Low-Moisture Mozzarella Cheese Yield Optimization
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Solution Overview
Problem
The existing processes for producing low moisture mozzarella cheese face challenges in achieving optimal acidification and drainage kinetics, leading to protein and fat losses in the whey, which affects cheese yield and functional properties like meltability and stretchability.
Innovation Solution
Optimization of the acidification and drainage kinetics by adjusting the dosage and type of thermophilic starter cultures and coagulants, including a higher pH at the whey off step and faster acidification rate, along with a shorter process time, to maintain cheese quality and increase yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional starter culture and coagulant dosing is used, then cheese production follows conventional yields, but protein and fat losses in whey occur reducing efficiency
Solution Approach 1:
The patent applies parameter changes by optimizing the dosage of thermophilic starter cultures (increasing from conventional levels) and coagulants (adjusting IMCU per 100kg milk), as well as controlling pH levels and temperature profiles. These parameter adjustments modify the acidification and drainage kinetics to reduce protein and fat losses in whey while maintaining cheese yield, directly resolving the contradiction between substance loss and productivity.
Solution Approach 2:
The patent implements feedback control by monitoring pH levels, drainage rate, and curd properties during the cheese-making process. The acidification rate and drainage kinetics are continuously adjusted based on measured parameters to optimize the balance between minimizing whey losses and maintaining efficient cheese production, enabling dynamic adaptation to achieve both reduced substance loss and high productivity.
2Loss of time
If faster acidification rate is achieved, then processing time is reduced, but drainage kinetics may be compromised affecting cheese quality
Solution Approach 1:
The patent uses parameter changes by optimizing the interaction between starter culture dosage, coagulant type and dosage, and temperature profiles to achieve faster acidification without compromising drainage kinetics. Specific adjustments to pH targets, acidification rate, and syneresis characteristics enable reduced processing time while maintaining reliable drainage and cheese quality through coordinated parameter modification.
Solution Approach 2:
The patent employs composite approaches by combining multiple thermophilic starter cultures with specific coagulants having particular proteolytic and clotting activities. This composite system enables simultaneous optimization of acidification speed and drainage characteristics, as the interaction between different microbial strains and coagulant enzymes produces synergistic effects that achieve both fast acidification and reliable drainage kinetics.
3Strength
If higher coagulant dosage is used, then firmness and curd structure improve, but proteolytic activity increases reducing stretchability and meltability
Solution Approach 1:
The patent applies parameter changes by precisely controlling coagulant dosage (expressed in IMCU per 100kg milk) and selecting coagulants with specific C/P ratios (clotting to proteolytic activity). By adjusting these parameters, the patent achieves optimal curd firmness while minimizing excessive proteolytic breakdown that would harm stretchability and meltability, thus resolving the contradiction between strength and harmful functional degradation.
Solution Approach 2:
The patent implements local quality by differentiating the functional requirements at different stages of cheese-making. The coagulant system is designed to provide strong clotting activity for curd formation while controlling proteolytic activity to preserve functional properties. This localized functional differentiation ensures firmness where needed while preventing harmful proteolysis that would degrade stretchability and meltability.
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 results in a higher cheese yield with reduced protein and fat losses, while preserving the functional properties of mozzarella cheese, such as meltability, stretchability, and shredability, and reducing processing time by 15%.
Implementation Method 1
adding to milk, a starter culture... rapid acidification (mainly by thermophilic starter culture)
Implementation Method 2
adding one or more coagulants to the composition of step A, renneting the composition of step B
Implementation Method 3
stirring and scalding the composition of step D while heating the composition to around 41° C.
Data Source
AI summary
The present invention relates to a process for making low-moisture mozzarella cheese using recent developments in the technical knowledge about the interactions between cultures, coagulants and cheese technology to increase cheese yields and maintain the cheese quality and functionalities. An optimization may lead to a higher pH and higher dry matter of the curd at the whey off step i.e. pH higher than 6.3 and ideally higher than 6.4 and solid non-fact content higher than 18%, without any modification of the curd composition at the stretching step, i.e. pH between 5.0 and 5.3 and more precisely between without any modification of the curd composition at the stretching step, i.e. pH between 5.0 and 5.3 and more precisely between 5.05 and 5.25, Ca/SNF between 1.7% and 2.4% and more precisely between 1.7 and 2.2%, dry matter between 53% and 55% and more precisely between 53.5% and 54.5%. The coagulant has a C/P ratio of at least 25. This optimization may also lead to a reduction in the processing time in the cheese vat (near 15%), so a real increase in the through-put and profitability of the cheese vats.