Nutritional bars, cores of nutritional bars, and methods of forming nutritional bars

Abstract

The present invention provides a base cake for a nutritional bar, the base cake having a water activity (aW) of 0.5 to 0.65 and comprising at least 50% by weight of protein, the protein comprising, based on the total weight of the protein in the base cake: 25% to 35% calcium caseinate; 20%-30% of whey protein; and 38% to 45% of beef collagen.

Description

[0001] The present invention relates to a base cake for a nutrition bar, and a nutrition bar (including a base cake), especially a sports nutrition bar, which has an ideal texture during a long shelf life. Specifically, the nutrition bar provides a high amount of protein and a low sugar content while maintaining an ideal texture that is neither dry nor brittle. The presence of a texture additive (such as biscuit pieces) provides a multi-dimensional texture feature, and the structure of the nutrition bar prevents the degradation of the texture additive during the shelf life.

[0002] Nutrition bars (also called energy bars) or protein bars are well known and there are many different nutritional bars on the market. Some are intended for quick and immediate consumption to provide energy release during exercise, while others are aimed at consumers who are trying to lose weight and therefore look for products that provide energy but do not contain high levels of sugar. In addition, some are targeted at consumers who want a high-protein snack that helps to gain muscle.

[0003] Available nutrition bars include the following brands: Rema 1000 TM 、Harvest Morn TM 、Tine YT TM , MuscleNation Custard TM , Nutrend Premium Protein 50% TM 、Layenberger New trition style TM 、MaxSport Collagen+ TM , Best Body Nutrition Premium SeriesCrunchy One TM 、Muscle Food TM 、Myprotein TM 、Nutramino Nutra-Go Plant TM 、Grenade CarbKilla TM 、Quest TM 、Fulfil TM Other existing nutrition bars include Cookies & Cream Flavour Protein Bar from The Hut Group, Atkins Advantage Caramel Fudge Brownie from Atkins Nutritionals and Crumblin' Cookies and Cream from Bulk Powders.

[0004] Nutrition bars typically contain a high ratio of protein to carbohydrates / fats. However, nutrition bars designed to release energy during exercise (i.e., energy bars) typically have a higher carbohydrate content than protein bars, which are more suitable for those looking to build muscle and / or lose weight. Protein bars are primarily targeted at people who want a convenient protein source that can be quickly and easily carried and consumed.

[0005] Nutrition bars are generally considered a snack and are designed to be consumed ready-to-eat with little to no equipment required to prepare or consume the product.

[0006] In the field of sports and fitness, it is well known that consuming protein after exercise helps build muscle. Whey protein is one of the most popular sources of protein for improving athletic performance. Another protein source includes egg white protein. Alternatively, protein bars can use insect protein as an ingredient, or use plant-based proteins from sources like pea, brown rice, hemp, and soy.

[0007] Protein bars can often be very dry, and consumers often find the product tastes bland and often lacks a sweet mouthfeel and softer texture. Specifically, consuming a nutrition bar after exercise (when the consumer's mouth is already very dry) can be uncomfortable. Including more water in a nutrition bar (to reduce dryness) often just causes some ingredients to become soggy and shortens the shelf life of the product.

[0008] Attempts have been made to provide a nutritional bar having a pleasing taste and texture and having a high content of protein.

[0009] EP 1755407 B1 discloses a food bar with extended shelf life, wherein carbohydrates account for 50% to 60% of the total weight of the food bar, the bar comprising (a) a protein-containing component accounting for more than 25% of the weight of the component; (b) a carbohydrate-containing component; and (c) a softener accounting for at least 0.1% of the component, the softener being selected from the group consisting of: highly branched indigestible dextrins, inulin, highly branched maltodextrins, oligofructose, polydextrose, and mixtures thereof. The softener is added to maintain the texture of the bar throughout the shelf life and to increase the initial softness of the bar after formulation.

[0010] US 6432457 B1 discloses a bar comprising (a) a proteinaceous material having a water absorption property of less than 2.5 grams of water per gram of protein at pH 5.5 and a medium to high emulsifying capacity, and (b) a carbohydrate material selected from the group consisting of digestible carbohydrates, non-digestible carbohydrates and mixtures thereof; wherein the bar is produced by cold extrusion; wherein both the proteinaceous material and the carbohydrate material are present in the bar at a relative weight ratio of protein: carbohydrate greater than 1, and wherein the proteinaceous material is a filler protein and a binding protein. In this document, it is disclosed that the use of such proteinaceous materials having a separation between water absorption properties and other functional properties makes them suitable for use in high protein bars without adversely affecting the palatability of the bar.

