Opening a commercial bakery requires making several capital investment decisions that will ultimately determine your profit margin. Investing in a facility to produce the dough for your baked goods and snacks represents the first substantial investment, closely followed by purchasing bakery machines and equipment to help you pursue a profitable production schedule.
Before 1994, batch mixers dominated the market for bakery machines and equipment. When Exact Mixing opened its facility in 1994, businesses relying on producing baked products discovered a new and improved process for making high-quality dough that also saved them money.
After joining the Reading Bakery Systems family of brands in 2008, Exact Mixing ramped up the production of continuous mixer models. Since then, the continuous dough mixing method has emerged as a viable alternative to the batch mixing process, which costs businesses more time and money.
Why Continuous Mixers Outperform Batch Mixers
Jim Warren, who serves as the Vice President of Exact Mixing, defines the primary difference between the two dough mixing methods. “Batch mixing is like walking up a flight of stairs, and continuous mixing is like taking the escalator,” Warren said. “Both get you to the same final destination, but with batch mixing, you have to go one step at a time and put in more effort; continuous mixing is just a steady-flowing process. Continuous mixing offers a consistent, uniform dough stream to a production line at the same rate that it is used. It provides consistent dispersion of ingredients, simpler dough feed equipment, and tighter control over the entire mixing process.”
Proven Applications
Exact Continuous Mixers come in a range of sizes, from 50 to 10,000 kg/hour, and are available based primarily on dough mixing stages or dough moisture levels. We offer Continuous Mixing solutions for a wide range of products, including (but not limited to:
Bakery Goods: Bakery products, such as bagels, pizza, cookies, pie crusts, pocket sandwiches, breakfast biscuits, pastries, pet treats, and more, can be produced in our EX Continuous Mixer. It is designed specifically for mixing these low- to mid-absorption, fully-developed doughs.
Crackers: Also consider the Exact EX Continuous Mixer for your cracker products and its low absorption, very stiff dough. The thorough mixing action develops a mass and evenly blends the leavening agents into the dough for a uniform piece size after the oven.
Wheat-Based Snacks: The EX Continuous Mixer is also ideal for wheat-based snack products where dough moisture levels range from very low to very high, including bread snacks, pretzels, bread chips, rye chips, and similar applications.
Buns, Breads & Rolls: Exact Mixing offers the HDX Continuous Mixer, explicitly designed for mixing ultra-high absorption, highly developed dough, such as for breads, hamburger and hot dog buns, hard rolls, English muffins, tortillas, multigrain products, and similar products.
Crisp Products: The Exact FX Continuous Mixer is designed for products where critical moisture levels determine final product texture, such as baked potato chips, stackable potato chips, rice crisps, corn chips, veggie chips, potato snacks, multigrain chips, and more.
Fillings, Icings & Batters: Exact Mixing offers the MX Continuous Mixer for high-fat, high-solid products, such as icings, batters, peanut butter, muffins, pie fillings, cake-style donuts, and other fat/sugar mixtures. Solid ingredients are quickly blended into solid fat to create a uniform mixture without excessive heat.
Exact Mixing offers your business a demonstration of how the continuous mixing process works. We also support our customers by encouraging them to visit the Science & Innovation Center in Sinking Spring, Pennsylvania. Learn more about our bakery machines and equipment by submitting the convenient Contact form or by calling Exact Mixing at 610-693-5816.
