Use this chocolate bar mold size guide to compare commercial polycarbonate bar formats by approximate finished weight, ounce equivalent, cavity dimensions, segmentation and bars per mold. The goal is to help you choose a mold that fits the finished product, packaging footprint and production output you actually need.
For the full current catalog, shop Chocolate Bar Molds. For production math, use the Chocolate Mold Capacity & Production Calculator. If you are choosing between mold types or stock versus custom tooling, see the Commercial Chocolate Mold Buyer’s Guide.
Chocolate Bar Mold Sizes at a Glance
Our current active chocolate bar mold range runs from compact approximately 20 g / 0.71 oz bars through large-format approximately 339 g / 11.96 oz bars. Weight is only one part of the decision. Two bars with similar weights can have very different lengths, widths, depths, segment counts and output per mold.
Use the comparison table below as a planning guide. Individual product pages remain the final source for the listed mold specifications.
| Approx. bar weight | Approx. oz | Pieces / design | Bars per mold | Cavity size | Approx. cavity size in inches |
|---|---|---|---|---|---|
| 20g | 0.71 oz | 2-piece square breaker | 12 | 50 × 50 × 6.7 mm | 1.97 × 1.97 × 0.26 in |
| 28g | 0.99 oz | 8 pieces, 2 × 4 | 7 | 92 × 31 × 13 mm | 3.62 × 1.22 × 0.51 in |
| 29g | 1.02 oz | 24 pieces, 4 × 6 | 3 | 130 × 28 × 7.4 mm | 5.12 × 1.10 × 0.29 in |
| 37g | 1.31 oz | Diamond lattice | 4 | 126 × 53 × 5 mm | 4.96 × 2.09 × 0.20 in |
| 46g | 1.62 oz | 10 pieces, 2 × 5 | 6 | 114 × 50 × 7 mm | 4.49 × 1.97 × 0.28 in |
| 48g | 1.69 oz | 6 pieces, 2 × 3 | 12 | 69 × 33 × 19 mm | 2.72 × 1.30 × 0.75 in |
| 63g | 2.22 oz | 6 pieces, 3 × 2 | 8 | 60 × 60 × 16 mm | 2.36 × 2.36 × 0.63 in |
| 65g | 2.29 oz | 21 pieces, 3 × 7 | 3 | 100 × 62 × 9 mm | 3.94 × 2.44 × 0.35 in |
| 70g | 2.47 oz | 24 pieces, 4 × 6 | 3 | 143 × 70 × 6.5 mm | 5.63 × 2.76 × 0.26 in |
| 80g | 2.82 oz | 3 textured designs | 3 | 155 × 75 × 10 mm | 6.10 × 2.95 × 0.39 in |
| 85g | 3.00 oz | 16 pieces, 4 × 4 | 3 | 145 × 66 × 7.8 mm | 5.71 × 2.60 × 0.31 in |
| 110g | 3.88 oz | 21 faceted pieces, 3 × 7 | 3 | 137 × 72 × 12 mm | 5.39 × 2.83 × 0.47 in |
| 339g | 11.96 oz | 10 pieces, 2 × 5 | 2 | 155 × 77 × 25 mm | 6.10 × 3.03 × 0.98 in |
Finished gram weights are approximate catalog sizing references. Actual chocolate weight can vary with formulation, inclusions and fill level.
How to Compare Chocolate Bar Mold Sizes
Start with the finished product rather than the mold. The most useful comparison points are the target chocolate weight, finished length and width, thickness, segmentation and the number of finished bars each mold produces per cycle.
A bar that is approximately 70 g is not automatically interchangeable with every other bar near that weight. Packaging footprint, shelf presentation, break-apart pattern and thickness can be completely different. When the bar must fit an existing wrapper, carton or display, cavity dimensions should be checked before weight.
Chocolate Bar Weight: Grams vs. Ounces
Our catalog uses grams because that is the most precise and consistent naming method across the chocolate mold range. Ounce equivalents are included here to make size comparison easier for U.S. buyers.
For planning purposes, approximately 28–29 g is close to 1 oz, 63–70 g falls in the low-to-mid 2 oz range, and 85 g is approximately 3 oz. These are not interchangeable bar formats: the cavity dimensions and segmentation still need to match the finished product and packaging.
Chocolate bar molds around 1 oz
The 28g 8-piece mold is approximately 0.99 oz per bar, while the 29g 24-piece mold is approximately 1.02 oz. The finished weights are close, but the formats are very different: one is a shorter 8-piece bar and the other is a long, slim 24-piece bar.
Chocolate bar molds around 2 oz
The 63 g, 65 g and 70 g molds all sit in the broader 2 oz range, but they serve different formats. The 63 g design is a compact 60 × 60 mm square-format bar, the 65 g design is a 100 × 62 mm 21-piece bar, and the 70 g design is a longer 143 × 70 mm 24-piece bar.
Chocolate bar molds around 3 oz
The 80 g textured mold is approximately 2.82 oz, while the 85 g 16-piece mold is approximately 3.00 oz. The 85 g option provides a conventional 4 × 4 segmented layout, while the 80 g mold emphasizes three different textured bar appearances.
Why Chocolate Bar Dimensions Matter as Much as Weight
Length, width and depth affect packaging fit, visual proportions and the way a finished bar feels in the hand. Depth also influences how much chocolate the cavity can hold. Two bars with a similar face size can have very different weights if one cavity is significantly deeper.
If packaging has already been designed, compare the usable internal package dimensions with the actual cavity length, width and thickness. Allow for any clearance required by the wrapper, insert, carton or protective tray. Do not choose a mold based only on the product title if packaging fit is fixed.
