Foodsure Machines Launches Automatic Protein Bar Making Line to Power India’s Functional Food Growth

The worldwide protein bar market is anticipated to surpass USD 6 billion by 2028, with India actively supporting this growth. The protein snack part of the market is growing at more than 15% CAGR. The demand for efficient, automated production lines is at an all-time high.

Yet, most small and medium producers are still utilizing manual or semi-automatic processors to help produce their snacks, hurting productivity, increasing waste, and complicating or even preventing consistency on a day-to-day basis. This is where Foodsure Machines comes to the rescue with their Automatic Protein Bar Making Line. A solution is designed to drive efficient scale, reduce labor costs, all while producing consistent, quality bars batch after batch.

The Hidden Gaps in Protein Bar Manufacturing

It is science to create a protein bar that is soft, chewy, and nutritionally stable. How do we do that? Protein, while important, can often make our bars too dense or dry, due to this often very high protein content. The problem is, without strict control of a set of variables related to temperature, mixing, and moisture, each batch can come out a little differently. Our product will also face a few bottlenecks during production when:

Most challenges come from poor control of critical variables like:

• Protein-to-moisture ratio
• Thermal load effect on binders
• Ingredient particle size & hydration
• Cooling time uniformity
• Compression force during forming

When these are not standardized, protein bars can:

• Become too hard, especially over shelf life
• Crack/crumble during cutting and wrapping
• Show oil separation due to unstable fat binding
• Lose texture and become chalky due to protein denaturation

Common Production Bottlenecks & Losses

Inconsistent Ingredient Distribution
Without continuous mixing systems, protein clumps and sugar alcohols crystallize unevenly → affecting bite and mouthfeel.

Manual Processing Slows Growth Hand-based line =
✔ more manpower
✘ lower output
✘ higher cost per unit
✘ tough to scale

Binder Reaction Variability
Incorrect temperatures can burn syrups, or fail to activate them → reducing structural integrity of the bar.

Texture Degradation Over Shelf Life
Water migration, oxidation, and protein hardening cause rapid staling if not engineered scientifically.

Cutting & Forming Issues
Bars mis-shaped or sticking to blades = wastage + rework + reduced commercial output.

Wrapping Failures
Irregular bar dimensions cause sealing problems → leakage + spoilage + returns.

Limited Capability for High-Protein Formulas
Conventional setups struggle once protein content crosses 25–30%, especially in clean-label bars without artificial humectants.

Foodsure’s Solution: Consistency = Confidence

The Foodsure Advanced automatic Protein Bar Machine ensures that all aspects of production, including mixing and molding, are carried out in accordance with the set parameters. 

Performance & Profitability Advantages

Perfect Shape & Size Every Time
Advanced forming and cutting units ensure uniform dimensions + ideal bar density to avoid rejections during wrapping.

Designed for High-Protein, Clean-Label Recipes
Can process 30–40% protein bars, nut bars, granola bars, energy bars, keto bars — without cracking or hardening.

Shelf-Life Stability Engineered
Controlled mixing temperatures prevent protein denaturation + sugar alcohol crystallization → softer texture over shelf life.

Low Manpower Dependency → Lower Cost/Unit
Automation reduces labor by up to 60%, allowing faster scaling without adding staff.

Inline Cooling for Texture Control
Prevents oil separation, stickiness, or moisture migration — maintaining bite consistency.

Technology That Scales With Your Brand

Modular Design
Start small → scale up to 500 kg/hr without changing the product line’s core systems.

Compatible With Multiple Binding Systems
Honey, glucose, maltitol, date paste, gum arabic, soluble fibers, nut butters — machine handles them all smoothly.

Future-Ready Integration
Optional:

• Nitrogen flushing packaging
• Metal detector
• Inline checkweigher
• Cooling tunnel upgrade

Why It Matters: Business Wins

The Advanced protein bar machine is available in four different models, each with production capacity: 50kg/hr, 100kg/hr, 200kg/hr, and 500kg/hr. Each production line includes PLC automation, temperature-controlled mixing, and an extrusion module built for food processing durability.

Designed by People Who Understand Factories

“We are not designing machines, we are designing for the people who operate food factories,”  says Mr. Himanshu Pratap, Founder of Foodsure Machines. “We have years of production floor experience that shows us where production slows down and how to identify real inefficiencies. In that information, we have based every design.” 

With 13 years of food automation experience and installations in 5 different countries, Foodsure Machines builds machines that think like manufacturing organizations, simple to run, engineered to last, and constructed, with many of our installations,  to work 98% of the time or greater.

Trusted by Growing Food Brands

• Scalable for all sizes: Whether you’re just getting started or a full-scale manufacturer, the same product line grows with you.
• Real-world results: A Gujarat-based nutrition brand tripled its production output within 90 days post-installation.
• Fully supported: Installations, staff training, and remote support round the clock — you will never stop producing.

Shaping the Future of Food Manufacturing

• As the functional food space in India continues to develop, automation is no longer optional; it is the default position to scale. 
• Foodsure Machines helps food entrepreneurs reduce human error, control costs, and provide product consistency, day-in-and-day-out. 
• Every system is intuitive, globally benchmarked, and is backed by an immediate response technical team to assist your operation well after your installation.

Serving brands in nutrition, fitness, and functional snack categories across India and beyond.