Discover how Continuous Mixing equipment from Exact Mixing can improve your bread and bun manufacturing process.
Exact Mixing, a Reading Bakery Systems brand, is the leading supplier of Continuous Mixing Systems for the baked food industry. We offer a full line of mixer models and sizes that will successfully mix a wide variety of food products.
We have developed continuous mixing systems that are ideal for the bread and bun, cookie, cracker, baked snack, sweet goods, pizza, and tortilla industries. Customers will also find continuous mixing solutions for non-bakery items, such as protein bars, peanut butter, icings, and pet treats.
How Batch and Continuous Mixing Compare
Material delivery systems: The delivery systems that deliver bulk materials to the mixer are the same for batch and continuous mixing, but adding raw materials to a Continuous Mixer is more accurate than with a batch mixer in almost every case.
Measuring materials: Getting a “proper size” batch of ingredients to the batch mixer often requires extra weighing equipment and controls. With a Continuous Mixer, all metering is done at the mixer itself, which leads to more automation, greater accuracy, and a significant cost savings in the long term.
Mixing: Studies show 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.
Batch sizes: Batch mixers make large “batches” of dough and manufacturers need additional equipment to resize them. This requires more time and unnecessary exposure to the environment where contamination can occur. In contrast, dough exits Continuous Mixers in a continuous stream that can be sliced automatically into usable size loaves by the mixer.
Continuous Mixing for Bread and Rolls
Exact Mixing manufactures the HDX Continuous Mixer specifically for ultra-high absorption, highly developed dough at low temperatures, such as for breads, hamburger and hot dog buns, hard rolls, English muffins, tortillas, and multi-grain products.
This Continuous Mixer is a two-stage system. First, all ingredients are mixed into a uniform mass with a twin-screw mixer. Then, in a separate section, the dough is kneaded to the proper development level with a single-screw mixer.
The Exact HDX Mixer offers dough production rates from 1,500 to 10,000 kg/hour. It provides precise and uninterrupted ingredient metering to the mixer and eliminates the chance of contamination because the dough is never exposed to the environment.
We encourage you to explore whether your process is a good fit for Continuous Mixing with our Continuous Mixing Calculator. To see your products being mixed in a continuous process, schedule a visit to our Science & Innovation Center in Sinking Spring, Pennsylvania, where pilot versions of all models of Exact Mixers are available.
Exact Mixing offers the most advanced Continuous Mixers for your bread and bun manufacturing process. With our equipment and expertise, we can help you improve consistency, reduce labor, cut costs, and simplify your mixing process. Call our Robesonia, Pennsylvania headquarters at (01) 610-693-5816 or contact us online to learn more.