product side of the business, don’t forget about the documentation and legal side of things. Those are just where a lot of products get hung up and stop you from getting to the market. Just “food” for thought.
Mark

instead of glucose syrup you can use HMCS or HFCS this is similar sweeter as glucose and this is less viscous then glucose, so i think it will work better…

Very true
Product is just one side
I’m only focusing on the product at the moment I enjoy and love food processing and coming up with healthy snacks substitutions
Another important side in business is the marketing and its very important

Your actions.
1- Table sugar should cover 25% of the total product. When you bring the boiling temperature to 150 degrees with 20% water to put in table sugar, add 0.015% citric acid. citric acid should be diluted with water.When syrup temperature reaches 150 degrees Celsius should be lowered over the fire.
2- Oatmeal and whey protein syrup prepared into the container prepared by pouring hot as a homogeneous mixture is provided quickly. After the mixture is provided, it is provided to cool down quickly by spreading on cold clean ground or pouring into molds.
If the product is not desired to be hard and brittle, 0.001% alpha tekoperol and glycerol may be added to the product in the same ratio. both the shelf life of the product is prolonged and the desired flexibility is provided.

I have concerns…you want to use extrusion…hence mixing and extruding to packaging…so cooking is not in your desired procedures? Have you tried mixing every ingridents, replace sugar with dates and extrude?

Well explained

This is cold extruder

More for shaping of dough only it seems on video, alignment into mould and packing.

Has a little like Nougat features to this bar

informative topic should be continue

protein #proteinbar #snackbar #productdevelopment