A METHOD INCLUDING CONTROLLED SMOKING, SLICING, AND DRYING / HEAT TREATMENT FOR THE PRODUCTION OF SMOKED CHEESE CHIPS.

Abstract

The invention relates to a production method for obtaining a crispy, shelf-life-enhanced food product in chip form from smoked cheeses by applying thin slicing, controlled heat treatment, and moisture removal steps. The method involves slicing smoked cheeses, obtained after traditional cheese production, into specific thicknesses and processing these slices while controlling temperature, time, and moisture parameters. This ensures the product achieves the desired crispness without burning, melting, or losing its shape. The smoked cheese chips produced using this method are a final product that retains its characteristic smoky aroma, has a homogeneous crispness, and is suitable for direct consumption.

Description

1 TARIFF CONTROLLED SMOKING, SLICING AND PROCESS FOR THE PRODUCTION OF SMOKED CHEESE CHIPS. A METHOD INVOLVING DRYING / HEAT TREATMENT Technical Area The invention relates to the production of a crispy food product in chip form from smoked cheese. a production process that includes controlled smoking, thin slicing, drying and / or heat treatment steps. It is related to the method. The invention specifically involves controlling the parameters of slice thickness, temperature, time and humidity within specific ranges. and with equipment such as ovens, dehumidifiers or conveyor belt heat treatment tunnels An innovative solution that enables the production of crispy smoked cheese chips on a repeatable and industrial scale. It is related to the method. State of the Art 15 Cheese production involves pasteurization of milk, fermentation, curd formation, and the removal of whey from the curd. It is a process that involves successive traditional milk processing steps such as separation and salting. And these steps are usually carried out in a standardized manner within specific temperature, time, and pH ranges. In this context, milk is heated to approximately 65–75 °C for 20 days to ensure microbiological safety. It is pasteurized within this range, then cooled to 35–40 °C and fermented with natural rennet. It is fermented and the pH value is controlled to obtain curd. The resulting curd is then separated from the whey. To remove the moisture, it is left to rest on cloths, then rinsed with hot water at a temperature range of 75–85 °C. It is cooked by boiling and finally shaped by resting under controlled conditions at 4–6 °C. The winning table cheese is obtained. 25 Cheese chip production, however, goes beyond the aforementioned traditional cheese production process, involving the products obtained... The cheeses are thinly sliced ​​and subjected to controlled heat treatment, moisture removal, and / or smoking. This requires undergoing additional process steps, such as those mentioned above; however, in current practices... The inability to simultaneously and precisely control temperature, time, and humidity parameters can lead to product 30 failure. This leads to quality problems such as burning, excessive drying, or failure to achieve sufficient brittleness. and reliably achieving the desired crispness, textural integrity, and homogeneous product quality. It makes things more difficult. 35 2 An example of cheese chip production using the current technique is document number EP3120710A1, titled “Method to Produce This invention is the subject of a patent application titled "Cheese Chips and Raised Cheese Chips". After the cheese slices are first subjected to a rapid cooling and freezing step with cold air Microwave and vacuum drying rapidly evaporates the water, thus reducing the volume of the cheese chips. It is related to a method that allows it to win. In this method, the cheese slices are dried beforehand and 5 It is cooled, then puffed up with a microwave-vacuum unit, and a crispy product is obtained through final drying. The physical properties of the produced product, such as density, porosity, and brittleness, are within certain limits. It is stated that this should be the case, but these types of drying-expanding processes are generally energy-intensive and require equipment. It involves costly and process-controllable techniques, and in existing processes, especially the heat and humidity profile... Because continuous monitoring is not possible, recurring quality problems may occur. 10 Similarly, document number WO2013039410A1 and “Methods of Producing Cheese Crisps, Cheese The subject of the patent application titled "Crisps and Consumer Goods Containing Cheese Crisps" It is an invention. The invention involves slicing, freezing, aeration by rapid water evaporation, and then microwave- This relates to the production of cheese chips using vacuum drying. In this method, the cheese slices are controlled for 15 minutes. passing through, freezing in cold air and low humidity after microbalm-vacuum foaming. The steps for obtaining a crispy product are described; however, this high efficiency used in practice... Technological drying equipment and procedures, application challenges in industrial-scale production, and Due to costs, commercial production may be practically limited, and process parameters may vary for cheese production. The need to optimize according to type still poses a technical problem. 