GB2573579A

GB2573579A - A cheese product

Info

Publication number: GB2573579A
Application number: GB1807719.8A
Authority: GB
Inventors: Glynn Melvin
Original assignee: Wyke Farms
Current assignee: Wyke Farms
Priority date: 2018-05-11
Filing date: 2018-05-11
Publication date: 2019-11-13
Anticipated expiration: 2038-05-11
Also published as: GB201807719D0; EP3790400A1; GB2573579B; GB2573579A8; WO2019215422A1

Abstract

A method for producing a composite cheese product, in which a first cheese surrounds at least a portion of a second cheese, comprises (i) inserting a quantity of cheese into a first mould which includes a recess, (ii) exposing the first cheese to a predetermined pressure in order to provide a first cheese form shaped to define a second recess located therein, (iii) inserting a quantity of a second cheese into the second recess of the first cheese to provide a composite cheese form comprising first and second cheeses, in which the first cheese surrounds at least a portion of the second cheese. The quantity of second cheese may have a predetermined shape prior to insertion into the second recess. A cheese product may be made by forming first and second composite cheese forms and joining them together. Preferably the cheese product is an imitation egg 10, with the first cheese mimicking the white and encompassing the second cheese mimicking the yolk (not shown). An outer coating may be provided, preferably of wax (not shown). The cheese eggs may be provided together with a storage container, preferably configured as an egg box or carton.

Description

A CHEESE PRODUCT

The present invention relates to cheese product comprising a first cheese substantially encompassing a second cheese, and a method for producing the cheese product.

BACKGROUND OF INVENTION

Cheese products are provided in a number of different shapes, colours and flavours.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a method for producing a composite cheese product comprising a first cheese surrounding at least a portion of a second cheese, the method comprising:

obtaining a first mould providing a first recess having predetermined shape and dimensions;

inserting a predetermined quantity of a first cheese into the first recess of the mould;

exposing the first cheese to a predetermined pressure in order to provide a first cheese form shaped to define a second recess located therein;

inserting a predetermined quantity of a second cheese or a second cheese form having a predetermined configuration into the second recess of the first cheese form to provide a first composite cheese form comprising first and second cheeses, in which the first cheese surrounds at least a portion fo the second cheese.

The first cheese may be exposed to pressure within the first mould using any suitable manufacturing techniques, such as for example vacuum formation. In one embodiment, the first cheese may be exposed to pressure by use of a pressing tool having suitable shapes and/or dimensions.

In one embodiment, the first cheese form is formed within the first recess of the first mould and the second cheese form is formed within a third recess provided by a second mould.

In one embodiment, the method may further comprise obtaining a second mould providing a third recess having predetermined shape and dimensions for providing a second cheese form for subsequent insertion within the second recess of the first cheese form. The method may further comprise inserting a predetermined quantity of a second cheese into the third recess of the mould. The method may further comprise exposing the second cheese within the third recess of the second mould to predetermined pressure in order to provide a second cheese form. The second cheese may be exposed to pressure using any suitable manufacturing technique, such as for example vacuum formation. In one embodiment, the second cheese is exposed to a predetermined pressure by using a pressing tool having a predetermined configuration to apply pressure to the second cheese within the third recess of the second mould to provide a second cheese form. The second cheese form is then subsequently removed from the second mould and placed within the second recess provided by the first cheese form to provide the composite cheese form.

In one embodiment, the first cheese form is formed within the first recess of the first mould and the second cheese form is formed in situ within the second recess provided by the first cheese form.

In one embodiment, the method comprises forming the second cheese form in situ within the second recess of the first cheese form. The method comprises inserting a predetermined quantity of a second cheese into the second recess of the first cheese form. The method may further comprise exposing the second cheese to predetermined pressure in order to provide a second cheese form. The second cheese may be exposed to pressure using any suitable manufacturing technique, such as for example vacuum formation. In one embodiment, the second cheese is exposed to pressure by using a pressing tool having a predetermined configuration to apply pressure to the second cheese within the second recess provided by the first cheese form to form a second cheese form shaped and dimensioned to correspond to the shape and dimensions of the second recess.

The term cheese form is preferably used herein to refer to a continuous cheese substrate.

