Energy costs are a major factor in every high-volume bakery operation. Continuous mixing technology offers an effective way to reduce energy consumption while improving dough quality, consistency, and output. Compared with traditional batch systems, Exact Mixing’s continuous mixers deliver measurable savings through mechanical efficiency and process control. Here’s how:
- Steady-State Operation
Batch mixers waste energy with every start and stop, as motors accelerate, decelerate, and idle between loads. Continuous mixers run in a steady, uninterrupted flow to keep motors and agitators at their most efficient speed. This consistent operation eliminates idle surges and reduces the average power draw per kilogram of dough.
In side-by-side bakery testing, Exact Mixing’s continuous mixer used 29% less total energy and maintained a median power draw 42% lower than a comparable batch mixer, while producing the same volume of dough.
For a bakery using around 80 kW per mixer, that efficiency equates to roughly 140,000 kWh saved annually, or about $14,000–$17,000 in yearly energy savings per line, based on average U.S. industrial rates.
- Fast, Controlled Mixing
Continuous systems meter and blend ingredients in real time, achieving optimal gluten development in seconds rather than the 8–15 minutes required for batch mixing. Because energy is applied evenly and precisely, these systems avoid the friction, overmixing, and inconsistent loading that waste power and generate unnecessary heat.
Maintaining stable dough temperatures also reduces post-mix cooling needs and lowers overall motor runtime. The result is 30–40% less kilowatt-hour usage per pound of dough and a longer lifespan for mechanical components. Over time, this efficiency can deliver a 2–4 year payback on equipment investment through energy savings alone.
- Streamlined Production Lines
Beyond the mixer itself, continuous systems simplify production by eliminating energy-intensive components such as trough elevators, dough chunkers, transfer pumps, and holding hoppers.
Removing this auxiliary equipment can cut an additional 5–10% from total line energy consumption, while reducing maintenance demands and electrical load across the production floor.
Because continuous mixing generates less frictional heat, it also helps stabilize dough temperature, reducing strain on HVAC and cooling systems and further lowering facility-wide energy use.
- Automation and Overall Efficiency
Exact Mixing’s continuous mixers feature automated feedback controls that constantly monitor and adjust torque, ingredient feed, and hydration in real time. This intelligent process control minimizes energy spikes, reduces manual oversight, and maintains consistent dough quality across every run.
By operating continuously at peak efficiency, the system produces more dough per kilowatt-hour consumed, lowering the overall cost per pound of finished product. For multi-line facilities, these energy and productivity gains can deliver annual savings of $50,000–$100,000 or more while advancing sustainability and carbon-reduction initiatives.
Discover the Power of Continuous Mixing
Exact Mixing’s line of continuous mixers offers reliable performance for bakeries of every size and product type. With throughputs up to 10,000 kg per hour, every mixer is engineered for maximum efficiency, durability, and precision, featuring:
- Configurations optimized for dough type, absorption rate, and mixing intensity
- Stainless steel construction and sanitary design for food safety and easy cleaning
- Advanced control systems that ensure consistent operation with minimal downtime or maintenance
- Seamless integration into automated production lines
Proven across hundreds of installations worldwide, Exact Mixing helps bakeries achieve 15–40% reductions in total energy use while improving process reliability and product quality. The result is a sustainable, cost-effective solution that lowers utility expenses, reduces carbon footprint, and supports long-term profitability and growth.
Contact Exact Mixing today to learn more about how continuous mixing can help your bakery save energy, reduce waste, and boost performance.
