CHEESE PRODUCTION

Pamella 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
4C
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
 Mildto extra sharp
 Orange color

 Undergoes a process called “cheddaring”

 According to the CFR
 Minimummilk 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