Running a commercial bakery means balancing efficiency, consistency, and production demands. As bakeries grow, so do production challenges. While batch mixing has been the go-to method for years, it often creates bottlenecks and inconsistencies. Exact Mixing’s continuous mixing technology offers a streamlined approach—eliminating everyday batch-mixing challenges and optimizing production.
A Smarter Alternative to Batch Mixing
Exact Mixing’s advanced continuous mixers automate the mixing process, ensuring precise ingredient incorporation, uniform hydration, and optimal temperature control. These features help bakeries increase production, reduce waste, and lower costs while maintaining superior dough consistency.
Here’s how continuous mixing solves common problems associated with batch mixing:
- Inconsistent Dough Quality
- The Problem: In batch mixing, slight variations in ingredient distribution, temperature, and mix time can result in inconsistent dough quality between batches.
- Exact Mixing’s Solution: Continuous mixing ensures consistent dough hydration, temperature, and ingredient dispersion by continuously feeding and blending ingredients in a controlled process. This eliminates batch-to-batch variation, producing uniform dough every time.
- High Labor Costs & Manual Intervention
- The Problem: Batch mixing requires frequent manual operation, from ingredient loading to dough transfer, increasing labor costs and the risk of human error.
- Exact Mixing’s Solution: Continuous mixing automates ingredient feeding and mixing, significantly reducing the need for manual intervention. This lowers labor costs and improves process reliability and efficiency.
- Slower Production & Downtime Between Batches
- The Problem: Each batch requires time for loading, mixing, unloading, and cleaning. This downtime adds up, limiting overall production capacity.
- Exact Mixing’s Solution: Continuous mixing runs nonstop, so there is no need for batch breaks. This increases dough output, allowing bakeries to increase production without increasing operational time.
- Ingredient Waste & Inconsistent Scaling
- The Problem: Measuring and handling ingredients for each batch often leads to overuse, underuse, or spillage, causing unnecessary waste.
- Exact Mixing’s Solution: Continuous mixers use precise ingredient metering to ensure the correct amount of flour, water, yeast, and other components are fed into the mixer, minimizing waste and maximizing cost efficiency.
- Temperature Control Challenges
- The Problem: Dough temperature fluctuates in batch mixing due to variable mixing times and inconsistent energy input, affecting fermentation and final product quality.
- Exact Mixing’s Solution: Continuous mixing utilizes energy-efficient cooling systems, maintaining optimal dough temperature for consistent fermentation and dough quality.
- Difficult Cleaning & Hygiene Concerns
- The Problem: Batch mixing requires frequent cleaning between cycles, increasing downtime and the risk of contamination if not properly maintained.
- Exact Mixing’s Solution: Exact Mixing models feature a streamlined design with fewer surfaces for buildup, making cleaning faster and easier. This improves hygiene, reduces sanitation downtime, and helps maintain food safety standards easily.
- Increased Wear & Tear on Equipment
- The Problem: Batch mixers experience frequent start-stop cycles, causing more mechanical stress and higher maintenance costs over time.
- Exact Mixing’s Solution: Continuous mixing operates at a steady state, reducing mechanical strain on mixing components. This leads to longer equipment lifespans and lower maintenance requirements.
With Mixer Models designed for bread, rolls, cookies, chips, and more, Exact Mixing helps bakeries streamline operations and scale production efficiently.
Upgrade Your Operations with Exact Mixing
Don’t let batch mixing slow you down. Exact Mixing’s commercial mixing technology delivers consistent dough quality, higher efficiency, and lower costs, helping bakeries optimize and increase production. Visit Exact Mixing or Contact Us to upgrade your operations today!
