Bar Basics

Shelves are stocked with food bars designed to fit nearly any consumer desire, whether meal replacement, nutritional boost or snack. Ingredient emphasis ranges from whole grains and protein enhancement to nutrient fortification and energy production. There are bars for breakfast, bars for snacks and some target specific demographics like athletes, children or dieters.

On the other hand, a typical family with everyone coming and going at different times requires bars for different interests and dietary needs. Parents are concerned about gluten-free products and diets that need specialization for allergies and potential allergies. However, “there could be a lot of different products out there that they can have enough sound nutrition and enough appeal that can be all-family,” says Anton Angelich, group vice president marketing, Virginia Dare, Brooklyn, NY. He doesn’t see parents buying “seven different kinds, this one for this child and that one for that one. They need to have that commonality that’s good for everybody. With the tightening economy it’s got to be cost effective.”

No matter the desired end attributes, developing bars follows a basic blueprint. Essentially, formulators combine proteins, grains carbohydrates and other nutrients with a binding sugar. They might mix in nuts, fruit pieces or other textural items such as crisps, and perhaps coat the bar for added flavor.

Protein parameters

Protein is critical to meeting daily nutritional targets. In a bar, the choice of a dairy or vegetarian protein must meet marketing objectives, but the type of protein can impact taste, texture and shelf life. For product designers, the question extends beyond a choice between dairy or plant proteins, and even between isolates (approximately 90% protein) or concentrates (about 70% protein). The functional benefits a protein brings to the table determine if it’s a good fit in the formulation. Keep in mind, similarly positioned products offered by different vendors may have tremendous variation in protein performance.

“Because of its importance to a bar’s nutritional appeal, functionality and cost model, the addition of protein is a critical decision that should be based on several factors, including use of other ingredients and overall protein target level,” notes Grace Harris, new business and applications development manager, Hilmar Ingredients, Hilmar, CA.

No bar formulation has just one ingredient, so other ingredients also have to be considered when determining protein selection.

Choosing the right protein within the context of the final matrix is essential to creating a product that maintains its texture over time. When chosen poorly, the bar will become hard and dry. “In high-protein bars, in particular, bar hardening during a bar’s shelf life can be a real issue,” says Jean Heggie, director of marketing, Solae, LLC, St. Louis. “If a marketer can ensure the eating quality of a bar over a longer period of time, that helps them more effectively manage distribution and ensure a positive consumer experience with their brand.”

Target protein levels in bars vary tremendously. “Some bars deliver as little as 5 grams of protein all the way up to 40 grams per bar or more in nutrition bars geared for the performance-nutrition consumer,” Heggie says. Higher levels often require an ingredient with a higher protein level.

Delivering optimum nutrition is key in many bar applications, so bar formulators should look at the protein quality. “A complete protein is defined as a protein that contains all the essential amino acids in amounts adequate for human use,” says Phil Tong, director, Dairy Products Technology Center, California Polytechnic State University, San Luis Obispo. “A high-quality protein is not merely complete. It contains the essential amino acids in amounts proportional to the body’s need for them. It’s also digestible, so that sufficient numbers of these amino acids reach the body’s cells to permit them to make the proteins they need.”

The most-effective formulations bring a variety of proteins together. In work commissioned by Dairy Management Inc.™ (DMI), Rosemont, IL, Tong found a blend of whey protein concentrate (WPC), milk protein concentrate (MPC) and soy protein concentrate (SPC) works well in bars containing 30% protein. “In addition, this research demonstrated that about 60% of the protein from WPC, 20% from MPC and 20% from SPC gives the bars good flavor and texture,” he says.

While proteins can be co-mingled, they might as easily work individually. Whether plant-based or dairy-based, they each excel in certain areas.

Selecting soy

Soy’s protein digestibility corrected amino acid score (PDCAAS) is 1.0, so its protein is nutritionally equivalent to meat or egg proteins. “As a high-quality protein, soy protein can support claims related to lean muscle mass support, satiety and sustained energy—important positioning claims in many bar products,” says Heggie. “The fact that it is plant-based ensures it is cholesterol-free, low in fat and lactose-free, and fits nicely with products promoted as healthy, natural and sustainable.

“We offer isolates that will prevent bar hardening, and thus extend the shelf life of nutrition bars. These same isolates can be used at varying ratios in a formula to target a specific, desired bar texture from very chewy to more cookielike,” Heggie continues.

