Matured Hard Cheese Production via Centrifugal Separation and Bactofugation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional matured hard cheese production processes are variable, lengthy, environmentally impactful, require preservatives, and have long maturing times, with inefficiencies in milk separation and fermentation control.
Innovation Solution
An automated, continuous process using centrifugation and bactofugation to separate and sanitize milk, eliminating preservatives and reducing maturation time, utilizing plant-derived rennet and controlled salting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If natural flotation skimming is used to separate milk and cream, then the separation process is simple and traditional, but the process is very variable and depends on multiple factors including milk composition, temperature, and splashing motion
Solution Approach 1:
The patent replaces the natural flotation skimming process with a centrifugal separation system. Instead of relying on gravitational flotation which is affected by temperature and milk composition variations, the invention uses centrifugal force generated by rotation to separate cream from skimmed milk. This mechanical substitution provides consistent and controllable separation regardless of milk characteristics or processing conditions.
Solution Approach 2:
The invention changes the separation parameter from gravitational field (natural flotation) to centrifugal field (rotational separation). By controlling the rotation speed and duration of the centrifugal process, the patent achieves reliable and repeatable separation results. The system can precisely control the fat content of the final product by adjusting separation parameters, eliminating the variability inherent in natural flotation.
2Reliability
If preservatives and anti-mould products such as lysozyme are added to prevent abnormal fermentation, then cheese safety is improved, but the cheese requires labeling and may trigger consumer allergies
Solution Approach 1:
The patent extracts and removes spores and bacteria from the milk through a dedicated bactofugation step before cheese production. By eliminating these potential contaminants upfront, the invention makes the addition of preservatives unnecessary. The system achieves fermentation control through physical removal of harmful microorganisms rather than chemical inhibition, producing cheese without lysozyme or other anti-mould agents.
Solution Approach 2:
The invention converts the potentially harmful spores and bacteria into a removable byproduct through bactofugation. The harmful microorganisms are separated and discarded, while the beneficial milk components proceed to cheese production. This approach transforms a safety risk into a controlled separation process, eliminating the need for preservatives and their associated labeling and allergy concerns.
3Reliability
If traditional salting and maturing processes are used for minimum 9 months, then cheese quality is developed, but the process is lengthy and has high environmental impact due to electricity consumption for temperature and humidity control
Solution Approach 1:
The patent performs preliminary sanitization of the milk through bactofugation before cheese production. By removing spores and bacteria upfront, the invention creates a controlled environment that reduces the risk of abnormal fermentation during maturing. This preliminary action allows for accelerated maturing processes without compromising quality, as the cheese is protected from contamination that would otherwise require extended maturing time to ensure safety.
Solution Approach 2:
The invention changes the maturing parameters by enabling higher temperatures and shorter durations. Traditional processes require 9+ months at controlled low temperatures to ensure safety. The bactofugation-treated cheese can mature faster because the harmful microorganisms have been removed, allowing the patent to reduce maturing time from 9 months to potentially 3-6 months while maintaining or improving quality through better initial microbiological control.
4Adaptability or versatility
If the process is insufficiently industrialized with manual operations, then flexibility is maintained, but the process is not rapid and requires skilled operators in delicate steps
Solution Approach 1:
The patent replaces manual flotation skimming with an automated centrifugal separation system. The centrifugal separator is a mechanical device that automatically separates cream from skimmed milk based on density differences under centrifugal force. This substitution eliminates the need for skilled operators to monitor and adjust natural flotation processes, enabling continuous automated operation while maintaining or improving separation quality.
Solution Approach 2:
The invention implements continuous centrifugal separation and bactofugation processes instead of batch manual operations. The centrifugal system can operate continuously, processing milk flows without interruption. The bactofugation step also operates continuously, removing spores and bacteria in real-time. This continuity enables rapid production while the automated control systems maintain process flexibility and adaptability to varying milk characteristics.
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 process achieves rapid cheese production without additives, reduced salt content, and shorter maturation, ensuring consistent quality and environmental efficiency.
Implementation Method 1
separating said raw milk in a centrifugation step, where said centrifugation step produces cream and skimmed milk with a fat content substantially equal to 0%
Implementation Method 2
a step of eliminating spores and bacteria from said skimmed milk by means of bactofugation
Implementation Method 3
adding rennet and whey starter; cooking in vats to obtain a cheese mass
Implementation Method 4
adding a whey starter, produced by the previous day's processing and rich in lactic bacteria, to start conversion of the milk into cheese
Implementation Method 5
immersing the cheese wheels obtained in a solution of water and salt to salt them, for a duration varying from 21 to 28 days... the salt has the function of flavouring the cheese, eliminating the residual whey and forming the rind
Data Source
AI summary
The invention relates to the food sector and concerns an industrial production process of a matured hard cheese and cheese obtainable with said process. The industrial production process comprising the steps of: - collecting milk and storing it in a single tank; - separating milk to obtain cream and at least semi-skimmed milk; - checking the percentage of the fat fraction; - adding rennet and whey starter; - cooking in vats to obtain a cheese mass; - treating the cheese mass and moulding it; - salting said cheese wheels; - maturing said cheese wheels, wherein: - said separating step comprises a step of pre-heating said stored raw milk and a centrifugation step, producing cream and skimmed milk with a fat content substantially equal to 0%; - it comprises a step of eliminating spores and bacteria from said skimmed milk by means of bactofugation; - it comprises titration of the skimmed milk with spores removed, delivered from the bactofugation process, and addition of cream recovered from the separating step, pasteurized, pre-heated to 65°C and cooled to 35°C, to bring the skimmed milk with spores removed to a fat content of 2.8-3% to obtain titrated milk with spores removed.