Title of Invention

PROCESS FOR MANUFACTURE OF SPRAY DRIED CHEDDAR FLAVOUR BASE/CONCENTRATE

Abstract

A process for the preparing spray dried cheddar cheese flavor base comprising of subjecting cheddar cheese slurry and biocatalysts having exogenous enzymes and NCDC-149 and NCDC-19 starter cultures obtained from National Collection of Dairy Cultures National Dairy Research Institute; wherein said cultures is added at the rate of 1 to 3% and 0.25 and 0.75% by weight of cow milk respectively to a biochemical reaction to produce hydrolyzed cheese slurry; the hydrolyzed cheese slurry having flavor components microencapsulated using combination of coat/well material and high-pressure homogenization; pasteurizing of slurry at temperature of 70°C to 85°C for a period of 5 to 20 minutes; the slurry is cooled at temperature of 0°C to 10°C the cheddar cheese slurry has 60 to 70% moisture, 4.5 to 5.5 pH and 4.5 to 5.5% salt-in-moisture; the slurry is ripened at temperature of 20 to 35°C for 3 to 6 days; the microencapsulated hydrolyzed cheese slurry being then spray dried, the spray dried CCFB appropriately packed and stored until use.

Full Text

FIELD OF INVENTION This invention relates to a process for producing cheese flavour concentrate. It is a cheap substitute for matured cheese, which is conventionally for flavouring processed chesses, spreads and other food products. The product has great commercial utility as intermediate cheese flavor ingredient for food industry. BACKGROUND OF INVENTION AND PRIOR ART: Enormous scientific information generated in couple of years to understand the biochemistry of cheese ripening and flavour generation has established beyond doubt that the typical flavour in cheese is a complex mixture of perhaps several hundred flavour components and is achieved during ripening as a result of action of various agents like starter bacteria and non-starter bacteria, rennet, milk enzymes, etc. on lactose, protein, and fat of cheese curd. The process of ripening which is necessary for flavour development, is very slow and usually takes 4 to 6 months to develop full flavour and is costly and time consuming. Several attempts have been made in the past with varying degree of accomplishment to accelerate cheese-ripening process (Law, 1979; Lee & Olson, 1982; Bottazzi and Scolari, 1983; Law, 1984; EI Soda, 1986; Fox, 1989; EI Soda and Panadian, 1991). The different methods studied to enhance ripening include addition of ripened cheese slurry (Singh and Kristoffersen, 1971; Thakar and Upadhyay, 1992); high temperature ripening (Fedrick, 1987); use of exogenous enzymes (Kanawjia and Singh, 1990; Bockelmann, 1995) and many others. It is now possible to develop typical cheese flavour in a given substrate (cheese curd slurry, recombines cheese curd, UF-retentate, buffalo milk cheese curd etc.) with the help of numerous combinations of the ripening agents (coagulants, starter culture, non-starter culture, adjunct starter, milk proteinases, lipases, etc.) and reaction conditions. Based on the information available in literature it was hypothesized that a controlled substrate-enzyme reaction would yield a cheese flavour in short time. The present research project was based on this hypothesis, and designed to develop concentrated cheese flavourant or more specifically Cheddar Cheese Flavour Base (CCFB) in paste and dried form, which would replace matured cheese in processed cheese and spreads. Cheese flavour base (CFB) is a variant of slurry system and enzyme-modified cheese (EMC), which involves addition of biocatalyst (mainly exogenous enzymes from starter and adjunct bacteria) to curd and/or cheese slurried and incubation at high temperature (30 to 45°C) for short time (12 to 36 h). This type of product is essentially utilized to provide a strong cheesy note at a low cost to processed cheeses and other food products (Moskowitz and Noelck, 1987). In general, the level of addition of this product in foods ranges from 0.1 to 2%, which ultimately reduces the requirement for matured cheese in processed cheese formulations (Kilara, 1985). The present investigation was undertaken with the specific objectives of a) standardization of process parameters for the production of Cheddar Cheese Flavour Base (CCFB) using biocatalysts; b) preservation of CCFB; and c) utilization of CCFB in processed cheese. OBJECTS OF THE INVENTION An object of this invention is to propose a novel process for producing cheddar cheese flavour concentrate Another object of this invention is to propose a process for producing cheddar cheese flavour concentrate having a high flovour intensity in comparison to that of natural cheese. Still another object of this invention is to propose a process for producing cheddar cheese flavor concentrate which may be in spray or paste form. Yet another object of this invention