A synergistic formulation, snack bar made therefrom and a process of making the same

Abstract

The present invention discloses a formulation and process for making snack bars having high organoleptic properties, long shelf life, offer enriched nutrients and help in eliminating easily perishable snack bars with high moisture content and low nutrient content, typically associated with currently available snack bars The present invention relates to a novel formulation comprising of natural ingredients with enriched nutrient, binding and flavoring components devoid of any added colors or preservatives; a snack bar made using said formulation and a process of making the same.

Description

[0001] A SYNERGISTIC FORMULATION, SNACK BAR MADE THEREFROM AND A PROCESS OF MAKING THE SAME

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY

[0003]

[0001] The present application does not claim priority from any patent application.

[0004] THE FIELD OF THE INVENTION

[0005]

[0002] The present invention relates to a formulation, ready to eat snack bars made therefrom and the process of making the same. Particularly, the invention relates to a ready to eat snack bar offering a nutritional product with desired taste and improved structure retention and shelflife and a process of making the same.

[0006] THE BACKGROUND OF THE INVENTION

[0007]

[0003] The food industry is ever-evolving, currently the fast-pace life of majority individuals demand a time effective yet nutritious solution. This demand has emphasized on the need for Snack bars which are potential functional foods containing a diverse group of ingredients that are rich in many nutrients. Their physical form offers a ready-to-eat solution making snack bars portable, versatile and convenient. Given their features, snack bars can be consumed “on-the-go” while traveling, and can nutritiously supplement traditional meals. Various combinations of food ingredients have been used by researchers to develop special bars intended for consumption by space crew, sportspersons, military personnel, trekkers, gym-goers, etc. However, all presently available bars come with a shortcoming of being high in sweetness as a result of the binders currently used by bars available in the market presently, as seen in US patent number US2017245539A1 which claims up to 70% by weight of a sweetener. Given the high intensity of sugar levels, the compensating nutrient levels fall rather low making the whole bar high on “empty calories” and thus low on the overall nutrient ratio.

[0008]

[0004] Efforts have been made to make food having calculated nutrients necessary for the consumer. Further, currently available snack bars which aim at reducing sugar content seldom offer a long shelf life, making the “healthy” snack bars challenging for exports, leaving the sole option to use ingredients focused on nuts and seeds. However, majority of Indian snacks demand a savoury taste and are high on ingredients such as rice puffs, gram flour / chickpea flour such as ‘bhel’, such ingredients unlike nuts and seeds fail to remain crisp and brittle upon coating without prior frying or such other fat based pre-treatments to prevent moisture from the binders to make the product soggy. Some attempts were made as seen in patent IN241409 to reduce the moisture content by heating to a high temperature, but this resulted in extremely brittle texture making the products unfit for export, the high temperatures also denatured the proteins and caused loss of nutrients leaving moisture reduction by heating an unviable option. Therefore, for Indian snacks to be offered in the Ready-To-Eat convenience food category and to offer a healthy snack bar to enable use in extreme conditions such as army camps, use in travel, through export routes etc. where the ideal use of a snack bar are applicable and demand a long shelflife, there needs to be an invention which overcomes the present challenges to meet the demands of health, improved shelflife, taste especially savoury, and structure retention.

[0009]

[0005] Therefore, there is a need for a ready-to-eat snack bar which can eliminate at least the above shortcomings. Unconventional processes are required to offer solutions beyond the presently available snack bars. Noting the demand of said snack bars and the importance of nutrients and taste in one’s diet, efforts to invent a solution to overcome at least one of the problems stated above has been presented here below.

[0010] SUMMARY OF THE INVENTION

[0011]

[0006] Before the present disclosure for a formulation, product made using said formulation and process of making said product is described, it is to be understood that this application is not limited to the particular formulation, product and process described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the present application. This summary is not intended to identify essential features of the invention nor is it intended for use in determining or limiting the scope of the subject matter.

[0012]

[0007] An aspect of the present invention relates to a formulation for making a ready-to-eat snack bar capable of encompassing nutrients into the form of a ‘bar’ .

[0013]

[0008] Another aspect of the present invention relates to a formulation for making a ready-to-eat snack bar having a long shelf life;

[0014]

[0009] Yet another aspect of the present invention relates to a snack bar and a process to make said snack bar having low moisture content.

[0015]

[0010] Yet another aspect of the present invention relates to a formulation containing a binding agent being a naturally derived component free of additives preferably being rice flour, caramel, jaggery or sugar syrup.

