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Granola bars forming Equipment

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

You make granola bars from caramelized nuts, grains, and cereals, baking and shaping them into crunchy snacks. Granola bar production involves mixing, forming, baking, and cutting into bars. The quality of granola bars is affected by baking. How the sugar caramelizes and blends with the other ingredients determines the final taste and texture of your granola bar.

Granola bars

Turn the mixture of your ingredients, into continuous slabs for processing into bars, stands, or other shapes. Reliable form slabs of pressure-sensitive or aerated products from substrates of a variety of consistencies. The pressure-free forming process ensures no change in density even for delicate product structures. This is a highly configurable line of smooth press rollers designed to accommodate a wide variety of process conditions.


<h2>A confectionery press for the most delicate substrates</h2>
The GP series of smooth press rollers from Buhler is a line of configurable confectionery rollers for producing tightly toleranced and highly consistent slabs of delicate confectionery substrates. Temperature, pressure, roller diameter, and nozzle style are all selectable and tightly controlled process variables. The height and configuration of the drive unit are also easily changed to seamlessly integrate with existing facilities and process equipment. In this Slab forming machine, the forming speed and slab thickness are infinitely adjustable and active substrate cooling during forming is available to ensure the highest quality confectionery product output.

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Slab forming machine

Form ingredient mixes into strands and slabs for further processing into bars, and other final product shapes. This is a universal roller press for soft to solid substrates including those with added components such as nuts or dried fruits. Form slabs and strands as wells as bars and an infinite variety of shapes with custom nozzle geometry and cutting options.


<h2>Consistent, high-quality shape forming from a universal rotary bar roller press</h2>
The DP series of rotary bar press rollers from Buhler is a line of configurable confectionery rollers for producing highly consistent and tightly toleranced slabs, strands, and shaped bars of soft to solid confectionery substrates. Substrates with added components of a different texture are also readily processed. Temperature, pressure, roller bar geometry, and nozzle style are all selectable and tightly controlled process variables. The temperature of the rollers, hopper, and nozzles can be adjusted independently and high system pressures can be achieved when necessary to ensure an output product that consistently meets customer requirements.

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Strand forming machine

Form two-ingredient mixes into the shapes and layer combinations required for your final product. This is a universal roller press for two soft to solid substrates, including those with added components such as nuts or dried fruits. Form filled, hollow, or multi-layered slabs and strands of any shape and any volume ratio.
<h2>Consistent, high-quality shape extrusion of two substrates from a universal rotary bar press</h2>
The DDP series of twin rotary bar press rollers from Buhler is a line of configurable confectionery rollers designed to produce highly consistent and tightly toleranced slabs, strands, and shaped bars of two confectionery substrates. Soft to solid confectionery substrates, including those with added different texture components, are readily processed. The equipment can create layered and filled products in any volume ratio and any shape thanks to independently variable roller speeds and customizable nozzle geometry. Process control of temperature, pressure, and speed assures a consistent high-quality layered of filled product.

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Strand forming machine for 2 masses

Form three ingredient mixes into the shapes and layer combinations required for your final product. This is a universal roller press for three soft to solid substrates including delicate ones including nuts and nougat. Form filled, hollow, or multi-layered slabs and strands of any shape and any volume ratio of one to three substrates.


<h2>Consistent, high-quality shape extrusion of three substrates from a universal rotary bar press</h2>
The DP3 series of triple rotary bar press rollers from Buhler is a line of configurable confectionery rollers for producing highly consistent and tightly toleranced slabs, strands, and shaped bars, of up to three substrates. Soft to solid confectionery substrates including those with added components of a different texture can readily be processed. Layered and filled products of up to three substrates can be created in any volume ratio and any shape thanks to three independent drives and customizable nozzle geometry. Independent process control of temperature, pressure and speed for up to three substrates assures a consistent high quality layered of filled product.

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Strand forming machine for 3 masses

Turn your ingredients mixture into strands and slabs for further processing into bars and other final product shapes. This is an easy-to-clean rotary Strand forming machine for creamy mixtures, soft or lightly whisked mixtures.


