Bread manufacturing requires precision, consistency, and efficiency at every stage. For bakeries aiming to improve quality and streamline operations, Exact Mixing’s continuous mixing systems provide a proven solution for large-scale bread production lines.
The Advantages of Continuous Mixing
Traditional batch mixing has been the standard for decades, but it comes with limitations such as inconsistent dough development, longer downtime, and more labor-intensive operation.
Continuous mixing, on the other hand, delivers a steady stream of dough to your production line at the same rate it’s being used. This ensures optimal dough temperature, uniform gluten development, and less variability in final products.
With continuous mixing, you can:
- Guarantee Product Consistency – Uniform mixing eliminates variations in loaf height, crumb texture, and crust color.
- Increase Output and Efficiency – Continuous operation minimizes downtime between batches, helping meet tight production schedules.
- Improve Food Safety and Cleanliness – Hygienic designs with stainless steel construction and optional clean-in-place (CIP) systems simplify sanitation and maintain compliance.
- Enhance Quality Control – Integrated monitoring systems automatically adjust for ingredient or temperature variations in real time.
Complete Mixing Solutions
Exact Mixing’s systems easily integrate into full-scale bread production lines, making them suitable for both existing facilities and new installations. Each system includes:
- Materials Handling – We partner with trusted vendors to offer solutions such as dilute phase, dense phase, vacuum, and pressure systems, customizing each to your plant’s layout and needs.
- Minor Ingredients Blending – Some minor ingredients can be automatically pre-blended before metering, reducing manual handling and increasing flexibility.
- Precision Ingredients Metering – Gravimetric, loss-in-weight technology ensures accurate, continuous delivery of dry ingredients. Liquid ingredients are metered via flow meters connected to a closed-loop control system.
- Continuous Mixing – Ingredients flow directly into the mixing chamber, where multi-stage mixing guarantees proper incorporation and gluten development.
- Development Stage – Dough is further developed for optimal texture and handling properties.
- System Monitoring – Automated controls watch for changes in temperature, ingredient flow, or moisture content, and adjust instantly to maintain quality.
- Operator-Friendly Interface – Intuitive controls let operators easily monitor performance, adjust settings, and keep production moving efficiently.
Benefits for Large-Scale Production
Exact Mixing’s continuous mixing systems are built to meet the demands of high-volume production, delivering results you can measure:
- Consistent Size and Shape – Every loaf, bun, and roll meets your exact specifications.
- Maximized Water Absorption – Improves yield and reduces ingredient costs.
- Fewer Defects – Eliminates common issues like surface imperfections.
- Smaller Risk During Downtime – Less dough is at risk if downstream equipment pauses.
- Reduced Labor Costs – Automated processes require fewer manual interventions.
- Easy Training – User-friendly systems mean quicker onboarding for new operators.
Test Before You Invest
Before investing in new equipment, you can experience Exact Mixing technology firsthand at the Reading Bakery Systems Science & Innovation Center. This fully licensed production facility allows bakeries to:
- Test our continuous systems with their own recipes.
- Validate ingredient performance and process efficiency.
- Conduct shelf-life studies and product evaluations.
- Explore process innovations that can improve profitability.
Our team will work with you to fine-tune recipes, optimize mixing parameters, and ensure a seamless integration into your operations.
Ready to Upgrade?
Switching to continuous mixing is an investment in consistency, efficiency, and long-term growth. With over 30 years of experience, Exact Mixing delivers solutions that help bread producers meet market demands without compromising quality.
Contact us today to discuss your production goals and learn how our continuous mixing systems can transform your bread manufacturing process for greater consistency, efficiency, and profitability.