[0016]

[0011] Yet another aspect of the present invention relates to a formulation capable of encompassing nutrients into a bar form having desirable structure retention, texture and taste.

[0012] Yet another aspect of the present invention relates to a formulation having high organoleptic properties, particularly a savory taste.

[0017]

[0013] Yet another aspect of the present invention relates to a formulation having high organoleptic properties while being devoid of any added colors, preservatives or additives.

[0018]

[0014] Yet another aspect of the present invention relates to a formulation and snack bar having enriched nutrient content.

[0019]

[0015] Yet another aspect of the present invention relates to a process of making a snack bar while employing the formulation of the present invention.

[0020]

[0016] Yet another aspect of the present invention relates to a process of making a snack bar capable of encompassing nutrients in a manner that they are protected from premature denaturing and deterioration due to moisture and heat.

[0021] BRIEF DESCRIPTION OF DRAWINGS

[0022]

[0017] Figure 1: Figure 1 illustrates flow chart showing a step-wise process of making a snack bar in accordance with an embodiment of the present invention.

[0023]

[0018] Figure 2: Figure 2 illustrates images of two snack bars made using the formulation of the present invention bar in accordance with an embodiment of the present invention.

[0024] DETAILED DESCRIPTION OF INVENTION

[0025]

[0019] Some embodiments of the present disclosure, illustrating all its features, will now be discussed in detail. It must also be noted that as used herein and in the appended claims, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure for a formulation, product made therefrom and processes for making the product is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.

[0026]

[0020] Various embodiments of the present invention relate to a synergistic nutritional snack bar formulation, snack bar made therefrom and process of making said snack bar.

[0027]

[0021] In an embodiment of the present invention a formulation capable of encompassing nutrients within the snack bar is disclosed, wherein the nutrients are encompassed such that they are protected from factors such as heat, moisture, etc.

[0028]

[0022] The formulation of the present invention comprises of at least the following components: i. Nutrient component; ii. Binding component;

[0029] iii. Flavouring component.

[0030] Wherein the flavouring component may include digestion aids (including carminative, stomachic, aromatic, Appetizers), Gastro-Protective components etc.

[0031]

[0023] In a preferred embodiment the synergistic nutritional snack bar formulation comprises of:

[0032] i. Nutrient component containing;

[0033] a. Carbohydrate source, present in the range of 65-75 g / 100 g;

[0034] b. Protein / amino-acid source, present in the range of 10-13 g / 100 g;

[0035] c. Lipid source, where the lipid contains PUFA and MUFA present in the range of 4- 7 g / 100g;

[0036] d. Fiber source, present in the range of 3-20 g / 100 g;

[0037] ii. Binding component contributing to total sugar content in the range of 14-20 % w / v of the formulation and moisture content which is later controlled by the baking process to <5 % w / v of the formulation;

[0038] iii. Natural flavouring component, capable of offering digestion aids being carminative, stomachic, aromatic, Appetizers, or Gastro-Protective components.

[0039] wherein the binding component maintains cohesion of all components and contributes to moisture levels which is later controlled by the baking process below 5% w / v, essential to maintaining structural stability during transport and extended shelf life of the other components without addition of artificial preservatives and despite low sugar content and wherein the flavouring components offer digestive aid in digestion of the other components.

[0040]

[0024] In an embodiment, the sugar content source is selected between sugar syrup made by mixing sugar with water and heating it at 90-100 °C for 30 min; or caramel sauce made by melting sugar at 90-100 °C, followed by adding fixed proportions of butter, milk, salt and water and cooking for 2-3 minutes.

[0041]

[0025] In a preferred embodiment the ingredients of a single snack bar formulation comprise of: i. Nutrient component including

[0042] a. Carbohydrate source selected from a group of cereals, preferably, puffed rice, oats, millets, or such other source that may be industrially acceptable;

[0043] b. Protein / amino-acid source selected from a group of pulses, preferably chickpea flour, dry fruits, sunflower / pumpkin seeds, or such other source that may be industrially acceptable;

[0044] c. Lipid source selected from a group of oils preferably, groundnut oil, butter, or such other source that may be industrially acceptable; ii. Binding components being rice flour, caramel, sugar syrup, jaggery, or a combination thereof; and

[0045] iii. Flavoring components selected from a group of spices preferably asafoetida, turmeric, curry leaves etc., and natural flavorants preferably, tamarind extract, coriander extract, lemon powder, salt, etc.

