Title of Invention

CHEESE AND METHODS OF MAKING SUCH CHEESE

Abstract The invention relates to a method of preparing a cheese product comprising: (a) providing a slurry that comprises one or more ingredients; (b) adding a dry powder ingredient to a cheese precursor; (c) combining the slurry with the cheese precursor to form an admixture; and (d) processing the admixture to form the cheese product.
Full Text CHEESE AND METHODS OF MAKING SUCH CHEESE
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional App. No. 60/568,029, filed May
3, 2004, and titled "Soft or Firm/Semi-Hard Ripened or Unripened Cheese and Methods of
Making Such Cheeses", the entire contents of which are herein incorporated by reference for
all purposes.
[0002] This application is also related to the following U.S. Patent Applications, all of
which are incorporated herein by reference in their entirety for all purposes:
[0003] 1. U.S. Provisional App. No. 60/568,022, filed May 3, 2004, entitled "Soft or
Firm/Semi-Hard Ripened or Unripened Blended Cheeses and Methods of Making Such
Cheeses", having attorney docket number O40179-OOO500US;
[0004] 2. U.S. Provisional App. No. 60/568,017, filed May 3, 2004, entitled
"Methods for Making Soft or Firm/Semi-Hard Ripened and Unripened Cheese," having
attorney docket number 040179-000600US;
[0005] 3. U.S. Patent Application filed on the same day as the present application,
and entitled "Blended Cheeses and Method for Making Such Cheeses," having attorney
docket number 040179-000510US; and
[0006] 4. U.S. Patent Application filed on the same day as the present application,
and entitled "Methods for Making Soft or Firm/Semi-Hard Ripened and Unripened Cheese
and Cheeses Prepared by Such Methods," having attorney docket number 040179-000610US.
BACKGROUND
[0007] Recently there has been an increase in the demand for cheeses that have widely
differing performance characteristics. This particular demand is driven in part by the
increasing variety of prepared foods in which such cheeses are included. In fact, there often
is a need for different performance qualities even for foods of the same general type because
of the different ways cheeses are utilized or because the cheese is exposed to differing
cooking environments or conditions. Pizzas illustrate this point well because there are so
many different types of pizzas. Pizzas, for example, have widely differing crusts, including
thick, thin, or somewhere in between. The cheese can also be exposed or wrapped in the
edge of the crust. Furthermore, the crust may be completely uncooked or it may he parbaked
before being put in the oven with the cheese. Each of these variables potentially impacts the
composition of the cheese required to provide satisfactory performance.
[0008] Demand for cheese with varying performance characteristics is also driven in part
by the significant increase in the different types of baking equipment and conditions that are
being used to prepare food products containing cheese. Some baking operations, for instance,
require relatively high oven temperatures (e.g., in the range of about 350 to 950 °F (177- 510°
C)) with short baking times (e.g., in the range of about 30 seconds to 15 minutes). Such
conditions may be used, for instance, in an impingement oven when baking a pizza having a
thin crust. Other ovens, such as deck ovens, in contrast, sometimes use a relatively long bake
time (e.g.. about 6 to 60 minutes) and a correspondingly lower oven temperature (e.g., about
300 to 750°F (149 to 399 ° C)). Instead of baking, some foods topped with or including
cheese are prepared by microwaving (e.g., about 1-6 minutes).
[0009] Consumer demand for cheeses with improved nutritional content (e.g., nutritionally
balanced, lower fat) has also increased the demand for new varieties of cheese.
[0010] There are a variety of challenges to providing cheeses that have a composition
which satisfies the desired performance characteristics and nutritional qualities. For instance,
it can be difficult to obtain the desired concentration level of some ingredients in a cheese.
Another problem is developing a process that activates the latent functional properties of
certain ingredients. Another problem is that many methods for preparing cheese involve the
loss of significant quantities of some cheese components during processing. This can occur,
for instance, when such cheeses undergo the heating and stretching process of the pasta filata
process. Often the heating is conducted in heated water, which can remove significant
amounts of cheese ingredients.
[0011] In view of the high demand for cheese and the foregoing shortcomings associated
with some existing methods for preparing such cheeses with the desired performance
characteristics, there thus remains a need for additional methods for preparing cheeses of
these types.
SUMMARY
[0012] Methods for preparing a variety of cheese products are disclosed. Systems for
preparing such cheeses and slurries, and cheeses produced by the disclosed methods are also
provided.
[0013] Some of the cheese processing methods involve initially providing a slurry that
comprises one or more ingredients that one seeks to incorporate into the final cheese product.
The slurry is then combined with a cheese precursor to form an admixture. The resulting
admixture is then processed to form the final cheese product. The slurry can be combined
with a variety of cheese precursors including a cheese curd ingredient, a mixture of cheese
curd ingredients, a coagulum, a cheese curd, a heated mass of cheese (e.g., a heated mass of
cheese curd), a dry mixed cheese, or a same day diced cheese. In some methods, the slurry
lacks a cheese curd. The slurry in other methods lacks one or more analog cheese ingredients
(e.g., an oil, a fat, a protein, a starch, a sequestrant and/or a salt).
[0014] A variety of ingredients can be incorporated into the slurry including, but not
limited to, a nonfat dry milk, a milk protein, an acidity regulator, an acid, an anticaking agent,
an antifoaming agent, a coloring agent, an emulsifier, an enzyme preparation, a flavoring
agent, a firming agent, a food protein, a gelling agent, a preservative, sequestrants, a
stabilizer, a starch, a thickener, an oil, a fat, a cheese powder, a salt, a nutritional supplement,
an acid, an enzyme, a neutraceutical, a carbohydrate, a vitamin, and a mineral. Examples
may further include procream, whey cream, a dairy solid, and foodstuffs of vegetable, fruit
and/or animal source. The foodstuffs may include fruit, vegetables, nuts, meat, and spices,
among other foodstuffs.
[0015] In some methods, the slurry is processed before it is combined with the cheese
precursor. Typical processing steps include one or more of the following processes: heating
the slurry, subjecting the slurry to high shear conditions, homogenizing the slurry and
adjusting the water content of the slurry.
[0016] Other methods for preparing a cheese involve combining a slurry with a heated
mass of cheese curd to form an admixture and then shaping and cooling the admixture to
form the final cheese product. In some of these methods, the slurry contains sufficient starch,
nonfat dry milk, gum or cellulose such that the cheese has one or more of the following
characteristics (i) a starch concentration of about 0.5 to 20 wt %, or (ii) a nonfat dry milk
concentration of about 0.5 to 25 wt %, or (iii) a gum or cellulose concentration of about 0.5 to
20 wt %.
[0017| Methods for preparing heated slurries that can be used in the preparation of cheeses
are also described herein. Some of these methods involve blending together a liquid and one
or more GRAS ingredients to form a slurry and then processing the slurry. Processing
typically involves heating the slurry to a temperature of about 90 °F to about 300 °F and
performing one or more additional processing steps selected from the group consisting of
subjecting the slurry to high shear conditions, homogenizing the slurry and adjusting the
moisture content of the slurry.
(0018] Various systems for manufacturing a cheese product are provided. Some of these
systems include a slurry preparation system that includes (i) a blender adapted to blend a
liquid and one or more generally recognized as safe (GRAS) ingredients together to form a
slurry, and (ii) a cooker that is operatively disposed to receive the slurry from the blender and
adapted to heat the slurry to a temperature of about 90 °F to about 300 °F. These systems also
include a first mixer operatively disposed to receive the slurry from the slurry preparation
system and adapted to mix the slurry with a heated mass of cheese curd to form an admixture.
A final processing system is also included which is operatively disposed to receive the
admixture and adapted to form a final cheese product.
[0019] Such systems can optionally also include a slurry mixing and moisture control
subsystem. These subsystems include one or more of the following units: (i) a shear pump
adapted to subject the slurry to high shear conditions; (ii) a homomgenizer adapted to
homogenize the water and the one or more ingredients in the slurry; and (iii) an evaporator
adapted to adjust the water content of the slurry to about 5-95 % by weight. The subsystem
in these systems is in communication with the cooker and the first mixer and the units within
the subsystem are in fluid communication.
[0020] The arrangement of some subsystems is such that the shear pump is operatively
disposed to receive the slurry from the heater and is in communication with the homogenizer.
The homogenizer in turn is operatively disposed between the shear pump and the evaporator
and adapted to receive the slurry from the shear pump. The evaporator is operatively
disposed to receive the slurry from the homogenizer and in communication with the first
mixer.
[0021 j Some systems also include a second dry or wet mixer that (i) is adapted to heat and
knead a mass of cheese curd that is introduced therein, and (ii) is in communication with the
first mixer such that the heated mass of cheese that is produced in the first mixer can be
transported to the second mixer.
[0022] Slurry preparation systems are also provided. Certain of these systems include a (a)
blender adapted for preparing a slurry, the slurry comprising water and one or more generally
recognized as safe (GRAS) ingredients, (b) a cooker adapted to heat the slurry to a
temperature of about 90 °F to about 300 °F; and (c) a slurry mixing and moisture control
subsystem. The subsystem itself includes one or more of the following units (i)a shear pump
adapted to subject the slurry to high shear conditions; (ii) a homogenizer adapted to mix the
water and the one or more ingredients in the slurry; and (iii)an evaporator unit adapted to
adjust the water content of the slurry to about 5-95 % by weight. In such subsystems, the
units making up the subsystem are in fluid communication and the blender, heater and slurry
mixing and control subsystem are in fluid communication.
[0023] A variety of cheeses (e.g., a soft or firm/semi-hard ripened or unripened cheese
product) are provided. Some of these have one or more of the following characteristics (i) a
nonfat dry milk concentration of greater than 11% by weight, or (ii) a starch concentration of
greater than 11 % by weight, or (iii) a gum or cellulose concentration of greater than 11 % by
weight. Some of these have one or more of the following characteristics (i) a nonfat dry milk
concentration of greater than 10% by weight, or (ii) a starch concentration of greater than
10% by weight, (iii) a gum or cellulose concentration of greater than 10% by weight.
[0024] Slurries of different compositions are also provided that can be used in the
preparation of cheese. Some slurries, for instance, have a temperature of about 90 °F to about
300 °F and have one or more of the following characteristics (i) a starch concentration of at
least 12 wt %, or (ii) a dairy solid concentration of at least 12 wt %.
[0025] A variety of cheeses (e.g., a soft or firm/semi-hard ripened or unripened cheese
product) are provided. Some of these have one or more ingredients added in the form of (i) a
slurry of varying composition, and/or (ii) a dry powder used in the preparation of cheese.
Some cheeses, for instance have ingredients added via the slurry such that 0.5-25% of an
ingredient is added in the final cheese. Other cheeses may have ingredients added via a dry
powder such that 0.5 to 15% of an ingredient is added in the final cheese. And still other
cheese may have both a slurry and a dry powder added simultaneously such that the
combination of slurry and powder result in ingredient amounts of about 0.5 to 25%.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0026] FIG. 1 depicts one example of a general method for making a cheese product using
a slurry.
[0027] FIGS. 2A-2C show different examples of general methods for making a cheese
product using a slurry.
[0028] FIGS. 3 A and 3B show in schematic form other examples of certain methods that
are disclosed herein to prepare cheese. FIG. 3 A depicts a method in which a slurry is
combined with a heated mass of cheese. FIG. 3B depicts a method in which a slurry is
combined with a curd or curd precursor.
[0029] FIGS. 4A-4E depict various exemplary systems for preparing various types of
cheese. FIG. 4A shows the major subsystems in certain manufacturing systems. FIG. 4B
shows a system that can be used to prepare a cheese by combining a slurry with a heated
cheese mass. FIG. 4C shows another system that is designed to prepare a cheese in which the
slurry is combined with a curd or curd precursor. FIGS. 4D and 4E illustrate respectively
examples for how ingredients can be introduced into a cheese in a parallel or serial fashion.
[0030] FIGS. 5A-B show cross sectional samples of finished cheeses.
DETAILED DESCRIPTION
I. Definitions
[0031] A "soft or firm/semi-hard cheese" as used herein generally includes cheeses that
have a percentage moisture on a fat free basis (MFFB) of about 54% or more, by weight. The
term includes firm/semi-hard cheeses that have a MFFB, for example, of about 54% to about
80%, by wt, and chesses with a MFFB, for example, of about 58% to about 75%, by wt. The
term may also include soft cheeses with a MFFB of greater than about 60%, by wt. The term
encompasses a variety of well known cheeses including, but not limited to, Colby, Havarti,
Monterey Jack, Gorgonzola, Gouda, Cheshire and Muenster, which are examples of
'firm/semi-hard cheeses." Also included in the term are popular "soft cheeses" such as
Mozzarella, cream cheese, and cottage cheese. A variety of mozzarella cheeses are included
by the term; these can be in the soft or firm/semi-hard category, or in between the two,
depending upon their moisture content. Standard mozzarella, for example, is a soft cheese,
part-skim mozzarella is between soft and firm/semi-hard, and low-moisture mozzarella and
low-moisture part-skim mozzarella are both designated as firm/semi-hard cheeses. The term
soft or firm/semi-hard as used herein includes cheeses meeting the CODEX definition of a
soft or firm/semi-hard cheese. The term also includes soft or firm/semi-hard cheeses as
defined bv other local, regional, national or international agencies or organizations.
[0032] Cheeses within the "soft or firm/semi-hard" category as defined herein can be
prepared using a variety of methods, including conventional methods, as well as by
"alternative make" provisions. The term includes, for instance, cheeses made by a process in
which a cheese curd is heated and kneaded to improve the stretchability or stringiness of the
final cheese, provided the cheese falls within the MFFB parameters set above. This process
and related processes are sometimes referred to as a pasta filata process of manufacturing.
Cheeses made by this process are known under a variety of names, including mozzarella,
pasta filata, provolone, Mexican style, scamorze, and pizza cheese. Cheeses made by
alternative make procedures are prepared by alternative methods of making cheeses, so long
as the procedure produces a cheese having the same physical and chemical properties of the
type of cheese made by a specified process (e.g., aprocess specified by a regulatory agency)
and falls within the MFFB parameters set forth above.
[0033] The "soft" and "firrn/serm-hard" cheeses that are provided include standard and non-
standard cheeses and cheese products having the foregoing moisture characteristics. Standard
cheeses are those that satisfy the standards as set forth by a regulatory body with respect to a
particular type of cheese. A non-standard cheese is one whose composition does not meet the
standard. A soft or firm/semi-hard cheese can also be a processed cheese. A soft or
firrn/semi-hard cheese can also be ripened or unripened.
[0034] "Mozzarella" cheese has a minimum milkfat content of 45% by weight of the solids