Soy protein crisps can add protein plus a crunchy texture to bar applications. Solae and ADM, Decatur, IL, both offer soy crisps with protein contents from 60% to 90%. While soy protein can easily deliver all or a significant portion of the protein, Heggie says, “as more and more marketers try to target very high protein contents, a common industry practice is to use soy protein in conjunction with dairy proteins, such as whey proteins or caseinate. Often, formulators find that ideal texture, economics and taste is achieved by combining proteins, particularly when targeting very high levels of protein.”

Soy offers “significant economic advantages vs. dairy proteins,” she notes. “Soy proteins are used extensively in the bar segment as an economic alternative to dairy proteins in delivering high-quality protein, at equivalent or better functional and taste performance.”

Expanding vegetarian proteins

Other plant proteins can be advantageous because they lack the allergen concerns with soy use, including canola, pea and hemp.

According to Martin Schweizer, Ph.D., manager, technical development, Burcon NutraScience, Winnipeg, Manitoba, canola protein is an affordable new protein source. “Canola proteins are complementary to other proteins,” he says. “They have a bland taste and do not have the beany flavor we all associate with soy. Canola proteins are also not one of the ‘big eight’ allergens in the Unites States, so they can appeal to a much broader market of consumers. They also have an excellent nutritional profile and will have a significant cost advantage over dairy proteins.”

Burcon offers two canola protein isolates. One is comprised principally of albumin proteins and described as having a slightly sweet flavor with no off flavors. Another is comprised mainly of globulin proteins, giving it a bland flavor without off flavors. It has moderate foaming ability and can retain air when baked. It has moderate water-binding ability and can act as an ingredient binder.

“Canola protein isolates have a well-balanced amino acid profile and are particularly rich in sulfur-containing amino acids,” says Schweizer. “For example, the high level of the amino acid cysteine in our canola protein isolate makes it particularly unique for a plant protein. Sulfur-containing amino acids are not highly available in other common proteins—with the exception of egg protein, an expensive protein source.”

Because of the newness of the ingredients, the company needs additional testing to establish the PDCAAS. “We still have lots of research to do on how canola protein will combine with other proteins, but our research team believes that it will work well in combination with other proteins,” says Schweizer. “In addition to incorporating it with the other proteins within the contents, we feel that it could also be added to bar coatings, delivering some extra protein in a unique way.”

Pea protein isolate from Farbest Brands, Montvale, NJ, has 92% protein on a dry basis and a PDCAAS score of 0.86. It is low in the amino acid tryptophan, so is best combined with other proteins. One gram of pea protein can bind 4 grams of water or 17 grams of oil. Its flavor is described as bland.

Mike Fata, president and co-founder, Manitoba Harvest, Winnipeg, Manitoba, suggests hemp protein powder for nutrition bars. It is easily digestible and “has a nutty flavor that works very well in bar applications.”

Cold-milling and screening hemp seed cake produces a hemp protein powder with 50% protein; 20% omega-3, -6 and -9; and 13% fiber. Hemp protein contains a 3.75:1 ratio of omega-6 to omega-3. It has a PDCAAS score of 0.46.

According to Fata, hemp protein is a rich source of omega-3 and omega-6 essential fats. “Because we’re manufacturing a whole-food protein powder, it still does have omega-3 and omega-6. Hemp actually contains more essential fats than flax, less omega-3 and a better balance of omega-6 to omega-3. Hemp also contains GLA and SDA, gamma-linolenic acid and stearidonic acid, which are two of the longer-chain fatty acids that flax does not have, so it’s a little bit closer to the fish spectrum.”

Although the hemp plant is related to marijuana, it does not contain tetrahydrocannabinol (THC). “When we lobbied the government to legalize hemp in Canada, the rules that were put forth were that all products had to be under 10 ppm THC,” says Fata. In many European countries that grow hemp, the limit is 50 ppm THC. “Our products, for the 10 years that we’ve been producing them, have been nondetectable THC (less than 1 to 2 ppm, depending on the lab). It’s not a concern of people eating hemp and failing a drug test or getting high,” he says.

Hemp protein often is combined with other proteins. A bar containing 30% protein powder might have 10% hemp protein. Fata notes that pea protein or rice protein blend well with the hemp and nutritionally complement each other. He has seen soy and hemp combined in equal ratios. “If it’s a vegetarian product, it’s really important to balance the different protein sources,” he says. Whey plus vegetarian protein source is a good combination, because “whey is very fast-acting on muscles, but the vegetarian protein has long staying power.”