<h2>Consistently form slabs and strands of any shape</h2>
A single bar rotary press especially suitable for soft, creamy masses. A wide variety of soft substrates can be consistently processed into tightly toleranced slabs or strands of shapes limited only by customizable nozzle geometry. Working widths from 100 mm to 800 mm are available. Substrates such as doughs, fruit pastes, marzipan, truffles, pralines, fats, smooth brittle, toffee, coconut, and nougat can readily be processed. Additives like nuts and fruit pieces can also be included without issue. Special scrapers eliminate sticking of the substrate to rollers ensuring evenly distributed and consistent deposition. The machine includes few wearing parts and can be opened up in a few steps in the field for easy access to all surfaces for cleaning.

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Strand forming machine for creamy mixtures

Cut continuous strands and slabs of your ingredient mix into bars, strips, and other final product shapes. A guillotine-style transverse cutting machine for strands or slabs of a wide variety of products. Working widths from 300m to 2400 mm and up to 5 axis servo control for precise adaptation to most transverse cutting applications.


<h2>A transverse cutter with up to 5 axis servo control</h2>
The MS series of transverse cutters are designed as universal transverse cutters for a wide variety of customer applications typically involving straight cuts. Two servo axes controlling the up and down movement of the knife and movement of the knife in the direction of belt travel are provided standard. Options for 3 additional servo axes for even more control are also available. Optimal cut paths are achieved through independent axis programming with the special software. The cutting movement of the knife is synchronized to the belt speed and cutting length ensuring consistent product shape and no distortion. Cutting speeds of up to 700 cuts/ minute can be obtained.

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Strand cutting machine

Cut continuous strands and slabs of your ingredient mix into bars, strips, and other final product shapes. This is a high-speed transverse cutter capable of up to 1,000 cuts/min on all types of confectionery products including sticky ones. Cutting speed is indexed to transport belt speed to ensure straight cuts of constant length.


<h2>Accurate, consistent cutting at high speed</h2>
The HS series of transverse cutting machines work with widths from 200mm to 2400mm and handle belt speeds up to 20 M/min. With the cutting knives indexed to the infinitely adjustable belt speed, reliably straight and consistent cuts are assured even as belt speed is adjusted. The HS series cutters include specially coated transport belts to capture crumbs and other materials left over from the cutting process so only clean, precisely cut products leave the machine. Captured materials are subsequently removed from the transport belt with scrapers. Cutting knives are also cleaned of any residual material after every cut by use of special scrapers which allows the unit to be very effective in cutting even sticky substrates.

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High-speed strand cutting machine

Cut continuous slabs of your ingredient mix into spaced strands for further processing into bars and other final product shapes. This is a longitudinal cutting machine for continuous slabs of all types of confectionery products. Rotating circular knives transform the solid product slabs into individual strands of any width.  Fanning features integrated into the belt feed system spread the product laterally to create consistent spaces between strands and no chance of sticking.


<h2>Cut and separate longitudinal strands with a single machine</h2>
The SG series of strand slitters are longitudinal cutting and spacing machines capable of cutting continuous slabs of virtually any product into strands of whatever width the customer’s product requires. Rotating knives perform the cutting against a special plastic backer or directly against the feed belt depending on the product. The knives are scraped clean with each rotation. The thickness, diameter, lubricating coating, and even temperature of the cutters is selectable to ensure consistent cutting without squeezing the slab for consistent uniform strand creation. Several options exist for spacing of the strands after cutting to adapt to any requirements of the customer’s subsequent processes.

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Longitudinal strand cutting machine

Start up your manufacturing of cereal bars or produce smaller batches to test and try out new recipes.


<h2>Automatic cereal bar made simple</h2>
The SnackFix from Buhler is an entry-level automatic cereal bar machine that serves the simple production of cereal bars and similar masses. The SnackFix consists of only two main components and represents an entry-level model for bar production. The cereal mixture is continuously mixed with a binder in the mass preparation unit. After mixing, the mass is delivered to the transport belt, formed to a continuous product slab by two equalizing rollers, and is then cut to the desired product width.

