Method of manufacture of natural cheese

Abstract: A method for incorporating concentrated milkfat into milk to form a concentrated milkfat/milk blend is provided. The concentrated milkfat/milk blend can be used in the preparation of natural cheese. The method provides a cost effective procedure for blending concentrated milk fat and milk without the use of added stabilizers. Fat in the concentrated milkfat/milk blend does not separate during additional processing required in producing a natural cheese from the concentrated milkfat/milk blend. In this process, a reduced-fat milk is blended with concentrated milkfat at a temperature sufficient to melt the concentrated milkfat to form a slurry. The slurry is homogenized, preferably using an in-line jet homogenizer at a pressure of about 90 to about 225 psig [about 0.62 to about 1.55 MPa gauge] or a piston type homogenizer operated at a pressure of about 500 to about 1500 psig [about 3.45 to about 10.34 MPa gauge], to obtain the concentrated milkfat/milk blend with an average fat particle size of about 1.0 to about 10 microns and a fat particle size distribution such that at least about 90 percent of the fat particles have a particle size of about 1,0 to about 10 microns. The concentrated milkfat/milk blend can be used to prepared natural cheese using conventional cheese-making techniques.

Description: Field of The Invention The present invention relates to a method for manufacturing natural cheese. More particularly, the present invention provides a method for incorporating concentrated milkfat into milk which can be used in the preparation of natural cheese. The method of incorporating the concentrated milkfat into milk helps insure that loss of milkfat during manufacture of the natural cheese is minimized. Background Natural cheeses are produced by combining various, but specific, ingredients to produce a resultant cheese. Natural cheeses are generally made by developing acidity in milk and setting the milk with a clotting agent, such as rennet, or by developing acidity to the isoelectric point of the protein. The set milk is cut and whey is separated from the resulting curd. The curd may be pressed to provide a cheese block. Curing typically takes place over a period of time under controlled conditions. Natural cheeses do not contain added emulsifiers and/or stabilizers. Natural cheeses are distinct from processed cheeses, which are a cheese product manufactured by combining a natural cheese with other ingredients. Processed cheeses are produced by processing (e.g., grinding) natural cheese and then mixing the prepared natural cheese with emulsifying agents (e.g., emulsifying salts). Typically, the resulting mixture is heated and worked to produce a homogenous mass of processed cheese. Accordingly, a processed cheese is literally a natural cheese which has subsequently been processed. An important step in producing natural cheeses is to provide a milk/milkfat blend with a desired fat level. One method for providing such a milk/milkfat blend is to blend concentrated milkfat with milk to provide a blend with the desired fat level. Concentrated milkfat must be thoroughly mixed with milk and/or cream at proper ratios to prevent the occurrence of defects in the final cheese product. Further, a concentrated milkfat/milk blend must be mixed in a manner effective for preventing fat separation during additional processing steps. Prior to this invention, it has not been possible to use concentrated milkfat/milk blends to prepare natural cheeses. Regulations governing the production of natural cheeses preclude the use of stabilizers in the milk to prevent fat separation. Accordingly, a cheese-maker must rely on proteins normally present in the native milk to act as emulsifiers for any non-native fat added to the process. In this regard, native protein in the milk and non-native fat must be brought together under certain homogenization conditions to prevent fat separation during additional processing. Current methods for incorporating concentrated milkfat into a milk stream relies on the use of piston-type homogenization. Due to high pressures and moving parts, piston-type homogenizers are capital intensive and difficult to maintain. Moreover, it is difficult to consistently obtain particle size distributions similar to that of natural milk. It would be desirable, therefore, to provide less expensive methods to incorporate fat, especially milkfat, into milk for use in the manufacture of natural cheese. It would also be desirable, therefore, to provide methods to incorporate fat, especially milkfat, to provide milk substrates having particle size properties essentially the same as natural milk and which can be used in the manufacture of natural cheese. The present invention provides such methods. Example III of United States Patent No. 3899605 includes as test 5 a description of the preparation of an emulsion having a fat content of 30% by weight by mixing butter oil at 60°C with skim milk, followed by homogenization at 35°C at 5 MPa and then at 1 MPa, and then mixing with an unspecified amount of skim