[0046] wherein the cereals are puffed rice; pulses are chickpea flour; millets are ragi, jowar, or both; dry fruits are almonds, cashews, or both; super foods are sunflower seeds, pumpkin seeds, or both; spices are asafoetida, turmeric, curry leaves, or a combination thereof; natural flavorants are tamarind extract, coriander leaves, lemon powder, or a combination thereof; and binders are sugar syrup, jaggery, rice flour, caramel, tamarind extract, lemon powder, or a combination thereof.

[0047]

[0026] In an additional embodiment the nutrient component includes

[0048] a. Carbohydrate source selected from a group of cereals, preferably, puffed rice, oats, millets, or such other source that may be industrially acceptable;

[0049] b. Protein / amino-acid source selected from a group of pulses, preferably chickpea flour, dry fruits, sunflower / pumpkin seeds, or such other source that may be industrially acceptable; c. Lipid source selected from a group of oils preferably, groundnut oil, butter, or such other source that may be industrially acceptable;

[0050] d. Vitamins sources being 0.170-0.185 mg / 100 g of Thiamine (Bl), 0.5 - 0.65 mg / 100 g of D- pantothenic acid (B5), 0.15-0.2 mg / 100 g of Niacin (B3), 0.6-0.7 mg / lOOg of Vitamin E, or a combination thereof; and

[0051] e. minerals sources, particularly 55 — 135 mg / lOOg of Calcium, 1.5 — 6 mg / lOOg of Iron, 150-155 mg / 100 g of Magnesium, or a combination thereof.

[0052]

[0027] In yet another embodiment of the present invention a process of making snack bar formulation of the present invention is disclosed. Referring to Figure 1, Said process comprises the following steps:

[0053] i. weighing all the ingredients as per the batch size (101).

[0054] ii. roasting the dry ingredients at 180-190 °C for 2-3 min, ensuring the ingredients are low on moisture to increase shelf life yet, not too brittle to retain their structure through transportation this step removes excess moisture and therefore provides a desirable crunchy / brittle texture to the final product (102).

[0055] iii. adding the roasted dry ingredients followed by uniform mixing of the other dry ingredients to form the bar mixture (103), simultaneously carrying out the preparation of sweetener component required for making the binder (105);

[0056] iv. mixing water, sweetener component and optionally a carrier to add a viscous texture, and heating the mixture to make the binder (106) v. Mixing the binder and bar mixture for about a minute to form the final mixture (107); vi. Bar forming- molding the bars immediately post mixing, in its preset dimensions measuring 80 L X 40 W X 15 H in mm (108);

[0057] vii. Baking the bars at 100 °C for 30 - 35 min; this is a critical step in the entire process that provides the desirable texture, color, flavor and shelf stability (109);

[0058] viii. Cooling the bars to attain 28 - 30 °C, yet another critical step contributing to the texture and shelf stability of the final product (110);

[0059] Wherein the baking time and temperature bring down the moisture levels below 5% w / v of the formulation and the moulded bar retain the moisture levels once reduced, essential to maintaining structural stability during transport and extended shelf life of the snack bar up to nine months.

[0060]

[0028] In an embodiment of the present invention, the dry ingredients are selected from cereals, pulses, oats, millets, dry fruits, super foods, cranberries, groundnut oil, spices, natural flavourants, binders, protein concentrate, salt and wherein the step of adding dry ingredients involves roasting and also optionally involves heating oil at 160-170 °C for tempering of the spices, adding the roasted dry ingredients and other ingredients (104) followed by uniform mixing of the mixture to form the bar mixture.

[0061]

[0029] In another embodiment, the binder making step involves either of the two options:

[0062] i) For sweet tasting snack bars where the sweetener is caramel sauce, addition of rice flour as carrier and caramel sauce as sweetener component, combining them and cooking the combination at 75-80 °C for 10 mins to attain a viscous binder; ii) Preferably for savoury tasting snack bars where the sweetener is sugar syrup, the binder is made by heating the syrup at 90-95 °C, for 8-10 minutes

[0063] wherein the binder additionally contains rice flour, tamarind extract, lemon powder, or a combination thereof to reduce the sweetener component to a total sugar level in the snack bar formulation to 14%-20%w / v.

[0064]

[0030] Referring to Figure 2, a nutritional snack bar made as per the present invention, wherein the formulation is moulded into a bar shape measuring 80 L X 40 W X 15 H in mm thereby maintaining moisture content of <5%w / v, retaining structural stability and extending shelf life up to nine months.

