Protein bar comprising low-sugar, high-dietary-fiber and plant-based protein, and method for manufacturing the same

Abstract

The present invention discloses a plant protein comprising isolated soy protein and rice flour; a dietary fiber comprising indigestible maltodextrin and chicory extract powder; a low-sugar component comprising allulose and enzyme-treated stevia and an auxiliary ingredient comprising MCT oil.

Description

Technology Field

[0001] The present invention relates to the field of health functional foods and convenient meal replacements, and more specifically, to a protein bar capable of simultaneously satisfying weight management and nutritional balance by combining low-sugar components, high-fiber and plant-based protein in optimal proportions, and a method for manufacturing the same. Background Technology

[0003] With the rapid increase in interest in health management, weight control, and muscle building in modern society, the consumption of protein bars, a convenient food product with protein as its main ingredient, is expanding. In particular, the protein bar market is showing steady growth as the consumer base seeking to conveniently supplement protein—such as office workers, students, and athletes—grows.

[0004] However, commercially available protein bars have several limitations. First, while they increase protein content, they often contain excessive amounts of sugar, which causes blood sugar spikes and is detrimental to weight management and metabolic health. Second, products with reduced sugar content often have an overly hard or dry texture, resulting in poor palatability and inconvenience in consumption. Third, many products rely on animal proteins such as whey protein (WPI, WPC), which places a burden on digestion and absorption or fails to meet the demands of vegetarian consumers.

[0005] Recently, consumers have shown a distinct preference for low-sugar, high-fiber products, driven by functional demands such as weight management, improved gut health, and blood sugar stabilization. In particular, despite reports indicating that consuming dietary fiber and protein together increases satiety and suppresses calorie intake, many products on the market have low dietary fiber content or contain only additives.

[0006] Furthermore, while chocolate coating is commonly used to ensure palatability in protein bar products, regular chocolate is sugar-based, making it difficult to classify as a low-sugar or low-GI food. Accordingly, there is a need for technology that can provide a crispy texture and diverse flavors while utilizing chocolate made with low-sugar ingredients.

[0007] Therefore, a new protein bar and manufacturing method are required that combine low-sugar ingredients (allulose, enzyme-treated stevia, etc.), high-fiber ingredients (indigestible maltodextrin, chicory extract powder, etc.), and plant-based proteins (isolated soy protein, grain protein, etc.) in optimal proportions, and combine this with protein ball structure and coating technology to lower the GI index while satisfying both convenience of consumption and palatability.

[0008] delete Prior art literature

[65535] Published Patent Application No. 10-2024-0128547 (20240826) The problem to be solved

[0009] The present invention aims to provide a protein bar and a method for manufacturing the same, which lowers the glycemic index and is effective for weight management by combining low-sugar components, high-fiber, and plant-based protein in optimal proportions, and simultaneously provides palatability and a crispy texture by forming protein balls, combining them into a bar shape, and applying low-sugar coating layers to the top and bottom.

[0010] Meanwhile, the technical problems to be solved by the present invention are not limited to those mentioned above, and other technical problems not mentioned will be clearly understood by those skilled in the art to which the present invention belongs from the description below.

[0011] delete means of solving the problem

[0012] An embodiment of the present invention may provide a protein bar comprising: a plant protein comprising isolated soy protein and rice flour; dietary fiber comprising indigestible maltodextrin and chicory extract powder; a low-sugar component comprising allulose and enzyme-treated stevia; and an auxiliary ingredient comprising MCT oil.

[0013] In addition, embodiments of the present invention may provide a protein bar comprising 30 to 50 parts by weight of the plant protein, 1 to 10 parts by weight of the dietary fiber, 5 to 15 parts by weight of the low-sugar component, and 0.5 to 10 parts by weight of the auxiliary ingredient.

[0014] In addition, an embodiment of the present invention may provide a protein bar formed by mixing the plant protein, the dietary fiber, and the low-sugar component to form a plurality of protein balls, and then compressing or molding the protein balls to combine them into a bar shape.

[0015] Additionally, an embodiment of the present invention may provide a protein bar further comprising a bottom low-sugar coating layer coated on the bottom of the bar and a top low-sugar coating layer coated on the top.

[0016] In addition, an embodiment of the present invention may provide a protein bar in which the protein ball is formed with a porous structure having pores of 10 μm to 100 μm inside.

[0017] In addition, an embodiment of the present invention may provide a protein bar in which the upper low-sugar coating layer comprises at least one of white chocolate and dark chocolate and is coated at a temperature of 30°C to 35°C.

[0018] In addition, embodiments of the present invention may provide a protein bar comprising at least one of nut powder, grain flakes, or dried fruit powder as the auxiliary ingredient.

[0019] In addition, embodiments of the present invention may provide a protein bar that further comprises at least one of the following components: γ-aminobutyric acid (GABA), lactic acid bacteria or probiotics, and prebiotics.

[0020] In addition, embodiments of the present invention may provide a protein bar that further includes micronutrients, such as vitamin C, vitamin B group, zinc, or magnesium, as auxiliary ingredients.

[0021] In addition, an embodiment of the present invention may provide a method for manufacturing a protein bar comprising: A) a step of preparing a plurality of protein balls by mixing a plant protein, dietary fiber, a low-sugar component, and auxiliary materials; B) a step of combining the plurality of protein balls into a bar shape by compressing or molding them; C) a step of cutting the bar into a predetermined size; D) a step of melting and tempering chocolate; E) a step of forming a bottom low-sugar coating layer on the bottom of the bar with the tempered chocolate; F) a step of forming a top low-sugar coating layer on the top of the bar with the tempered chocolate; G) a step of cooling the bar coated with the bottom low-sugar coating layer and the top low-sugar coating layer; H) a step of inner-packaging the bar into individual units; I) a step of inspecting the inner-packaged product with a metal detector; and J) a step of outer-packaging the product.

[0022] In addition, an embodiment of the present invention may provide a manufacturing method in which step D) melts the chocolate at 45°C to 55°C and tempers it at 25°C to 30°C.

[0023] In addition, an embodiment of the present invention may provide a manufacturing method in which the bar is cut to a certain length using multiple knives in step C).

[0024] In addition, an embodiment of the present invention may provide a manufacturing method in which step G) is cooled under conditions of 0°C to 10°C.

[0025] In addition, an embodiment of the present invention may provide a manufacturing method in which, in step H), the inner packaging uses a multilayer film comprising a moisture barrier layer or an oxygen barrier layer.

[0026] In addition, an embodiment of the present invention can provide a manufacturing method in which, in step I), the metal detector can detect foreign substances of Fe 1.5 mm or larger and stainless steel 2.0 mm or larger, and simultaneously includes a function to determine the weight and shape of the product.

[0027] In addition, an embodiment of the present invention may provide a manufacturing method in which, in step J), the outer packaging uses a packaging material having an NFC tag or QR code inserted therein that allows for product unit identification.

[0028] In addition, an embodiment of the present invention may provide a manufacturing method that further includes a step of storing the product at a temperature of 28°C or lower after the outer packaging step.

[0029] In addition, an embodiment of the present invention may provide a manufacturing method in which, in step A), the plant protein is mixed with 30 to 50 parts by weight, the dietary fiber with 1 to 10 parts by weight, the low-sugar component with 5 to 15 parts by weight, and the auxiliary raw material with 0.5 to 10 parts by weight. Effects of the invention

[0031] According to an embodiment of the present invention, by optimally combining low-sugar components, high dietary fiber, and plant-based protein, and by applying a protein ball structure and a low-sugar coating layer, it is possible to provide a protein bar that simultaneously satisfies satiety and palatability while lowering the glycemic index.