The recess(es) provided by the cheese form or moulds may have any suitable shapes and/or dimensions. For example, the first recess may have a hemi-spherical or semi-ellipsoidal shape. In one embodiment, the first recess may have a substantially egg shaped cross-section. The second and/or third recesses may be substantially hemi-spherical or semi-ellipsoidal in shape. The second and third recesses preferably have identical shapes and dimensions.

The method may further comprise cooling the mould(s) during insertion of one or more of the first and/or second cheeses. Preferably, the mould is cooled to a temperature of less than 15 °C, preferably less than 10 °C, for example less than 8 °C during and/or prior to insertion and/or formation of the cheese form(s) in order to ensure that the resultant cheese form(s) is removable from the mould(s). The temperature of the mould may be at least 1 °C, preferably at least 3 °C, for example at least 5 °C. The temperature of the mould(s) may be in the range of between 1 °C and 15 °C, preferably between 3 °C and 10 °C, more preferably between 5 °C and 8 °C.

The first and/or second cheeses may be introduced in any suitable form into the mould. For example, the method may further comprise grating one or more, preferably each, of the first and/or second cheeses prior to introducing into the corresponding mould.

According to a second aspect, the present invention provides a method for producing a cheese product comprising a first cheese substantially encompassing a second cheese, the method comprising:

forming a first composite cheese form and a second composite cheese form having substantially identical shapes and dimensions according to the method as described herein; and placing and/or joining the first composite cheese form adjacent to and/or with the second composite cheese form so as to provide a cheese product in which the first cheese of the first and second composite cheese forms are arranged to substantially encompass the second cheese of the first and second composite cheese forms.

The method may further comprise smoothing one or more surfaces of the composite cheese forms prior to assembling the first composite cheese form together with the second composite cheese form and/or one or more surfaces of the resultant cheese product. The smoothing step may comprise smoothing the one or more surfaces with a cheese smoothing iron.

The method may further comprise depositing a layer of wax on to the outer surface of the resultant cheese product. The layer of wax preferably substantially seals the resultant cheese product from external environmental conditions.

The method may further comprise placing the resultant cheese product, optionally sealed with a layer of wax, within outer packaging, such as for example vacuum packaging.

The method may further comprise surrounding the outer surface of the cheese product, for example the outer surface of the first cheese forms, with a protective coating. The protective layer may be any suitable protective layer capable of protecting the cheese product from the external environment. The protective layer may comprise a film, such as for example a plastic or polymer film, and/or a wax coating. For example, the method may further comprise contacting the outer surface of the cheese product with wax. In particular, the method may further comprise removing the first and second cheese forms from the mould and contacting an outer surface of the cheese product, for example an outer surface of the first continuous cheese form(s) with wax. The cheese product may be dipped in wax.

According to a third aspect, the present invention provides a composite cheese form comprising at least a first cheese form at least partially encompassing a second cheese form.

The composite cheese form may have any suitable shape and/or dimensions. For example the composite cheese form may be hemi-spherical, semi-elliptical, cuboid, cube or any suitable polygonal shape or any suitable truncated shapes. The composite cheese form preferably has a first end and a second opposed end, and an axis of symmetry extending therebetween. Preferably, the composite cheese form is substantially half egg-shaped.

According to a fourth aspect, the present invention provides a cheese product comprising at least a first cheese and a second cheese, in which the first cheese substantially encompasses the second cheese.

The cheese product may have any suitable shape, such as for example spherical, hemi-spherical, ovaloid, cuboid, cube or any suitable polygonal shape or any suitable truncated shapes. The cheese product preferably has a first end and a second opposed end, and an axis of symmetry extending therebetween. Preferably, the cheese product is substantially egg-shaped.

Preferably, the first cheese provides an outer substantially egg-shaped surface of the cheese product, and in which the second cheese product is substantially spherical in shape. It is however to be understood that the second cheese product may be substantially ovaloid in shape.

The first and second cheeses may be any suitable cheeses. Preferably, the first cheese is composed of different cheese to the second cheese. The first cheese may for example have a different flavour, texture, density, and/or colour, or any combination thereof to the second cheese. The second cheese is preferably substantially darker in colour than the first cheese. In one embodiment, the first cheese is a substantially white or cream coloured cheese, for example a mild white Cheddar, and the second cheeses is a coloured cheese, preferably a yellow or orange coloured cheese, such as for example a coloured Cheddar, double Gloucester or Red Leicester.