The line is a perfect solution for producing cereal bars if a wide range with a throughput of up to 130 kg/hr.

Both units can also be operated as stand-alone machines. The mass preparation unit can be continuously operated.
The cross-cutting unit can be used as an inexpensive forming and cutting line.

Buhler supplies more than an entry-level automatic cereal bar production line for starting with automatic bar production. They provide everything - from delicious recipe ideas for granola bars to the ingredients for binder production.

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Entry-level automatic cereal bar machine

The small-scale manual production of crunchy cereal bars, brittles, and similar products can be time-consuming and labour-intensive. Achieving the correct control of temperature to allow for mixing and spreading, and then cooling might be very challenging without professional equipment. A dedicated manual cereal bar cutting table is a perfect way to begin a start-up production.


<h2>Dedicated production table for high-quality crunchy cereal and brittle products</h2>
The Manual Process Table from MIA Food Tech is a purpose-built solution for the small-scale production of crunchy products=, cereal or nougat bars.

This high-specification manual table has an inbuilt heating and cooling system. The heating system keeps the product mix at the right temperature after cooking to allow it to be spread, rolled and combined more easily and quickly. Inbuilt cooling reduces the time before the rolled mass is ready for cutting and removal.

With single-operator use in mind the table is appropriately sized to avoid the need for excessive leaning. The stainless steel guide rails are easy to fit and remove, and the manual cutter blade is effortless to operate thanks to easy gliding wheels on the base of the unit.

Weighing just 200kg, with dimensions of 1000mm x 1000mm x 1000mm, the Manual Process Table is ideal for small sites, and has been designed for batch production of between 5 and 10kg of product.

Entry level cereal bar cutting table

Cereal and grain bars are increasingly popular, both as snack foods and as functional foods using natural ingredients. Traditionally, a higher-quality softer bar has been difficult to produce economically in small-to-medium production environments. Additionally, standard machines have only been able to produce either moulded dry-grain based bars or extruded dried fruit paste-based bars, limiting production flexibility. A modern, purpose-designed machine that can address these issues is therefore an attractive proposition.


<h2>Flexible bar machine for grain or fruit paste-based products</h2>
The Bar 2 from DSC is a flexible entry-level machine for the production of extruded or moulded soft cereal bars.

For dry cereal mixes, the product is dosed onto a conveyor which passes it through a laminating roller to assert the initial thickness. A further laminating roller then produces the final product dimension.

For dried fruit pastes, two specially designed rollers shape the pre-mixed product into a fully adjustable extrusion.

For both product types the final stage is to cut to final product size. Cut dimensions can be selected by means of the built-in touchscreen control interface.

The HMI allows the creation and storage of multiple product recipes for easy recall, meaning simple one-person operation.

The whole machine has been designed to be simple to clean, with all product contacting surfaces easily accessible for hot water washdown.

Entry-level cereal bar making machine

In high-speed packaging environments, creating secure packages quickly and efficiently is paramount. Challenges include maintaining a consistent seal, accommodating various film widths, and meeting rigorous regulatory standards.
<h2>Seal flexible wrapping material rapidly</h2>
The Carina 500 from Delfin is a horizontal flow pack unit designed to create secure, three-sided seals using flexible wrapping material from reels. Equipped with three brushless motors, it reaches mechanical speeds of up to 200 cycles per minute. The unit supports a standard film width of 500 mm and complies with EC standards, ensuring that it meets European safety and performance criteria. Ideal for high-speed packaging lines, it offers a dynamic and modern combination of performance and visual appeal.

