CA2260129A1 - Process for producing cheese, curd and yoghourt products from soya beans - Google Patents

Abstract

The description relates to a process for producing cheese, curd or yoghourt products from soya beans involving the steps; (a) preparation of soya milk from soya beans; (b) addition of vegetable sugar to the soya milk in the proportion of 1 to 5 wt %; (c) emulsifying vegetable fats and/or oils in a total proportion of some 15 wt % in the soya milk; (d) preparation of a culture cocktail with a pH between 3.8 and 4.5 by the addition of commercially available cheese cultures and animal lactose in a proportion of some 10 wt % of the vegetable sugar added in step (b) to the soya milk as in step (a); (e) addition of the culture cocktail to the soya milk as per step (c) to curdle it and ferment it as desired, and (f) subsequent ripening and final processing in the prior art manner to provide the desired cheese, curd or yoghourt product.

Description

Process For Producing Cheese, Curd and Yo~hourt Products From Soya Beans This invention relates to a method for the manufacture of cheese, curd and yogurt products from soybeans or from the beans of other legumes.

Soy products are well-known and are widely used in many different forms. The 100~ vegetable protein obtained from the soybean is easily digestible and is a valuable substitute for animal protein. Soy products also contain no cholesterol and no animal fats, excessive amounts of which substances can have a harmful effect on health. Soy products are also particularly important for people who are allergic to the protein in animal milk or who cannot digest cholesterol or lactose, or who are diabetic. Soybean protein is also significantly easier to digest than animal milk protein by people suffering from stomach and intestinal illnesses.

Finally, there has been a constant increase in the number of people who, for a variety of reasons, are required to or choose to eat vegetarian food exclusively.

Soybean protein can theoretically rep]ace animal protein in any food. The disadvantage of foods manufactured using soybean protein is only that they always have the taste typical of soybeans, which can be subjectively more or less unpleasant, in particular if foods from such a source must be eaten frequently.

DE-OS 37 30 384 describes a method of the prior art for the use of soy milk to manufacture a product that is similar to a Camembert cheese. Using this method of the prior art, however, it is not possible to completely eliminate the typical aftertaste of soybeans.

DE-A-2 406 600 describes a method of the prior art for the manufacture of a yogurt product that does not contain any milk products from soybean flour, in which the typical soybean test is largely eliminated. For this purpose, the soybean flour and the cake formed from it are washed, the soy milk filtrate is acidified and, after sugar has been added, homogenized, sterilized and inoculated with a lactic acid culture. The fermented soy milk is then incubated.

GB-A-1-383 149 relates to a soy cheese and a method for its manufacture, wherebv the taste is said to be altogether similar to that of natural cheese, without the use of milk or dairy products. In this method, a mixture of soy milk and a fat compound is fermented using a cheese starter culture that forms lactic acid, whereby the fermented mixture is then coagulated for transformation into quark, from which it is finally processed into soy cheese. Fssential to this method are the ingredients of the fat compound, which represents a mixture of at least one natural fat with the exception of milk fat, with at least one compound that contains a low alkanoly group with a maximum of 12 carbon atoms, and whereby the mixture also contains one or more compounds with alkanoyl groups that are derived from C4 and/or C6 fatty acids, and have a defined weight relationship. The addition of various fatty acids and different alkanol groups, however, is difficult, expensive and time consuming, and is thus considered a disadvantage.

The object of the invention is therefore to create a method for the manufacture of cheese, quark and yogurt products from soybeans, by means of which the typical slight taste of soybeans can be eliminated.

The invention teaches that this object can be accomplished by a method of the type described above which is characterized by the process steps disclosed in Claim 1.

The method can also be used for the manufacture of cheese, quark and yogurt products from the beans of other legumes, although it is undoubtedly of the greatest importance for soybeans.

Using this method, it becomes possible for the first time to manufacture various types of cheeses, such as cream cheese, soft cheeses and hard cheeses on a purely vegetable basis, which in terms of their taste, their scent, their appearance and their consistency differ little or not at all from the corresponding types of cheese manufactured from cow's milk, and in some instances are even superior to cheeses made from cow's milk.