The cheese product preferably further comprises a protective coating substantially encompassing the first and second cheeses. The protective coating may be composed of any suitable material capable of substantially sealing the first and second cheeses from the external environment so as to prolong the life of the cheese. Preferably, the protective coating is composed of wax or a film, such as for example a plastic of foil film.

The cheese product may have any suitable dimensions. Preferably, the cheese product has a length which is greater than its cross-sectional dimensions. The length of the product is preferably measured between the first and second opposed ends. A longitudinal axis preferably extends between the first and second opposed ends. The maximum width of the product is preferably measured between opposed side portions in a plane extending substantially perpendicular to the length and/or longitudinal axis of the cheese product.

In one embodiment, the cheese product has similar dimensions to an egg, for example a chicken's egg. Preferably, the cheese product has a length of around 7 cm and a width of around 5 cm. It is however to be understood that the cheese product may have any suitable shape and/or dimensions.

According to a further aspect, the cheese product assembly comprises:

at least one cheese product as herein described; and a storage container shaped and dimensioned to receive and support at least a portion of the at least one cheese product.

Preferably, the cheese product assembly comprises a plurality of cheese products.

The storage container preferably comprises at least one recess shaped and dimensioned to receive and support at least a portion of the at least one cheese product.

The storage container preferably provides a plurality of recesses provided in an array. The storage container may comprise any suitable number of recesses provided in an array having any suitable configuration. The array may comprise a plurality of recesses arranged into one or more rows and one or more columns. The array may contain any suitable number of rows and columns depending on the particular requirements for the assembly.

In one embodiment, the storage container comprises six recesses provided in a 2 x 3 array to resemble an egg-box arrangement. Preferably, each recess in a first row is aligned with a corresponding recess in a neighbouring row. Preferably each recess within a row is aligned with the other recesses within the same row.

The storage container preferably comprises a base portion shaped and dimensioned to receive and support at least a portion of the cheese products. The storage container preferably further comprises a lid portion. The storage container is preferably moveable between a first closed configuration in which the lid portion contacts, and preferably releasably engages, and extends across the base portion to define an inner cavity for storing the cheese product(s); and a second open configuration in which the lid portion is arranged to provide the user with access to the cheese product(s) supported within the base portion.

One or more of the lid portion and/or base portion may comprise at least one engagement feature configured to releasably engage the corresponding lid portion and/or base portion. Preferably, each of the lid portion and/or base portion comprises at least one engagement feature configured for releasable engagement. Each of the engagement features may be selected from complementary pairs of male and female engagement features including for example: protrusions, tabs, recesses, openings and cavities, or any combination thereof.

In one embodiment, in the first closed configuration, the inner cavity is isolated, for example substantially sealed, away from an external environment.

The storage container may be composed of any suitable material. For example, the storage container may be composed of one or more of: cardboard or plastic, or any combination thereof.

The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. This description is given for sake of example only, without limiting the scope of the invention. The reference figures quoted below refer to the attached drawings.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a photograph of the cheese product assembly according to one embodiment of the present invention in the first closed configuration;

Figure 2 is a photograph of the cheese product assembly of Figure 1 in the second open configuration;

Figure 3 is a photograph of the cheese product according to one embodiment of the present invention;

Figure 4 is a photograph of a first composite cheese form comprising first and second cheese used to form the cheese product of Figure 3; and

Figure 5 is a flow chart of the process of manufacturing the cheese product according to one embodiment of the present invention.

DETAILED DESCRIPTION

With reference to the Figures, the cheese product 10 is formed by obtaining a first mould (not shown) having one or more first recesses (not shown) with predetermined shapes and dimensions for forming the final cheese product. In the illustrated embodiment, each first recess is shaped to correspond to half of a final egg shaped product. In particular, each first recess has a substantially half egg shaped cross-section. It is however to be understood that the shape of the first recess will depend on the predetermined resultant shape and dimensions of the final cheese product and as such the first recesses are not to be limited to being half egg-shaped.

A first cheese is grated using a grating machine and the grated first cheese is inserted into the or each first recess within the first mould. It is to be understood that the first cheese does not necessarily have to be grated prior to introduction into the first mould. The cheese may be introduced in any suitable form into the first recess. Grating of the first cheese does enable the cheese to be more easily moulded into the desired shape within the first mould. The first cheese in the illustrated embodiment is a mild white Cheddar representative of a white of an egg. It is however to be understood that the skilled person will select the desired first cheese depending on the requirements for the final cheese product.