milk to give a cheese milk with a fat content of 3.0% by weight. The cheese obtained from this cheese milk is reported in Table A to be putty-like after 6 weeks and to have a rating after 3 months which is inferior to cheeses made from cheese milks in which the emulsion with a fat content of 30% is made using whey instead of skim milk. Milchwissenschaft, Vol. 52, 1997, pages 618 to 622, teaches the manufacture of Jben, Moroccan traditional fresh cheese, from properly recombined milk with normal (12.5%) or double the level (25%) of total solids using low or high-heat milk powders, or mixtures of fresh and recombined high-heat milk. A procedure for preparation of recombined milks is described which involves mixing reconstituted skim milk containing 9% or 18% total solids and anhydrous milkfat at a temperature of 35°C to 40°C, followed by pasteurization and double stage homogenization at 14 MPa and 3.45 MPa using a Manton Gaulin homogenizer (Type 125E) so as to form a recombined cream which is then mixed with reconstituted milks to form a recombined milk with a fat content of 3.5% or 7%. Such a recombined milk can also be mixed with fresh milk in a ratio of 75:25 or 25:75. The cheese milk in each case can be used to make Jben cheese. In Australian Journal of Dairy Technology, Vol. 54, 1999, pages 28 to 35, there is described the flavor development in full-fat cheddar-type cheeses made from skim milk homogenized with several vegetable fats. Experiments were performed with various fat substitutes and skim milk. The cheese manufacture in this study included the use of emulsifiers or butter milk powder prior to homogenization, and subsequent cheese manufacture. The results from this study revealed that cheddar flavor development in cheese was possible with anhydrous milk fat, but not with vegetable fats. SUMMARY The present invention is directed to a method for incorporating concentrated milkfat (generally greater than about 70 percent fat) into milk to form a concentrated milkfat/milk blend or substrate which can be used in the preparation of natural cheese. According to the present invention there is provided a method for incorporating concentrated milkfat into milk, the method comprising: (1) blending from 4 to 10 percent by weight of concentrated milkfat with 90 to 96 percent by weight of milk, preferably a milk with a fat content of 0.01 to 3 percent by weight, at a temperature of 125 to 145°F [51.7 to 62.8°C] sufficient to melt the concentrated milkfat to form a slurry; and (2) homogenizing the slurry using a jet homogenizer operated at a pressure of 90 to 225 psig [0.62 to 1.55 MPa gauge] or a piston type homogenizer operated at a pressure of 500 to 1500 psig [3.45 to 10.34 MPa] to provide a concentrated milkfat milk blend having fat particles with an average diameter of from about 1.0 to about 10 microns and with at least about 90 percent of the fat particles having a particle size of about 1.0 to about 10 microns, wherein the concentrated milkfat/milk blend is suitable for preparing a natural cheese which is substantially free of emulsifiers or stabilizers. The invention also provides a method for preparing natural cheese using a concentrated milkfat/milk blend, said method comprising: (1) preparing a concentrated milkfat/milk blend by a process as defined in the preceding paragraph; (2) pasteurizing the concentrated milkfat/milk blend; (3) cooling the pasteurized concentrated milkfat/milk blend to a temperature below 100°F [37.8°C]; (4) forming a standardized milk substrate by blending 25 to 50 percent by weight of the cooled and pasteurized concentrated milkfat/milk blend with 50 to 75 percent by weight of a pasteurized reduced-fat milk; (5) treating the standardized milk substrate to form curd and whey; (6) separating the curd and whey; and (7) treating the curd to form the natural cheese; wherein the natural cheese is substantially free of emulsifiers or stabilizers. The invention thus provides a cost effective method for blending concentrated milkfat and milk without the use of added stabilizers. This invention also provides a method for the production of natural cheese using a milk substrate prepared from a concentrated milkfat and milk blend. In an important aspect of the invention, the method is effective for providing a concentrated milkfat/milk blend or substrate where fat does not separate during additional processing required in producing natural cheese. The cost of milkfat, either in the form of cream (fat content of about 18 to 45 percent fat) or concentrated milkfat (fat content of greater than about 70 percent fat), can vary significantly through the year. Generally, the cost is lower in the first half of the year and higher in the second half. For example, the maximum cost of concentrated milkfat in the second half of the year is often as much as 50 percent higher than the minimum cost in the first half. Thus, it would be very advantageous to collect and store milkfat during period of low cost for use at other times of the year. Concentrated and frozen milkfat can be stored for extended periods (generally at least about 