Cream cheese manufacturing method

Abstract

The present invention provides a method for producing cream cheese, the method comprising: (i) providing cheese curds; (ii) providing a whey protein solution by blending a sweet rennet whey solution and an acid whey solution, the sweet rennet whey solution being present in a greater amount by weight than the acid whey solution; (iii) concentrating the whey protein solution by ultrafiltration to a whey protein concentration of 5 to 15% by weight, based on the weight of the concentrated whey protein solution; (iv) subjecting the concentrated whey protein solution to a cavitation treatment sufficient to heat the concentrated whey protein solution to a temperature of at least 70° C. to provide a heat-treated whey protein solution; (v) mixing the cheese curds with the heat treated whey protein solution to form a mixture; (vi) subjecting the mixture to a texture-building heat treatment to form a cream cheese; The whey in the whey protein solution provided in step (ii) comprises whey from the sweet rennet whey solution and whey from the acid whey solution.

Description

[Technical Field]

[0001] The present invention relates to a method for producing cream cheese. In particular, it relates to providing cream cheese with a desirable smooth texture. The method allows for the production of cream cheese directly from a so-called "thin whey" source without an evaporation step. [Background technology]

[0002] Cream cheese is a soft cheese made from ingredients including milk and cream, and is generally spreadable. It is also generally mild in taste, although flavorings can be added to impart specific flavors, such as garlic cream cheese. Cream cheese can include single cream cheese and double cream cheese. Cream cheese is also typically offered in various fat contents, such as full fat, low fat, and extra light.

[0003] Cream cheese has been enjoyed for many years in many settings around the world. While cream cheese can be used in many different culinary applications as desired by consumers, it is most commonly used on bagels, in salads, as an ingredient in flavored spreads, frostings, and cheesecakes, and as an ingredient in various culinary recipes such as pasta and traybakes. A variety of different methods for making cream cheese have been developed and used over the years. Most of these methods typically involve adjusting cream and milk to a specific fat:protein ratio, followed by pasteurization, fermentation, coagulum formation, stirring, centrifugation, ultrafiltration, or cloth filtration to obtain sour whey and concentrated curd, and finally blending the concentrated curd with cream, heating, adding stabilizers and / or gums as needed, and packaging the cream cheese. EP 2649884 discloses a known method for producing cream cheese.

[0004] Although stabilizers and additives can be incorporated into cream cheese mixtures, it is generally not desirable to have many additives in cream cheese because consumers prefer cream cheese with more natural products and minimal amounts of additives.

[0005] One of the challenges surrounding the production of cream cheese in plants that produce a variety of different types of dairy products is that there are often waste streams of whey protein solutions produced from these processes, including the sweet whey protein waste stream from the hard cheese making process. Addressing this is important for the environmental sustainability of the production of foods like cream cheese.

[0006] These waste streams often contain valuable ingredients that can be used in other dairy products and are usually produced at certain points in the production of other cheese or dairy products. In particular, various cheese-making processes result in side streams of sweet whey (also known as rennet whey) and / or acid whey (also known as sour whey), which can be produced in varying amounts and concentrations at different stages of the cheese or other dairy product production process.

[0007] When one or more side streams of whey protein solution are produced, they generally need to be used within a short time, preferably when they are produced.If the whey protein solution is not used promptly, large storage tanks are required to store the solution at low temperatures, or the solution must be discarded, which is wasteful.In addition, using the waste stream of whey protein solution can reduce costs for manufacturers, since these components can be obtained at a significantly lower cost than the alternative of purchasing the components and transporting them to a plant.

[0008] In a preferred process for producing cream cheese, the cream cheese mixture is subjected to a texture-building heat treatment step used to build a creamy texture during cream cheese production. EP 2649884 describes a texturing step performed by heating and shearing the mixture, for example, at temperatures between 65 and 90°C. This texturing step is performed on a mixture of cheese curd and whey protein concentrate. Prior to the texture-building step, the whey protein concentrate is heat-treated to denature the whey proteins. This heat treatment step has generally been performed using any conventional heating means. The heat treatment step is described in EP 2649884 as S6-1 or S6-2 and is usually performed with simultaneous homogenization.

[0009] Before the texture building process can occur, the whey proteins that form the whey protein concentrate (WPC) must be functionalized. Functionalization is achieved by applying thermal energy for a specific time (e.g., 80°C with a 2-minute hold time) to reach the desired degree of denaturation of the whey proteins. Traditionally, this is done in a batch process using ubiquitous heating devices such as double-jacketed tanks. This usually presents challenges in ensuring the desired denaturation range is not exceeded, especially with larger batches during large-scale production.

[0010] The functionalization of WPC is well known and is discussed in various patents (U.S. Pat. No. 7,579,029 B2, U.S. Pat. No. 8,349,379 B2, and EP Pat. No. 1698231 B1) that focus on the functionalization of WPC from sweet rennet whey. Such functionalized WPC is also described in EP Pat. No. 2649884 B1 and U.S. Pat. No. 9,775,366 B2.

[0011] Continuous processes for functionalizing whey protein concentrates (e.g., scraped surface heat exchangers) exist on the market, but generally suffer from severe scaling of the equipment and protein buildup due to the reactivity of whey proteins.

