Turn Ingredients into Revenue
Invest in the future of nutrition bar manufacturing. Our cutting-edge twin-screw technology in Gurugram delivers superior consistency and scalability, from 50 kg/hr to 500 kg/hr.
Turn your protein bar ideas into reality. Request a machine quote today and start producing delicious, crunchy bars with ease.
A single-screw extruder for protein bars operates quite differently from a plastic extruder. The operation of the machine is not based on high heat or high shear, but on the idea of moving a dense, sticky mixture in a gentle way while keeping everything intact: the proteins, flavors, and nutrients.
This serves as an entry unit or as a research and development unit. Volume is not a critical factor in this situation, as you will achieve flexibility and protection for your ingredients. The screw is approximately 50-65 mm with a somewhat short L/D ratio of 8:1 to 12:1.
Therefore, the time in the barrel from dough is minimal consisting even when using proteins and vitamins. The motor draws 7.5-11 kW while providing high torque for denser, stickier doughs.
As production scales up, the commercial side changes everything. The screws will grow in diameter to 75 – 90 mm, which will achieve about four times the output (given the correct RPM and channel depth). The L/D ratios will also increase to accommodate constant pressure, which will range from 10:1 – 16:1.
Motors will now exceed 15 – 22 kW and will need to move larger masses of the dough efficiently, also. Cooling the screw feed area is just as important, having integral chillers that take shear heat out of the screw.
This describes a process that runs at a very high speed. The screws may be between 100-130mm, the motors are 30-45kW, and all components need to be made robust enough to withstand the continual mass of thick dough.
The aspect ratio of the screws can be anywhere between 12:1 and 24:1 to redistribute the pressure through the large die evenly. The machine design is not to allow for any optional cooling, as the cooling barrels, jackets, screw-core, and feed-throat cooling eliminate the breakdown of heat of friction.
A twin screw extruder processes the protein bar cookie dough, unlike a single screw extruder. It will mix and homogenize the dough better due to the use of modular screw elements. In the end, you will return from the extruder your dough with inclusions (nuts, chocolate chips, syrup binder) well incorporated throughout, and the dough will not stop moving through the machine during operation.
The machine has specifically been designed for R&D and limited potentially pilot-scale applications with an emphasis on accuracy and flexibility. The smaller screw diameter (30-40 mm) allows for continuous control of small volumes.
And the longer aspect ratio L/D of (24:1 – 36:1) utilizes mixing zones based on the complicated nature of the high caloric formulations. Motor output is 7 kW -15 kW with high torque and minimal energy loss while operating denser dough.
This element satisfies the requirements of industrial production rates. The screws accept diameters from 50–70 mm for doubling the volumetric flow rate and have a length-to-diameter (L/D) ratio from 28:1 to 40:1 for further mixing of conversions at elevated speeds.
The screw profile is designed for throughput by using a longer metering zone that allows some time for moisture and pressure to stabilize directly and allows some flexibility for measuring bar weights with less accuracy.
This production system is high volume, with full production capabilities. Elements are heavy-duty, robust to include but not limited to the screws, either 80 or 110 mm. The L/D ratio is optimized from 32:1 to 48:1 for continuous mixing and de-aerating.
Motors range from 55 to 90 kW with a high-torque gearbox. The design is based on the modular screw section, allowing for gentle pumping and de-aerating of the floating force.
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Feature
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Start-up machinery
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Commercial Machinery
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Automation
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Semi-Automatic
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Fully Automatic
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Capacity
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50 - 200 kg/hr
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50 - 500 kg/hr
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Power Load
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10 - 40 KW
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20 - 65 KW
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Area Required: sq Feet
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1000 - 2500 sq feet
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1500 - 4000 sq feet
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Size of the Machine: L x W (Feet) approx.
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8 ft × 4 ft
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8 ft × 4 ft to 200 ft × 12 ft
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Material
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Stainless Steel SS 202 / SS 304
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Food Grade Stainless Steel SS 304
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We will clarify the distinction between a start-up line and a commercial line for producing protein bars by extrusion. A start-up line will run in the capacity of 50-200 kg/hr with a reasonable power load of 10-40 kW. These systems are smaller lines, and would typically fit in a rented 1,000-2,500 sq ft space, and are generally constructed from SS 202 and SS 304 to reduce initial capital costs, and more easily test small product runs and new formulations.
A commercial line is a fully automated line that operates at capacities of 50-500 kg/hr and requires 20-65 kW to power the high-torque, high-speed motors, longer cooling tunnels, and feeding systems. The footprint/hardware space will be 1,500-4,000 sq ft to maintain cooling belt requirements while utilizing multi-stage packaging, and all food contact surfaces must be constructed of SS 304 for Hygiene and regulatory compliance. Fully automatic machines are where the heavy labor sits. Fully automatic will feed, mix, extrude, cut, cool, and keep the whole process on autopilot for you. Fully automatic machines will handle 100 to 200 kilogram outputs per hour. Multi-zone heating, water-cooled barrels, and PLC controls will ensure everything is accurate and consistent. But when you scale your business into a fully automatic it will give you consistency and scale without a lot of additional thought.
We work with you to figure out exactly what you need, even if that’s a single protein bar making machine for startups or a full production setup. We’re not here to sell you more than you need. We ask the right questions, dig into your goals, and match you with systems that fit the way you want to grow.
Let’s be honest: your equipment should work as hard as you do. That’s why every protein bar machine we build is made to last and made to deliver. We stick to strict quality checks at every step, so when it lands in your facility, it just works clean, consistent, and made for real production.
We make sure your protein bar machine gets to you safely, on time, and set to run. From careful packing to on-site setup, every step is handled with precision so you can get to work without the usual delays
What this means is we don’t just sell you a protein bar machine; we stay with you long after it’s up and running. When something needs fixing or fine-tuning, our technical team is quick to step in, solve the problem, and keep your line moving. That’s how trust is built.
FAQs
Everything you need to know about our protein quality, supply, and delivery answered
Machines used for production include mixture extruders, batter mixers, and flavor coating barrels.
A smaller-scale production would benefit from a semi-automatic or mixture extruder.
A nutrition bar making machine is a machine that can mix the various ingredients and produce the nutrition bar in a shape or shape and cool.
A standard mixer is not designed to process thick and sticky dough used in protein bars. An extruder can process the sticky dough and produce the same shape and texture with each run of the equipment. .
There is one machine that can produce either protein bars, energy bars, or cereal bars if the right screwdriver, die shape, and proper feeding system can be used.
Our protein bar machines are trusted worldwide — from the USA to Oman, Zambia to Bangladesh.
We help you select the ideal food machine for your business requirements.
