GB2237178A

GB2237178A - Preparation of cheese from natural ingredients

Info

Publication number: GB2237178A
Application number: GB9021063A
Authority: GB
Inventors: Joseph Patrick Mcauliffe; Timothy Anthony O'mullane
Original assignee: CHARLEVILLE RES
Current assignee: CHARLEVILLE RES
Priority date: 1989-10-12
Filing date: 1990-09-27
Publication date: 1991-05-01
Anticipated expiration: 2010-09-27
Also published as: GB2237178B; GB9021063D0; ZA898646B; IE62639B1; IE893290A1; BE1001651A6

Abstract

A process for the preparation of cheese from natural ingredients to have a shelf life of at least six months comprises blending a mixture of 15 to 25% by weight natural cheese, natural fat, 12 to 16% by weight casein. whey and water, and pasteurizing the mixture at a temperature of not less than 105 DEG C. The natural cheese may constitute 19% of the mixture. The casein may constitute 14% of the mixture and acts as an emulsifying agent. The mixture may be raised to a pasteurization temperature of 110 DEG C by the introduction of steam over a seven minute period. On reaching the pasteurization temperature, the mixture may be immediately cooled over a five minute period to 94 DEG C at which stage it is pumped into moulds. In an example the mixture formed also comprises concentrated dried cheese powder as flavouring, yeast extract, salt, calcium carbonate, vegetable dye.

Description

The present invention relates to a process for the preparation of cheese from natural ingredients, the invention also relates to cheese prepared in accordance with the process.

Where it is desired to prepare cheese with a relatively long shelf life, typically six to eighteen months, it has been found necessary to include additives, such as emulsifying salts which are generally the sodium salts of phosphates, polvphosphates and citrates. These are all classed as additives. With the present relatively high level of awareness of the benefit of natural products in maintaining good health, there is a general trend away from foods, and in particular, cheeses which include such additives. So far, known processes for producing cheese without these additives result in a cheese with a relatively short shelf life, generally of the order of three to four weeks. This has been found unsatisfactory.

There is therefore a need for a process for preparing cheese from natural ingredients which results in a cheese of relatively long shelf life, typically over six months, and there is also a need for a cheese prepared from natural ingredients using the process.

The present invention is directed towards providing such a process and cheese.

According to the invention, there is provided a process for the preparation of cheese from natural ingredients comprising blending a mixture of natural cheese, natural fat, casein, whey, and water and pasteurizing the mixture in a cooker after being blended, wherein the casein constitutes in the range of 12% to 16% by weight of the mixture, the natural cheese constitutes in the range of 15% to 25 by weight of the mixture, and the mixture is pasteurized at a pasteurization temperature of not less than 1050C.

In one embodiment of the invention, the mixture is raised to the pasteurization temperature during a time period in the range of 5 to 9 minutes. Preferably, the mixture is raised to the pasteurization temperature in a time period of 7 minutes. In another embodiment of the invention, the mixture is cooled to a second temperature immediately on being raised to the pasteurization temperature. Preferably, the mixture is pumped from the cooker on being cooled to the second temperature.

Advantageously, the mixture is cooled from the pasteurization temperature to the second temperature in a time period in the range of 4 to 6 minutes, and preferably, the mixture is cooled from the pasteurization temperature to the second temperature in 5 minutes. Preferably, the second temperature is in the range of 92"C to 96"C, and advantageously is 94"C.

In one aspect of the invention, the mixture is pasteurized by introducing steam into the mixture.

Advantageously, the casein constitutes 14% by weight of the mixture, and preferably, the cheese constitutes 19% by weight of the mixture. In a preferred embodiment of the invention, the pasteurization temperature is in the range of 1050C to 1150C, and preferably, the pasteurization temperature is 110 C. In one embodiment of the invention, the whey constitutes in the range of 8% to 11% by weight of the mixture. In another embodiment of the invention, the natural fat constitutes in the range of 15% to 2370 by weight of the mixture. In another embodiment of the invention, the water including condensate constitutes in the range of 35% to 40% by weight of the mixture.

In another embodiment of the invention, the ingredients of the mixture are delivered into the cooker over a time period of approximately 3 minutes and the ingredients are liquidized in the cooker during the time they are being delivered into the cooker.

Additionally, the invention provides cheese comprising a mixture formed by blending natural cheese, natural fat, casein, whey and water, wherein the casein constitutes in the range of 12% to 16% by weight of the mixture, the cheese constitutes in the range of 15% to 25% by weight of the mixture, and the mixture is pasteurized at a pasteurization temperature of not less than 105"C.

The invention will be more clearly understood from the following description of an embodiment thereof, given by way of the following non-limiting example.

