CHEESE MOISTURE CONTROL. May 29 th, 2013

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1 CHEESE MOISTURE CONTROL May 29 th, 2013 OPTIMISATION

2 Key drivers of moisture control in cheese Simple methods for measuring yield Quality and cost impacts of changing moisture levels. Importance of consistent practices for moisture control. Understanding impact of seasonal variation. 2

3 Why worry Impact of moisture content Reduced fat cheese with 39% moisture Reduced fat cheese with 45% moisture To make 39% moisture uses 12.4 litres milk, to make 45% uses 10.5 litres of milk per kg At 40c per litre = 90 cents difference per kg cheese 3

4 Why worry Impact of weight if selling by set weight Camembert at 14kg per 100 litre milk Portion weight of 255g or 280g 549 units vs 500 units 4

5 Optimise vs.. Maximise Maximise = to increase to a maximum value Optimise = Making something as perfect, as functional, as possible 5

6 Optimise vs.. Maximise Cheddar, maximum 38 Minimum 34.0 What differences between the two Work out your market 6

7 Optimise vs. Maximise Camembert 1% change in moisture affects shelf life by 1 week What is your market? 7

8 Know what you want General impacts of moisture increase? Softer body Breakdown more rapid Maturation more rapid Shelf life reduced Greater yield What are you trying to do?? 8

9 Causes of variation Decide on your aim Milk composition Cheesemaking in the vat Post vat handling maturation 9

10 Milk quality Fresher best In cold storage psychrotrophic bacteria produce enzymes that attack casein Older milk = less casein = less cheese 10

11 Milk age milk sitting in the silo longer than 24 hours or equal to 24 hours tends to lose protein by 0.08 % due to proteolysis by the thermostable enzymes of the psychrotrophs. Such milk also will lose fat by 0.06 percent due to lipolytic enzymes. Food Processing Optimisation 11

12 Composition Mostly water therefore small change in solids big impact on yield Seasonal variation How does each component affect yield? Animal & breed type Casein % 12

13 Seasonal variation July August September October November December January February March April Fat Protein May June 13

14 Fat Generally increasing milk fat content will reduce moisture Fat can stop moisture loss in soft cheese during draining 14

15 Protein Main part of cheese body, Casein most important part Casein matrix holds in the fat and water Casein 78-80% of total protein Protein varies during year and casein percentage of total protein varies. Cows feed will impact on protein level 15

16 Protein : fat ratio Lower fat = higher moisture, more soluble whey solids held Higher fat, = higher cheese fat, less moisture If don t or can t standardise be aware that composition will affect yield. When higher fat may need to vary make to remove moisture 16

17 Cheese Yield 100 litres milk = kg soft cheese 10.5 kg semi hard e.g. cheddar 9.5 kg mozzarella 8.3 kg parmesan Food Processing Optimisation 17

18 Control of impact of varying Data, data, data Know your milk composition Budget accordingly - know that at some times of year you will get less cheese Have standards Yield measures 18

19 Milks solids in the vat Adjust solids in vat, milk fat, constant fat : protein ratio, UF so constant protein Adjust the volume in the vat to keep same block size Do nothing knowing that yield and block size will vary 19

20 Pasteurisation Increasing pasteurisation temperature > 78 C will increase yield Whey proteins denatured then get trapped in casein micelle May impact on quality 20

21 Cheesemaking in vat Set strength Cutting Stirring Cook speed Time in whey 21

22 Cheesemaking in vat Set strength General rule Firmer set = higher moisture Firmer set = more fat loss due to curd shattering Some varieties or plant may experience something different 22

23 Coagulation Gel strength impacted by: Acid development, more acid quicker set Temperature, higher temp. quicker set Consistent Temperature, amount of culture, time, amount of rennet Accuracy in measurement. 23

24 Curd firmness Affected by calcium Add calcium some times of year Dutch always add calcium Added benefit, reduces rennet amount required 24

25 Calcium Chloride impact approx 0.2g/litre Increases ionic Ca2+ and colloidal calcium phosphate Decreases ph 25

26 Causes of poor renneting Low protein levels High ph Prolonged holding of milk at low temperatures High somatic cell count High enzyme activity 26

27 Cutting Same firmness each day = consistent product Heal time Allows surface of cut particles to heal/strengthen If stirred too quickly then higher fat losses 27

28 Cut size Helps determine final moisture Larger particle size = more moisture Normally soft cheese 20mm Semi hard e.g. cheddar 10mm, final size pea Hard cheese very small, final size wheat grain 28