[0012] Various other heating methods are known in the art. These include batch, short-time, or high-temperature pasteurization. Autoclaves can also be used to heat milk. A combined heating and homogenization process involves forcing the mixture through small openings under high pressure while simultaneously heating to a predetermined temperature. These methods have been used extensively in cream cheese manufacturing processes.

[0013] Cavitation is generally known in the art as a method of providing heat treatment. The cavitation process generally involves heating, mixing, and atomizing a solution, and is known as an alternative heating method for dairy-containing mixtures. US Patent Application Publication No. 20180249733 discloses a process for microparticulating ideal whey protein using a cavitation device to produce a microparticulated ideal whey protein preparation with a creamy and rich texture. In particular, the microparticulated ideal whey protein preparation is used in milk or dairy-based products such as cheese, yogurt, and quark.

[0014] WO 2022 / 157611 discloses a method for producing cream cheese. It would be desirable to provide a method for producing cream cheese that has lower energy costs and minimizes problems associated with excessive waste streams. It would therefore be desirable to provide cream cheese with improved or equivalent texture that can be obtained at lower energy costs and / or to address at least some of the problems associated with the prior art or at least provide a commercially viable alternative. [Prior art documents] [Patent documents]

[0015] [Patent Document 1] European Patent No. 2649884 [Patent Document 2] U.S. Patent No. 7,579,029 [Patent Document 3] U.S. Patent No. 8,349,379 [Patent Document 4] European Patent No. 1698231 [Patent Document 5] US Patent Application Publication No. 2018 / 0249733 [Patent Document 6] International Publication No. 2022 / 157611 Summary of the Invention

[0016] According to a first aspect, there is provided a method for producing cream cheese, the method comprising: (i) providing cheese curds; (ii) providing a whey protein solution by blending a sweet rennet whey solution and an acid whey solution, wherein the sweet rennet whey solution is present in a greater amount by weight than the acid whey solution; (iii) concentrating the whey protein solution by ultrafiltration to a whey protein concentration of 5 to 15 wt. % based on the weight of the concentrated whey protein solution; (iv) subjecting the concentrated whey protein solution to a cavitation treatment sufficient to heat the concentrated whey protein solution to a temperature of at least 70°C to provide a heat-treated whey protein solution; (v) mixing the cheese curds with the heat-treated whey protein solution to form a mixture; (vi) subjecting the mixture to a texture-building heat treatment to form a cream cheese; A method is provided wherein the whey in the whey protein solution provided in step (ii) comprises whey from the sweet rennet whey solution and whey from the acid whey solution.

[0017] The present invention will now be further described. In the following sections, different aspects of the present invention are defined in more detail. Each aspect so defined can be combined with one or more other aspects, unless a different definition is explicitly stated. In particular, any feature indicated as being preferred or advantageous can be combined with any other feature or features indicated as being preferred or advantageous.

[0018] Cream cheese production generally relies on the use of a concentrated whey stream, which produces a whey protein concentrate (WPC) that is combined with cheese curds in a further process step to make cream cheese. These WPCs are generally made in a process that involves the use of an evaporator. Evaporators are known to be an unreliable component of the standard cream cheese making process, and therefore, it is desirable to find a process that can address the loss of this critical component on the production line.

[0019] The present inventors have discovered a method for producing cream cheese from a so-called "thin whey" source. That is, the cream cheese is made without prior concentration of the whey source. The method does not require the use of an evaporator to concentrate the whey source or the whey protein solution (obtained by blending the whey sources). This helps avoid the need for significant pieces of equipment that can be out of service for extended periods of time. This is particularly important when dealing with whey streams obtained from other cheese-making processes, such as hard cheese production, because the whey stream needs to be used quickly to avoid having to be discarded.

[0020] The present inventors have attempted to use various different whey sources to make cream cheese, relying on ultrafiltration as an alternative approach to concentrate the protein content of whey protein solution.Ultrafiltration is desirable because it is a conventional component of cream cheese production system.However, the present inventors have found that if conventional heat treatment process is used to functionalize the whey protein concentrate obtained by ultrafiltration, the subsequent texture construction process is too long and not commercially viable.

[0021] The inventors have unexpectedly found that the unconcentrated whey protein concentrate described herein can be used as an ingredient in cream cheese by using a cavitation treatment sufficient to heat the whey protein solution to a temperature of at least 70° C. In particular, it has been found that the inclusion of a cavitation step to heat an ultrafiltration-concentrated whey protein solution unexpectedly results in a heat-treated whey protein solution that is suitable for use in a texture-building heat treatment step to develop and build a creamy texture.

[0022] Thus, the present inventors have discovered that specific whey protein blends can be used that are useful for rapid texturization when functionalized with a new cavitation approach. This combination of specific whey protein blends, ultrafiltration concentration, and cavitation provides cream cheese with desirable physical properties that can be produced with a relatively short texturization step. This means that a commercially viable process can be provided that does not rely on a functioning evaporator (or the associated time and cost of operating it). This process avoids the need for a pre-concentration step for any of the constituent whey protein sources.