Decidedly dairy

When formulating a bar for nutrition or meal-replacement, Gwen Bargetzi, director of marketing, Hilmar Ingredients notes “whey protein is a complete protein with a PER of 3.2 and a ‘perfect’ PDCAAS of 1.0. Because of its nutritional quality, whey protein can be used as a complementary protein to boost the quality of other proteins, particularly vegetable and grain proteins that are limiting in one or more amino acids.”

Bargetzi calls whey protein an “amiable” protein. “It plays well with other proteins and ingredients,” she says, noting that Hilmar’s scientists develop formulations that incorporate several proteins. “With their backgrounds in different protein types and extensive training from ingredient manufacturers and industry, our application scientists are particularly adept at employing whey’s abilities to work with other protein sources and providing a unique blend of actions within food systems.”

Whey protein is very bland, enabling high use levels in bar formulations. Whey crisps can be added for additional protein and texture.

“Whey proteins have a range of functionalities that can be designed-in during their manufacturing process,” says Harris. “For example, knowledgeable manufacturers can specifically produce whey protein hydrolysates that can help improve bar shelf life, extrudability and flavor.”

Grains galore

Grains are often the heart of a bar, adding protein and other valuable nutrients, as well as providing texture. According to Bill Bonner, senior vice president, R&D and technical sales, 21st Century Grain Processing, Kansas City, MO, flaked or puffed grains are best suited to chewy bar applications. “Usually it’s a whole oat flake,” he says. “The density of the bar is affected by the size of the oat flake you use, and usually the whole oat flake is the one of choice for those types of products.” A quick flake would be too dense and excessively pack together for bar products.

The oat flake is first baked, then a binding syrup brings the grains together. “Usually, the nuts and fruits are not baked into the cereal,” explains Bonner, “but are separate for extended shelf life.”

Increasing grain content does not impact water activity. “The technology for a chewy bar is pretty well established,” says Bonner. “You can use products with the cooked-grain portion or the cereal-base portion down around 5% (plus or minus 2%) moisture, and the associated water activity with that, and be able to make very good consumer-type bars.”

Because the bar likely will pick up moisture and become tough, “you have to use a coated grain,” cautions Bonner. “You have to basically adjust the moisture balance and get the water out of the oat, if you will. The coated grain is prebaked and creates flavor and texture.”

Most chewy bars are based on coated or precooked grain, according to Bonner. “I don’t want to say they’re just oats,” he says, naming wheat, barley and some “ancient grains” as bar candidates, usually in the flake form. Coated grains are basically coated with sugars. “We don’t do much with high-fructose corn syrup, we do more with brown rice syrup and tapioca syrup as substitutes for high-fructose corn syrup these days,” he says. “They can have cinnamon, vanilla or sweet-adjunct-type flavors. Some people are working on savory things right now.”

The sweeteners that bind

In bar formulations, sweeteners work double duty. Besides adding sweetness and flavor, they help hold the ingredients together.

According to Ram Santhanagopalan, food scientist, Tate & Lyle, Decatur, IL, “When choosing a sweetener for bars, product developers should consider the functionality, which is determined by its glass-transition temperature, and relative sweetness of the sweetener.” He points out that crystalline fructose provides a low glass-transition temperature, which helps in maintaining moisture and a stable shelf life for bars. Crystalline fructose adds 4 calories per gram and can be used at levels lower than sugar to maintain a soft, moist and chewy texture.

Santhanagopalan says Tate & Lyle is “seeing a strong interest in bars with reduced sugar content and added health-and-wellness benefits. Through sweetener optimization, sucralose can be blended with nutritive and non-nutritive sweeteners to provide lower levels of calories and sugar while maintaining a level of sweetness and same great taste that developers are seeking, at a reduced cost.” Sucralose, a non-nutritive sweetener, is 600 times more potent than sugar.

Blending crystalline fructose with sucralose lowers calories while maintaining a sweetness profile similar to sugar. This combination can help create a browned appearance and caramelized flavor. “When used with other ingredients such as maltodextrins or fiber, it can help maintain a soft, moist and chewy texture during extensive product storage,” Santhanagopalan says.

