In high-volume bakery production, every minute counts. Traditional batch mixing slows output with constant stops for loading, mixing, and cleaning. Exact Mixing’s continuous mixing systems eliminate these interruptions by creating a steady flow of ingredients and dough, allowing bakeries to produce more product in less time without compromising consistency or quality.
Continuous Operation for Greater Throughput
Exact Mixing’s systems are designed for non-stop production. Dry and liquid ingredients are continuously metered into the mixer, where they are blended and developed in real time. Dough exits the mixer at a consistent rate and is fed directly into downstream forming or sheeting equipment.
This continuous process eliminates downtime between batch cycles. Instead of waiting for one batch to finish before starting the next, production runs at a constant rate, which significantly increases overall throughput. Large-scale bakeries can achieve up to 40% more output than traditional batch systems.
Precise Ingredient Metering and Mixing Control
A major advantage of Exact Mixing technology is automated ingredient metering. Each component is measured with high accuracy using mass flow meters and load cells. This precision guarantees consistent dough properties across extended runs, which means fewer rejected products and reduced waste.
Continuous mixers also maintain real-time control of dough temperature and energy input. Variable-speed mixing elements adjust automatically to maintain the desired dough development. This automation removes the guesswork from mixing, ensuring every kilogram of dough meets exact specifications.
Uniform Dough Development Across All Shifts
In batch mixing, product quality can vary depending on the operator or environmental conditions. Exact Mixing systems create repeatable dough consistency because the process is entirely automated, and recipe parameters are stored digitally. This consistency is essential for high-volume bakeries that operate 24/7 and depend on uniform results across shifts, plants, and product lines.
Faster Changeovers and Less Cleaning Time
Exact Mixing’s continuous mixers are designed for easy cleaning and quick changeovers, allowing bakeries to switch between recipes with minimal downtime. Components such as ingredient hoppers, pumps, and mixing chambers are easily accessible and can be cleaned or flushed without lengthy disassembly.
Compared to batch mixing, which requires manual cleaning after every cycle, continuous systems can run for hours or days before cleaning is needed. This design minimizes unproductive time and keeps production running longer.
Seamless Integration with Large-Scale Production Lines
The Large Capacity Continuous Mixer line integrates directly with upstream and downstream equipment, including bulk ingredient handling, pre-hydration systems, sheeters, and extrusion lines. This seamless connection forms a continuous, automated dough stream from ingredient storage to oven feed.
Because Exact Mixing’s systems can operate at capacities of up to 20,000 pounds (9,000 kilograms) of dough per hour, they are well-suited for high-volume production environments, such as bread, bun, cracker, and snack lines.
Lower Energy and Labor Costs
Continuous mixing also reduces operational costs. The steady-state process uses less power per pound of dough than repetitive batch cycles. Fewer operators are required to monitor the system since recipe control, ingredient metering, and dough discharge are automated. This results in measurable savings on both energy and labor while maintaining consistent quality.
Proven Results at Industrial Scale
With decades of experience and installations across North America, Europe, and Asia, Exact Mixing has helped leading commercial bakeries boost output, reduce costs, and improve process reliability. Each system is custom-built to match production capacity and formulation requirements for seamless integration into existing lines.
By eliminating batch delays, lowering energy use, and maintaining consistent dough quality, Exact Mixing’s continuous mixers deliver measurable gains in efficiency and product uniformity. Contact us today to learn more about increasing your bakery’s capacity and performance.