and a moisture content of more than 52% but not more than 60% by weight. "Low-moisture
mozzarella" cheeses have a minimum milkfat content of 45% by weight of the solids and the
moisture content is more than 45% but not more than 52% by weight. "Part-skim
mozzarella" has a moisture content of more than 52% but not more than 60% by weight, and
a milk fat content that is less than 45% but not less than 30% calculated on the solids basis.
"Low-moisture part-skim" mozzarella has a moisture content of more than 45% but not more
than 52% by weight and a milkfat content, calculated on the solids basis, of less than 45% but
not less than 30%. Further details regarding these various mozzarella cheeses is provided by
21 C.F.R. §1.33.155-133.158.
[0035] The term "cheese precursor" as used herein refers broadly to any ingredient that is
used to prepare a cheese curd, mixtures of such ingredients and subsequent processed forms
of the chsese curd other than the final cheese product. Examples of cheese precursors that
are ingredients include, but are not limited to, unpasteurized milk (sometimes referred to in
the industry as "raw milk"), the growth medium and bacteria used in the cheese making
process (sometimes referred to in the industry as "starter"), and cream. Mixtures of such
ingredients are also included. One specific example of such mixtures is "vat liquid", which is
a term used to refer to a combination of pasteurized milk, starter and cream. The term also
includes coagulum, cheese curd, and processed cheese curd (e.g., curd that has been heated
and/or stretched to form a homogeneous mass of cheese).
[0036] The term "cream" means the liquid milk product high in fat separated from milk
which may have been adjusted by adding thereto: milk, concentrated milk, dry whole milk,
skim milk, concentrated skim milk, nonfat dry milk or other GRAS ingredients. "Whey
cream" is the liquid milk product high in fat separated from whey (cheese, casein, or other),
which may have been adjusted, by adding thereto: whey, concentrated whey, dry whey, or
other GRAS ingredients. "Procream" is the liquid milk product high in fat collected as
retentate from a whey filtration process such as microfiltration which may have been adjusted
by adding thereto: whey, concentrated whey, dry whey, or other GRAS ingredients.
[0037] The term "curd precursor" refers to any soft or firm/serni-hard cheese ingredient,
mixture or composition that exists or is formed prior to formation of the cheese curd. The
term thus includes, for example, raw milk, starter, cream, cheese vat liquids and coagulum.
II. Overview
[0038] Methods for preparing a variety of different types of cheeses are provided, including
for example, soft or firm/semi-hard ripened and unripened cheese. The methods that are
provided generally involve combining a slurry with a cheese precursor to form an admixture
that is subsequently processed to form the final product. The slurry typically contains a
liquid (e.g., water, milk and/or cream) and one or more ingredients (added either as a liquid
or a dry powder, for example) that are selected in accord with the final cheese product that is
desired. Once the slurry and cheese precursor are thoroughly mixed together, the resulting
admixture is processed to yield the final soft or firrn/semi-hard cheese product. Systems for
preparing such cheeses and slurries are also disclosed.
[0039] The methods, for instance, can be used to introduce various ingredients, either in the
slurry and/or with another component of the cheese, to control: 1) melt and fiowability of the
final cheese product, which is a measure of how well the cheese melts and flows into a
homogenous mass, preferably with little or no individual shreds of cheese still detectable; 2)
stretch, which is measure of the ability of the cheese to form interconnected strings when the
heated cheese is pulled; 3) texture, which is a measure of chewiness and smoothness; 4)
coloring, which is a measure of the actual color of the melted cheese; 5) blister
characteristics, which may include size, color and extent of coverage; and/or 6) nutritional
composition.
[0040] The use of a slurry in the methods disclosed herein may also provide significant
improvements in yield. A typical cheese process in its basic approach involves acidifying
and coagulating milk to form a coagulum that contains cheese curd and whey, removing the
whey from the curd, and then processing the curd into a final cheese product. The whey that
is removed in conventional cheese manufacturing often contains many dissolved or
suspended ingredients, which often means that a significant quantity of dissolved substances
(e.g., protein, fat, carbohydrate and minerals) are lost when the whey is separated from the
curd. If any ingredients are added before the whey is separated from the curd, many of these
ingredients, because they are at least partially soluble in the whey fraction, are also lost.
[0041] As a specific example of the extent of this problem, for each 100 pounds of milk
that is used to prepare a cheese, it is not uncommon using conventional cheese manufacturing
techniques to only be able to produce 10 pounds of cheese. By using some of the slurry-
based methods that are disclosed herein, the yield can be increased in some instances to about
15,18, 20 22, or 50 or more pounds of cheese for each 100 pounds of milk. Thus, with some
methods, the yield can be increased by 1.5-2 times or more. The increase in yield is due in
part to the use of slurries that allow ingredients to be integrated into a precursor of the final
cheese product when essentially all the ingredients in the slurry are retained, as compared to
earlier in the process in which a significant proportion of added ingredients are lost.
[0042] One approach is to add the nonfat dry milk to the milk that is used to prepare the
cheese. If added at this stage, it is not uncommon for about 75% of the nonfat dry milk to be
lost, including proteins, lactose and minerals in the nonfat dry milk. If the nonfat dry milk is
instead incorporated into some of the slurries that are provided and the resulting slurry mixed,
for instance, into a cheese precursor (e.g., a homogenized mass of cheese curd) as described
herein, much, if not essentially all, of the nonfat dry milk may be incorporated into the final
cheese product.
[0043] In some methods, the slurry is processed so it is in a form that confers useful
properties on the final cheese product and/or facilitates preparation of the cheese. Some
methods, for instance, utilize a heated slurry that may also have been sheared and/or
homogenized. Such processing can influence the performance of the final cheese product in
various ways. For example, this processing can be used to achieve higher concentrations of
certain ingredients in the final cheese product as compared to traditional approaches.
Without intending to be bound by theory, it is believed that the shearing and homogenization
process can reduce particle size of the components of some cheese ingredients. These
resulting particles because of their reduced size are thus better able to become incorporated
into the overall cheese matrix, thereby allowing more ingredient to be introduced into the
final cheese product.
[0044] The reduced particle size also makes it easier to remove excess water during the
manufacturing process to the level desired in later manufacturing stages. The ability to
control water content is an important factor in being able to regulate the stability of cheese
and thus its shelf life. Reduced particle size also facilitates forming a compact cheese that
can be easily processed (e.g., shredded, sliced, or diced). Shearing and homogenization can
also be important in reducing the viscosity of the slurry, which aids in various processing
steps (e.g., transport of the slurry).
(0045] Use of a slurry that has been heated, sheared and/or homogenized during the
manufacturing process also is useful in activating, exposing the functionality and/or in
hydrating the ingredients, such that the ingredient has different properties than the
corresponding unheated ingredients. As a specific example, it can be difficult to incorporate
nonfat dry milk into a cheese as a dry powder in certain cheese manufacturing methods
because the nonfat dry milk never becomes fully hydrated. This makes the nonfat dry milk
susceptible to burning when cooked, for example. By using certain of the slurry-based
methods disclosed herein, ingredients such as nonfat dry milk can be better hydrated, thus
mitigating against the burning problem. The hydration of other ingredients can have other
beneficial results.
[0046] Some methods also involve a process in which the water content of the slurry is
adjusted. This is useful because the water content in a cheese is an important factor in
stability, shelf life and the ability to slice, shred and dice the final cheese product.
[0047] In sum, the use of slurries to introduce ingredients into cheeses at certain stages of
the manufacturing process can be used to help tailor the performance and nutritional
characteristics of the final cheese product.
III. Methods for Preparing Soft or Firm/Semi-hard Cheese
A. General
[0048] FIG. 1 provides a flow diagram that summarizes one general scheme 10 for
preparing a cheese product, such as a soft or firm/semi-hard cheese. As this figure indicates,
some methods involve providing a slurry 12 that contains one or more ingredients. The
ingredients in the slurry are selected to in accordance with the final cheese product that is
desired and are described in detail below. The slurries in the methods described herein
typically do not contain curd and thus lack cheese curd, but may, for example, instead include
other ingredients selected to impart a taste, performance and/or nutritional characteristic on
the final cheese product (e.g., mouthfeel, blister size, melt characteristic, texture or color).
Some slurries also do not contain ingredients that are commonly used in the preparation of
analog cheese. Methods using such slurries thus typically omit one or more or all of the
following: an oil, a fat, a protein, a starch, a sequestrant and a salt. Other methods, however,
utilize slurries that contain some or all of these ingredients. The slurry is combined 14 with a
cheese precursor to form an admixture. This admixture is then processed 16 to form the final
cheese product.
[0049] Another example of a general method is shown in FIG. 2A. This process 20
involves providing 22 a slurry that contains one or more ingredients and providing 24 a
cheese precursor. In this particular method, the cheese precursor (e.g., milk, cream,
coagulum and/or curd) is mixed 26 with one or more ingredients. This mixture is then
combined 28 with the slurry to form an admixture. Additional ingredients can subsequently
be added 30 to the admixture, thus providing another opportunity to control the composition
of the final cheese product. The admixture is then subjected to final processing 32 to obtain
the desired cheese product. Although the method in FIG. 2A includes two processes in which
additional ingredients are added (i.e., processes 26 and 30), other methods include only one
or neither of these processes.
[0050) FIG. 2B presents a variation of the general method shown in FIG.2A. In this
method 30, a cheese precursor is provided 24, mixed 26 with one or more ingredients and
then combined 28 with a slurry 22 to form an admixture. In contrast to the method shown in
FIG. 2A, however, the resulting admixture is then divided 29 into multiple portions (e.g., a
first and second admixture). Each admixture is then processed separately. For instance, a
first ingredient or set of ingredients can be added 30a to the first admixture portion and the
resulting mixture further processed 32a to form a first cheese product. A second ingredient or
set of ingredients (typically different from the first ingredient or ingredient set) is then added
30b to the second admixture portion and then subjected to further processing 32b to form a
second final cheese product. This approach is useful, for instance, to prepare different
cheeses with similar base compositions but somewhat different ingredients. Although FIG.
2B shows a method in which the initial admixture is divided into only two separate portions,
it should be understood that the initial admixture could be divided into a greater number of
portions with parallel processing of each portion as indicated in FIG. 2B. Further, although
the method in FIG. 2B shows ingredients being added 26 to the cheese precursor before the
cheese precursor and slurry are mixed, this step need not be performed in all methods.
[0051] A second variation of the method shown in FIG. 2A is depicted in FIG. 2C. In this
method 40, the providing 22, 24 and mixing 26 processes are as described with respect to
FIG. 2A. In this particular method, however, once the slurry and cheese precursor have been
combined 28, multiple ingredients are added in a serial process (as compared to the parallel
process illustrated in FIG. 2B). Thus, for example, one or more first ingredients are added 30
to form an initial admixture and then one or more second ingredients added 31 to form a final
admixture, which is subsequently further processed 32 to form the final cheese product. The
first and second ingredient can be the same or different. The first and second ingredient can
also be a single ingredient or a plurality of ingredients. It should further be understood that
although FIG. 2C illustrates a method in which there are two serial additions of ingredients
that more serial additions could be made.
[0052] Methods of the general type shown in FIG. 2C are useful, for example, when
separate additions of ingredients allows for improved incorporation into the cheese {e.g.,
adding all the ingredients at once may prevent the ingredients from becoming fully mixed
into the admixture).
[0053] The various primary processes involved in the methods that are provided, such as
those described in FIGS. 1 and 2A-2C, are discussed in detail in the following sections.
1. Slurry Preparation and Pre-Mixing Process
[0054] The process of providing the slurry can comprise several aspects. Some methods,
for example, generally involve blending a liquid (e.g., water, oil, milk and/or cream) and one
or more ingredients to form the slurry. The resulting slurry is then subjected to a pre-mixing
process to adjust the slurry to a form that will integrate well with the cheese precursor with
which the slurry is mixed. The pre-mixing process usually includes cooking the slurry,
typically to about 90-300 °F, 90-293 °F or 100-250 °F (38-121° C), but this is not mandatory.
This pre-mixing processing also optionally includes one, two or all of the following
processes: (1) subjecting the slurry to high shear conditions, (2) homogenizing the slurry,
and/or (3) adjusting the water content of the slurry, usually to about 5-95%, or 15-80% by
weight. As noted above, these processes are helpful in controlling processing parameters and
the ultimate performance characteristics of the final cheese product.
[0055] Different methods can incorporate different combinations of two or all three of the
foregoing optional processes. So, for example, in some methods, the pre-mixing processing
involves (1) and (2) but not (3). Other processes include (1) and (3) but not (2). Still other
pre-mixing processes include (2) and (3) but not (1). And still other processes include (1), (2)
and (3). The other remaining combinations can also be utilized depending upon the particular
requirements of an application. In some instances, it is sufficient to simply shear the slurry
without homogenizing it. But the pre-mixing process may involve both, in which case the
slurry is first typically sheared and then homogenized, although the order can be reversed.
[0056] In some methods, some of the pre-mixing processes are optionally carried out at the
same time (e.g., subjecting the slurry to high shear conditions while homogenizing the slurry;
or heating the slurry while subjecting it to high shear conditions and/or homogenizing the
slurry). Cooking can optionally be performed during the shearing and/or homogenizing. In
general, however, the pre-mixing processing steps conclude by adjusting the water content of
the slurry.
[0057] Some ingredients need to be subjected to high shear conditions to become
functional (e.g., hydrated or converted to a form that displays functional binding groups).
High shear conditions as used herein generally refers to conditions in which 10,000 to
500,000 s-1 of shear is applied. In some methods, the slurry is typically sheared by a high-
shear mixer or colloid mill, at a temperature of about 90 to 293° F (15 to 82° C) for about
0.01 to 0.5 seconds.
[0058] Homogenization of the slurry, if performed, generally involves the process of
reducing the particle size of fluid products under conditions of extreme pressure, shear,