For bars that target glycemic response, Cargill offers several sweeteners that offer a low glycemic impact. Isomaltulose is a nutritive, natural sweetener. It contains 4 calories per gram, but is digested much more slowly than sugar. Erythritol is a natural, non-nutritive bulk sweetener with 0.2 calories per gram.

New fortification creations

“Bars are becoming a popular and most-convenient way to pack nutrients from all categories that can address specific health conditions for consumers of all ages, especially those with an on-the-go lifestyle,” observes Ram Chaudhari, Ph.D., FACN, CNS, senior executive vice president, chief scientific officer, Fortitech, Schenectady, NY. “B vitamins and antioxidants should always be part of the nutritional profile, and adding whole grains and superfruit-type of functional food ingredients can optimize the nutritional profile of a bar as well, without compromising taste and texture.”

Over the past two years, Chaudhari has noticed that “manufacturers have been very proactive in the development of the bars concept as an excellent vehicle for health, nutrition and energy, and as meal-replacement options. The availability of healthy and nutritional bars in various distributor channels—supermarkets, foodservice, health and sports clubs—has widened, and the market is ready for bars with new benefits and improved taste and texture.”

Chaudhari sees new developments in bar fortification, such as using stabilized minerals to combat lingering metallic notes and/or aftertaste, and advances in nanotechnology to deliver functional food ingredients with minimum interactions and improved bioavailability. This is especially beneficial for conjugated linoleic acid (CLA), collagen, omega-3 and amino acids. He notes widespread use of soy and whey proteins, peptides and peptones, along with vitamins and minerals for high protein and sports bars.

“In addition to fiber, a breakfast bar that targets enhanced cognitive function might include CoQ10, omega-3s, antioxidants, B-complex vitamins and zinc, isoflavones, and oligosaccharides,” Chaudhari says. “An energy bar may include taurine and guarana and, within the female demographic, for instance, a pregnant woman who may have problems sleeping might benefit from a bar that combines omega-3s to promote a healthy newborn with nutrients such as GABA (gamma-aminobutyric acid), and tryptophan that can aid in sleep.”

Raising the flavor bar

Flavors are especially critical when designing fortified bars. “You can design a flavor to be anything if you work with a masking agent that overcomes the undesirable taste that may come out over time,” says Angelich. He points to “very specific masking systems that cover up certain minerals, various vitamins, various combinations of vitamins, energy supplements, and all the efficacious botanicals. If you want to create something that tastes like a strawberry or blueberry, and it’s got a lot of things in there that go countercurrent to the tastes, first you have to neutralize that and build from that platform.” He also notes that shelf life is “critically important, because if those things are not properly stored or you don’t have a good handle on the shelf life, they will start to come through over time.”

Angelich believes the energy-bar category has been changing, and the traditional bars have been crowded out by a surplus of products in the marketplace. The bars have a “limited shelf life because of all the active energy ingredients, vitamins, B vitamins and minerals. You had an awful lot of things sitting on the shelf at a high price that just weren’t moving. I think companies had to move away from that and say, ‘What can I put in it that’s probably not going to change in flavor over time and yet still provide enough nutrition the consumer wants?’” He sees many companies moving away from some fruit-type products “that began turning into tobacco-type notes, but weren’t strong enough to cover up the minerals and the vitamins,” and looking at more of the “browns, caramel, toffee, brown sugar, maple, the nut, the pecan type of things.”

Nut-type flavors, especially pecan, are a good choice in bars because they complement soy protein, says Angelich. “So if the soy starts to come through, you still have a good taste, because the expectation is pecan, and the pecan and soy together deliver the end result,” he says.

Flavors like dulce de leche may be getting passé in bar applications. “I think indulgent desserts became another area where flavors were new and exciting and gave a new twist and competitive advantage in taste acceptance and improvability,” says Angelich.

However, “consumers were getting tired of that and the novelty went away,” Angelich continues. “It became more of a snack product and turned to cereal bars.” He believes cereal bars should relate ingredients found in cereal, such as blueberry, maple, banana and strawberry, and for a broad-based appeal in tough economic times, rely on basics like vanilla, chocolate and strawberry.

In the end, the key to bar success lies in making bars taste as good as they can, no matter the market target.

Cindy Hazen, a 20-year veteran of the food industry, is a freelance writer based in Memphis, TN. She can be reached at [email protected].