[0032] Meanwhile, the effects obtainable from the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art to which the present invention belongs from the description below. Brief explanation of the drawing

[0034] FIG. 1 is a flowchart showing the manufacturing process of a protein bar according to one embodiment of the present invention. Specific details for implementing the invention

[0035] Hereinafter, embodiments of the present invention will be described in more detail with reference to the accompanying drawings. Embodiments of the present invention may be modified in various forms, and the scope of the present invention should not be interpreted as being limited to the embodiments below. These embodiments are provided to more fully explain the present invention to those with average knowledge in the art. Accordingly, the shapes of the elements in the drawings have been exaggerated to emphasize clearer explanations.

[0036] The configuration of the invention to clarify the solution to the problem to be solved by the present invention is described in detail with reference to the attached drawings based on preferred embodiments of the present invention. In assigning reference numbers to the components of the drawings, the same reference number is assigned to identical components even if they are located in different drawings, and it is noted in advance that components of other drawings may be cited if necessary when describing the drawings.

[0037] The protein bar of the present invention is manufactured through a systematic manufacturing process as illustrated in FIG. 1. The manufacturing process begins with a material preparation step (S10), where all raw materials are prepared in advance and their quality is verified. The main raw materials used at this time include plant-based proteins including isolated soy protein and rice flour, dietary fibers including indigestible maltodextrin and chicory extract powder, low-sugar components including allulose and enzyme-treated stevia, and auxiliary materials including MCT oil.

[0038] Soy protein isolate is a high-purity protein with over 90% purity containing a balanced amount of essential amino acids, making it effective for maintaining muscle mass during weight management. Rice flour is gluten-free, minimizing allergic reactions and contributing to a soft texture. Indigestible maltodextrin exhibits a prebiotic effect by remaining undigested in the small intestine and traveling to the large intestine to serve as food for beneficial gut bacteria. Chicory extract powder is rich in inulin, contributing to suppressing blood sugar spikes and enhancing satiety. Allulose is a rare sugar with a glycemic index (GI) close to zero that causes minimal blood sugar or insulin responses, while enzyme-treated stevia removes the characteristic bitterness of stevia through enzymatic processing, providing a natural sweetness. MCT oil is composed of medium-chain fatty acids, offering a rapid energy supply while simultaneously promoting fat burning.

[0039] Meanwhile, auxiliary ingredients may additionally include various optional ingredients such as the following to enhance the functionality and nutritional value of the product.

[0040] First, at least one of nut powder, grain flakes, or dried fruit powder may be further included as an ingredient to improve texture and enhance nutrition. Almond powder, walnut powder, or pistachio powder are used as nut powders, and the particle size is controlled to 100 to 300 μm to impart a nutty flavor without compromising the crispy texture. Nut powders are rich in unsaturated fatty acids and vitamin E, providing antioxidant effects, and are added in an amount of 2 to 8 parts by weight relative to the total weight. Oat flakes, brown rice flakes, or quinoa flakes are used as grain flakes, processed to a thickness of 0.5 to 1.5 mm and a size of 3 to 8 mm to add chewing enjoyment. Grain flakes are rich in complex carbohydrates and beta-glucan, enhancing satiety, and are added in an amount of 3 to 10 parts by weight relative to the total weight (weight of auxiliary ingredients). Dried strawberry powder, dried blueberry powder, and dried cranberry powder are used as dried fruit powders, and are manufactured by freeze-drying to preserve functional components such as vitamin C and anthocyanin to the maximum extent. The dried fruit powders provide a natural sweetness and a refreshing aroma, and are added in an amount of 1 to 5 parts by weight relative to the total weight.

[0041] Second, at least one of γ-aminobutyric acid (GABA), lactic acid bacteria or probiotics, or prebiotics may be additionally included as an ingredient to enhance functionality. As a neurotransmitter, GABA helps relieve stress and improve sleep quality, and 0.1 to 0.5 parts by weight of fermented GABA with a purity of 99% or higher is added relative to the total weight (weight of auxiliary ingredients). If the amount is less than 0.1 parts by weight, the functional effect is negligible, and if it exceeds 0.5 parts by weight, the bitter taste becomes strong, which may impair palatability. Lactobacillus acidophilus, Bifidobacterium longum, Lactobacillus rhamnosus, etc., are used as lactic acid bacteria, and coating technology is applied to increase resistance to stomach acid, allowing them to survive until they reach the intestines. The number of lactic acid bacteria is set to 1 billion to 10 billion CFU per product to ensure the effect of improving intestinal balance. Inulin, fructooligosaccharides, and galactooligosaccharides are additionally used as prebiotic ingredients, promoting the growth of lactic acid bacteria and exhibiting a synergistic effect.

[0042] Third, micronutrients including vitamin C, B vitamins, zinc, or magnesium may be additionally included as ingredients for micronutrient supplementation. Vitamin C is added in the form of ascorbic acid and contains 50 to 100 mg, equivalent to 50 to 100% of the recommended daily allowance, to provide antioxidant effects and boost immunity. Since vitamin C is sensitive to oxidation, coated, stable vitamin C is used to ensure stability throughout the product's shelf life. The B vitamins include vitamin B1 (thiamine), B2 (riboflavin), B6 ​​(pyridoxine), B12 (cobalamin), folic acid, and pantothenic acid, each containing 25 to 75% of the recommended daily allowance to support energy metabolism and nervous system function. Zinc is added in the form of zinc gluconate or zinc picolinate and contains 3 to 8 mg, equivalent to 30 to 80% of the recommended daily allowance, to support immune function and wound healing. Magnesium is added in the form of magnesium oxide or magnesium glycinate and contains 80 to 240 mg, which is 20 to 60% of the recommended daily allowance, to support muscle function and neurotransmission. All of these micronutrients are encapsulated to prevent interactions with other ingredients and improve stability.

[0044] The material preparation step (S10) and the chocolate preparation step (S15) are carried out in parallel to increase production efficiency. The chocolate first undergoes a melting process at 45°C to 55°C. This temperature range is important because below 45°C, the chocolate does not melt completely, making it difficult to achieve a uniform coating, and above 55°C, the cocoa butter in the chocolate separates, resulting in reduced gloss and texture. After the melting is complete, the chocolate then undergoes a tempering process at 25°C to 30°C. Below 25°C, the chocolate hardens excessively, reducing workability, and above 30°C, stable V-shaped crystals are not formed, which may cause blooming.

[0046] Next, in the mixing step (S20), the prepared raw materials are quantitatively mixed and uniformly blended. The mixing process is carried out using a ribbon blender or a paddle mixer, and the capacity of the mixer is selected from 50L to 500L depending on the throughput. Before mixing, all raw materials are pretreated at room temperature of 20℃ to 25℃ to control the moisture content to 5% or less.

[0047] Mixing is carried out through a precise three-stage process. In the first stage, 30 to 50 parts by weight of isolated soy protein and 5 to 15 parts by weight of rice flour are first added to a mixer. Since the isolated soy protein has a fine particle size of 50 to 150 µm, the mixer is pre-mixed for 3 to 5 minutes by setting the rotation speed to a low speed of 30 to 50 rpm to prevent scattering. At this time, nitrogen gas is injected into the mixer at a pressure of 0.1 to 0.3 MPa to prevent oxidation and suppress the generation of static electricity. Since the rice flour has a particle size of 100 to 300 µm, which is larger than that of isolated soy protein, the isolated soy protein added first is distributed uniformly between the rice flour particles.

[0048] In Step 2, 0.5 to 7 parts by weight of indigestible maltodextrin and 0.5 to 3 parts by weight of chicory extract powder are added sequentially. Since indigestible maltodextrin is highly hygroscopic and prone to clumping due to static electricity, it is stored in an environment with a relative humidity of 40% or lower using a dehumidifier prior to addition. When adding, a vibrating feeder is used to slowly add the ingredients at a speed of 50 to 100 g / min, while increasing the mixer rotation speed to 60 to 80 rpm and mixing for 2 to 3 minutes. Because chicory extract powder has a high inulin content and is sensitive to temperature, cooling water at 15°C to 20°C is circulated through the mixer jacket to prevent a temperature rise caused by frictional heat during mixing.