is to propose a process for producing cheddar cheese flavor concentrate which has a substantiate shelf life. DESCRIPTION OF INVENTION According to this invention there is provided a process for the preparing spray dried cheddar cheese flavor base comprising: a) subjecting cheddar cheese slurry and biocatalysts having exogenous enzymes and NCDC-149 and NCDC-19 starter cultures obtained from National Collection of Dairy Cultures National Dairy Research Institute; wherein said cultures is added at the rate of 1 to 3% and 0.25 and 0.75% by weight of cow milk respectively to a biochemical reaction to produce hydrolyzed cheese slurry; b) the hydrolyzed cheese slurry having flavor components microencapsulated using combination of coat/well material and high-pressure homogenization; c) pasteurizing of slurry at temperature of 70°C to 85°C for a period of 5 to 20 minutes; the slurry is cooled at temperature of 0°C to 10°C. d) the cheddar cheese slurry has 60 to 70% moisture, 4.5 to 5.5 pH and 4.5 to 5.5% salt-in-moisture; the slurry is ripened at temperature of 20 to 35°C for 3 to 6 days; e) the microencapsulated hydrolyzed cheese slurry being then spray dried, the spray dried CCFB appropriately packed and stored until use. In accordance with this invention, the process comprises in preparing spray dried cheddar cheese flavor base comprising: a) a process the cheddar cheese has about 60 to 70 percent moisture, about 4.5 to 5.5 pH and about 4.5 percent to 5.5 percent salt-in-moisture; b) the slurry made using specially prepared cow milk cheddar cheese having mild flavor intensity; c) the cow milk cheddar cheese made using NCDC-149 and NCDC-19 starter cultures obtained from National Collection of Dairy Cultures (NCDC) National Dairy Research Institute, Karnal; d) said cultures added at the rate of about 1 percent to about 3 percent and about 0,25 percent and about 0.75 percent by weight of cow milk respectively; Such a cheese is dried, waxed and ripened. A slurry of the ripened cheese in a Fryma disc mill grinder, slurry being a process for the preparing spray dried cheddar cheese flavour base comprising: adjusted to about 60 percent to 70 percent moisture, about 4.5 to 5.5 pH and about 4.5 percent to 5.5 percent salt-in-moisture; wherein the slurry is ripened at temperature from about 20 degree C to 35 degree C for about 3 to about 6 days; The slurry is pasteurized at temperature from about 70 degree C to 85 degree C for a period of about 5 minutes to 20 minutes; the slurry cooled at temperature from about 0 degree C to 10 degree C. The bacterial esterase mixed with slurry is in amount from about 0.010 percent to about 0.040 percent by weight of slurry to be treated; The bacterial protease and peptidase combined preparation mixed with slurry is in amount from about 0.005 percent to 0.020 percent weight of slurry to be treated; The slurry and biocatalysts/enzymes are mixed thoroughly and the mixture incubated at temperature from about 20 degree C to 55 degree C for a period of about 10 hours to 40 hours for development of flavour components and intense cheese flavour; the ripened slurry so obtained is pasteurized at temperature from about 65 degree C to 85 degree C for a period of about 20 minutes to 40 minutes; and cooled to 10 degree C to 20 degree C; The ripened and pasteurized cheese slurry is heated at temperature from about 40 degree C to 60 degree C for a period of about 2 minutes to 5 minutes; the heated slurry mixed with about 35 percent to 55 percent solution of coat material, and mixture homogenized at pressure (a) 1st stage; from about 200 kg/cm2 to 300 kg/cm2 (b) 2nd stage: from about 30 kg/cm2 to 50 kg/cm2 for emulsification; The process according to claim 1 wherein: the coat/wall material for microencapsulation of emulsified and ripened slurry selected from the group consisting of Whey Protein Concentrate, Casein and Maltodextrins, and mixture thereof; The process comprises (A) heating a mixture comprising (1) about 30 percent to 55 percent pasteurized ripened slurry, (2) about 20 percent to 50 percent coat/wall material; (B) the mixture emulsified using Fryma disc mill/grinder and double stage high pressure homogenizer; (C) the mixture cooled at temperature from about 5 degree C to 10 degree C; Homogenized mixture of ripened cheese slurry and coat material is heated (at temperature from about 30 degree C to 50 degree C; (B) Spray drying at (a) inlet air temperature from about 140 degree C to 240 degree C, (b) outlet air temperature from about 60 degree C to 85 degree C, (c) feed temperature from about 20 degree C to 40 degree C, (d) total solid of feed from about 35 percent to 55 percent; EXAMPLE i) Cow Milk: Whole cow milk was obtained from the herd maintained in NDRI, Karnal ii) Cheddar Cheese: Cheddar Cheese from cow milk was made in experimental dairy plant using standard