An additional advantage of the method is that it is suitable not only for the manufacture of different types of cheeses, but also for the manufacture of quark and yogurt products, if the subsequent ripening and final processing are performed in the customary manner for these products.

It is also particularly advantageous if the final product manufactured is not only free of animal ingredients and therefore contains no animal protein, no animal fat, no cholesterol and no lactose (milk sugar), but also no sodium chloride and no refined sugar.

As a result of the addition of very small amounts of animal lactose (in particular sugar from cow's milk), which is fermented in its entirety into lactic acid, the lactic acid bacteria in the lactose weaning phase are stimulated to ferment the plant sugars that are available in copious amounts. The way is thereby opened for the decomposition of the plant protein by the generic mold and yeast mold fungi symbiosis described below. As the process continues, the enzymes of the above named species, by lipolysis, produce the cheese taste typical of the corresponding type of cheese.

As a result of the addition of vegetable fats and vegetable oils, the fat content of the final product can be adjusted to meet the desired and requirements of the final consumer. The same is true for the selection of the type, quality or grade of fat.

The subclaims disclose advantageous refinements of the method.

Quark and cream cheese products are manufactured in particular as disclosed in Claim 6. The method disclosed in Claim 7 is particularly well suited for the manufacture of soft cheese, while the method disclosed in Claim 13 is preferably used for the manufacture of hard cheese.

Three particular preferred and advantageous methods are described below by way of example.

In all three examples, soy milk is first obtained from the soy-beans in the usual manner. For this purpose, the soybeans are preferably soaked in cold water, with or without their shells or hulls, for approximately 12 to 14 hours, whereby the quantity of water is approximately five times greater than the quantity of soybeans, and the water is removed after the soaking.

The beans are then ground into a puree with an amount of hot water that is approximately six times greater in a colloid mill. The fibrous material (i.e. okara) is then separated through a sieve or using a decanter or a centrifuge.

The soy milk discharged has a solid matter content from approx-imately 5 to 15% (normally 12~) and is then subjected to a heating process of the prior art, such as a pasteurization or an ultra-pasteurization.

Before or after the heating, a significant portion of the undesirable scent and taste substances (purines) are extracted from the soy milk by vacuum degassing.

The soy milk prepared in this manner is the primary materia]
for the further processing as claimed by the invention into cheese, quark or yogurt products, as indicated in the following examples.

Example 1:
1.1) To manufacture a cream cheese or another product similar to quark, the soy milk is first ad;iusted to a solid matter content of approximately 12% by weight.

1.2) Dextrose or glucose is then added to the soy milk in a proportion of 1 to 5% by weight, preferably 27 by weight.
Approximately 0.1% by weight of vegetable food coloring can also be added.

1.3) The soy milk is then heated to 70 to 90~C, preferably 85~C.

1.4) Then the vegetable fats and vegetable oils containing a high percen~age of unsaturated fatty acids are added and emulsified in the soy milk, whereby the vegetable fats and vegetable oils are preferably added in equal amounts, and their total concentration is approximately 15% by weight.

1.5) This soy milk is then mixed with a culture cocktail in the form of a soy milk suspension of 1 to 47 by weight, preferably 2% by weight, which is prepared as follows:

1.6a) Soy milk is mixed at 45 to 35~C, preferably 38~C, with commercial cheese cultures for cream cheese such as Series M
"Probat" and/or a thermophilic culture such as Series V yogurt, both of which are commercially available from the firm of Wiesby in Niebull, and are described in the "Wiesby Product Manual" (1996). Sugar from cow's milk is also added, the amount of which is approximately 107 by weight of the dextrose or glucose added in Step 1.2).

1.6b) The soy milk inoculated in this manner is acidified at approximately 38~C to a pH from 3.8 to 4.5, preferably 4.1, and forms the culture cocktail (i.e. soy milk suspension) described above.

