Continuous Mixers: The Eco-Friendly, High Volume Alternative To Batch Mixing

21 October 2014
 Categories: Industrial & Manufacturing, Blog


Batch mixing is fine when you need precise formulations, or when you are mixing many diverse products in the same facility. When you are producing a high volume, single product, continuous mixing can help you increase production while leaving a smaller carbon footprint. Read on to learn about the benefits and limitations of continuous mixers.


The output of batch mixers is measured in kg/batch, while the output of continuous mixers is measured in kg/hour. For speed and efficiency in the production of a single formulation, continuous mixing is clearly the superior choice. Up to 500 tons per hour can be produced in a continuous mixer.

Ingredients are weighed, measured, fed, mixed and discharged simultaneously into the continuous mixer, requiring fewer workers to produce product when compared to traditional batch mixing.

The specific ingredient loading in a continuous mixer is done automatically, reducing human error in measuring and weighing ingredients. Less waste means a more sustainable operation.

Continuous mixers are more compact than batch mixers, which can make them an ideal choice in a smaller facility.

When compared to batch mixing an equal amount of product, continuous mixing uses less energy, resulting in lower utility costs for your business as well as a lower carbon footprint in your community. Continuous mixers do not require frequent cleaning, as batch mixers do, meaning water and cleaning product usage are reduced, further increasing your company's green credibility and lowering your overall costs.


Continuous mixers are not as reliable for producing very specific mix ratios. For applications such as pharmaceutical products and others requiring precise, consistent formulations, batch mixing is the better option.

While continuous mixers are less expensive than batch mixers, setting up material feeds and hoppers can increase the cost when compared to batch mixing systems.

Continuous mixers also require more calibration than batch mixers. Discharged product must be examined and analyzed on a regular basis to ensure consistency and proper product performance.

The feeders and other components of the system must be maintained adequately for the entire continuous mixing system to operate at high efficiency. Maintenance costs will be higher than for batch mixers.

It's worth it to compare the advantages of continuous mixers over batch mixers if your facility produces one or several high volume products that do not require absolute precision in the final formulation. Contact an industrial mixer supplier such as American Baking System today to discover the production value and sustainable benefits of a continuous mixing system.