[0011] US 7556836 B2 discloses a high protein snack product comprising a sticky product mixture in a polyvinylidene chloride casing material, wherein the sticky product mixture comprises about 2.5 wt % to about 3.5 wt % of a binder, about 2 wt % to about 3 wt % of salt, up to about 35 wt % of a sweetener, about 35 wt % to about 60 wt % of a textured soy protein product (wherein the textured soy protein soy protein product is hydrated and shredded to form fiber), and about 2 wt % to about 4 wt % of a fruit flavoring, wherein the textured soy protein product comprises a blend of wheat gluten and soy protein isolate, wherein the soy protein isolate blend comprises at least 2 parts by weight of hydrolyzed soy protein isolate per part by weight of unhydrolyzed soy protein isolate, and wherein the textured soy protein product comprises at least 75 wt % protein, wherein the protein in the textured soy protein product is at least 66 wt % soy protein.

[0012] KR 102140774 B1 discloses a high-protein snack bar having 100 parts by weight of a first component including puffed soy protein isolate and puffed cereals; 120 to 170 parts by weight of a second component containing a syrup solution including raw syrup, sugar, stevia and salt; at least one of nuts, dried fruits and cereals; 180 to 25 parts by weight of a third component including non-puffed soy protein, vitamins and minerals, and a high-protein snack bar with a protein content of 30 to 45% by weight.

[0013] While the use of proteins, including dairy-derived proteins, in nutritional bars is generally known, existing protein bars lack desirable sensory properties, including texture and moistness, while being high in protein and having a long shelf life.

[0014] Therefore, there is a need to provide a nutritional bar that has a high protein content while also having good sensory properties, including moisture (ie, relatively high water content) and a desirable texture, as well as a long shelf life.

[0015] According to a first aspect of the present invention, there is provided a nutritional bar having at least 30 wt% protein and less than 3.3 wt% sugar, the nutritional bar comprising a coating layer at least substantially encapsulating:

[0016] (a) a base cake having a water activity (aW) of 0.5 to 0.65 and comprising at least 50% by weight protein comprising:

[0017] Calcium caseinate;

[0018] Whey protein; and

[0019] Beef collagen;

[0020] (b) a fat-based cream layer, the fat-based cream layer being located on the base cake; and

[0021] (c) one or more texturizing additives, the one or more texturizing additives being located on or embedded in the fat-based cream layer,

[0022] A fat-based cream layer separates one or more texturizing additives from the base cake.

[0023] The present invention will now be further described. In the following paragraphs, different aspects of the present invention are defined in more detail. Unless otherwise clearly indicated to the contrary, each aspect so defined may be combined with any other one or more aspects. Specifically, any feature indicated as "preferably" or "favorably" may be combined with any other one or more features indicated as "preferably" or "favorably".

[0024] A first aspect provides a nutrition bar. A nutrition bar is a food product in the shape of a cube or a cylinder or any other suitable shape, which is edible once any associated packaging is removed and provides a high (e.g., greater than 30% by weight) amount of protein. The nutrition bar can be a protein bar or an energy bar. A typical serving size of a nutrition bar is 50 g to 75 g, and preferably about 60 g.

[0025] The nutrition bar has a protein content of at least 30% by weight and has less than 3.3% by weight sugars. Preferably, the nutrition bar has a protein content of 30% to 50% by weight, more preferably a protein content of 33% to 40% by weight. Preferably, the nutrition bar has less than 3.3% by weight sugars, preferably less than 3% by weight sugars, and more preferably less than 2% by weight sugars. In some embodiments, the nutrition bar will be substantially free of sugars.

[0026] The amount of protein and sugar is calculated relative to the total weight of the nutrition bar. Both sugar and protein have their normal meaning in food chemistry. In a 60g protein bar, the protein content will preferably be at least 18g, more preferably at least 20g, such as 20g to 25g. The sugar content will preferably be less than 2g, preferably less than 1.5g. Preferably, the nutrition bar has no added sugar. It should be noted that small amounts of sugar may be present in some ingredients as naturally occurring sugars.

