Quick answer: In the planning model used below (100 g bars, 45% chocolate shell, 55% filling, 5% process loss), one 11 lb (5 kg) tub of Nuvelah Pistachio & Kataifi Mix fills about 86 bars. Ingredient cost lands around $1.76 to $1.87 per bar at current case prices, before packaging, labor and overhead. One 20 lb case of chocolate melts shells about 190 bars, so you will use roughly 2.2 tubs of filling per case of melts.
We sell these ingredients, so we have shown every input and formula. Swap in your own bar weight, ratio and prices to get your own numbers.
By Nuvelah, Writer at Nuvelah. Last updated October 25, 2026.
Who this guide is for
This is for bakeries, dessert shops, cafés and small confectionery makers moving from a few hand-made bars to repeatable batches. If you are still deciding what goes into a Dubai chocolate bar, start with our explainer on what Dubai chocolate is made of. If you are comparing bulk suppliers, see our wholesale Dubai chocolate ingredients buying guide. This page covers production: yield, cost, equipment, process and shelf life.
Anatomy of a bar, and the one ratio that matters
A Dubai-style bar has two parts: a chocolate shell and a pistachio-and-kataifi filling. Production decisions mostly come down to the shell-to-filling ratio, because it controls cost, snap and crunch.
- More filling: a gooier, more generous bar, but a thinner shell that is more likely to crack, leak or soften.
- More shell: a stronger bar that is cheaper to ship, but less of the pistachio flavor customers are paying for.
The model in this guide uses 45% shell and 55% filling by weight. Treat that as a starting point and adjust it after your own test batch.
Yield per 11 lb tub
An 11 lb tub is about 4,990 g. The formula:
Bars per tub = (4,990 g × 0.95) ÷ filling grams per bar
The 0.95 allows for 5% loss from scraping, spills and test bars. If your loss is lower or higher, change that number.
| Bar weight | Filling per bar | Bars per 11 lb tub | Bars shelled per 20 lb melts case |
|---|---|---|---|
| 50 g | 27.5 g | ~172 | ~383 |
| 100 g | 55 g | ~86 | ~191 |
| 350 g | 192.5 g | ~24 | ~54 |
Planning model, not a measured result: 45% shell / 55% filling, 5% loss. Always confirm with a test batch.
Cost per bar
Using current Nuvelah sale prices as of October 25, 2026 (check the product pages for today's price):
- Pistachio & Kataifi Mix, 11 lb: $79.99
- Premium Milk Chocolate Melts, 20 lb case: $179.98
- Premium Dark Semi-Sweet Chocolate, 20 lb case: $169.98
- White Chocolate Flavor Melts, 20 lb case: $159.98
| 100 g bar | Filling cost | Shell cost | Ingredient total |
|---|---|---|---|
| Milk shell | $0.93 | $0.94 | $1.87 |
| Dark shell | $0.93 | $0.89 | $1.82 |
| White shell | $0.93 | $0.84 | $1.76 |
What is not in these numbers: molds, packaging, labels, labor, energy, shipping, waste beyond 5%, decoration, and any cocoa butter or extra kataifi you add. For pricing, add those to the ingredient cost, then work back from your selling price:
Margin per bar = selling price − (ingredients + packaging + labor + overhead)
Labor is the cost most new producers underestimate. Time one full batch from mold prep to packed bars and divide by the number of bars before you set a price.
The production workflow
- Prep the molds. They must be clean, dry and polished. Moisture or fingerprints show up on the finished surface.
- Make the shell. Temper (or melt, depending on your chocolate; see below), fill each cavity, tap out air, invert to drain, scrape flush and let it set.
- Fill. Weigh or portion the filling to your target grams per bar. Press it into the corners so there are no hollow spots, and leave a few millimetres (about a quarter inch) of headspace so the back can seal fully.
- Seal. Cover with chocolate, scrape flush, and tap or vibrate to release air bubbles.
- Set. Cool until the chocolate contracts and releases from the mold. Check snap and gloss on the first bars before committing the whole batch.
- Pack and label. Use moisture-resistant packaging, add a lot code, and record the batch so any issue can be traced.
Our roasted shredded kataifi is sold toasted and ready to use, so there is no pan-toasting step. If you add extra kataifi to a filling, keep it dry and let anything warm cool completely before mixing, because hot filling can soften the chocolate and moisture ruins crunch.
Tempering or melt-and-pour?
This depends on what your chocolate actually is, so check the spec sheet for your melts.
- Real chocolate (cocoa butter): temper it. Untempered chocolate sets dull, blotchy and soft, and loses its snap.
