In commercial bakeries, efficiency and consistency are key to meeting growing demand while maintaining high-quality products. If your bakery is aiming to enhance production, finding the best equipment supplier is the first step. At Exact Mixing, our continuous mixing systems are engineered to help bakeries streamline ingredient handling, precise metering, and automated control to deliver uniform dough continuously and reliably.
How Continuous Mixing Works
Continuous mixing is a process where ingredients are continuously and precisely fed into a mixer, producing a steady flow of consistently mixed dough or product. Mixing often happens in stages to ensure thorough incorporation of all ingredients. This method overcomes the limitations of traditional batch mixing by eliminating downtime between batches and delivering the same high-quality dough throughout production.
Expert Engineering and Comprehensive Systems
At Exact Mixing, our engineering team, with its combined mechanical, process, and control expertise, delivers systems that are optimized for performance, sanitation, and ease of maintenance. Using advanced 3D modeling software, they tailor each system to meet the unique needs of your bakery operation, ensuring safety and efficient workflows. This level of expertise ensures that you can trust the quality and reliability of our systems.
Each system includes:
Advanced Materials Handling
A critical first step in continuous mixing is efficient materials handling. Bulk raw ingredients, whether dry or liquid, must be brought into the mixing area in a controlled, uninterrupted flow. For dry ingredients, pneumatic transfer from silos, bulk bags, or smaller containers is typical, while liquids are delivered through bulk lines, totes, or drums. To simplify processing, minor dry ingredients are often pre-blended before entering the system, reducing complexity and improving consistency.
Precision Ingredients Metering
Quality dough starts with precise ingredient delivery. Exact Mixing integrates advanced metering systems with every mixer to ensure accurate quantities of ingredients enter the process continuously.
- Dry Ingredients Metering: Using gravimetric Loss-in-Weight feeders, dry ingredients are measured with exceptional accuracy. The system constantly compares the target ingredient amount (set point) with the actual delivery rate, automatically adjusting and alerting operators if discrepancies occur.
- Liquid Ingredients Metering: Liquid components are managed with metering pumps and flow meters under closed-loop control. This system also continuously compares the set target against actual flow, ensuring exact hydration levels. When necessary, liquid lines can be jacketed for heating or cooling to maintain optimal ingredient temperatures.
- Special Ingredient Metering: For more complex materials like solid fats, pastes, or fragile particulates, Exact Mixing custom-engineers specialized metering solutions that preserve ingredient integrity and ensure proper incorporation.
User-Friendly Operator Interface and Control
Exact Mixing systems feature an integrated touchscreen that controls mixing and materials delivery. With menu-driven recipe selection, clear real-time process data, and alarm notifications, our systems make it easy for operators to monitor and adjust production. This user-friendly interface is designed to make the operation of our systems intuitive and stress-free.
- The Main Operator Screen shows the overall system status at a glance—motors, recipe targets, and any active alarms.
- Equipment-specific screens allow manual operation and detailed monitoring of individual components.
- Historical data is stored and visualized for trend analysis, helping improve quality control.
- New recipes can be securely added and managed through password-protected formula entry screens.
- Pre-blending operations for minor ingredients are also controlled directly from the interface.
Integrated Dry and Liquid Handling Systems
Exact Mixing’s systems are designed for flexibility and automation:
- Dry Materials Handling: Ingredients can be introduced automatically or manually from various sources, including silos and bulk bags. Pre-blending of minor ingredients ensures uniform distribution and simplifies system design.
- Liquid Materials Handling: Small tanks adjacent to the mixer feed liquid ingredients to the metering system. These tanks are automatically refilled, optimizing continuous flow and precise control.
Get Started Today
Unlock greater efficiency, consistent product quality, and scalable production with Exact Mixing’s continuous mixing systems. Contact us to discover how our solutions can transform your commercial bakery operations.
