Baking & Snack - July 2019 - 74

BAR TECHNOLOGY

An enrober and cooling
tunnel set the attractive
finish on multiple
varieties of snack bars.
Bühler Group

manufacturing candy vs. cold bars is that candy bars are
typically enrobed - covering the formed piece - and
cold-formed bars are much more nutritious, and the finished bar needs to have a perfect finish," Mr. Clemens
said. "The surface needs to be size-controlled as well as
perfectly formed."
While baked lines require ovens, cold-formed bars
may require extensive cooling tunnels and other systems
to properly set and chill the bars, especially after enrobing and before they enter the packaging department at
rates of often a couple hundred a minute.
"Enrobing the product covers a multitude of sins,"
Mr. Knott pointed out. "If you have a nice, coated finish
to the product, you're not as worried about what it looks
like inside the bar. The consumer just sees the enrobed
finish and not the extruded bar finish."
From a baked perspective, many similarities exist
between cookie and bar manufacturing. "Both involve
portioning a product that retains the characteristics the
producer wants to maintain - with great piece identity, weight control and reduced labor," Mr. McIsaac
observed. "From a product development perspective,
cookie and bar producers are among the most creative
people we know."
During the baking process, many manufacturers prefer to maintain the bars' more natural, "naked" or unprocessed look. "Typically, you don't want to pick up any
color when baking a bar, especially not a color like you see
with a cookie with its nice, golden toast color," Mr. Knott
said. "That's not the case with an extruded energy bar."

One tough process
Additionally, bar formulas and processes often result
in vastly different mouthfeel than their cookie counterparts. "An energy bar is tougher to eat than a cookie,"
Mr. Knott said.
And it's tougher to make. "The mixing technology is
different. It's more of a blend than an actual mixing of
the batch that you get with a cookie," he added.
Likewise, the motors on extruders used for bars need
to be ramped up for proper processing. "We have to up-

74 Baking & Snack July 2019 / www.bakingandsnack.com

grade the side of the drives and the gearbox - the whole
extruder is much beefier for a protein or energy bar than
it is for a cookie," Mr. Knott said. "It needs to be substantially so because the dough is much tougher to extrude."
Because bars incorporate molasses, syrups and other
viscous binders, such "blending" of a sticky batch requires
greater torque and energy than what's needed to make a

The nutritional composition
and visual appeal of
bars are critical to their
success in the market.
cookie batter. Often a mixer listed at 1,000-lb capacity can
turn out 600-lb batches because of the batch's tacky texture.
Wirecut machines have been used for decades to form
products for both the cookie and confectionery markets,
and most recently, they have expanded into nutritional,
protein and breakfast bars, according to Sam Pallottini,
director of cookie, cracker and pet food sales, Reading
Bakery Systems (RBS).
He noted the new RBS servo-driven wirecut model
offers advanced "game changing" technology, but the
operation of it is fairly simple. It comes with a pair of
saw-tooth feed rolls that gently push the batter through
the filler block and die to form the bar. This new wirecut
design enables manufacturers to select a head that best
suits forming their products.
Mr. Pallottini added that a standard head for extruding soft bars and cookies comes with the machine. It
consists of a 250- or 312-mm-diameter feed roll, filler
block and a 125- or 165-mm-wide die plate, depending on the product's characteristics. "This head can be
interchanged with a specialized design for coextrusion
to run two dough cookies, fig bars, breakfast bars and
two-color cookies," he said.
For some high-protein products or stiffer doughs,
RBS offers a heavy-duty head design. "This comes with
larger feed rolls, stronger die support rails and larger


