IL181682A - Process for producing traditional type cheeses - Google Patents

Description

22002/07 181682 ϊ'Π I 453497 τηχ Γϊτπτιυτ] mm rr.unn rrj- ij u NOVEL TECHNOLOGY FOR TRADITIONAL TYPE CHEESES / NOVEL TECHNOLOGY FOR TRADITIONAL TYPE CHEESES The present invention relates to the manufacture of cheeses and particularly, the manufacture of traditional orYipened types of cheese from powder protein concentrates containing less lactose.

The manufacture of cheese from milk powder is a well-known process. This way of manufacturing cheeses is particularly advantageous, because it allows dissociating both in time and placing the manufacture of cheeses and the supply of fresh milk. This makes possible the production of cheese at request and/or in areas having no dairy resources.

Known processes of manufacture of cheese from milk powder are fast processes, allowing the production of cheese in some stages only: mixing the milk powder with water, acid solutions or greases, possible addition of enzymes, heating the thus obtained mixture, addition of various additives. The types of cheese obtained are either fresh or molten cheeses.

Patent WO03/051130 describes a fast process with respect to the conventional process in which fermentation is replaced with the direct addition of an acid, brining is replaced with the addition of salt in the starting preparation. Obtaining the finished product rapidly uses the technology of process cheese with emulsifying salt contribution. The manufactured product's taste will undergo little or no change by time, and will show relatively neutral organoleptic characteristics.

However, there is a great demand for traditional or ripened types of cheese. In fact, it is ripening that will develop specific gustatory qualities of each type of cheese. Ripening includes the successive transformations which the cheese undergoes from the end of salting to the moment it is consumed. The temperature, the percentage of moisture, specificities of the ferments used, more or less significant ventilation as well as the care of the refiner (washing, brushing, reversal, displacement) determine the final taste of the cheese. The process of ripening increases the cohesion of cheese, this one becomes compact. Gradually, its aspect undergoes changes: its skin hardens, it becomes a crust. Its taste is definite and its texture is modified.

The purpose of the present invention is to propose a manufacturing process of cheeses of traditional or ripened type from powder protein concentrates containing less lactose.

According to a first aspect, the invention relates to a process of manufacturing cheese of the traditional/ripened type including, as known, the stages molds, salting and initially includes the following stages: a. introducing, into a solid-liquid mixer, a basic composition containing: - water, - fat, - powders including dairy protein concentrates containing less lactose; b. operating the mixer at a minimum stirring speed of 1,500 turns per minute, at a temperature ranging between 45°C and 55°C, in order to emulsify and homogenize said composition, then de- aerating it under vacuum, until a de-aerated and emulsified homogeneous paste is obtained; c. cooling said paste at a temperature lower than or equal to 40°C; d. adding to the cooled paste, auxiliaries of manufacture, which are selected among the group including: acidification ferments, flavor-generating ferments, coagulation enzymes; and e. making sure that the paste thus added is homogenous.

The process according to the invention may include an additional stage of pasteurization of said emulsified paste obtained after stage b, at a temperature of at least 72°C, for 15 seconds, or by any equivalent treatment.

In a characteristic way, the process according to the invention includes, after the stage of hooping, a stage of oven drying or maturation, which is carried out without elimination of whey. Oven drying takes place at a temperature ranging from 28°C to 31°C, and at a maximum rate of hygrometry to avoid frosting effect and desiccation of surface, until obtaining a pH of 4.8 to 5.3 (for soft pastes and pressed ones respectively).

The stage of salting (in brine or dry salt) is carried out preferably after the stage of removing from molds, and before ripening. Salting can be carried out at the same time as the addition of the auxiliaries of manufacture, by adding salt to the cooled paste.

According to a second aspect, the invention relates to a basic composition implemented in the process of manufacturing cheeses of the traditional/ripened types, including: - water, - fat, - powders including dairy protein concentrates containing less lactose, the protein/water ratio by weight ranging between 0.3% and 0.9%.

According to a third aspect, the invention relates to powders used in the composition implemented in the process of manufacturing cheeses of the traditional/ripened type, said powders including less than 10% by weight of lactose. These powders are characterized by a protein content of over 65% by weight and preferably of over 75% by weight. The total casein/protein ratio is higher than the milk ratio (i.e. 80%) and preferably ranges between 85% and 92%.

