BioTechUSA triples protein bar production capacity and launches 2 new premium product lines
BioTechUSA Group, a Hungarian-owned company, is undertaking the largest investment in its history, worth approximately €22 million. The first phase of the investment, worth €13.5 million, has just been completed with the inauguration of a complex multi-layer protein bar production line, which not only triples the company’s annual bar production capacity, but also allows the company to launch a new premium protein bar product range. Besides this, BioTechUSA also plans to launch a new premium vitamin product range as well. In addition to this unique development in Europe, a new shaker logo plant was built, social improvements for the well-being of its employees continued and the energy modernisation of its production complexes was continued. At the BioTechUSA and Scitec Nutrition sites, a solar panel system was installed that will provide 30% of future electricity consumption, significantly reducing environmental impact.
A production facility unique in Europe, with an in-house developed software system
Following the installation in 2024 of its automated warehouse system capable of picking up to 8 orders per minute, BioTechUSA Group has made another significant investment. The company has delivered a state-of-the-art multi-layer protein bar line at its Szada site, bringing its total production capacity to 75 million bars per year. The design and construction phase of the development project took a total of 3 years. “The professional preparation and execution of the project, technology development and product development was a great team effort of which we can be justifiably proud. We are currently conducting test production, with live production scheduled for the second half of 2025,” said Diána Markovics, COO and Managing Director of the BioTechUSA Group.
With an investment of more than €11 million, a machine complex has been put into operation that is fully tailored to BioTechUSA’s needs. “The special feature of this robotised unit, which requires minimal human intervention from the first step to the last, is the “Barfactory” programme developed in-house by our Process Development team, which has also enabled the multi-layer protein bar production line to be integrated into our ERP system. Our aim is to maximise the capacity and efficiency of the equipment, taking into account the ever-increasing demands of the market,” adds Diána Markovics.
Protein bars with outstanding enjoyment value
The possibilities of BioTechUSA’s new multilayer protein bar line are “endless”, as it allows the group to flexibly adapt to consumer demands: it can create a variety of fillings, chocolate coatings, sprinkles and masses. This will give BioTechUSA and its B2B partners a significant competitive advantage not only in developing the Group’s own products, but also in contract manufacturing.
“We started the development because we noticed that other European factories producing this type of complex protein bars were in a monopoly position: they dictated higher transfer prices while offering standard products with inflexible service. With the new multilayer protein bar line we want to solve these problems for ourselves and for other European brands who, like us, place a high value on quality and design and want to take advantage of our Szada production and logistics complex as part of our contract manufacturing service,” says Bálint Lévai, CEO and co-owner of the Group.
“Thanks to this investment, we are able to develop high quality protein bars with no added sugar and excellent indulgence. As a result of our ongoing portfolio diversification, this development means that we have no competitors in this segment on the domestic market, but we can also achieve a much more competitive price on our foreign markets, as our own production at the quality level we represent is unique in the protein bar market. In terms of new products, we are launching 5 flavours – Salted Caramel, Peanut Butter, White Chocolate Coconut, Hazelnut Chocolate and Pistachio – in 50g packs as planned. This is a major step forward for us in the domestic market, as the enjoyment value of our new Crush Bar protein bar, with no added sugar, exceeds that of the usual supermarket sweets,” added Bálint Lévai.
Developments to reduce environmental impact
In addition to commissioning the Protein bar line, the company has also made significant investments in energy: solar panels have been installed at both sites, providing almost 30% of the electricity used by the BioTechUSA and Scitec Nutrition brands. They have also upgraded the lighting at their Szada and Dunakeszi plants and replaced their gas boilers with energy efficient ones. At the Szada plant, they also installed a new compressor, refrigerant drying equipment and a control system to improve the energy efficiency of the compressed air system to reduce energy consumption and environmental impact.
New shaker logo facility in Szada
Another recent major investment is BioTechUSA’s new shaker logo facility in Szada, which will help the company’s Shakerstore business to operate more efficiently. Automated sieving and tamponing equipment was purchased as part of the development of the sub-brand, which produces custom shakers, canteens and pill holders. The project was challenging due to the rapid design and implementation time, the development of the organisational structure, the recruitment of new colleagues, the learning of a completely new technology for the company, the organisation of the associated packaging department and the integration of the plant operations into the ERP system. The investment is motivated by a surge in demand, which the company intends to meet with existing capacity.
Investing in the future in challenging times
“In 2025, we will continue to focus on reviewing and improving workflows in our supply areas, further increasing the productivity of our manufacturing facilities and improving the efficiency of our logistics. In addition, it remains important for us to provide an attractive working environment for our employees, to increase their loyalty and thus to work together for many years to come. That’s why, in addition to the already developed employee gym and significantly increased changing and dining areas, we are planning further social improvements to increase our staff retention rate above the industry average” – said Diána Markovics, COO and Managing Director of BioTechUSA Group.
In 2024, the company slightly exceeded its previous record, increasing its revenue by 3.5% to 236 million euros, closing the best year in its history, while investing more than 5% of its revenue in pure plant development. BioTechUSA Group launched 25 new products, opened 20 new stores, increased its country coverage to 103 with 5 new countries and signed a unique global partnership with FC Barcelona, one of the world’s most famous football clubs.
We presented the latest developments at a press event.