12 months), thereby making it an excellent vehicle for storing milkfat for later use. Unfortunately, it has not been possible to use such concentrated milkfat for preparing natural cheeses since stabilizers have been required to form milk substrates using concentrated milkfat. Since stabilizers are not allowed in natural cheese under the current Standards of Identity, it has not been possible to prepare natural cheeses using concentrated milkfat/milk blends. This present invention provides a method for preparing concentrated milkfat/milk blends without the use of added emulsifiers and/or stabilizers. Using such concentrated milkfat/milk blends, natural cheeses can now be prepared which are virtually identical to natural cheeses prepared from natural milk. Using this invention, milkfat can be collected and stored as concentrated milkfat during periods of low cost for later conversion to natural cheeses. Moreover, during periods of high milkfat cost, full-fat milk can be skimmed, the cream sold for other uses, and milkfat replaced using concentrated milkfat to produce a milk substrate that can be used to prepare natural cheeses, thereby increasing the overall efficiencies and economic return associated with the production of natural cheese. In one embodiment of the present invention which is generally illustrated in Figure 1, native fat in raw milk is reduced to provide a reduced-fat raw milk containing less than about 3 percent fat and preferably a skim milk containing about 0.05 to about 2 percent fat. The resulting cream can be sold as is or used in other products. A first portion of the reduced-fat raw milk is heated to about 125 to about 145°F [about 51.7 to about 62.8°C] and concentrated milkfat (or other fat), preferably in the form of relatively small particles, is added to the milk at a level of about 4 to about 10 percent to form a slurry. The slurry is maintaining at this elevated temperature until all of the concentrated milkfat has melted. The slurry is homogenized to obtain a concentrated milkfat/milk blend or substrate containing fat particles having an average particle size and a particles size distribution similar to natural milk. More specifically, the fat particles in the substrate have an average diameter of about 1.0 to about 10.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the substrate should have diameters of about 1.0 to about 10.0 microns. More preferably, the fat particles in the substrate have an average diameter of about 1.0 to about 5.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the substrate should have diameters of about 1.0 to about 5.0 microns. Preferably the homogenization is effected using a jet homogenizer, and more preferably an in-line jet homogenizer, at a pressure of about 90 to about 200 psig [about 0.62 to about 1.55 MPa gauge]. The resulting milkfat/milk blend may be used for the production of natural cheese using conventional procedures. More preferably, the resulting milkfat/milk blend, after pasteurization and cooling (preferably to below about 100°F [about 37.8°C]), is blended with additional pasteurized reduced-fat milk (also preferably cooled to below about 100°F [about 37.8°C]), in a final blending step to form a standardized blended substrate which is then used for the production of natural cheese. Preferably and as illustrated in Figure 1, the additional reduced-fat milk, preferably skim milk, is also obtained as a second portion of the reduced-fat milk treated in the separator. Preferably, the resulting standardized blended substrate formed in the final blending step contains about 25 to about 50 percent milkfat/milk blend (i.e., the first portion from the separator) and about 50 to about 75 percent reduced-fat milk (i.e., the second portion from the separator), and even more preferably, about 25 to about 35 percent milkfat/milk blend and about 65 to about 75 reduced-fat milk. Importantly, the fat droplet size of the resulting milkfat/milk blend and/or the standardized blended substrate, is sufficiently small such that fat loss is minimized during the manufacture of the desired natural cheese. Another embodiment of the present invention is illustrated in Figure 2, This embodiment differs from the first embodiment discussed above mainly in that the reduced-fat milk of portions 1 and 2 need not be taken directly from a cream separator and that the reduced-fat milk of portions 1 and 2 need not be taken from the same source and can, if fact, be different starting materials. Thus, for example, the reduced-fat milk starting materials for portions 1 and 2 can differ, if desired, in fat content; protein content, and the like. Like the first embodiment, the resulting standardized milk substrate can be used to prepare natural cheese using conventional cheese-making techniques. Brief Description of the Drawings Figure 1 provides a flow chart illustrating the general process of the present invention for producing a blended substrate using concentrated milkfat and reduced-fat milk. Figure 2 provides a flow chart illustrating the general process of the present invention for producing natural