When choosing the right mixer for your bakery, discover the benefits of Exact Mixing’s unparalleled range of Continuous Mixers and explore how they can help improve your products and process.
Exact Mixing, founded in Memphis, Tennessee in 1994, became a Reading Bakery Systems brand in 2008 and continues to deliver innovative mixing solutions to customers and industries around the globe. Our equipment is engineered and manufactured at the main Reading Bakery Systems facility in Robesonia, Pennsylvania.
Comparing Batch and Continuous Mixing
Batch mixing has existed far longer than Continuous Mixing. However, the development of improved mixers, control systems, and metering devices over the past decade has resulted in 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. Additions by hand 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 greater 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.
Exact Mixing offers a comprehensive line of mixer models and sizes with production volumes ranging from 50 kg/hour to over 10,000 kg/hour that will successfully mix a wide variety of food products. They include:
Exact EX Continuous Mixer – designed for wheat-based snack products, such as crackers, and other low- to mid-absorption stiff doughs.
Exact HDX Continuous Mixer – a two-stage system designed for manufacturing ultra-high absorption, highly developed doughs at low temperatures, such as for buns, bread, and rolls.
Exact FX Continuous Mixer – designed for products where critical moisture levels determine final product texture, such as baked potato chips and crisp products.
Exact MX Continuous Mixer – our most versatile mixer that is designed for products that require high energy mixing as well as a wide range of other products, including cookies, snacks, batters, icings, and pastes.
Exact LDX Continuous Mixer – is a great choice for cookies and other products that require ingredient blending before flour is added,
Look no further than Exact Mixing when choosing the right mixer for your industrial bakery. Contact us at (01) 610.693.5816 or reach out to us online. We can help you produce consistent products all day, every day.