CHEESE PRODUCTIONPamella Wipperfurth

11April 2011

BSE 461

OVERVIEW

History of Cheese Basic Principles in Cheese Making Cheddar Cheese

Cheddarding Mozzarella cheese Processed cheese Limburger and Mimolette cheese

HISTORY OF CHEESE

Legend Began in the Middle east Form of sour milk

Archeologists have discovered 6000 BC cheese had been pretended from cow's

and goat's milk and put in big jars 2000 BC Egyptians grave wall painting showing

butter and cheese being made

HISTORY OF CHEESE

Romans Develop cheese making in to fine art

Light, weight survival food 7 x the protein 5 x the calcium 40-50 % fat (dry basis)

Greeks Odyssey (1200 BC) – Homer

Cyclops – was a goats milk cheese maker

HISTORY OF CHEESE IN WISCONSIN Over 160 years European immigrants

To preserve excess milk farmers would make cheese 1841 – First cottage industry cheese factory

Mrs. Anne Pickett 1858 – First cheese vat was obtained

John Smith 1859 – Full-scale cheese factory

Hiram Smith Today ~ 13,000 dairy farms with over 1.26 million

cows 90% milk produced is made into cheese at 138 plants 2.6 billion lbs of cheese a year 26% of all domestic cheese

BASIC PRINCIPLES IN CHEESE MAKING

Same for all natural cheese Coagulate or curdle the milk to form curds and

whey Curdles – the milk sours and forms acid curds

(natural spoilage process) Cheese is a controlled spoilage process

STEP 1 – MILK INTAKE

Milk is tested for quality and purity

Approximately 10 lbs of milk makes 1 lb of cheese

STEP 2 – STANDARDIZATION

Heat treated or pasteurized 72-73 C for 15-20

seconds Ensure product

safety and uniformity

Non-pasteurized milk cheese must be

ripened for at least 60 days at temperature not less than 4 C

STEP 3 – STARTED CULTURE AND COAGULANT

Starter cultures, or good bacteria are added to start the process.

They help determine the ultimate flavor and texture of the cheese.

Next, a milk-clotting enzyme called rennet is added to coagulate the milk, forming a custard-like mass.

ACIDIFICATION

Lowers the pH of the milk Starter culture

Bacteria feed on the lactose in the milk and produce lactic acid Mesophilic cultures – thrive at room temperature

Cheddar and Gouda Thermophilic cultures – heat-loving bacteria

Curd is cooked as high 132 C Swiss and Italian cheeses

COAGULATION

Converting the milk into curds and whey Casein proteins in the milk form a curd that

entraps fat and water Acid coagulation

cream and cottage cheese Enzyme coagulation

Lower moisture without excessive hardening Rennet

Made from the lining of the fourth stomach of calves Genetically engineered – produced by the fungus

Aspergillus niger

STEP 4 – CUTTING It's then cut into small

pieces separating the liquid

(whey) from the milk solids (curds)

Large curds are cooked at lower temperatures, yielding softer cheeses like Mascarpone and Ricotta

Curds cut smaller are cooked at higher temperatures, yielding harder cheeses like Gruyere and Romano.

STEP 5 – STIRRING, HEATING AND DRAINING

Cheesemakers cook and stir the curds and whey until the desired temperature and firmness of the curd is achieved.

The whey is then drained off, leaving a tightly formed curd.

CHEESE VAT

STEP 6 – CURD TRANSFORMATION

Different handling techniques transformed into the

many cheese varieties

STEP 7 –PRESSING

Pressing determines the characteristic shape of the cheese and helps complete the curd formation

Most cheeses are pressed in three to 12 hours, depending on their size.

STEP 8 – CURING Depending on the

variety and style of cheese, another step may be curing.

Curing is used for aged cheeses and helps fully develop its flavor and texture.

The cheese is moved to a room that is carefully controlled for required humidity and temperature and may be aged for up to 10 years.

VIDEO -CHEESE PRODUCTION Modern Marvels – Cheese

Start – 2:20- 7:18

CHEDDAR CHEESE

One of the worlds most well know cheeses Originated in Cheddar, England around the

1100s Semi-hard cows milk cheese

Mild to extra sharp Orange color

Undergoes a process called “cheddaring” According to the CFR

Minimum milk fat content of 50% (dry weight) Maximum moisture content of 39%

CHEDDARING PROCESS

Starts the same as most cheese making

Water is added heated under

constant string Heated to around

100 degrees Helps the curds to

starts melt together

CHEDDARING PROCESS

The water is drained off

Curds are pushed together Drain off more water

and whey

CHEDDARING PROCESS

Curds Are let to sit Then they are cut

and stacked up to press out liquid

CHEDDARING PROCESS

CHEDDARING PROCESS

CHEDDARING PROCESS

Cut into smaller pieces and put through a mill CHEESE CURDS

Curds are then salted, mixed and put into molds

Process makes for a mellower, less sour cheese as it ages

CHEDDARING MACHINE

CHEDDAR CHEESE –MECHANIZED PRODUCTION

MOZZARELLA CHEESE

Traditional made from water buffalo milk Semi-firm cheese non aged, rindless cheese Involves a step of heat-treating and

stretching the curds Most popular cheese in the US

COOKER-STRETCHER

COOKER-STRETCHER

COOKER-STRETCHER

MOZZARELLA MANUFACTURING

VIDEO -CHEESE PRODUCTION How It's Made: Mozzarella Cheese

Start – 0.30

http://www.youtube.com/watch?v=qlg7SaR5UQE

PROCESSED CHEESE

1915 - First processed cheese James L Kraft

Wanted a more consistent product with longer self life

Heat treated so ripening is completely halted Addition of emulsifying agents Mixing

ADVANTAGES OF PROCESSED CHEESE

Extended shelf-life Resistance to separation when cooked Uniform product Use of emulsifiers results in cheese that

melts smoother Cheaper to produce

Less expensive ingredients

TYPES PROCESSED CHEESE

Pasteurized Process Cheese Made for one or more cheese

Pasteurized Process Cheese Food Made from not less than 51% cheese Moisture <44% Fat content >23%

Pasteurized Process Cheese Spread Must to spreadable at 70 F Moisture between 44 and 60% Fat content >20%

VIDEO -CHEESE PRODUCTION Modern Marvels – Cheese

Start – 24:13- 26:00

LIMBURGER CHEESE

Produced in Monroe, Wisconsin Only plant in the US

Known as “ The Stinky German Cheese” Trappist Monks in Belgium

During aging the bricks are bathed repeatedly with brine of salt water and Brevibacterium linens Bacteria give the cheese yellowish-orange rind

and smell

MIMOLETTE CHEESE Made from Cow’s milk Best served when it aged for 18 months

Aging process weekly the cheese is turned cheese mites are brushed off which have been feeding

on it

PROCESS FLOW OF CHEESE PRODUCTION