Custom Protein Bar Packaging
A protein bar is sticky, oily and sold both singly and in multipacks. The wrapper has to survive a hot car and the multipack carton has to hold a stack of soft, irregular bars without crushing them.
Skip the blank page
You already know what you are packaging, so there is nothing to set up. This opens the design engine with the pillow / back-seal pouch structures on screen — then you type your own dimensions and the dieline is generated at that exact size.
The structures protein bar packaging actually ship in
Every one of these is a construction TWOFORM generates a real production dieline for, at your own dimensions — not a template you have to fit your product into. Each opens the engine already on that package type.
Settle this before you design
Bars soften, and the pack has to hold its shape when they do
Above room temperature most bars go pliable and take the shape of whatever is around them. A wrapper too loose lets the bar slump into an unappealing lump; a multipack with no divider lets twelve soft bars fuse into a block. Either wrap close to the bar's real dimensions or put a tray inside the carton.
The mistake that costs a print run
Dense ink over the crimp
The crimped ends of a flow wrap take heat and pressure, and heavy ink there gives a weak, inconsistent seal on an oily product that will find every gap. Keep dense coverage back from both ends, and remember that the crimp eats around a centimetre at each end of the printed length.
How you actually make it
- Open the structure above and type your real dimensions. The dieline is generated at that exact size and validated against real manufacturing limits as it draws — if a size cannot be folded, glued and shipped, it says so before you design anything on it.
- Describe your brand and the AI designs the artwork directly onto that dieline — not onto a picture of a package.
- Place your own logo, barcode and any required panel yourself. The AI leaves them exactly as placed unless you ask it to change them.
- Fold it in live 3D to check it, then download print-ready files to use with any printer — or have TWOFORM manufacture it.
Questions about custom protein bar packaging
What size wrapper does a standard bar need?
For a 60 g bar around 3.5 × 6.5in flat, which allows for the back seam and about a centimetre of crimp at each end. Measure the bar warm, since it spreads slightly as it softens.
Do multipack bars need a tray inside the carton?
If the bars are soft, yes. Without a divider they press together and fuse, which makes them hard to separate and unappealing when they do come apart.
Does a bar wrapper need a barrier film?
Yes for anything with nuts, oils or a chocolate coating. Oxygen turns the fats rancid and the pack loses aroma long before the bar changes texture.