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Baking & Snack - July 2019

Table of Contents for the Digital Edition of Baking & Snack - July 2019

Baking & Snack - July 2019
Contents
Contents
Editorial - The collegiality of baking
Newsfront - Consumer insights reframe snacking for Mondelez
Pepperidge looks to ‘unleash the growth’ in Goldfish
DowDuPont merging two business units
News - BEMA announces 2019 board executives
Rich Hoskins recieves lifetime achievement award
Context becoming critical for food additives
In Memoriam
Arnott’s begins construction on $45 million warehouse
People/In Brief
Food Safety Series - farm-to-fork FOOD SAFETY
IBIE Committee Roundtable - EVOLVING WITH THE TIMES
Bud’s Best Cookies - THE RIGHT STUFF
The magic of tray loading
One connection can chart a company’s course
International Series: Asia - SEA OF CHANGE
Where’s the growth throughout Asia?
Gums and Stabilizers - PRESERVING APPEAL
Fortification - an EXTRA BOOST
Bar Technology - breaking down BARRIERS
Conveyors - ENSURING SAFE TRAVELS
Playing it safe with acetal belting
Moulders - Shaped for Control
Inline Quality Control - AS FAR AS IT CAN SEE
FSMA advances X-ray, vision systems
INDUSTRY INSIGHT - SUCCESSFUL PROJECTS
Meeting Preview: IBIE - Totally Immersed
Meeting Preview: AACCI - READY TO MINGLE
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
Baking & Snack - July 2019 - Baking & Snack - July 2019
Baking & Snack - July 2019 - Baking & Snack - July 2019
Baking & Snack - July 2019 - FC - 1
Baking & Snack - July 2019 - FC - 2
Baking & Snack - July 2019 - 2
Baking & Snack - July 2019 - 3
Baking & Snack - July 2019 - 4
Baking & Snack - July 2019 - 5
Baking & Snack - July 2019 - 6
Baking & Snack - July 2019 - 7
Baking & Snack - July 2019 - 8
Baking & Snack - July 2019 - Contents
Baking & Snack - July 2019 - 10
Baking & Snack - July 2019 - Contents
Baking & Snack - July 2019 - Editorial - The collegiality of baking
Baking & Snack - July 2019 - Pepperidge looks to ‘unleash the growth’ in Goldfish
Baking & Snack - July 2019 - DowDuPont merging two business units
Baking & Snack - July 2019 - 15
Baking & Snack - July 2019 - In Memoriam
Baking & Snack - July 2019 - People/In Brief
Baking & Snack - July 2019 - 18
Baking & Snack - July 2019 - Food Safety Series - farm-to-fork FOOD SAFETY
Baking & Snack - July 2019 - 20
Baking & Snack - July 2019 - 21
Baking & Snack - July 2019 - 22
Baking & Snack - July 2019 - 23
Baking & Snack - July 2019 - 24
Baking & Snack - July 2019 - 25
Baking & Snack - July 2019 - 26
Baking & Snack - July 2019 - IBIE Committee Roundtable - EVOLVING WITH THE TIMES
Baking & Snack - July 2019 - 28
Baking & Snack - July 2019 - 29
Baking & Snack - July 2019 - 30
Baking & Snack - July 2019 - 31
Baking & Snack - July 2019 - Bud’s Best Cookies - THE RIGHT STUFF
Baking & Snack - July 2019 - 33
Baking & Snack - July 2019 - 34
Baking & Snack - July 2019 - 35
Baking & Snack - July 2019 - 36
Baking & Snack - July 2019 - 37
Baking & Snack - July 2019 - The magic of tray loading
Baking & Snack - July 2019 - 39
Baking & Snack - July 2019 - 40
Baking & Snack - July 2019 - 41
Baking & Snack - July 2019 - One connection can chart a company’s course
Baking & Snack - July 2019 - 43
Baking & Snack - July 2019 - International Series: Asia - SEA OF CHANGE
Baking & Snack - July 2019 - 45
Baking & Snack - July 2019 - 46
Baking & Snack - July 2019 - 47
Baking & Snack - July 2019 - Where’s the growth throughout Asia?
Baking & Snack - July 2019 - 49