turbulence, acceleration and impact, to make them more stable and have a better texture. The
effect is typically achieved by forcing the slurry through a special homogenizing valve at a
very high pressure. Homogenization can be done in one or multiple steps. For most
methods, two steps are sufficient. It is common that the main homogenization takes place in
the first homogenization valve and a mild homogenization in the second valve. The second
homogenization valve can enhance the product quality. This step, for example, can break
down newly formed fat globule clusters formed directly after the first valve due to re-
agglomeration. Homogenization is usually conducted at a temperature of about 90-293 °F
(32-145° C) or 100-250 °F (38-121° C) for about 0.01 to 0.5 seconds.
[0059] As indicated above, if the water content of the slurry is adjusted, the moisture
content is generally adjusted to about 5-95 percent, in some instances from about 15-80
percent, in other instances 20-75%, and in still other instances 30-60%. After such
processing, the slurry that is mixed with the cheese precursor, generally has a temperature of
about 100-180° F (37-83° C), or about 120-165° F (48-74° C). It also typically has a
viscosity of 1000 to greater than about 1,000,000 centipoise in this temperature range.
2. Exemplary Methods for Providing Cheese Precursor
[0060] As noted above, various cheese ingredients or mixtures thereof can serve as the
cheese precursor. Other cheese precursors include compositions formed during processing of
the starting ingredients, including, for example: 1) the pasteurized milk; 2) cheese milk
formed by the acidification of the pasteurized milk; 3) the coagulum formed during the
coagulation process; and/or 4) the cheese curd.
[0061 ] Cheese curd can be prepared, for example, from pasteurized cow's milk, buffalo
milk, goat's milk, or other milk source (e.g., concentrated milk, reconstituted milk or milk
protein powders). The milk is acidified to form cheese milk. The acidification step can be
performed either microbially or directly, or by a combination of both microbial and direct
acidification. Microbial acidification is accomplished by the addition of a starter culture of
one or more lactic acid-producing bacteria to the milk, and then allowing the bacteria to grow
and multiply. When making a mozzarella variety cheese, a bacterial starter culture composed
of coccus, rods, or a combination of both is preferably used. In some methods of
acidification, an acid added as a processing aid, such as acetic acid (e.g., vinegar), phosphoric
acid, citric acid, lactic acid, hydrochloric acid, sulfuric acid, or glucono-delta lactone (GdL),
lactobionic acid, etc., is added to standardize pH and is followed by addition of microbial
starter to complete the acidification process.
[0062] Following addition of the microbial and/or GRAS acids, the cheese milk is
coagulated to form a coagulum that consists of cheese curd and whey. Rennet, or another
suitable enzyme, is typically added to the milk to enhance the coagulation activity. The
resulting coagulum is cut and the whey drained off to obtain the cheese curd. The curd can
optionally be scalded (cooked) for about 0.08 to 1.0 hours at about 86-120° F (30-49° C) °C.
[0063] When dairy milk is used as a precursor, the sweet cream fraction of the milk, or a
portion thereof, may be separated and replaced by other types of creams and/or fats prior to
acidification. For example, the sweet cream may be replaced by whey cream and/or pro-
cream {i.e., a mixture of protein and cream) that is included with the whey fraction that is
separated from the cheese curd. The replacement of the dairy sweet cream, or a portion
thereof, with the whey cream and pro-cream reduces waste by making use of the whey cream
and pro-cream, as well as making the higher value sweet cream available for sale in the
marketplace.
[0064] In some methods, the cheese curd is heated and kneaded in a cooker/mixer to form a
heated mass of cheese curd (also referred to simply as a heated mass of cheese). The heating
and kneading process is generally done at a temperature of about 120-180°F (48-82° C) for a
time of about 1-15 min. Typically, the resulting mass has a temperature from about 120-150°
F (48-66° C). The heating and kneading process can be conducted simultaneously or
separately.
[0065] The heating and kneading process is generally conducted under low shear
conditions. Heating can be conducted, for instance, in a kneading mixer/extruder via 1)
immersion in hot water or brine, 2) direct steam injection, 3) indirect heating via an indirect
heat exchanger, and/or 4) by microwave. The steam injection option generally involves
releasing live steam into the kneading and stretching chamber. When live steam is used to
heat the curd, the steam condensate is absorbed by the curd and forms part of the final mass
of cheese. When using live steam in the mixer/cooker, typically the water content of the curd
immediately prior to entering the mixer/cooker is about 45 to 65 wt.%, and sufficient steam is
released into the kneading and stretching chamber such that the water content of the mass of
cheese immediately after exiting the machine is up to about 5 percentage points higher, e.g.,
about 0.5 to 10 points higher. Often, it will be about 2.5 to 8.5 points higher. So, for
example, if the water content of the curd entering the machine is 45 wt.%, then usually the
amount of injected steam that is used to bring the curd up to the necessary temperature to
obtain a homogenous mass of cheese will be an amount that raises the water content to no
more than about 55 wt.%. Indirect heating can be accomplished, for example, by conduction,
through the wall of the kneading and stretching chamber, e.g., by use of a hot water jacket.
[0066] In some methods, heating and kneading can be performed in the absence of any
exogenous water. By "exogenous water" is meant water that is used to bathe the curd and
which is subsequently separated from the homogenous cheese mass that is formed. A
shortcoming of the use of exogenous water during the heating and kneading process is that,
when the water is separated, valuable protein, fat, and other solids that otherwise would be
bound up in the finished cheese are removed. Various cookers can be used to heat the cheese
curd in this fashion. One option is the RotaTherm™ cooker available from Gold Peg
International Pry. Ltd. (Moorabbin, Vic, Australia).
[0067] Kneading is often accomplished by working the heated cheese curd with pressure
via single or dual helical intermeshing screws. The whole of the heating and kneading step is
sometimes referred to as a plasticization or pasta filata process, which refers to the heating of
curd to around 120-155°F (48-69°C) and kneading the hot curd. Successful plasticization of
the curd requires that the viscoelastic paracasein matrix undergoes limited flow and stretches
without breaking. Plasticization is believed to be accompanied by changes at a
microstructure level within the curd, including partial aggregation and tightening of the
paracasein gel matrix followed by formation of linear paracasein fibers with high tensile
strength. The cheese fat coalesces into elongated pools entrapped between paracasein fibers
showing their same orientation. This process aids in obtaining the proper functionality in the
final product.
[0068] The heating and kneading process described herein ensure complete mixing of the
heated curd. This is important because incomplete mixing results in the separation of fat and
water and the loss of these ingredients, as well as other such as fat, lactose and minerals.
3. Mixing of Slurry and Cheese Precursor
[0069] The slurry is combined with a cheese precursor to form an admixture. So, for
instance, the slurry can be combined at any stage along the process for preparing a soft or
firm/semi-hard cheese as outlined in the preceding section. Mixing of the slurry with a
cheese precursor can be accomplished using standard mixing apparatus that are known in the
industry.
[0070] In some methods, the slurry is mixed with a heated mass of soft or firm/semi-hard
cheese that has undergone the heating and kneading process that is associated with the pasta
filata process. For ease of reference, cheese curd that has undergone such a heating and
kneading process is simply referred to herein as a "heated cheese mass." In methods such as
this, the mixing typically is performed at a temperature of about 120 to about 170° F (49-77°
C). The temperature in some applications is relatively high, such as between 150-170 °F. In
other methods, the temperature is at or slightly below that of pasteurization (65° C, 150 °F),
for example in the range of about 120-150° F. (49-65° C). Mixing is usually conducted for
about 2-15 or 5-10 minutes. Mixing is generally performed under low shear conditions.
[0071J Combining the slurry with the heated cheese mass is a useful approach because the
slurry can be fully worked into the heated cheese mass with mininal loss of ingredients
during the mixing process and subsequent processing steps. This thus is useful in reducing
waste flow from the manufacturing process, thereby conferring significant cost benefits and
reducing waste disposal issues.
4. Optional Addition of Ingredients
[0072] Some methods optionally involve the further addition of ingredients at points along
the cheese preparation process other than the blending of ingredients with a liquid to form the
initial slurry. Ingredients can be added, for example, to the cheese precursors listed above
(e.g., to the curd ingredients, the coagulum and/or the cheese curd). These ingredients can be
added as liquids and/or powders.
[0073] In certain methods, ingredients are added to the heated cheese mass, the processed
slurry (e.g., after the slurry has been heated, homogenized, sheared and/or the water content
adjusted) or the admixture formed once the heated slurry and heated cheese mass are mixed
together. These ingredients are often added in a dry form (e.g., as a powder), but in some
instances can be added in liquid form. Powdered solids can be added using any of a number
of conventional approaches, including sprinkling the solids onto the cheese mass, usually
across the entire surface of the cheese mass and typically after application of agents or
ingredients in liquid form, if any. Liquid agents or ingredients can be sprayed down onto the
surface of the cheese mass as it passes through the mixing chamber, usually in a spray that
covers substantially the entire surface of the cheese.
5. Final Processing
[0074] Once the slurry and cheese precursor have been combined, the admixture is further
processed to obtain the desired final soft or firrn/serni-hard cheese product. The particular
processing steps required, depend in part upon the cheese precursor with which the slurry is
mixed. If the cheese precursor is a cheese ingredient such as milk or cream, for instance, then
the final processing involves completing the cheese manufacturing process to form a cheese
curd that contains the added slurry, followed by its further processing to yield the final
product. If the slurry is mixed with a cheese curd, the slurry/curd mixture can optionally be
heated and stretched in a pasta filata type process, or this mixture can be pressed together to
form a final cheese product. Thus, in some instances, final processing simply involves
compressing and molding the cheese curd using conventional cheese compression and
molding operations to form a mass of cheese.
[0075] If the process involves a heating of the cheese curd, the still-warm cheese (e.g., at a
temperature in the range of about 110-175 °F (43-80° C)) can be formed into any desired
shape depending upon the ultimate intended use. General options include, but are not limited
to, 1) forming relatively large pieces of cheese which are packaged; 2) comminuting the
cheese into smaller pieces that are packaged without freezing but instead refrigerated; 3)
comminuting, packaging and freezing the cheese, and 4) comrninuting, freezing, then
packaging the cheese.
[0076] In some methods, for instance, the admixture is extruded as a continuous
dimensionally flat Ribbon™, which is discharged into a cold sodium chloride brine channel
or tank, for example as described in U.S. Pat. No. 4,339,468 to Kielsmeier or U.S. Pat. No.
5,200,216 to Barz et al. (both of which art incorporated herein in their entirety). The cheese
Ribbon™ is sometimes contacted with cold sodium chloride brine (in one or more tanks or
vessels) until its core temperature drops to about 75° F (24° C) or below. Then the cooled
Ribbon™ can be cut into segments having dimensions suitable for the intended use of the
cheese.
[0077] Other options include: 1) floating the cheese in a coolant; 2) placing the cheese on a
perforated belt and spraying coolant on the cheese surface; 3) placing the cheese on a solid
belt and spraying coolant on the underside of the belt; 4) transfer through a cooling chamber;
and 5) refrigeration of the heated cheese.
[0078] If a string cheese is the desired product [e.g., a cheese having a diameter of about
1/8 to 1.0 inch (0.32 to 2.54 cm.)], the segments of the string are generally about 1 1/2 to 12
inches (410 30.5 cm) long. If the string cheese is to be baked only while enclosed in pizza
crust (e.g., in a stuffed crust pizza), it typically is unnecessary to age the cheese before using
it. If desired, the string cheese can be frozen and stored.
[0079] The warm cheese can also be molded/extruded into blocks of any of a variety of
sizes that are convenient. Some blocks, for example, are about 4 inches high, 4-8 inches
wide, and 4-24 inches long.
[0080] If the finished cheese is to be used as an exposed topping for a pizza, then the
continuous Ribbon™, typically is rectangular in cross section, and can be cut into loaves, for
example having a width of about 4 to 3 6 inches (10 to 92 cm.), a height of about 1/16 to 4
inches (0.15 to 10 cm.), and a length of about 4 to 36 inches (10 to 92 cm.). The loaves can
then be further cooled in sodium chloride brine, for example to a core temperature in the
range of about 26 to 75° F (-16 to 24° C), and then removed from the brine and comminuted,
and the pieces individually quick frozen, for example by the process described in U.S. Pat.
No. 5,030,470 to Kielsmeier, et al., which is hereby incorporated herein by reference.
[0081] Depending on the composition of the cheese, it may be preferable to store it for a
time [e.g., about 7 to 21 days, at about 3 5 to 45° F (2 to 7° C)] after it is removed from the last
brine tank and before it is comminuted and frozen. However, as described in U.S. Pat. No.
5,200,216 (Barz et al.), if the process is controlled such that the cooled cheese removed from
the brine has a moisture content of about 45 to 60 wt. %, a milk fat content of at least about
30 wt. % (dried solids basis), and a combined moisture and wet milk fat content of at least
about 70 wt. %, the cheese can be frozen immediately and will still perform satisfactorily
when heated under a variety of conditions.
[0082] The final processing procedure can also be as described in U.S. Patent No.
5,902,625, which is incorporated herein by reference in its entirety for all purposes.
[0083] Methods based on the foregoing processes can be conducted in a batch format or
continuously. Batch methods, for example, involve providing batches of slurry and cheese
precursor that are subsequently combined in batches. The resulting mixtures are
subsequently processed to obtain the desired final cheese product. The process is then
repeated.
[0084] In continuous methods, at least the slurry preparation process and the process in
which the slurry is combined with the cheese precursor is conducted in a continuous process.
In some methods, essentially each of the steps listed above are conducted continuously such
that slurry preparation, cheese precursor preparation, combining of the slurry and precursor,
optional addition of ingredients, and final processing steps are all continuously ongoing.
B. Exemplary Methods
[0085] FIG. 3 A provides a specific example of a method in which a heated slurry and
heated cheese mass are combined to form an admixture that can subsequently be processed to
yield a final cheese product, such as a soft or finn/semi-hard cheese product. As noted
above, in some instances the slurry is heated because this can be useful in increasing the
amount of certain ingredients that can be incorporated into the final cheese product and in
unmasking the functionality of some ingredients.
[0086] This particular method 100 includes a slurry preparation process 105 in which a
liquid (e.g., water, milk and/or cream) and one or more ingredients are blended 110 together
to form the initial slurry. The pre-mixing process 107 involves cooking/heating 115 the
resulting slurry to a temperature of about 90-300 °F. This heated slurry is subsequently
