This invention relates to foodstuffs having a reduced fat content, and more particularly to natural cheese and process cheese product of reduced fat content.

Methods for preparing low fat cheese are known to the art. For example, US. 5,080,913 relates to a process for preparing natural cheese having a low fat content. This process is carried out by dissolving a carrageenan with liquid milk having a fat content of 0-0.3%, adding a lactic acid producing culture thereto, and processing the resulting cheese formulation with clotting enzymes, heating the curd and whey, and separating the whey and ripening the curd. While this process successfully produces low fat natural cheese, the low fat cheese does not possess all of the organoleptic properties of full fat natural cheese.

U.S. 4,476,143 discloses a method of producing low fat natural cheese using a culture of Lactobacillus bulgaricus and Streptococcus thermophilus and with a culture of Lactobacillus casei in addition to a normal cheese starter culture. The use of such a combination of cultures is said to enhance flavor, provide rapid fermentation of lactose, and assist in the hydrolysis of protein.

U.S. 5,192,569 discloses the use of microcrystalline cellulose intimately admixed with a galactomannan gum such as guar gum as a fat substitute for foods such as salad dressings, dairy products such as frozen desserts, e.g., ice cream, and the like.

A number of publications that discuss low fat natural cheese and other dairy products include the following: "Second Thoughts," Dairy Field. p41- 45 (Jan. 1993); Center for Dairy Research, Lowfat Cheddar Seminar, November 7, 1991 ; "Light Cheese Products: Characteristics and Economics," Food Technology. p93-96 (Oct. 1990); Carol Chen, "Reduced Fat Cheeses," Wisconsin Cheese Course, University of Wisconsin, Sept. 23, 1992; and Reisfield, R.A. and Harper, W.J., 1955, A Low-fat Soft Ripening Cheese, Milk Products J. 46(2):24.

The present invention relates to a process for the preparation of reduced fat natural cheese, and to the natural cheese which can be

produced by the process. The natural cheese of the invention possesses excellent organoleptic properties, very similar to the flavor, mouthfeel, and consistency of full fat natural cheese. Low fat natural cheeses known to the art rarely combine the flavor, mouthfeel, and consistency of full fat natural cheese, being more or less deficient in one or more of these important characteristics.

In a process of this invention, a cheese is made using a reduced fat milk having microparticles of a microcrystalline cellulose dispersed therein. The milk may optionally contain a gelling polysaccharide. In another process of this invention, the reduced fat natural cheese is used to make a processed cheese.

The following definitions of cheese, as used herein, conform to those found in the United States, Nutrition Labeling Education Act (NLEA): Cheese is defined as a food for which at least 50% of its calories come from fat and which is commonly consumed in small quantities. For the definitions provided here, the reference amount is 30 grams, and the small serving size is 50 grams.

The following definitions, as used herein, conform to those promulgated by the National Cheese Institute:

The term "Pasteurized Process Cheese Product" denotes a process cheese product which contains at least 45% of natural cheese as a base for the pasteurized process cheese product; any natural cheese can be used. The term "Low fat" denotes a cheese having < 3 grams of fat for both the reference amount and the small serving size.

The equivalent terms "Fat Free" and "Non-Fat" denote a cheese having < 0.5 grams of fat per reference amount.

Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about". A reduced fat, especially low fat and non-fat cheese, and process cheese product, can be produced using the process of this invention.

One way of making a reduced fat cheese according to this process is by using a reduced fat milk having microparticles of microcrystalline cellulose or of a microcrystalline cellu!ose/gum aggregate dispersed therein.

Another way of making a reduced fat cheese according to this process is to additionally including a gelling polysaccharide in the milk. A reduced fat cheese can be made according to this process by

I) dispersing into liquid milk having a butterfat content of from 0.05 to 1.5%, preferably from 0.5 to 1.5%, more preferably from 0.75 to

1.25%, and most preferably 1.0 ± 0.1 %, a) from 0.05 to 0.5%, preferably from 0.1 to 0.3% by weight of microparticles that are an aggregate of from 60 to 99%, preferably from 70 to 95% by weight of microcrystalline cellulose and from 40 to 1 %, preferably from 30 to 5% by weight of a gum, preferably a galactomannan, and b) optionally from 0.0075 to 0.2%, preferably from 0.01 to 0.03% by weight of a gelling polysaccharide, provided that if the gelling polysaccharide is λ-carrageenan it has a relatively low molecular weight; wherein the above percentages by weight of microparticles and the gelling polysaccharide are based on the weight of the liquid milk;

II) heating the above milk dispersion at a temperature and for a time sufficient to pasteurize the milk; III) adding at least one cheese culture to the milk dispersion and incubating as needed to achieve propagation of the culture; IV adding rennet or another clotting enzyme to the milk dispersion to form a coagulum; and V) processing the coagulum to obtain a reduced fat natural cheese.

