As consumers seek healthier snack options, cracker manufacturers in Odawara, Japan, are adapting their production to include whole-grain, gluten-free, and high-protein varieties. To stay competitive, they must also maintain efficiency and scalability. Exact Mixing’s advanced continuous mixers streamline production, helping businesses meet these market demands without compromising quality or output.
Keeping Up with Consumer Trends: Clean-Label & Specialty Crackers
Exact Mixing supports the production of specialty crackers with natural ingredients, fewer additives, and functional nutrition by delivering precise ingredient control, optimized hydration, and consistent dough quality:
Whole Grain & High-Protein Crackers
Crackers with whole grains, legumes, or high-protein ingredients require precise hydration and uniform mixing to prevent dry, tough textures. Exact Mixing models provide:
- Advanced Hydration Control – Ensures even moisture distribution in high-protein and whole-grain doughs, preventing cracking and density issues.
- Even Ingredient Dispersion – Prevents separation, ensuring a consistent taste, texture, and appearance in every cracker.
- Scalability – Supports high-volume production without slowing down processing speeds.
Gluten-Free Crackers
Gluten-free dough is delicate and prone to separation, making it challenging to maintain uniformity at scale. Exact Mixing’s real-time metering and automated mixing adjustments ensure:
- Stable Dough Structure – Prevents clumping and uneven hydration, resulting in smooth, uniform cracker formation.
- Minimized Ingredient Waste – Gluten-free ingredients are costly, but precision metering optimizes usage and reduces waste.
- Scalability Without Quality Loss – Continuous mixing allows for high-output gluten-free production while preserving texture and crispiness.
Clean-Label Production
Consumers are looking for snacks free from artificial stabilizers and unnecessary additives. Exact Mixing’s systems support clean-label cracker production by:
- Precision Ingredient Metering – Ensures exact ingredient ratios, reducing the need for stabilizers or processing aids while enhancing product consistency and shelf stability.
- Hydrobond Technology – Enables rapid, uniform hydration, eliminating the need for excessive emulsifiers or binders and improving dough structure for better final product quality.
- Consistent Mixing for Reduced Waste – Prevents overuse of ingredients, reducing product defects and improving cost efficiency by maintaining uniform texture and minimizing batch-to-batch variations.
Enhancing Operations: Advanced Automation & Process Control
Exact Mixing incorporates innovative features that enhance efficiency, minimize inconsistencies, and reduce manual labor to maintain high-quality output at scale.
Real-Time Monitoring & Automated Adjustments
Control over ingredient blending, hydration, and process optimization allows manufacturers to maintain consistent quality with minimal manual oversight.
- Precision Ingredient Blending – Gravimetric metering delivers ±0.25% accuracy in ingredient measurements, eliminating overuse and reducing waste.
- Automated Hydration Control – Instantly adjusts moisture levels to prevent overhydration or dry spots, ensuring consistent dough quality.
- Data-Driven Process Optimization – Operators can track and fine-tune mixing parameters on the spot, ensuring every batch meets exact specifications.
Automating these critical processes eliminates batch inconsistencies and helps manufacturers achieve reliable, high-quality results with minimal operator intervention.
Clean-in-Place (CIP) Technology
Hygiene is critical in large-scale cracker production. Exact Mixing’s Clean-in-Place (CIP) technology simplifies sanitation by automating cleaning cycles and reducing production downtime.
- Crevice-Free Stainless Steel Design – Prevents ingredient buildup and contamination risks.
- Automated Cleaning Cycles – Eliminates manual disassembly, reducing cleaning time.
- Minimized Downtime – Faster sanitation means increased production time and fewer disruptions.
With Exact Mixing systems, manufacturers can increase uptime, improve food safety, and reduce labor-intensive cleaning while upholding strict hygiene standards.
Stay Ahead of the Competition with Exact Mixing
Don’t let outdated mixing methods hold back your cracker manufacturing production: upgrade to an innovative, more efficient solution. Exact Mixing’s advanced continuous mixing systems provide the precision, scalability, and automation to stay ahead in Odawara, Japan’s competitive and evolving market.
Contact Exact Mixing today to explore the best continuous mixing system for your cracker production facility!