[0023] Furthermore, the process of the present invention provides a smoother cream cheese, even though the whey stream has not been subjected to a prior evaporation step. This is particularly surprising because the same whey protein solution, when subjected to a conventional functionalization process (i.e., heat rather than cavitation), does not result in a desirable cream cheese. Instead, conventional functionalization results in a less sweet cream cheese with an undesirable grainy texture.

[0024] The use of cavitation devices is not conventional in cream cheese manufacturing. However, in unpublished UK Patent No. 2100677.0, filed January 19, 2021, the inventors provided an alternative method using cavitation technology to functionalize concentrates. This process requires the use of ideal whey, obtained by microfiltration of milk. This, combined with an evaporator for whey concentration, generally addresses the problem that the presence of ideal whey, when functionalized with conventional heating methods such as those in EP 1698231(B1), does not texture or build the desired creamy texture and mouthfeel. That is, the inventors discovered that conventional heat-treated whey protein concentrates (WPCs) containing ideal whey cannot be used in texture-building methods such as those disclosed in EP 2649884.

[0025] According to the invention of the unpublished British Patent No. 2100677.0, a compression process was described in which a whey protein solution was obtained by microfiltration, sweet whey obtained from rennet cheese production, sweet whey concentrate obtained by evaporation (from either ideal whey or rennet whey), and acid whey obtained by separation techniques in cream cheese production. These whey streams were the direct products of the combined process, and therefore the process minimized its by-products. The whey protein level was sufficiently high based on the use of ideal whey material and the concentrated whey stream.

[0026] When this whey protein solution is subjected to mechanical and thermal energy by hydrodynamic cavitation, a functionalized whey protein concentrate that is surprisingly compatible with the texturing process is obtained. However, the invention in unpublished British Patent No. 2100677.0 requires the use of a concentrated whey protein source and therefore generally relies on an evaporator. In contrast, the present invention does not involve an evaporator, or indeed, does not involve an ideal whey component.

[0027] The present invention relates to a method for producing cream cheese. As noted above, cream cheese is a soft cheese made from ingredients including milk and cream, and is generally spreadable and mild in taste.

[0028] Cream cheese can be sold in a variety of fat contents. For example, widely available cream cheese ranges are full-fat, low-fat, and extra-light cream cheese. Lighter cream cheeses tend to rely on the addition of more proteins, gums, and stabilizers to retain their desirable creamy texture.

[0029] The method involves providing a cheese curd. Cheese curds suitable for making cream cheese are well known in the art. Cheese curds are coagulated solids obtained when milk is acidified with a bacterial culture or rennet. This production process also produces a sour (also known as acid) whey solution that can be used as a starting material for the methods described herein.

[0030] Preferably, the cheese curd is obtained by a process comprising providing a dairy liquid containing cream, milk (either raw or pasteurized and homogenized processed milk), and microfiltered milk concentrate; fermenting the dairy liquid to form cheese curd and acid whey; and separating the cheese curd from the acid whey by ultrafiltration. Preferably, sour whey can be used as the acid whey solution in step (ii). This is the most efficient method for producing the desired curd for use in cream cheese production. More preferably, the fermentation is by mesophilic fermentation. Optionally, the dairy liquid can also be pasteurized and homogenized prior to the fermentation step.

[0031] Dairy liquid means a liquid derived from milk or its components. In particular, dairy liquids contain fractions containing milk and / or cream components. Preferably, dairy liquids contain mainly cream and, optionally, milk protein concentrates.

[0032] Preferably, the dairy liquid is prepared by separating milk into cream and skim milk; The method is achieved by microfiltering skim milk to produce a microfiltered milk concentrate as a retentate and a sweet ideal whey as a permeate, and mixing the cream and microfiltered milk concentrate with milk to form a dairy liquid. This method is a reliable method for producing a dairy liquid with the desired properties for cream cheese production. This process provides a microfiltered milk concentrate that is desirable for making cheese curds.

[0033] The method includes the further step of providing a whey protein solution. Whey is the liquid remaining after coagulating a dairy liquid and then draining it. Coagulation is typically achieved by adding rennet or lactic acid to the dairy liquid to coagulate the casein and separate it into clumps. Whey protein is typically produced as a by-product of cheese or casein production and has several commercial uses. In cream cheese production, coagulation is achieved using a culture that generates lactic acid, naturally coagulating the milk solution. In the case of cream cheese, the dairy liquid is typically a protein-enriched cream, and the protein is provided as a milk concentrate.

[0034] Preferably, the whey protein solution is provided at room temperature, more preferably at a temperature below 10° C. This is optimal for the stability of the whey protein solution.

[0035] There are various types of whey protein solutions, including acid whey and sweet whey. These classifications are generally determined by the pH and how they are obtained. Sour whey has a pH of about 4.7, e.g., 4.4 to 4.9, while sweet whey has a more neutral pH (about 6.5, e.g., 6.3 to 6.8).

[0036] Sweet whey can be further classified as sweet rennet whey, a by-product resulting from the manufacture of rennet-type hard cheeses such as Cheddar and Swiss cheese. This is also known as "rennet whey." Rennet is added to coagulate milk, and the resulting liquid solution is a sweet whey solution with a near-neutral pH (about 6.5, e.g., 6.3-6.8) due to the production of either no acidification or only very mild acidification. In sweet whey produced using rennet, whey proteins may be somewhat denatured.