Three-side sealing flow pack machine

In modern industrial settings focused on packaging a wide variety of products, efficiency and reliability are critical. This often includes the need to package fresh, frozen, and dry items quickly while ensuring easy access for maintenance and cleaning.
<h2>Package products in continuous vertical motion</h2>
The Vegatronic 6000 by IMA is a continuous vertical form, fill, and seal (VFFS) system designed to handle a range of products from fresh to frozen and dry goods. Known for its unparalleled accessibility and ergonomic design, the Vegatronic 6000 is built with a full open-frame structure that makes all components easily reachable for maintenance. The machine can handle various packaging styles including pillow, gusseted pillow, block bottom, Quattro, and doy-style Shark. It supports eco-friendly materials such as compostable and biodegradable films, enhancing its capability to meet sustainability goals. The system is equipped with a quick-change mechanism for forming tubes and film reels, reducing downtime. Its high-speed wrapping capacity is up to 210 cycles per minute, making it suitable for large-scale operations. Moreover, the ultrasonic sealing option drastically reduces leak rates, material waste, and energy consumption, while maintaining hygienic standards with wash-down execution.

Continuous vertical form fill seal packaging solution

When producing different snacks and sweets, each product will match a different carton size in packaging. A flexible cartoning system that can quickly switch from one packaging size to another maximizes production capacity while reducing the footprint of the working area.


<h2>Pack all cartons with a smart horizontal cartoning system</h2>
The VENTO Cartoner, from Mpac, is a hygienic food cartoning system often set up for customers who pack chocolate bars, energy bars, sweets, and other snacks. The unit is equipped with an advanced intelligent machine interface that provides information on machine status, predictive maintenance, and quick changeover procedures for better flexibility. It is made of hygienic stainless steel materials with an accessible design for easy cleaning. The system is servo-driven and coupled directly to its components for reliable operation and minimum wear over time. Its open design allows an optimal view of the machine’s operation and product flow. Packaging processes include carton erecting, loading, transportation, and closing.

Cartoning Machine For Snacks and Sweets

Accuracy is a primary concern for case-packing pre-packaged foods such as milk or preserves. But in order to position items into large cases at high speeds, the infeed system must quickly adjust to different packaging options, including cartons, cans, pouches, and doypacks.


<h3>Pack foodstuffs automatically in RSC and WA cases at high-speeds</h3>
The ALISIO, from Mpac, is a side-load case packing system for a range of pre-packaged formats. Snacks, beverages, and foods may be loaded into regular slotted cases (RSC) or wrap-around (WA) cases. The high-speed system reaches a maximum output of 25 cases per minute. At the same time,  the intuitive, user-friendly controls with Intelligent Machine Interface are designed for automatic changeovers of less than 10 minutes.

The system supports small batches allowing operators to switch between RSC and WA cases. Its open and robust construction makes all components accessible and easy to clean. The case magazine can be adjusted to accommodate up to 300 cases. The ALISIO is servo-driven and directly coupled to its components to minimize wear and improve operating life. A modular infeed design makes handling bags, pouches, cartons, and other types of packaging easy. The unit is designed to operate continuously with fewer stops for maximum productivity and is rated at 98% efficiency.

Side Load Case Packer For Packaged Food

Chocolate bars are popular snacks and gifts for many occasions and events, dating back to the Mayans and the Aztecs. They may also include other ingredients such as caramel, fruits, or nuts. Considering making chocolate bars? Make sure, though, that your chocolate bar making equipment can cover various processes such as grinding and melting, tempering, refining, and cooling.

Chocolate bars

The cereal bar production line consists of mixing, cutting and cooling a dough of chosen ingredients. These can be seeds, nuts, chocolate chips, dried fruits - and many more options. It may seem simple, but it needs attention to provide an appetizing look and taste.

Cereal bars

In NASA's early years, a research program was established on how to provide food for astronauts while in space. In fact, in the 1960s, nutrition bars were launched with a label called "Space Food Sticks" because they were designed to allow astronauts to eat them easily while wearing their helmets. Protein bar manufacturing equipment is used to mix ingredients, extrude the mixture at a set temperature, cool the product before cutting it to size, coating it, and allowing it to cool to prepare it for packaging.