subjected 120 to high shear conditions and then homogenized 125 to obtain a slurry in which
the ingredients are of the desired particle size. Thereafter, the water content of the heated
slurry is adjusted 130, typically to about 5-95 wt. %. The slurry is transferred to the
combining and mixing state 170 through the use of a pump at the discharge of a surge hopper,
which maintains the slurry at a constant volume 131. As the slurry is transferred, it may be
filtered 132 to remove any large particles formed in the slurry during the cooking/heating step
115 (or other extraneous materials), and also exposed to a magnetic field 133 to remove any
metal fragments in the slurry generated by metal to metal contact of the moving parts of the
process equipment.
[0087] As further shown in FIG. 3A, the process of providing 150 a cheese precursor in this
particular method involves several processes to obtain a heated cheese mass. The process is
initiated by forming 155 a cheese curd. Once formed, the cheese curd is heated and kneaded
160 to form a heated cheese mass. During the heating process, the curd is typically heated to
about 120-155 °F.
[0088] Once the heated slurry and heated cheese mass have been formed, they are mixed
170 together to form an admixture. This particular method includes a process of mixing in
175 one or more optional ingredients into the admixture. But as noted above, such additions
are optional and not all methods include this process. Furthermore, although this particular
method shows the additional ingredients being added to the admixture of slurry and heated
cheese mass, the ingredients could also be added to the slurry or to the heated cheese mass
just prior to mixing. Alternatively, the slurry, heated cheese mass and ingredients can be
combined simultaneously. The admixture that is formed is subsequently processed 180 to
form the final soft or firm/semi-hard cheese product. In the particular method depicted in
FIG. 3A, final processing 180 involves shaping 185 the admixture into a desired form and
cooling 190 the shaped cheese to form the final cheese product. Although FIG. 3A shows the
final processing step to first involve the shaping process followed by the cooling process, this
order can be reversed or performed simultaneously.
[0089] Although the particular method illustrated in FIG. 3 A shows the slurry and heated
cheese mass being mixed together, in other methods the slurry is mixed with another cheese
precursor (e.g., milk, coagulum or unprocessed cheese curd). Systems for performing such
methods are shown in FIG. 4C.
[0090] Another example of a method for preparing soft or firm/semi-hard cheese is shown
in FIG. 3B. In general, method 102 illustrates certain methods in which a curd or a curd
precursor is combined with the slurry, instead of a heated mass of cheese. In the method
illustrated in FIG. 3B, a slurry is provided 105 as described with respect to FIG. 3 A. The
process of providing 150 a cheese precursor in methods of this type, however, involves
providing 151 a curd or curd precursor. In this particular method, one or more additional
ingredients can be mixed 152 into the curd or curd precursor, but not all methods include
such additions. The curd or curd precursor is then combined 153 with the slurry to form an
admixture. The resulting mixture may then be heated and kneaded 171 to form a heated mass
of cheese as in a pasta filata process. Method 102 also includes a process in which one or
more additional ingredients are added 162 and mixed 172 with the admixture. Here, too,
however, not all methods include such additions. The admixture is then processed 180 to
form the final soft or firm/semi-hard cheese product.
[0091J The final processing 180 of each of the exemplary methods shown in FIGS. 3A and
3B can involve any of the processing options described above or generally known in the art.
So, for example, in some methods final processing involves individually quick freezing
pieces of the cheese as described in U.S. Patent No. 5,030,470. Other methods involve a
same day dice procedure such as described, for example, in U.S. Patent No. 5,200,216. In
still other methods, the cheese is not comminuted but formed into blocks that are directly
packaged and refrigerated. Those of skill will recognize that a variety of other processing
options are available. Further examples are provided in the section on "Final Processing"
above.
IV. Ingredients
A. General
[0092] A number of different types of generally recognized as safe (GRAS) ingredients can
be incorporated into the slurry and optionally added at other stages of the overall
manufacturing process as described herein. If added at a stage other than the slurry, most
ingredients can generally be added as a powder or as part of a solution. The ingredients that
are incorporated are selected, for example, to tailor the performance, nutritional, and taste
characteristics of the final soft or firm/semi-hard cheese product.
[0093] As noted above, some of the ingredients included in the slurry generally fall into
two general categories: 1) ingredients that one seeks to incorporate at relatively high
concentration levels; and 2) ingredients that need to be heated and/or hydrated to become
functionalized, i.e., to be converted into a form that has the chemical and/or physical
properties that are important for imparting the desired characteristics to the final soft or
firm/semi-hard cheese product. But a variety of other ingredients can also be included in the
slurry.
[0094] Examples of such ingredients include, but are not limited to, nonfat dry milk, a milk
protein, an acidity regulator, an acid, an anticaking agent, an antifoaming agent, a coloring
agent, an emulsifier, an enzyme preparation, a flavoring agent, a firming agent, a food
protein, a gelling agent, a preservative, sequestrants, a stabilizer, a starch, a thickener, an oil,
a fat, a cheese powder, a salt, a nutritional supplement, an acid, an enzyme, a neutraceutical, a
carbohydrate, a vitamin, and a mineral. Examples may further include procream, whey
cream, a dairy solid, and foodstuffs of vegetable, fruit and/or animal source. The foodstuffs
may include fruit, vegetables, nuts, meat, and spices, among other foodstuffs.
[009S] Examples and additional specific information regarding the types of ingredients that
can be incorporated to tailor the performance, nutritional and taste characteristics of the final
soft or firm/semi-hard cheese product follow.
[0096] Dairy Solids. A dairy solid can be added to improve various characteristics of the
final cheese product such as: firming the cheese, improving water binding capacity,
improving the melt appearance of the cooked cheese, and/or increasing the blistering of the
cooked cheese. Dairy solids that can be utilized include, but are not limited to, whey protein
concentrate, casein hydrolyzate, milk fat, lactalhumin, cream, milk protein concentrate, milk
protein isolate, lactose, casein, whey protein isolate, hydrolyzed whey protein, denatured
whey protein, skim cheese powder, natural casein isolate, nonfat dry milk, delactose
permeate, procream, mixer overflow liquid, and milk minerals. In general, dairy solids can
be incorporated into the final product from about 0.5-25 wt. %.
[0097] Incorporation of a dairy solid such as nonfat dry milk into a heated slurry is one
approach for obtaining relatively high concentration levels in the final product. For example,
the dairy solid concentration in some soft or firm/semi-hard cheeses that are prepared
according to the methods disclosed herein can be at least 11,12 or 13 wt. %, and can include,
for example, up to about 16, 17, 18,19, 20 or 25 wt. % of the final product. Thus, the
concentration of the dairy solids in the slurry is generally adjusted such that the level of dairy
solid in the final cheese product is about 0.5- 25, about 3-18, about 4-16, or about 11-25 wt.
%. This means that the concentration of the dairy solid in the slurry itself is generally within
the range of about 0.5 to 95 wt. %, for example about 10-80%, or about 30-70%, by wt.
[0098] Starches. Incorporating starches into the heated slurry is also beneficial in some
instances because the functionality of some starches is increased when heated, hydrated
and/or subjected to high shear conditions. Once functionalized in this manner, the starch can
thicken or gel to bind to proteins in the cheese (e.g., casein). In general, starch can be
incorporated into the final product in the range of about 0.5-20 wt. %.
[0099] Some methods add starch such that the starch concentration in the final cheese
product is at least 4, 6, 11, 12, 13 or 20 wt. %. Thus, in some instances, the starch
concentration can range from about 4-20 wt.% or from about 5-16 wt. % in the final cheese
product. This means that the starch concentration in the slurry itself is typically about 0 -95
wt. %, for example about 0.5-50%, or about 1-25% by wt.
[0100] A number of different types of starches can be incorporated into the final cheese
product. Suitable starches include vegetable starches (e.g., potato starch, pea starch, and
tapioca) and grain starches (e.g., corn starch, wheat starch, and rice starch). Specific
examples cf suitable corn starches include dent corn starch, waxy com starch, and high
amylose corn starch. The starches can be used individually or in combination.
[0101] The starch can be modified or native. Modified food starches differ in their degree
of cross-linking, type of chemical substitution, oxidation level, degree of molecular scission,
and ratio of amylose to amylopectin. Examples of some commercially-available modified
food.sarches that are suitable include Mira-Cleer 516, Pending 200, Purity 660, Batterbind
SC, Penbind 100, MiraQuick MGL, Novation 3300, and Gel-n-Melt. A suitable
commercially-available native (unmodified) starch is Hylon V.
[0102] Mira-Cleer 516, from A. E. Staley Company, is a dent corn starch that is cross-
linked and substituted with hydroxypropyl groups. The cross-linking increases its
gelatinization temperature and acid tolerance. The hydroxypropyl substitution increases its
water binding capability, viscosity and freeze-thaw stability. MiraQuick MGL, also from A.
E. Staley Company, is an acid-thinned potato starch. The acid thinning breaks amylopectin
branches in the starch, creating a firmer gel. Batterbind SC, from National Starch, is a cross-
linked and oxidized dent com starch. Purity 660, also from National Starch, is a cross-hnlced
and hydroxypropyl substituted dent com starch. Hylon V, also from National Starch, is an
unmodified, high amylose com starch. Pending 200, from Penwest Foods, is an oxidized
potato starch. The oxidation increases its capacity to bind water and protein. Peribind 100,
also from Penwest Foods, is a cross-linked potato starch.
[0103] Emulsifiers, Gelling Agents, Stabilizers and Thickeners. Gums, celluloses, and
alginates are some examples of emulsifiers, gelling agents, stabilizers and thickeners. Many
of the considerations that apply to starches also apply to gums and celluloses. Certain gums
and celluloses, for example, should be hydrated and/or heated to realize their full functional
characteristics. Heating and hydration also enables increased levels of the gums, celluloses,
or alginates to be included in the final product. Some of the soft or firm/semi-hard cheeses
that are provided herein contain at least about 0.01, 0.5 or 3.0 wt. % gum, cellulose, or
alginate. The products thus generally have a gum, cellulose, or alginate concentration of
about 0.01-3.0 wt. %. This means that the concentration of the gum, cellulose, or alginate in
the slurry itself is typically about 0.02-6.0 wt. % or 0.05-5.0 wt. %.
[0104] Different types of celluloses can also be incorporated into the cheese. The cellulose
can be either natural or modified. One cellulose or combinations of different celluloses can
be utilized. Types of celluloses that can be utilized include, hut are not limited to,
microcrystalline cellulose, powdered cellulose, methylcellulose, propylene glycol alginate,
and sodium alginate. One specific example of a commercially available modified cellulose is
METHOCEL A-l 5™ that is available from Dow Chemical Company (Midland, MI).
[0105] Examples of suitable gums that can be incorporated include, but are not limited to,
xanthan gum, guar gum, konjac flour and locust bean gum. Examples of suitable stabilizers
include chondrus extract (carrageenan), pectin, gelatin, and agar.
[0106] The total amount of gums and stabilizers included in the final cheese product is
typically up to about 0.01, about 0.50, or about 3.0 % by weight. More specifically, the
amount of gums and/or stabilizers can range from about 0.01 to 3.0%, from about 0.25 to 2.5
%, from about 0.5 to 2.0 % , or about 0.75-1.5% by weight of the final cheese product. Gums
and stabilizers concentrations in the slurry are typically in the range of about 0.02 - 6.0, or
0.50 - 5.0 wt. %.
[0107] Acidity Regulators, Anticaking Agents, and Firming Agents. Acidity regulators,
anticaking agents, and firming agents of various types can be included in the cheese.
Typically, these agents are inorganic salts, but other types of acidity regulators, anticaking
agents, and firming agents can also be used. Examples of acidity regulators, anticaking
agents, and firming agents may include calcium chloride, tricalcium phosphate, calcium
hydroxide, powdered cellulose, disodium phosphate, and potassium hydroxide. These agents
are typically added as part of a solution, (but could be used as a powder) either by
incorporation in the slurry or in a non-heated liquid that is incorporated into the admixture of
the slurry and heated cheese mass.
[0108] The total amount of acidity regulators, anticaking agents, and firming agents
incorporated into a slurry is sufficient so the concentration of the acidity regulators,
anticaking agents, and firming agents in the final cheese product is generally up to about
0.05, 1.2, or 3.0 % by weight. More specifically, the amount of acidity regulators, anticaking
agents, and firming agents can range from about 0.05 to 3.0%, from about 0.1 to 2.5 %, or
from about 0.5 to 2.0 % by weight. This means that the concentration of the acidity
regulators, anticaking agents, and finning agents in the slurry is typically about 2 to 95 % by
weight.
[0109] Sequestrants. A number of different sequestrants can be incorporated into the final
cheese product. Sequestrants that can be utilized include, but are not limited to, various
phosphate salts {e.g., sodium hexametaphosphate, monosodium phosphate, sodium
polyphosphate, disodium phosphate, trisodium citrate and potassium phosphate), calcium
citrate, calcium gluconate, oxystearin and sorbitol.
[0110] The total amount of sequestrant is usually up to about 0.1, 1, or 4 % by weight of
the final cheese product. So, for example, the amount of sequestrant in the final cheese
product can range from about 0.1 to 4%, from about 0.25 to 3.0 %, or from about 0.4 to 2.5 %
by weight. The concentration of the sequestrants in the slurry itself thus is generally about
0.1 to 95 wt. %.
[0111] Acids. An acid can be incorporated to adjust the pH of the finished cheese to a
desired level. Various acids can be employed; examples of suitable acids include, but are not
limited to, adipic acid, lactic acid, glucono-delta-lactone, phosphoric acid, lactobionic acid,
hydrochloric acid, acetic acid, or Genlac C, the latter being a blend of water, citric acid, lactic
acid, acetic acid and artificial flavors. Acid is typically added to adjust the pH of the finished
cheese to a pH from about 5-6 is reached, and more typically from pH 5.10-5.70.
[0112] If included in the slurry, the acid agent is included in an amount sufficient to adjust
the pH of the slurry within the range of about 0.0 to 8.0, for example, from about 0.5-6.5, or
1-5.
10113] Cheese powders. Cheese powders can also be mixed into the cheese to impart a
different cheese flavor to the finished product. Such powders are typically added to the
heated cheese mass formed during the pasta filata process as a powder rather than as part of
the slurry.
[0114] Examples of suitable cheese powders include, but are not limited to, Parmesan,
cheddar, Monterey Jack, Romano, muenster, Swiss, and provolone powders. The amount of
cheese powder in the finished cheese is generally about 0.25 to 10%, and in some instances
about 1 to 5% by weight. Cheese powders are available from a variety of commercial
suppliers, including, for example, Armour Foods of Springfield, Ky.
[01 IS] Colorants. A colorant can be incorporated into the cheese to adjust its natural color.
This can be useful, for example, if consumers have a preference for a color other than the
naturally-occurring color. Examples of suitable colorants include annatto, tumeric, titanium
dioxide, and beta-carotene. Colorants may be of both the natural or artificial color. If one
