Patent Description:
Typical natural cheeses have well known texture attributes. Processed cheese, such as American cheese, is a food product made from natural cheese with the addition of other ingredients such as emulsifiers, sodium citrate, calcium phosphate, sorbic acid, enzymes, cheese culture, vitamin D3, milk fat, extra salt, saturated vegetable oils, whey and/or artificial food colorings. Processed cheese has several advantages over natural cheese including resistance to oiling offs when heated and a uniform look and physical behavior. Disadvantages include an elevated amount of sodium and artificial ingredients.

<CIT> refers to a rapid manufacturing process for making a fat-containing stable dairy based food product.

<NPL> refers to a method for making cheese that combines the ultrafiltration of milk to produce a milk concentrate with the homogenization of the cream.

The present invention is as set out in the claims. Any embodiment not falling within the scope of the claims is included for illustrative purposes only.

The present invention includes a method for producing natural cheese with specific texture attributes including the steps of creating a stream of concentrated acidified milk by adding an acidulant to skim milk to reduce the milk pH and ultrafiltrating the acidified milk, creating a mineral reduced milk stream by re-blending a portion of the concentrate acidified milk with a diluent, creating a stream of cream having greater than <NUM>% milk fat, creating a stream of one of raw milk and skim milk, creating a stream of homogenized milk having between <NUM>-<NUM>% milk fat, combining the five streams and making natural cheese from the combined streams.

The present invention includes a natural cheese made from a natural cheese make process with an ingredient statement as that of a Standard of Identity cheese and having the following characteristics: moisture <NUM>-<NUM> %, fat <NUM>-<NUM>%, FDB <NUM>-<NUM>%, salt <NUM>-<NUM>%, pH <NUM>-<NUM>, calcium <NUM> to <NUM>/<NUM> grams of cheese and lactose <<NUM>%.

The cheese made from a natural cheese make process with an ingredient statement as that of a Standard of Identity cheese has the following characteristics: less stringiness, less oiling off, controlled melt behavior, smooth melt, and homogeneous melt.

Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:.

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of constructions and the arrangement of components set forth in the following description or illustrated in the drawings.

The invention relates to the production of natural cheese with specific texture attributes. The invention utilizes processes within the boundaries of conventional cheese make technology which allow for the tuning of natural cheese texture while maintaining an ingredient statement as that of a Standard of Identity cheese.

With reference to <FIG>, an embodiment of one method for making natural cheese with specific texture attributes is shown. The method is divided into split streams relating to calcium reduction for melt behavior for example and relating to controlled homogenization for restricted oiling off for example. As shown in <FIG>, for example, a total of five streams are produced and recombined, however, other numbers of streams can also be utilized.

In stream <NUM>, raw milk is separated and an acidulant, such as lactic acid, is added to reduce the skim milk pH. Other acidulants, such as using a CO<NUM> injection, can also be utilized. The pH is reduced to between <NUM> and <NUM>, more particularly reduced to between <NUM> to <NUM> and, more particularly reduced to <NUM>. Following pH adjustment, the acidified skim milk is ultra-filtrated, as is known in the art, to concentrate the acidified skim milk to <NUM>-<NUM>-fold, more particularly to <NUM>-<NUM> fold, and more particularly to <NUM>.

In stream <NUM>, a portion of the concentrated acidified milk is re-blended with water to produce a mineral reduced milk stream. The resultant stream will have reduced mineral contents such as calcium and phosphorus.

In stream <NUM>, the raw milk is separated to produce cream with greater than <NUM>% milk fat, more particularly in the range of <NUM>-<NUM>%, and more particularly <NUM>%.

In stream <NUM>, raw milk is standardized to between with between <NUM>-<NUM>% milk fat, more particularly to between <NUM>-<NUM>% milk fat, and more particularly to <NUM>% milk fat. After the desired milk fat is obtained, the stream is then homogenized, as is known in the art.

In <FIG>, the streams can be combined in equal or differing percentages to form a unified stream that enters the pasteurization step as will be set forth in more detail below.

Turning now to <FIG>, a second embodiment of a method for making natural cheese with specific texture attributes not according to the claimed invention is shown.

Streams <NUM>, <NUM> and <NUM> are the same as described above with respect to <FIG>. Stream <NUM> is composed of skim milk. In stream <NUM>, raw milk is standardized to between with between <NUM>-<NUM>% milk fat, more particularly to between <NUM>-<NUM>% milk fat, and more particularly to <NUM>% milk fat. After the desired milk fat is obtained, the stream is then homogenized, as is known in the art.