1.7) As in Step 1.5), the soy milk is acidified at approxi-mately 38~C with the culture cocktail to a pH from 4.1 to 4.8, preferably 4.5. Then up to 30% by weight of the water is separated and removed. Then the processing continues in the conventional manner, e.g. by seasoning, ripening, heating and packaging, to obtain the desired finished product. The cream cheese described above can be manufactured by the following steps:

1.8) The soybean protein is combined with approximately 0.5%
by weight of sea salt and with the flavor enhancing ingredients customary in cream cheese, such as chives, parsley, pepper, onions or prepared fruits, the proportion of which is approximately 0.1% by weight for the dry ingredients, and approximately 10% by weight for the ingredients containing water.

1.9) The product is then pumped through a quark mill, to improve its creamy consistency, and for preservation is conducted through a heat treatment line in which it is heated to approximately 62~C for approximately 1 to 5 seconds. It is then mechanically packaged in appropriate containers and refrigerated at a temperature from 4 to 6~C until it reaches the final consumer.

With regard to its appearance, its consistency, its scent and its taste, this product does not differ significantly from an identical product made from animal milk.

Example 2:

2.1) To manufacture soft cheese or another product similar to Camembert, the primary material is the same soy milk as in example 1.

2.2) This soy milk is treated as descrlbed in Steps 1.1) to 1.4) in Example 1.

2.3) This soy milk is then mixed at approximately 85~C with a coagulant, and preferably Nigari (= magnesium chloride) from sea salt, in a proportion of from 0.1 to 5% by weight, preferably 0.15% by weight, and distributed by gentle agitation so that approximately 20% by weight of water is discharged during the coagulation. This water is removed.

2.4) The coagulated soybean protein is then washed once or twice with hot water (approximately 90~C). Stable protein globules result, which are of major importance for the proper consistency and attractive appearance of the final product.

2.5) For further dehydration to a moisture content of approxi-mately 70% by weight and for the shaping of the final product, the soybean protein - preferably at approximately 90~C - is treated in a pressing and molding system of the type conven-tionally used in the cheesemaking industry. The press pressnre is applied to appropriate molds for Brie or Camembert, and is increased over one hour from 0 to approximately 5 kg/cm . The product is then turned in the mold, and the manufacturer determines whether it has developed sufficient strength. If necessary, the molding is continued at approximately 5 kg/cm2 for a maximum of 30 minutes.

2.6) The cheese is then cooled to a temperature below 45~C.

2.7) Using hollow needles, the cheese is injected on the sides, top and bottom at intervals of up to 1 cm with a culture cocktail which is produced as described in the steps under 2.8), and is injected in quantities that are as great as the cheese can absorb. The limit of absorption can be observed because the substance injected becomes visible on its surface.
The cheese is thereby acidified and fermented.

As an alternative to Steps 2.5) to 2.7), the soybean protein can first be cooled to approximately 45~C (Step 2.6)). Then the culture cocktail is injected (Step 2.7) and the injected cheese is then molded and shaped, as described in Step 2.5).

The culture cocktail is prepared as follows:

2.8a) Soy milk is first treated as described in Step 1.6a) in example 1.

2.8b) 1 to 10~ by weight, preferably 5~ by weight, of commer-cial Kombucha-Teepilz culture symbiosis or tea fungus is then added to this soy milk.

2.8c) The soy milk inoculated in this manner is then acidified to a pH of 3.8 to 4.5, preferably 4.1, by the cultures added as described in Step 2.8a) at approximately 38~C.

2.8d) 1 to 2 doses ("units") of mold fungus culture are then added to each liter of this suspension, namely Penicillium candidum and/or Penicillium camemberti and/or Geotrichum candidum. The cultures in question are commercial cheesemaking cultures that are available from the company named in Step 1.6a).

To enhance the taste typical of a specific variety of cheese, cheese flavor can also naturally be added to the culture cocktail.

2.9) The injected and molded cheese is then placed in a saturated sea salt brine at a temperature of approximately 15 to 18~C to equalize the salt content. The salt brine contains an aqueous solution of bedstraw and the cultures of cheese bacteria necessary for the desired variety of cheese.

2.10) The ripening of the product begins at approximately 16 to 18~C and at a relative humidity of approximately 70 to 80%
for a hold time of approximately 24 hours. Then the ripening continues for 6 to 8 days at approximately 15 to 16~C and at a relative humidity of 90 to 95%. A more rapid ripening can be performed at 17 to 18~C and the same relative humidity. The ripening conditions can be adapted individually to the specific requirements and qualities.

