Dar has successfully completed the design and construction supervision of the strategic new filled bar production lines at MARS Egypt’s manufacturing plant in 6th of October City. Fully funded by Mars, Inc., this USD 280 million investment is a major industrial milestone, generating over 20,000 direct and indirect jobs.

The facility has risen to become one of MARS’ top five manufacturing sites globally in terms of size and production capacity through this expansion, which also, in turn, positioned the city as a mega export hub.

The project introduces new high-tech production lines that produce Snickers®, Mars®, and Bounty® along with a new chocolate-making plant and an expanded Goods-Out zone. With these additions, the plant’s chocolate production capacity more than doubled, bringing it to 65,000 tons annually.

Today, with the new lines, the facility manufactures leading Mars global brands, including Galaxy, Jewels, Flutes, Twix, Snickers, Mars, and Bounty, exporting over 90% of its production to more than 50 markets across the Middle East, Africa, the UK, and Australia. This surge in export capacity has contributed to Egypt’s rising prominence in the global confectionery sector, with the country recently ranking 11th worldwide in chocolate exports.

Beyond increasing production volumes, the expansion strategically positions the factory as a primary supplier for additional markets in Central Asia and Europe, effectively bridging production gaps and securing product availability for regions previously impacted by shifting global logistics.

Firmly aligned with MARS’ global “Clean Design” guidelines, Dar’s architectural and engineering approach prioritized hygiene and operational efficiency to support the facility’s large-scale expansion.

The plant now incorporates specialized structural systems, most notably hollow tube sections designed to maintain a pristine manufacturing environment. The project also introduces advanced MEP utilities, including upgraded chiller plants, steam boilers, and a robust SCADA system for real-time monitoring of mechanical equipment.

The new facility started production of the filled bar range in August, with the first locally produced Snickers, Mars and Bounty chocolates rolled out and appearing on shelves across the plant’s export markets soon after. This signaled an active presence and expanded regional reach. The new lines were officially inaugurated in October 2025.

Reflecting on the achievement, Project Director Naji Edde, Dar’s Partner in Mechanical and Industrial Engineering, shared: “We are proud to support MARS Egypt in this transformative phase of their growth in Egypt. By integrating rigorous 'Clean Design' principles, we have delivered a facility that not only meets the immediate demand for increased capacity but does so responsibly, setting a new standard for industrial excellence not only in the region but also internationally.”