NL2011459C2 - Method for producing a shaped cheese and production line. - Google Patents

Method for producing a shaped cheese and production line. Download PDF

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Publication number
NL2011459C2
NL2011459C2 NL2011459A NL2011459A NL2011459C2 NL 2011459 C2 NL2011459 C2 NL 2011459C2 NL 2011459 A NL2011459 A NL 2011459A NL 2011459 A NL2011459 A NL 2011459A NL 2011459 C2 NL2011459 C2 NL 2011459C2
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Netherlands
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cheese
pressing
shape
pressing step
mold
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NL2011459A
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Dutch (nl)
Inventor
Tjalling Osinga
Johannes Gerhardus Maria Wammes
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Ware Production B V A
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    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01J—MANUFACTURE OF DAIRY PRODUCTS
    • A01J25/00—Cheese-making
    • A01J25/12—Forming the cheese

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  • Life Sciences & Earth Sciences (AREA)
  • Animal Husbandry (AREA)
  • Environmental Sciences (AREA)
  • Dairy Products (AREA)

Description

Method for producing a shaped cheese and production line.
FIELD OF THE INVENTION
The invention relates to a method for producing a shaped cheese, a shaped cheese and a production line.
BACKGROUND OF THE INVENTION US3700373 (Fowler) describes a method for forming rounded cheese from a rectangular block of cheese curd. Assisted by cheesecloth, a rectangular block of cheese curd is pressed into a rounded cheese hoop mould, yielding two cylindrical pieces of cheese. These pressed cheeses are typically further processed, typically by a brine treatment, followed by encasing in a coating and ripening.
The Dutch patent NL9201812 shows a comparable rectangular or flat-cylindrical cheese with rounded edges, obtained by pressing a rectangular piece of cheese curd in a rounded flattened cylindrical mould.
The European patents EP0278550 and EP2606718 try to obtain similarly shaped cheeses by cutting away sharp corners. However, such methods lead to additional production steps, the waste and loss of valuable cheese material, and decreased protection of the cheese at the cut locations against microorganisms or undesired dehydration.
OBJECT AND SUMMARY OF THE INVENTION A disadvantage of the method according to US3700373 is that the resulting cheese tends to form cracks on the outer surface due to internal stress in the cheese. This disadvantage is known in the art, as acknowledged in par. [0005] of the patent application EP2606718. The formation of cracks in the cheese surface is undesirable, as the cracks promote the deterioration of the cheese during storage. Cracks may cause uncontrolled dehydration, and promote the development of moulds and other undesirable micro-organisms. The occurrence of shearing or cracks leads to an increase of failed quality tests as known in the art. Failing quality tests may cause cheese products to be categorized in a lower, less desirable quality class, or to be rejected.
It is an object of the invention to obtain shaped cheese of improved quality, in particular rectangular or flattened cylindrical shaped cheese.
The invention provides a method for producing a shaped cheese from cheese curd, comprising the steps of a) providing cheese curd having a first shape; b) placing the cheese curd in a first pressing mould, wherein the shape of the pressing mould corresponds to the first shape; c) a first pressing step, wherein the cheese curd is pressed forming a cheese mass having the first shape; d) placing the cheese mass into a second pressing mould for providing a second shape, different from the first shape; e) a second pressing step, wherein the cheese mass is pressed into a shaped cheese having the second shape; f) optionally contacting the shaped cheese with brine during a predetermined brining time; g) optionally applying a protective coating to the shaped cheese; and h) ripening the shaped cheese during a predetermined ripening time.
The shape of the cheese curd is typically determined by the shape of the vessel wherein the cheese curd particles are collected. Typically, cheese curd is provided in regularly shaped blocks such as rectangular blocks or cylindrical blocks.
The pressing moulds for cheese would typically comprise shape-determining members that may be pressed together through mechanical means, as well as openings through which whey is pressed out of the cheese curd. The cheese mass obtained after the first pressing step typically has a lower water content and a greater mechanical strength than the cheese curd block it is obtained from. Preferably, the cheese mass retains the general shape of the cheese curd block it is obtained from.