[0027] The nutritional bar includes a coating, and the coating at least substantially encapsulates components (a) to (c). By coating is meant an edible product on the surface of the remaining components of the nutritional bar. The coating at least substantially encapsulates components (a) to (c). Thus, the coating must substantially encapsulate or coat components (a) to (c), but may completely encapsulate components (a) to (c) such that the coating forms a shell surrounding the remaining components of the nutritional bar. By "substantially" is meant that the coating covers at least 50% of the surface area of ​​the nutritional bar, or at least 60% of the surface area of ​​the nutritional bar, or at least 70%, preferably greater than 80%, and more preferably greater than 90%. Most preferably, the coating completely encapsulates components (a)-(c).

[0028] Suitable materials for the coating are chocolate preparations and composite coating materials. In order to achieve the desired low sugar content, these low sugar or no added sugar preparations should be used. Such compositions are well known in the art and are commercially available. Most preferred are coating preparations with no added sugar. The coating is preferably a chocolate type coating, but other flavorings may also be used. The coating is preferably a fat-based coating or an anhydrous coating.

[0029] When applied, the coating preferably has a thickness of 1 mm to 4 mm, preferably 2 mm-3 mm. The goal is to have a substantially constant thickness of the coating, present on all sides of the product. However, it should be understood that the texture additive may cause damage or pooling of the coating. Therefore, the thickness measurement is preferably an average of those areas of the coated stick other than those areas on and immediately around the texture additive.

[0030] The coating should form a barrier to prevent moisture loss from the base cake and especially to prevent moisture migration into the texturizing additive (inside the package and around the cream layer). This is why it is necessary to provide a consistent coating around at least the exposed surface of the base cake. This is also why coatings are usually fat-based to mitigate moisture migration. The coating also helps keep the texturizing additive attached to the rest of the product and prevents any chunks of the additive from falling out of the cream layer.

[0031] The nutrition bar also has a base cake. By base cake is meant the part of the nutrition bar that forms the core of the product. It ideally has a soft texture, easy to bite through, and not dry or crunchy. The base cake has a water activity (aW) of 0.5 to 0.65. The water activity of a food is the ratio between the vapor pressure of the food itself when in a completely undisturbed equilibrium with the surrounding air medium and the vapor pressure of distilled water under the same conditions. Water activity is a conventional measure in the art and can be determined, for example, with a Novasina AW SPRINT at 25°C.

[0032] Water activities greater than 0.85 are prone to bacterial, yeast and mold growth. Therefore, it is desirable to have a water activity high enough to give the product a moist mouthfeel and texture, but not too high, otherwise the product will be susceptible to mold, thereby shortening the shelf life of the product. A water activity of 0.5 to 0.65 provides this desired balance. Preferably, the water activity is 0.55 to 0.62, more preferably 0.58 to 0.60. These water activities ensure a good mouthfeel and texture while allowing for an ideal shelf life. Water acts as a plasticizer, maintaining the flexibility of the bar matrix.

[0033] The base cake comprises at least 50% by weight of protein. Preferably, the protein is present in an amount of 55% to 65% by weight of the base cake, more preferably 57% to 63% by weight. The protein in the base cake (present in at least 50% by weight) comprises calcium caseinate, whey protein (preferably whey protein) and beef collagen. Other sources of protein may also be present.

[0034] Calcium caseinate is a protein derived from casein in milk. It has a good flavor and low viscosity, making it an attractive protein source for use in high-protein foods. Whey protein is prepared from whey concentrate, and the most preferred form is whey protein isolate. Whey protein isolate is whey protein that has been filtered in the process to help remove lactose in the powder itself. Beef collagen, preferably hydrolyzed beef collagen, is a structural protein derived from cattle. It contains type I and type III collagen, which are beneficial for muscle recovery. So-called hydrolysis refers to the breakdown of beef collagen into smaller protein units (or collagen peptides) through a process called hydrolysis. Hydrolyzed beef collagen makes it possible that collagen can be easily dissolved in hot or cold liquids, which makes it convenient to process and mix with other ingredients during the manufacturing process. All of these ingredients are well known and commercially available.