wished to color the cheese a red an artificial color such as FD&C red # 40 can be used.
Annatto is useful to give mozzarella cheese the appearance of cheddar. This allows one to
produce a cheese for pizza baking that has the desired melt characteristics of mozzarella, hut
with a different appearance than that of traditional white mozzarella. Annatto-colored
mozzarella can be used as a replacement for cheddar cheese in many food products (e.g.,
Mexican-style prepared foods). Tumeric imparts a yellowish color to mozzarella, which
naturally is white. The yellowish color often is preferred by consumers who perceive it to
indicate a "richer" product upon cooking on a pizza. Colorants such as armatto and tumeric
can be obtained, for example, from Chris Hansens Labs of Milwaukee, WI.
[0116] Colorants can be incorporated into the final cheese product by inclusion in the
slurry. If added apart from the slurry, the colorant is generally sprayed onto the heated
cheese mass as an unheated solution or dispersion in water. The amount of colorant added is
typically in the range of about 0.01 to 2%, based on the weight of the finished cheese.
Tumeric, if used, is generally added in an amount of about 0.05 to 0.5%. If annatto is added,
it normally is added to about 0.1 to 0.9% by weight.
[0117] Flavoring Agents. Various flavoring agents can also be incorporated into the cheese
to tailor the flavor profile of the cheese to meet consumer preferences. Suitable flavors for
mixing into the heated cheese include, for example, cheddar cheese flavor and parmesan
cheese flavor.
[0118] Flavoring agents are typically added in an amount such that the concentration in the
final cheese product is within the range of about 0.01 to 5 wt. %. If incorporated into the
slurry, the concentration of the flavoring agent in the slurry is generally is in the range of
about 0.02 to 5 wt. %.
[0119J Non-dairy protein isolate. A non-dairy protein isolate can also be incorporated into
the soft or fiim/semi-hard cheese. It is to alter the texture of the cheese and/or to change the
sire, color, or integrity of the blisters that are formed when the cheese is baked on a pizza, as
well as other cook characteristics. Examples of suitable non-dairy protein isolates include,
but are not limited to, soy protein (sometimes called "soy powder"), gelatin, wheat germ, com
germ, ghnxn, and egg solids.
[0120] The protein isolate is added such that the concentration of the protein isolate in the
final cheese product is up to about 1, 15 or 30 wt. %. The concentration of the protein isolate
in the slurry is thus adjusted so the concentration is about 2 to 95 % by weight of the slurry.
[012]] Oils. Various oils can also be incorporated into the cheese. They are generally
added to alter the fatty acid profile and/or cost of the cheese and/or to change the size, color,
or integrity of the blisters that are formed when the cheese is baked, as well as other cook
characteristics. Examples of suitable oils include, but are not limited to, vegetable oils, soy
bean oil, corn oil, flax seed oil, walnut oil, palm oil, linoleic acid, fish oil, omega 3 fatty
acids, and medium chain triglycerides, among others. Any of the oils may be partially or
completely hydrogenated. If blended into the initial slurry, the oil is added in a concentration
such that the concentration of the oil in the final cheese product is up to about 1.0,20 or 35
wt. %. The concentration of the oil in the slurry is thus adjusted so the concentration is about
0 to 65, by weight, (e.g., about 5 to 50 % wt.) of the slurry.
[0122] Salt. Salts of various types, but typically sodium chloride, can be added to tailor the
flavor of the final cheese. The salt can be incorporated into the final cheese product by
including it in the heated slurry or by adding it in granular form or as an unheated solution
apart from the slurry. Regardless of how introduced, the salt concentration in the final cheese
product is usually added at a level of about 0.1-5 wt. %. When added as an ingredient of the
slurry, this means that the salt concentration in the slurry is generally about 0.0 to 25.0 wt. %,
for example about 0.5-22%, or about 1-18% by wt.
[0123J Antifoaming Agents. Various antifoaming agents can be incorporated to facilitate
processing. Examples include, but are not limited to, microcrystalline wax, oxystearin and
polydimethylsiloxane.
[0124] Carbohydrates. A variety of simple sugars {e.g., mono- and disaccharides), as well
as more complex carbohydrates can be included in the cheese. Examples include, but are not
limited to, glucose, sucrose, and fructose.
[0125] Enzymes. Enzymes may be used to create flavors, texture, melt, and/or other
functional characteristics in the final cheese product, and/or in the slurry that can then be
transferred to the final cheese product once the slurry and cheese have been mixed together.
Examples of such enzymes, and this is not an all inclusive list, would be lipases, proteases,
oxidoreductases, and transglutaminase.
[0126] Neutraceuticals. Neutraceuticals may be included to deliver nutrients not normally
present in cheese. Examples of neutraceuticals include, but are not limited to lycopene,
antioxidants, probiotics, prebiotics, phosphatidylserine, vegetable sterols, immunoglobulins.
These products in particular may be added as part of the slurry or to the mixer (mixer 290, fig
4B).
V. Slurries and Slurry Preparation Methods
[0127] Slurries that are combined with a cheese precursor to produce the soft or firm/semi-
hard cheese product are also provided. As described, these compositions contain one or more
of the ingredients or ingredients listed in the preceding section. In general, the concentration
of these ingredients is sufficient to obtain a final soft or firrn/semi-hard cheese product having
the desired concentration of the ingredient (see preceding section). More specifically, the
ingredient concentrations are in the range listed above.
[0128] The slurries utilized to prepare the soft or firrn/semi-hard cheeses that are provided
typically are water-based compositions. But some slurries alternatively or in addition include
another liquids such as milk or cream. The water in some compositions typically accounts
for from about 5 - 95 % of the slurry by weight. Slurries may also include emulsions of water
and oil and/or fat.
[0129] The slurries are optionally processed to be in a form that mixes well with another
cheese ingredient (e.g., curd or heated cheese mass), that promotes dissolution of ingredients
and/or that confers the desired processing or performance characteristics. Details regarding
the slurry preparation process are described above, including FIGS. 3A and 3B and
accompanying text.
[0130] One example of a useful base slurry is one that contains cream, nonfat dry milk and
water. To obtain high concentrations on nonfat dry milk, it can be useful to include an acid
and salt. Above about 60% nonfat dry milk, for example, the slurry can get very viscous and
thus difficult to pump through the slurry processing system described above. By adding acid
as a processing aid, and salt to the slurry, the viscosity can be reduced sufficiently such that
the slurry containing the desired high levels of nonfat dry milk can be transported through the
processing system. Although any acid and salt could be added elsewhere during the process,
inclusion in the slurry can be useful for the reasons just listed.
[0131] To reiterate a point made earlier, slurries can be used to provide various benefits
during the cheese manufacturing process, including increased yield. Nonfat dry milk contains
about 27 wt. % casein protein and about 73% other components (e.g., ash, lactose, whey
protein, etc). If the nonfat dry milk is added to the milk at the beginning of the cheese
manufacturing process, much of the casein becomes incorporated into the cheese, but much,
or all, of the other components are lost. Using slurries and methods such as provided herein,
essentially all of the casein and whey protein can be incorporated into the final cheese
product, thus significantly increasing the yield of the overall process.
VI. Systems for Preparing Soft or Firm/semi-Hard Cheese Products
[0132] FIG. 4A depicts one example of a generalized system 200 that can be used to carry
out die foregoing methods to prepare the soft or firm/semi-hard cheeses that are described
herein. This exemplary system includes the following subsystems: (1) a slurry preparation
system 205; (2) a cheese precursor preparation system 260 that is in fluid communication
with slurry preparation system 205; and (3) a final processing system 300 that is in
communication with cheese precursor preparation system 260. The slurry preparation system
includes the equipment necessary to prepare the slurry that contains the one or more
ingredients selected for inclusion in the final cheese product. The cheese precursor
preparation system generally includes the equipment and devices required to prepare a cheese
precursor, and can include a mixer or related device to combine the slurry with the precursor.
The final processing system includes the equipment to convert the admixture of the slurry and
cheese precursor into the desired final product.
[0133] A wide variety of different systems have this general design. Although specific
examples of such systems are described below, it should be understood that these systems are
only examples and not intended to be an exhaustive list of the types of systems that can be
used to carry out the cheese processing methods that are described herein or of the type of
systems that can be used to prepare the type of soft or firm/semi-hard cheeses that are
disclosed herein.
[0134] One exemplary system that can be used to perform the methods that are disclosed
herein is shown in FIG. 4B. This particular system 202 is for use primarily in methods in
which a slurry is combined with a heated mass of cheese (see, e.g., FIG. 3 A). The cheese
precursor preparation system 260 of system 200 generally includes a curd preparation
subsystem 261 that is connected to cooker/kneader 270 by transfer tube 268. Cooker/kneader
270 is connected in turn by transfer tube 269 to mixer 290, which is also in communication
with slurry preparation system 205 via transfer tube 255. In operation, curd is thus prepared
in curd preparation subsystem 261 and can be transported through transfer tube 268 into
cooker/kneader 270, where the cheese curd is heated and kneaded to form a heated cheese
mass. This mass can then be combined with the slurry prepared in slurry preparation system
205. The cheese precursor preparation system 260 also includes dispenser 251 which is
connected to curd preparation system 261. Thus, additional control over the composition and
preparation of the final cheese product can be achieved by adding ingredients from dispenser
251 to compositions in the cheese curd preparation system 261 via transfer tube 252. But not
all systems include such a dispenser.
[0135] The slurry preparation system 205 of system 200 generally includes the equipment
necessary to blend, heat, shear, homogenize and adjust the water content of the slurry to
obtain the desired slurry composition. More specifically, system 205 includes a blender 210
and cooker 220 that are connected to one another via transfer tube 215. The transfer tube 215
may include a pump sniffer that moves the slurry to the cooker 220. The pump stuffer may
include two augers that move the slurry and a hopper that takes up the slurry into the augers
from the blender 210. A liquid {e.g., water, milk and/or cream) and one or more slurry
ingredients can thus be introduced into blender 210, where they are blended together to form
an initial slurry. This resulting slurry can then be transported into cooker 220, where the
slurry is heated to form a heated slurry. Slurry preparation system 205 in this system also
includes slurry mixing and moisture control subsystem 208. The particular subsystem 208
shown in FIG. 4B includes shear pump 230, homogenizer 240 and evaporator 250.
Subsystem 208 is in communication with cooker 220 and mixer 290.
10136] In the particular subsystem shown in FIG. 4B it is shear pump 230 of subsystem 208
that establishes the link with cooker 220, as shear pump 230 is connected to cooker 220 via
transfer tube 225. Shear pump 230 is also connected to homogenizer 240 by transfer tube
235, which in turn is connected to evaporator 250 by transfer tube 245. Subsystem 208 is
connected to mixer 290 by transfer tube 255, which connects evaporator 250 and mixer 290.
[0137] Thus, heated slurry from cooker 220 can flow into shear pump 230 via transfer tube
225, where the slurry is subjected to shear conditions. The sheared slurry can subsequently
be transferred to homogenizer 240 through transfer tube 235, where the slurry and the
ingredient(s) it contains are homogenized. The resulting homogenized slurry can then flow
through transfer tube 245 into evaporator 250. Evaporator 250 adjusts the moisture content
so it is within the desired range. The final slurry then flows from evaporator 250 into mixer
290 via transfer tube 255.
[0138] The heated slurry from slurry preparation system 205 can then be combined with the
heated cheese mass from cheese precursor preparation system 260 in mixer 290. Ingredients
can also optionally be introduced into mixer 290 from additive dispenser 286, which is in
communication with mixer 290 through transfer tube 287. The admixture formed in mixer
290 can then be transported via tube 291 and processed in final processing system 300. Final
processing system 300 as depicted in this particular system includes extruder 305 that is
connected to cooling system 315 by tube 310. Various other final processing systems,
however, can also be utilized as described herein.
[0139] It will be appreciated by those of ordinary skill in the art that certain units within
slurry preparation system 205 (e.g.s cooker 220, shear pump 230, homogenizer 240 and
evaporator 250) need not be included. Most slurry preparation systems include a blender to
blend the liquid and ingredients together. But the slurry preparation system can include none
of the other units just listed (i. e., cooker, shear pump, homogenizer and evaporator),
individual units, combinations of multiple units or all the units depending upon the particular
requirements of the application. It should also be understood that these units can be arranged
in a variety of other configurations. For instance, although shown as separate units in FIG.
2C, shear pump 230 and homogenizer 240 can be part of a single unit in other systems. Other
combinations that can optionally be utilized in still other systems are those in which cooker
220 and shear pump 230 are part of the same unit, and systems in which cooker 220, shear
pump 230 and homogenizer 240 are all part of the same integrated unit.
[0140] The order in which cooker 220, shear pump 230 and homogenizer 240 appear in
FIG. 4B can also be altered in other systems such that all the various permutations are
possible. Examples of optional arrangements that can be utilized in other systems include: 1)
coolcer-homogenizer-shear pump, 2) shear pump-homogenizer-cooker, 3) shear pump-
cooker-homogenizer, 4) homogenizer-shear pump-cooker, 5) homogenizer-cooker-shear
pump, and the other various permutations.
[0141] Another exemplary system is illustrated in FIG. 4C. This figure depicts a system
203 that would typically be used to conduct methods in which the slurry is mixed with a
cheese curd or curd precursor (see, e.g., FIG. 3B). The resulting admixture can then be
heated and kneaded as in a pasta filata type process.
[0142] The slurry preparation system 205 for system 203 is as described for system 202.
The cheese precursor preparation system 260 includes various units utilized in the preparation
of cheese curd. Cheese precursor preparation system 260 in the particular system shown in
FIG. 4C thus includes, for instance, curd preparation system 261, which includes curd
containers 262 of cheese ingredients (e.g., milk, starter and cream) or mixtures thereof (e.g.,
cheese vat), a system for forming coagulum 264, and containers 266 of curd. Cheese
precursor preparation system 260 also includes mixer 290, but some systems omit this mixer.
In operation, ingredients or mixtures thereof in containers 262 can be moved to the system for
making the coagulum 264 via transfer tube 263. The coagulum can subsequently be
transported from system 264 to container 266 through tube 265. The curd can then be moved
from containers 266 to mixer 290 through transfer tube 267. Curd preparation system 261
may also include ingredient dispenser 251, which can be connected to ingredient containers
262, coagulation system 264 and/or curd container 266 via transfer lines 253a, 253b, 253c,
respectively. This thus allows the option of adding ingredients at each of these stages of the
process.
[0143] In system 203, slurry can be transported through lines 255 and lines 256a, 256b,