According to a fourth aspect, the invention relates to cheeses of the traditional/ripened types: hard paste cheeses, pressed paste cheeses, soft cheeses (cooked or not cooked), obtained by the implementation of the process of the invention.

Other characteristics and advantages will appear in the detailed description of the process according to the invention, which is given as a non-limiting example only with respect to the diagram given in the single figure.

The manufacturing process of cheeses of the traditional/ripened types includes a first stage consisting in introducing into a solid-liquid mixer, a basic composition containing water, fat and powders including dairy protein concentrates containing less lactose. The mixer can be of double wrap material, double defloculator type in the bottom of the tank, allowing even a vortex mixing. Said mixer must develop a minimum stirring speed of 1,500 turns per minute. Said mixer is then put in operation and mechanical work with recirculation of mixes is carried out for approximately 30 minutes, the set being heat-treated at a temperature ranging between 45°C and 55°C, preferably between 50°C and 55°C. In this stage, the following operations are carried out successively: - emulsion of fat in a part of proteins; - final enrichment in proteins; and - rehydration of all the proteins.

The speed of circulation, the direction of rotation and counter-rotation, the deflector of material flow and the rotor-stator type tools of various materials allow a good reconstitution of the mix.

During this time, vacuuming the equipment allows obtaining a smooth, homogeneous and de-aerated paste.

In a characteristic way, the entirely reconstituted pre cheese mix shows a high rate of dry matter ranging between 40% and 65% by weight, and preferably between 51% and 55% by weight. The process according to the invention thus allows obtaining a pre cheese whose level of dry matter is higher than that of the pre cheeses obtained particularly from liquid milk, by ultra filtration or some other non denaturing techniques, such as thermal evaporation.

In a variant embodiment, said double-rap material is also used to carry out heat treatments of pasteurization and cooling, the latter being intended to bring back said emulsified paste to a temperature lower than or equal to 40°C, necessary for hooping. Before hooping, the auxiliaries of manufacture are added to the emulsified, possibly pasteurized and cooled paste. These auxiliaries of manufacture are selected among the group including: acidification ferments, aromatic ferments, coagulating enzymes, and flavors. A complementary phase of mixing ensures the homogeneity of incorporation of such auxiliaries. In this variant embodiment, we can start the operation of hooping at the same time as the draining of the tank is carried out. Hooping can be carried out with a variety of materials, perforated or not perforated, advantageously cloth-lined micro perforated materials (of pressed paste type) to preserve the aspect of traditional cheese.

In another variant embodiment, the double-rap material is used only to carry out reconstitution. The stages of heat treatment, then of cooling at a temperature lower than or equal to 40°C, can be carried out by a complementary tubular or scraped-surface equipment, followed by the on-line incorporation of the technological auxiliaries or the auxiliaries of manufacture (ferments, coagulants, flavors) and supplemented by the always uninterrupted passage in a dynamic mixer in order to ensure a perfect homogeneity of the added paste. Hooping is carried out necessarily in an uninterrupted way, as soon as the paste is out of the dynamic mixer.

The ferments of acidification and development of flavors, added to said cooled paste are selected among the group including: mesophilic ferments, thermophilic ferments, which belong to the Lactobacillus and/or Streptococcus kinds.

The enzymes of coagulation added at stage d of the process are selected among the group including: rennet, protease, and lipase.

In all the cases, the stage of pasteurization of the emulsified paste is carried out at a temperature of at least 72°C, for a period of 15 seconds, or by any equivalent treatment.

The pasty texture of the pre cheese obtained after the stage e makes it possible, by its degree of dry matter, by its viscosity that is higher than 20Pa.s (as measured with a Haake viscosimeter) and by its homogeneity, to hoop cheese directly in molds or receptacles having no perforations or having perforations of 0.2 millimeters (mm) to 0.5 mm in diameter, without any risk of flow of the pre cheese that is still liquid through the holes, i.e. before its coagulation under the effect of a coagulant, particularly of rennet.

The pre cheese not yet coagulated, which is put into molds or perforated receptacles, may become a personalized printed and caked cheese after its coagulation, due to a mere contact of the pre cheese matter with the weft or the three-dimension drawing of the mold/receptacle.