cheeses starting with whole milk. Figure 3 illustrates the fat particle size distribution in concentrated milkfat/milk blends prepared by the method of this invention as compared to the fat particle size distribution in a natural milk sample and an untreated concentrated milkfat/milk blend. Detailed Description The present invention is directed to a method for incorporating concentrated milkfat into milk to produce a concentrated milkfat/milk blend which has fat particle size characteristics is essentially identical to natural milk. The present invention is directed to a method for incorporating concentrated milkfat into milk to produce a concentrated milkfat/milk blend which has fat particle size characteristics is essentially identical to natural milk and which can be used in the preparation of natural cheese. The invention provides a cost effective method for blending concentrated milk fat and milk without the use of added stabilizers. This invention is also directed to a method for the production of natural cheese using a milk substrate prepared from a concentrated milkfat and milk blend. In an important aspect of the invention, the method is effective for providing a concentrated milkfat/milk blend where fat does not separate during additional processing required in producing the natural cheese. As used herein, the term "concentrated milkfat" describes a composition prepared by the separation of cream from milk to provide a dairy based composition which is at least about 70 percent milkfat. The concentrated milkfat may be fresh or provided as a frozen concentrate as described in U.S. Patent No. 6,096,352 (August 1, 2000) "Substantially free of emulsifiers" and/or "substantially free of stabilizers" are intended to denote compositions in which no significant amount of emulsifier, emulsifiers, stabilizer, and/or stabilizers have been added. Preferably, such a composition would contain less than about 2.5 percent emulsifier or stabilizer; and more preferably, less than about 0.1 percent emulsifier or stabilizer. Thus, conventional emulsifiers normally used to prepare process cheese such as, for example, disodium phosphate, trisodium phosphate, tripotassium citrate, trisodium citrate, and the like, are neither required or desired. Likewise, conventional stabilizers normally used to prepare concentrated milkfat/milk blends such as, for example, lecithin, mono- and diglycerides, polysorbates, sodium stearoyl lactylate, and the like, are neither required or desired. By avoiding the use of such emulsifiers and/or stabilizers, the cheeses produced using the concentrated milkfat/milk blend can be classified as natural cheeses under the current Standards of Identity. As used herein, the term "natural cheeses" refers to cheese that may be derived from the treatment of any dairy liquid or substrate that provides cheese curds upon renneting (regardless of whether it meets the current Standards of Identity) and which is substantially free of emulsifiers and/or stabilizers. Such liquids include whole milk, reduced fat milk, skim milk, and any such milk further containing added dairy fractions. Such dairy fractions may be chosen, by way of nonlimiting example, from cream fractions, concentrated milk fractions obtained, for example, by evaporation, diafiltration and/or ultrafiltration of milk, and comparably treated dairy liquids. The dairy liquid employed in the cheese making fermentation may further contain dried solid components of milk fractions, such as non-fat dry milk, cream solids, and the like. As used herein, "dairy liquid" relates to milk, milk products obtained by fractionating raw milk to provide a liquid fraction, or reconstituted solid milk fractions. For example, the milk may be treated to remove some or all of the butterfat, providing low fat milk or skim milk, respectively. Furthermore, whole milk, low fat milk, or skim milk may be concentrated by methods such as evaporation and/or ultrafiltration (with or without diafiltration) and the like. Evaporation provides dairy liquids containing a higher concentration of all the nonvolatile components, whereas ultrafiltration provides dairy liquids with a higher concentration of the components that are nonpermeable to the ultrafiltration membrane. In any case, the dairy proteins including casein and whey protein are included among the retained solids, such that their concentrations in the resulting liquids are increased. Furthermore any of the above dairy liquids may be evaporated to dryness, providing milk solids originating from whole milk, low fat milk, or skim milk. Any of these solids may be reconstituted by the addition of water or a suitable aqueous composition including milk or a milk fraction. Reconstitution of dry milk thus provides dairy liquids that in general may have a broad range of final concentrations of the component proteins, butterfat, and other components. All the above liquids are included in the designation of "dairy liquids" as used herein. Rennet is a generic term used in the field of dairy science and in the field of cheese making to designate an activity obtained