The cheese mass may be transferred from the first pressing mould to the second pressing mould by manual or automated means. The orientation of the cheese mass may be changed during this transfer, for instance the cheese may be deposited upside-down in the second mould compared to the orientation in the first pressing mould. Alternatively, the cheese mass may remain in place and the mould may be changed around the cheese.
In the second pressing step, the cheese is shaped into its final shape. Preferably, the second shape is different from the first shape. For instance, the second shape may have a comparable geometry but a smaller volume then the first shape. Best results are obtained when the second shape is similar to the first shape, in order to avoid excessive internal tension inside the cheese. For instance, second shape may have only a single deformation step from the first step, such as a more round or more sharp edge, or the dulling or sharpening of a distal end. The possible three-dimensional transformations are restricted by the mechanical strength provided by the cheese curd used. Examples of three-dimensional transformations include for instance scaling transformations, rounding edge transformations, and truncation, as well as the reverse transformation. More specific shape transformations include transitions from a cube to a rounder cube; rombohedron to a rounded rombohedron; prism to a rounded prism, triangular prism to a rounded triangular prism; pyramid to a truncated pyramid, and the reverse transformations thereof.
Optionally, the cheese is brined. The contact time of the cheese with the brine, the salt content of the brine and optional other steps, are known in the art, and determine the type of the cheese, in particular with respect to taste.
Also optionally, a protective coating may be applied to the shaped cheese, either with or without a preceding brining step. Various protective coatings are know in the art, and may be applied. The protective coating may for instance be a cheese coating, by plastic, wax, oil or other suitable materials. The coating may comprise a packaging, for instance a plastic packaging. Multiple layers of protective coating may be applied, and various different protective coatings may be combined.
The ripening step allows the cheese to mature before being consumed. Ripening time and conditions depend on the cheese type and quality to be produced. Typically, the occurrence of cracks in the outer surface occurs in cheese during the ripening process.
Optionally, also other processing steps may be applied, for instance the application of spices and herbs to the cheese surface. It depends on the desired type of cheese to which further processing steps the shaped cheese may be subjected.
Quality tests, such as those provided in the Examples below, show that shaped cheeses according to this method are of superior quality compared to cheeses that are prepared in a single pressing step. The method is particularly valuable for the production of hard- and semi-hard cheese types.
It is postulated that in the described method, the mechanical stress occurring in the cheese mass during or after the forming of the shape, and in particular during the ripening process, is reduced compared to the direct pressing method, resulting in an improved cheese quality. Eventually, this leads to a lower percentage of cheeses that have to be rejected due to failed quality tests, or cheeses that are categorized at a lower quality level.
Preferably, the second shape is a derivative of the first shape. The method shows best results if the second shape requires relatively small deformation starting from the first shape.
It is preferred if the first shape has at least one sharp edge and the second shape is a derivative of the first shape, having at least one rounded edge replacing the sharp edge. In a one-step process, the transformation from a sharp edge to a rounded edge gives rise to an increased risk of crack formation, whereas in the two-step pressing process as described herein significantly less cracks are formed. Similarly, the method as described herein could be applied to the reverse transformation process wherein the first shape has at least one rounded edge and the second shape is a derivative of the first shape, having at least one sharp edge replacing the rounded edge.
In a preferred embodiment, the first shape is a rectangular shape having sharp edges, and the second shape is a rectangular shape having at least one rounded edge, preferably of the Bollewang type.
In another preferred embodiment, the first shape is a sharp-edged cylindrical shape, and the second shape is a rounded cylindrical shape or a domed shape, preferably of the Edam type.
It is advantageous if the pressure applied to the cheese curd in step b) is essentially homogeneous to retain the first shape, and wherein the pressure in step e) is essentially inhomogeneous in order to reform the first shape into the second shape.
In a preferred embodiment, the cheese mass obtained from the first pressing step is cut into two or more equally shaped cheese mass parts, wherein each separate cheese mass part is subjected to the second pressing step. A greater number of possible shapes for the final cheese product become easily accessible. For instance, a rectangular cheese mass could be divided in multiple smaller rectangular forms, or triangular forms, that could be pressed into their final forms in the second pressing step. Cutting the cheese mass after the first pressing step also leads to less losses when compared to cutting the cheese curd before the first pressing step, as after the first pressing step the cheese mass has an improved structural integrity and mechanical strength compared to the cheese curd.
