If your commercial bread and roll production lines utilize a traditional batch mixer, you may be interested in the advantages of Continuous Mixing equipment from Exact Mixing.
Exact Mixing, a Reading Bakery Systems brand, is the leading supplier of Continuous Mixing Systems for the food industry. We are dedicated to solving complex mixing challenges for customers around the globe and have installed more than 100 Continuous Mixers worldwide.
Differences Between Batch and Continuous Mixing
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 sized” batch of ingredients to a batch mixer often requires additional weighing equipment and controls. With a Continuous Mixer, all metering is done at the mixer itself. This leads to more automation, greater accuracy, and significant cost savings in the long term.
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.
Mixing: Studies show that Continuous Mixing eliminates problems associated with batch cycles and produces a consistent product all day, every day. 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 costly, and savings increase as production rates increase.
Advantages of Continuous Mixing
- Improves reliability and repeatability
- Eliminates bun surface imperfections
- Creates consistent bun and roll shape
- Accommodates “within spec” flour variations
- Maximizes water absorption—reduces the cost of ingredients and improves yield
- Eliminates dough contamination
- Quick and easy sanitation
- Reduces labor and peak energy demand
- Eliminates mixer loading errors
- Easy to learn and operate
- Allows consistent time between mixing and further processing
- Dough exits the mixer in usable sized loaves
Consider the Exact HDX Continuous Mixer
The Exact Mixing HDX Continuous Mixer was designed specifically to manufacture ultra-high absorption, highly developed dough at low temperatures for bread, rolls, buns, English muffins, tortillas, and multi-grain products.
This high-development Continuous Mixer is designed to mix all ingredients into a uniform mass in the first stage with a twin-screw mixer. In the second stage, the dough is kneaded to the proper development level with a single-screw mixer.
The Exact HDX Mixer provides precise and uninterrupted ingredient metering to the mixer and eliminates the chance of contamination because the dough is never exposed to the environment. This mixer offers dough production rates of up to 10,000 kg/hour.
Get in touch with Exact Mixing at (01) 610.693.5816 or contact us online to learn more about our commercial mixing equipment for your bread and roll production lines or other applications.