Example Cheese is prepared using the process according to the invention described below from the following natural ingredients blended in the percentage by weight of the total mixture set out below.

cheddar cheese 19% salted butter 17% casein 14% whey 9.5Z flavouring 0.95% yeast extract 0.06% salt 0.61% calcium carbonate 0.61% water condensate 14.13% water 24.13% vegetable dye 0.01% In this example, the cheese is natural cheddar cheese which is firm and of good texture. The flavouring is a concentrated dried cheese powder produced from natural cheese. The vegetable dye is a dye derived from the seed of a tropical annatto tree. The salted butter acts as a natural fat. The condensate is accounted for by steam used in the pasteurization process described below. The total weight of the mixture is 260Kg. The ingredients are blended and liquidized in a cooking chamber of a cooker of the vacuum type having a high speed cutter formed by a plurality of cutting blades rotatable at speeds of 750 revs per minute and 3,000 revs per minute.The capacity of the cooking chamber is 400Kg. On being fully blended and liquidized, the mixture is pasteurized by introducing steam into the mixture in the cooking chamber.

The ingredients are delivered into the cooking chamber of the cooker over a period of three minutes. During the three minute period while the ingredients are being delivered into the cooker, the cutting blades are continuously rotated at a speed of 3,000 revs per minute and continue to rotate for a further 1 minute after all the ingredients have been delivered into the cooker to fully blend and liquidize the mixture. The power to the cutting blades is then switched off and the cutting blades come to rest.

On all the ingredients being added to the cooker, the cooking chamber is sealed and evacuated to a vacuum of approximately -0.5 bar. The cutting blades are rotated again at a speed of 750 revs per minute and continue to rotate until the pasteurization temperature has been reached. The mixture is pasteurized by introducing steam at a pressure of 4.5 Bar at a temperature of 156"C into the cooking chamber. On the temperature of the mixture reaching 600C, the vacuum is switched off and steam continues to be delivered into the cooking chamber until the temperature of the mixture reaches the pasteurization temperature, in this case 110 C. In this example, the steam is delivered into the cooking chamber for seven minutes. On the pasteurization temperature being reached, the steam is shut off and the cutting blades are switched off. The mixture is immediately cooled. The mixture is cooled to a second temperature, in this case a temperature of 940C over a time period of 5 minutes. In this example, the cooling is achieved by introducing cold water into a jacket surrounding the cooking chamber of the cooker On the temperature of the mixture reaching 940C, the mixture is then pumped out of the cooker and into moulds for setting.

Agitating paddles are continously rotated within the cooking chamber during the entire process from the time the ingredients are being delivered into the cooking chamber until the pasteurized mixture has been pumped out of the cooking chamber.

The process according to the invention for preparing the cheese from natural ingredients produces new and surprising results. It has been found that the shelf life of the cheese produced according to the process of the invention is at least six months and cheese prepared according to the process has been found to have a shelf life of up to eighteen months. The reason for this is not fully understood, however, it is believed that the casein acts as an emulsifier, and the combination of using casein as an emulsifier and pasteurizing the cheese to a temperature of 110 C provides the cheese with a shelf life of six to eighteen months.

While it has been common practice to use casein in the preparation of known cheese, in general the quantity of casein used in known cheese seldom exceeds 7% by weight of the mixture. Further, where known cheese is pasteurized, the pasteurization temperature seldom exceeds 90"C and rarely 1000C. It is believed that by increasing the quantity of casein to 14% by weight of the mixture provides sufficient emulsification to enable known emulsifying salts to be dispensed with in the preparation of the cheese, and the higher pasteurization temperature further facilitates the emulsifying salts to be dispensed with.

It is believed that adequate results would be achieved by maintaining the case in content of the mixture in the range of 12% to 16% by weight of the total mixture, and pasteurizing the mixture up to a temperature of not less than 1050C. However, it is believed that it is preferable that pasteurization should be carried out at a pasteurization temperature in the range of 105"C to 1 150C.

It is believed that the natural cheese content of the mixture could be varied within the range of 15% to 25% by weight of the total mixture.

Further, it is envisaged that the added natural fat content of the cheese could be varied within a range of 15% to 23% by weight of the total mixture while still providing adequate results. While butter has been described as being the natural fat, any other suitable natural fat could be used without departing from the scope of the invention and it is not necessary that the fat should be salted. Where the butter is not salted, it is envisaged that the quantity of salt may be increased slightly.

Further, it will be appreciated that small variations in the quantity of yeast, flavouring, vegetable dye and calcium carbonate could be made without departing from the scope of the invention. Indeed, in certain cases some of these ingredients may be dispensed with altogether.

It is further envisaged that the quantity of water may be varied between 35% and 40% by weight of the total mixture.

Additionally, it will be appreciated that the quantity of whey in the mixture may be varied and in general it is envisaged that adequate results would be achieved once the whey content in the mixture is kept within the range of 8% to 11% by weight of the total mixture.

While the mixture has been described as being cooled immediately after pasteurization to a second temperature of 940C, it is envisaged that the mixture may be cooled to a temperature in the range of 920C to 960C without affecting the results. Indeed, in certain cases it is not essential that the mixture should be cooled immediately. Further, while the time period for cooling the mixture from the pasteurization temperature to the second temperature has been described as being five minutes, in certain cases, it is envisaged that the time period may be in the range of four to six minutes without departing from the scope of the invention.