The process according to the invention includes, after the stage of hooping, a stage of oven drying or maturation, in order to perfect coagulation and acidification; this stage consists in putting the cheeses in molds at a temperature ranging between 28°C and 31°C, and a hygrometry rate ranging between 99% and 100%, for a period of time of some hours to 20 hours, until obtaining a pH of about 5.3 to 4.8.

In a characteristic way according to the invention, the oven drying stage is carried out without elimination of whey. This has many advantages such as: - no elimination of liquid product in the factory; - dryer and less polluted manufacturing premises; - less fermentable stains, and thus an easier cleaning; - no by-product to be developed; and - a rational use of infrastructure and transport means.

The process according to the invention allows carrying out the operation of hooping the directly apportioned cheese.

After oven drying, cheeses are removed from molds, and then salted in brine or dry salt following the methods known to the person skilled in the art. For certain types of cheese, particularly those of small weight, salt can be added directly at stage d, at the same time as the auxiliaries of manufacture.

The other operations correspond to the usual techniques of cheese production. The products thus obtained from powder and without the presence of by-products to be treated, such as whey, have the characteristic of being very similar to traditional cheeses, and can be ripened as such.

Certain freshly manufactured young cheeses (like Burgos) can be consumed as they are or white, and without crust.

It is possible to develop crusts that are natural, moldy, morge, coated, and even filmed, in comparison with certain references such as Gouda, Leerdamer, Emmental, Saint Paulin, Brie.

In the same way, we can develop textures of more or less firm pastes, blind ones, and pastes with mechanical or ferment eyes.

The invention will be better understood after reading the description of several examples of manufacturing cheeses of the traditional types, from powder protein concentrates containing less lactose.

Example 1: The process can apply to a cheese with blind paste, of American Cheddar type (orange yellow colored paste).

We put in the mixer 71.3 kg of water, 42.2 kg of anhydrous milk fat, 36.5 kg of a powder protein concentrate with 78% of protein and 6% of lactose.

The mixer is operated at a stirring speed of 1,500 turns per minute and the mix is recirculated for approximately 30 minutes at 50°C.

The mix is pasteurized at 72°C for 15 seconds, and then cooled to 40°C. The auxiliaries are then added and well mixed with the whole mix. To 2,200 kg of mixes are added: - 5 ml of a solution of a coloring agent (Rocou A 320 WS) from Chr. Hansen France (3 ml of coloring agent in 6 ml of water); - Cheddar Flavor 9808 from Chr. Hansen France at a rate of 2%; - 1.5 ml of an STB-01 solution (Streptococcus thermophilus) from Chr. Hansen France (2 g of STB-01 in 24 ml of water); - 1.5 ml of an SDMB-04 solution (Lactococcus lactis) from Chr. Hansen France (2 g of SDMB-04 in 24 ml of water); and - Temperature adjustment to 35°C, then addition of 1 ml of rennet 520 mg/l of rennin diluted in a l/10th per kg of the mix.

Cheeses are molded in rectangular plastic molds. Then, the following stages are carried out: acidification to a pH of 5.25; cooling to 12°C; removing from molds, and pickling in brine.

Cheese is conditioned after salting in tight plastic sachets. It is then: - ripened in anaerobe at 12°C for 7 days; - kept cold for 10 days; - unpacked and vacuum conditioned; and - stored at 4°C.

Cheeses with an unctuous and melting paste are thus obtained. The cut is homogeneous. The taste is pleasant, slightly similar to American Cheddar.

Results of tasting cheeses (Panel of ten tasters): Aspect: Parallelepipedic, homogeneous cake without crust of slight orange color Smell: Very light, fruity Texture: Can be cut with a knife, rather firm and slightly sticky The paste is completely closed, blind, and not breakable. Taste: When put in mouth, the taste is rather soft, and then a more typified ripened taste of sharp/sourish type appears.

Conclusion: The cheese is identified as American Cheddar.

Example 2 The process can apply to a standard Emmental cheese, with or without propionic eyes.

We put in the mixer 47 kg of water, 28 kg of anhydrous milk fat, 24 kg of a powder protein concentrate with 78% of nitrogenous matter and 6% of lactose.