and/or 256c such that the slurry becomes combined with the ingredients or mixtures in
containers 262, the coagulum in coagulation system 264, and/or the curd in containers 266.
System 203 is designed to allow for various processing options once the slurry and cheese
precursor are combined to allow for a curd/slurry admixture. One option, for example, is to
transport the admixture through tube 291 to the final processing system 300 to form the final
product. In an alternative configuration, however, curd preparation system 261 is in
communication with cooker 270 via tube 267, which in turn is connected to mixer 290 via
tube 267. Mixer 290 may be connected to final processing system 300 by transfer tube 291.
Alternatively, the transfer tube 291 may divert the flow of the admixture between coloring
units 293 and 294. Coloring unit 293 may add coloring (e.g., orange coloring) to the
admixture to give it the appearance of, for example, cheddar cheese, while coloring unit 294
may add no color and leave the cheese substantially white in color. The entire admixture
may be diverted through one or the other coloring units 293 and 294, as well as being
adjustable to split the admixture between the coloring units to create, for example, a cheese
combination from the admixture.
[0144] Another option is for the admixture to be moved to cooker 270 through tube 267.
Once the admixture has been heated and kneaded, the resulting heated admixture can be
transported to mixer 290 via tube 288. This thus allows additional ingredients to be
introduced into the admixture from dispenser 286 as described with respect to system 202.
Once the additional ingredients are mixed in with, the slurry and cheese precursor admixture,
the resulting admixture can be transported to final processing system 300 through tube 291.
[0145] Embodiments of the system also include the introduction of ingredients in parallel
and serial fashion. Referring to FIG. 4D, for example, a system 400 is shown with a
configuration that has transfer tube 321 diverting the admixture from mixer 320 into two
mixers 290a and 290b. Transfer tubes 287a and 287b connect the mixers 290a and 290b to
ingredient dispensers 286a and 286b, respectively, which can add the same or different
ingredients to admixtures. The final admixtures may then be sent through transfer tubes 291 a
and 291b to final processing systems 300a and 300b, respectively. In another example, FIG.
4E shows system 410 that has one or more ingredients added sequentially from ingredient
dispensers 286 and 332. In system 410, a first ingredient (or first plurality of ingredients) is
dispensed to mixer 290 from ingredient dispenser 286 via transfer tube 287. The resulting
admixture may be sent through transfer tube 336 to mixer 330, where one or more additional
ingredients may be added by a second ingredient dispenser 332 coupled to the mixer 330 via
transfer tube 334. The additional ingredients may be the same as, or different than the first
ingredient (or first plurality of ingredients). The resulting admixture formed in mixer 330
may be sent through transfer tube 338 to the final processing system 300.
[0146] The final processing system utilized in these exemplary systems can vary, but can
include a pre-brine tank that includes super cold sodium chloride brine into which molten
cheese or cheese ribbons can flow. A cutter can cut the cheese into loaves as the cheese
ribbon exits the pre-brine tank. The cooled and salted loaves are then transferred to a main
brine tank where they stay until removed by a conveyor. An exemplary system of this
general design is described in U.S. Patent No. 5,902,625, which is incorporated herein by
reference in its entirety for all purposes.
[0147] A variety of different types of equipment can be utilized in the foregoing systems.
For example, different types of blenders can be used to mix the ingredients together to form
the initial slurry. In general, the blender simply needs to be capable of mixing relatively
viscous fluids. One common blender is a twin-screw mixer or extruder such as is common in
the food industry. Ribbon blenders or pipelines that include a series of pumps and static
mixers can also be utilized.
[0148] The cooker used in the slurry preparation systems can be of various types, including
the lay-down cooker, swept surface heat exchanger, agitated direct heating pipeline cooker.
The cookers are capable of heating a slurry of the compositions defined herein to
temperatures ranging from about 90 - 293° F. Specific examples of suitable cookers include
the RotaTherm™ cooker available from Gold Peg International Pty. Ltd. (Moorabbin, Vic,
Australia) or the FusionCooker™, available from Blentech Corporation, Rohnert Part, CA),
the continuous mixer from READCO Manufacturing (York, PA), or single or Evolum 145
twin screw extruders from Clextral Inc. (Tampa FL). The cookers can heat the slurry by
convection (e.g., a heated blanket surrounds the cooker), conduction, or radiation, or by
directly injecting steam into the cooker.
[0149] Various types of shear pumps can be utilized. Suitable types of shear pumps
mclude inline mixers, or colloid mills. Examples of pumps that can be used include
Silverson in-line mixer (East Longmeadow, MA) and Stephan cooker (Stephan Machinery
Corporation (Columbus, OH), or a colloid mill supplied by Waukesha Cherry Burrell
(Charlotte, NC). The shear pump should be capable of generating a shear rate of at least
10,000 to 500,000 s"1.
[0150] A number of homogenizers are also suitable for use in the systems that are provided.
Examples of homogenizers that can be used include those manufactured by APV Gaulin
(Kansas City, MO) and Waukesha Cherry Burrell (Charlotte, NC). Evaporators of different
types can also be utilized. In general, the evaporator should be able to handle relatively
viscous solution. Flash vacuum vessels are one example of a suitable evaporator.
Evaporators of this type are available from Invensys APV (Lake Mills, WI) or De Dietrich
Process Systems (Bridgeton, MO). Some systems include a feedback system that is
connected to the evaporator (e.g., a near infrared monitor). This system may include a sensor
that can monitor the moisture level in the slurry coming from the evaporator and send a signal
to the evaporator signaling the evaporator to increase, decrease or maintain the level at which
water is removed from the slurry so the desired moisture content in the slurry is achieved.
[0151] For systems in which the cheese curd is heated and kneaded, a number of different
kneading mixers can be used to form the heated mass of cheese, One exemplary device for
performing this operation is a single or twin-screw mixer or a twin-screw extruder, either
fitted for steam injection or having a heated jacket, or a combination of both. When using a
twin-screw mixer or extruder to perform the heating and kneading, the screws (i.e., augers)
are typically arranged so they overlap, to insure morough mixing.
VII. Soft or Firm/semi-Hard Cheeses
[0152] The methods that are described herein can be utilized to prepare soft or firm/semi-
hard cheeses that contain one or more of the ingredients at the concentration ranges described
herein. As indicated above, some of the methods that are disclosed herein can be utilized to
manufacture soft or firm/semi-hard cheeses that contain ingredients that become
functionalized when included in a slurry and are subject to heating and/or hydration. Some of
the soft or firm/semi-hard cheeses can also include relatively high concentrations of certain
ingredients. As set forth above, some of the soft or firm/semi-hard cheeses can contain at
least 10,11,12 ,13 or 14 wt. % of one or more of the ingredients listed above. So, for
instance, some of the cheeses that are provided have one, two, three or more of the following
characteristics.
[0153] Some of the soft-or semi soft cheeses that are provided are characterized by having
a starch concentration of at least 10, 11,12,13 or 14 wt. %. So, for example, some of the soft
or Firm/semi-hard cheeses have a starch concentration of about 12-14 wt. %, others a starch
concentration of about 14-16 wt. %, and still others a starch concentration of about 16-20 wt.
%.
[0154] A characteristic of other soft or firm/semi-hard cheeses that are provided is that they
have a dairy solid (e.g., nonfat dry milk) concentration of at least 10, 11,12,13 or 14 wt %.
Other soft or firm/semi-hard cheeses have dairy solid concentrations up to about 16,17,18,
19, or 20 wt. %. Some soft or firm/semi-hard cheeses of this type thus have dairy solid
concentrations of about 12-14 wt %. Other soft or firm/semi-hard cheeses have a dairy solid
concentration of about 14-16 wt. %, or about 16 - 20 wt. %.
[0155] Other soft or firm/semi-hard cheeses that are provided have a cellulose
concentration of at least 0.01, 0.5, or 3.0 wt. %. Such cheeses, for instance, thus have
cellulose concentrations that range from about 0.01-3.0, or 0.25-2.5, or 0.5-2.0 wt. %.
[0156] The soft or firm/semi-hard cheeses that are provided typically have a protein content
of about 10 -40 wt. %, a moisture content of about 35-65%, and a fat content of about 0-60%
on a dry basis (FDB). The actual composition varies somewhat depending upon the
particular type of cheese that is to be produced. For certain soft or firm/semi-hard cheeses
(e.g., mozzarella cheeses) that are provided, the milk fat content is at least 45% by weight of
solids and the moisture content is about 52-60 wt. %. The low-moisture soft or firm/semi-
hard cheeses (also sometimes referred to as low-moisture mozzarella cheeses) that are
provided generally have a minimum milk fat content of 45% by weight of solids and a
moisture content that is about 45-52 wt. %. Part skim-milk soft or firm/semi-hard ripened
and unripened cheeses (also called part skim mozzarella cheeses) that are provided, in
contrast, have a milk fat content that ranges from about 30-45% by weight of solids and a
moisture content that is about 52-60 wt %. The low-moisture, part-skim soft or firm/semi-
hard ripened and unripened cheeses (also referred to as low-moisture, part skim mozzarella
cheeses) that are provided usually have a milk fat content of about 30-45% by weight of the
solids and a moisture content of about 45-52 wt %. The foregoing moisture percentages are
for bound plus free water, i.e., the percent of weight lost when the cheese is dried for 17 hrs +
1 hr in a 100°C oven.
[01571 The soft or firm/semi-hard cheeses that are provided can be in a variety of different
forms including loavts, Ribbons™, comminuted forms (e.g., diced or shredded forms) and
other forms known in the art. The pH of the soft or firrn/semi-hard cheese generally ranges
from about 5.00 to about 6.00, such as about 5.10 to about 5.90.
VIE. Food Products and Methods of Manufacturing Such Food Stuffs
[0158] The soft or firrn/semi-hard cheeses that are provided can be utilized in essentially
any baking application that involves the use of soft or firrn/semi-hard cheese and can be
incorporated into a wide variety of foodstuffs and food products. The soft or firrn/semi-hard
cheeses, for instance, can be included as an ingredient in a variety of convenience foods,
including entrees, snack foods and appetizers.
[0159] The term "food product" is intended to broadly encompass any type of food to
which one can add cheese. Examples of suitable types of foods into which the provided
cheeses can be added, include, but are not limited to: cereal-based products; poultry, beef,
pork or seafood-based entrees; potatoes; vegetables; fruit; candy; and nuts. The cereal-based
products can be of diverse types including, for instance, pizzas, burritos, dough-enrobed
sandwiches, hand-held foods, breads, bagels, pastries, and grain-based snack foods (e.g.,
crackers and pretzels). The cheese can be included with a variety of different forms of
potatoes, including, chips, French fries, hash browns, and strings. Likewise, vegetables of
various types can be combined with the cheeses that are provided. Exemplary vegetables
include, mushrooms, zucchini, peppers (e.g., jalapenos) and cauliflower.
[0160] The soft or firm/semi-hard cheeses can be incorporated into the food product,
layered onto or in the food product or used as a coating. One common use, for example, is as
an exposed cheese on a pizza or as the string cheese rolled in the outer Up of a pizza crust (a
so-called "stuffed crust pizza").
[0161] As those skilled in the art will recognize, the foregoing list is simply illustrative and
is not intended to be an exhaustive list of the types of foods that can be combined with the
cheeses that are provided herein.
[0162] The soft or firm/semi-hard cheeses that are provided are suitable for use in
essentially any type of cooking including convection heating, steam injection heating and
microwave heating, for example. In some microwave heating applications, for example, the
food product is exposed to microwave energy in an amount and for a duration sufficient to
heat and melt the cheese, whereby the cheese melts to form a uniform mass of cheese. The
cheeses can generally be heated in a variety of microwaves, such as microwaves having
wattages of 400-1000 watts, or full power microwave ovens of 650-85.0 watts that are
common home microwave ovens. The cheeses can be cooked over a range of cooking times
such as from 0.5 to 20 minutes, or 0.5-10 minutes, or 2-5 minutes, which are the typical
microwave cook times used to prepare frozen or refrigerated entrees and appetizers.
[0163] The soft or firm/semi-hard cheeses that are disclosed herein can be combined with
food products such as those just listed using any of a variety of methods. For example, the
food product can be dipped in melted cheese. Alternatively, the cheese can be sprinkled or
layered onto the food product using conventional food processing equipment. In such
processes, die cheese is typically first comminuted to form relatively small pieces of cheese
or shredded cheese. Once the cheese has been combined with the food product, the resulting
food product can optionally be refrigerated or frozen for future sale or use.
[0164] The following examples are presented to illustrate certain aspects of the methods
and soft or firm/semi-hard cheeses that are disclosed herein. These examples should not be
construed to limit the scope of the claims.
EXAMPLES
[0165] Three different levels of nonfat dry milk (NDM) (2.5%, 6.0%, and 12.0%, by
weight) were incorporated into Mozzarella cheese, either directly in powder form (see
Examples a, c, and e) or as part of a slurry added to the cheese curds (see Examples b, d, and
f). The slurry compositions included the NDM, as well as salt, cream, water, and gluconic
acid, where the gluconic acid is added to the slurry as a processing aid to cause a reduction in
[0166] The final cheese product included conventional starter cultures and the composition
targets were 49.0% moisture, 40.0 FDB, 5.35 pH, and 1.80% salt. Ribbon™ cheese (7 x 9 x
2-inches) was extruded and tire packaged cheese samples were stored at 35°F (1.7°C) for 14
days before being shredded on an Urchell CC shredder (Urchell Laboratories, Inc., Indiana,
USA) into cuts with approximate dimensions of 1.25"-3" by 0.20" by 0.095". The cuts were
individually frozen and stored at -20°F. Two-pound samples of cheese were removed,
thawed at 35°F (1.7°C) and melted on two different types of pizza, including a conveyor-bake
pizza (Middleby Marshall oven at 420°F (215.6°C) for 6.5 minutes) composed of 7-oz of
cheese on a regular pizza crust with 4-oz of pizza sauce. The cheese was also melted on a
frozen pizza composed of 5.6-oz of frozen cheese placed on a ready-made crust with 3-oz of
sauce and frozen for 24 hrs prior to melting in a home oven at 425°F for 19 minutes.
[0167) The shred cut qualities and melt grades of the cheeses produced in Examples a-f
were then measured. The melt grade measurements of the cheeses on the service oven pizzas
and cooked frozen pizzas included comparisons of the blister color, blister %, blister size,
melt, stretch, and oiling-off. The melt grade measurements were made with a 20-point scale,
with 10 being the best grade, while 1 is too little, and 20 is too much. Table 2 summarizes
the melt grade grading system:
[0169] FIGS. 5A-B show the difference in the quality of the final cheese products when the
NDM is added directly as a powder to the cheese curd versus adding the NDM as a
component of a liquid slurry. Adding the dry powder NDM at both the 6% and 12% levels
causes powdered lumps in the finished cheese as shown in FIG. 5A. The lumps give the
cheese an inferior taste and feel, and can also damage dicer blades that are used to shred the
cheese. In contrast, a slurry that is added to cheese having NDM at the same levels (i.e., 6%
and 12% by wt. NDM in the finished cheese) results in a smooth, homogenous finished
cheese as shown in FIG. 5B.