In a preferred embodiment, the first pressing step is performed during a first pressing time, and the second pressing step during a second pressing time, wherein the first pressing step is longer than the second pressing step.
Good results are obtained when the first pressing step is performed during 40-120 minutes, and wherein the second pressing step is performed during 10-30 minutes.
The best quality is obtained when the first pressing step is preformed at a relatively low pressure, whereas the second pressing step is done at a second pressure, wherein the second pressure is higher than the first pressure pressing step. The pressure may be increased during each of the pressing steps.
Preferably, the first pressing step is performed at an increasing pressure over time, whereas the second pressing step is performed at an essentially constant pressure. More preferably, the first pressure is increased during the first pressing step.
It is preferred if the first pressing step is performed at a pressure increasing from 0-500 gr/cm2’ preferably increasing pressure over time, and wherein the second pressing step is performed at a pressure essentially above 400 gr/cm2. More preferably, the first pressing step is performed at a pressure increasing from 0-500 gr/cm2 over a period of 40-120 minutes, whereas the second pressing step is performed at a constant pressure essentially above 400 gr/cm2 during 10-30 minutes.
The invention further provides a shaped cheese obtainable through the method as Hesr.riheH h<=»rain
Preferably, the cheese is of the ‘Bollewang’ type having a rounded rectangular or flattened cylindrical shape.
The invention further provides a production line for performing the method as described herein, wherein the production line comprises - a cheese curd unit for producing cheese curd from milk, wherein the cheese curd is produced in cheese curd portions having a first shape, provided with transport means for transporting the cheese curd to a first pressing unit; - first pressing unit, provided with a first mould for pressing the cheese curd forming a cheese mass having the first shape; wherein the first pressing unit is provided with transport means to a second pressing unit; - second pressing unit provided with a second pressing mould for pressing the cheese mass into a shaped cheese having the second shape; provided with an exit to transport the shaped cheese away from the production line.
Preferably, the transport means between the first and second pressing unit comprises a switch, where in a first position of the switch, the transporting means transport the cheese mass to the second pressing unit, and where in a second position the transporting means transport the cheese mass to the exit.
BRIEF DESCRIPTION OF THE DRAWINGS DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be elucidated by the following non-restricting examples. Although the method is suitable and adaptable to many different kinds of cheese, it is particularly suitable for semi-hard or hard cheese types. "Semi-hard" and "hard" cheeses are understood to comprise a moisture fat-free content (MFFB) of 54 - 69 % and 49 - 56 %, respectively. The MFFB value equals 100% * weight of moisture in the cheese / (total weight of cheese - weight of fat in cheese). The invention is found particularly suitable for a semi-hard cheese of the well known Gouda type or Edam type. 1. Comparison of production methods
Starting from identical blocks of cheese curd, rectangular cheese with rounded edges, also known as the ‘Bollewang’ type is prepared according to two methods. In the first method A, the cheese curd is pressed directly into a mould adapted for obtaining the predetermined rounded shape. This method is known from NL9201812. In the second method B, the shape is obtained in a two-step process, wherein the cheese curd is subjected to a first press step in a sharp-edged rectangular mould, and then transferred to the mould adapted for obtaining the predetermined rounded shape for a second press step. The obtained cheeses are then further processed identically with a brine treatment, and the surface of the obtained cheese is visually inspected. 1.1 Method A (reference method, direct pressing)
In the reference method A, a block of cheese curd is introduced in a pressing mould adapted to produce a pressed cheese with dimensions 500x300mm, having rounded edges at the distal ends of the rectangle with a radius of 50mm. The cheese curd is pressed in four phases at different pressures.
Phase 1:15 minutes, 80 gr/cm2 Phase 2: 20 minutes, 160 gr/cm2 Phase 3: 10 minutes, 400 gr/cm2 Phase 4: 25 minutes, 440 gr/cm2
After the pressing, the obtained rounded rectangular cheese is treated with brine during 55 hours, in a brine bath having a strength of 18 °Be at 14°C. The strength of the brine is measured in degrees Baumé (°Be). For cheese making, brine having a strength of 18-20 °Be is used, containing approximately 180-200 g of sodium chloride salt per litre.