The microparticles, used in step 1 of the present process, is best characterized as an aggregate, a microcrystalline cellulose that is associated with a galactomannan gum, which aggregate is prepared by coprocessing these two ingredients to form the microparticles according to the process of U.S. 5,192,569. The term "aggregate," as used herein, denotes a stable, substantially physical mixture of two or more components in its wet or dry state, which components, although more firmly bound to each other when dried, remain intact if reconstituted in water under typical food processing conditions. A simple mixture of microcrystalline cellulose and a galactomannan does not behave in the same manner, because, in a simple mixture, the microcrystalline cellulose and the galactomannan are

not associated. Other gums besides galactomannan can be used. The glucomannans are also usable.

The microcrystalline cellulose, used in making the microparticles has a particle size of from 0.1 to 250 microns, preferably from 0.1 to 100 microns, more preferably from 5 to 15 microns. The galactomannan gum, used in making the microparticles, is preferably guar gum, although other carbohydrate polymers containing galactose and mannose, such as locust bean gum, can also be used. Moreover, as disclosed in U.S. 5,192,569, the microparticles are preferably, but not necessarily, substantially spheroidal in shape, and can optionally be coated with a hydrophilic material such as sodium caseinate, whey, egg albumin, or vegetable protein. The microparticles are formed by intimately mixing the microcrystalline cellulose with the galactomannan gum in an aqueous medium, followed by spray- drying to form the microparticles in the above size range. Alternatively, other gums that are compatible with microcrystalline cellulose can be used in this manner to produce a coprocessed microcrystalline cellulose/gum. These include any of the polysaccharides listed below.

The gelling polysaccharide component which is used either to make a coprocessed microcrystalline cellulose/gum or a separate component that can be used in conjunction with microcrystalline cellulose or with coprocessed microcrystalline cellulose/gum can be any gelling polysaccharide. A gelling polysaccharide that is believed to bind protein can be used. A gelling polysaccharide, such as guar gum, an alginate, an agar, a pectin, a konjac, locust bean gum, carboxymethyl cellulose, tragacanth, acacia, furcellaran, gum arabic, carrageenan or any other gelling hydrocolloid can be used. Taste, texture, and melt properties of the cheese may vary depending on the gelling hydrocolloid used.

The gelling polysaccharide can be used as a powder or it can be premixed with water, milk, or other suitable liquid. This component is effective at a low use level. At a high use level it interferes with the cheese making process through dramatic viscosity increases. Based on the weight of the milk, less than 0.0075 percent gelling polysaccharide can be effective. Generally, from 0.00075 to 0.2% is effective.

Carrageenan, when it is used as the gelling polysaccharide, is in the form of a powder, and can be K-, λ-, ι-, or any mixture of these carrageenans, and will depend in part on the end product cheese selected.

However, where λ-carrageenan is employed, either alone or in a mixture with other carrageenans, it should be of relatively low molecular weight, i.e. a 1.5 wt. % concentration of λ-carrageenan in water should have a viscosity between 50 and 200 mPas at 167°F (75°C). The liquid milk component is a liquid milk having the butterfat content set forth above. Whole milk can be employed with excess butterfat being removed. Various low fat milks can be used, to provide lower fat content cheese. Skim milk can be used optionally with the addition of cream or whole milk to adjust the butterfat content into the desired range. The microparticles and carrageenan are dispersed into the milk by stirring, e.g. at ambient temperature. Preferably, in order to prevent clumping of the carrageenan, a dry blend of the microparticles and the carrageenan is formed and this dry blend is then dispersed with stirring into the milk. Sources for the microparticles include Novagel®RCN-10, a spray- dried microparticle of microcrystalline cellulose and guar gum (90: 10 weight ratio), and NOVAGEL®RCN-15, a spray dried microparticle of micro¬ crystalline cellulose with guar gum (85:15 weight ratio). A suitable dry blend is NOVAGEL®NC 200, a dry blend of a spray-dried microparticle of microcrystalline cellulose and guar gum. (85:15 weight ratio) blended with carrageenan. NOVAGEL is a trademark of FMC Corporation for products containing microparticles of a microcrystalline cellulose that has been co¬ processed with a galactomannan by spray drying.

