Formulation of high-protein energy bars using whey protein and dried fruit blends

Abstract:

Off-the-shelf energy bars on Egyptian retail shelves typically carry 6-10 g of protein per 50 g serving, whereas sports-nutrition targets call for 15-20 g in the same portion size. This research developed and optimised a high-protein energy bar using whey protein concentrate (WPC) and dried fruit blends suitable for the Egyptian consumer market. Six formulations (F1-F6) with WPC inclusion from 15% to 38% (w/w) were prepared at the Cairo University pilot food processing unit during May-November 2023. Final protein content ranged from 14.2 g to 30.8 g per 100 g bar. Sensory acceptability followed a quadratic pattern with a peak at F4 (28% WPC, 23.4 g protein per 100 g bar, sensory score 8.7/9). Texture analysis showed hardness rising with WPC inclusion (F1: 34.2 N; F6: 118.7 N), with F4 at 71.3 N remaining within the acceptable range (45-85 N) for semi-soft energy bars. Storage research across 90 days at ambient conditions showed no Salmonella or Coliform development, peroxide value stayed below 8 meq/kg oil, and sensory scores dropped by only 0.6 units. The optimised F4 formulation delivers a bar that meets sports-nutrition protein benchmarks at a production cost of EGP 32 per 50 g serving, close to mid-tier commercial bars.