[0170] It is understood that the examples and embodiments described herein are for
illustrative purposes only and that various modifications or changes in light thereof will be
suggested to persons skilled in the art and are to be included within the spirit and purview of
this application and scope of the appended claims. The cheeses of the present invention may
be made by the methods described herein, or by any other method that produces a finished
cheese product having the same physical or chemical properties as the present cheeses. All
publications, patents and patent applications cited herein are hereby incorporated by reference
in their entirety for all purposes to the same extent as if each individual publication, patent or
patent application were specifically and individually indicated to be so incorporated by
reference.
We Claim:
1. A method of preparing a cheese product comprising:
(a) providing a slurry that comprises one or more ingredients;
(b) adding a dry powder ingredient to a cheese precursor;
(c) combining the slurry with the cheese precursor to form an admixture; and
(d) processing the admixture to form the cheese product.
2. The method as claimed in claim 1, wherein the cheese precursor is selected
from the group consisting of a cheese curd ingredient, a mixture of cheese curd
ingredients, a coagulum, a cheese curd, concentrated milk, and a heated mass
of cheese.
3. The method as claimed in claim 2, wherein the cheese precursor is a cheese
curd ingredient selected from the group consisting of unpasteurized milk,
pasteurized milk and cream.
4. The method as claimed in claim 2, wherein cheese precursor is a mixture
containing pasteurized milk, starter, and cream.
5. The method as claimed in claim 2, wherein the cheese precursor is a
coagulum.
6. The method as claimed in claim 2, wherein the cheese precursor is an
unprocessed cheese curd.
7. The method as claimed in claim 2, wherein the cheese precursor is a heated
mass of soft or firm/semi-hard cheese.
8. The method as claimed in claim 7, comprising preparing the heated mass of
soft or firm/semi-hard cheese by heating a mass of cheese curd in the absence
of exogenous water.
9. The method as claimed in claim 1, wherein the slurry lacks cheese curd.
10. The method as claimed in claim 1, wherein the slurry lacks one or more
analog cheese ingredients.
11. The method as claimed in claim 1, wherein the one or more ingredients are
selected from the group consisting of nonfat dry milk, a milk protein, an acidity
regulator, an acid, an anticaljng agent, an antifoaming agent, a coloring agent, an
emulsifier, an enzyme preparation, a flavoring agent, a firming agent, a food
protein, a gelling agent, a preservative, sequestrants, a stabilizer, a starch, a
thickener, an oil, a fat, a cheese powder, a salt, a nutritional supplement, an acid,
an enzyme, a neutraceutical, a carbohydrate, a vitamin, and a mineral.
12. The method as claimed in claim 1, wherein the one or more ingredients are
selected from the group consisting of procream, whey cream, a dairy solid, a
foodstuff, and a food product.
13. The method as claimed in claim 1, wherein the slurry is processed by :
heating the slurry to about 90°F to about 300° F;
subjecting the slurry to high shear conditions;
homogenizing the slurry; and
adjusting the water content of the slurry to about 5-95 wt. %.
14. The method as claimed in claim 1, wherein the slurry is heated by injecting
steam directly into the slurry.
15. The method as claimed in claim 13, wherein the slurry is heated by an
indirect heat source.
16. The method as claimed in claim 13, wherein combining comprises mixing one
or more dry ingredients with the slurry and the heated mass of cheese curd.
17. The method as claimed in claim 1, wherein the composition of the slurry and
the cheese precursor are controlled such that the final cheese product has a
combined moisture and wet milkfat content of at least about 70% and processing
comprises cooling the admixture in a brine solution and freezing within about 5
minutes to 48 hours after being removed from the brine solution.
18. The method as claimed in claim 1, wherein processing comprises
comminuting the admixture into small particles, freezing the particles and
packaging the particles before moisture loss.
19. The method as claimed in claim 1, wherein the cheese product has a
moisture on a fat-free basis (MFFB) of 54-80 weight percent.
20. The method as claimed in claim 1, wherein the cheese product has a MFFB
of greater than 60 weight percent.
21. A soft or firm/semi-hard cheese manufacturing system, comprising:
(a) a slurry preparation system to prepare the slurry in the absence of a heated
mass of soft or firm/semi-hard cheese comprising (i) a blender adapted to blend
a liquid and one or more generally recognized as safe (GRAS) ingredients
together to form a slurry, wherein the blender does not substantially alter a size
of the GRAS ingredients which are solid before they contact the liquid, and (ii) a
cooker that is operatively disposed to receive the slurry from the blender and
adapted to heat the slurry to a temperature of about 90° F to about 300°F ;
(b) a first mixer operatively disposed to receive the slurry from the slurry
preparation system and adapted to mix the slurry with a heated mass of soft or
firm/semi-hard cheese to form an admixture; and
(c) a final processing system operatively disposed to receive the admixture and
adapted to form a final cheese product.
22. The system as claimed in claim 21, wherein the slurry preparation system
comprises a slurry mixing and moisture control subsystem, which comprises one
or more of the following units
(i) a shear pump adapted to subject the slurry to high shear conditions;
(ii) a homomgenizer adapted to homogenize the water and the one or more
ingredients in the slurry; and
(iii) an evaporator adapted to adjust the water content of the slurry to about 5-95
% by weight, wherein the subsystem is in communication with the cooker and the
first mixer and the units within the subsystem are in fluid communication.
23. The system as claimed in claim 22, wherein the subsystem comprises at
least two of the units.
24. The system as claimed in claim 22, wherein the subsystem comprises all
three of the units.
25. The system as claimed in claim 22, wherein
the shear pump is operatively disposed to receive the slurry from the heater and
is in communication with the homogenizer;
the homogenizer is operatively disposed between the shear pump and the
evaporator and adapted to receive the slurry from the shear pump; and
the evaporator is operatively disposed to receive the slurry from the homogenizer
and in communication with the first mixer.
26. The system as claimed in claim 22, comprising a second mixer that (i) is
adapted to heat and knead a mass of cheese curd that is introduced therein to
produce the heated mass of cheese curd, and (ii) is in communication with the
first mixer such that the heated mass of cheese curd that is produced in the
second mixer can be transported to the first mixer.
27. The system as claimed in claim 22, wherein the evaporator unit is a flash
vacuum vessel.
28. A system for preparing a slurry in the absence of a cheese precursor before
being admixed with a cheese precursor, the system comprising:
a) a blender adapted for preparing a slurry, the slurry comprising water and one
or more generally recognized as safe (GRAS) ingredients, wherein the blender
does not substantially alter a size of the GRAS ingredients which are solid when
they contact the water;
b) a cooker adapted to heat the slurry to a temperature of about 90°F to about
300°F ; and
c) a slurry mixing and moisture control subsystem that comprises one or more of
the following units.
(i) a shear pump adapted to subject the slurry to high shear conditions;
(ii) a homomgenizer adapted to mix the water and the one or more ingredients in
the slurry; and
(iii) an evaporator unit adapted to adjust the water content of the slurry to about
5-95% by weight, wherein
the units of the subsystem are in fluid communication and the blender, heater
and slurry mixing and control subsystem are in fluid communication.
29. A soft or firm/semi-hard ripened or unripened cheese product that has one or
more of the following characteristics (i) a nonfat dry milk concentration of greater
than 10 % by weight or (ii) a starch concentration of greater than 10 % by weight,
or (iii) a gum or cellulose concentration of greater than 10 % by weight.


