Custom Machine for Vegetable-Based Healthy Protein Bar

Challenge

One of the startup companies had developed a vegetable-based healthy protein bar, made entirely from natural and plant-derived ingredients.
While their product concept was innovative and health-focused, they faced a major challenge in scaling up production.

Conventional bar-making machines available in the market were not suitable for their unique mixture, which had:

• Uneven texture due to fibrous vegetable content

• Sticky consistency causing feeding and forming difficulties

• Requirement for accurate weight and shape control

• Hygienic handling and easy cleaning needs

They needed a custom-built solution that could handle this material smoothly, ensure uniform forming, and remain economically viable for a startup-scale operation.

Solution

A custom protein bar forming and cutting machine was designed and manufactured specifically for their application.

Key highlights of the developed solution included:

• Customized feeding and compression system to handle sticky and fibrous mixture

• Adjustable roller arrangement to maintain consistent thickness and density

• Servo-driven cutter ensuring precise bar length and clean edges

• Food-grade stainless steel construction for easy cleaning and hygiene compliance

• Compact and modular design suitable for limited production space

The machine could process their natural blend efficiently, producing uniform, cleanly cut bars with minimal wastage and high repeatability.

Result

With the newly developed machine, the startup successfully moved from manual preparation to automated production.
The key outcomes included:

• Consistent shape, size, and weight control

• Smooth operation even with fiber-rich mix

• Faster production rate and reduced manual dependency

• Scalability for future automation and capacity increase

This project demonstrated how a custom-engineered solution can help startups convert an innovative food concept into a scalable, commercially viable product.