Baking & Snack - July 2019 - 50
Baking & Snack - July 2019 - Gums and Stabilizers - PRESERVING APPEAL
Baking & Snack - July 2019 - 52
Baking & Snack - July 2019 - 53
Baking & Snack - July 2019 - 54
Baking & Snack - July 2019 - 55
Baking & Snack - July 2019 - 56
Baking & Snack - July 2019 - 57
Baking & Snack - July 2019 - 58
Baking & Snack - July 2019 - 59
Baking & Snack - July 2019 - 60
Baking & Snack - July 2019 - Fortification - an EXTRA BOOST
Baking & Snack - July 2019 - 62
Baking & Snack - July 2019 - 63
Baking & Snack - July 2019 - 64
Baking & Snack - July 2019 - 65
Baking & Snack - July 2019 - 66
Baking & Snack - July 2019 - 67
Baking & Snack - July 2019 - 68
Baking & Snack - July 2019 - Bar Technology - breaking down BARRIERS
Baking & Snack - July 2019 - 70
Baking & Snack - July 2019 - 71
Baking & Snack - July 2019 - 72
Baking & Snack - July 2019 - 73
Baking & Snack - July 2019 - 74
Baking & Snack - July 2019 - 75
Baking & Snack - July 2019 - 76
Baking & Snack - July 2019 - 77
Baking & Snack - July 2019 - 78
Baking & Snack - July 2019 - Conveyors - ENSURING SAFE TRAVELS
Baking & Snack - July 2019 - 80
Baking & Snack - July 2019 - 81
Baking & Snack - July 2019 - 82
Baking & Snack - July 2019 - Playing it safe with acetal belting
Baking & Snack - July 2019 - 84
Baking & Snack - July 2019 - 85
Baking & Snack - July 2019 - 86
Baking & Snack - July 2019 - Moulders - Shaped for Control
Baking & Snack - July 2019 - 88
Baking & Snack - July 2019 - 89
Baking & Snack - July 2019 - 90
Baking & Snack - July 2019 - 91
Baking & Snack - July 2019 - 92
Baking & Snack - July 2019 - 93
Baking & Snack - July 2019 - 94
Baking & Snack - July 2019 - 95
Baking & Snack - July 2019 - 96
Baking & Snack - July 2019 - 97
Baking & Snack - July 2019 - 98
Baking & Snack - July 2019 - Inline Quality Control - AS FAR AS IT CAN SEE
Baking & Snack - July 2019 - FSMA advances X-ray, vision systems
Baking & Snack - July 2019 - 101
Baking & Snack - July 2019 - 102
Baking & Snack - July 2019 - 103
Baking & Snack - July 2019 - 104
Baking & Snack - July 2019 - INDUSTRY INSIGHT - SUCCESSFUL PROJECTS
Baking & Snack - July 2019 - 106
Baking & Snack - July 2019 - Meeting Preview: IBIE - Totally Immersed
Baking & Snack - July 2019 - 108
Baking & Snack - July 2019 - 109
Baking & Snack - July 2019 - 110
Baking & Snack - July 2019 - Meeting Preview: AACCI - READY TO MINGLE
Baking & Snack - July 2019 - Events
Baking & Snack - July 2019 - 113
Baking & Snack - July 2019 - 114
Baking & Snack - July 2019 - 115
Baking & Snack - July 2019 - Featured Innovation Center
Baking & Snack - July 2019 - 117
Baking & Snack - July 2019 - Ingredients & Formulating
Baking & Snack - July 2019 - 119
Baking & Snack - July 2019 - Equipment & Packaging
Baking & Snack - July 2019 - 121
Baking & Snack - July 2019 - 122
Baking & Snack - July 2019 - 123
Baking & Snack - July 2019 - Patents
Baking & Snack - July 2019 - 125
Baking & Snack - July 2019 - New on the Shelf
Baking & Snack - July 2019 - 127
Baking & Snack - July 2019 - MARKETPLACE
Baking & Snack - July 2019 - 129
Baking & Snack - July 2019 - 130
Baking & Snack - July 2019 - 131
Baking & Snack - July 2019 - 132
Baking & Snack - July 2019 - 133
Baking & Snack - July 2019 - 134
Baking & Snack - July 2019 - 135
Baking & Snack - July 2019 - 136
Baking & Snack - July 2019 - AD INDEX
Baking & Snack - July 2019 - 138
Baking & Snack - July 2019 - 139
Baking & Snack - July 2019 - 140
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