20 Another example is the invention that is the subject of patent application number JP2018526023A. The invention is cheese. by freezing the slices in a specific way and then inflating them with microwave-vacuum drying steps, making chips. It is related to obtaining similar products. This method also involves freezing and rapid moisture evaporation. The aim of these processes is to increase the volume and crispness of the cheese. However, in this method, 25 The rapid moisture evaporation and expansion techniques used both increase equipment requirements. It also requires precision in terms of process control; in practical application, it depends on the type of cheese. Achieving the expected level of crispness depending on slice thickness and process variables. It can become difficult. In current technology, process parameters such as smoking, controlled temperature and humidity management are particularly important. a repeatable and reliable cheese chip production method that provides precise control Shortcomings persist. For example, methods such as industrial microwave-vacuum drying. While directly affecting the internal moisture profile and texture development of cheese, current approaches... It does not adequately ensure that the parameters are optimized according to cheese types; as a result, 35 The product's quality may vary over time, and the desired crispness and texture performance may not be achieved. It cannot be obtained consistently. 3 In conclusion, the production of smoked cheese chips eliminates the disadvantages inherent in the current technique. The need for this method and the inadequacy of existing solutions in the relevant technical field This has made improvement necessary. Brief Description of the Invention 5 The present invention meets the aforementioned requirements while eliminating all disadvantages. and obtaining a crispy food product in the form of chips from smoked cheeses that brings some additional advantages. controlled smoking, thin slicing, drying and / or heat treatment steps for this purpose It relates to a production method that includes 10. Based on the current state of the art, the aim of the invention is to produce chips from smoked cheese slices. In product manufacturing, critical parameters such as temperature, time, humidity, and slice thickness are controlled. The aim is to eliminate quality and repeatability problems arising from the inability to perform the test. The purpose of the invention is to enable precise slicing of cheese into slices within a specific thickness range. The goal is to ensure homogeneous heat transfer during the baking or drying stages. Another purpose of the invention is the continuous monitoring of the firing and / or heat treatment temperature at specific ranges. And thanks to this control, the cheese slices achieve the desired crispness without burning or drying out too much. 20 The goal is to ensure that it reaches that level. Another purpose of the invention is to develop dehumidification units or systems that provide controlled airflow. This method ensures that the excess moisture in the inner structure of the cheese slices is balanced. The goal is to ensure its removal. 25 Another purpose of the invention is to carry out the smoking process at a controlled time and temperature. Thanks to this, the smoky aroma permeates the cheese homogeneously, and the product has its characteristic flavor. The goal is to ensure the protection of the profile. Another purpose of the invention is to create different types of heat treatment tunnels, such as ovens, dehumidification chambers, or conveyor belt tunnels. Production flexibility is increased by designing a viable process in production infrastructures. The goal is to ensure scalability. Another aim of the invention is to optimize temperature, time and humidity parameters together. 35 thanks to this, smoked cheese chips of consistently high quality can be obtained from different types of cheese. is to ensure. 4 Another purpose of the invention is to allow the product to be placed on the shelf thanks to vacuum packaging applied after processing. The goal is to prolong its lifespan and protect it from external factors. The structural and characteristic features and all the advantages of the invention are given in the figures below and in relation to these figures. This will be understood more clearly thanks to the detailed explanation written with references, this 5 Therefore, the evaluation should be made taking these figures and detailed explanations into consideration. is required. Brief Description of the Figures The structure of the current invention and the best understanding of its advantages, including additional components. This should be evaluated together with the figures explained below. Figure 1 shows the workflow diagram for producing smoked cheese chips using an oven. Figure 2 shows the workflow diagram for the production of smoked cheese chips using a dehumidification chamber. 15 Figure 3 shows the workflow diagram for the production of smoked cheese chips using a conveyor belt. Detailed Description of the Invention This detailed description explains that the invention is a crispy food product in chip form made from smoked cheese. 