[0049] In step 3, 3 to 10 parts by weight of allulose and 2 to 5 parts by weight of enzyme-treated stevia are added. Allulose is a crystalline sugar with a particle size of 200 to 500 µm and is sensitive to humidity, so caking may occur at relative humidity of 50% or higher. Therefore, before addition, it is dried in a dryer at 60°C to 80°C for 30 minutes to control the moisture content to 0.5% or less. Since enzyme-treated stevia is in powder form with a very fine particle size of 10 to 50 µm, it is added after passing through an ionization device to prevent static electricity. In this step, the mixer rotation speed is set to 100 to 120 rpm and high-speed mixing is performed for 5 to 8 minutes, while the cooling system is operated so that the internal temperature of the mixer does not exceed 30°C.

[0050] In the final step, 0.5 to 10 parts by weight of MCT oil are added through a spray nozzle. Since MCT oil has good fluidity with a viscosity of 25 to 35 cP at 25°C, the spray pressure is set to 0.3 to 0.5 MPa to spray it as fine droplets with an average particle size of 50 to 100 μm. Four to eight spray nozzles are placed at 120-degree intervals on the upper part of the mixer to ensure uniform dispersion throughout the raw material. When adding MCT oil, the mixer rotation speed is increased to 150 to 200 rpm, and the oil addition rate is adjusted to 10% to 20% of the total amount per minute, allowing for gradual injection over 10 to 15 minutes. At this time, a scraper is operated at intervals of 2 to 3 minutes to prevent oil from adhering to the walls of the mixer.

[0051] The entire mixing process is carried out for 20 to 30 minutes, and the internal temperature of the mixer is maintained between 25°C and 35°C. If the temperature exceeds 35°C, the viscosity of the MCT oil drops excessively to 15 cP or less, causing it to run off the surface of the raw material particles and making uniform coating difficult; if the temperature is below 25°C, the viscosity of the MCT oil rises to 50 cP or more, which may reduce spray efficiency and cause solidification. After mixing is complete, the quality is verified by measuring the particle size distribution, moisture content, and bulk density through sampling. The bulk density of the mixture is adjusted to be 0.4 to 0.6 g / cm³, and the moisture content to be 3% to 5%.

[0052] If the plant-based protein content is less than 30 parts by weight, the protein content is insufficient, which reduces the weight management effect, and in particular, it becomes difficult to supply more than 20% of the recommended daily protein intake. If it exceeds 50 parts by weight, the texture becomes rough and binding strength decreases, and due to excessive aggregation of protein, it becomes difficult to create a uniform shape when molding protein balls in subsequent processes. In addition, if the protein content is excessive, the amount of static electricity generated during mixing increases, which reduces work safety and increases the risk of dust explosions.

[0053] When the dietary fiber content is less than 1 part by weight, the effects on satiety and gut health are negligible, and it is impossible to supply more than 5% of the recommended daily dietary fiber intake. If it exceeds 10 parts by weight, it may cause indigestion or abdominal bloating, and due to the excessive water absorption capacity of the dietary fiber, the water activity of the product rises above 0.7, increasing the risk of microbial growth. In addition, excessive dietary fiber reduces the fluidity of the mixture, which worsens workability in subsequent molding processes.

[0054] If the low-sugar content is less than 5 parts by weight, the sweetness is insufficient, leading to reduced palatability, and the sweetness intensity decreases to 30% or less compared to sugar. If it exceeds 15 parts by weight, not only does the burden of consumption increase due to excessive sweetness, but the cooling properties of allulose become excessive, damaging the texture, and the characteristic aftertaste of enzyme-treated stevia remains strong, disrupting the overall flavor balance. Additionally, if the low-sugar content is excessive, caking may occur during storage due to hygroscopicity.

[0055] If the amount of MCT oil, an auxiliary ingredient, is less than 0.5 parts by weight, the binding effect is insufficient, making it difficult to maintain the shape during protein ball molding. Additionally, since the compression molding pressure must be increased to 10 MPa or more, there is a risk that the porous structure will be destroyed. If it exceeds 10 parts by weight, the excessive oil content causes the product to become sticky and adhere to the hands, and the risk of rancidity during storage increases, shortening the shelf life to less than 3 months. Furthermore, an excessive amount of MCT oil results in an excessively high calorie density of the product, making it unsuitable for weight management purposes.

[0056] The uniformly mixed raw materials are formed into a number of protein balls in the protein ball molding step (S30). These protein balls are formed with a porous structure having pores of 10㎛ to 100㎛ inside, which is a key element in achieving a crispy crunchy texture.

[0057] Protein ball molding is carried out through a four-step precise process. First, in the first step, 0.1 to 0.5 parts by weight of sodium bicarbonate, which acts as a foaming agent, is added to the mixed raw materials relative to the total weight. The sodium bicarbonate is used in powder form with an average particle size of 50 to 150 µm and is food-grade with a purity of 99% or higher. When adding, lumps are removed using a vibrating sieve, and then the mixture is uniformly dispersed throughout the raw materials by mixing at 30 to 50 rpm for 2 to 3 minutes using a low-speed mixer. If the sodium bicarbonate is less than 0.1 parts by weight, the amount of carbon dioxide generated during thermal decomposition is insufficient, making it difficult to form sufficient pores; if it exceeds 0.5 parts by weight, excessive foaming reduces the structural stability of the protein balls and leaves a strong sodium taste, impairing palatability.

[0058] In step 2, the raw material mixture to which sodium bicarbonate has been added is heated at a temperature of 80°C to 120°C for 5 to 15 minutes using a conveyor oven or a rotary heater. The heating is carried out in three stages: first, it is preheated to 60°C to 80°C for 2 minutes to uniformly disperse the moisture inside the raw material, then the temperature is raised to 80°C to 100°C for 3 to 8 minutes to induce the initial decomposition of sodium bicarbonate, and finally, it is heated to 100°C to 120°C for 3 to 5 minutes to achieve complete thermal decomposition. During this process, sodium bicarbonate (2NaHCO3) decomposes to produce sodium carbonate (Na2CO3), water (H2O), and carbon dioxide (CO2), and in particular, carbon dioxide gas forms fine pores of 10 µm to 100 µm in size inside the raw material. If the heating temperature is below 80°C, the decomposition rate of sodium bicarbonate is insufficient at 30% or less, so pore formation does not occur properly, and if it exceeds 120°C, thermal denaturation of isolated soy protein occurs, which reduces the functionality of the protein and causes a bitter taste. During heating, the raw material is stirred every 2 to 3 minutes to ensure that heat is transferred uniformly, and the relative humidity inside the heater is controlled to 30% to 50% to prevent excessive moisture evaporation.

[0059] In Step 3, the pore structure of the heat-treated raw material is fixed through rapid cooling. Cooling is carried out for 3 to 7 minutes using a forced-air cooler, blowing cold air at a temperature of 5°C to 15°C at a speed of 3 to 5 m / s. During this process, the temperature of the raw material is rapidly lowered from 120°C to 30°C or lower to fix the structure and prevent the formed pores from shrinking. If the cooling speed is too slow, the pores will shrink, reducing the final pore size to 5 µm or less; if it is too fast, the raw material may crack due to thermal shock caused by the temperature difference. After cooling is complete, the pore size and distribution are checked under a microscope to verify that more than 90% of the pores have been formed within the range of 10 µm to 100 µm.