Once in place within the first mould, the first cheese is then subjected to a predetermined pressure by any suitable manufacturing technique. For example, the first cheese may be exposed to a pressing force, either by hand or by machine, during a first pressing stage in order to compress and mould the grated first cheese to provide a first cheese form within the first recess. During pressing of the first cheese, a tool head is inserted into the or each recess, preferably during the application of the pressing force, such that the tool head is placed into contact with the first cheese within the or each first recess. The tool head is shaped and dimensioned to correspond to the predetermined shape of the second recess. The pressing cycles operate at a rate of about 8 cycles per minute.

During the first pressing stage, the first mould and first cheese are cooled. The temperature is preferably lowered to a temperature of between 5 to 8 °C for a predetermined time period. In the illustrated embodiment, the mould is cooled for 23 minutes. It is however to be understood that the temperature and/or cooling time period will vary depending on the particular requirements for the resultant product.

After the first pressing stage, the first cheese form is present in a continuous form and provides a second recess having a predetermined shape and dimensions.

A second cheese or second cheese form is then introduced into the second recess. The second cheese is preferably a different cheese to the first cheese. For example, the second cheese has a different colour, texture and/or flavour, or any combination thereof compared to the first cheese. In the illustrated embodiment, it can be seen that the second cheese has a deep yellow colour representative of a yolk of an egg. The second cheese in the illustrated embodiment is a coloured cheese, such as for example a coloured Cheddar cheese. It is however to be understood that the skilled person would select the second cheese based on the particular requirements for the cheese product.

The second cheese form may be formed in situ within the second recess provided by the first cheese form.

For example, grated second cheese may be introduced into the second recess. It is however to be understood that the second cheese may be introduced in any suitable form and is not to be limited to grated cheese.

The second cheese is then subjected to a pressing force, either by hand or by machine, during a second pressing stage in order to compress and mould the grated second cheese to provide a second cheese in the shape of the corresponding second recess. During the second pressing stage, the first mould is cooled to a temperature of approximately 5 to 8 °C for a period of 23 minutes. It is however to be understood that the cooling parameters and duration will vary depending on the particular requirements for the final cheese product.

It is also to be understood that the second cheese form may be made separately within a third recess of a second mould. The second cheese may be introduced into the third recess of the second mould in any suitable form, such as for example grated cheese.

The second cheese within the second mould is then subjected to a pressing force, either by hand or by machine, during a second pressing stage in order to compress and mould the grated second cheese to provide a second cheese in the shape of the corresponding third recess. During the second pressing stage, the second mould is cooled to a temperature of approximately 5 to 8 °C for a period of 23 minutes. It is however to be understood that the cooling parameters and duration will vary depending on the particular requirements for the final cheese product.

After the second pressing stage, a first composite cheese form comprising the first cheese and the second cheese is provided as shown in Figure 4. The first composite cheese form is in the shape of half of an egg comprising a continuous first cheese section representative of an egg white and a centrally located continuous second cheese section representative of an egg yolk. It can be seen from Figure 4 that the first composite cheese form as an axis of symmetry extending from a first end to an opposed second end of the first continuous cheese form.

A second composite cheese form is prepared according to the same process described above. The first and second composite cheese forms are aligned and positioned adjacent to each other to provide the cheese product such that the continuous first cheese section extends around and substantially encompasses the continuous second cheese section located therein. The first and second cheese sections of the first composite cheese form may be joined with the corresponding first and second cheese sections of the second composite cheese form. Alternatively, the first and second composite cheese forms may be positioned such that the first and second cheese sections of the first cheese form are adjacent to or in contact with the respective first and second cheese sections of the second cheese form.

In the illustrated embodiment, the outer surface of the cheese forms are covered with a protective layer of wax to protect the cheese product from the external environment. The cheese forms, once assembled into the desired arrangement, may be dipped in wax to provide a continuous protective layer of wax extending around the entire outer surface of the cheese product. Prior to dipping in wax, a fabric strip (not shown) may be wrapped around at least a portion of the periphery of the cheese product. Once coated in wax, the coated fabric strip may be utilised by the user to open and thereby remove the protective wax layer from the cheese product. It is also to be understood that the protective layer may be provided by a film or foil layer.