[0065]

[0031] In yet another embodiment of the present invention a process of making a snack bar employing the formulation of the present invention is disclosed. Said process including the following steps:

[0066] i. Weighing all the ingredients as per the batch size. ii. Roasting the oats, sunflower seeds and pumpkin seeds at 90-100 °C for 3-4 min. This process assists in removal of moisture and therefore provides a desirable crunchy texture to the final product.

[0067] iii. Preparation of the bar mixture by adding the dry ingredients together followed by uniform mixing.

[0068] iv. Simultaneously carrying out the preparation of sugar syrup by mixing sugar with water and heating it at 90-100 °C for 30 min.

[0069] v. Binder making- adding rice flour to the sugar syrup and heating the mix at 90-95 °C. vi. Mixing the binder and bar mixture for about a minute.

[0070] vii. Bar forming- molding the bars immediately post mixing, in its preset dimensions. viii. Baking the bars at 100 °C for 30 min; this is a critical step in the entire process that provides the desirable texture, color, flavor and shelf stability.

[0071] ix. Cooling the bars to attain 28 - 30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0072] x. Packing- This involves primary packaging in suitable laminates, secondary packaging in cartons and tertiary packaging in master cartons.

[0073]

[0032] In yet another embodiment of the present invention a process of making a snack bar employing the formulation of the present invention is disclosed. Said process including the following steps:

[0074] i. Weighing all the ingredients as per the batch size.

[0075] ii. Roasting the oats, sunflower seeds and pumpkin seeds at 90-100 °C for 3-4 min. This process assists in removal of moisture and therefore provides a desirable crunchy texture to the final product.

[0076] iii. Preparation of the bar mixture by adding the dry ingredients together followed by uniform mixing.

[0077] iv. Simultaneously carrying out the preparation of caramel sauce by adding sugar and melting it at 90-100 °C. Once completely melted, fixed proportions of butter, milk, salt and water is added. This sauce is cooked for 2-3 mins.

[0078] v. Binder making- addition of rice flour to the caramel sauce and cooking it at 75-80 °C for 10 mins to attain a viscous binder.

[0079] vi. Mixing the binder and bar mixture for about a minute.

[0080] vii. Bar forming- molding the bars immediately post mixing, in its preset dimensions. viii. Baking the bars at 100 °C for 30 min; this is a critical step in the entire process that provides the desirable texture, color, flavor and shelf stability. ix. Cooling the bars to attain 28 - 30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0081] x. Packing- This involves primary packaging in suitable laminates, secondary packaging in cartons and tertiary packaging in master cartons.

[0082]

[0033] In yet another embodiment of the present invention a process of making a snack bar employing the formulation of the present invention is disclosed. Said process including the following steps:

[0083] i. Weighing all the ingredients as per the batch size.

[0084] ii. Roasting the oats and millet puffs (ragi and jowar) at 150-160 °C for 3-4 min. This process assists in removal of moisture and therefore provides a desirable crunchy texture to the final product.

[0085] iii. Preparation of the bar mixture by adding the dry ingredients together followed by uniform mixing.

[0086] iv. Simultaneously carrying out the preparation of caramel sauce by adding sugar and melting it at 90-100 °C. Once completely melted, fixed proportions of butter, milk, salt and water is added. This sauce is cooked for 2-3 mins.

[0087] v. Binder making- addition of rice flour to the caramel sauce and cooking it at 75-80 °C for 10 mins to attain a viscous binder.

[0088] vi. Mixing the binder and bar mixture for about a minute.

[0089] vii. Bar forming- molding the bars immediately post mixing, in its preset dimensions. viii. Baking the bars at 100 °C for 30 min; this is a critical step in the entire process that provides the desirable texture, color, flavor and shelf stability.

[0090] ix. Cooling the bars to attain 28 - 30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0091] x. Packing- This involves primary packaging in suitable laminates, secondary packaging in cartons and tertiary packaging in master cartons.

[0092]

[0034] In an embodiment, the process of making the binder involves either one of the below steps: 1. Mixing sugar with water and heating it at 90-100 °C for 30 min. Further, adding rice flour to the sugar syrup and heating the mix at 90-95 °C until it reaches to 75-80 °C; or

[0093] 2. Adding sugar and melting it at 90-100 °C. Once completely melted, pre-measured proportions of butter, milk, salt and water is added. This binder is cooked for 2-3 mins followed by addition of rice flour and cooking at 75-80 °C for 10 mins to attain a viscous binder.