20 To obtain it, controlled smoking, thin slicing, drying and / or heat treatment are used. A production method that includes these steps is merely an example to help better understand the subject. and is described in a way that will not create any limiting effects. The invention describes the process of thinly slicing smoked cheese, controlled heat treatment, and moisture removal steps. by applying this process, a food product in the form of chips is obtained, which has a crispy texture and an extended shelf life. It relates to a production method aimed at traditional cheese production. The resulting smoked cheeses are sliced ​​into specific thicknesses, and these slices are then subjected to temperature, time, and humidity control. It is based on processing by keeping the parameters under control, ensuring the product does not burn or melt. and ensures that it reaches the desired level of crispness without losing its shape. 30 are obtained with this method. The smoked cheese chips produced retain their characteristic smoky aroma, have a homogeneous crispness, and It is a final product suitable for direct consumption. The cheeses used within the scope of this invention are: Abaza (braided) cheese, Circassian cheese, basket cheese, and baton cheese. Semi-hard or hard cheeses, such as cheese and cheesesticks, made from curd and suitable for heat processing. 35 These are types of cheese. Abaza (braided) cheese, thanks to its fibrous and firm structure, does not fall apart when sliced ​​thinly. Smoked cheese is known for its ability to maintain its integrity and retain its smoky aroma homogeneously. It is preferred in the production of chips. Circassian cheese is known for its low moisture content and non-elastic structure. Thanks to this, it has a crisp texture without melting during high temperature or drying processes. It constitutes a suitable raw material in terms of its ability to reach the desired state. Basket cheese, with its curd structure... Its balanced structure and porous internal composition allow for controlled removal of moisture. It is preferred because it ensures a homogeneous crispness by recognizing the texture. Baton cheese, 5 Its uniform geometric form allows for the achievement of consistent and repeatable slice thickness. Its ability to be recognized and its resistance to shape deformation during heat treatment provide an advantage in production. Stick cheese, thanks to its compact structure and fiber-resistant texture, provides both baking and other benefits. It provides stable results in both dehumidification and conveyor belt heat treatment applications. It is used because of... 10 All of the cheeses mentioned are made from full-fat cow's milk and undergo pasteurization. fermentation, curd formation, separation of whey from curd, boiling and resting, etc. It is transformed into a table product by going through traditional cheese production steps. It is then used in chip production. Before processing, the cheeses are stored in cold storage at approximately 4°C for 15 days. Their structural stability is preserved and they remain suitable for slicing and heat treatment. These cheeses... The smoked versions are produced using natural oak and beech wood through a process called "smoking". It is obtained as a result of the (smoking) process; during this process, the internal structure of the cheese acquires a smoky aroma. by allowing it to penetrate, the characteristic taste, smell and aroma profile of the final smoked cheese chip is achieved. This is ensured. 20 The method described in the invention primarily involves smoking cheeses, optionally with spices and / or... The fruit extracts are then transferred to a mixing machine where they are mixed to ensure even distribution across the entire surface. Mixed homogeneously. Simple production without any additions at this stage. As can be done, different spices can be used depending on customer demand and market expectations. 25 Flavored product varieties can also be obtained by using combinations or natural fruit extracts. During the mixing process, a low-speed, controlled mixture should be used to avoid damaging the structural integrity of the cheese. Mixing is preferred to ensure that the added ingredients adhere evenly to the cheese surface. It is provided. After the mixing process, the cheeses are moved to the slicing stage and sliced ​​with adjustable precision. With the help of a slicing machine, it is cut into thin slices ranging in thickness from 0.5 mm to 1.5 mm. This ensures that the slice thickness remains within this range during subsequent heat treatment or dehumidification stages. This ensures the cheese dries evenly from the surface to the center, minimizing the risk of melting or burning. This prevents spoilage and ensures that each slice reaches the same level of crispness. 35 below this range increased brittleness of slices at higher thicknesses, and sufficient crispness at higher thicknesses. 