[0035] Preferably, of the proteins in the base cake, 20% to 40% by weight are calcium caseinate, such as 25% to 35% by weight are calcium caseinate, more preferably 28% to 33% by weight, and most preferably about 28% by weight. Preferably, of the proteins in the base cake, 15% to 35% by weight are whey proteins (preferably whey proteins), such as 20% to 30% by weight, more preferably 22% to 27% by weight, and most preferably about 25% by weight. Preferably, of the proteins in the base cake, 30% to 55% by weight, such as 38% to 45% by weight are collagen, more preferably 40% to 43% by weight, and even more preferably 41% to 42% by weight. Among them, the amount of collagen is the most flexible, and this can be adjusted to a lower value within the range to account for the presence of up to 10% by weight of other protein sources.

[0036] This specific combination of calcium caseinate, whey protein and beef collagen in the amounts described allows the base cake to maintain a water activity of 0.5 to 0.65, which means that the base cake has a good moisture content and a moist texture, thereby producing ideal sensory properties. In addition, the base cake has a high protein content, making the base cake advantageous for use in nutrition bars.

[0037] The protein content of the bar is directly related to the hardening of the bar during shelf life as water migrates from the binder into the protein and cocoa ingredients (if present). This affects the ability to maintain textural softness. The inventors have found that the key to reducing this phenomenon is to use the right protein type and blend to achieve the final product specifications. The inventors have found in particular that calcium caseinate can cause the bar to be brittle. Whey protein will increase crispness and chewiness. Hydrolyzed beef collagen shows a fairly neutral effect on texture, but will affect the aW phase as water is absorbed. Proteins used in combination can contribute to the overall water binding and flavor of the bar.

[0038] In addition to protein, the base cake will contain additional ingredients. Preferably, the additional ingredients include 15% to 25% by weight of glycerol; and / or 10% to 20% by weight of fat; and / or up to 10% by weight of cocoa powder. Ingredients such as cocoa butter provide flavor and color to the base cake. Preferably, the base cake includes 5% to 10% by weight of cocoa powder (about 3% by weight in the final nutrition bar) because this provides good flavor and appearance. Glycerol and fat increase the structure and softness of the bar while minimizing the amount of water required to be added. Alternatives to glycerol are well known, such as corn syrup, propylene glycol, etc. As needed, the base cake will generally also include a certain amount of water as well as flavorings and sweeteners. The added water can be in the range of 10% to 20% by weight, wherein the specific amount selected is to provide good sheetability and ideal moisture content of the mixture.

[0039] Ideally, the base cake is unbaked. The specific ingredients discussed above allow the base cake to be provided by mixing and compacting. This helps to speed up the production process and avoid degradation of the protein ingredients.

[0040] The nutrition bar further comprises (b) a fat-based cream layer on the base cake. The fat-based cream is an anhydrous product having a soft and plastic form. The cream filling preferably has a moisture content of less than 5 wt%, preferably less than 1 wt% and preferably has substantially no moisture content.

[0041] An example of cream is the milky white layer often found between dark biscuits in black and white sandwich biscuits. The cream layer may include food polyols (such as maltitol), fats (such as palm oil) and flavorings (such as vanillin flavorings). Additional sweeteners or structurants may be included, such as starch and / or sucralose. The cream layer is applied to the base cake during manufacture so that the cream layer is located on one face of the base cake. The cream layer is fat-based, meaning that it has a large amount of fat, preferably at least 25 weight %, more preferably at least 30 weight %. In some embodiments, the fat content will be 30 weight % to 50 weight % of the cream.

[0042] The nutrition bar also includes (c) one or more texture additives located on or embedded in the fat-based cream layer. The texture additives are preferably selected from biscuit pieces, fruit pieces, chopped nuts, protein crisps and chocolate chips. Protein crisps help to further increase the protein content of the product. One or more texture additives are preferably biscuit pieces, such as dark biscuit pieces and / or crumbs found on either side of the inner cream layer in black and white sandwich biscuits. Preferably, the dark biscuits are sugar-free. Alternatively, one or more texture additives may include chocolate chips, preferably dark chocolate chips with milk or sugar-free. One or more texture additives may be located on the top of the cream layer so that they are as far away from the base cake as possible in space, or they may be embedded in the cream layer so that they are at least partially or completely surrounded by the cream layer. When damp, components such as biscuit pieces and protein crisps are particularly prone to losing their crisp texture.

[0043] Preferably, the texture additive has a particle size of 1 mm to 5 mm, preferably 2 mm to 4 mm. Preferably, the texture additive is substantially free of particles smaller than 1 mm. This can be achieved, for example, by sieving. This size range is ideal to ensure that the texture additive is discernible when the bar is eaten, but not so large as to damage the coating or provide manufacturing difficulties. The absence of dust particles (less than 1 mm) also improves the manufacturing process and avoids the appearance of a dry dust layer in the product structure.

