Exact Mixing provides automated, continuous mixing equipment for snack production lines. Designed to meter, blend, and mix ingredients without batching, these solutions comprise several integrated components that work together to produce a steady, uniform dough or batter.
1. Operator Interface
The operator interface, also called the control panel, serves as the central control system for the entire Exact Mixing system. It allows production staff to:
- Start and stop the process
- Set recipes and ingredient ratios
- Monitor ingredient feed rates, mixer performance, and system alarms
- Adjust parameters to accommodate changes in recipe or production rate
Each step of continuous mixing is tied into this control platform, which records production data that can be reviewed or adjusted as needed.
2. Continuous Mixing Unit
The continuous mixing unit is the core of the system and is responsible for converting accurately metered ingredients into finished dough or batter. The mixer:
- Receives precisely metered dry and liquid ingredients
- Mixes and hydrates ingredients as they move through the unit
- Discharges a uniform product stream for downstream processes such as sheeting, extrusion, or baking
Exact Mixing offers multiple mixer models optimized for different snack products, formulations, and output volumes.
3. Dry Materials Receiving
Before ingredients are metered into the system, dry materials must be received and staged. This component manages bulk receipt from:
- Outdoor silos
- Bulk bags
- Tote dumping stations
Materials are transferred into receiving bins positioned above the feeders, enabling efficient, low-touch ingredient flow.
4. Dry Materials Handling
Dry materials handling refers to the equipment used to move ingredients from storage to the receiving and metering systems. This may include:
- Conveyors
- Vacuum transfer systems
- Bucket elevators
Depending on the plant’s automation level, handling systems can be fully automated or semi-manual, allowing flexibility across different facility sizes.
5. Dry Materials Blending
Blending occurs before ingredients enter the mixer to ensure even distribution of solids. Standard blending functions include:
- Pre-mixing minor ingredients, such as salt or spices, with flour
- Creating dry ingredient blends that improve consistency and reduce metering variation
A very small percentage of ingredients may be introduced at this stage to improve dispersion.
6. Dry Materials Metering
Dry materials metering ensures ingredients such as flour, sugar, salt, and powders are delivered in precise quantities. Exact Mixing systems typically use loss-in-weight gravimetric feeders:
- Each ingredient hopper sits on a scale
- Weight loss is measured in real time as material is discharged
- Feed rates are automatically controlled to maintain correct proportions
This precision prevents recipe drift and supports consistent results during long production runs.
7. Liquid Ingredients Metering
Liquid ingredients, including water, oil, liquid flavors, and syrups, are also metered continuously. Flow meters integrated into the control system:
- Measure liquid flow as it enters the process
- Coordinate liquid delivery with dry ingredient feed rates
- Maintain consistent hydration and product quality
Accurate liquid metering is critical in snack production, where moisture and texture directly impact the finished product.
Mixing That Keeps Snack Lines Moving
By integrating ingredient receiving, handling, metering, and mixing equipment into a single coordinated process, Exact Mixing continuous systems help maintain stable, uninterrupted production. Compared to batch mixing, these systems support:
- More consistent dough or batter quality
- Reduced manual labor and operator variability
- Higher production rates with more straightforward scale-up
- Lower energy consumption and reduced waste
- Automated monitoring and production data tracking
For snack manufacturers operating high-speed lines, this coordinated approach reduces process variability at the mixer. It improves downstream stability, helping keep forming, baking, and packaging equipment running efficiently over long production runs.
Contact Exact Mixing to discuss what continuous mixing equipment can best support your snack production lines.