The streams can be combined in the same or differing percentages to form a unified stream that enters a pasteurization step. Examples of various percentages for the seven streams described in <FIG> and <FIG> is as follows:.

The total amount demineralized protein prior to milk standardization is preferably in the range of <NUM>-<NUM>%, and more particularly in the range of <NUM>-<NUM>%, of total proteins in the vat. The total amount of homogenized fat is preferably in the range of <NUM>-<NUM>%, and more particularly <NUM>%, prior to milk standardization. The milk concentration factor is preferably approximately <NUM> - <NUM>, and more particularly <NUM>. The target protein:fat ratio in the final milk is preferably around <NUM>-<NUM>, and more preferably <NUM>-<NUM>. Preferably, these are the parameters that determine the ratios of each stream to the vat.

Unacidified skim milk concentrates can also be utilized to satisfy the standardization requirements such as amount of demineralized proteins, protein: fat ratio, and milk concentration factor as can be seen in example CT <NUM> (stream <NUM>). Lactose powder (Stream <NUM>) is added to compensate the lactose removal as a result of ultrafiltration as well to aid in acid development during the cheesemaking (CT5 V1 to V3). Portion of cream is added with lipolytic enzyme prior to homogenization to generate lipolytic flavor in the final cheese (Stream <NUM> in CT4 V4).

After pasteurization, the cheese make process proceeds as is known in the art. Additional lactic acid can be added after pasteurization to bring the pH of cheese milk down in the range of <NUM>-<NUM>, and more specifically around <NUM>-<NUM>.

The results of the method shown in <FIG> and <FIG> include tailored texture attributes including controlled breakdown of the cheese structure and controlled melting and oiling off in particular. Further attributes include reduced stringiness, reduced oiling off, smooth melt, slightly adhesive, mild flavor, creamy, less acidic, and slightly lipolytic.

The natural cheese produced from the method disclosed herein preferably has the following compositional characteristics:.

The cheese made according to <FIG> and <FIG> can also be tuned to add flavors. For example, a flavor can be added by blending a flavor ferment into the curd after salting and prior to pressing.

Examples CT1-CTS. An overview of five different example formulations for making a natural cheese is set forth in Table <NUM> and Table <NUM>.

The mineral composition of Stream <NUM> in the examples is given in Table <NUM>. The reduction of calcium and phosphorus achieved by ultrafiltration at pH <NUM> and dilution to starting volume with water is approximately <NUM>% and <NUM>% compared to the starting skim milk.

In Example CT1, the cheese make process was designed to achieve a composition and mimic processing for Monterey Jack type cheese as follows:.

Processing times for Examples CT1-CT4 are set forth in Table <NUM>.

In the Examples, calcium and phosphorus reduction in cheese is obtained when using at total of <NUM>% of demineralized split stream <NUM> and <NUM> to raise the concentration factor of the milk to <NUM>, reducing milk pH prior to milk-ripening to pH <NUM> with lactic acid and at a starter dosage of 25U/<NUM>. A pre-ripening time of <NUM> minutes and salting at pH of <NUM> contributed to the effective mineral reduction. In addition to the reduced mineral content in the split stream, the short make time and low pH in the final cheese contributed to additional calcium and phosphorus reduction. See Table <NUM>.

Cheese firmness is measured instrumentally under cold conditions (refrigerator, shredding/slicing temperature) and melting properties were measured by two empirical tests, modified Schreiber test for melt area and the extent of oiling-off. The data is summarized in Table <NUM>.

The calcium content of the final cheese influences the hot functionality of the cheese such as melt behavior. Despite higher extent of demineralization, cheeses spread less upon melting than the reference cheeses with normal calcium and phosphate content at near identical moisture content.

Partial homogenization is effective to reduce the extent of oiling-off, compared to the reference cheese and to other variants without homogenized cream. See for example relative thickness of oil and oiling off results of CT2 Vatl-<NUM> (<FIG> and <FIG>). Vat <NUM> and vat <NUM> had <NUM>% of fat homogenized, vat <NUM> and vat <NUM> non-homogenized. Referring to <FIG>, the upper pictures show shreds before heating, the lower pictures after heating. Oil exudation can be observed as dark zone around the melted cheese.

To assess cold functionality, the firmness (stress at fracture) and shortness (strain at fracture) is measured by uniaxial compression test. Data are given in Table <NUM>. Fracture stress is translated to firmness and fracture strain to shortness. The firmness of the cheeses differed from around <NUM> kPa to <NUM> kPa and it appeared to be most strongly correlated with moisture contents. The level of calcium in cheese was not found to be related to firmness. Fracture strain, shortness (= opposite to long/elastic) appeared to be correlated with calcium content of the cheese while pH appeared not to influence the fracture strain.