Although the illustrated embodiments describe the method for producing a substantially egg shaped and coloured cheese product, it is to be understood that the cheese product may be in any suitable form and is not limited to an egg shaped product.

The present invention has been described with respect to the Figures, but the invention is not limited thereto but only by the claims. The Figures described are only schematic and are nonlimiting. Each Figure may not include all of the features of the invention and therefore should not necessarily be considered to be an embodiment of the invention. In the Figures, the size of some of the elements may be exaggerated and not drawn to scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.

The terms first, second and the like in the description and in the claims are used for distinguishing between similar elements and not necessarily for describing a sequence. It is to be understood that the terms so used are interchangeable under appropriate circumstances.

Reference throughout the specification to an embodiment or an aspect means that a particular feature, structure or characteristic described in connection with the embodiment or aspect is included in at least one embodiment or aspect of the invention. The particular features, structures or characteristics of any embodiment or aspect of the invention may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments or aspects.

It is also to be appreciated that while some embodiments described herein include some features included in other embodiments, combinations of features of different embodiments are intended 5 to be within the scope of the invention, and form yet further embodiments, as will be understood by those skilled in the art.

Claims

1. A method for producing a composite cheese product comprising a first cheese surrounding at least a portion of a second cheese, the method comprising:

inserting a predetermined quantity of a first cheese into the first recess of the first mould;

inserting a predetermined quantity of a second cheese or a second cheese form having a predetermined configuration into the second recess of the first cheese form to provide a first composite cheese form comprising first and second cheeses, in which the first cheese surrounds at least a portion of the second cheese.

2. A method as claimed in claim 1, in which the first recess has a substantially half egg shaped cross-section.

3. A method as claimed in either of claims 1 and 2, further comprising cooling the mould during insertion of one or more of the first and/or second cheeses.

4. A method as claimed in any preceding claim, in which the second recess is substantially hemi-spherical in shape.

5. A method as claimed in any preceding claim, further comprising grating one or more of the first and/or second cheese prior to insertion.

6. A method for producing a cheese product comprising a first cheese substantially encompassing a second cheese, the method comprising:

forming a first composite cheese form and a second composite cheese form having substantially identical shapes and dimensions according to the method as claimed in any one of claims 1 to 5; and placing and/or joining the first composite cheese form adjacent to and/or with the second composite cheese form so as to provide a cheese product in which the first cheese of the first and second composite cheese forms are arranged to substantially encompass the second cheese of the first and second composite cheese forms.

7. A method as claimed in claim 6, further comprising surrounding the cheese product with a protective coating.

8. A composite cheese form comprising at least a first cheese form at least partially encompassing a second cheese form.

9. A cheese product comprising at least a first and a second cheese, in which the first cheese substantially encompasses the second cheese.

10. A cheese product as claimed in claim 9, in which the cheese product is substantially eggshaped.

11. A cheese product as claimed in either of claims 9 and 10, in which the first cheese provides an outer substantially egg-shaped surface of the cheese product, and in which the second cheese product is substantially spherical in shape.

12. A cheese product as claimed in any one of claims 9 to 11, in which the product has a first end and a second opposed end, and an axis of symmetry extending therebetween.

13. A cheese product as claim in claim 12, in which the second cheese is substantially darker in colour than the first cheese.

14. A cheese product as claimed in any one of claims 9 to 13, further comprising a protective coating substantially encompassing the first and second cheeses.

15. A cheese product as claimed in claim 14, in which the protective coating is composed of wax.

16. A cheese product assembly comprising:

at least one cheese product as claimed in 9 to 15; and a storage container shaped and dimensioned to a receive and support at least a portion of the at least one cheese product.

17. A cheese product assembly as claimed in claim 16, in which the assembly comprises a plurality of cheese products.

18. A cheese product assembly as claimed in either of claims 16 and 17, in which the storage container comprises at least one recess shaped and dimensioned to receive and support at least a portion of the at least one cheese product.

19. A cheese product assembly as claimed in any one of claims 16 to 18, in which the storage container a provides a plurality of recesses provided in an array.

20. A cheese product assembly as claimed in claim 19, in which the storage container comprises six recesses provided in a 2 x 3 array.

21. A cheese product assembly as claimed in any one of claims 16 to 20, in which the storage container is composed of cardboard.