[0094]

[0035] In an embodiment of the present invention, the oats, millet puffs, sunflower seeds and pumpkin seeds are roasted for removal of excess moisture and for providing a desirable aroma and texture. This is a critical step as; improper roasting may lead to moisture retention that can cause sogginess in the final product and also influence its shelf stability. The consistency of the developed natural binder is maintained by judiciously monitoring the heating temperature and brix of the solution.

[0095]

[0036] In another embodiment of the present invention, the bar mixture is prepared by optimizing precise proportions of dry ingredients to develop a bar with acceptable flavor, taste and texture, the mixing proportions of the binder and bar mixture is optimized. The optimized proportion enables uniform coating of the binder to the bar mixture providing a desirable taste, structure and crunchy texture to the bar, the optimized baking and cooling temperatures governs the final moisture % of the bar directly influencing the texture and shelf stability of the product.

[0096]

[0037] In an embodiment, the consistency of the developed natural binder i.e. sugar syrup, rice flour, caramel, jaggery, or a combination thereof is maintained by judiciously monitoring the heating temperature and brix of the solution.

[0097]

[0038] In an embodiment of the present invention, the optimized pre-processing of the ingredients and sequence of ingredient addition ensures a product with desirable structure, texture and shelf life. It also ensures a moisture level as low as <5 % in the snack bar.

[0098]

[0039] In another embodiment of the present invention, optimized proportion of binder and bar mixture ensures a product with desirable structure, texture and shelf life.

[0099]

[0040] In another aspect of the process, the bar mixture is prepared by optimizing precise proportions of dry ingredients to develop a bar with acceptable flavor, taste and texture.

[0100]

[0041] In yet another aspect, the dry ingredients are roasted to maintain the moisture and for providing a desirable aroma, shelflife and texture. This is a critical step as; improper roasting may lead to moisture retention that can cause sogginess in the final product and also influence its shelf stability.

[0101]

[0042] In a further aspect of the process, the mixing proportions of the binder and bar mixture is optimized. The optimized proportion enables uniform coating of the binder to the bar mixture providing a desirable taste, structure and crunchy texture to the bar.

[0102]

[0043] In an even further aspect of the process, the optimized baking and cooling temperatures governs the final moisture % of the bar directly influencing the texture and shelf stability of the product.

[0103]

[0044] EXAMPLES

[0104]

[0045] EXAMPLE 1 with reference to Figure 1.

[0105]

[0046] All the ingredients as per the batch size were weighed as per Table: 1.

[0106]

[0047] Part I - Preparing Binder

[0048] The preparation of caramel sauce was carried out in a cook wok by adding sugar and melting it at 90-100 °C. Once completely melted, fixed proportions of butter, milk, salt and water is added. This sauce was cooked for 2-3 mins. Simultaneously bar mixture was prepared by adding the dry ingredients together in a cook wok followed by uniform mixing.

[0107]

[0049] Binder making- rice flour was added to the caramel sauce in a cook wok and cooked at 75-80 °C for 10 mins to attain a viscous binder.

[0108]

[0050] Part II- Pre-Processing dry ingredients

[0109]

[0051] oats, peanuts, sunflower seeds and pumpkin seeds were roasted at 90-100 °C for 3-4 mins for the removal of moisture and to provide a desirable aroma and texture. Sequence of ingredient addition dictates the final taste and texture of the product.

[0110]

[0052] Part III- bar formation

[0111]

[0053] The dry ingredients and binder thus formed were mixed for 1 min in a ratio comprising ~ 60 % of the dry base and ~ 40 % of binder. This ratio of dry ingredients to binder optimized uniform coating of the binder to the bar mixture providing a desirable taste especially to maintain a low sweetness quotient, structure and crunchy texture to the bar.

[0112]

[0054] The bars were moulded into dimensions (80 LX40WX 15 Hin mm) using pre-set moulds

[0055] Part IV- Baking

[0113]

[0056] The bars were baked at 100 °C for 30 min- this is a critical step in the entire process that provides the desirable texture, color, flavor and shelf stability. It ensures a moisture content of < 5 % leading to a shelf stable snack bar.