[0037] Another type of sweet whey protein is ideal whey. Ideal whey is whey containing undenatured or "native" whey proteins. It is generally obtained by filtering milk through an appropriately sized membrane. Ideal whey obtained from filtering milk is free of somatic cells, lactic acid bacteria, bacteriophages, rennet remnants such as caseinomacropeptide, and cheese fines that may be present in sweet rennet whey obtained from the cheese-making process. Ideal whey is also not acidified, and therefore has a near-neutral pH of about 6.5, e.g., 6.3-6.8.

[0038] Acid whey (also known as sour whey) is a by-product in the production of acidic dairy products such as cottage cheese or strained yogurt. Acid whey is acidic because lactic acid is used to coagulate the milk, and therefore the pH of the whey protein solution is lowered to produce acidic / sour whey (e.g., about 4.7, e.g., 4.4-4.9). In acid whey, the whey proteins may be somewhat denatured.

[0039] The whey protein solution in this method is provided by blending a sweet rennet whey solution with an acid whey solution. The whey in the whey protein solution consists of whey from the sweet rennet whey solution and whey from the acid whey solution. That is, the whey protein solution does not contain any added ideal whey. The sweet rennet whey solution is from the hard cheese making process, i.e., as a by-product. Using whey from the hard cheese making process also advantageously allows for the use of by-products that would otherwise be discarded during the production of hard cheese.

[0040] Preferably, the whey protein solution comprises acid whey from fermenting dairy liquid, preferably dairy liquid used to produce cheese curd. The use of acid whey from the process of fermenting dairy liquid (to make cheese curd and sour whey) is beneficial because it allows this by-product to be used in cream cheese production rather than being discarded. The use of acid whey can also add beneficial flavor notes and be used to adjust product pH.

[0041] The sweet rennet whey solution is present in a greater amount (by weight) than the acid whey solution. The amount (by weight) includes the amount of water present, but because the solutions are not concentrated, they typically have similar levels of solids content. That is, preferably, the sweet whey is also present in a greater amount, on a dry solids basis, than the acid whey.

[0042] Preferably, the weight ratio of sweet whey solution to acid whey solution blended in step (ii) is 6:4 to 9:1, preferably 7:3 to 8:2. Similarly, this amount (by weight) includes the amount of water present, but because the solutions are not concentrated, they typically have similar levels of solids content. Preferably, the sweet whey is present in a weight ratio of 6:4 to 9:1, preferably 7:3 to 8:2, on a dry solids basis, to the acid whey of step (ii).

[0043] Preferably, the whey protein solution has a solids content of 3-10% by weight, preferably 4-8% by weight, and most preferably about 6% by weight. Preferably, the sweet rennet whey solution and the acid whey solution each have a solids content of 3-10% by weight, preferably 4-8% by weight, and most preferably about 6% by weight. These levels of solids are consistent with those naturally occurring in the process from which they are obtained, minimizing the need for additional processing.

[0044] The method includes the further step of concentrating the whey protein solution by ultrafiltration to a whey protein concentration of 5-15% by weight, based on the weight of the concentrated whey protein solution. This step of concentrating the whey protein solution reduces the water content in the solution, enabling the subsequent texture-building heat treatment step (vi). Furthermore, this step also preferably removes lactose and minerals that are soluble in aqueous solutions. In step (ii), the whey protein solution is concentrated, preferably by ultrafiltration, to a whey protein concentration of 10-12% by weight, based on the weight of the concentrated whey protein solution.

[0045] Preferably, the whey protein solution, when first formed, has a pH of 5.7 to 6.1. This is the optimal pH range for whey protein solutions to solubilize minerals to the desired extent. If these are not removed, the ultrafiltration process may not function as well. This is achieved by providing a blend of acid whey and sweet whey, as these values ​​lie between their natural values. Citric acid can be added to further adjust the pH.

[0046] Typically, sweet rennet whey and acid whey solutions used in cream cheese production have a whey protein content of 0.5-1.2% by weight, preferably 0.6-1% by weight. Therefore, the ultrafiltration step concentrates it approximately 20-fold to reach the desired whey protein concentration of 10-12% by weight. Concurrently with concentrating the whey, the ultrafiltration process removes lactose and mineral content. Therefore, further increasing the whey content is associated with a reduction in lactose content.

[0047] Increasing the whey protein content is important to achieve the desired microstructure when this type of protein is heated and sheared. However, maintaining a sufficiently high level of lactose is also important because it helps protect the protein from heat damage during the functionalization and texturization steps. Increasing the whey content to 10-12 wt% means that the lactose content is approximately 60 wt% of the WPC solids. Increasing the whey content to 15 wt% means that the lactose content is approximately 20 wt% of the WPC solids. Beyond this point, the whey protein is not adequately protected from subsequent heating steps.

[0048] This is also important for increasing the solids concentration by ultrafiltration before the cavitation step, helping to allow the cavitation to heat the whey protein solution sufficiently. The concentrated whey protein solution preferably has a solids content of 18-24% by weight. Of these solids, 25-75% by weight, preferably 40-60% by weight, and preferably about 55% by weight, is whey protein. Preferably, the total protein content is 8-14% by weight, more preferably 10-12% by weight. This is the optimal solids content of the whey protein solution to obtain cream cheese with the desired creamy texture.