from the lining of the stomachs of immature mammals that consume maternal milk. The natural function of rennet is to initiate the digestion of the milk in order to provide the nutrition contained in the milk protein to the young mammal. In cheese making, rennet is used to clot the dairy liquids, thereby forming cheese curd and whey. The term "renneting" relates to the process of treating a dairy liquid with a rennet to provide a cheese curd and whey. Synonyms for "renneting" include "curding ." "clotting," and "setting". As used in contemporary dairy science, "rennet" connotes the enzyme earlier called "rennin" and now termed "chymosin". Chymosin is a member of the family of proteases known as aspartyl endopeptidases. The method of this invention are generally illustrated in Figures 1 and 2. As shown in Figure 1, native fat in raw milk is reduced to provide a reduced-fat raw milk containing less than about 3 percent fat and preferably a skim milk containing about 0.05 to about 2 percent fat. The resulting cream (preferably containing greater than about 16 percent fat, and more preferably about 40 to about 45 percent fat) can be sold as is or used in other products. A first portion of the reduced-fat raw milk is heated to about 125 to about 145°F [about 51.7 to about 62.8°C] and concentrated milkfat (or other fat), preferably in the form of relatively small particles, is added to the milk at a level of about 4 to about 10 percent to form a slurry. Preferably, the concentrated milkfat, normally in the form of large blocks (e.g., about 25 to about 55 Ibs [about 11.34 to about 24.95 kg]) at a temperature of less than about 32°F [about 0°C], and more preferably less than about 0°F [about -17.8°C], is first ground to relatively small particles (e.g., on the order of about fraction of inches [a few mm] to a few inches [a few cm] in any one dimension)in order to increase the surface area to make melting easier. The amount of concentrated milkfat added will, of course, depend on the amount of milkfat desired in the final milk substrate. Generally, the amount of concentrated milkfat added to the first portion of the reduced-fat raw milk is about 4 to about 10 percent. The slurry is maintained at this elevated temperature until all of the concentrated milkfat has melted. The slurry is homogenized to obtain a concentrated milkfat/milk blend or substrate containing fat particles having an average particle size and a particles size distribution similar to natural milk. More specifically, the fat particles in the substrate should have an average diameter of about 1.0 to about 10.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the substrate have diameters of about 1.0 to about 10.0 microns. More preferably, the fat particles in the substrate have an average diameter of about 1.0 to about 5.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the substrate have diameters of about 1.0 to about 5.0 microns. The homogenization can be carried out with convention homogenizers so long as the desired particle size and particle size distribution can be achieved. Preferably the homogenization is effected using a jet homogenizer, and more preferably an in-line jet homogenizer, at a pressure of about 90 to about 200 psig [about 0.62 to about 1.55 MPa gauge]. The resulting milkfat/milk blend may be used for the production of natural cheese using conventional procedures. More preferably, the resulting milkfat/milk blend, after pasteurization and cooling (preferably to below about 100°F [about 37.8°C]), is blended with additional pasteurized reduced-fat milk (also preferably cooled to below about 100°F [about 37.8°C]), in a final blending step to form a standardized blended substrate which is then used for the production of natural cheese. Preferably and as illustrated in Figure 1, the additional reduced-fat milk, preferably skim milk, is also obtained as a second portion of the reduced-fat milk treated in the separator. Preferably, the resulting standardized blended substrate formed in the final blending step contains about 25 to about 50 percent milkfat/milk blend (i.e., the first portion from the separator) and'about 50 to about 75 percent reduced-fat milk (i.e., the second portion from the separator), and even more preferably, about 25 to about 35 percent milkfat/milk blend and about 65 to about 75 reduced-fat milk. Importantly, the fat droplet size of the resulting milkfat/milk blend and/or the standardized blended substrate, is sufficiently small such that fat loss is minimized during the manufacture of the desired natural cheese. Figure 2 illustrates another embodiment of the present invention. This embodiment differs from the first embodiment discussed above mainly in that the reduced-fat milk of portions 1 and 2 need not be taken directly from a cream separator and that the reduced-fat milk of portions 1 and 2 need not be taken from the same source and can, if fact, be different starting materials. Thus, for example, the reduced-fat milk starting materials for portions 1 and 2 can differ, if desired, in fat content, protein content, and the like. Like the first embodiment, the resulting standardized milk substrate can be used to prepare natural cheese using conventional cheese-making techniques. Importantly, the standardized milk substrate produced in this invention is similar in many respects to natural milk and can be used to prepare natural cheeses. More specifically, the standardized milk substrate produced in this invention has an average particle size and a particle size distribution similar to natural milk. More specifically, the fat particles in the standardized milk substrate should have an average diameter of about 1.0 to about 10.