After the brine treatment, a cheese coating is applied to the cheese every 2 days, and visually inspected after 28 days of ripening. 1.2 Method B (two step pressing)
Method B, according to the method as described herein, is visualised in figure 1. Holes for pressing whey out of the mould are omitted for clarity. A block of cheese curd 1 is introduced in a fitting rectangular pressing mould 2 with dimensions 500x300mm, and a height of 100mm. The mould has sharp edges. In the first pressing step, the cheese curd 1 is compressed to a smaller volume in four phases at different pressures measured in gr/cm2, resulting in a rectangular block 3 of cheese mass. In this process, the cheese curd looses water to become a solid cheese mass 3.
Phase 1:15 minutes, 80 gr/cm2
Phase 2: 20 minutes, 160 gr/cm2 Phase 3: 10 minutes, 400 gr/cm2 Phase 4: 25 minutes, 440 gr/cm2
In the second press step, the cheese mass 3 is turned and transferred to a second pressing mould 4 with dimensions 500x300mm, having rounded edges at the distal ends of the rectangle with a radius of 50mm, identical to the mould used for the reference method A. In this rounded mould 4, a second pressing step is performed, which reshapes the sharp edges of the initial shape into a rounded rectangular shaped cheese 5.
Phase 5: 12 minutes, 480 gr/cm2
After the second shaping pressing step, the obtained rounded rectangular cheese 5 of the ‘Bollewang’ type is treated with brine during 55 hours, in a brine bath having a strength of 18°Be.
After the brine treatment a regular cheese coating is applied to the cheese every 2 days, and visually inspected after 28 days of ripening. 1.3 Comparison
Multiple samples prepared according to the reference method A and according to method B according to the invention, and visually inspected for irregularities. Results are presented in table I.
Table I: amount of irregularities, in particular cracks, in cheeses produced according to method A (reference) or B, using an amount of n samples. n cracked surface # %
Method A (reference) 19 18 95%
Method B 39 1 2%
It was determined that the majority (>95%) of the rounded cheeses according to the reference method A showed small cracks (2-10 mm) in the surface coating, whereas the rounded cheeses according to method B only showed such cracks in less than 2% of the tested samples. It can be concluded that, even though the product starting materials are the same, the round-edged cheese produced by method B has superior mechanical qualities over the reference products prepared by method A. 2. Alternative method
Figure 2 shows a schematic presentation of a variation on method B as described above. This illustrates that the method can be used to produce variously shaped cheeses, starting from a differently shaped block of cheese curd. Holes for pressing whey out of the moulds are omitted for clarity.
Figure 2 shows a cheese curd block 10, which is first introduced into a similarly shaped rectangular mould 11 adapted for producing a rectangular cheese block 12 having sharp edges. After being subjected to the first pressing step, a compressed rectangular cheese mass 12 is obtained, having sharp top and bottom edges. In this example, the block is divided by cutting according to cutting line 13, resulting into two identical rectangular cheese mass blocks 14. Each cut of cheese mass 14 is transferred to a second pressing mould for the second pressing step to yield the final cheese shape. In this case, a pressing mould having one rounded side was used, resulting in a half ‘Bollewang’ shape, but many alternative shapes could be used in a similar way.
In other alternative methods, other divisions and shapes could be used, such as cutting diagonally to yield two triangular blocks, or cross cutting two yield four rectangular or triangular cheese mass pieces. 3. Alternative shapes
Figure 3 shows a cylindrical cheese curd block 20, which is first introduced into a similarly shaped cylindrical mould 21. Holes for pressing whey out of the moulds are omitted for clarity. After being subjected to the first pressing step, a compressed cylindrical cheese shape 22 is obtained, having sharp top and bottom edges. The cylindrical cheese is then introduced into a rounded cylindrical mould 23. The inner dimensions of the mould 23, as indicated with the dotted line 24, are predetermined for the typical Edam cheese shape. After being subjected to a secondary pressure step in the rounded mould 23, a rounded cylindrically shaped cheese 24 is obtained. This shape may be subjected to further process steps, such as brine treatment, coating and ripening. This cylindrical shape has superior mechanical qualities compared to cheese directly obtained from a rounded mould. The shape as shown here could be used for the production of Edam cheese types. This is an example to illustrate that the method as described herein can be used to produce various cheese shapes of superior mechanical integrity.