[0114]

[0057] Finally, the bars were cooled to attain the product temperature at 28-30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0115]

[0058] The formulation considered for the bar made as per above was as follows:

[0116]

[0117]

[0118] (Table: 1)

[0119]

[0059] EXAMPLE 2

[0120]

[0060] All the ingredients as per the batch size were weighed as per Table:2, Table:3 and Table:4 below to prepare three different flavoured bars. For preparing each bar the following steps were performed using the ingredients as disclosed in the Table:2, Table:3 and Table:4 below.

[0121]

[0061] Part I - Preparing Binder

[0122]

[0062] Sugar was mixed with water and heated at 90-100 °C for 30 min.

[0123] Rice flour was added to the sugar syrup and heated the mixture at 90-95 °C for 8-10 min.

[0124]

[0063] Part II- Pre-Processing dry ingredients

[0125] Puffed rice was roasted at 180-190 °C for 2-3 min in a cook wok for the removal of moisture and to provide a desirable aroma and texture. However, when preparing the lemon bhel bars, first oil was heated at 160-170 °C, to which the roasted dry ingredients were added and other ingredients followed by uniform mixing of the mixture to form the bar mixture. Sequence of ingredient addition dictates the final taste and texture of the product. In case of oats dry fruits snack bars, the oats and dry fruits are roasted at 90-100 °C for 3-4 min.

[0126]

[0064] Part III- bar formation

[0127]

[0065] Binder making- mixed water, sugar syrup and jaggery in a cook wok, heated the syrup at 90-95 °C. Subsequently, mixed the puffed rice along with other ingredients in a cook wok for the preparation of bar mixture. The binder and bar mixture were mixed for about 1 minute.

[0128]

[0066] Bar forming- bars were formed and moulded in the bar forming machine, immediately post mixing in its preset dimensions of 80 L X 40 W X 15 H in mm

[0129] This ratio of dry ingredients to binder optimized uniform coating of the binder to the bar mixture providing a desirable taste especially to maintain a low sweetness quotient, structure and crunchy texture to the bar.

[0067] Part IV- Baking

[0130]

[0068] The bars were baked at 100 °C for 30 min- this is a critical step in the entire process that provides the desirable texture, colour, flavour and shelf stability. It ensures a moisture content of < 5 % leading to a shelf stable snack bar.

[0131]

[0069] Finally the bars were cooled to attain the product temperature at 28-30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0132] The formulations considered for the bars made as per above was as follows:

[0133]

[0134] (Table :2)

[0135]

[0136]

[0137] (Table:3)

[0138]

[0139]

[0140] (Table :4)

[0141]

[0070] EXAMPLE 3

[0142] All the ingredients as per the batch size were weighed as per Table:5 below.

[0143]

[0071] Part I - Preparing Binder

[0144]

[0072] The preparation of caramel sauce was carried out in a cook wok by adding sugar and melting it at 90-100 °C. Once completely melted, fixed proportions of butter, milk, salt and water is added. This sauce was cooked for 2-3 mins. Rice flour was added to the caramel sauce in a cook wok and cooked at 75-80 °C for 10 mins to attain a viscous binder

[0145]

[0073] Part II- Pre-Processing dry ingredients

[0146] Millet puffs were roasted at 150-160 °C for 3-4 mins for the removal of moisture and to provide a desirable aroma and texture.

[0147]

[0074] Part III- bar formation

[0148] Simultaneously bar mixture was prepared by adding the dry ingredients together in a cook wok followed by uniform mixing.

[0149] The dry ingredients and binder thus formed were mixed for 1 min in a ratio comprising ~ 60 % of the dry base and ~ 40 % of binder. This ratio of dry ingredients to binder optimized uniform coating of the binder to the bar mixture providing a desirable taste especially to maintain a low sweetness quotient, structure and crunchy texture to the bar.

[0150] The bars were moulded into dimensions (80 L X40 W X 15 H in mm) using pre-set moulds

[0075] Part IV- Baking

[0151] The bars were baked at 100 °C for 30 min- this is a critical step in the entire process that provides the desirable texture, colour, flavour and shelf stability. It ensures a moisture content of < 5 % leading to a shelf stable snack bar.

[0152]

[0076] Finally, the bars were cooled to attain the product temperature at 28-30 °C. This is another critical step dictating the texture and shelf stability of the product.