- Compound coating (non-cocoa-butter fats): follow the melt-and-pour instructions on the package. It generally does not need tempering.
For tempered chocolate, typical working ranges are below. Always follow your chocolate manufacturer's own curve when it differs.
| Type | Melt to | Cool to | Working temperature |
|---|---|---|---|
| Dark | 115–122°F | 82–84°F | 88–90°F |
| Milk | 113–118°F | 81–83°F | 85–87°F |
| White | 110–115°F | 80–82°F | 82–84°F |
Equipment by scale
| Stage | What you need | Where it strains |
|---|---|---|
| Small batch | Polycarbonate or silicone molds, melting pot or microwave, probe thermometer, gram scale, scraper, refrigerator or cool room | Hand-pouring is slow, and bar weight varies from person to person |
| Mid volume | Tabletop tempering machine, vibrating table, mold racks, cooling cabinet, portioning scoops or a hand depositor | Cooling space and mold count usually become the bottleneck before the tempering machine does |
| Production line | Piston depositor, cooling tunnel, automated demolding, flow-wrap or cartoning | Capital cost, plus filling with inclusions (kataifi pieces) needs a depositor that tolerates particulates |
Shelf life and storing the crunch
A bar's shelf life is limited by whichever runs out first: the shortest best-by date among your ingredients, or the point where the kataifi stops being crisp. Three things drive that:
- Moisture. Kataifi absorbs moisture from the air and from the filling, so it softens over time. Sealed, moisture-resistant packaging matters more than anything else you do after the bar is made.
- Temperature swings. Warm-to-cool cycles cause fat bloom (pale streaks) and condensation when a cold bar comes out into warm air. Store in a cool, dry, steady place, and let refrigerated product come up to room temperature in its packaging before you open it.
- Odors and light. Chocolate picks up smells. Keep bars away from strong-smelling foods and out of direct light.
Do not guess the finished-bar shelf life. Run a simple test: make a batch, store samples the way you will ship and sell them, and snap-test and taste weekly until the crunch drops below your standard. Set your best-by date inside that window and inside your ingredients' dates.
Common problems and fixes
| Problem | Likely cause | Fix |
|---|---|---|
| Dull, soft or blotchy shell | Chocolate not tempered, or set too warm | Temper properly, or switch to melt-and-pour if using a compound coating |
| Soggy, soft filling | Moisture exposure, or warm filling mixed in | Keep ingredients dry, cool anything warm first, upgrade packaging |
| Filling leaks or cracks the shell | Shell too thin, or cavity overfilled | Thicker shell coat, less filling, more headspace |
| Bars stick in the mold | Poor temper or not fully set | Fix the temper and cool longer before demolding |
| Hollow corners | Filling not pressed to the edges | Press the filling into the corners before sealing |
| White streaks over time | Fat bloom from temperature swings | Steady, cool storage |
Allergens, labeling and compliance
Read the label on every ingredient and declare allergens accurately on your finished bar. A Dubai-style bar commonly involves tree nuts (pistachio), wheat (kataifi), milk and soy (chocolate), and possibly sesame (tahini), depending on your formulation. Rules for licensing, kitchen requirements and labeling vary by state and by how you sell. Many sellers use “Dubai-style” to describe where the recipe comes from, but check your claims with your local authority or a food-safety professional. This is general information, not legal advice.
Sourcing checklist
- Filling: Pistachio & Kataifi Mix, 11 lb
- Extra crunch: Roasted & Shredded Kataifi, 11 lb case
- Shell: milk, dark or white chocolate melts and Dubai chocolate ingredients
- Volume orders: see our pallet shipping options
- Your own brand: see private label
Frequently asked questions
How many bars does an 11 lb tub of filling make?
About 86 bars at 100 g with 55 g of filling each and 5% loss. The formula is (4,990 g × 0.95) divided by the filling grams per bar, so smaller or larger bars scale proportionally.
How much does it cost to make a Dubai chocolate bar in bulk?
In this model, ingredients cost about $1.76 to $1.87 for a 100 g bar depending on the shell. Add packaging, labor and overhead to get your true cost.
Do I need to temper the chocolate?
If your chocolate contains cocoa butter, yes, for gloss and snap. If it is a compound coating, follow the melt-and-pour instructions instead. Check the spec sheet.
What is the shelf life of a finished bar?
It depends on your ingredients' best-by dates, your packaging and your storage. Test samples weekly in your real storage conditions and set the date inside the results.
Can I change the shell-to-filling ratio?
Yes. Replace the 45/55 split in the formulas with your own and the yield and cost numbers update with it.