[0044] The fat-based cream layer separates the one or more textural additives from the base cake. By "separated" is meant that the one or more textural additives are spatially distant from the base cake, such that the one or more textural additives are not in direct contact with the base cake. They must be isolated from the base cake because the moisture content of the base cake may cause the texture of these additives to deteriorate.

[0045] The nutritional bar of the first aspect of the present invention advantageously has good organoleptic properties resulting from the base cake, cream layer and texturizing additives containing moisture. The specific combination of proteins in the base cake maintains a high water activity in the range of 0.5 to 0.65 and a desirable texture in the base cake. In addition, the fat-based cream layer prevents water from migrating from the base cake into the texturizing additives, thereby causing these texturizing additives to become softer or even soggy. Thus, the nutritional bar has a long shelf life during which the desirable organoleptic properties are maintained.

[0046] Thus, the inventors have provided a product that meets the nutritional requirements of a sports bar while providing a multi-dimensional experience. The textural additives (such as cookie pieces) remain crisp despite being close to the base cake, adding another element to the experience. The nutritional bar has a soft and desirable base cake at its core, with a crispy textural additive, without losing these desirable properties during its shelf life.

[0047] Nutrition bars are usually packaged after production. This packaging is usually flow-wrapped. This ensures the product is hermetically sealed from the environment, helping to prevent moisture loss from the product.

[0048] The product generally has a shelf life of at least 9 months, preferably at least 12 months. This means that the texture has not deteriorated significantly during this period and the product is still commercially viable.

[0049] In the final product, preferably, relative to the weight of the final product:

[0050] The base cake is present in an amount of 60 wt% to 70 wt%;

[0051] The fat-based cream layer is present in an amount of 10 to 20 wt. %;

[0052] The texture additive is present in an amount of 1 wt % to 6 wt %, and

[0053] The coating layer is present in an amount of 15 to 25 wt%.

[0054] More preferably, in the final product, relative to the weight of the final product, preferably:

[0055] The base cake is present in an amount of 62 wt% to 65 wt%;

[0056] The fat-based cream layer is present in an amount of 12 to 18 wt. %;

[0057] The texture additive is present in an amount of 2 wt % to 5 wt %, and

[0058] The coating layer is present in an amount of 17 to 23 wt%.

[0059] Preferably, the nutrition bar does not include any water-based fill composition or layer. Examples of water-based fills are fruit fillings and caramel fillings. Such materials can introduce undesirably high levels of moisture into the product.

[0060] In another aspect of the present invention, there is provided a base cake for a nutrition bar, the base cake having a water activity (aW) of 0.5 to 0.65 and comprising at least 50% by weight protein, based on the total weight of protein in the base cake, the protein comprising:

[0061] 25%-35% calcium caseinate;

[0062] 20%-30% whey protein (preferably isolate); and

[0063] 38%-45% beef collagen.

[0064] The details of the first aspect of the invention with respect to the base cake apply to this other aspect of the invention. In addition, the preferred features of the baked cake (a) of the first aspect of the invention also apply to this other aspect of the invention.

[0065] In another aspect of the present invention, there is provided a method of forming a nutritional bar according to the first aspect of the present invention, the method comprising:

[0066] preparing a base cake premix comprising at least 50% by weight protein, the protein comprising calcium caseinate, whey protein and beef collagen;

[0067] rolling the base cake premix to provide a base cake sheet having a water activity (aW) of 0.5 to 0.65;

[0068] applying a fat-based cream to form a fat-based cream layer on the base cake sheet;

[0069] applying one or more texturizing additives to the fat-based cream layer to form a composite sheet product;

[0070] dividing the composite sheet product into a plurality of nutrition bar precursors;

[0071] The nutritional bar precursor is coated with a coating layer to form a nutritional bar.

[0072] The details of the base cake of the first aspect of the present invention are applicable to this other aspect of the present invention. In addition, the preferred features of the baked cake (a) of the first aspect of the present invention are also applicable to this other aspect of the present invention. Specifically, based on the total weight of the protein in the base cake, the protein in the base cake most preferably includes:

[0073] 25%-35% calcium caseinate;

[0074] 20%-30% whey protein (preferably isolate); and

[0075] 38%-45% beef collagen.