[0060] In step 4, the cooled raw material is molded into spherical protein balls with a diameter of 8 to 15 mm by applying a pressure of 0.5 to 2.0 MPa for 5 to 15 seconds using a pelletizer or an extrusion molder. Molding is performed by extruding the raw material through a die hole and cutting it into a sphere with a rotary blade. If the pressure is less than 0.5 MPa, the binding force of the raw material is insufficient, causing the molded protein balls to break easily; if it exceeds 2.0 MPa, the pore structure formed is compressed due to excessive pressure, resulting in a loss of porosity. If the molding time is less than 5 seconds, sufficient compression is not achieved, resulting in uneven density of the protein balls; if it exceeds 15 seconds, excessive compression causes the porosity to decrease to 30% or less. The density of the molded protein balls is adjusted to 0.6 to 0.9 g / cm³ and the porosity to 40% to 60%, and the compressive strength is set to 20 to 40 N so that they can maintain a crispy texture without breaking during subsequent processes. After molding is completed, the size, shape, and pore distribution of the protein balls are monitored in real time through a quality control system, and products that do not meet the specifications are automatically sorted out and reprocessed.

[0062] The molded protein balls are compressed or molded in the bar molding step (S40) to form a bar. The bar molding is carried out as a two-stage process combining a continuous extrusion molding machine and a hydraulic press.

[0063] In the first step, molded protein balls are quantitatively fed into a continuous mold via a hopper. The mold is constructed from 316L stainless steel, and its inner surface is treated with a mirror finish (Ra 0.4㎛ or less) to improve the surface quality of the molded product. The internal dimensions of the mold are designed to be 1,200 to 1,600 mm in length, 22 to 32 mm in width, and 12 to 17 mm in depth, leaving a margin of 10% to 15% compared to the final product. The protein ball supply volume is precisely controlled via a vibrating feeder to be between 70% and 85% of the mold volume, and the feeding speed is set to 500 to 800 g / min. If the supply volume is less than 70%, the density becomes uneven after molding, and if it exceeds 85%, the raw material overflows from the mold due to overfilling, contaminating the working environment.

[0064] After the protein balls are filled into the mold, the gaps between the protein balls are minimized through a vibration alignment system. Vibration is applied for 5 to 10 seconds with a vibration frequency set to 50 to 100 Hz and an amplitude set to 0.5 to 2.0 mm. During this process, the protein balls are rearranged to achieve an optimal packing density, and the porosity inside the mold is controlled to 15% to 25%. If the vibration frequency is less than 50 Hz, the alignment effect is insufficient, and if it exceeds 100 Hz, the internal pore structure of the protein balls may be damaged due to excessive vibration.

[0065] In the second step, compression molding is performed using a hydraulic press at a pressure of 2.0 to 5.0 MPa. The compression is divided into three stages: in the initial compression, a low pressure of 0.5 to 1.0 MPa is applied for 10 to 15 seconds to induce initial contact between the protein balls; in the intermediate compression, a medium pressure of 1.5 to 3.0 MPa is applied for 15 to 20 seconds to initiate binding between the protein balls; and in the final compression, a high pressure of 2.0 to 5.0 MPa is applied for 20 to 30 seconds to achieve complete binding. The total compression time is 45 to 65 seconds, and the pressure increase rate is controlled to 0.1 to 0.2 MPa / sec to prevent rapid pressure changes.

[0066] At pressures below 2.0 MPa, the binding force between protein balls is insufficient, making it difficult to maintain the bar shape, and the tensile strength drops to 5 N / cm² or less, increasing the risk of breakage during subsequent processes. If the pressure exceeds 5.0 MPa, the porous structure of the protein balls is compressed due to excessive pressure, reducing the porosity to 20% or less and resulting in a loss of crispy texture. Additionally, excessive pressure can cause MCT oil to be extruded, leading to an oiling phenomenon where oil seeps out onto the product surface.

[0067] During compression molding, the mold temperature is heated to 40°C to 60°C to increase the fluidity of the MCT oil and promote binding between the protein balls. If the mold temperature is below 40°C, the viscosity of the MCT oil is high, reducing the binding effect, and if it exceeds 60°C, shape stability decreases due to excessive fluidity. Pressure and temperature sensors are installed inside the mold to monitor molding conditions in real time, and the pressure and temperature are automatically controlled through a PLC control system.

[0068] The formed bar is manufactured in the form of a continuous bar with a length of 1,000 to 1,500 mm, a width of 20 to 30 mm, and a thickness of 10 to 15 mm. The dimensional accuracy of the molded product is controlled within ±0.5 mm, and the surface roughness is maintained at Ra 2.0 μm or less. The density of the bar is controlled to be 0.8 to 1.2 g / cm³ and the moisture content to be 3% to 5%, and the compressive strength is set to 50 to 100 N / cm² so that it can be processed without breakage during the subsequent cutting process. After the molding is completed, the mold is tilted 5 to 10 degrees to discharge the continuous bar using gravity for demolding, and it is transferred to the next process via a conveyor. During demolding, vegetable oil is used as a release agent and applied to the mold surface at a rate of 0.1 to 0.2 g / m² to prevent product adhesion and ensure smooth demolding.

[0070] When bar forming is completed, in the bar cutting step (S50), the continuous bar is cut into individual product sizes of 100 to 120 mm using multiple knives. Bar cutting is carried out as a continuous cutting process using a high-precision multi-knife system.

[0071] The cutting system uses a rotary multi-knife head driven by a servo motor, and the knives are made of tungsten carbide to ensure wear resistance and cutting precision. The thickness of the knife blades is 0.3 to 0.5 mm, and the cutting angle is set to 25 to 35 degrees to achieve optimal cutting performance. If the thickness of the knife blades is less than 0.3 mm, vibration occurs during cutting, resulting in an uneven cut surface, and if it exceeds 0.5 mm, the cutting resistance increases, applying compressive stress to the product, which may damage the porous structure.

[0072] The multi-knife system features 8 to 12 knives spaced 100 to 120 mm apart, allowing multiple products to be cut simultaneously in a single pass. The tolerance of the knife spacing is managed within ±0.2 mm, and the spacing is monitored in real-time via a laser measuring system to ensure uniformity of the cutting length. During the cutting process, a continuous bar is transported at a constant speed via a conveyor, and the position of the bar is detected via a photo sensor to control the operation of the knives at the precise cutting position.

[0073] The cutting speed is controlled to 10 to 30 mm / sec, which refers to the downward speed of the knife. If the cutting speed is less than 10 mm / sec, the knife contacts the product for an excessively long time, generating frictional heat and potentially causing the cut surface to be compressed and deformed; if it exceeds 30 mm / sec, the rapid cutting causes the cut surface to become rough and scatters protein balls, damaging the appearance of the product. Additionally, if the cutting speed is too slow, the number of products that can be cut per hour decreases to 300 or fewer, resulting in reduced productivity.

[0074] During cutting, the gap between the knife and the continuous bar is precisely adjusted to 0.1 to 0.3 mm to optimize cutting quality. If the gap is less than 0.1 mm, there is a risk that the knife will collide with the base and damage the blade, and if it exceeds 0.3 mm, the cut may be incomplete, leaving the product connected to each other. The cutting pressure is set to 50 to 150 N / cm² to achieve a clean cut while preserving the porous structure of the product.

[0075] In the cutting process, ultrasonic vibration is applied to the knife to improve cutting performance. The ultrasonic frequency is set to 20 to 40 kHz and the amplitude to 10 to 30 µm to reduce friction between the knife and the product and improve the quality of the cut surface. Applying ultrasonic vibration reduces cutting resistance by 30% to 50%, which minimizes compressive stress applied to the product, and improves the roughness of the cut surface to Ra 5 µm or less.

[0076] In a continuous bar with a length of 1000mm, approximately 8 to 10 individual products can be obtained by considering the knife spacing and cutting loss. The cutting loss rate is managed to be 2% to 5% of the total length, which is mainly due to losses caused by the ends of the bar and the knife thickness. To minimize cutting loss, the length of the continuous bar is manufactured to be 1200 to 1500mm, and the effective cutting length is maximized by precisely controlling the cutting start and end points.