6 Since it may not be possible to achieve this, the specified thickness range is crucial for the effectiveness of the method. It has been identified as a critical parameter. Depending on the production method, the sliced ​​cheeses are neatly arranged in food-grade crates. placed, laid on stainless steel trays or directly on stainless steel conveyor belt 5 They are arranged in a single layer and prepared for heat treatment. During this placement phase... ensuring the slices do not overlap and that there are sufficient gaps between them for air circulation. Care is taken to ensure that all slices of cheese are left intact during heat treatment or dehumidification. This ensures processing under uniform conditions and the achievement of a homogeneous product quality. The heat treatment and dehumidification steps included in the invention are: furnace use, dehumidification. There are three different production methods: chamber use or conveyor belt heat treatment tunnel use. This can be achieved through these production methods. These production methods depend on the facility infrastructure, production capacity, and Depending on the targeted product range, it can be applied in alternative ways, and each of the methods... One of them is designed to provide the same product quality. The common feature of these three methods is 15 Sensors monitor critical process parameters such as temperature, time, and ambient humidity throughout the process. through continuous monitoring and precise control within predetermined limits. The main goal in all three methods is to remove excess moisture from the inner structure of the cheese slices. removal in a gradual and controlled manner, during which the cheese may not melt, burn, or to prevent it from becoming excessively hard and losing its structural integrity, and to achieve the desired crispness and 20 in the final product. The goal is to obtain a crispy texture. This is achieved through heat treatment, involving sudden and high-temperature applications. This is achieved by avoiding moisture removal and maintaining temperature profiles suitable for the cheese's structure. The drying process is planned in such a way as to prevent uneven drying between the product's surface and its interior. The ovens, dehumidification chambers, and conveyor belt heat treatment tunnels used during the process are designed to protect the food. The equipment consists of surfaces that come into contact with food, all made from food-grade materials. 25 and in a way that will ensure the cheese slices are processed uniformly and under equal conditions It is designed with particular attention to airflow, heat distribution, and product handling arrangements to ensure all slices reach the same temperature. and structured in a way that ensures it is exposed to humidity conditions, within the party and parties The aim is to ensure consistent product quality across the board. In the production method carried out using the oven shown in Figure 1, pre-sliced ​​smoked meat is used. The cheeses are packed in food-grade crates or stainless steel trays in a single layer. They are placed in the oven in this way. The cheese slices should not overlap or touch each other. minimizing heat loss, ensuring even distribution of hot air to each slice, and achieving homogeneous drying. This is important in terms of ensuring the oven temperature is approximately 100 °C. 35 The temperature is adjusted to maintain the moisture content of the cheese without compromising its structural integrity. It is preferred in a way that will allow for the removal of the cheese slices. The baking process allows for the separation of the cheese slices. 7 Depending on thickness, initial moisture content, and desired level of crispness, 2 to 3 hours This process is carried out between these times. During this period, the oven temperature is checked at regular intervals and Adjustments are made as needed to ensure the process proceeds stably. Thermal During the process, the water in the cheese's internal structure evaporates slowly and steadily, without causing sudden evaporation. This process removes the excess liquid, thus preventing the cheese from melting, becoming excessively hard, or burning. Undesirable situations are prevented. The target moisture level is achieved at the end of the baking process. The cheese slices, once they reach a crispy texture, are removed from the oven and left to dry briefly at room temperature. They can be subjected to resting. Then the resulting smoked cheese chips undergo cracking and moisture recovery. The food is transferred to food-grade containers or a packaging line in a way that minimizes the risk. Thanks to this method, the smoked 10 has its aroma preserved, is homogeneously dried, and has high sensory quality. Cheese chips are produced. In the production method carried out using the dehumidifier shown in Figure 2, Sliced ​​smoked cheeses are placed vertically in food-grade crates with sufficient air circulation between them. They are stacked on top of each other, leaving sufficient gaps, and these crates are placed in the dehumidification chamber. 