What if your snack dough could be mixed perfectly every time without stopping production? With continuous mixing equipment from Exact Mixing, that’s precisely what manufacturers achieve. Here’s a closer look at why continuous mixing matters in snack production.
How Continuous Mixing Improves Snack Production
Continuous mixing replaces traditional batch processes with a nonstop, automated flow. Instead of stopping to load, unload, and clean between cycles, dry and liquid ingredients are continuously metered, blended, and developed in real time.
For snack manufacturers, this means more than just automation, offering:
- Consistency Across Every Batch: Real-time ingredient control ensures consistent dough characteristics across products, eliminating batch-to-batch variation.
- Higher Output with Less Downtime: Continuous mixing runs non-stop, feeding and discharging simultaneously for up to 40% higher throughput.
- Reduced Labor and Energy Costs: Automation minimizes manual handling, while steady-state operation reduces power use and maintenance needs.
- Seamless Line Integration: Exact Mixing systems connect directly to forming, sheeting, extrusion, or cutting equipment for streamlined production.
The Right Mixer for Every Snack Application
Exact Mixing offers five specialized continuous mixer models, each designed to deliver the ideal dough consistency, temperature, and structure for a specific type of snack.
- Crackers and Pretzels: EX Mixer
For classic baked snacks like crackers and pretzels, consistency and dough strength are essential. The EX Mixer handles low-absorption, stiff doughs with precision. It gently kneads and develops gluten structure without overworking the dough, producing the uniform texture needed for crisp, evenly baked products.
- Potato- and Corn-Based Snacks: FX Mixer
Fabricated chips, extruded curls, and other low-moisture snacks rely on powder-based formulations that demand precise hydration. The FX Mixer is engineered for dry and hygroscopic ingredients, ensuring uniform moisture distribution and preventing clumping. This control leads to consistent chip thickness and crunch while improving downstream extrusion and forming.
- Cookies and Snack Bars: MX Mixer
Snack doughs that include inclusions such as chocolate chips, nuts, or fruit pieces benefit from the MX Mixer’s versatility. Designed for higher-energy mixing, it maintains ideal dough development without damaging inclusions or altering product structure. The MX ensures uniform blending for cookies, bars, and other high-fat, high-moisture snack bases.
- Filled and Sandwich Cookies: LDX Mixer
For dual-component products such as sandwich cookies or filled bars, the LDX Mixer features a two-stage design. The first stage mixes creams or minor ingredients, and the second completes dough development. This process ensures a perfect texture and balance between the fillings and dough layers, enhancing product quality and production efficiency.
- Breadsticks, Flatbreads, and Soft Baked Snacks: HDX Mixer
Soft, high-absorption doughs for flatbreads or breadsticks require careful gluten development. The HDX Mixer, equipped with a twin-screw and kneading stage, delivers optimal hydration and dough strength at low temperatures. For soft, pliable doughs, the HDX ensures consistency and scalability without compromising quality.
Why Snack Manufacturers Choose Exact Mixing
Snack producers around the world rely on Exact Mixing for one reason: proven performance. With hundreds of installations globally, these systems are built for reliability, precision, and hygiene.
- Scalable Performance: Throughputs up to 10,000 kg/hour to meet industrial demands.
- Food Safety and Sanitation: Stainless steel construction and enclosed mixing chambers simplify cleaning and comply with strict food-safety standards.
- Process Integration: Seamless connection with forming, sheeting, and extrusion lines for complete automation.
- Comprehensive Support: From pilot testing and ingredient trials at the RBS Science & Innovation Center to installation, training, and maintenance, Exact Mixing provides end-to-end service.
Discover the Future of Snack Production
With Exact Mixing, snack manufacturers can improve product quality, reduce operating costs, and achieve consistent results at scale. Contact us today to schedule a pilot test or discuss how continuous mixing can help your snack line perform at its best.
