Breakfast cereal applications
Advanced processing technologies for soft and filled bar production line
Coperion delivers fully integrated soft and filled bar production line technologies, covering every process from ingredient preparation and mixing to forming, shaping, baking, and finishing. Our solutions help food manufacturers create consistent, high-quality bars with reliable performance and scalable efficiency.
How soft and filled bar manufacturing creates texture and structure
Bars are more than ingredients coming together. They are built layer by layer, where texture, bite, and structure are shaped right from the start. Every step matters because it affects how the bar holds together, how it cuts, and how it feels when eaten.
Unlike simple compressed snacks, soft and filled bars are created through controlled shaping. This allows soft and filled bar manufacturing to support a wide range of products, from breakfast and energy bars to richer, more indulgent snack formats.
This is how simple ingredients are transformed through bar manufacturing into consistent, high-quality bars that meet different consumer preferences for everyday breakfast and snack products.
Integrated processing solutions for soft and filled bar production
A complete bar production line brings ingredient handling, mixing, forming, baking, and finishing together into one continuous process. This ensures a stable product flow while maintaining precise control over structure, thickness, and consistency.
Coperion provides integrated processing solutions that connect each stage seamlessly. By doing so, bar manufacturers can produce a wide range of bar formats with reliable structure, consistent texture, and the flexibility to develop both simple and filled products as market demand evolves.
The technology brands behind our cereal bar solutions
Examples of innovative cereal bar applications
Bring cereal bars to life in every form, from wholesome breakfast bars to indulgent filled bars. With advanced processing technology and deep application expertise, Coperion helps manufacturers turn diverse concepts into consistently high-quality, scalable products with reliable performance and production flexibility.
Breakfast bars
Filled bars
How soft and filled bars production line works
Ingredient handling
The Shick Esteve Bag dump stations provide a safe, dust-free way to manually add dry ingredients.
Liquid ingredients, such as glucose, are temporarily stored in our Shick Esteve Tank systems, or Tote systems, and then delivered through pumps.
For automated ingredient handling and recipe preparation, Coperion MIH systems enable precise ingredient dosing, process documentation, and batch traceability to support consistent product quality.
Mixing
The process begins by combining oats, syrups, fats, and inclusions into a cohesive mass. Consistent mixing is essential to achieve proper binding and an even distribution of ingredients, creating the foundation for a bar with the right texture and structure.
High-viscosity cereal bar formulations require mixing technology that can process sticky, dense masses while preserving the quality of inclusions such as grains, nuts, seeds, and dried fruit.
The Shaffer Single Sigma Arm mixer is engineered for high-viscosity applications, delivering a uniform blend while gently handling inclusions to maintain product integrity and texture.
For applications that require fast, efficient batch mixing, the Baker Perkins High speed mixer provides excellent ingredient dispersion through its unique shaftless mixing blade. The system produces a homogeneous mixture and supports automated discharge into downstream feeding or forming equipment, helping manufacturers maintain a continuous and efficient bar production process.
Forming & shaping
After mixing, the product is discharged into a Baker Perkins TruClean Wirecut using a Baker Perkins Compact dough feed. The mixed mass is formed into continuous slabs or individual bars with precise control over thickness, weight, and shape. Filling can be added where applicable. Accurate forming ensures consistent structure, clean cutting, and a uniform appearance across every product.
The Baker Perkins TruClean™ Wirecut enables manufacturers to produce a wide variety of bar formats, including filled or fully encapsulated bars. It supports diverse shapes, fillings, and functional ingredients such as whole grains, nuts, fruit pieces, fiber, and protein inclusions, giving manufacturers the flexibility to create innovative soft and filled bar products.
Baking & cooling
Consistent heat distribution is essential to achieve uniform color and moisture across the product using a Baker Perkins TruBake HiCirc oven.
Cutting
Bars can be cut before baking if you want a closed end product, or after baking for a clean cut leaving a consistent bar shape or showing the filling using the Baker Perkins TruClean™ bar cutter.
See bar production in action
Discover how Coperion can enhance your cereal bar production line
See how modern bars come to life with our integrated processing solutions. Our technologies help snack manufacturers improve production efficiency, maintain consistent product quality, and achieve reliable performance at every stage of the process.
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