[0049] Preferably, the pH of the concentrated whey protein solution is then adjusted prior to the cavitation step to obtain a final pH of 4.5 to 5.1. The preferred pH of the whey protein solution prior to being subjected to the cavitation step (iv) is 4.6 to 5.0, and even more preferably about 4.8. Adjustment of the pH of the concentrated whey protein solution can be achieved either by the addition of citric acid or by fermentation with lactic acid bacteria, but is preferably achieved by the addition of citric acid. Because the whey protein solution is composed using sweet whey and acid whey, the acid whey acts to lower the pH, and less, if any, citric acid is required.

[0050] The method further includes subjecting the concentrated whey protein solution containing ideal whey to a cavitation treatment sufficient to heat the whey protein solution to a temperature of at least 70°C to provide a heat-treated whey protein solution. The cavitation step is particularly advantageous in heat-treating the whey protein solution in a specific manner, which allows the whey protein solution (along with other ingredients) to develop a creamy texture in the subsequent texture-building heat-treatment step (vi). Cavitation can be carried out according to the teachings of U.S. Patent Application Publication No. 2018024973, which is incorporated herein by reference in its entirety.

[0051] Preferably, the cavitation treatment is sufficient to heat the whey protein solution to a temperature of 75° C. to 90° C., preferably 80 to 85° C. This is the ideal temperature to which the whey protein solution should be heated to be compatible with the texture-building heat treatment step (vi).

[0052] The method further comprises mixing the cheese curd with the heat-treated whey protein solution to form a mixture. Mixing can be performed using a stirrer, shaker, rotating device, or other commonly used means for mixing ingredients. Preferably, mixing the cheese curd with the heat-treated whey protein solution is performed by homogenization.

[0053] Preferably, the heat-treated whey protein solution is added to the cheese curd at a weight ratio of heat-treated whey protein solution to cheese curd of 1:19 to 2:3, preferably 1:15 to 1:5, which is optimal for the subsequent texture-building heat treatment step to obtain cream cheese with a desirable creamy texture.

[0054] The method further comprises subjecting the mixture to a texture-building heat treatment to form the cream cheese. Such a method preferably comprises heating the mixture to a temperature of 65-90°C while shearing for at least 15 minutes. Such a process is described in more detail in EP 2649884, the entire contents of which are incorporated herein by reference.

[0055] Preferably, the method further includes filling the cream cheese into packaging, preferably directly from the texture-building heat treatment. Filling the cream cheese into packaging directly from the texture-building heat treatment allows the liquid cream cheese (i.e., liquid because it is still warm) to be easily poured into the packaging and allowed to set within the packaging, rather than having to be cut into slices to be packaged, which is more efficient. The cream cheese is then preferably cooled in a cooling chamber for at least 12 hours prior to sensory evaluation. The cream cheese is then shipped for sale within a few days or weeks.

[0056] Preferably, the step of combining the cheese curd and the heat-treated whey protein solution to form a mixture further comprises adding one or more additional ingredients selected from the group consisting of milk solids, salt, stabilizers, and gums, which can help impart a longer shelf life to the cream cheese.

[0057] Preferably, the method is a continuous process from subjecting the whey protein solution to the cavitation treatment to forming the cream cheese. Having steps (iii)-(v) be a continuous process is advantageous because it allows for maximum efficiency in the use of equipment and does not require a storage medium to hold the mixture for significant periods between steps.

[0058] Preferably, in the methods described herein, no evaporation steps are performed on either the sweet rennet whey solution, the acid whey solution, or the whey protein solution.

[0059] According to a further aspect, there is provided a cream cheese obtainable by the methods described herein. The cream cheese obtained by this method is unique and distinguishable from other cream cheeses. In particular, it has a smaller particle size when examined under a microscope due to the cavitation process and a more uniform texture as a result of the texture building step.

[0060] Preferably, the cream cheese contains less than 33% by weight total solids. The present method advantageously allows cream cheese to be produced at less than 33% by weight total solids while still having a creamy mouthfeel and texture, which allows more cream cheese to be produced per given amount of solids. This range distinguishes cream cheese produced with a texture-building process from cream cheese that is not produced with such a process. For example, full-fat cream cheese may have 32.5% by weight total solids when made with a texture-building process, but about 37% by weight when not using a texture-building process. Light cream cheese may have 26% by weight total solids when made with a texture-building process, but about 35% by weight when not using a texture-building process.

[0061] Preferably, the cream cheese is a full fat cream cheese having a fat content of less than 63% by weight.

[0062] Whey protein concentrate can then be incorporated into the final cream cheese in varying amounts to obtain cream cheeses with different fat contents. In particular, full-fat cream cheeses can be made with 6-8% whey protein concentrate by weight of the cream cheese. Light cream cheese products have 10-14% whey protein concentrate by weight of the cream cheese, and extra-light cream cheese products have 35-40% whey protein concentrate by weight of the cream cheese product. By incorporating more whey protein concentrate into the cream cheese, less fat can be present in the final product while still developing a creamy texture during the texture-building heat treatment step.

