Sequential Coating for Cheese Slicing and Protection
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Solution Overview
Problem
Existing methods for coating cheese fail to achieve an optimal balance between the quality of the coated cheese and process economy, as they either provide inadequate protection or poor slicing properties, depending on the solids content of the coating composition, with low solids coatings being vulnerable to microbial attack and high solids coatings being difficult to cut.
Innovation Solution
A method involving sequential coating with a high solids composition (35-80 wt.% solids) followed by a low solids composition (15-40 wt.% solids), along with an aqueous cheese coating composition devoid of water-swellable clay particles, to enhance protection and slicing properties while controlling viscosity and moisture permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cheese is coated with a low solids coating composition, then the cheese can be favourably sliced or cut without significant deformation, but the cheese becomes more vulnerable to microbial attack and mechanical damage
Solution Approach 1:
The coating process is divided into multiple sequential applications rather than a single application. The patent applies coating composition in several thin layers over time, allowing each layer to dry and form a protective barrier before the next is applied. This segmented approach builds cumulative protection without creating a single thick layer that would impair slicing
Solution Approach 2:
The cheese is pre-treated with brine before coating, and the coating process begins while the cheese is still relatively fresh. This preliminary preparation ensures the cheese surface is ready to receive the coating and that the coating adheres properly, maximizing protective benefits from the start of the ripening process
2Reliability
If a cheese is coated with a high solids coating composition, then the cheese is well protected against microbial attack, but the cheese becomes difficult to slice or cut without deformation
Solution Approach 1:
The total coating solids are distributed across multiple thin applications rather than applied as one thick layer. Each application deposits a small amount of solids that dries to form a flexible protective layer, and subsequent layers build upon this foundation without creating excessive thickness that would make the cheese difficult to slice
Solution Approach 2:
The coating composition's viscosity and solids content are dynamically adjusted between applications. The patent uses compositions with solids content in the range of 20-70%, optimizing the balance between protectiveness and applicability. The coating system adapts to the cheese's changing surface characteristics during ripening
3Reliability
If water-swellable clay particles are added to increase coating solids content, then the coating provides better protection, but the viscosity increases strongly making the coating too thick to apply
Solution Approach 1:
The patent modifies the physical and chemical parameters of the coating composition by selecting specific polymer types (vinyl acetate-vinyl versatate copolymers) with controlled molecular weights and glass transition temperatures. These parameter changes allow the composition to maintain adequate viscosity for application while still providing sufficient solids content for effective protection
Solution Approach 2:
The coating composition is formulated as a composite system combining polymer dispersions with specific additives and modifiers. This composite approach allows optimization of multiple properties simultaneously - the polymer matrix provides film-forming capability and protection, while additives control viscosity and application characteristics
Data Source
AI summary
The present invention relates to a method for providing a coated cheese comprising coating at least part of a cheese with a high solids coating composition and subsequently coating at least part of the cheese thus obtained with a low solids coating composition. The coating compositions are preferably provided as half-sided coating treatments. The low solids coating composition is preferably an aqueous cheese coating composition having a solids content selected from the range of 20-34 wt.% with respect to the total weight of the composition, comprising a polymer obtainable by emulsion polymerisation and an organic thickener selected from the group consisting of a poly(vinyl alcohol), poly(vinyl pyrrolidone), xanthan gum, guar gum, locust bean gum, carrageenan, hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose or a salt thereof, and methylcellulose, wherein the aqueous cheese coating composition is essentially free of particles from a sheetlike water-swellable material, and specifically water-swellable clay particles.