When production starts pushing the limits of a batch mixing process, adding more mixers is not always the best answer. Many manufacturers are turning to continuous mixing to simplify operations, improve consistency, and support higher throughput without adding unnecessary complexity.
From ingredient handling and metering to automated controls and continuous dough production, Exact Mixing systems help bakeries and snack producers get more from their industrial production lines.
Overview of a System
An Exact Mixing Continuous Mixing System is a fully integrated solution that automates ingredient handling and delivers consistent product quality. The system typically includes:
- Dry ingredient receiving and handling systems to move ingredients from storage to production
- Dry blending equipment to ensure uniform ingredient distribution
- Loss-in-weight feeders that accurately meter dry ingredients into the mixer
- Liquid metering systems with closed-loop controls to precisely add water, oils, and other liquids
- A continuous mixer that produces a steady flow of product without the stop-and-start cycles of batch mixing
- Integrated controls and an operator interface that monitor the process, manage recipes, and record production data for quality assurance and process optimization
By combining these components into one system, manufacturers can improve consistency, efficiency, and control over production.
Continuous Mixer Models
Exact Mixing offers a range of continuous mixer models engineered to support different snack formulations, processing requirements, and production capacities.
EX Mixer
Designed for low- to mid-absorption wheat-based doughs, the EX Continuous Mixer is best for pretzels, crackers, baked wheat snacks, and similar products. Its gentle mixing action promotes consistent dough development while minimizing heat generation.
Production capacity: up to 7,500 kg/hour
MX Mixer
The MX Continuous Mixer is ideal for versatile and complex snack formulations, including extruded snacks, snack bars, filled snacks, coated products, and products containing inclusions. Its high-energy mixing capabilities ensure thorough ingredient incorporation while preserving product quality.
Production capacity: up to 8,000 kg/hour
FX Mixer
The FX Continuous Mixer is engineered for low-moisture, powder-based applications such as potato chips, corn snacks, rice snacks, and multigrain chips. It excels at distributing small amounts of moisture evenly throughout dry ingredient blends.
Production capacity: 100 to 1,250 kg/hour
LDX Mixer
The LDX Continuous Mixer utilizes a two-stage crème-up process that incorporates fats and other ingredients before the addition of flour. This design is ideal for cookie-based products requiring controlled ingredient incorporation.
Production capacity: up to 9,000 kg/hour
HDX Mixer
The HDX Continuous Mixer is designed for highly developed, high-absorption doughs used in bread-based snacks, filled buns, English muffins, and other soft-baked products. It provides the dough development necessary for softer textures and greater structure.
Production capacity: 1,500 to 10,000 kg/hour
The Continuous Mixing Advantage
By replacing repeated batch cycles with a steady, automated process, continuous mixing offers several key benefits:
- More consistent products through precise ingredient metering and reduced batch-to-batch variation
- Higher production capacity with a continuous flow of dough or batter supplied directly to the production line
- Reduced labor requirements by automating ingredient handling, metering, and mixing functions
- Lower operating costs through improved ingredient utilization, reduced waste, and lower energy consumption
- Greater process control with real-time monitoring, recipe management, and production data collection
- Improved food safety and sanitation through enclosed ingredient handling and more controlled production conditions
- Easier scalability as production grows, without the need for additional mixers, labor, or floor space
For high-volume manufacturers, these benefits often become even more significant as throughput increases, helping support long production runs, consistent product quality, and efficient growth.
Partner with Exact Mixing
Ready to explore how continuous mixing can improve your industrial bakery production line? Contact Exact Mixing to discuss your operation, schedule product testing, or learn more about the right continuous mixing solution for your facility.