2.11) Before packaging, the product is coo]ed for 24 to 48 hours to approximately 8~C.

This product is comparable in terms of its taste and scent with an identical product made from animal milk. With regard to consistency, it is even superior to a product made from animal milk as a result of its creaminess. There are slight differ-ences with regard to taste, but they are not at all detrimental.

Other cheeses similar to Roquefort, for example, are manufac-tured as described in Example 2, whereby the mold fungus cultures necessary for the specific type of cheese are used, and the ripening conditions are adapted accordingly.

For spreadable red cheeses such as Limburger, bacteria cultures of the type Brevibacterium linens are a~ded to the culture cocktail (Step 2.8)) as described in the "Wiesby Product Manual" (See Step 1.6a) or a similar source, which is available from the company named in Step 1.6a).

Example 3:

3.1) To manufacture hard cheese such as Tilsit or Gouda, for example, or a similar product, the primary material is the same soy milk as in Example 1.

3.2) This soy milk is treated as described in Steps 1.1) to 1.4) in Example 1.

3.3) A proportion of 1 to 4 % by weight, preferably 2.57O by weight, of a coagulant of the prior art, preferably Nigari (i.e. magnesium chloride) is then added to the soy milk at approximately 85~C. The water that is discharged during coagulation is removed.

3.4) The coagulated soybean protein is then washed once or twice with hot water (approximately 90~C). Stable protein globules result, which are of major importance for the proper consistency and attractive appearance of the final product.

3.5) The soy protein that results is then transported to a molding and pressing system of the prior art appropriate for the specific variety of cheese, and is dehydrated by pressing to a content of approximately 65% by weight water. The residual dehydration is performed in a pressing process by increasing the press pressure from 0 to approximately 15 kg/cm for one hour. The cheese is then turned once. The pressing process is continued for 4 hours, during which time the product is turned once every hour.

3.6) The cheese is then cooled to a temperature of approxi-mately 38~C.

3.7) Using hollow needles, the cheese is then inoculated as described in Step 2.7), whereby the culture cocktail is manufactured as described in Step 3.8).

As an alternative to Steps 3.5) to 3.7), the soybean protein can also first be cooled to approximately 38~C (Step 3.6)).
Then the culture cocktail is injected (Step 3.7)) and the injected cheese is then pressed and molded, as described in Step 3.5).

3.8) The acidification and fermentation of the cheese is performed using a culture cocktail that is manufactured as described in Steps 2.8a~ to 2.8c). The bacterial strain Brevibacterium linens can also be a(lde~ to the culture cocktail.

To produce a Gouda or a similar cheese, bacteria producing probionic acid are also added to the cocktail in a dosage as indicated in the "Wiesby Product Manual" (See Step 1.6a)).

3.9) The product is then stored in a sea salt brine at a temperature of approximately ]5~C for approximately 12 hours to equalize the salt content, whereby the pH is set to approxi-mately 5.2 with soy lactic acid.

3.10) The subsequent ripening takes approximately 4 to 6 weeks and is carried out at a temperature of 14 to 16~C and a relative humidity of 90~.

This product is equivalent to a corresponding product made from animal milk, in particular with regard to its taste and appear-ance. The holes is somewhat more pronounced.

Claims (20)

Claims

1. Method for the manufacture of cheese, quark or yogurt products from soybeans, characterized by the following process steps:
(a) Preparation of soy milk from soybeans;
(b) Addition of vegetable sugar to the soy milk in a proportion from approximately 1 to 5% by weight;
(c) Emulsification of vegetable fats and/or vegetable oils with a total content of approximately 15% by weight into the soy milk;
(d) Preparation of a culture cocktail suspension with a pH of between approximately 3.8 and approximately 4.5 by the addition of commercial cheese cultures and animal lactose in a proportion of approximately 10% by weight of the vegetable sugar added in Step (b) to soy milk as described in Step (a);
(e) Addition of the culture cocktail to the soy milk as described in Step (c), to acidify the soy milk and to ferment it if necessary, and (f) A final ripening and processing in the manner of the prior art into the desired cheese, quark or yogurt product.

