Continuous Cooker Stretcher for Pasta Filata Cheese
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Solution Overview
Problem
Existing methods for producing pasta filata cheese face challenges such as significant cheese component loss during processing, difficulty in achieving desired ingredient concentrations, and prolonged maturation times, which limit inventory turnover and product functionality.
Innovation Solution
An apparatus and method utilizing a chamber with a flighted auger and independent temperature control for the auger and jacket fluids, allowing for precise temperature management and eliminating the need for cooking in water, thereby reducing fat loss and enabling continuous, non-batch production with rapid temperature adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cheese curd is heated in circulating hot water to achieve target temperature, then the cheese is cooked to desired temperature, but significant cheese solids are lost to the cooker water
Solution Approach 1:
The harmful element (water) is extracted from the cooking system. The patent replaces water-based heating with direct steam injection, eliminating the medium that causes solids loss while maintaining effective heat transfer to the cheese curd.
Solution Approach 2:
Steam is introduced as an intermediary heating medium that transfers heat directly to the cheese curd without requiring the cheese to be submerged in water. The steam condenses on the cheese surface, providing efficient heat transfer while preventing solids dissolution.
2Reliability
If traditional pasta filata processing is used to achieve cheese functionality, then cheese can be produced, but significant quantities of cheese components are lost during processing
Solution Approach 1:
The patent changes the thermal processing parameters by using direct steam injection at controlled temperatures and rates. This modifies the heating mechanism from water immersion to steam condensation, achieving the same functional result with minimal component loss.
Solution Approach 2:
The mechanical stirring and water-based heating system is replaced with a steam injection system that uses phase change heat transfer. This substitution eliminates the need for mechanical agitation in water while achieving effective cheese processing.
3Shape
If cheese undergoes heating and stretching in heated water, then cheese is processed to desired texture, but significant amounts of cheese ingredients are removed
Solution Approach 1:
Water is extracted from the processing system and replaced with direct steam heating. This eliminates the leaching effect that removes cheese ingredients while maintaining the thermal energy transfer needed for texture development.
Solution Approach 2:
The patent converts the potentially harmful effect of water contact (ingredient loss) into a beneficial steam-based system. The steam provides necessary heat for texture development without the harmful leaching effect of water immersion.
4Reliability
If prolonged maturation time is allowed for cheese to exhibit target functionality, then cheese performance is optimized, but inventory turnover is reduced
Solution Approach 1:
The patent performs preliminary actions during the cooking and stretching phases that advance the maturation process. By optimizing the thermal and mechanical treatment early in processing, the cheese reaches functional readiness faster, reducing required maturation time and improving inventory turnover.
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
This approach enhances cheese yield, reduces wastewater, and allows for predictable temperature control, enabling faster maturation and improved product consistency while minimizing fat loss and inventory turnover.
Implementation Method 1
a first heated fluid from a first reservoir passes through a hollow shaft and a hollow fluid chamber coupled to solid flights of the auger
Implementation Method 2
rotating the pair of auger members to knead and melt cheese curd in the interior of the chamber
Implementation Method 3
a second heated fluid from a second reservoir passes through a jacket surrounding the chamber
Implementation Method 4
rotating the pair of auger members to knead and melt cheese curd
Implementation Method 5
knead and melt cheese curd in the interior of the chamber
Data Source
Figure 1
Figure 2
AI summary
The disclosure relates to methods and apparatuses for the production of cheese. In one embodiment, the disclosure relates to methods and apparatuses for making pasta filata cheese. In one embodiment, a continuous cooker stretcher is used for the production of pasta filata cheese.