Exact Mixing is a global leader in bakery mixing technology. Our Continuous Mixers mix many different types of dough with production volumes ranging from 50 kg/hour to over 10,000 kg/hour.
Exact Mixing, a Reading Bakery Systems brand, has supplied Continuous Mixing Systems to the food industry since 1994. We have solved complex mixing challenges for customers across the globe, enabling them to eliminate the problems associated with batch mixing and produce a consistent product all day, every day.
Exact Mixing joined Reading Bakery Systems in 2008 and continues to bring innovative solutions to a growing number of customers and industries. Our mixers are now engineered and manufactured at the main Reading Bakery Systems facility in Robesonia, Pennsylvania.
We offer a full line of mixer models and sizes that will successfully mix a wide variety of baked and non-baked food products.
How Batch Mixing and Continuous Mixing Compare
Batch mixing has existed far longer than Continuous Mixing, but the development of better mixers, control systems, and metering devices over the past decade has produced Continuous Mixing Systems that are accurate, reliable, and easy to use and maintain, including for breads, cookies and crackers.
- Bulk delivery of materials: The delivery systems used to deliver bulk materials to the mixer are exactly the same for batch and continuous mixing. In general, they are brought from a source such as a silo or super sack unloader to the mixing receiver by pneumatic transfer. Manual additions are also possible in continuous mixing by using a ribbon blender. The difference is that adding raw materials to a continuous mixer is more accurate than with a batch mixer in nearly every case.
- Measuring of materials into the mixer: Additional weighing equipment and controls are often required to get the “proper size” batch of ingredients to the batch mixer. With a continuous mixer, all metering is done at the mixer itself. Metering directly at the mixer leads to more automation, greater accuracy, and a significant cost savings over the long term.
- Mixing: Studies have shown that continuous mixing eliminates the problems associated with batch cycles and produces a consistent product all day, every day. In terms of cost, batch mixing is slightly less expensive than continuous mixing at the lowest production rates (500 to 1500 pounds per hour). At higher rates, continuous mixing is less expensive, and the savings increase as production rates increase.
- Dough leaves mixer in usable size loaves: Batch mixers make large “batches” of dough. Manufacturers need additional equipment to resize the batches. This can cause time delays and unnecessary exposure to the environment where contamination can occur. Continuous mixers produce a continuous stream of dough that can be sliced automatically into loaves by the mixer.
The Exact Mixing Hydrobond Technology brings liquids and a dry ingredient stream (typically flour) together quickly, with little temperature gain. It can be used with a continuous mixer to make the mixing process more efficient or with a pre-hydration system to mix flour, minors and water directly into a brew holding tank. This system speeds up the continuous process, allowing for the use of a shorter mixer, which means a smaller footprint, lower equipment costs, and lower energy costs.
To learn more about incorporating continuous mixing technology in your industrial bakery process, get in touch with Exact Mixing at (01) 610.693.5816 or contact us online.