procedure (Kosikowski, 1982) Starter culture (NCDC-149) and adjunct bacteria (NCDC-19) and microbial rennet (i.e., Meito renner). Cow milk were used to make Cheddar cheese. The 10 kg blocks were made, dried , waxed and ripened for one month. iii) Old Cheddar Cheese (OCC) Slurry: One-month-old Cheddar Cheese was converted into slurry with Fryma disc mill/grinder. The pH, moisture and salt-in-moisture of OCC-Slurry were appropriately adjusted. The OCC-Slurry was used as substrate for biochemical reactions or ripening. iv) Substrate Biocatalyst Reaction or Ripening OCC-Slurry: OCC-Slurry was ripened with two exogenous enzymes in combination. The mixture (OCC-Slurry and enzymes) was appropriately ripened intense cheese flavour. After ripening, the enzymes were inactive by appropriately heating ripened slurry with continuous agitation. This was called CCFB-paste. v) Microencapsulation of CCFB-Paste: Microexcapsulation (MCP) was done employing high speed and high-pressure homogenization using Fryma disc mill/grinder and Homogenizer. CCFB-paste was heated and mixed with solution of wall materials. CCFB-paste and wall material solution were thoroughly mixed and passed through Fryma disc mill/grinder twice. Thereafter, it was homogenized employing two stage high presuusre homogenizer to obtain emulsified CCFB-paste referred as E-CCFB-paste. vi) Process of Spray Drying of E-CCFB-paster: E-CCFB-paste was dried using spray drying process. The basic conditions for spray drying standardized were: inlet air temperature; outlet air temperature; temperature of feed; total solids of feed; type of atomizer. The targeted final product moisture ranged from 4.5-5.0%. These process condition were standardized to obtained better flavour retention and flow ability. vii) Storage Conditions: E-CCFB spray powder was packed and sealed in metalized polyester laminated pouches (500g.) and stored at 15°C until used. WE CLAIM: 1. A process for the preparing spray dried cheddar cheese flavor base comprising: a) subjecting cheddar cheese slurry and biocatalysts having exogenous enzymes and NCDC-149 and NCDC-19 starter cultures obtained from National Collection of Dairy Cultures National Dairy Research Institute; wherein said cultures is added at the rate of 1 to 3% and 0.25 and 0.75% by weight of cow milk respectively to a biochemical reaction to produce hydrolyzed cheese slurry; b) the hydrolyzed cheese slurry having flavor components microencapsulated using combination of coat/well material and high-pressure homogenization; c) pasteurizing of slurry at temperature of 70°C to 85°C for a period of 5 to 20 minutes; the slurry is cooled at temperature of 0°C to 10°C. d) the cheddar cheese slurry has 60 to 70% moisture, 4.5 to 5.5 pH and 4.5 to 5.5% salt-in-moisture; the slurry is ripened at temperature of 20 to 35°C for 3 to 6 days; e) the microencapsulated hydrolyzed cheese slurry being then spray dried, the spray dried CCFB appropriately packed and stored until use. 2. A process as claimed in claim 1, wherein: the bacterial esterase mixed with slurry is in amount of 0.010% to 0.040% by weight of slurry to be treated; the bacterial protease and peptidase combined preparation mixed with slurry is in amount of 0.005 to 0.020% weight of slurry to be treated; 3. The process as claimed in claim 1, wherein: the slurry and biocatalysts/enzymes are mixed thoroughly and the mixture incubated at temperature of 20°C to 55°C for a period of 10 to 40 hours for development of flavor components and intense cheese flavor; the ripened slurry so obtained is pasteurized at temperature of 65°C to 85°C for a period of 20 to 40 minutes; and cooled to 10° C to 20°C; 4. The process as claimed in claim 1, wherein: the ripened and pasteurized cheese slurry is heated at temperature of 40°C to 60°C for a period of 2 to 5 minutes; the heated slurry mixed with 35 to 55% solution of coat material, and mixture homogenized at pressure (a) 1st stage; from 200 kg/cm2 to 300 kg/cm2 (b) 2nd stage: from 30 kg/cm2 to 50 kg/cm2 for emulsification; 5. The process as claimed in claim 1, wherein: the coat/wall material for microencapsulation of emulsified and ripened slurry selected from the group consisting of Whey Protein Concentrate, Casein and Maltodextrins, and mixture thereof;

Documents:

1181-DEL-2007-Abstract-(19-07-2012).pdf

1181-del-2007-abstract.pdf

1181-del-2007-Claims-(12-08-2013).pdf

1181-DEL-2007-Claims-(19-07-2012).pdf

1181-del-2007-claims.pdf

1181-DEL-2007-Correspondence Others-(19-07-2012).pdf

1181-del-2007-Correspondence-Others-(12-08-2013).pdf

1181-del-2007-correspondence-others.pdf

1181-DEL-2007-Description (Complete)-(19-07-2012).pdf

1181-del-2007-description (complete).pdf

1181-del-2007-form-1.pdf

1181-del-2007-form-2.pdf

1181-del-2007-form-3.pdf

1181-del-2007-GPA-(12-08-2013).pdf

1181-DEL-2007-GPA-(19-07-2012).pdf