15 The vertical placement of the cheese slices allows the surface area to come into maximum contact with the air. By providing this, it increases moisture removal efficiency and prevents the slices from losing their shape. Moisture removal The room temperature should be 35, allowing the cheese to dry before it starts to melt. The temperature is set between °C and 60 °C. Under these conditions, the cheese slices are left for approximately 12 hours. It undergoes a controlled drying process. During the process, the ambient temperature and relative humidity are maintained at 20°C. The process is continuously monitored to ensure it progresses stably. Additionally, the locations of the crates are checked every 2 hours. The boxes are being adjusted or their directions are being turned to ensure all the cheese slices receive an equal amount of airflow. and exposure to heat is ensured. This practice prevents damage that may occur in different areas of the cases. It minimizes the negative effects of temperature and humidity differences on product quality. Dehumidification. Thanks to the controlled airflow circulating inside the machine, the excess 25% of the cheese slices' internal structure is removed. Dehumidification is achieved by converting water from vapor to liquid state without forming condensation on the surface. It is passed through the machine and removed from the environment via a discharge pipe. In this way, the internal and external structure of the cheese is preserved. This ensures a balanced moisture distribution between the slices, allowing for even crisping. It becomes smoked. At the end of the processing time, it reaches the target moisture level and the desired crispness level. The cheese chips are removed from the dehumidification chamber and are ready for packaging or further processing steps. 30 It is transformed into this state. In the production process carried out using the conveyor belt heat treatment tunnel shown in Figure 3, Sliced ​​smoked cheeses are placed in a single layer on stainless steel trays or 35 homogeneously placed directly onto a conveyor belt made of food-grade stainless steel. The cheese slices are spread out and fed into the heat treatment tunnel. The cheese slices should not overlap on the conveyor belt. The positioning ensures that each slice has even contact with the hot air and that product quality is maintained. 8 It ensures standardization. The operating temperature of the heat treatment tunnel, rapid moisture removal and surface The temperature is set to approximately 200°C to 250°C to create the desired crispness. Cheese slices, Moving continuously and at a controlled speed on the conveyor belt, it passes through the tunnel from the sides, top, and They are subjected to heat treatment for 3 to 5 minutes, preferably with hot air streams directed from below. This A short but high-temperature process will prevent the cheese from melting, running, or burning. This is balanced with the process time and conveyor speed. Thus, the cheese slices are coated on both their surface and... While the moisture in the internal structure is removed quickly and in a controlled manner, the internal structure of the product is porous and A fragile structure is formed. The temperature distribution and air inside the tunnel during the heat treatment process. By continuously monitoring the circulation, the temperature that may develop in different parts of the tunnel can be determined. This prevents fluctuations in color, texture, and crispness throughout the cheese chips. A homogeneous product is obtained in this respect. When the heat treatment is complete, the desired level of crispness is achieved. The cheese chips that have arrived are automatically placed into food-grade crates or collection points at the tunnel exit. They are collected by falling into the units and made ready to be sent to the packaging stage. In all three production routes, after the completion of the heat treatment and moisture removal steps, 15 The resulting smoked cheese chips are vacuum-packaged without being exposed to environmental conditions. This is done by removing oxygen from inside the package during the vacuum packaging stage. Preventing contact with air and moisture leads to oxidation, staleness, and loss of aroma, which degrade quality. These effects are prevented. This ensures the crispy texture, smoky flavor, and sensory characteristics of the cheese chips. It is preserved for a long time and its shelf life is significantly extended. Vacuum-sealed packages contain product information, ingredients 20 and labeled to include the production date for traceability and food safety purposes. They are brought up to standard. Packaged products are ready for direct shipment. It can be stored, or if needed, kept at controlled temperatures in cold storage facilities. By maintaining these conditions, product stability can be further enhanced. Thus, storage and logistics... This prevents fluctuations in product quality throughout the processes. 25 The invention method, as defined in this way, involves heat treatment using an oven, dehumidification chamber, or conveyor belt. It is easily adaptable to different equipment and production infrastructures, such as tunnels, and is used By keeping temperature, time, and humidity parameters under control, regardless of the method used. 30 high-value smoked cheese chips that maintain the same quality and crispness level every time. It enables controlled and repeatable production.

