Exact Mixing has supported commercial bakeries for more than 25 years with continuous mixing systems that replace batch variability with a stable, repeatable process built for high-volume baked food production. Designed to integrate seamlessly into modern production lines, these systems help bakeries improve efficiency, reduce waste, and maintain consistent results over long runs.
Explore the top advantages of continuous mixing for baked food production lines:
Improved Ingredient Distribution and Dough Quality
Continuous mixing systems use precise ingredient feeding with loss-in-weight control to accurately meter flour, water, yeast, fats, and minor ingredients. Ingredients are introduced into the mixer at a constant rate, stabilizing hydration and dough development throughout long runs.
This consistency supports uniform dividing weights, predictable proofing behavior, and reliable finished product structure. Even distribution of minor ingredients also reduces the risk of localized overdosing that can occur in high-capacity batch mixing.
Higher Throughput with One Mixer
Exact Mixing’s continuous mixers support production rates from approximately 50 kg per hour to more than 10,000 kg per hour, depending on the model and application. This capacity often allows a single continuous mixer to replace multiple batch mixers while maintaining consistent output.
In many facilities, a single mixer can supply dough to one or more downstream production lines, reducing equipment duplication and simplifying the overall line layout.
Steady Dough Supply for Automated Lines
Continuous mixing produces dough in an uninterrupted flow rather than in discrete batches. This steady delivery aligns with high-speed dividers, sheeters, and forming equipment, helping stabilize throughput and reduce disruptions caused by batch timing mismatches.
Reduced Labor, Energy, and Operating Costs
By automating ingredient handling, metering, mixing, and controls, Exact Mixing systems reduce manual intervention and operator dependence. Many bakeries operate continuous systems with minimal staffing compared with batch-mixing processes. Operating at steady-state conditions also reduces energy use by up to 40% per unit of dough and lowers operating costs over time.
Improved Sanitation and Food Safety
Exact Mixing equipment features a clamshell-style design that opens fully for access to the mixing chamber. This simplifies inspection, cleaning, and sanitation compared to enclosed batch systems. Reducing handling during production further lowers the risk of contamination and supports food safety programs.
Faster Changeovers and Reduced Dough Loss
Continuous mixers typically enable faster transitions between products because disassembly between runs is not required. In addition, the amount of dough in process at any moment is much lower than in batch operations. If a downstream stoppage occurs, less product is at risk, and restarts are more controlled.
Scalable Production and Line Integration
Because one continuous mixer can handle high output volumes, bakeries often achieve greater capacity with a smaller footprint than batch installations. Exact Mixing systems integrate with upstream ingredient handling and downstream equipment, and in some configurations, a single mixer can reliably supply multiple production lines.
Data Tracking and Process Control
Exact Mixing systems continuously track ingredient feeds, mixing performance, throughput, and key operating parameters. Production data is stored electronically, giving bakers clear visibility into process history, recipe accuracy, and performance trends to support quality assurance and ongoing process improvement.
Smarter Mixing Starts Here
By investing in Exact Mixing’s continuous mixing technology, food producers can increase consistency, lower costs, scale production more effectively, and maintain tighter control over product quality. Whether your line makes crackers, sweet goods, breads, or snacks, continuous mixing streamlines production and reduces variability compared to traditional batch systems.
To see how continuous mixing can support your production goals, contact Exact Mixing today.
