How Sweet Solutions Eliminated a Manual Production Step for a Protein Bar Manufacturer
August 5, 2026
A protein bar manufacturer came to Sweet Solutions with a specific problem.
They needed a high-protein caramel that would work with their equipment, but their current supplier's product was creating extra work on the production floor.
The caramel was shipped in 50-pound cases, and employees had to manually cut it into smaller pieces before it could be added to the production line. The product itself worked, but the packaging made production slower and more labor intensive.
The Challenge
The customer wasn't looking for a completely new caramel.
They needed a product that matched their existing caramel so they could keep the same ingredient statement and nutrition facts on their packaging.
At the same time, they wanted to eliminate the extra handling required every time they ran production.
That meant solving two problems:
Develop a caramel that performed like their current product. Package it in a way that worked with their equipment.
The Solution
Sweet Solutions developed a high-protein, reduced-sugar caramel designed specifically for use as a protein bar layer.
Once the formulation was approved, we created a packaging solution that made production easier.
Instead of packing the caramel in large cases that required operators to cut it apart, the product was packaged in food-safe, non-stick cardboard trays. The trays allowed the caramel to be removed quickly and added directly to the customer's equipment with minimal handling.
The Results
The project moved from development to an approved product and packaging solution in less than 60 days.
The customer received:
A high-protein, reduced-sugar caramel that matched their existing product. Packaging designed for their production equipment. Less manual handling during production. Reduced production time by eliminating an unnecessary preparation step. Looking Beyond the Ingredient
When companies think about product development, they often focus only on the formulation.
This project shows that packaging can have just as much impact on production efficiency as the ingredient itself.
By developing both the caramel and the packaging together, Sweet Solutions delivered a solution that fit the customer's process—not just their recipe.
If your current ingredients are slowing production or creating unnecessary handling, Sweet Solutions can help develop a product and packaging solution designed around your manufacturing process. Contact us today to start the conversation.