Continuous Production of Analogue Cheese
19 December 2007 10:16
Cream cheese and pizza cheese are traditionally based on milk components but these can be substituted by other less expensive raw materials. Substitute and imitation cheese is commonly called analogue cheese. These cheese types use case in which is a milk by-product and vegetable oil in place of the expensive milk fat offering not only cost savings but also functional advantages. Today, many producers of analogue cheeses use a batch system which has certain disadvantages such as higher risk of post contamination of the final product. Trials on pilot scale show that it is an advantage to produce analogue cheese continuously on a consistator (a Scraped Surface Heat Exchanger (SSHE)) plant from Gerstenberg Schröder (GS) and that the system offers flexibility as it is possible to produce various kinds of analogue cheese on the same line.
In coorporation with customers recipes for cream cheese and pizza cheese have been tested in our pilot facilities with success.
PROCESS DESCRIPTION
Analogue cream cheese:
The mixture is supplied from the preparation area at approx. 50°C to the SSHE in which it is pasteurised at 85°C, held at the temperature and subsequently transferred to the homogeniser in which it is homogenised at 200 bars. If needed, the product can be cooled to approx. 67°C and diverted to the buffer tank for filling. If different kinds of species or fruit (e.g. pineapple) are part of the product specification, these can be added here or in a separate tank after homogenisation.
The objective of the thermal treatment is to prolong the shelf life of the product and by the swelling of the starch to give the desired consistency of the final product. The heat treatment up to 85°C for a certain time reduces the number of undesired micro-organisms.
The homogenising pressure is important for the final texture of cream cheese. If it is too high the texture gets to firm, while too low pressure results in an open texture. Quality requirements for cream cheese are a good spreadability and a creamy texture.
Analogue pizza cheese:
The production of analogue pizza cheese is almost identical to the process for cream cheese except that the homogenisation process is avoided. However, it is a more sophisticated process because the final texture of the product is highly affected by the temperature, time and shear. It is important to find the right balance between these parameters to get a product with the desired texture.
Typically, the product is heated from approx. 30 to 85°C and held at this temperature for a certain time. During this period, the gelatinisation of the protein occurs and a network is created. The melting salt creates a stable emulsion and improves the melting down properties of the final product. The shear in the SSHE is also essential for the final texture of the product, because it affects the final stringiness of the product.
After heating the product goes to a buffer tank for hot filling. As the cheese firms up at lower temperature, hot filling is required in order for the product to be workable when packed in sausage-shaped bags or bag-in-box.
To avoid colour change from white to reddish due to the Maillard reaction or browning fast cooling to approx. 10°C is required after filling. Quality requirements for pizza cheese are good shred properties, a good stringiness and good melting down properties.
For more information on this company:
Gerstenberg Schröder - Crystallised and Emulsified Food Processing Equipment
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