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the standardized milk substrate have diameters of about 1.0 to about 10.0 microns. More preferably, the fat particles in the standardized milk substrate should have an average diameter of about 1.0 to about 5.0 microns and a particle size distribution such that at least about 90 percent of the fat particles in the standardized milk substrate have diameters of about 1.0 to about 5.0 microns. The homogenization can be carried out with conventional homogenizers so long as the desired particle size and particle size distribution can be achieved. Preferably the homogenization is effected using a jet homogenizer, and more preferably an in-line jet homogenizer, at a pressure of about 90 to about 200 psig [about 0.62 to about 1.55 MPa gauge]. Examples of suitable jet homogenizers are provided in U.S. Patent 4,585,357 (April 29, 1986) and 5,958,495 (September 28, 1999). The ability of a homogenizer to reduce and control fat particle size is determined by the disruption of fat globules. The best measure and/or monitoring of this disruption is through controlling pressure generated within the homogenizer. In operation, the particle size and particle size distribution can be determined as a function of homogenization conditions in order to determine operating parameters to achieve the desired particle size and particle size distribution. For jet or impingement homogenizers (see, e.g., Example 1), fat globules are disrupted when two streams of substrate make contact with one another at high pressures and at a perpendicular angle. Because the angle is fixed, the only way to control particle size is to increase the velocity with which they make contact. Velocity is generated by a pump feeding liquid through the orifices of the homogenizer. The speed of the pump can be changed to generate different pressures, these different pressures are measured as back pressure at the inlet of the jet unit . Velocity can also be increased by reducing the number of orifices while maintaining the same overall flowrate through the homogenizer. This is accomplished but replacing one or more orifice nozzles with "plugs" to block flow and force fluid through a smaller overall cross-section of nozzle area. For Example 1, an APV Hydroshear 40 jet homogenizer was setup with a series of nozzles and plugs to produce 8 streams, and thus 4 impingement zones. The pressure can be controlled by changing the pump speed. For piston homogenizers (see, e.g., Example 2), fat globules are disrupted when a piston forces the substrate at high velocity through a small channel into a metal impact ring. Homogenization occurs as both mechanical energy from the piston and cavitational energy from high and low pressure zones are imparted on the fat globules. Pressure is controlled by changing the cross-sectional area of the channel the fat is forced through. Feed pressure and channel size should be held constant to maintain a steady homogenization. In Example 2, a two-stage piston APV Gaulin homogenizer with standard setup was fed with positive displacement pump at 60 psig [0.41 MPa gauge]. Both stages were used for homogenization. For the first stage, the channel was reduced to approximately 0.1 mm to generate about 500 psig [3.45 MPa gauge]; the second channel was closed until the total pressure reached 750 psig [5.17 MPa gauge]. At higher pressures of about 750 to about 1500 psig [about 5.17 to about 10.34 MPa gauge], both stages are also employed. At higher pressures, the channel on the first stage would be closed until 500 psig [3.45 MPa gauge] was generated, then the channel on the second stage was closed until the total desired pressure was reached. The concentrated milkfat/milk blends or substrates produced by the present invention can be used in a conventional cheese-making process to produce natural cheeses which are substantially free of emulsifiers and/or stabilizers. The following examples are intended to illustrate the invention and not to limit it. Unless otherwise indicated, all percentages and ratios are by weight. Example 1. This example illustrates the production of cheddar cheese using the process of this invention employing a jet or impingement type homogenizer. Raw whole milk (575 lbs [260.82 kg]; 3.8 percent fat, 3.2 percent protein, and 8.9 percent non-fat solids) was skimmed in a centrifugal separator to produce a reduced-fat milk (2.1 percent fat, 3.3 percent protein, and 9.2 percent non-fat solids). The reduced-fat milk (550 lbs [249.48 