Protein bars

Making ice cream is all about mixing and homogenizing. First you need to blend, pasteurize and standardize your mixture. Then store it in tanks and freeze and aerate the mix until it reached the right consistency. Now you can add fruits, cookies and other solids if you like. In the final step the mix goes through an air blast hardening machine and it's ready to store and ship.

Ice cream

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Do you know how many different bars are on the market? From protein bars to cereal bars to chocolate bars, the options are endless. And if you want to beat the heat on a hot summer day, don’t worry; ice cream bars will come your way.

What all these bars have in common is that they often come in multi-packs sold in supermarkets or other shops. With all the different flavors and textures available, we asked Luc Smeet and Frank van Bentum from Mpac Group, if it matters what type of bar you put into the carton.

“<em>I see no differences. A bar is a bar for us,</em>” says Frank. Okay, we didn’t see this coming.


<h2>So what does matter when packing your bars into multipacks?</h2>
<em>“Finding the best solution based on a certain speed matters. So you’ll have high speed and low count and low speed and high count,” </em>says Frank.

That's because bars are sold in 4- or 6-packs, which are intended for supermarkets as well as in 24-pack display cases, for example, for gas stations.

Luc adds: “<em>When you have a brittle bar, you’ll need to reduce the speed a bit, but in general, the way we handle them is the same.</em>”

Bar orientation is important to figure out whether to use a pick-and-place system with suction cups or mechanical grippers. “<em>When the product is not flat or is packed on edge, the size of the product is not wide enough for the suction cups to hold the bars</em>,” Frank comments.

As for the box, the rotary feeder opens the carton a little at a time, in 3 or 6 steps, to avoid any damage. “<em>Doing it in steps makes the opening process more reliable than a single, strong movement</em>,” points out Luc.
<h2>Oops, it turns out there is a difference after all if you are making ice cream bars</h2>
Frozen food producers require a wash-down or hose-down system in their cartoning line to comply with the hygiene and cleaning requirements.

Bars containing dairy products are more susceptible to bacterial growth, and you need to clean the machine with steam and chemicals using a wash-down version. If your ice cream is dairy-free, a hose-down version that uses only warm water to clean spills and debris is enough.

You should also carton the ice cream bars quickly to prevent them from thawing.

“<em>Bars are kept at -18 °C,  and no one wants to work in such extreme temperatures. That’s why we have only 10 minutes to take them out and pack the bars without damaging them,</em>” concludes Frank.

Bottom line, no matter what type of bar you are making, do not hesitate to ask Luc and Frank for assistance in selecting the right solution to pack them in a box.

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Experts in a box – What type of snack bar are you packing?

Food

You can’t buy happiness, but you can buy chocolate; that’s basically the same thing. We were not surprised to discover that chocolate - to be specific, cocoa beans – was so valuable that it was used as a currency in Mayan times. When making chocolate, cocoa beans need to be dried, fermented, and roasted before using chocolate making equipment to turn them into your favorite chocolate product.

Chocolate

<span style="font-weight: 400">Cocoa production and the cocoa industry uses industrial processing technology to process and manufacture high quality cocoa products in many different forms. Did you know that cacao cultivation goes back centuries - to be specific, about 5300 years? </span><span style="font-weight: 400">This plant, with its long history, is also known for its versatile usage. From </span><span style="font-weight: 400">cocoa nips to cocoa butter, cocoa becomes a base to produce multiple products, ranging from food products to cosmetics. As you may already know, chocolate products are all made from cocoa as well. Hence, depending on what you intend to produce as the end product, as well as your recipe, your cocoa processing equipment line may change.</span>

Cocoa

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

During the Middle Ages, sugar sweets were a delicacy only for the rich due to the high cost of sugar. Thankfully, the discovery that sugar could be extracted from sugar beets made sweets affordable for everyone. The sweet category is broad, covering chocolates, chewing gums, sugar candies, and candied/glazed products with sugar. To make these confections, sugar manufacturing equipment needs to cover different steps within the production line such as sugar dissolution, syrup cooking and cooling.

Sweets

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