Claims (15)

1. Werkwijze voor het vervaardigen van gevormde kaas uit kaaswrongel, omvattende de stappen: a) het verschaffen van kaaswrongel in een eerste vorm; b) het plaatsen van de kaaswrongel in een eerste persmal, waarbij de vorm van persmal overeenkomt met de eerste vorm; c) een eerste persstap, waarbij de kaaswrongel wordt geperst tot een kaasmassa met de eerste vorm; d) het plaatsen van de kaasmassa in een tweede persmal voor het verschaffen van een tweede vorm, anders dan de eerste vorm; e) een tweede persstap, waarbij de kaasmassa wordt geperst tot een gevormde kaas met een tweede vorm; f) optioneel het in contact brengen van de gevormde kaas met pekel gedurende een vooraf bepaalde pekeltijd; g) optioneel het rijpen van de gevormde kaas gedurende een vooraf bepaalde rijptijd.A method for manufacturing shaped cheese from cheese curd, comprising the steps of: a) providing cheese curd in a first form; b) placing the cheese curd in a first pressing mold, the shape of pressing mold corresponding to the first shape; c) a first pressing step, wherein the cheese curd is pressed into a cheese mass with the first shape; d) placing the cheese mass in a second pressing mold to provide a second mold, other than the first mold; e) a second pressing step, wherein the cheese mass is pressed into a molded cheese with a second mold; f) optionally contacting the formed cheese with brine for a predetermined brine time; g) optionally ripening the formed cheese during a predetermined ripening time. 2. Werkwijze volgens conclusie 1, waarbij de tweede vorm een afgeleide is van de eerste vorm.The method of claim 1, wherein the second form is a derivative of the first form. 3. Werkwijze volgens een van de voorgaande conclusies, waarbij de eerste vorm een rechthoekige vorm met scherpe randen is, en waarbij de tweede vorm een rechthoekige vorm is met ten minste één ronde rand, bij voorkeur van het Bollewang type.Method according to one of the preceding claims, wherein the first shape is a rectangular shape with sharp edges, and wherein the second shape is a rectangular shape with at least one round edge, preferably of the Bollewang type. 4. Werkwijze volgens een van de voorgaande conclusies, waarbij de eerste vorm een cilindrische vorm met scherpe rand is, en waarbij de tweede vorm een afgeronde cilindrische vorm is, bij voorkeur van het Edam type.Method according to one of the preceding claims, wherein the first shape is a sharp-edged cylindrical shape, and wherein the second shape is a rounded cylindrical shape, preferably of the Edam type. 5. Werkwijze volgens een der voorgaande conclusies, waarbij de druk toegepast op de kaaswrongel in stap b) in hoofdzaak homogeen is om de eerste vorm te behouden, en waarbij de druk in stap e) in hoofdzaak inhomogeen is om de eerste vorm te hervormen tot de tweede vorm.A method according to any one of the preceding claims, wherein the pressure applied to the cheese curd in step b) is substantially homogeneous to retain the first shape, and wherein the pressure in step e) is substantially inhomogeneous to reform the first shape into the second form. 6. Werkwijze volgens een der voorgaande conclusies, waarbij de kaasmassa verkregen uit de eerste persstap c) in twee of meerdere gelijkvormige kaasmassadelen wordt gesneden, waarbij elk afzonderlijk kaasmassadeel wordt onderworpen aan de tweede persstap e).6. Method as claimed in any of the foregoing claims, wherein the cheese mass obtained from the first pressing step c) is cut into two or more identical cheese mass parts, wherein each separate cheese mass part is subjected to the second pressing step e). 7. Werkwijze volgens een der voorgaande conclusies, waarbij de eerste persstap c) wordt uitgevoerd gedurende een eerste perstijd, en de tweede persstap e) wordt uitgevoerd gedurende een tweede perstijd, waarde de eerste persstap langer duurt dan de tweede persstap.A method according to any one of the preceding claims, wherein the first pressing step c) is carried out during a first pressing time, and the second pressing step e) is carried out during a second pressing time, if the first pressing step takes longer than the second pressing step. 8. Werkwijze volgens conclusie 7, waarbij de eerste persstap wordt uitgevoerd gedurende 40-120 minuten, en waarbij de tweede persstap wordt uitgevoerd gedurende 10-30 minuten.The method of claim 7, wherein the first pressing step is performed for 40-120 minutes, and wherein the second pressing step is performed for 10-30 minutes. 