With respect to cold functionality, the results of the instrumental compression-fracture measurement are in line with sensory perceived firmness of the cheeses.

With respect to hot functionality, with regard to melt area (modified Schreiber test), the amount of spread is comparable with that the targeted processed cheese counterparts.

With respect to oiling-off, the effect of emulsion properties is pronounced in the oiling-off behavior as shown in <FIG>.

In one example, the cheese milk standardized with the various streams according to the one process has the following characteristics: Protein:fat = <NUM>, protein content = <NUM> % (i.e., concentration factor <NUM> compared to normal milk with <NUM> % protein), lactose content = <NUM>% (CT5/vat <NUM>), i.e., a dilution by <NUM> % compared to starting milk (<NUM> % lactose), proportion of demineralized protein (retentate + diluted retentate) is <NUM>% of total protein in the standardized cheese milk, and the proportion of homogenized fat is <NUM>% of total fat in the standardized cheese milk.

The natural cheeses produced had the following approximate composition: moisture content <NUM> - <NUM>%, NaCl content <NUM> %, fat content <NUM>% and pH - <NUM>. The calcium and phosphorus content of these cheeses is reduced by approximately <NUM>% and <NUM>% respectively, compared to a reference cheese.

To evaluate the cheese melting properties analytically, temperature sweeps by oscillating small strain rheology were conducted. This methodology relates to the dynamic changes in the ratio between a system's elastic/solid and viscous/liquid behavior (tan δ = G"/G'), as function of temperature. For comparison purpose, a commercially procured sample of Monterey Jack was also evaluated against the cheeses. Parameters used for the evaluations are described in Table <NUM>.

The visco-elastic behavior upon heating to <NUM> and cooling was markedly different from a standard natural cheese (Monterey Jack), and approached that of processed cheese. As can be seen in Table <NUM>, the Tan δmax (heat) was highest in the natural cheese sample whereas, the Tan δmax (heat) was comparatively low for the processed cheese sample. The Tan δmax (heat) for all the test cheeses ranged from <NUM> to <NUM>. CT5 cheeses are less fluid-like and assumingly more cohesive than the natural cheese. The cross-over temperature was found to be typically higher for processed cheeses. The processed cheeses achieved liquid-like properties only at comparatively higher temperature, compared to the natural cheeses. See <FIG> and <FIG>. Cheeses CT5 are closest to the behavior of the processed cheese, notably in the cooling trajectory between <NUM> and <NUM>.

With respect to <FIG>, temperature sweep experiment (from <NUM>-<NUM>: Heating) of cheeses CT5 @<NUM> weeks, processed cheese (<NUM> different lots) and Monterey Jack (MJ) @<NUM> weeks by small strain oscillating rheology. Tan δ (G"/G') is given as function of temperature (avg of n=<NUM> for CT5 samples, average of <NUM> lots n=<NUM> for processed cheese, average of n=<NUM> for Monterey Jack.

With respect to <FIG>, temperature sweep experiment (from <NUM>-<NUM>: Cooling) of cheeses CT5 @<NUM> weeks, processed cheese (<NUM> different lots) and Monterey Jack (MJ) @<NUM> weeks by small strain oscillating rheology. Tan δ (G"/G') is given as function of temperature (avg of n=<NUM> for CT5 samples, average of <NUM> lots n=<NUM> for processed cheese, average of n=<NUM> for Monterey Jack). The box indicates the temperature range during cooling which is relevant from consumption point of view.

The rheological analysis indicates differences in molecular assembly of the fat-filled protein matrix of the processed cheese and that of the texture-tuned cheeses of CT6. The processed cheese attains fluid-like character at higher temperatures (T crossover heating <NUM> higher) and maximum Tan δ remains approx. <NUM>% lower (indicating a higher cohesivity).

Claim 1:
A method for producing natural cheese said method including the steps:
creating a stream of concentrated acidified skim milk by adding an acidulant to the skim milk to reduce the milk pH and thereafter ultrafiltrating the acidified skim milk;
creating a calcium reduced skim milk stream by re-blending a portion of the concentrate acidified skim milk with a diluent;
creating a stream of cream having greater than <NUM>% milk fat;
creating a stream of raw milk or skim milk;
creating a stream of homogenized milk having between <NUM>-<NUM>% milk fat;
combining the five streams; and
making cheese from the combined streams by conventional cheese make technology.