[0077] After removing cutting debris and dust from the cut products using an air blow system, they are transported to the next process via a vibrating conveyor. The air blow system uses compressed air at 0.2 to 0.4 MPa and maintains product cleanliness by using sterile air purified through a filter. Quality inspection of the cut products is performed automatically via a vision system, which automatically sorts out defective products by inspecting the dimensions of length, width, and thickness, as well as the condition of the cut surface, in real time. The inspection criteria are a length of 100 ± 2 mm, a width of 20 ± 1 mm, and a thickness of 10 ± 1 mm, and the flatness of the cut surface allows for irregularities of 0.5 mm or less.

[0079] The cut bar sequentially forms a lower low-sugar coating layer and an upper low-sugar coating layer in the coating layer formation step (S60). The coating process is carried out on an automated continuous coating line and consists of a two-stage process in which temperature and viscosity are precisely controlled.

[0080] In the first step of forming the bottom low-sugar coating layer, tempered low-sugar chocolate is used. The low-sugar chocolate is manufactured using sugar substitutes based on erythritol and stevia, and dark chocolate with a cocoa solid content of 35% to 55% is mainly used. The chocolate is pre-treated in a tempering machine to form a complete V-shaped crystal structure, and the tempering process proceeds in three stages: complete melting at 45°C -> cooling to 27°C to form crystal nuclei -> reheating to 31°C to stabilize.

[0081] The tempered low-sugar chocolate is stored in an immersion tank maintained at a temperature of 30°C to 35°C. The immersion tank is constructed with a double-wall structure and precisely controls the temperature through a circulating hot water system, managing temperature deviations within ±0.5°C. A low-speed stirrer is installed inside the immersion tank and rotates at 5 to 10 rpm to maintain temperature uniformity of the chocolate and prevent surface hardening. Below 30°C, the viscosity of the chocolate increases to 15,000 to 25,000 cP, making uniform coating difficult and increasing bubble formation; above 35°C, the viscosity drops excessively to 2,000 cP or less, causing the coating layer to become thin and resulting in the problem of the chocolate dripping from the bar.

[0082] The immersion of the bottom surface of the bar is performed automatically via a conveyor system. The cut bar is placed in the correct position using a vacuum picker, and the bottom surface is immersed to a depth of 2 to 4 mm from the chocolate surface using a lifting device. The immersion time is 3 to 7 seconds; if the immersion depth is less than 2 mm, the coating layer becomes uneven, and if it exceeds 4 mm, the coating extends to the sides, which may damage the appearance of the product. After immersion, the bar is slowly lifted from the chocolate surface, and a dripping process is performed for 5 to 10 seconds to allow excess chocolate to naturally drip off. During this process, fine vibrations of 10 to 20 Hz are applied using a vibration device to facilitate the removal of excess chocolate and to uniformly adjust the coating layer thickness to 0.8 to 1.2 mm.

[0083] The bottom coating is completed and passes through a cooling tunnel to cure the coating layer. The cooling tunnel is 3 to 5 m long, the internal temperature is set to 10 to 15°C, and the relative humidity is controlled to 50% to 60%. The cooling time is 60 to 90 seconds, and during this process, the V-shaped crystal structure of the chocolate is stabilized to achieve gloss and snap. If the cooling speed is too fast, cracks may occur due to the temperature difference, and if it is too slow, bloom may occur.

[0084] In the second step of forming the upper low-sugar coating layer, white chocolate or dark chocolate is applied using a drizzle method. The chocolate for drizzle is heated to a temperature of 35°C to 40°C, which is 5°C to 10°C higher than that for the lower coating, to lower the viscosity to 1,000 to 3,000 cP and increase fluidity. The drizzle device uses a multi-nozzle system with 8 to 12 nozzles arranged with holes of 0.5 to 1.0 mm, and the nozzle spacing is set to 15 to 25 mm to uniformly cover the entire width of the product.

[0085] The drizzle pattern is applied as a zigzag or stripe pattern; for the zigzag pattern, the amplitude is set to 5 to 10 mm and the period to 20 to 30 mm, and for the stripe pattern, the line spacing is adjusted to 3 to 5 mm. The drizzle speed is set to 10 to 20 mm / sec in synchronization with the product transfer speed, and the chocolate dispensing volume is precisely controlled to 0.1 to 0.3 g / sec through pressure control. If the drizzle pressure is less than 0.1 MPa, the dispensing becomes unstable and breaks occur, and if it exceeds 0.3 MPa, the pattern may be distorted due to excessive dispensing.

[0086] The total coating amount is adjusted to be 5 to 15% of the product weight. The bottom coating layer accounts for 60% to 70% of the total coating amount, and the top drizzle coating layer accounts for 30% to 40%. If the coating amount is less than 5%, the protective effect and taste improvement effect of the coating are negligible, and if it exceeds 15%, the product's calorie content increases due to excessive chocolate, making it unsuitable for weight management purposes. The coating thickness is monitored in real-time using a laser meter and is managed to be 0.8 to 1.2 mm for the bottom coating layer and 0.3 to 0.7 mm for the top drizzle coating layer.

[0087] The product with the top coating completed passes through a secondary cooling tunnel for final curing. The secondary cooling is carried out at 5 to 10°C for 120 to 180 seconds, during which the drizzle coating layer is completely cured to prevent damage during transportation. After cooling is complete, the thickness, uniformity, and appearance of the coating layer are checked through quality inspection, and the presence of internal bubbles or foreign substances is inspected through X-ray inspection.

[0089] After the coating is completed, the coating layer is cured through a precisely controlled three-stage cooling system in the cooling step (S70). The cooling process is carried out in a continuous cooling tunnel, and the tunnel length is designed to be 15 to 25 m to ensure sufficient cooling time.

[0090] In the first stage of pre-cooling, the coated product is pre-cooled at a temperature of 15°C to 20°C for 3 to 5 minutes. This step is intended to prevent thermal shock caused by rapid temperature changes and to induce initial curing of the coating layer surface. The relative humidity of the pre-cooling chamber is controlled to 45% to 55% to prevent condensation, and a uniform temperature distribution is maintained through laminar air circulation. The air velocity is set to 0.5 to 1.0 m / s to promote heat transfer to the product surface without damaging the coating layer.

[0091] In the second stage of main cooling, primary cooling is carried out for 15 to 20 minutes at a temperature of 5 to 10°C. The main cooling chamber is divided into multi-stage temperature zones, and the temperature is gradually lowered to 10°C at the inlet, 7°C at the middle, and 5°C at the outlet to achieve uniform curing of the coating layer. Precision temperature sensors are installed at 1m intervals inside the cooling chamber to manage temperature deviations within ±0.3°C, and the temperature is controlled in real-time via a PLC control system. Relative humidity is maintained at 40% to 50% to prevent moisture condensation on the product surface, and humidity is continuously controlled using a dehumidifier.

[0092] During the main cooling process, a forced-circulation fan is used to enhance convective cooling with an airflow velocity of 2 to 4 m / s. The cooling air is clean air that has passed through a multi-stage filter system (pre-filter -> HEPA filter -> activated carbon filter) to remove fine dust and odors. Anti-vibration pads are installed on the floor of the cooling chamber to prevent vibrations from the compressor or fan from being transmitted to the product and to prevent cracking of the coating layer.

[0093] In the third stage, final cooling, final curing is carried out at a temperature of 0°C to 5°C for 5 to 10 minutes. This stage ensures quality in the subsequent packaging process by uniformly lowering the internal temperature of the product along with the complete solidification of the coating layer. An infrared thermometer is installed in the final cooling chamber to monitor the product surface temperature in real-time using a non-contact method and to verify whether the target temperature of 5°C ± 1°C has been reached. Relative humidity is lowered to 35% to 45% to completely prevent condensation on the product surface, and an electrostatic discharge device is used to prevent sticking to the packaging material.

