Expanded Cheese Production via Microwave Heating and Air Cooling

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Solution Overview

Problem

Existing methods for producing expanded dairy products result in fragile and friable pieces, contamination of molds, and difficulties in product traceability due to the use of finely divided cheese, leading to inconsistent quality and nutritional value.

Innovation Solution

A process involving cutting a seasoned hard cheese piece from the outer edge, subjecting it to microwave processing, and controlled cooling to produce expanded dairy products with enhanced mechanical strength and homogeneity, while maintaining nutritional and organoleptic properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If cheese is finely divided and placed in molds for microwave expansion, then expansion is achieved, but the pieces become fragile and friable leading to considerable fragmentation during packaging

Engineering Contradiction:

Improveexpanded formVSAvoidbreaking strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The cheese is divided into granules of specific size range (0.5-5 mm) rather than being finely divided, creating a segmented structure that maintains strength while allowing expansion. The granules are then enclosed in a porous matrix that provides structural support during expansion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A porous matrix or shell is formed around the cheese granules before microwave treatment. This flexible shell contains the granules during expansion, preventing fragmentation while allowing the cheese to expand and achieve the desired shape.

Inventive Principle:

Principle #30Flexible shells and thin films

2Shape

If cheese is finely divided for processing, then expansion is achieved, but mold contamination by cheese grease occurs requiring cleaning between uses

Engineering Contradiction:

Improveexpanded formVSAvoidmold contamination

Core Design Contradiction:

ShapeVSObject-generated harmful factors

Solution Approach 1:

The cheese granules are extracted from the mold before the cheese grease can contaminate it. The expansion process is designed to complete quickly, and the mold is removed before significant grease migration occurs, eliminating the contamination problem.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A disposable liner or parchment paper is placed in the mold during processing. This single-use barrier prevents grease contamination of the mold, eliminating cleaning requirements between uses.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Shape

If grinded cheese is used in processing, then expansion is achieved, but product traceability becomes difficult due to mixing of different batches

Engineering Contradiction:

Improveexpanded formVSAvoidproduct traceability

Core Design Contradiction:

ShapeVSLoss of information

Solution Approach 1:

The cheese is segmented into granules rather than being ground into a fine powder. This coarser segmentation maintains batch identity and traceability while still allowing for uniform processing and expansion. Different batches remain visually distinguishable.

Inventive Principle:

Principle #1Segmentation

4Length of moving object

If pieces of cheese are expanded to large dimensions, then consumer appeal is improved, but mechanical strength decreases leading to fragmentation

Engineering Contradiction:

Improvepiece dimensionVSAvoidbreaking strength

Core Design Contradiction:

Length of moving objectVSStrength

Solution Approach 1:

The expanded cheese product is formed as a composite structure with cheese granules embedded in a porous matrix or bound together in a structured arrangement. This composite structure provides mechanical strength even as the overall piece dimension increases, preventing fragmentation.

Inventive Principle:

Principle #40Composite materials

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 yields expanded dairy products with higher breaking strength, improved preservation, and consistent taste, ensuring better product quality and traceability, with enhanced nutritional benefits and reduced carbohydrate content.

Implementation Method 1

subjecting a piece of cheese to a microwave oven processing

Methodology Applied

Scientific EffectMicrowave radiation: Microwave Radiation

Implementation Method 2

The power of the microwave oven is preferably comprised between 400 and 1.700 watt

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 3

The piece, coming from the treatment by microwave, is cooled by forced air in temperature reducer

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentEP3032957B1Process for the preparation of an expanded dairy product and product obtained thereby

Publication Date: 2018.10.10 OLYMPIA KK

AI summary

The invention relates to a process for the preparation of an expanded dairy product having the largest dimension of at least 1 cm, directly from a piece of seasoned cheese, without subjecting the seasoned cheese to grinding, which process consists in subjecting a piece of cheese obtained by cut from a wheel of hard cheese at a distance comprised between 1 mm and 2 cm, to a microwave oven treatment, followed by a quick cooling by air. The invention also relates to the expanded dairy product obtainable thereby.