Cheese Block Moisture Variability Reduction via Brine Injection
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Solution Overview
Problem
Conventional cheese manufacturing processes result in moisture gradients within large cheese blocks, leading to uneven texture and increased microbial loads, particularly in reduced fat and high moisture cheeses, making it difficult to achieve uniform moisture content and sensory properties.
Innovation Solution
The implementation of controlled cooling methods, such as the injection method using chilled brine solution or the intermediate temperature method, to reduce moisture variability by cooling the central portion of the cheese block or using an intermediate cooling room, thereby maintaining uniform moisture distribution throughout the cheese block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling methods are used to cool large cheese blocks from manufacturing temperature to refrigerated temperature, then the cheese blocks can be stored and cured, but moisture gradients develop causing non-uniform texture and increased microbial loads
Solution Approach 1:
The patent applies preliminary action by injecting chilled brine solution into the cheese curd mass before the cheese block is fully formed and before conventional cooling begins. This pre-cooling step establishes a temperature gradient that prevents excessive moisture migration to the exterior during subsequent cooling, thereby preventing moisture gradients and texture variability before they can develop.
Solution Approach 2:
The patent uses chilled brine solution as an intermediary substance to transfer heat from the interior of the cheese curd mass. The brine injection system acts as a mediator that delivers cooling directly to the core region, balancing the thermal fields between interior and exterior portions during the cooling process, thereby preventing moisture migration caused by temperature differentials.
2Adaptability or versatility
If reduced fat cheese is manufactured to comply with U.S. Standards of Identity, then consumer demand is met, but moisture content increases making it difficult to achieve uniform moisture distribution
Solution Approach 1:
For reduced fat cheese with higher moisture content, the patent applies preliminary action by injecting chilled brine solution into the curd mass before pressing and forming. This pre-cooling step is particularly important for high-moisture cheeses as it establishes thermal balance that prevents moisture migration during the extended cooling period, ensuring uniform moisture distribution despite the higher overall moisture content required by reduced fat formulations.
Solution Approach 2:
The patent changes the thermal parameters of the cheese curd mass by introducing chilled brine at temperatures significantly below the curd temperature. This parameter change creates a controlled temperature gradient that directs moisture distribution uniformly throughout the block, addressing the moisture uniformity challenge in reduced fat cheeses that have higher baseline moisture content.
3Productivity
If large cheese blocks are produced to enable convenient division and packaging, then productivity increases, but moisture variability between center and exterior regions increases
Solution Approach 1:
The patent applies preliminary action by injecting chilled brine solution into large cheese blocks during the forming stage, before the blocks are removed for storage and curing. This pre-cooling step establishes a thermal foundation that prevents moisture migration during the extended cooling period required for large blocks, ensuring that even though the blocks are large and will take multiple days to cool, the moisture content remains uniform from center to exterior.
Solution Approach 2:
The patent addresses the moisture uniformity problem in large blocks by changing the dimension of heat transfer - moving from external surface cooling alone to internal volumetric cooling through brine injection. This dimensional change in the cooling approach allows thermal energy to be removed from the interior of large blocks as effectively as from the exterior, preventing the development of moisture gradients that would otherwise occur in large-dimensional cheese blocks.
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
These methods significantly reduce moisture variability by 50% to 90% compared to conventional processes, ensuring a uniform texture and sensory properties across the cheese block, while also reducing the strain on downstream whey and waste water processing, leading to cost savings.
Implementation Method 1
cooling the cheese block from a manufacturing temperature of about 85-90° F. to a refrigerated temperature of about 32-40° F.
Implementation Method 2
The implementation of controlled cooling methods, such as the injection method using chilled brine solution or the intermediate temperature method
Data Source
AI summary
The present invention is directed to processes for making blocks of cheese having reduced moisture variability using controlled cooling of cheese curd to form the final cheese blocks.