2. Method as claimed in Claim 1, characterized by the fact that the undesirable scent or flavor components are removed from the soy milk described in Step (a) by vacuum degassing.

3. Method as claimed in Claims 1 or 2, characterized by the fact that the soy milk as described in Step (a) is adjusted to a solids content of 12% by weight.

4. Method as claimed in one of the preceding claims, characterized by the fact that the vegetable sugar described in Step (b) is dextrose or glucose.

5. Method as claimed in one of the preceding claims, characterized by the fact that vegetable fats and vegetable oils with a high content of unsaturated fatty acids are added in a ratio of 1 to 1 by weight.

6. Method as claimed in one of the preceding Claims, in particular for the manufacture of quark or cream cheese products, characterized by the fact that as claimed in Step (e) in Claim 1, the soy milk is acidified with the culture cocktail described in Step (d) to a pH of approximately 4.5 and then up to 30% by weight of water is separated and removed, and then, as claimed in Step (f) in Claim 1, approximately 0.5% sea salt and herb and/or fruit preparations are added to enhance the taste.

7. Method as claimed in one of the Claims 1 to 5, in particular for the manufacture of soft cheese such as Brie or Camembert, characterized by the fact that following Step (c) in Claim 1, the soybean protein from the soy milk is coagulated by the addition of a coagulant, and the water that is discharged is removed.

8. Method as claimed in Claim 7, characterized by the fact that the coagulant is magnesium chloride from sea salt, which is added to the soy milk in a proportion of approximately 0.15% by weight at a temperature of the soy milk of approximately 85°C.

9. Method as claimed in Claim 7 or 8, characterized by the fact that the coagulated soybean protein is washed once or twice with water at a temperature of approximately 90°C.

10. Method as claimed in one of the Claims 7 to 9, characterized by the fact that 1 to 10% by weight of Kombucha-Teepilz culture symbiosis is added to the culture cocktail prepared as described in Step (d) in Claim 1.

11. Method as claimed in Claim 10, characterized by the fact that 1 to 2 doses (units) per liter of mold fungus cultures such as Penicillium candidum and/or Penicillium camemberti and/or Geotrichum candidum are also added to the culture cocktail.

12. Method as claimed in one of the Claims 7 to 11, characterized by the fact that the coagulated soybean protein is dehydrated by pressing in appropriate molds to a moisture content of approximately 70% by weight, and the culture cocktail is injected into the cheese by means of hollow needles, to acidify and ferment the cheese.

13. Method as claimed in Claim 7, in particular for the manufacture of hard cheese, characterized by the fact that the coagulant is magnesium chloride from sea salt, which is added at a temperature of the soy milk of approximately 85°C in a proportion of approximately 2.5% by weight.

14. Method as claimed in Claim 13, characterized by the fact that the coagulated soybean protein is washed once or twice with water at a temperature of approximately 90°C.

15. Method as claimed in Claims 13 or 14, characterized by the fact that 1 to 10% by weight Kombucha-Teepilz culture symbiosis is added to the culture cocktail prepared as claimed in Step (d) in Claim 1.

16. Method as claimed in one of the Claims 13 to 15, characterized by the fact that the bacterial strain Brevi-bacterium linens is added to the culture cocktail.

17. Method as claimed in one of the Claims 13 to 16, characterized by the fact that probionic acid bacteria are added to the culture cocktail.

18. Method as claimed in one of the Claims 13 to 17, characterized by the fact that the coagulated coy albumin is dehydrated by pressing in appropriate molds to a moisture content of approximately 65% by weight, and the culture cocktail is injected into the cheese by means of hollow needles, to acidify and ferment the cheese.

19. Method as claimed in one of the preceding Claims, characterized by the fact that instead of soy milk, the milk used is derived from the beans of another legumes.

20. Cheese, quark or yogurt product from soybeans, and manufactured using a method as claimed in one of the proceding Claims, characterized by the fact that it is free of animal ingredients and contains no animal protein, no animal fat, no cholesterol, no lactose (milk sugar), no salt on the form of sodium chloride and no refined sugar.