kg]) was heated in a plate-and-frame heat exchanger (Thermaline, Auburn, WA) to a temperature of 135°F [57.2°C] and transferred to a jacketed kettle (Viatic, Charlevoix, Ml) equipped with an impeller mixer (Braun, Holland, Ml) while maintaining the temperature at about 135°F [about 57.2°C]. Frozen concentrated milkfat (80 percent fat and 19 percent moisture; 55 lbs [24.95 kg] blocks) was size reduced to approximately ¼" x ¼" x 3" [6.35 mm x 6.35 mm x 76.20 mm] in an Extructor (Reetz, Santa Rosa, CA). The ground milkfat (48 lbs [21.77 kg]) was added to the heated reduced-fat milk (550 Ibs [249.48 kg]; ratio of about 1:9) using mixing to produce turbulent conditions throughout the jacketed kettle; approximately 0.001 percent food grade defoamer was added to reduce froth during agitation. The temperature of the slurry was about 125°F [about 51.7°C] once the ground milkfat was completely melted. The slurry composition was about 8.4 percent fat, about 3.0 percent protein, and about 8.4 percent non-fat solids. A Waukesha 30 positive-displacement pump (Waukesha, Delevan, WI) was used to force the slurry through an APV Hydroshear 40 impingement homogenizer (APV Gaulin, Everett, MA) at a flowrate of about 36 Ibs/minute [about 16.33 kg/minute] and a back pressure of about 160 psig [about 1.10 MPa]. The fat particles had an average particle size of about 5.3 microns after homogenization. The homogenized mixture was pasteurized at about 165°F (about 73.9°C] for about 15 seconds and then added to a 1000 lb [453.59 kg] double-O cheese vat (Damrow, Fond Du Lac, WI). The homogenized mixture was blended with a pasteurized reduced-fat milk (600 lbs [272.16 kg]; 2.0 percent fat, 3.3 percent protein, and 9.2 percent non-fat solids) at a ratio of 1:3 to produce a standardized milk substrate having 4.3 percent fat, 3.3 percent protein, and 9.0 percent non-fat solids. A cheddar cheese was prepared from the standardized milk substrate using the following procedure. The standardized milk substrate (900 lbs [408.23 kg]) was heated to about 88°F [about 31.1 °C] in a separate 1000 lb [453.59 kg] double-O cheese vat. A DVS Lactococcus lactis starter culture (70 g) (Chr. Hansen, Milwaukee, WI) was added, by 40 mL of an aqueous calcium chloride (40 percent) solution. After a 30 minute ripening period 60 mL of Chymax 2X rennet (Chr. Hansen, Milaukee, WI) was added to set the coagulum. After a 35 minute set, the coagulum was then cut. After 3 minute heal, the curd was cooked at 102°F [38.9°C] for 35 minutes followed by 30 minutes stirring without further heating. The cooked curd was pumped to a drain table where it was matted and cheddared for 3 hours. After draining, the cheddar curd was milled and salted at 0.025 Ibs salt/lbs curd [0.025 kg salt/kg curd]. The salted curd was hooped and pressed under 35 psig [0.24 MPa gauge] for 8 hours before vacuum packing in 40 lbs [18.14 kg] blocks. For comparison purposes, a control cheddar cheese was prepared using essentially the same procedure starting with a conventional milk substrate. The conventional milk substrate was prepared by blending pasteurized whole milk (1000 Ibs [453.59 kg]; 3.8 percent fat, 3.2 percent protein, and 8.9 percent non-fat solids) and pasteurized sweet cream (9 lbs [4.08 kg]; 43.9 percent fat; 1.8 percent protein, and 5.0 percent non-fat solids). The resulting conventional milk substrate had 4.2 percent fat, 3.2 percent protein, and 9.0 percent non-fat solids. The fat particles had an average particle size of about 4.8 microns. The following data was obtained for the inventive milk substrate and the conventional milk substrate: Control Milk Substrate Inventive Milk Substrate Fat (%) Protein (%) Fat (%) Protein (%) Milk 3.8 3.2 2.1 3.3 Sweet Cream 43.9 1.8 - - Milkfat Slurry - - 8.4 3.0 Standardized Milk Substrate 4.2 3.2 4.3 3.2 Whey (drain table) 0.65 - 0.69 - Whey (at pressing) 0.16 - 0.33 - Control Milk Substrate Inventive Milk Substrate Specific Surface Area (cm 2 /cm 3 ) 15,025 14,827 Median Diameter (µ) 4.15 4.43 Mean Diameter(µ) 4.84 5.34 Mean Diameter (µ) at percentage 10% 2.60 2.37 30% 3.35 3.30 50% 4.16 4.47 70% 5.44 6.37 90% 8.12 9.57 As shown in the above table, the milk substrate prepared by the inventive method was essentially equivalent to conventional milk substrates (e.g., reduced-fat milk standardized with cream) of comparable fat and protein contents used in cheese-making. For comparison purposes, a comparable unhomogenized milkfat slurry had median and mean diameters of about 59 and about 58 microns, respectively. The particle size distributions of the various samples are shown in Figure 3. The cheddar cheese prepared form the inventive substrate and the conventional substrate, after ageing 30 days, are comparable in organoleptic and other properties. Thus, cheeses can be prepared from reduced-fat milk standardized with concentrated milkfat which are comparable to cheeses prepared from conventional milk substrates (e.g., reduced-fat milk standardized with cream). Example 2. This example illustrates the production of cheddar cheese using the process of this invention employing a piston type