[0063] In one embodiment, the product is a full-fat cream cheese, and 6-8% by weight of the product is WPC. The WPC is 23% solids by weight, of which 50-60% by weight is protein. In another embodiment, the product is a light cream cheese, and 10-14% by weight of the product is WPC. The WPC is 23% solids by weight, of which 50-60% by weight is protein. In another embodiment, the cream cheese is an extra-light cream cheese, and 35-40% by weight of the product is WPC. The WPC is 23% solids by weight, of which 50-60% by weight is protein.

[0064] Cream cheese quality can be measured using the Stevens Firmness Test (Cold), which should have a value of about 100g, and certainly at least 80g. The Cold Stevens Firmness Test is performed using a Texture Analyzer and involves measuring the peak force required to puncture the cream cheese product with a conical 45° probe. [Brief explanation of the drawings]

[0065] The invention will now be described with reference to the following non-limiting figures. [Figure 1]1 shows a flow chart of a prior art method for producing cream cheese. [Figure 2] 1 shows a flowchart of the method described herein. DETAILED DESCRIPTION OF THE INVENTION

[0066] 1, milk 205 and cream 210 are mixed in mixing unit 215. A mixture 220 of milk 205 and cream 210 is then sent to pasteurization / homogenization unit 225 where mixture 220 is subjected to pasteurization and homogenization.

[0067] The resulting pasteurized mixture 230 is sent to a fermentation unit 235 where the pasteurized mixture 230 is fermented with added cultures.

[0068] The fermented mixture 240 is then sent to a curd thickening unit 245 where the sour whey 250 is removed and the curd 255 is sent to a blending unit 280. The curd thickening unit 245 may also be referred to as a separator.

[0069] Whey protein concentrate 270 and additional ingredients 275 are added to a mixing unit 280 and mixed with the curd 255. Additional ingredients 275 include additives and stabilizers.

[0070] Whey protein concentrate 270 comprises heat-treated acid and sweet whey and has a solids level of 20-25% by weight, approximately half of which is whey protein. Whey protein concentrate 270 is obtained by providing a concentrated whey protein solution 260 containing sweet whey and sour whey and passing whey protein solution 260 to heating and homogenization unit 265, where whey protein solution 260 is subjected to a process of homogenization with simultaneous heating to denature the whey proteins.

[0071] The heated, homogenized mixture 270 is then mixed with curd 255 and other additional ingredients 275 in a mixing unit 280 to provide a combined mixture 285. The combined mixture 285 is sent to a texture-building heat-processing unit 290, where the combined mixture 285 is heated to a temperature of 65-90°C, preferably about 80°C, with shearing for at least 15 minutes to provide a cream cheese product 295.

[0072] The cream cheese product 295, while still hot, is then sent to packaging equipment 300 and packaged into containers.

[0073] 2, raw milk 5 is provided and subjected to a process 10 to pasteurize and / or homogenize the raw milk 5 and provide processed milk 15 suitable for cheese making.

[0074] A first portion 15.1 of the processed milk 15 is sent to a centrifuge 20 to separate the skim milk 25 from the cream 30.

[0075] The skim milk 25 is sent to a microfiltration unit 35 where the microfiltered milk concentrate 40 is retained as a retentate. The retentate is primarily a casein-rich concentrate.

[0076] The microfiltered milk concentrate 40, cream 30, and second portion 15.2 of the processed milk 15 are sent to a mixer 70 to form a dairy liquid 75. The dairy liquid 75 is then pasteurized and homogenized in a pasteurization and homogenization unit 77. The resulting pasteurized and homogenized dairy liquid 79 is then sent to a fermenter 80, which ferments the dairy liquid to form a mixture 85 of cheese curds 95 and acid whey 100.

[0077] The mixture 85 is sent to a concentration unit 90 for ultrafiltration to separate cheese curds 95 from the acid whey 100 .

[0078] Acid whey 100 and sweet whey 50 (from the hard cheese making process) are mixed together in mixing unit 105 to form whey protein solution 110. Whey protein solution 110 is sent to ultrafiltration unit 115 to concentrate the protein content of whey protein solution 110 to produce concentrated whey protein solution 120.

[0079] The pH of concentrated whey protein solution 120 is adjusted to 4.8-4.9 by the addition of citric acid, and then sent to cavitation device 125, where concentrated whey protein solution 120 is subjected to a cavitation treatment sufficient to heat the solution to a temperature of at least 70°C, preferably about 80°C, to provide heat-treated whey protein solution 130.

[0080] The concentrated, heat-treated whey protein solution 130 and cheese curd 95 are mixed in a mixer 135 to form a first mixture 140. The first mixture 140 is sent to a pasteurization and homogenization unit 145, where the mixture is subjected to pasteurization and homogenization to produce a pasteurized and homogenized first mixture 150. The pasteurized and homogenized first mixture 150 is then sent to a texturization unit 155, which subjects the mixture 150 to a texture-building heat treatment process that includes heating the mixture 150 to a temperature of 65-90°C while shearing for at least 15 minutes. This process then provides a cream cheese 160.

