Spreadable Cheese Production Using Starch Modification
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Solution Overview
Problem
The cheese industry faces waste and inefficiency due to constant high curd production levels that do not align with fluctuating market demands for different cheese types, leading to scrap cheese that requires rework for low-value products.
Innovation Solution
Redirecting curd intended for hard cheese into a spreadable cheese product by incorporating a specific combination of amylomaltase-treated starch and pregelatinized starch, which involves coagulating milk, partially draining whey, mixing with the starches, heating, and cooling to create a stable, spreadable cheese.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If curd production is kept at constant high levels to balance milk supply, then productivity is improved, but waste increases due to scrap cheese that needs rework
Solution Approach 1:
The invention changes the processing parameters of the curd by using a specific combination of starches (amylomaltase-treated starch and pregelatinized starch) and modifying the heating and cooling process to transform hard cheese curd into spreadable cheese, allowing the same curd to be converted into different product types based on market demand
Solution Approach 2:
The invention introduces dynamic adaptability to cheese production by enabling the same curd to be processed into different cheese types (hard or spreadable) depending on market conditions, making the production system flexible rather than fixed
2Adaptability or versatility
If curd is redirected to make spreadable cheese instead of hard cheese, then adaptability to market demand is improved, but manufacturing precision is worsened due to process deviation
Solution Approach 1:
The invention uses specific parameter changes including the addition of amylomaltase-treated starch (2-8 wt%) and pregelatinized starch (1-5 wt%), heating to 70-80°C, and controlled cooling to transform the curd structure from hard to spreadable cheese while maintaining process control
Solution Approach 2:
The invention introduces starches as intermediary substances that mediate the transformation of curd into spreadable cheese, with the starches acting as structuring agents that enable the desired texture and spreadability while maintaining manufacturing consistency
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 method allows for adaptable cheese production that meets market demands, reduces waste, and maintains production levels without the need for rework, resulting in a product with good consistency and creaminess.
Implementation Method 1
coagulating wholly or partly the protein of a milk product through the action of rennet or other suitable coagulating agents
Implementation Method 2
heating and shearing the mixture at a temperature between 70 and 80°C
Implementation Method 3
heating and shearing the mixture at a temperature between 70 and 80°C followed by cooling the mixture under stirring
Data Source
AI summary
The invention relates to the field of cheese making, in particular to the production of a soft cheese or a spreadable cheese. Provided is a method for preparing a spreadable cheese product, comprising the steps of (a) coagulating wholly or partly the protein of a milk product through the action of rennet or other suitable coagulating agents; (b) partially draining the whey resulting from the coagulation to obtain a cheese curd; (c) preparing a mixture of the cheese curd, water, an amylomaltose-treated starch (ATS) and a pregelatinized starch (PS); (d) heating and shearing the mixture at a temperature between 70 and 80º C; followed by (e) cooling the mixture under stirring to obtain a spreadable cheese product. Also provided is a spreadable cheese obtainable by the method.