Claims

1. A process for the preparation of cheese from natural ingredients comprising blending a mixture of natural cheese, natural fat, casein, whey, and water and pasteurizing the mixture in a cooker after being blended, wherein the casein constitutes in the range of 12% to 16% by weight of the mixture, the natural cheese constitutes in the range of 15% to 25% by weight of the mixture, and the mixture is pasteurized at a pasteurization temperature of not less than 1050C.

2. A process as claimed in Claim 1 in which the mixture is raised to the pasteurization temperature during a time period in the range of 5 to 9 minutes.

3. A process as claimed in Claim 2 in which the mixture is raised to the pasteurization temperature in a time period of 7 minutes.

4. A process as claimed in any preceding claim in which the mixture is cooled to a second temperature immediately on being raised to the pasteurization temperature.

5. A process as claimed in Claim 4 in which the mixture is pumped from the cooker on being cooled to the second temperature.

6. A process as claimed in Claim 5 in which the mixture is cooled from the pasteurization temperature to the second temperature in a time period in the range of 4 to 6 minutes.

7. A process as claimed in Claim 6 in which the mixture is cooled from the pasteurization temperature to the second temperature in 5 minutes.

8. A process as claimed in any of Claims 4 to 7 in which the second temperature is in the range of 92"C to 960C.

9. A process as claimed in Claim 8 in which the second temperature is 940C.

10. A process as claimed in any preceding claim in which the mixture is pasteurized by introducing steam into the mixture.

11. A process as claimed in any preceding claim in which the casein constitutes 14% by weight of the mixture.

12. A processias claimed in any preceding claim in which the natural cheese constitutes 19% by weight of the mixture.

13. A process as claimed in any preceding claim in which the pasteurization temperature is in the range of 1050C to 1150C.

14. A process as claimed in any preceding claim in which the pasteurization temperature is 110 C.

15. A process as claimed in any preceding claim in which the whey constitutes in the range of 8% to 11% by weight of the mixture.

16. A process as claimed in Claim 15 in which the whey constitutes 9.5% by weight of the mixture.

17. A process as claimed in any preceding claim in which the natural fat constitutes in the range of 15% to 23% by weight of the mixture.

18. A process as claimed in any preceding claim in which the natural fat constitutes 17% by weight of the mixture.

19. A process as claimed in any preceding claim in which the natural fat is salted butter.

20. A process as claimed in any preceding in which the water including condensate constitutes in the range of 35% to 40% by weight of the mixture.

21. A process as claimed in any preceding in which the water including condensate constitutes 38% by weight of the mixture.

22. A process as claimed in any preceding claim in which the natural cheese is a firm cheese of good texture.

23. A process as claimed in any preceding claim in which the natural cheese is cheddar cheese.

24. A process as claimed in any preceding claim in which the mixture further comprises yeast extract, the yeast extract constituting approximately 0.06% by weight of the mixture.

25. A process as claimed in any preceding claim in which the mixture further comprises salt, the salt constituting approximately 0.61% by weight of the mixture.

26. A process as claimed in any preceding claim in which the mixture further comprises calcium carbonate, the calcium carbonate constituting approximately 0.61% by weight of the mixture.

27. A process as claimed in any preceding claim in which the ingredients of the mixture are delivered into the cooker over a time period of approximately 3 minutes and the ingredients are liquidized in the cooker during the time they are being delivered into the cooker.

28. A process as claimed in Claim 27 in which the ingredients are liquidized by a high speed cutter comprising cutter blades rotating within the cooker.

29. A process as claimed in Claim 28 in which the cutter blades rotate at a speed of approximately 3,000 revs per minute.

30. A process as claimed in Claim 29 in which the mixture is liquidized for a further period of approximately 1 minute after all the ingredients have been delivered into the cooker.

31. A process as claimed in any of Claims 10 to 30 when dependent on Claim 10 in which the steam is introduced to the cooker after the ingredients have been liquidized in the cooker.

32. A process as claimed in Claim 31 in which the mixture is continuously agitated in the cooker by rotating the cutter blades at a speed of approximately 750 revs per minute while the steam is being introduced.

33. A process as claimed in Claim 30 or 31 in which the steam is shut off on the temperature of the mixture reaching the pasteurization temperature.

34. A process substantially as described herein with reference to the accompanying example.

35. Cheese prepared according to the process of any of Claims 1 to 34 in which the cheese comprises a mixture formed by blending natural cheese, natural fat, casein, whey and water, wherein the casein constitutes in the range of 12% to 16% by weight of the mixture, the natural cheese constitutes in the range of 15% to 25% by weight of the mixture, and the mixture is pasteurized at a pasteurization temperature of not less than 1050C.

36. Cheese comprising a mixture formed by blending natural cheese, natural fat, casein, whey and water, wherein the casein constitutes in the range of 12% to 16% by weight of the mixture, the natural cheese constitutes in the range of 15% to 25% by weight of the mixture, and the mixture is pasteurized at a pasteurization temperature of not less than 1050C.

37. Cheese substantially as described herein with reference to the accompanying example.