[0081] The cream cheese is then filled into packages while still warm in a filling step 165.

[0082] The invention will now be described with reference to the following non-limiting examples. [Example]

[0083] Example 1 Milk, cream, and microfiltered milk concentrate were blended to produce a dairy liquid containing 15% solids, 5.5% fat, 4% protein, and 4.5% lactose. The dairy liquid was pasteurized, homogenized, and subjected to mesophilic fermentation with lactic acid bacteria at 20°C to a final pH of 4.8-5.0. After stirring the formed coagulum, it was separated into concentrated curd and whey using membrane ultrafiltration with a concentration factor of 2.2-2.5. The curd was blended with whey protein concentrate.

[0084] Whey protein concentrate was produced by mixing the following streams to a total of 100% by weight: - in an amount of 25% by weight of acid whey having a total solids content of 6.0% obtained from the centrifugal separation of fermentation curd and whey in the cream cheese process; - Sweet whey concentrate obtained from hard cheese production of 6.0% total solids in an amount of 75% by weight.

[0085] The blend obtained from these two streams was subjected to ultrafiltration to obtain a concentrated whey solution (WPC) with 20.3% solids and 11.8% protein content.

[0086] The WPC was subjected to hydrodynamic cavitation at 81°C (end temperature) with a degree of denaturation of 75% before being mixed with the curd.

[0087] A comparative batch was prepared by mixing another portion of the same curd with another portion of the same whey protein concentrate after standard heat treatment (i.e., heat treatment instead of cavitation) to a degree of denaturation of 79.0%.

[0088] The mixture of both the curd and their respective whey protein additives was then further processed in a separate manner using pasteurization and homogenization to form a dairy liquid which was then textured in a final creaming step.

[0089] The final product has 26% dry matter, 11.0% fat, 7.4% protein, 5% lactose.

[0090] There is a significant difference in texturing performance. Despite a similar degree of modification, the cavitation process provides a composition in which texture building begins much sooner. This makes the process much more economically viable, as a product can be produced in a fraction of the time.

[0091] It is particularly noted that the inventive examples reach a higher maximum viscosity (i.e., 3600 cP vs. 2800 cP). Furthermore, it is noted that the comparative product only reaches 2000 cP after 165 minutes, whereas this is achieved in 30 minutes for the inventive compositions.

[0092] Unless otherwise stated, percentages herein are on a weight basis.

[0093] As used herein, "solids" refers to the material remaining after all water has been removed. Thus, a solution containing 20% ​​solids by weight will also contain the remainder (i.e., 80% by weight) of water.

[0094] Although preferred embodiments of the invention have been described in detail herein, those skilled in the art will recognize that modifications can be made without departing from the scope of the invention or the appended claims. The present invention provides, for example, the following items. (Item 1) 1. A method for producing cream cheese, the method comprising: (i) providing cheese curds; (ii) providing a whey protein solution by blending a sweet rennet whey solution with an acid whey solution, wherein the sweet rennet whey solution is present in a greater amount by weight than the acid whey solution; (iii) concentrating the whey protein solution by ultrafiltration to a whey protein concentration of 5 to 15 wt. % based on the weight of the concentrated whey protein solution; (iv) subjecting the concentrated whey protein solution to a cavitation treatment sufficient to heat the concentrated whey protein solution to a temperature of at least 70°C to provide a heat-treated whey protein solution; (v) mixing the cheese curds with the heat-treated whey protein solution to form a mixture; (vi) subjecting the mixture to a texture-building heat treatment to form the cream cheese; The method of claim 1, wherein the whey in the whey protein solution provided in step (ii) consists of whey from the sweet rennet whey solution and whey from the acid whey solution. (Item 2) Item 2. The method according to item 1, wherein the whey protein solution in step (ii) has a solids content of 4 to 8% by weight. (Item 3) 3. The method according to claim 1, wherein the concentrated whey protein solution has a solids content of 18 to 24% by weight. (Item 4) The method of any preceding item, wherein the sweet rennet whey solution and the acid whey solution each have a solids content of 3 to 10% by weight, preferably 4 to 8% by weight. (Item 5) 3. The method of any preceding item, wherein the weight ratio of the sweet rennet whey solution to the acid whey solution blended in step (ii) is 6:4 to 9:1, preferably 7:3 to 8:2. (Item 6) The method of any preceding item, wherein no evaporation step is performed on either the sweet rennet whey solution, the acid whey solution, or the whey protein solution. (Item 7) The method of any preceding item, wherein in step (ii), the whey protein solution is concentrated by ultrafiltration to a whey protein concentration of 10 to 12 wt. % based on the weight of the concentrated whey protein solution. (Item 8) 3. The method according to any preceding item, wherein after step (ii) and before step (v), the pH of the whey protein solution is adjusted by fermentation with lactic acid bacteria or by addition of citric acid to obtain a pH of 4.5 to 5.1, preferably 4.8 to 4.9. (Item 9) The cheese curds Providing a dairy liquid comprising cream, microfiltered milk concentrate, and milk; fermenting the dairy liquid to form the cheese curds and acid whey; and separating the cheese curd from the acid whey by ultrafiltration. (Item 10) The dairy liquid Separating the milk into cream and skim milk; microfiltering the skim milk to produce a microfiltered milk concentrate as a retentate and an ideal whey as a permeate; and mixing the cream and microfiltered milk concentrate together with the milk to form the dairy liquid. (Item 11) 11. The method of claim 9 or 10, wherein the whey protein solution comprises acid whey from fermenting the dairy liquid. (Item 12) The method of any preceding item, wherein the cavitation treatment is sufficient to heat the whey protein solution to a temperature of between 75°C and 90°C. (Item 13) The method of any preceding item, wherein the texture-building heat treatment comprises heating the mixture to a temperature of 65°C to 90°C with shearing for at least 15 minutes. (Item 14) The method of any preceding item, wherein the heat-treated whey protein solution is added to the cheese curd in a weight ratio of heat-treated whey protein solution to cheese curd of from 1:19 to 2:3. (Item 15) The method of any preceding item, wherein the method further comprises filling the cream cheese, preferably directly from the texture-building heat treatment, into packaging. (Item 16) The method of any preceding item, wherein combining the cheese curd and the heat-treated whey protein solution to form a mixture further comprises adding one or more additional ingredients selected from the group consisting of salts, stabilizers, and gums. (Item 17) The method of any preceding item, wherein the method is a continuous process from subjecting the whey protein solution to cavitation treatment to forming the cream cheese. (Item 18) The method of any preceding item, wherein the cream cheese contains less than 33% total solids by weight. (Item 19) A cream cheese obtainable by the method described in any preceding item.