[0094] Temperature control during the cooling process is critical, as temperatures below 0°C can cause thermal shock due to rapid cooling, leading to microcracks in the coating layer. In particular, since the coefficient of thermal expansion of chocolate differs from that of the product body, the greater the temperature difference, the greater the risk of delamination or cracking at the interface. Conversely, if the temperature exceeds 10°C, the crystallization rate of the chocolate slows down, resulting in incomplete V-shaped crystal formation and potentially causing blooming or whitening. Additionally, the slow cooling rate reduces the throughput to less than 200 units per hour, significantly lowering productivity.

[0095] Cooling time must also be precisely controlled, and the time allocation for each stage within the total cooling time of 10 to 30 minutes is important. With a cooling time of less than 10 minutes, complete curing does not occur within the coating layer, resulting in a crystallinity of 70% or less according to DSC (Differential Scanning Calorimetry) analysis, and increasing the risk of damage during the subsequent packaging process. If it exceeds 30 minutes, power consumption increases by more than 25%, and the processing capacity of the entire production line is limited, leading to a deterioration in economic efficiency.

[0096] After cooling is complete, the condition of the coating layer is checked using an automated quality inspection system. Inspection items include coating layer gloss (85 or higher at a 60-degree angle), hardness (75 or higher on a Shore A hardness tester), adhesion (no peeling via tape test), and color match ( Examples include an E value of 2.0 or less. Additionally, ultrasonic inspection is used to check for air bubbles or peeling within the coating layer, and products that do not meet the acceptance criteria are automatically separated for rework or disposal. Once cooling is complete, the products are transferred to the next packaging process after it is confirmed that the temperature has reached 5℃±1℃; a cold-insulating conveyor is used during transfer to prevent temperature rise.

[0098] The cooled product is packaged in individual units during the inner packaging step (S80). The inner packaging is carried out using a high-barrier packaging system that uses an innovative 5-layer multilayer film, which is a next-generation packaging technology with barrier performance improved by more than 3 times compared to conventional 3-layer packaging materials.

[0099] The 5-layer structure of the packaging material consists of, from the outside inward, a protective layer (25㎛ PET) - a printing layer (5㎛ ink) - a barrier layer (15㎛ EVOH + 20㎛ Nylon) - an adhesive layer (5㎛ urethane-based adhesive) - a sealing layer (50㎛ CPP), with a total thickness of 120㎛. Each layer is bonded using a dry lamination method to prevent delamination or lifting between layers.

[0100] The moisture barrier layer contains 32 mol% EVOH (ethylene-vinyl alcohol copolymer), achieving a moisture permeability of 0.05 g / m² / day or less. This represents a 50% improvement in barrier performance compared to the 0.1 g / m² / day of conventional packaging materials, maintaining the moisture activity inside the product at 0.3 or less to completely block microbial growth. The thickness of the EVOH layer was optimized to 15 µm to ensure sufficient barrier performance while maintaining flexibility, and adhesive strength was improved by 30% through a special corona treatment.

[0101] 20㎛ biaxially oriented nylon (BOPA) is applied to the oxygen barrier layer to limit oxygen permeability to 0.3cc / m² / day or less. This represents a 70% improvement in performance compared to the industry standard of 1cc / m² / day, effectively preventing the oxidation of MCT oil and protein within the product. 0.1% of iron powder with oxygen scavenger properties is added to the nylon layer to completely remove residual oxygen, thereby improving the product's oxidation stability by more than five times compared to the existing method.

[0102] The PET film serving as the protective layer contains a UV blocker to limit ultraviolet transmittance to 5% or less, while maintaining visible light transmittance of 85% or more to ensure the visual quality of the product. Additionally, through antistatic treatment, the surface resistance is lowered to 10¹²Ω or less to suppress static electricity generation and prevent dust adsorption.

[0103] The packaging process is carried out in a fully automated VFFS (Vertical Form Fill Seal) system. First, the product is introduced into a packaging machine filled with nitrogen gas to reduce the residual oxygen concentration to 100 ppm or less. The packaging material is formed as it passes through a preheated heater block (120℃±2℃), and after the product is introduced, more than 99% of the air inside the packaging is removed through vacuum treatment. Subsequently, nitrogen gas (99.99% purity) is injected at a pressure of 0.1 MPa to create a MAP (Modified Atmosphere Packaging) environment.

[0104] The sealing process utilizes ultrasonic sealing technology, improving sealing strength by 40% compared to conventional thermal sealing. Sealing is performed under conditions of an ultrasonic frequency of 20 kHz, an output of 500 W, and a sealing time of 0.3 seconds, with the sealing area width set to 5 mm to ensure sufficient sealing performance. After sealing, micro-leaks are inspected using a leak detector, with a detection limit of 10 -6 It is set to mbar·L / s to ensure perfect sealing.

[0105] Oxygen and humidity indicators are printed on the inside of the packaging, allowing the packaging condition to be checked visually. The oxygen indicator changes to pink at an oxygen concentration of 500 ppm or higher, and the humidity indicator changes to blue at a relative humidity of 60% or higher, enabling immediate detection of packaging defects. Additionally, a Time-Temperature Indicator (TTI) is applied to track temperature history during distribution and can indicate quality degradation through a color change when exposed to temperatures above 25°C for 24 hours.

[0106] The packaging contains 5% biodegradable additives and is designed to biodegrade by more than 60% within 18 months when landfilled, adding value as an eco-friendly packaging material. It also specifies a recycling code to encourage consumers to properly separate and dispose of waste.

[0107] Through these barrier performance and innovative technologies, product oxidation and deterioration are completely prevented, extending the shelf life threefold from the conventional 6 months to 18 months and maintaining quality for 7 days even after opening. In particular, lipid oxidation is effectively inhibited by maintaining the acid value (AV) of MCT oil at 0.2 or less and limiting the peroxide value (POV) to 5 meq / kg or less. Additionally, nutritional quality is preserved for a long period by limiting changes in the amino acid composition of proteins to within 1%.

[0109] The packaged product undergoes multidimensional quality analysis through an AI-based integrated quality inspection system at the metal detection stage (S90). Unlike conventional simple metal detectors, this system is an innovative all-in-one inspection platform that simultaneously performs metal detection, weight measurement, shape analysis, X-ray inspection, and spectrum analysis.

[0110] The metal detection system applies a simultaneous 3-frequency detection method to detect foreign substances larger than 1.5mm for Fe, 2.0mm for stainless steel, and 1.8mm for non-magnetic metals. By simultaneously using low frequency 50kHz (optimized for Fe detection), medium frequency 200kHz (optimized for stainless steel detection), and high frequency 800kHz (optimized for non-magnetic metal detection), the detection accuracy has been improved to over 95%. This is an innovative technology that reduces the false detection rate by 70% and the non-detection rate by 80% compared to the existing single-frequency method.

[0111] The detection sensor is designed with a differential coil 3D array structure, and a total of 16 sensors are arranged at 120-degree intervals in all directions (up, down, left, and right) to scan all sides of the product. The detection sensitivity of each sensor is adjusted in real time and automatically calibrated according to product characteristics to maintain optimal detection performance. To prevent signal interference between sensors, sequential detection is performed using a time-division method (at 0.1ms intervals), enabling high-speed processing with a total inspection time of less than 0.5 seconds.

[0112] The detection system utilizes machine learning algorithms to learn unique signal patterns for each product and precisely distinguishes between metal foreign object signals and product signals. The training data was built based on over 100,000 samples, and a discrimination accuracy of over 99.8% was achieved through a deep learning neural network. Metal foreign objects smaller than this size are harmless to the human body according to FDA standards, and setting excessive sensitivity risks classifying normal products as defective, potentially reducing production efficiency by more than 20%.

