Advantages of Continuous Mixing for Bakery Producers

For a long time now, continuous mixing equipment has been available, but only recently has the idea of constant processing taken root in the baking business

FREMONT, CA: Continuous mixing equipment has been available for quite some time, but the baking industry has only just begun to embrace the concept of continuous processing. Batch mixing is the norm, and processors have not seen it necessary to alter their production strategies.

Nonetheless, a few innovations have prompted bakery producers to reconsider their operations with continuous mixing in mind:

The requirement for higher quality and more consistent reliability: Developing consumer trust demands quality and consistency. If you provide products that are sometimes too soft and crispy, your customers will switch to a different brand that consistently delivers the same experience.

The requirement for greater throughput: Food manufacturers have struggled to keep up with demand, particularly since the onset of the pandemic. This has motivated several businesses to construct new manufacturing lines or retool old ones to increase output.

Labor deficits: The rapidly decreasing manufacturing workforce has prompted corporations to use increasingly automated procedures.

Continuous mixing helps bread producers overcome these obstacles and gives additional benefits. Let's examine this.

Principal advantages of continuous mixing

Consistency throughout the entire procedure

Consistency is the greatest advantage of continuous mixing on a baking line. There is numerous potential for discrepancies to arise during batch mixing. For instance, the operator may not precisely load the ingredients, or the dough may not be hydrated uniformly.

Suppose you create cookies using a batch-processing technique. After 10 minutes of mixing in the mixer, the dough is sent to a receiving hopper on the dough makeup line, where it remains for 12 minutes. Another batch is mixed for 10 minutes in the mixer before being transferred to the receiving hopper, where it sits for 12 minutes.

There are two doughs in the hopper that are at various stages of development: the elder dough (22 minutes old) and the younger dough (12 minutes old).

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Ten minutes can significantly change dough qualities, such as temperature and density. These variations produced during mixing can result in erroneous weighing, irregular baking, and varying product quality.

Continuous mixing ensures uniformity at the beginning of the line, allowing for uniformity throughout the remainder of the process. Continuous mixing ensures that every part of the dough is treated identically, from fermentation through weighing and portioning to baking by supplying a con

stant dough stream.

This saves waste because fewer products must be discarded for failing to satisfy the criteria. Even evidence suggests that delivering dough with constant settings can extend the oven's service life!

Increased throughput with reduced footprint

Batch systems have limited output capacity. Even a machine that can process 5,000 pounds of dough each batch is limited to a certain number of batches per hour, and time is lost between the completion of one batch and the start of the next. To expand production, a second mixer would have to be installed.

Continuous processing methods eliminate waiting time. As long as ingredients continue to be loaded (an automatic procedure), the mixer will continue to combine. The continuous mixers can process up to 40,000 kilograms of dough every hour.