Claims

1. 1. A method for producing cream cheese, the method comprising: (i) providing cheese curds; (ii) providing a whey protein solution by blending a sweet rennet whey solution with an acid whey solution, wherein the sweet rennet whey solution is present in a greater amount by weight than the acid whey solution; (iii) concentrating the whey protein solution by ultrafiltration to a whey protein concentration of 5 to 15% by weight, based on the weight of the concentrated whey protein solution; (iv) subjecting the concentrated whey protein solution to a cavitation treatment sufficient to heat the concentrated whey protein solution to a temperature of at least 70°C to provide a heat-treated whey protein solution; (v) mixing the cheese curds with the heat-treated whey protein solution to form a mixture; (vi) subjecting the mixture to a texture-building heat treatment to form the cream cheese; The method of claim 1, wherein the whey in the whey protein solution provided in step (ii) consists of whey from the sweet rennet whey solution and whey from the acid whey solution.

2. 10. The method of claim 1, wherein the whey protein solution in step (ii) has a solids content of 4 to 8% by weight.

3. 3. The method of claim 1, wherein the concentrated whey protein solution has a solids content of 18 to 24% by weight.

4. 2. The method of claim 1, wherein the sweet rennet whey solution and the acid whey solution each have a solids content of 3 to 10% by weight.

5. 2. The method of claim 1, wherein the weight ratio of the sweet rennet whey solution to the acid whey solution blended in step (ii) is from 6:4 to 9:

1.

6. 10. The method of claim 1, wherein no evaporation step is performed on either the sweet rennet whey solution, the acid whey solution, or the whey protein solution.

7. 2. The method of claim 1, wherein in step (ii), the whey protein solution is concentrated by ultrafiltration to a whey protein concentration of 10-12 wt. % based on the weight of the concentrated whey protein solution.

8. 2. The method of claim 1, wherein after step (ii) and before step (v), the pH of the whey protein solution is adjusted by fermentation with lactic acid bacteria or by addition of citric acid to obtain a pH of 4.5 to 5.

1.

9. The cheese curds Providing a dairy liquid comprising cream, microfiltered milk concentrate, and milk; fermenting the dairy liquid to form the cheese curds and acid whey; and separating the cheese curd from the acid whey by ultrafiltration.

10. The dairy liquid Separating the milk into cream and skim milk; microfiltering the skim milk to produce a microfiltered milk concentrate as a retentate and an ideal whey as a permeate; and mixing the cream and microfiltered milk concentrate together with the milk to form the dairy liquid.

11. 11. The method of claim 10, wherein the whey protein solution comprises acid whey from fermenting the dairy liquid.

12. 10. The method of claim 1, wherein the cavitation treatment is sufficient to heat the whey protein solution to a temperature of from 75°C to 90°C.

13. 10. The method of claim 1, wherein the texture-building heat treatment comprises heating the mixture to a temperature of 65°C to 90°C with shearing for at least 15 minutes.

14. 10. The method of claim 1, wherein the heat-treated whey protein solution is added to the cheese curd at a weight ratio of heat-treated whey protein solution to cheese curd of from 1:19 to 2:

3.

15. 10. The method of claim 1, wherein the method further comprises filling the cream cheese into a package.

16. 10. The method of claim 1, wherein the step of combining the cheese curd and the heat-treated whey protein solution to form a mixture further comprises adding one or more additional ingredients selected from the group consisting of salts, stabilizers, and gums.

17. 10. The method of claim 1, wherein the method is a continuous process from subjecting the whey protein solution to cavitation treatment to forming the cream cheese.

18. 10. The method of claim 1, wherein the cream cheese contains less than 33% by weight total solids.

19. Cream cheese obtained by the method of claim 1.

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