[0153] The formulation considered for the bar made as per above was as follows(Table:5):

[0154]

[0155]

[0156] (Table: 5)

[0157]

[0077] EXPERIMENTAL DATA

[0158]

[0078] I) Experimental analysis

[0159] Following are the analytical parameters of the products made using the present invention, evaluated to understand its physical properties such as moisture, and dimensions were measured. Other tests were performed as per industrial standards to examine chemical, microbial and sensory properties. Results were seen as shown in the Table: 6, Table:7 and Table:8 below:

[0160]

[0079] II) Results

[0161] Following are the results of the products made using the present invention

[0162] 1. Physical properties

[0163]

[0164]

[0165] Chemical properties

[0166]

[0167]

[0168] (Table:7)

[0169]

[0080] Overall, the savory and sweet snack bars comprise of total carbohydrates (60-75 g / lOOg), protein (10-14 g / lOOg), total fats (15-21 g / lOOg), MUFA (6-7.5 g / lOOg), PUFA (1-7.5 g / lOOg) and dietary fiber (3-22.5 g / lOOg) that contributes for the energy (415-470 Kcal / lOOg). Cholesterol is present in very trivial concentrations (11-15 mg / lOOg) only in the Oats caramel and Millet protein caramel bars respectively. 3. Microbial safety

[0170] < < < <

[0171] < < < <

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[0174] < < < <

[0175]

[0176] (Table: 8)

[0177]

[0081] The savory and sweet bars were shelf stable up to 9 months with very low microbial counts except for Oats and dry fruits bar that was stable up to 3 months 5 from the date of manufacture.

[0178]

[0082] UTILITY

[0179]

[0083] The following utility features are non -limiting and non-exhaustive in nature. The below mentioned list is merely for a better understanding of the invention disclosed in the present document.

[0180] 10 a) The formulation is aimed at having a long shelf life, enriched nutritional value and high organoleptic properties, especially offering low sweetness quotient despite adding sweet binders.

[0181] b) The formulation of the present invention is devoid of preservatives and artificial colours.

[0182] 15 c) The formulation of the present invention offers a healthy alternative to the commonly available bars, as it is low in saturated fat, does not comprise trans-fat, has low sugar, and yet offers adequate calorie content, fiber and protein. d) The process of the present invention offers a novel sequence of steps which offer optimal solubility of ingredients required to make a binding agent while maintaining the moisture levels at the base minimal at every stage to ensure the texture of the final product is maintained crispy and brittle.

[0183] e) The formulation of the present invention can be administered as supplementary foods;

[0184] h) All ingredients utilized by the present invention are food grade materials; i) The formulation of the present invention takes into consideration the inherently available nutrients as well as the co-existing nutrients within the other components of the formulation which may otherwise negate the effects of non-compatible and co-existing nutrient components, this is ensured by the formula’s processing technique as well as the uniquely measured ratios of each component present in the formulation;

[0185] j) The formulation of the present invention prioritizes the source of nutrients from natural and ayurveda as opposed to highly processed or other detrimental sources k) The formulation of the present invention may be prepared by incorporating variety of permutations and combinations of nutrient components, to address a versatile list of dietary needs and requirements while maintaining the properties of the product and formulation as per the present invention.

[0186]

[0083] INDUSTRIAL APPLICABILITY

[0187]

[0084] It is apparent that the snack bar formulation and the process disclosed in this document provides a solution for large- scale production of snack bars having a much longer shelf life, higher organoleptic properties, higher nutrient preservation and overcoming the hinderances posed by conventionally available solutions. It is thus evident that the products made using the process of the present invention offer improved snack bar formulation and process of making the same.

[0188]

[0085] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modification of the disclosed embodiments incorporating the substance of the invention may occur to person skilled in the art, the invention should be construed to include everything within the scope of the disclosure.

