Cheese Blocks with Convex Sides for Reduced Cutting Losses
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Solution Overview
Problem
Existing methods for preparing hard or semi-hard cheese blocks with convex sides result in high cutting losses, uneven salt distribution, and consumer preference for flat pieces, while also being costly and prone to cracking or disintegration.
Innovation Solution
A method involving pressing curd into a rectangular mold, brining, and cutting back edges before or during ripening to create convex sides, reducing waste and maintaining cheese integrity, with the edges being removed to avoid sharp, salty rinds and facilitate easier cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional round cheese blocks are used, then consumers can obtain uniform flat slices, but high cutting losses occur with hard dry rind pieces
Solution Approach 1:
The cheese block is pre-shaped with convex sides before slicing, so that when slices are cut, the convex surfaces naturally produce uniform flat pieces without requiring excessive trimming. This preliminary shaping action eliminates the need to cut away large portions of rind, thereby reducing cutting losses while maintaining slice uniformity
Solution Approach 2:
The cheese block is given a convex curved surface instead of a flat or sharp edge. This curvature allows slices to be cut that are uniformly flat on the consumer-facing side while minimizing waste material, as the convex shape naturally tapers toward the edges without creating large triangular waste sections
2Loss of substance
If rectangular cheese blocks are used, then cutting losses are eliminated, but corners and edges have excessive salt content
Solution Approach 1:
The cheese block has different geometries at different locations: convex curved surfaces at the corners and edges, and flat surfaces in the center. This local variation in geometry controls the brining process so that salt penetration is more uniform throughout the cheese, preventing the excessive salt accumulation that occurs at rectangular corners and edges while maintaining zero cutting losses
3Productivity
If rectangular cheese blocks are used, then production efficiency is high, but consumers do not appreciate the appearance
Solution Approach 1:
The cheese block features convex curved surfaces on its exterior while maintaining a rectangular core structure. This curved geometry provides the aesthetic appeal and craftsmanship appearance that consumers prefer, while the overall block shape still allows for efficient production and standardized slicing operations
4Shape
If molds with rounded surfaces are used, then cheese blocks with convex sides are obtained, but production cost increases and cracking risk rises
Solution Approach 1:
Instead of using complex rounded molds during cheese formation, the cheese is first formed in simple rectangular molds, then the convex surfaces are created later by removing material from the corners and edges. This preliminary formation in simple molds avoids the high cost of specialized rounded molds while achieving the desired convex shape
Solution Approach 2:
The convex surfaces are created by extracting or removing material from the corners and edges of the rectangular cheese block. This extraction process, performed after the cheese has set, creates the desired convex shape without requiring complex molds, and the removed material can be reused in subsequent production batches
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces cheese blocks with convex sides that are preferred by consumers, reducing waste and salt content, maintaining rind quality, and enhancing the cheese's texture and taste, while being cost-effective and minimizing the risk of cracking.
Implementation Method 1
pressing the curd contained in the mold in a pressing station, such that a rectangular shaped curd block is obtained
Implementation Method 2
bringing the pressed curd block in a brining bath
Data Source
Figure 1~2a
Figure 2b~3
Figure 4~5
AI summary
The present invention relates to a method for preparing blocks of hard or semi-hard cheese (17) having at least one convex side (18, 19, 25, 26, 31-33) said method comprising: providing curd and placing the curd in a rectangularly shaped mold; pressing the curd contained in the mold in a pressing station, such that a rectangular shaped curd block (1) is obtained; bringing the pressed curd block (1) in a brining bath; removing the curd block (1) from the brining bath; and ripening the curd block (1) over a desired period of time, such that a block of hard or semi-hard cheese (8) is formed; and wherein at least one of the sides (13-16) of the block (8) is rendered convex by cutting back at least one of the edges (9-12) of that side. The invention further relates to hard or semi-hard rectangular shaped cheese blocks (17) obtainable by said method, and to slices (28-30) or pieces (22, 23) obtainable by said method.