The mixer is operated at a stirring speed of 1,500 turns per minute and the mix is recirculated for approximately 30 minutes at 50°C. The mix is pasteurized at 72°C for 15 seconds, and then cooled to 40°C.

The technological auxiliaries and additives are then added, and well mixed with the whole mix. To 12 kg of the mix are added: - 8 ml of an STB-01 solution (Streptococcus thermophilus) from Chr. Hansen France (2 g of STB-01 in 24 ml of water); - 8 ml of an SDMB-04 solution (Lactococcus lactis) from Chr. Hansen France (2 g of SDMB-04 in 24 ml of water); - 8 ml of an LHB-01 solution (Lactobacillus helveticus) from Chr. Hansen France (2 g of LHB-01 in 24 ml of water); - 4 ml of a PS-1 solution from Chr. Hansen France (0.5 g of propionic ferment in 25 ml of water); - 12 ml of rennet (520 mg/l of rennin diluted in 1/10™; and - 8.5 ml of afilact (lyzozyme liquid) from Chr. Hansen France.

Cheeses are put in round and smooth plastic molds and cloth-lined micro-perforated plastic molds to obtain a traditional crust of cloth-lined Emmental. Then, the following operations are carried out: acidification until a pH of 5.20-5.2; cooling to 15°C; removing from molds; pickling in saturated brine at a rate of 2 hours per kilo of weight of cheese (for a cheese of 12 kg, pickling in brine for 24h).

After salting, cheese is vacuum conditioned partially in tight plastic sachets. It is then: - pre ripened at 12°C for one week; - put at 3-4°C for two weeks and a half; and - ripened at 17-18°C in a traditional cellar with a hygrometry of 98-99%, for 2 to 3 weeks.

At this stage, a part of the cheeses is put under vacuum and stored at 4°C, while another part is put in aerobic ripening with surface treatment in a hot cellar at 18°C, for drying and crust making, for 15 days, then stored at 4°C.

The vacuum ripened cheeses present a closed and smooth paste without dessication and crust effect.

The Emmental taste is marked, showing that there is no loss of the gas produced by the propionics.

The cheeses with crust, which are ripened with surface treatment, have a slightly ventilated paste (some eyes), and are homogeneous and unctuous, but quite firm to be cut with a knife.

The crust is then cleaned and dried, so that cheese can be conditioned under vacuum in portions, and so as to obtain a perfect conservation at 2°C /4°C.

Results of tasting cheeses ( Panel of ten tasters): Aspect: Crust cheese showing micro points corresponding to the weft of the manufacturing cloth.

The crust is clean, of gold yellow color and firm.

The paste is cream-colored - yellow cream and it looks smooth and homogeneous.

When cut, eyes resulting from fermentation can be seen.

Smell: Rather slight, a bit fruity.

Texture: Not sticky, and can be cut with a knife.

The paste is rather firm, but melting without too much mastication.

Taste: Typical of the Emmental, fruity and soft.

A slightly sharp note (typical of the Emmental) was noticed by a majority of tasters (6 out of 10) Conclusion: The cheese is identified as an Emmental that one can find in a supermarket.

Example 3 The process can apply to a cheese of the Holland type (Gouda, Edam, Mimolette) whose dry extract will be about 51-53%.

We put in the mixer 45.3 k g of water, 16 kg of anhydrous milk fat, 18.7 kg of a powder protein concentrate with 76% of protein and 8% of lactose.

The mixer is operated at a stirring speed of 1,500 turns per minute and the mix is recirculated for approximately 30 minutes at 50°C. The mix is pasteurized at 72°C for 15 seconds, and then cooled to 32.5°C.

The technological auxiliaries are then added and well mixed with the whole mix. To 1.5 kg of the mix are added: - 1.5 ml of an STB-01 solution (Streptococcus thermophilus) from Chr. Hansen France (2 g of STB-01 in 24 ml of water); - 0.7 ml of an SDMB-04 solution (Lactococcus lactis) from Chr. Hansen France (2 g of SDMB-04 in 24 ml of water); and - 0.8 ml of rennet (520 mg/l of rennin from Chr. Hansen France diluted in 1/10TH.

Cheeses are put in molds. Then, the following stages are carried out: acidification until a pH of 5.20 at 31°C; cooling at 15°C; removing from molds; pickling in a brine of a density of 1,180° B, at 12°C.