29 Cooking Too rapid temperature rise, case hardening, proteins on surface dehydrate, less permeability to water movement locks in moisture, and lactose = acid, pasty cheese, general rule cheddar 1 C every 5 minutes 29

30 Cooking Final temperature can be used as moisture control, Raise temperature to reduce moisture, reduce temperature to increase moisture Combination of effect on starter activity and physical impact 30

31 Stirring More stirring = more collisions = less moisture Seasonal variation control 31

32 Wash Water Adding wash water increases moisture Havarti, Lower temperature wash water = higher moisture Other varieties, e.g. reduced fat cheddar decrease wash water by 2 C increase moisture 1-2% 32

33 Washing curd Why does it have an impact? Removes whey solids, yield down Dilutes lactose in the whey Lactose moves from curd to whey due to osmotic pressure 33

34 Washing curd Less acid produced in the curd Less syneresis Less contraction of the casein micelle Higher moisture 34

35 Summary Change amount of culture or ripening time Change cut size Change cooking temperature Add Calcium chloride Change stirring time 35

36 Whey drainage Treat curd carefully Shattered curd will lower yield Fat loss Curd fines 36

37 Culture speed More acid at drain time More syneresis, more moisture expulsion, lower ph Less acid at drain time, less syneresis, less moisture expulsion, higher ph Different cheese ph at drain affects calcium level affects cheese body Food Processing Optimisation 37

38 Moisture Oven method, 100C 15 hours, analytical scale to at least 0.0g NIR machine $30K to $50K Heat lamp style 38

39 Moisture Moisture oven $3000, new Weigh cheese into alum pan, 2-3 grams to 0.01g record weight A Leave in oven at 100c 16 hours, cool and weigh again B 39

40 Moisture test A B = weight moisture % total solids = (A B)/A = C % Moisture = 100-C 40

41 No Lab Accurately measure milk into vat Same amount each day Record number of cheese produced Record weights of a set number at 24 hours, e.g. 5 Weight variation = yield variation 41

42 Yield formula Accurate data Observe trends What are your aims 42

43 Formulas Van Slyke Developed 1936, study of US cheddar plants Primarily Cheddar but can be used when using similar equipment e.g. making mozz in cheddar plant. Used to determine what should get, can modify formula to suit particular plant. 43

44 Van Slyke Y = [0.93F + (C-0.1)] x M Y = Yield in kg cheese per 100kg milk F = kg of fat per 100kg milk(%) C = kg casein per 100kg milk (%) M = kg moisture per 100 kg cheese (%) 44

45 Van Slyke 0.93F = normally 93% of the milk fat ends in cheese Rest in the whey C-0.1 = means casein -0.1 ends in cheese 1.09 means that 9% of solids other than fat and casein is recovered, (minerals, salt, lactose, whey proteins) 45

46 Van Slyke Milk fat 3.8%, casein 2.45%, moisture 37% Y = [(0.93 x 3.8) + ( )] x Y = [(3.53) + (2.44)] x Y = = kg per 100kg milk 46

47 Modified van slyke Can be used for all varieties Need to be able to test salt, moisture, whey solids Could use estimated values Y = [( KF ) + (C-0. 1) X 1.016] 1 S M/(1-WS) 47

48 Modified K = fat recovery for cheese type S = salt % M = Moisture % WS = whey solids % 48

49 Modified Van slyke Type Moisture % Salt % Fat Recovery Yield kg/100 Cheddar Gouda Swiss Tilsitt Cambe Mozz

50 Changes to recoveries Modified Van Slyke Yield per 1000 litres kg / 100kg Milk Litres per kg type milk fat casein fat recoverysalt moisture whey solids Mozzarella % 45% 6.50% Mozzarella % 46% 6.50% Mozzarella % 47% 6.50% Mozzarella % 48% 6.50%

51 Simple Yield Yield = cheese weight /milk + starter (if using bulk)+ salt *100 Eg day 1 100kg cheese/1000 l milk + 2kg salt = 100/1002 * 100 = 9.98 Day 2 110/ *100 = 10.9 What has caused the difference 51

52 Acidity Aims Should be part of the recipe Record, ph of milk, set or cut, whey off, 24 hr. What tell Activity of starter Moisture impact, more acid, less moisture, less acid, more moisture 52

53 Summary Moisture control has important impacts on quality of the cheese and profitability of the organisation. Need to balance both Milk varies and need to understand this Cheesemaking practices in the vat can be used to control moisture Data is important 53