Traditional batch mixing often limits production, increases labor requirements, and introduces batch-to-batch variation. Continuous mixing, on the other hand, offers a smarter, more efficient approach. By automating ingredient delivery and dough development, Exact Mixing’s continuous mixing systems help modern bakeries achieve the best quality, reduce operating costs, and keep production running smoothly.
How does it help increase output?
Continuous mixers run continuously, without the pauses required for loading or unloading dough. This uninterrupted operation keeps production moving and can boost throughput by 20–40% or more compared to batch systems.
How does continuous mixing impact labor costs?
Labor savings are one of the most significant advantages. Batch mixing is labor-intensive, requiring operators to weigh, load, unload, and clean between cycles. Continuous mixing automates nearly all of those steps.
With automated ingredient feeding and steady dough flow, one operator can often manage multiple mixing lines. Many bakeries report labor savings of 30–50%, along with improved workplace safety and efficiency.
What about energy savings?
Continuous mixing operates in a steady-state mode, so motors don’t constantly start and stop. That efficiency alone can reduce energy use by 15–40% compared to batch systems.
Because continuous dough production generates less frictional heat, bakeries also spend less on cooling and air handling, delivering significant savings on utilities while improving sustainability.
Is Exact Mixing equipment compatible with automation and modern bakery lines?
Yes. Exact Mixing systems are built to integrate with automated ingredient feeding, forming, and baking equipment.
Smart controls monitor torque, ingredient feed, and hydration in real time, automatically adjusting to maintain optimal dough development. This allows bakeries to maintain precision without constant supervision, which is ideal for data-driven operations.
Continuous mixing also reduces floor space requirements by eliminating troughs, chunkers, and holding hoppers. The streamlined layout lowers maintenance needs and improves overall workflow and efficiency.
How easy is cleaning and sanitation?
Continuous mixing simplifies cleaning and maintenance. Exact Mixing’s stainless steel construction and enclosed design reduce dough buildup and eliminate the need for multiple bowls or troughs.
Fewer moving parts mean faster washdowns and less downtime between production runs. Many bakeries find that one operator can clean a continuous line in the time it would take a team to clean several batch mixers.
Is it scalable for growing bakeries?
Exact Mixing offers a full range of mixers, each engineered for various dough types and scalable production volumes. With throughputs of up to 10,000 kg per hour, these systems grow with your business, giving you the flexibility to expand product lines or increase output without major reconfiguration.
What’s the return on investment (ROI)?
Continuous mixing delivers a fast, measurable ROI. Between labor savings, energy efficiency, and reduced waste, many bakeries recover their investment in two to four years. Beyond cost savings, consistent product quality and higher throughput create long-term value that lasts throughout the life of the equipment.
Why choose Exact Mixing?
With hundreds of installations worldwide, Exact Mixing has helped bakeries of every size transition to continuous production. Customers benefit from process support, operator training, and readily available parts to keep systems running at peak performance.
Ready to discover the future of industrial baking?
Contact Exact Mixing today to schedule a pilot test or discuss how continuous mixing can help modernize your bakery and achieve its best performance in efficiency, consistency, and profitability.