Claims

9 REQUESTS 1. A method for producing a crispy food product in chip form from smoked cheese. It is a production method, and its characteristic is; - semi-hard or hard and curd-based smoked cheeses, during heat treatment 5 at specified thicknesses to prevent melting, burning and deformation. slicing, - Heat treatment of sliced ​​cheeses in ovens, dehumidification chambers, or on conveyor belts. Temperature, time, and ambient humidity parameters are continuously monitored using at least one of the systems. Heat treatment and / or moisture removal within a monitored and controlled process 10 by subjecting it to this process, the moisture content in the cheese's internal structure is gradually reduced. removal, - As a result of the aforementioned processes, the cheese slices are homogeneous without melting or burning. transforming it into a crispy chip form, - The resulting products are vacuum-packaged to extend the shelf life of the final product by 15 days. The conversion process involves several steps.

2. The method complies with Claim 1, and its characteristic is that it has structural properties suitable for heat treatment in production. Abaza (braided) cheese, Circassian cheese, basket cheese, baton cheese and stick cheese, at least The use of one involves the process step.

3. The method conforming to Claim 1 is characterized by the absence of melting, burning, and deformation during heat treatment. To achieve homogeneous crispness without creasing, smoked cheeses should be cut to a thickness of 0.5 mm to 1.5 mm. The process involves slicing the material into pieces with a thickness range of mm.

4. This method complies with Claim 1 and is characterized by being smoked before or after slicing. The cheeses are mixed homogeneously with spices and / or fruit extracts in the mixing machine. It involves the mixing process step. 25 5. This method complies with Claim 1 and its characteristic feature is that the heat treatment and moisture removal steps are performed in the furnace. It involves the process step of being carried out using [method / method].

6. The method conforming to claim 5, characterized by the fact that the cheese slices are baked at a temperature of approximately 100 °C for 2 to 3 hours. This involves a baking process for a period of hours.

7. The method conforming to claim 5 is characterized by the circulation of hot air every 30 minutes during the baking process. To ensure even distribution of cheese slices, use stainless steel trays or food-grade plates. The process involves placing them in a single layer within suitable casings.

8. This method complies with Claim 1 and is characterized by its heat treatment and dehumidification step. The process involves performing the operation using the room.

9. The method conforming to claim 8, characterized by the fact that the cheese slices are heated in a temperature range of 35 °C to 60 °C. This process involves subjecting the animal to controlled drying for approximately 12 hours.

10. The method conforming to claim 8, characterized by its homogeneous moisture removal from cheese slices. They should be placed vertically in the dehumidification chamber and at specific intervals during the process. This involves the step of relocating the safes.

11. This method complies with Claim 8 and is characterized by controlled air circulation within the dehumidifier. with the flow, the excess water in the internal structure of the cheese slices is removed without forming condensation on the surface, 5 It is converted from vapor to liquid state, passed through a dehumidifier, and discharged through a drain pipe. This involves the process of removing it from the environment.

12. This method complies with Claim 1 and its characteristic is that the heat treatment and moisture removal steps are carried out on a conveyor. The process involves performing the treatment using a belt heat treatment tunnel.

13. The method conforming to claim 12, characterized by the fact that the cheese slices are heated at a temperature of 200 °C to 250 °C. The process step involves exposing the area to a stream of hot air for 3 to 5 minutes. It includes.

14. This method complies with Claim 12 and its characteristic is that the cheese slices are conveyed on a stainless steel conveyor belt. heated air is moved across it in a single layer, directed from the sides and top. It involves the process step of subjecting the patient to timed heat treatment. 15 15. The method compliant with Claim 1 is characterized by the fact that it does not involve heat treatment or moisture removal steps. after completion, the smoked cheese chips obtained are exposed to oxygen and moisture. The process involves vacuum packaging before cutting.

16. This method complies with Claim 1 and its characteristic is that vacuum-packaged products are labeled. 20 It includes the process step.

17. This method complies with Claim 1 and is characterized by its repeatable consistency in product quality within and between batches. Temperature, time, and ambient humidity are controlled throughout all production steps to ensure proper functioning. monitoring of parameters via sensors and within predetermined limits It includes the step of checking the process. 25

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