[0113] Weight measurement is managed within a range of ±2g (±5%) based on a standard weight of 40g using a high-precision load cell (resolution 0.01g). The load cell is equipped with a temperature compensation function, maintaining a measurement error of within ±0.1% even with changes in ambient temperature (10℃ to 40℃). Weight measurements are taken on a vibration-damping platform, and an active vibration control system blocks the influence of external vibrations by more than 99%. Weight data is transmitted in real-time to the SPC (Statistical Process Control) system to monitor process variations, and an alarm is automatically triggered if the control limits are exceeded.

[0114] Shape analysis utilizes a 3D vision system to verify compliance with specifications for length (100±2mm), width (25±1mm), and thickness (12±1mm). The vision system is based on laser triangulation and offers a measurement precision of ±0.1mm. By simultaneously capturing images from four directions (up, down, left, and right), the product's overall shape is reconstructed in 3D, and surface defects, cracks, and deformation are automatically detected through AI image analysis. The shape analysis algorithm was developed based on a Convolutional Neural Network (CNN) and trained on over 500,000 image data points, demonstrating a detection accuracy of over 99.5%.

[0115] An X-ray inspection system is additionally applied to inspect internal pore distribution, density uniformity, and the presence of foreign substances. The X-ray source operates at 90kV and 1mA, and a high-resolution digital detector (pixel size 50㎛) images the internal structure with a resolution of 0.1mm. Products with a porosity outside the 40–60% range or a density deviation of 15% or more are determined to be defective. X-ray images are automatically analyzed via AI, and inspections are conducted within a lead-shielded room to ensure radiation safety.

[0116] The spectrum analysis system non-destructively analyzes the ingredient composition of a product using near-infrared (NIR) spectroscopy. It verifies compliance with ingredient specifications by measuring protein content (30 to 50%), fat content (5 to 15%), sugar content (5 to 15%), and moisture content (3 to 5%) in real time. NIR spectra are collected in the wavelength range of 900 to 2500 nm, and ingredient content is predicted through Partial Least Squares (PLS) regression analysis. The prediction accuracy achieves high precision, with Root Mean Square Error of Prediction (RMSEP) of ±1% for protein, ±0.5% for fat, and ±0.3% for sugar.

[0117] Inspection results are transmitted to the Manufacturing Execution System (MES) in real time, and the quality history for each product is automatically recorded. Defective products are automatically ejected using an air jet method, with the ejection speed set to 10 m / s to prevent cross-contamination with normal products. The defect rate is managed to be 0.1% or less, and areas for process improvement are identified through statistical analysis of defect types.

[0118] The inspection system is designed with a processing speed of 600 items per minute, making it suitable for high-speed production lines, and demonstrates high reliability with an uptime of over 99%. Furthermore, through self-diagnostic functions, it detects sensor anomalies, measurement errors, and system errors in real time, and minimizes system downtime through preventive maintenance alarms. This integrated inspection system improves inspection accuracy by 50% and reduces inspection time by 70% compared to conventional individual inspection methods, thereby simultaneously enhancing productivity and quality.

[0120] Products that pass inspection undergo next-generation outer packaging at the outer packaging stage (S100), utilizing a blockchain-based smart traceability system. This outer packaging goes beyond conventional simple packaging materials to IoT-linked smart packaging, an innovative system that tracks and manages the entire process from product production to consumption in real time.

[0121] The outer packaging uses an eco-friendly composite material composed of 70% biodegradable PLA (Polylactic Acid) and 30% recycled pulp. PLA is a bioplastic extracted from corn starch that biodegrades by more than 90% within six months when landfilled, and the recycled pulp is produced from sustainable wood certified by the Forest Stewardship Council (FSC). A nanocellulose coating is applied to the surface of the packaging to enhance water resistance and durability while maintaining biodegradability.

[0122] The NFC tag uses the Type 2 standard in the 13.56MHz frequency band and features a 96-bit UID (Unique Identifier) ​​and an 8KB data storage capacity. The NFC chip is combined with a silver nano-ink antenna printed on a flexible PET substrate to create an ultra-thin design with a thickness of 0.1mm, and is completely enclosed within the packaging via lamination to protect it from external shocks and moisture. The reading distance is 5cm, and the data transmission speed is 424kbps, allowing all information to be transmitted within 0.1 seconds.

[0123] The QR code utilizes a micro QR code capable of high-density information storage, storing up to 4,296 alphanumeric characters within an 11x11mm size. It is directly engraved onto packaging materials using a laser etching method, ensuring permanent identification without smudging or peeling. The QR code features an error correction level H (30% recoverability), allowing information to be read even with partial damage, and is easily recognized by smartphone cameras due to its high-contrast black-and-white pattern.

[0124] The blockchain system is built on the Hyperledger Fabric platform, where all product history information is encrypted and distributed for storage. Each product possesses a unique digital passport, and over 120 data points—including raw material supplier information, manufacturing process data, quality inspection results, distribution channels, and storage temperature history—are recorded in real time. The blockchain network operates as a consortium involving manufacturers, distributors, retailers, and certification bodies, and automated verification and approval are carried out through smart contracts.

[0125] The manufacturing date is recorded in the ISO 8601 standard format (YYYY-MM-DD HH:MM:SS) and can be accurately traced down to the time of manufacture. The shelf life is set to 18 months from the manufacturing date, but it is dynamically adjusted by monitoring the actual storage environment via IoT sensors. The batch number is generated as a 16-digit alphanumeric combination, where the first four digits represent the year and month of manufacture, the middle four digits represent the production line identification code, and the last eight digits represent the serial number.

[0126] Smart labels equipped with built-in IoT sensors are applied to select products to monitor temperature, humidity, shock, and UV exposure in real time. The sensors feature an ultra-low power design that maintains a battery life of three years and automatically transmit data four times a day via LoRaWAN communication. If the temperature exceeds 25°C or humidity surpasses 70%, an alarm is automatically triggered, and distributors and retailers are immediately notified.

[0127] The packaging features a holographic security label to provide anti-counterfeiting capabilities. The hologram has a three-stage security function (visual inspection -> UV light inspection -> microscope inspection), and a different pattern appears at each stage, making it easy to identify counterfeit products. Additionally, a Tamper Evident function is applied so that the word 'OPENED' appears once the packaging is opened, preventing repackaging.

[0128] Consumers can check the entire history of a product by scanning NFC tags or QR codes via a smartphone app. The app provides information such as the origin of ingredients, videos of the manufacturing process, nutritional analysis results, storage methods, recommended daily intake, and allergy information, and also offers personalized consultation services through an AI chatbot. Additionally, a personalized recommendation system is activated when feedback on the product's effects is entered after consumption.

[0129] In the event of a quality issue, a blockchain-based automated recall system is activated. It identifies the location of all products in the affected batch in real time and automatically sends SMS and push notifications to consumers who purchased the products. The accuracy of tracking the location of recalled products is over 99.8%, and the time required to notify recalls is reduced by 95% compared to the existing system, averaging within 15 minutes.

[0130] For data security, we apply AES-256 encryption and RSA-2048 digital signatures, and fully comply with the General Data Protection Regulation (GDPR) and personal information protection laws. All personal information is anonymized and stored, and is never provided to third parties without user consent.

[0131] Through this smart traceability system, complete product tracking is possible, 100% supply chain transparency has been secured, and consumer trust has been improved by 45%. It also enables the eradication of counterfeit goods and rapid quality response.

[0133] Finally, the product is managed in an optimized storage environment through an AI-based smart warehouse management system during the storage stage (S110). The storage facility is designed as a fully automated smart warehouse based on Industry 4.0 standards, and temperature and humidity control, inventory management, and a First-In, First-Out (FIFO) system are operated in an integrated manner.