The invention relates to a method of preparing a cheese product comprising: (a)
providing a slurry that comprises one or more ingredients; (b) adding a dry
powder ingredient to a cheese precursor; (c) combining the slurry with the
cheese precursor to form an admixture; and (d) processing the admixture to
form the cheese product.

Documents:

03279-kolnp-2006 abstract.pdf

03279-kolnp-2006 claims.pdf

03279-kolnp-2006 correspondence others.pdf

03279-kolnp-2006 description(complete).pdf

03279-kolnp-2006 drawings.pdf

03279-kolnp-2006 form1.pdf

03279-kolnp-2006 form2.pdf

03279-kolnp-2006 form3.pdf

03279-kolnp-2006 form5.pdf

03279-kolnp-2006 international publication.pdf

03279-kolnp-2006 international search authority report.pdf

03279-kolnp-2006 pct request.pdf

03279-kolnp-2006 priority document.pdf

03279-kolnp-2006-assignment.pdf

03279-kolnp-2006-correspondence-1.1.pdf

03279-kolnp-2006-correspondence-1.2.pdf

03279-kolnp-2006-correspondence-1.3.pdf

03279-kolnp-2006-p.a.pdf

3279-KOLNP-2006-ABSTRACT 1.1.pdf

3279-KOLNP-2006-AMANDED CLAIMS.pdf

3279-kolnp-2006-assignment.pdf

3279-KOLNP-2006-CORRESPONDENCE 1.3.pdf

3279-kolnp-2006-correspondence.pdf

3279-KOLNP-2006-DESCRIPTION (COMPLETE) 1.1.pdf

3279-KOLNP-2006-DRAWINGS 1.1.pdf

3279-KOLNP-2006-EXAMINATION REPORT REPLY RECIEVED.pdf

3279-kolnp-2006-examination report.pdf

3279-KOLNP-2006-FORM 1-1.1.pdf

3279-kolnp-2006-form 18.1.pdf

3279-kolnp-2006-form 18.pdf

3279-KOLNP-2006-FORM 2-1.1.pdf

3279-kolnp-2006-form 26.pdf

3279-KOLNP-2006-FORM 3-1.1.pdf

3279-kolnp-2006-form 3.pdf

3279-KOLNP-2006-FORM 5-1.1.pdf

3279-kolnp-2006-form 5.pdf

3279-kolnp-2006-granted-abstract.pdf

3279-kolnp-2006-granted-claims.pdf

3279-kolnp-2006-granted-description (complete).pdf

3279-kolnp-2006-granted-drawings.pdf

3279-kolnp-2006-granted-form 1.pdf

3279-kolnp-2006-granted-form 2.pdf

3279-kolnp-2006-granted-specification.pdf

3279-KOLNP-2006-OTHER PATENT DOCUMENT-1.1.pdf

3279-KOLNP-2006-OTHER PATENT DOCUMENT.pdf

3279-KOLNP-2006-OTHERS.pdf

3279-kolnp-2006-others1.1.pdf

3279-KOLNP-2006-PETITON UNDER RULE 137-1.1.pdf

3279-kolnp-2006-reply to examination report.pdf

3279-kolnp-2006-translated copy of priority document.pdf

abstract-03279-kolnp-2006.jpg


Patent Number 251851
Indian Patent Application Number 3279/KOLNP/2006
PG Journal Number 15/2012
Publication Date 13-Apr-2012
Grant Date 12-Apr-2012
Date of Filing 09-Nov-2006
Name of Patentee LEPRINO FOODS COMPANY
Applicant Address 1830 WEST 38TH AVENUE, DENVER, COLORADO 80211 U.S.A.
Inventors:
# Inventor's Name Inventor's Address
1 MERRILL, RICHARD, K 9115 SOUTH FOX FIRE DRIVE, HIGHLANDS RANCH, COLORADO 80129 U.S.A.
2 SINGH, MAYANK 10598 EAST JEWELL AVENUE, AURORA, COLORADO 80012 U.S.A.
PCT International Classification Number A23C 19/00
PCT International Application Number PCT/US2005/015270
PCT International Filing date 2005-05-03
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 60/568,029 2004-05-03 U.S.A.