Thickness and Cavity Depth
Cavity depth varies substantially across the current chocolate bar catalog. Thin, wide bars such as the 70 g 24-piece format use a relatively shallow cavity, while compact bars such as the 48 g and 63 g designs are considerably deeper.
Thickness changes more than appearance. It can affect cooling behavior, bite, inclusion capacity, packaging depth and how a filled or layered product behaves. If you are developing a filled bar or using inclusions, verify that the cavity depth supports the intended formulation and process.
Pieces per Bar and Segmentation
Piece count describes the number of defined break-apart sections in one finished bar. Segmentation affects portioning, appearance and brand presentation.
- 2-piece: simple breaker format.
- 6-piece: compact 2 × 3 or 3 × 2 formats.
- 8-piece: 2 × 4 format.
- 10-piece: 2 × 5 format.
- 16-piece: 4 × 4 format.
- 21-piece: 3 × 7 format.
- 24-piece: commonly 4 × 6 in the current catalog.
Some chocolate bars, such as the diamond lattice and textured designs, are better described by their surface pattern than by a traditional piece count.
Bars per Mold and Production Output
Bars per mold has a direct effect on output per fill-and-release cycle. A 12-bar mold produces four times as many finished bars per mold as a 3-bar mold, but the finished products are also different sizes and weights.
For example:
- Ten 20 g molds can produce 120 bars per cycle.
- Ten 63 g molds can produce 80 bars per cycle.
- Ten 70 g molds can produce 30 bars per cycle.
- Ten 339 g molds can produce 20 large bars per cycle.
Use the Chocolate Mold Capacity & Production Calculator when you need to convert those mold counts into total chocolate required, output per cycle and cycles required for a production target.
Choosing a Chocolate Bar Mold for Packaging
If the finished package already exists, work backward from the package. Confirm the maximum usable bar length, width and thickness before comparing mold options. This is especially important when using flow wrap, paper sleeves, cartons, inserts or rigid trays.
If the packaging has not been finalized, choosing the mold first gives the packaging designer a fixed physical bar size to work around. This can be simpler than trying to force an existing package around a mold that is only approximately the right size.
Choosing a Chocolate Bar Mold for Commercial Production
For commercial production, bar size should be evaluated together with equipment and throughput. Check the overall mold footprint as well as the cavity layout. Many molds in the current range use an overall polycarbonate sheet close to 275 × 175 mm, but not every mold has the exact same thickness or footprint.
If molds must fit a depositor, vibrating table, cooling rack, tray, storage system or automated handling setup, verify the exact mold dimensions on the individual product page before ordering production quantities.
Small Bars vs. Large Bars
Smaller bars generally allow more cavities per mold, which can increase piece output per cycle. Larger bars usually reduce the number of bars that fit on the same mold footprint but can support premium products, larger portions, filled formats or stronger shelf presence.
The right choice depends on how the bar will be sold. A 20 g or 28 g format can make sense for sampling, multipacks or compact servings. Mid-range bars around 46–85 g fit many conventional retail formats. The 110 g and 339 g options serve larger-format products where the finished size itself is part of the product positioning.
When an Existing Chocolate Bar Mold Is Not the Right Size
If none of the current molds match the required weight, dimensions, segmentation, logo or packaging footprint, adapting the product to the wrong stock mold can create problems later. In that situation, a Custom Chocolate Mold may be the better path.
Custom development can be based around target finished dimensions, approximate gram weight, segmentation, artwork, packaging constraints and production requirements. For the complete planning process, read How to Order Custom Chocolate Molds for Commercial Production.
Chocolate Bar Mold Size FAQs
What size is a standard chocolate bar mold?
There is no single standard finished chocolate bar size. Commercial bars vary widely in weight, length, width, depth and segmentation. Choose the mold based on the finished product and packaging requirements rather than assuming one standard dimension.
What chocolate bar mold is closest to 1 oz?
The current catalog includes a 28 g mold at approximately 0.99 oz and a 29 g mold at approximately 1.02 oz. Compare their cavity dimensions and segmentation because the finished shapes are very different.
What chocolate bar mold is closest to 2 oz?
One ounce is approximately 28.35 g, so 2 oz is approximately 56.7 g. The current catalog does not use an exact 56.7 g mold name. The closest current formats above that target include 63 g and 65 g designs, while the correct choice should still be based on dimensions and finished product requirements.
What chocolate bar mold is closest to 3 oz?
The 85 g 16-piece mold is approximately 3.00 oz and uses a 145 × 66 × 7.8 mm cavity with three bars per mold.
Does a larger gram weight always mean a physically larger bar?
Not necessarily. Weight depends on cavity volume and chocolate density, while the visible footprint depends on length and width. A thicker compact bar can weigh more than a larger-looking shallow bar.
How many bars can one chocolate mold make?
The current active bar catalog ranges from 2 to 12 bars per mold depending on the format. Check the bars-per-mold column in the table above and the individual product page before planning production.
How do I calculate how many chocolate molds I need?
Use your target bar quantity, bars produced per mold and planned production cycles. The Chocolate Mold Capacity & Production Calculator can estimate mold count, chocolate required and cycles needed.
Compare Chocolate Bar Molds
When you are ready to choose a production mold, browse the complete Chocolate Bar Molds collection. For other molded chocolate shapes, browse Polycarbonate Chocolate Molds. If you need help deciding between formats, use the Commercial Chocolate Mold Buyer’s Guide.