[0076] The method comprises a first step of preparing a base cake premix comprising at least 50% by weight protein. The preparation of the base cake premix can be accomplished by mixing the desired ingredients in a suitable mixing device. First, the relevant ingredients can be weighed and then they can be mixed continuously or in batches in a device such as a blade mixer. The protein ingredients can be weighed and mixed separately and then added to the remaining ingredients, or all ingredients can be weighed and mixed together in one step. The proteins in the base cake premix include calcium caseinate, whey protein and beef collagen.

[0077] The next step requires rolling the base cake premix to provide a base cake sheet having a water activity (aW) of 0.5 to 0.65. This step of rolling the base cake premix can be performed in batches or as a continuous process using standard rolling techniques and equipment known in the art (such as a forming drum). The base cake sheet is preferably rolled to a thickness of about 0.5 cm to 3 cm.

[0078] Once the base cake sheet is formed, a fat-based cream is applied to the available face of the sheet. The cream can be applied using techniques and equipment known in the art, such as a drum tablet press. The cream layer can be applied to the entire face of the base cake sheet. For ease of manufacturing, the cream layer preferably covers the top surface of the base cake sheet.

[0079] Then, one or more texture additives are applied to the fat-based cream layer to form a composite sheet product. The one or more texture additives can be added to or in the cream layer in a uniform or random configuration. The crumbs can be sprinkled on the food product using known techniques and equipment. When cut vertically downward, the composite sheet will preferably have the configuration of a bottom base cake layer, with a cream layer on top of the base cake, and then one or more texture additives in or on the cream layer. The one or more texture additives do not contact the base cake layer.

[0080] The composite sheet product is then divided into a plurality of nutrition bar precursors. This is accomplished by known cutting methods, such as using a rolling knife. The composite sheet may be cooled by block cooling before being divided into a plurality of nutrition bar precursors. The use of a sheeting machine and cutting system makes the process more efficient, resulting in faster and cheaper production. The base cake is selected so that it is easy to cut without cracking, and the structure of the cream and texture additives is also compatible with the process.

[0081] Finally, each nutrition bar precursor is coated with a coating layer to form an individual nutrition bar. This can be done using known methods, such as by dipping each precursor into a coating composition to partially or completely coat / encapsulate each nutrition bar precursor. The step of coating the nutrition bar precursor preferably includes coating at least the base cake so that the base cake is not in direct contact with air. The coating step may preferably coat the entire precursor so that all of the base cake, cream layer and texture additives are coated and the outer surface of the precursor is completely covered by the coating layer.

[0082] The method of the present invention advantageously enables the production of nutritional bars according to the present invention without the need to extrude each nutritional bar individually. This makes the process more efficient, meaning that more nutritional bars can be produced in a given amount of time, which also makes the process economically advantageous. The inventors have found that a consistent product can be produced in much higher quantities, thereby reducing manufacturing time and complexity.

[0083] The present invention will now be described with reference to the following non-limiting drawings, in which:

[0084] Figure 1 Shown is a cross-section of a nutritional bar described herein.

[0085] Figure 2 A flow chart showing the key steps of the process described herein.

[0086] FIG. 3A to FIG. 3D The stages and components in the manufacturing process are shown. Specifically, Figure 3A The texturizing additive is shown in the form of crushed biscuits. Figure 3B An uncoated piece is shown with a texturizing additive visible against the cream layer. Figure 3C Blocks cut into stick sections (approximately 3.2 cm wide, 1.8 cm high and 10 cm long) are shown. Figure 3D A coated nutritional bar product is shown.

[0087] Figure 4A shows a cross-section of a nutrition bar product, and Figure 4B A side view of a nutritional bar product is shown.

[0088] The present invention relates to a nutrition bar 1. Suitable dimensions are 3cm-5cm wide and 10cm-20cm long. The height of the nutrition bar 1 may vary, but is typically 1cm to 3cm. The nutrition bar 1 typically has a total product weight of about 60g, such as 55g to 65g.

[0089] The nutrition bar 1 comprises a base cake 5 having a high protein content. The base cake 5 typically has an Aw of 0.55 to 0.65. As the base cake is preferably prepared by rolling and cutting sheets, it typically has a generally cubic shape.

[0090] The base cake 5 supports a cream layer 10. Its thickness is typically 1 mm - 5 mm, such as 2 mm - 3 mm. The cream 10 is a water-free filling composition, ie it is a fat-based filling.