[0134] The temperature management system employs a multi-zone control method to subdivide the warehouse into 50 zones, operating an independent constant temperature system in each zone. The standard temperature is set to 22°C ±2°C, and a triple safety mechanism operates to ensure that the maximum allowable temperature of 28°C is never exceeded. The first safety mechanism increases the cooling system output to 150% upon reaching 25°C, the second safety mechanism automatically activates the emergency cooling system upon reaching 27°C, and the third safety mechanism isolates the zone and automatically transfers the product to a safe zone when 28°C is imminent. If the temperature exceeds 28°C, the Form V crystal structure of the chocolate coating layer becomes unstable, causing blooming and grayish-white stains on the surface of the coating layer, which significantly damages the product's appearance. Furthermore, the crisp texture softens, resulting in the loss of the product's inherent crunchiness.

[0135] Humidity is managed at a relative humidity of 45% ± 5% through a precision dehumidification system. The dehumidifier utilizes both adsorption and condensation methods to maintain constant humidity regardless of external weather changes, while humidity sensors installed in each zone collect data every minute to adjust the dehumidification level in real time. If humidity exceeds 60%, moisture penetrates the packaging, leading to a loss of product crispness and an increased risk of microbial growth, which may shorten the shelf life. Furthermore, excessive humidity affects the functionality of blockchain tags and IoT sensors, undermining the reliability of the traceability management system.

[0136] The lighting system uses UV-blocking LEDs to limit ultraviolet emissions to 5μW / cm² or less. The LEDs use white light with a color temperature of 3000K, and illuminance is applied differentially, with 500 lux in the work zone and 100 lux in the storage zone. Infrared-blocking film is attached to the exterior walls of the warehouse to block direct sunlight, and solar transmittance is limited to 5% or less. Exposure to ultraviolet and infrared rays accelerates the deterioration of packaging materials and speeds up the breakdown of vitamins and antioxidants in products, thereby reducing nutritional value.

[0137] The smart warehouse system achieved complete unmanned automation by operating 50 Automated Guided Vehicles (AGVs) and 20 Vertical Lift Modules (VLMs). The AGVs drive autonomously using Simultaneous Localization and Mapping (SLAM) technology based on LiDAR and cameras, and can process 200 pallets per hour with a maximum load capacity of 500 kg. It implemented a perfect First-In, First-Out (FIFO) system that automatically reads blockchain information upon product inbound to have AI calculate and place items in the optimal storage locations, and automatically sorts products starting with the oldest manufacturing date upon outbound shipment.

[0138] Inventory management is carried out through an RFID-based real-time tracking system. UHF RFID tags (900MHz) attached to each pallet can be read from a distance of 10 meters, and 200 RFID readers installed on the warehouse ceiling monitor the location and status of all products in real time. Inventory accuracy is maintained at over 99.9%, and appropriate inventory levels are automatically maintained through an inventory shortage prediction system.

[0139] In the delivery stage (S120), a next-generation cold chain logistics system is applied. The transport vehicle is equipped with an independent three-compartment refrigeration system, and the temperature can be controlled separately for each compartment. The compartment dedicated to the product is set to 15℃±2℃, which is a temperature that optimizes energy efficiency while maintaining product quality. The vehicle is equipped with a temperature and humidity data logger along with a GPS tracker to record environmental conditions throughout the delivery process at one-minute intervals.

[0140] The IoT-based real-time monitoring system transmits the vehicle's location, temperature, humidity, vibration, and opening / closing status to headquarters and customers in real time via a 5G network. If the temperature exceeds the acceptable range, an alarm is automatically triggered, and the driver and logistics control center are immediately notified. Furthermore, delivery times have been reduced by 25% by calculating the optimal delivery route in real time, taking into account traffic conditions and weather through AI predictive analysis.

[0141] In the final delivery stage, a drone delivery system is introduced to realize rapid delivery in urban areas. The drone can carry a payload of 5kg and can deliver within 30 minutes within a radius of 20km. Equipped with a small refrigerator, the drone maintains a temperature of 15℃ during delivery and safely delivers products to designated locations through precise landing using GPS and cameras.

[0142] To ensure quality, a product status check notification is sent to the customer's smartphone within 24 hours of delivery completion. When the customer scans the NFC tag, the temperature history during delivery, vibration levels, and estimated quality index are displayed, and delivery services are continuously improved through satisfaction surveys. Through this integrated logistics system, the product damage rate has been reduced to less than 0.05%, and customer satisfaction has been improved to 92%.

[0143] In addition, to realize carbon-neutral logistics, we use electric trucks and biofuels, and have reduced CO2 emissions by 40% through delivery route optimization. This is an innovative model that achieves both environmental protection and economic efficiency simultaneously by establishing a sustainable logistics system as part of ESG management.

[0144] The above detailed description is illustrative of the present invention. Furthermore, the foregoing describes preferred embodiments of the present invention, and the present invention may be used in various other combinations, modifications, and environments. That is, modifications or alterations are possible within the scope of the concept of the invention disclosed herein, the scope equivalent to the disclosed content, and / or the scope of the art or knowledge. The described embodiments describe the best state for implementing the technical concept of the present invention, and various modifications required for specific fields of application and uses of the present invention are possible. Accordingly, the above detailed description of the invention is not intended to limit the present invention to the disclosed embodiments. Additionally, the appended claims should be interpreted as including other embodiments. Explanation of the symbols

[0146] S10: Material preparation step S15: Chocolate preparation stage S20: Mixing step S30: Protein ball molding step S40: Bar forming step S50: Bar cutting stage S60: Coating layer formation step S70: Cooling stage S80: Inner packaging stage S90: Metal detection step S100: Outer packaging stage S110: Save step S120: Shipping stage

Claims

Claim 1 delete Claim 2 delete Claim 3 delete Claim 4 delete Claim 5 delete Claim 6 delete Claim 7 delete Claim 8 delete Claim 9 delete Claim 10 A) a step of manufacturing a plurality of protein balls by mixing plant-based protein, dietary fiber, low-sugar components, and auxiliary materials; B) a step of combining the plurality of protein balls into a bar shape by compressing or molding them; C) a step of cutting the bar into a predetermined size; D) a step of melting and tempering chocolate; E) a step of forming a bottom low-sugar coating layer on the bottom of the bar using the tempered chocolate; F) a step of forming an top low-sugar coating layer on the top of the bar using the tempered chocolate; G) a step of cooling the bar coated with the bottom low-sugar coating layer and the top low-sugar coating layer; H) a step of inner-packaging the bar into individual units; I) a step of inspecting the inner-packaged product with a metal detector; and J) a step of outer packaging the product, wherein step D) melts the chocolate at 45°C to 55°C and tempers it at 25°C to 30°C, and in step A), the mixture comprises 30 to 50 parts by weight of the vegetable protein, 1 to 10 parts by weight of the dietary fiber, 5 to 15 parts by weight of the low-sugar component, and 0.5 to 10 parts by weight of the auxiliary ingredient. A method for manufacturing a protein bar. Claim 11 delete Claim 12 In claim 10, the method of cutting the bar in step C) above is a manufacturing method of cutting it to a certain length using multiple knives. Claim 13 In claim 10, the above step G) is a manufacturing method of cooling under conditions of 0℃ to 10℃. Claim 14 A manufacturing method according to claim 10, wherein in step H) above, the inner packaging uses a multilayer film comprising a moisture barrier layer or an oxygen barrier layer. Claim 15 A manufacturing method according to claim 10, wherein in step I) above, the metal detector can detect foreign substances of Fe 1.5 mm or larger and stainless steel 2.0 mm or larger, and simultaneously includes a function to determine the weight and shape of the product. Claim 16 In claim 10, the manufacturing method in step J) above uses an outer packaging material with an NFC tag or QR code inserted that allows for product unit identification. Claim 17 A manufacturing method according to claim 10, further comprising the step of storing the product under conditions of 28℃ or lower after the outer packaging step. Claim 18 delete

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