9. Werkwijze volgens een der voorgaande conclusies, waarbij de eerste persstap wordt uitgevoerd bij een relatief lage druk, en waarbij de tweede persstap wordt uitgevoerd bij een relatief hoge druk.A method according to any one of the preceding claims, wherein the first pressing step is carried out at a relatively low pressure, and wherein the second pressing step is carried out at a relatively high pressure. 10. Werkwijze volgens conclusie 9, waarbij de eerste druk wordt opgevoerd tijdens de eerste persstap.The method of claim 9, wherein the first pressure is increased during the first pressing step. 11. Werkwijze volgens een van de voorgaande conclusies, waarbij de eerste persstap wordt uitgevoerd bij een druk toenemend van 0-500 gr/cm2, en waarbij de tweede persstap wordt uitgevoerd bij een druk in hoofdzaak boven 400 gr.cm2.A method according to any one of the preceding claims, wherein the first pressing step is carried out at a pressure increasing from 0-500 g / cm 2, and wherein the second pressing step is carried out at a pressure substantially above 400 g / cm 2. 12. Gevormde kaas verkrijgbaar door de werkwijze volgens een der voorgaande conclusies.A molded cheese obtainable by the method according to any one of the preceding claims. 13. Gevormde kaas volgens conclusie 12, waarbij de kaas van het ‘Bollewang’ type is met een afgeronde rechthoekige vorm, of van het ‘Edam’ type met een afgeplatte cilindrische vorm.Shaped cheese according to claim 12, wherein the cheese is of the "Bollewang" type with a rounded rectangular shape, or of the "Edam" type with a flattened cylindrical shape. 14. Productielijn voor het uitvoeren van de werkwijze volgens een der voorgaande conclusies 1-11, waarbij de productielijn omvat - een kaaswrongel eenheid voor het produceren van kaaswrongel uit melk, waarde de kaaswrongel wordt geproduceerd in kaaswrongelporties met een eerste vorm, voorzien van transportmiddelen voor het transporteren van de kaaswrongel naar een eerste perseenheid; - een eerste perseenheid, voorzien van een eerste mal voor het persen van de kaaswrongel tot een kaasmassa met een eerste vorm, waarbij de eerste perseenheid is voorzien van transportmiddelen naar een tweede perseenheid; - een tweede perseenheid voorzien van een tweede persmal voor het persen van de kaasmassa met een tweede vorm, voorzien van een uitgang voor het weg transporteren van de gevormde kaas van de productielijn.A production line for performing the method according to any one of the preceding claims 1-11, wherein the production line comprises - a cheese curd unit for producing cheese curd from milk, where the cheese curd is produced in cheese curd portions with a first form, provided with transport means for transporting the cheese curd to a first pressing unit; - a first pressing unit, provided with a first mold for pressing the cheese curd into a cheese mass with a first mold, wherein the first pressing unit is provided with transport means to a second pressing unit; - a second pressing unit provided with a second pressing mold for pressing the cheese mass with a second mold, provided with an outlet for transporting the formed cheese away from the production line. 15. Productielijn volgens conclusie 14, waarbij de transportmiddelen tussen de eerste en tweede perseenheid een wissel omvatten, waarbij in een eerste positie van de wissel de transportmiddelen de kaasmassa naar de tweede perseenheid transporteren, en waarbij in een tweede positie de transportmiddelen de kaasmassa naar de uitgang transporteren.15. Production line according to claim 14, wherein the transport means comprise a switch between the first and second pressing unit, wherein in a first position of the switch the transport means transport the cheese mass to the second press unit, and wherein in a second position the transport means transport the cheese mass to the transport exit.
NL2011459A 2013-09-17 2013-09-17 Method for producing a shaped cheese and production line. NL2011459C2 (en)

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NL2011459A NL2011459C2 (en) 2013-09-17 2013-09-17 Method for producing a shaped cheese and production line.

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