[0091] A texture additive 15 or so-called "wrapping" is deposited throughout the cream layer 10. A preferred texture additive 15 is biscuit crumbs. The texture additive 15 typically has a particle size of 1 mm to 5 mm. Since the texture additives 15 are applied to the cream layer 10, they do not directly contact the base cake 5. This means that they are protected from the relatively high moisture base cake 5 which could result in a loss of the desired texture of the texture additive 15.

[0092] A coating layer 20 is applied to the final structure, covering the base cake 5, cream layer 10 and texturizing additive 15. It is possible that some of the texturizing additive 15 is not fully coated on all sides, but this is not critical to the final product since the nutrition bar 1 is typically sealed in packaging and the high moisture base cake 5 is typically completely isolated from the texturizing additive 15 by the cream layer 10 and coating layer 20. The coating layer 20 typically has a thickness of 1 mm to 4 mm.

[0093] A suitable formulation for each component is given below:

[0094] Percentage (weight %) Base Cake 60 wt% - 70 wt% Calcium Caseinate 20 wt% (i.e. 33 wt% protein in base cake) Whey protein 15 wt% (i.e. 25 wt% protein in base cake) Hydrolyzed Beef Collagen 25 wt% (i.e. 41 wt% protein in base cake) Cocoa powder 5 wt% glycerin 20% by weight Fat 15 wt% Water, sweeteners and flavorings The remainder Cream layer 10 wt% - 15 wt% Fat 30% by weight Maltitol 60% by weight Sweeteners and flavorings The remainder Coating 20 wt% - 25 wt% No added sugar chocolate 100% by weight Texture Additives 2 wt% - 5 wt% Crumbled sugar-free dark cookies 100% by weight

[0095] The method for making the nutritional bar 1 will now be further described.

[0096] In the first step, a base cake 5 is prepared. A liquid premix 101 is prepared by mixing together water, glycerine, fat and water-soluble sweeteners and flavoring ingredients. Dry ingredients 105, including protein ingredients and cocoa powder, are weighed out separately. The liquid premix 101 and dry ingredients 105 are then mixed together in a high-speed mixer 110. For a 500kg-1000kg batch, a typical mixing time is about 10 to 20 minutes. If desired, the mixer can be operated in a continuous mode.

[0097] After the mixture is thoroughly mixed, it is fed to the forming drum 115. The forming drum 115 may be equipped with a collecting hopper (not shown). The forming drum 115 is used to roll out a flat sheet of the base cake mixture.

[0098] Separately, a cream premix 120 is prepared from melted fat ingredients and maltitol. The cream premix 120 is conveyed to a drum sheeter 125 which applies a layer of cream on a sheet of base cake mix. The cream layer 10 formed is typically 2 mm to 3 mm thick.

[0099] Separately, appropriately sized texture additives 15 are provided in the form of sugar-free dark cookie crumbs 130. They are applied to the cream layer 10 using a sprayer with an automatic feeding conveyor 135. This forms a texture additive layer 15 on the cream layer 10. The texture additive layer 15 may be incomplete, depending on how much texture additive 15 is desired.

[0100] The composite product of base cake 5, cream layer 10 and texturizing additive 15 is then cooled in a cooling step 140 and then cut into individual sticks by a guillotine 145. These individual sticks are then coated 150 with a coating layer 20 and packaged 155 in a flow packaging machine. Example

[0101] The present invention will now be further described with reference to the following non-limiting examples.

[0102] The inventors have experimented with different protein sources including different proteins in different proportions. Wheat protein and pea protein as well as skim milk powder have been experimented with. In addition, different proportions of calcium caseinate, whey protein and hydrolyzed beef collagen were evaluated, as well as combinations with these other protein sources. These products differ in the moisture content (related to Aw) of the possible formulations and the final product texture. The optimal formulation for ensuring moisture content compatible with long shelf life and desirable texture is described herein with particular reference to the above table.

[0103] The optimal nutritional information for the final product is provided below:

[0104] Nutrition bar samples

[0105] Ingredients: Milk chocolate with sweetener 20% (sweetener (Maltitol), cocoa butter, whole milk powder, cocoa mass, flavouring, emulsifier (soya lecithin)), hydrolysed collagen, humectant (glycerol), calcium caseinate (from milk), whey protein (from milk), sweeteners (maltitol, sucralose), palm oil, water, low fat cocoa powder (3%), wheat flour, starch, rapeseed oil, raising agent (polydextrose), salt, emulsifier (soya lecithin), raising agents (ammonium carbonate, sodium carbonate), wheat starch, acidity regulator (sodium hydroxide), flavouring.

