Protein Bar Machine P160 Three Layer Stuffed Energy Bar Production Line 99pcs/min Encrusting Equipment with PLC

The P160 Three Layer Protein Bar Machine is a specialized encrusting production system engineered for the automated manufacturing of multi-layer stuffed protein bars, energy bars, and nutrition bars with distinct casing and filling layers. Built on Papa Industrial's proven P160 encrusting platform, this machine applies advanced co-extrusion and encrusting shutter technology to form precisely layered bars, featuring up to three distinct material layers in a single product, with outer casing encasing inner filling cores. The fully automatic operation processes 60 to 99 pieces per minute with programmable recipe control for layer thickness ratios, making it the definitive solution for sports nutrition brands, contract manufacturers, and health food producers seeking to differentiate their protein bar product lines with innovative multi-layer formulations.

• Three Layer Co-Extrusion Encrusting Technology: The P160 employs a proprietary multi-channel encrusting head that simultaneously extrudes outer casing dough, middle filling layer, and inner core material into a single continuous bar. The casing-to-filling ratio is digitally adjustable from 1:9 to 10:0 through the PLC touchscreen panel, enabling manufacturers to fine-tune layer proportions for optimal taste, texture, and nutritional composition. This three-layer capability allows production of innovative products such as chocolate-coated protein dough with fruit jam core, nut butter encased in oat dough with caramel center, and high-protein casing with vitamin-enriched gel filling.
• High Speed 99 Pieces Per Minute Output: With a production rate of up to 99 pieces per minute at maximum configuration, the P160 delivers industrial-scale throughput suitable for international brand supply chains. The variable frequency drive system allows operators to adjust production speed to match downstream operations such as cooling tunnels, chocolate enrobing lines, and flow wrapping machines, ensuring balanced line synchronization without accumulation or starvation at transfer points.
• Stainless Steel 304 Food-Grade Construction: All product-contact components including the encrusting head, hopper, conveyor belt frame, and forming shutters are fabricated from AISI 304 stainless steel with food-grade surface finishing. The machine meets HACCP, GMP, and CE hygiene requirements, with tool-free disassembly of the encrusting head assembly for rapid sanitation between production batches. The PU conveyor belt and PE forming moulds are BPA-free and compliant with EU and FDA food contact material regulations.
• PLC Intelligent Control with Touchscreen HMI: The P160 features a full-color touchscreen control panel running Papa Industrial's proprietary encrusting control software. Operators can program recipes with parameters for casing dough thickness, filling flow rate, intermediate layer composition, product weight within a 10 to 270 gram range, and production speed. The system stores up to 50 product recipes and includes multi-level user access control, production counting with batch traceability, and guided fault diagnostics that reduce mean time to repair by presenting step-by-step troubleshooting procedures.
• Versatile Product Shape Configuration: By changing the encrusting shutter profile and adjusting the conveyor speed ratio, the P160-PB can produce protein bars in spherical, tapered, round, rectangular, serrated edge, and terraced shapes. Custom shutter profiles are available for proprietary bar geometries, enabling brand differentiation through distinctive product appearance. The shape changeover process requires no specialized tools and can be completed by a trained operator in under 15 minutes.
• Seamless Downstream Equipment Integration: The P160 platform integrates directly with optional downstream modules including the automatic bar cutting machine for precise length cutting of continuous bar output, the automatic ball roller machine for spherical energy ball forming, the automatic tray aligning machine for systematic tray loading, and the rotary powder coating machine for surface finishing with chocolate sprinkles, sesame seeds, or ground nuts. This modular architecture allows manufacturers to start with the core encrusting unit and expand line capabilities incrementally as production demands grow.
• Japanese and Taiwanese Precision Components: The P160 is built with Panasonic or Delta variable frequency drives and Liming electric motors, ensuring exceptional speed stability and long service life under continuous production conditions. These proven industrial-grade components, combined with Papa Industrial's precision-engineered encrusting shutter assembly, deliver consistent product weight accuracy within plus or minus 1 gram across extended production runs.

The P160 Three Layer Protein Bar Machine is engineered for the industrial production of a comprehensive range of stuffed and layered nutrition bars. Primary applications include three-layer protein bars with chocolate coating and fruit filling, stuffed energy bars with nut butter cores, high-protein meal replacement bars with vitamin-enriched gel centers, multi-layer granola bars with caramel and chocolate layers, fig bars and date-filled nutrition bars with biscuit casing, layered cereal bars with yogurt filling, and functional snack bars combining protein, fiber, and superfood ingredients in distinct layers. The machine is ideally suited for sports nutrition manufacturers producing private-label protein bars for gym chains and supplement retailers, health food companies developing innovative layered bar concepts for the functional food market, contract manufacturers serving multiple brand clients with diverse recipe requirements, and traditional confectionery producers expanding into the premium nutrition bar segment. The P160-PB's ability to create visually distinctive layered cross-sections provides a powerful product differentiation advantage in crowded retail environments where shelf appeal directly drives consumer purchase decisions.

Each P160 Three Layer Protein Bar Machine is securely packed in a fumigation-free export-grade wooden case with internal moisture barrier and custom-cut foam cushioning for safe international transit. Every machine undergoes a comprehensive 48-hour continuous production trial at our factory using actual protein bar formulations, with detailed performance data documented in the shipment package. We provide a full 12-month warranty covering all mechanical, electrical, and control system components. After-sales support includes lifetime remote technical assistance with video diagnostics, express spare parts delivery to any global destination within 72 hours, and optional on-site installation and commissioning by Papa Industrial certified service engineers. Our technical team also provides complimentary recipe consultation to help customers optimize their three-layer bar formulations for the P160-PB platform.