Batch mixing may be popular, but it may not be the most practical solution for your commercial bakery. Exact Mixing has provided information that will help you make an informed decision concerning continuous vs. batch mixing.
Exact Mixing, a Reading Bakery Systems brand, is the leading supplier of Continuous Mixing Systems for the food industry. Since 1994, we have solved complex mixing challenges for customers across the globe and installed more than 100 Continuous Mixers.
With our equipment and expertise, we can help you reduce labor, cut costs, improve consistency and simplify your mixing process. We offer a full line of mixer models and sizes that will successfully mix a wide variety of food products.
What is the Difference Between Batch and Continuous Mixing?
Batch mixing is a process in which the ingredients for one batch are loaded (either at once or in a pre-defined sequence), mixed, and discharged from the mixer before another batch is introduced.
Continuous Mixing, on the other hand, is the process of continuously metering ingredients directly into the mixing chamber and generating a continuous stream of mixed product at the exit of the mixer. The mixing may be done in stages to ensure all ingredients are properly incorporated.
What are the Advantages of Continuous Mixing Over Batch Mixing?
- Consistent finished product weight, size and texture
- Eliminates variables due to batch process
- Even hydration of dough
- Better integration of minor ingredients
- High production rates with one mixer
- One mixer can feed multiple lines
- Self-monitoring and self-correcting system
- Quick and easy changeovers
- Easy to sanitize, maintain, clean and inspect, due to its clamshell design
- Consistent, steady supply of dough
- Dough leaves mixer in usable size loaves
- Can be operated with less labor and energy than batch mixing
- Requires little training to operate, due to its user-friendly interface control panel
- Excellent traceability
- Error elimination
- Eliminates chance of contamination
- Simplifies the mixing process and dough feed equipment
- Smaller footprint than batch mixers, which saves space, money and energy
- Achieve verifiable kill temperatures (pet foods)
The Continuous Mixing process eliminates the problems associated with batch cycles and produces a consistent product all day, every day.
What Products Can Be Made with a Continuous Mixer?
Almost any product that can be made with a traditional batch mixer can be made on a Continuous Mixer. No single type of batch mixer is ideal for all products. This is also true for continuous mixers. This is why Exact Mixing offers a range of continuous mixer models. Try our Continuous Mixing Calculator to explore whether your process is a good fit for continuous mixing.
If you would like to see your products being mixed in a continuous process, we encourage you to visit our Science & Innovation Center in Sinking Spring, Pennsylvania, where pilot versions of all types of Exact Mixers are available.
To learn more about batch mixing vs continuous mixing and find out which one may be best for your process, get in touch with Exact Mixing at (01) 610.693.5816 or contact us online.