[0106] Unless otherwise indicated, all percentages herein are by weight.

[0107] The term "comprising" is intended to be inclusive and means that there may be additional elements in addition to the listed elements. The term "consisting of" means that there are no other elements in addition to the listed elements. The term "consisting essentially of" is intended to mean that there are no other elements in addition to the listed elements, unless the other elements do not significantly affect the basic and novel features of the invention.

[0108] Although the preferred embodiment of the present invention has been described in detail herein, it will be appreciated by those skilled in the art that various modifications may be made thereto without departing from the scope of the invention or the appended claims.

Claims

1. A base cake for a nutrition bar, the base cake having a water activity (aW) of 0.5 to 0.65 and comprising at least 50% by weight protein, based on the total weight of protein in the base cake. include: 25%-35% calcium caseinate; 20%-30% whey protein; and 38%-45% beef collagen.

2. A nutritional bar having at least 30% protein by weight and less than 3.3% sugar by weight, the nutritional bar comprising a coating layer at least substantially encapsulating: (a) a base cake having a water activity (aW) of 0.5 to 0.65 and comprising at least 50% by weight protein, the protein include: Calcium caseinate; Whey protein; and Beef collagen; (b) a fat-based cream layer, said fat-based cream layer being located on said base cake; and (c) one or more texturizing additives, said one or more texturizing additives being located on or embedded in said fat-based cream layer, wherein the fat-based cream layer separates the one or more texturizing additives from the base cake.

3. The nutritional bar of claim 2, wherein the protein in the base cake is include: 25%-35% calcium caseinate; 20%-30% whey protein; and 38%-45% beef collagen.

4. The nutritional bar of claim 3, wherein the protein in the base cake comprises up to 10 wt% of an additional protein source, optionally selected from wheat protein and pea protein, and combinations thereof, based on the total weight of protein in the base cake.

5. The nutritional bar of any one of claims 2 to 4, wherein the base cake comprises 55% to 65% by weight protein.

6. The nutritional bar according to any one of claims 2 to 5, wherein the base cake include: 15 to 25% by weight of glycerol; and / or 10 to 20% by weight of fat; and / or Up to 10% by weight of cocoa powder.

7. The nutritional bar according to any one of claims 2 to 6, wherein the base cake has a water activity of 0.55 to 0.62, preferably 0.58 to 0.

62.

8. The nutritional bar of any one of claims 2 to 7 having a shelf life of at least 9 months.

9. The nutritional bar of any one of claims 2 to 8 further comprising an airtight sealed package.

10. The nutritional bar of any one of claims 2 to 9, wherein the texturizing additive is selected from cookie pieces, fruit pieces, chopped nuts, protein crisps and chocolate chips.

11. A nutritional bar according to any one of claims 2 to 10 wherein the texture additive has a particle size of from 1 mm to 5 mm and is preferably substantially free of particles less than 1 mm.

12. The nutritional bar of any one of claims 2 to 11 wherein the fat-based cream filling is anhydrous and comprises at least 25% by weight fat.

13. A nutritional bar according to any one of claims 2 to 12, wherein the coating is a sugar free chocolate or compound coating and preferably has a thickness of 2mm - 3mm.

14. The nutritional bar according to any one of claims 2 to 13, wherein, relative to the weight of the final product: The base cake is present in an amount of 60 wt % to 70 wt %; The fat-based cream layer is present in an amount of 10 to 20 wt %; The texture additive is present in an amount of 1 wt % to 6 wt %, and The coating layer is present in an amount of 15 to 25 wt%.

15. A method of forming a nutritional bar according to any one of claims 2 to 14, the method include: preparing a base cake premix comprising at least 50% by weight protein, the protein comprising calcium caseinate, whey protein and beef collagen; rolling the base cake premix to provide a base cake sheet, the base cake sheet having a water activity (aW) of 0.5 to 0.65; applying a fat-based cream to form a fat-based cream layer on the base cake sheet; applying one or more texturizing additives to the fat-based cream layer to form a composite sheet product; dividing the composite sheet product into a plurality of nutritional bar precursors; The nutritional bar precursor is coated with a coating layer to form a nutritional bar.

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