After salting, the cheese is conditioned in tight plastic sachets. It is then: - pre ripened in anaerobe at 12°C for 7 days; - dried at surface by ventilation, for 2 to 3 days, in a ripening cellar in aerobe at 12°C, at a moisture rate of 95-96% in order to form a crust, and increase the dryness of the product by desiccation; - cooled; - coated with wax; and - cooled and stored at 4°C.

A homogeneous texture of pressed paste type is obtained without eyes. The paste is flexible, can easily be cut with a knife and it tastes like fruit, hazel nuts.

Cheeses can be stored at 4°C for several weeks and even several months.

With ripening, we can obtain cheeses of young Gouda type, and semi-dried type after several weeks of complementary ripening.

Results of tasting cheeses (Panel of ten tasters): Aspect: The cheese has a crust on its surface and a weft can be seen (manufacturing cloth or cloth-lined micro perforated molds). The crust is of a shiny golden color.

The paste is white cream-colored, closed and quite homogeneous.

Smell: Very slight, of fruity flavor.

Texture: Average firm paste, soft and can be cut with a knife. The texture is tender in mouth.

Taste: Pleasant, soft and particularly fruity. A note of diacetyl and of hazel nut.

Conclusion: The cheese is identified as a Holland young Gouda type.

Example 4: The process can apply to a soft paste cheese with a moldy crust, of 42-44% of dry extract. We put in the mixer 91.2 kg of water, 25.8 kg of anhydrous milk fat, 33 kg of a powder protein concentrate with 80% of protein and 4.5% of lactose.

The mixer is operated at a stirring speed of 1,500 turns per minute and the mix is recirculated for approximately 30 minutes at 50°C. The mix is pasteurized at 72°C for 15 seconds, and then cooled at 31°C.

The technological auxiliaries are then added and well mixed with the whole mix. To 1.5 kg of the mix are added: - 1.5 ml of an STB-01 solution (Streptococcus thermophilus) from Chr. Hansen France (2 g of STB-01 in 24 ml of water); - 1.5 ml of an SDMB-04 solution of (Lactococcus lactis) from Chr. Hansen France (2 g of SDMB-04 in 24 ml of water); and - 0.5 ml of a CHN19 solution (mesophilic mix) from Chr. Hansen France (2 g of CHN19 in 24 ml of water).

The cheeses are put in molds. Then, the following operations are carried out: drying at 31°C; acidification until a pH of 6.50; rennet addition, with 0.5 ml of rennet and 520 mg/l of rennin, from Chr. Hansen France diluted to the 1/10™, acidification until a pH of 5.10-5.15; cooling at 15°C; pickling for 30 minutes in a brine of a density of 1,180° B, at 12°C.

After salting, the cheese is conditioned in tight plastic sachets, for pre ripening in anaerobe, at 12°C for 7 days. Then, the cheeses are removed from the plastic bags and are sprayed on the surface with a liquid preparation of Penicillium candidum.

The white moldy cheeses are packed, then cooled and stored at 4°C.

The cheese obtained is of a soft moldy paste type. The paste is soft, homogeneous and unctuous. The surface flora is correctly distributed on the surface. The taste is pleasant, fresh, soft and creamy.

Results of tasting cheeses (Panel of ten tasters): Outer aspect: The cheese is rather moldy and white.

Aspect of the cut: Quite homogeneous and smooth cut, showing some small eyes (mechanical or ferment eyes).

The moldy crust is not too thick.

Smell: Pleasant of mature cream, a fruity note of diacetyl. Texture: Slightly sticky to the knife.

Soft and melting in mouth.

Taste: Pleasant, fresh and creamy at the same time.

Conclusion: The cheese is identified as a soft paste with a moldy crust of the pasteurized Brie type.

According to a second aspect, the invention relates to a composition implemented in the manufacturing process of cheeses of the traditional/ripened types, said composition including: - water, - fat, - powders including dairy protein concentrates containing less lactose, the protein/water ratio by weight ranging between 0.3% and 0.9%. The protein/water ratio by weight is minimum 0.3% for soft cheeses, and maximum 0.9% for hard cheeses.

Said fat is selected among the group including: butyric fat, cream, and vegetable fats.

