Cheese Block Cooling to Reduce Moisture Variability
Find Innovative SolutionsGenerate Solutions
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 preferences.
Innovation Solution
The implementation of controlled cooling methods, including the 'injection method' using chilled brine solution and the 'intermediate temperature method', where cheese blocks are cooled from the center or placed in an intermediate temperature room to reduce moisture variability, ensuring uniformity throughout the cheese block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used to cool large cheese blocks from 85-90°F to 32-40°F, then the cheese blocks can be stored and cured, but moisture gradients develop with higher moisture at exterior surfaces and lower moisture at core regions
Solution Approach 1:
The patent applies preliminary action by cooling the cheese blocks slowly through an intermediate temperature range (40-50°F) before reaching the final storage temperature. This preliminary controlled cooling phase allows moisture to redistribute uniformly before the block is cooled to final storage conditions, preventing the formation of moisture gradients that would otherwise occur during rapid cooling.
Solution Approach 2:
The patent implements dynamics by varying the cooling rate at different temperature ranges. The cooling process is not uniform but rather adaptive: slower cooling through the intermediate range (40-50°F) and faster cooling at other stages. This dynamic cooling approach allows moisture to migrate uniformly during the critical phase when the cheese is most susceptible to gradient formation.
2Quantity of substance
If reduced fat cheese is manufactured with higher moisture content to meet consumer demand, then consumer preference is satisfied, but moisture variability between center and edge regions increases
Solution Approach 1:
For reduced fat cheeses with higher moisture content, the patent applies preliminary action by maintaining the blocks at intermediate temperatures (40-50°F) for extended periods before final cooling. This allows the higher moisture content to distribute uniformly throughout the block through controlled migration, preventing the development of moisture gradients that would otherwise occur in high-moisture cheeses cooled rapidly.
3Productivity
If cheese blocks are cooled rapidly to reduce processing time, then productivity increases, but moisture gradients and texture variability worsen
Solution Approach 1:
The patent implements dynamics by adjusting cooling rates based on the cheese composition and size. For reduced fat and high-moisture cheeses, slower cooling through intermediate temperatures is applied to prevent moisture gradients. For standard composition cheeses, faster cooling may be used. This dynamic approach optimizes both productivity and texture uniformity based on specific product requirements.
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% between the center and edges of cheese blocks, improving texture uniformity and sensory properties, while minimizing the use of excess water and reducing downstream processing costs.
Implementation Method 1
introducing a chilled brine solution into a central portion of the cheese block prior to cooling the entire cheese block
Implementation Method 2
cool the large pressed blocks of cheese from the manufacturing temperature of about 85-90° F. to a refrigerated temperature of about 32-40° F.
Implementation Method 3
a moisture gradient has been observed to occur in the cheese blocks during the cooling period. Moisture has tended to migrate from the core or central region of the cheese blocks towards the exterior surfaces
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.