homogenizer. Raw whole milk (2080 lbs [943.47 kg]; 3.6 percent fat, 3.3 percent protein, and 8.9 percent non-fat solids) was skimmed in a centrifugal separator to reduce a reduced-fat milk (2.0 percent fat, 3.3 percent protein, and 9.1 percent non-fat solids). The reduced-fat milk (2000 lbs [907.18 kg]) was heated and maintained in a jacketed double-O cheese vat (Damrow, Fond Du Lac, WI) at a temperature of 135°F [57.2°C] by circulating steam through the jacket. Frozen concentrated milkfat (80 percent fat and 19 percent moisture; 55 lbs [24.95 kg] blocks) was size reduced to approximately ¼" x ¼" x 3" [6.35 mm x 6.35 mm x 76.20 mm] in an Extractur (Reetz, Santa Rosa, CA). The ground milkfat (83 lbs [37.65 kg]) was added to the heated reduced-fat milk (2000 lbs [907.18 kg]; ratio of abut 1:25). Mixing provided by the double-O agitators kept the melted milkfat in suspension; approximately 0.001 percent food grade defoamer was added to minimize foam during agitation. The temperature of slurry was approximately 130°F [54.4°C] once the ground milkfat was completely melted. The slurry composition was 3.9 percent fat, 3.2 percent protein and 8.9 percent non-fat solids. A Waukesha 30 positive-displacement pump (Waukesha, Delavan, WI) was used to feed a Gaulin piston-type homogenizer 75DJF38BS (APV Gaulin, Everett, MA) at a feed pressure of 60 psig [0.41 MPa gauge]. The slurry was homogenized using both stages of the two-stage homogenizer, with the first stage generating a pressure of 500 psig [3.45 MPa gauge] and the second stage generating 250 psig [1.72 MPa gauge] for a total of 750 psig [5.17 MPa gauge]. The fat had an average particle size of 2.64 microns after homogenization. The homogenized mixture was pasteurized at 163°F [72.8°C] for 15 seconds and then added to a 1000 lb [453.59 kg] double-O cheese vat (Damrow, Fond Du Lac, WI). The homogenized mixture (330 lbs [149.69 kg]) was blended with a pasteurized reduced-fat milk (640 lbs [290.30 kg]; 2.0 percent fat, 3.3 percent protein and 9.0 percent non-fat solids) and pasteurized cream (30 lbs [13.61 kg]; 43.3 percent fat, 1.8 percent protein and 4.9 percent non-fat solids) to prepare a standardized milk substrate. The standardized milk substrate had the following particle size properties: Inventive Milk Substrate Specific Surface Area (cm 2 /cm 3 ) 25,545 Median Diameter (µ) 2.5 Mean Diameter (µ) 2.64 Mean Diameter (µ) at percentage 10% 1.60 30% 2.09 50% 2.51 70% 2.98 90% 3.83 The particle size distribution of the this sample is also shown in Figure 3. Using this standardized milk substrate, cheddar cheese was prepared using the same procedure as Example 1. The resulting cheddar cheese, after aging, had excellent organoleptic properties. Numerous modifications and variations in practice of the invention are expected to occur to those skilled in the art upon consideration of the foregoing detailed description of the invention. Consequently, such modifications and variations are intended to be included within the scope of the following claims.

Claims: A method for incorporating concentrated milkfat into milk, the method comprising: (1) blending from 4 to 10 percent by weight of concentrated milkfat with 90 to 96 percent by weight of milk at a temperature of 125 to 145°F [51.7 to 62.8°C] sufficient to melt the concentrated milkfat to form a slurry; and (2) homogenizing the slurry using a jet homogenizer operated at a pressure of 90 to 225 psig [0.62 to 1.55 MPa gauge] or a piston type homogenizer operated at a pressure of 500 to 1500 psig [3.45 to 10.34 MPa gauge] to provide a concentrated milkfat milk blend having fat particles with an average diameter of from about 1.0 to about 10 microns and with at least about 90 percent of the fat particles having a particle size of about 1.0 to about 10 microns, wherein the concentrated milkfat/milk blend is suitable for preparing a natural cheese which is substantially free of emulsifiers or stabilizers. A method according to claim 1, wherein the milk has a fat content of 0.01 to 3 percent by weight. A method for preparing natural cheese using a concentrated milkfat/milk blend, said method comprising: (1) preparing a concentrated milkfat/milk blend by a process according to claim 1 or claim 2; (2) pasteurizing the concentrated milkfat/milk blend; (3) cooling the pasteurized concentrated milkfatlmilk blend to a temperature below 100°F [37.8°C]; (4) forming a standardized milk substrate by blending 25 to 50 percent by weight of the cooled and pasteurized concentrated milkfat/milk blend with 50 to 75 percent by weight of a pasteurized reduced-fat milk; (5) treating the standardized milk substrate to form curd and whey; (6) separating the curd and whey; and (7) treating the curd to form the natural cheese; wherein the natural cheese is substantially free of emulsifiers or stabilizers.

Inventors: OSTERGAARD SCOTT T, SADOWSKY IV JOHN RICHARD, TROP SANDRA A, OSTERGAARD, SCOTT T., SADOWSKY IV, JOHN RICHARD, TROP, SANDRA A.
Applicants: KRAFT FOODS HOLDINGS INC, KRAFT FOODS HOLDINGS, INC.
Application year: 2001
Main classification: A23C19
IPC codes: A23C9, A23C19