In high-volume bun production, the slightest inconsistency can create big problems. A dough that’s slightly too warm or a mix that’s a little underdeveloped can ripple through the entire line, causing slowdowns, rejects, or wasted ingredients. Exact Mixing offers an alternative that eliminates those variables. Our continuous mixing systems keep bun lines moving smoothly and consistently for improved dough quality, reduced waste, and a smoother process from start to finish.
What You Can Expect
For bun production lines, Exact Mixing’s continuous mixers offer measurable advantages across performance, output, and operational efficiency:
- Precision Dough Development for High-Speed Forming
Control mix energy, temperature, and water absorption in real time, producing dough that flows smoothly through forming lines without additional resting or remixing. This ensures better shape retention, fewer process disruptions, and a more uniform finished product.
- Throughput from 50 kg/hr to over 10,000 kg/hr
Whether running a mid-size bakery or a large-scale industrial facility, Exact Mixing systems can be configured to meet your current demands and expand as your business grows. Facilities with high-volume targets can run multiple lines in parallel or increase line capacity without redesigning the entire system.
- Ingredient Waste Reduced to Less Than 1%
Traditional batch systems often suffer from overmixing, inaccurate dosing, or inconsistent mixing times, resulting in product waste. Exact Mixing uses precision ingredient metering and inline water absorption monitoring to reduce material loss. With waste typically under 1%, bakeries experience significant savings on flour, water, yeast, and enrichment ingredients over time.
- Up to 70% Labor Reduction
Because continuous systems eliminate manual loading, monitoring, and frequent cleaning between batches, fewer operators are needed to oversee mixing. Staff can be reallocated to higher-value roles elsewhere on the line.
- Lower Energy Consumption and Production Footprint
Continuous mixing runs on a steady-state power model, avoiding energy spikes caused by frequent motor startups in batch systems. The compact, linear design also allows a single Exact Mixing system to replace two or more batch mixers, freeing up floor space for packaging, storage, or future expansion.
- Clean-in-Place Systems for Easy Maintenance
Our CIP-compatible equipment is designed to comply with FDA and global food safety regulations. These systems reduce cleaning time by at least 50% while ensuring consistent sanitation between product runs. CIP also reduces staff water usage and chemical exposure.
Start with Better Mixing
Exact Mixing offers five core mixer models, each customizable based on your dough type, capacity requirements, and facility layout. Our systems feature Hydrobond Technology for instant hydration, automated ingredient delivery for precision, and real-time control systems to ensure consistency. Their modular design allows easy expansion without replacing your existing equipment. You can scale up production with less cost, less complexity, and greater control over the process.
Each mixer model is easily integrated with downstream equipment such as bun dividers, rounders, proofers, and ovens. This seamless connection eliminates the need for intermediate dough handling, reducing contamination risk and optimizing dough flow from mix to form.
By improving dough quality, minimizing waste, and simplifying line integration, our mixing systems help bakeries operate more efficiently today and scale confidently for tomorrow. Ready to optimize your bun production lines? Contact Exact Mixing to learn how we can support your goals.