Claims

CLAIMSClaim 1. A synergistic nutritional snack bar formulation comprising:a. Nutrient component containing:i. Carbohydrate source, present in the range of 65-75 g / 100 g;ii. Protein / amino-acid source, present in the range of 10-13 g / 100 g; iii. Lipid source, where the lipid contains PUFA and MUFA present in the range of 4-7 g / lOOg;iv. Fiber source, present in the range of 3-20 g / 100 g;b. Binding component having a sweetener component, contributing to lowering total sugar content in the range of 14-20 % w / v of the formulation and moisture content which is later controlled by the baking process to <5 % w / v of the formulation andc. Natural flavouring component, capable of offering digestion aids being carminative, stomachic, aromatic, Appetizers, or Gastro -Protective components;wherein the binding component maintains cohesion of all components and contributes to moisture levels which is later controlled by the baking process below 5 % w / v, essential to maintaining structural stability during transport and extended shelf life of the other components without addition of artificial preservatives and despite low sugar content and wherein the flavouring components offer digestive aid in digestion of the other components.Claim 2. A nutritional snack bar formulation according to claim 1, wherein the formulation is moulded into a bar shape measuring 80 L X 40 W X 15 H in mm thereby maintaining moisture content of <5 % w / v, retaining structural stability and extending shelf life up to nine months.Claim 3. The formulation as claimed in claim 1 wherein:i. Carbohydrate source is selected from a group of cereals, preferably, puffed rice, oats, millets, or such other source that may be industrially acceptable;ii. Protein / amino-acid source selected from a group of pulses, preferably chickpea flour, dry fruits, sunflower or pumpkin seeds, or such other source that may be industrially acceptable;iii. Lipid source selected from a group of oils preferably, groundnut oil, butter, or such other source that may be industrially acceptable;iv. Fiber sources are selected from millets, oats and dry fruitsv. Binding components having water, a sweetener component being caramel, sugar syrup, jaggery, or a combination thereof, and having non-sweet carriers having binding properties selected from rice flour, lemon powder, tamarind extract, or a combination thereof; andvi. Flavoring components selected from a group of spices preferably asafoetida, turmeric, curry leaves etc., and natural flavorants preferably, tamarind extract, coriander extract, lemon powder, salt, etc.Claim 4. The formulation as claimed in claim 1, the sweetener component is either sugar syrup or caramel sauce made as per claim 9; wherein the sweetener component is selected as caramel for all sweet-tasting bar formulations and sugar syrup is selected as the sweetener component for all savoury tasting bar formulations.Claim 5. The formulation as claimed in claim 1 wherein the binding component contains non-sweet carriers to reduce the total sugar level in the snack bar formulation to 14 % - 20 % w / v.Claim 6. The formulation as claimed in claim 1 wherein the nutrient component additionally comprises of vitamins being 0.170-0.185 mg / 100 g of Thiamine (Bl), 0.5 - 0.65 mg / 100 g of D- pantothenic acid (B5), 0.15-0.2 mg / 100 g of Niacin (B3), 0.6-0.7 mg / lOOg of Vitamin E, or a combination thereof and minerals sources, particularly 55 — 135 mg / lOOg of Calcium, 1.5 — 6 mg / lOOg of Iron, ISO-155 mg / 100 g of Magnesium, or a combination thereof.Claim 7. A process of manufacturing snack bar comprising the following steps: a. weighing all the ingredients as claimed in claim 1, as per the batch size. b. roasting the dry ingredients at 180-190 °C for 2-3 min to reduce moisture, ensuring the ingredients are low on moisture to increase shelf life yet, not too brittle to retain their structure through transportation; c. adding the roasted dry ingredients followed by uniform mixing of the other ingredients to form the bar mixture, simultaneously carrying out the preparation of sweetener component required for making the binder; d. mixing water, sweetener component and optionally a carrier to add a viscous texture, and heating the mixture to make the binder . e. Mixing the binder and bar mixture for 1 minute to form the final mixture.f. Moulding the final mixture immediately after mixing, into its preset dimensions of a bar measuring 80 L X 40 W X 15 H in mm; g. Baking the bars at 95-105 °C for 30 - 35 min;h. Cooling the bars to attain 28 - 30 °C;Wherein the baking time and temperature bring down the moisture levels below 5 % w / v of the formulation and the moulded bar retain the moisture levels once reduced, essential to maintaining structural stability during transport and extended shelflife of the snack bar up to nine months.Claim 8. The process as claimed in claim 7 wherein the dry ingredients are selected from cereals, pulses, oats, millets, dry fruits, super foods, cranberries, groundnut oil, spices, natural flavourants, protein concentrate, saltClaim 9. The process as claimed in claim 7 wherein the step of adding the dry ingredients involves heating oil at 160-170 °C for tempering of the other ingredients, adding the roasted dry ingredients and other ingredients selected from curry leaves, turmeric and asafoetida followed by uniform mixing of the mixture to form the bar mixture.Claim 10. The process as claimed in claim 7 wherein the step of binder making involves addition of rice flour as carrier and caramel sauce as sweetener component, combining them and cooking the combination at 75-80 °C for 10 mins to attain a viscous binder; where the sweetener is sugar syrup, the binder is made by heating the syrup at 90-95 °C, for 8-10 minutes.

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