In industrial baking, consistency and efficiency define success. Whether producing bread, rolls, cookies, or snacks, the quality of the dough determines the quality of the final product. Around the world, leading bakeries are upgrading their production lines with continuous mixing systems from Exact Mixing, a proven solution that delivers uniform dough, higher output, and greater operational reliability.
The Shift from Batch to Continuous Mixing
Traditional batch mixing has long served as the standard in industrial baking, but it comes with familiar challenges: frequent stops for loading, unloading, and cleaning; variable dough quality between batches; and high labor requirements. These interruptions slow production and make it difficult to maintain consistency across shifts.
Exact Mixing’s continuous mixers change that. By metering and blending ingredients in real time, the system creates a steady, uninterrupted flow of dough ready for forming and baking. The result is smooth, predictable production that eliminates downtime and variation, keeping operations running at peak performance.
Precision Control for Consistent Dough
Each Exact Mixing system integrates advanced process controls and automated ingredient feeders that precisely manage ratios of flour, water, yeast, and other ingredients. Real-time monitoring of torque, hydration, and temperature ensures optimal dough development and uniformity across every kilogram produced.
This level of control helps bakeries achieve consistent texture, elasticity, and bake characteristics across high-absorption breads, crispy crackers, and soft snack doughs. A process that once relied on operator intuition is now governed by precise, repeatable automation.
Efficiency That Impacts the Bottom Line
Continuous mixing not only improves product quality but also transforms production efficiency. Because motors operate in steady state, bakeries avoid the start-and-stop energy surges typical of batch systems. Many operations experience 20–40% higher throughput and up to 40% lower energy consumption, along with significant labor savings.
Shorter cleaning and changeover times further enhance output. Dough never sits in open troughs or batch bowls, which simplifies sanitation and extends production runs. The result is measurable improvement in overall equipment efficiency (OEE) and faster return on investment within 2 to 4 years.
Mixers Designed for Every Dough Type
Exact Mixing offers a complete range of mixers for different dough characteristics and production goals:
- EX Mixer: For low-absorption, stiff doughs such as crackers, pretzels, and pet treats.
- HDX Mixer: For high-absorption breads, buns, and rolls.
- MX Mixer: Versatile for cookies, snacks, and batters.
- FX Mixer: For low-moisture, powder-based blends and fabricated chips.
- LDX Mixer: A two-stage system for filled cookies and creme-up formulations.
Each system integrates easily into automated bakery lines and supports throughputs up to 10,000 kg per hour, offering scalable performance for bakeries of every size.
Built for Reliability and Food Safety
Exact Mixing systems are engineered for long-term durability and hygiene. Stainless-steel construction and enclosed mixing environments minimize contamination risks and simplify cleaning. With fewer moving parts and accessible components, maintenance is straightforward and downtime is minimal. This is an essential advantage for bakeries operating around the clock.
Comprehensive Global Support
As part of Reading Bakery Systems (RBS), Exact Mixing provides complete lifecycle support, from pilot testing and system design to installation, training, and preventive maintenance. Customers also have access to the RBS Science & Innovation Center, where formulations and processes can be tested and optimized before full-scale production.
With hundreds of installations worldwide, Exact Mixing is an excellent choice for bakeries seeking to improve their dough-mixing operations. By combining automation, precision, and reliability, Exact Mixing helps bakeries produce better dough faster and more efficiently.
Contact Exact Mixing to learn how continuous mixing technology can transform your production line and drive measurable performance gains across every shift.