Said composition may also include filling agents, such as starches, maltodextrines, fibers, guar, carob, in addition to the milk dry extract, as allowed in the local legislation.

According to a third aspect, the invention relates to milk powders including dairy protein concentrates. These powders contain a protein ingredient containing less lactose (from 3% to 10% of lactose by weight) and highly concentrated in native and non-denatured dairy proteins (content over 65% of proteins by weight). Preferably, these dairy proteins have a casein/protein ratio higher than the milk ratio (80%) and preferably ranging between 85% and 92%.

According to a fourth aspect, the invention relates to cheeses of the traditional/ripened type: cooked or not cooked hard paste, pressed paste, soft cheeses, obtained by implementing the process of the invention. Cheeses of the traditional/ripened type, obtained by implementing the process, are selected among the group including: Gouda, Edam, Mimolette, Leerdamer, Emmental, Saint Paulin, Cheddar, Gruyere, Brie, Camembert, Kashkaval. Their organoleptic characteristics are very close to those of the reference product.

Claims (14)

181682/3 16 Claims

1. Process to produce a cheese of traditional / ripened type comprising in manner known per se the steps of moulding, steaming / acidification, mould release, salting and ripening, characterized in that it firstly comprises the following steps: a) adding, to a solid-liquid mixer, a basic composition comprising water, fat, and powders containing lactose-reduced dairy protein concentrates, namely containing 10 weight % or less of lactose; b) setting the mixer in operation at a minimum mixing speed of 1500 revs/minute and at a temperature of between 45 and 55°C so as to emulsify and homogenize said composition, followed by vacuum de-aerating until a de-aerated, emulsified, homogeneous paste or pre-cheese mix is obtained; c) cooling said mix down to a temperature of 40°C or less; d) adding cheese-making auxiliaries to the cooled mix chosen from the group: acidification bacteria, flavour-producing bacteria, coagulating enzymes e) homogenizing the resulting mixture obtained.

2. Process according to claim 1 , characterized in that the wholly reconstituted pre-cheese mix has a dry matter content of 40 to 65 wt. %, preferably 51-55 wt. %.

3. Process according to either of claims 1 or 2, characterized in that it comprises a step to pasteurize said emulsified mix obtained after step b), at a minimum temperature of 72°C for 15 seconds or by equivalent treatment. 181682/3 17

4. Process according to any of claims 1 to 3, characterized in that the moulding step is performed without any loss of liquid pre-cheese in moulds having perforations with a diameter of 0.2 to 0.5 millimetres or having no perforations.

5. Process according to any of claims 1 to 4, characterized in that, after the moulding step, it comprises a steaming or ripening step performed without elimination of whey, for a maximum time of 20h at a temperature of the order of 28 to 31 °C and hygrometry of 99 to 100% until a pH in the order of 4.8 to 5.3 is obtained.

6. Process according to any of claims 1 to 5, characterized in that the salting step is conducted in brine or by dry salting after the mould release step and before the ripening step.

7. Process according to any of claims 1 to 6, characterized in that the salting step is conducted by adding salt to said cooled mix at the same time as the cheese-making auxiliaries.

8. Process according to any of the preceding claims, characterized in that the acidification bacteria added to the cooled mix are chosen from the group: mesophilic cultures and thermophilic cultures and belonging to the genii Lactobacillus and / or Streptococcus.

9. Process according to any of the preceding claims, characterized in that the coagulation enzymes are chosen from the group: rennet, protease, lipase. 181682/3 18

10. Process according to any of claims 1 to 9, characterized in that the protein/water weight ratio of the basic composition lies between 0.3 and 0.9.

11. 1 1. Process according to any of claims 1 to 10, characterized in that the fat in the basic composition is chosen from among: butyric fat, cream, vegetable fat.

12. Process according to any of claims 1 to 11 , characterized in that the powders have a casein / total protein weight ratio of between 0.85 and 0.92.

13. Process according to claim 12, characterized in that the powders have a weight content of native, non-denatured proteins of 65% or more.

14. Process according to any of claims 1 to 13 to produce a traditional / ripened cheese of soft type, pressed type, cooked or uncooked hard type, chosen from the group: gouda, edam, mimolette, leerdamer, emmental, Saint Paulin, cheddar, gruyere, Brie, Camembert, Kashkaval.