In addition to the microparticles and the gelling polysaccharide, non-fat dry milk can also be added in a quantity of from 0.1 to 1.0, preferably 0.4 to 0.6% by weight, based on the weight of the liquid milk. While the addition of non-fat dry milk is optional, it is preferred since it acts as a dispersant for the microparticles and the gelling polysaccharide, and also increases the casein level of the dispersion. At this stage, cheese flavoring agents, such as lipase enzymes, can be added or they can be added during or following step II. Also, various ions, e.g. K+, NH4+ and Mg++ can be added to control or adjust the texture of the finished cheese. Other additives such as casein stabilizers and vegetable colors such as annatto seed extract or beta carotene can also be added as desired.

In step II the milk dispersion is heated to a temperature of from 162 to 190°F (72.2-87.8°C) to pasteurize the milk. The heating time will depend on the temperature selected. With a preferred temperature range of 180-185°F

(82.2-85°C), a heating time of 16 seconds is optimum. The heating time is not critical, provided sufficient time is allowed to complete the pasteurization process. The above temperature ranges are higher than the usual pasteurization temperature of about 161°F (71.7°C). Although the usual pasteurization temperatures can be used, the use of higher temperatures has been found to provide better and faster dissolution of the gelling hydrocolloid, dispersion of the microparticles, and denaturing of the whey proteins.

Following step II, from 0.01 to 0.02%, preferably 0.02% by weight, based on the weight of liquid milk, of calcium chloride is then optionally added. The addition of calcium chloride, while not essential to the present process, is highly desirable since it provides additional calcium and also assists in achieving an interaction between the gelling hydrocolloids, if any occurs, and milk proteins, and provides a firmer curd structure. In step III, a cheese culture or cultures is/are added to the milk dispersion. Preferred cheese cultures depend in part on the end product cheese desired. For example, for a reduced fat cheddar cheese, Lactococcus lactis subsp. cremoris, strain SKII or Lactococcus lactis subsp. diacetylactis, strain JVI or a mixture of the two are preferred. Other cultures that can be employed for reduced fat natural cheeses include Streptococcus lactis, Streptococcus cremoris, Strepococeus thermophilus, Lactobacillus helveticus, Lactobacillus bulgaricus, and Lactobacillus casei. Pure strains of these bacteria cultures can be obtained commercially. The milk dispersion containing the culture or cultures is incubated as needed to achieve propagation of the culture throughout the milk dispersion. The incubation temperature and incubation time are dependent on the culture or cultures used. Generally, a temperature of 80-100°F (26.7-37.8°C) for an hour is satisfactory, provided the temperature chosen does not inactivate or interfere with the propagation of the bacteria. It is highly preferred in the practice of this invention to add the cheese culture in a quantity approximately double that normally used for the culture and the natural cheese being manufactured. It was discovered that when such double quantities are used, the incubation period can usually be eliminated, or at least substantially reduced. Following incubation, if employed, the milk dispersion is maintained at a temperature of about 90°F (32.2°C).

Step IV is carried out by adding to the milk dispersion from 125 to 165 ml, preferably from 130 to 150 ml of pure liquid rennet per 1000 lbs. (373.2 kg) of milk dispersion. If double strength rennet is used, or if another clotting enzyme is employed, the quantity thereof is preferably adjusted to be equivalent in coagulating activity to the above single strength rennet. Upon addition of the rennet or other clotting enzyme, the milk dispersion is allowed to stand until coagulation occurs, usually within 30 to 35 minutes. The above quantity of rennet is greater than quantities normally used in cheese manufacture, and is employed in the present process to provide firm curd clotting in relatively short periods of time, i.e. within a 15 to 35 minute time frame, in order to entrap the microparticles uniformly within the curd structure before they can settle to the bottom of the processing vat.

In step V the coagulum is processed to obtain the reduced fat natural cheese. This step can be carried out by techniques well known to the art of cheese manufacture, and such techniques do not comprise part of the present invention. The following standard technique has proven to be useful in processing the coagulum:

1. the coagulum (curd) is cut into 1/4 inch (0.63 cm) cubes and allowed to heal for from 3 to 5 minutes. 2. the cubed curd is cooked by raising the temperature to 100°F

(37.8°C) over a period of at least 30 minutes with agitation, and then held at 100°F (37.8°C) for 45 minutes.

3. the curd is allowed to settle and the whey is drained off.

4. the curd is then matted and cut into slabs. . 5. the curd is next milled with acidifying agents and salt.

6. the milled cheese is hooped and pressed for 16 hours. The reduced fat natural cheese product which can be produced by the process of the invention is accordingly a ripened curd from a pasteurized clotted cheese formulation containing A) a liquid milk having a butterfat content of from 0.5 to 1.5%;

B) microparticles consisting essentially of an aggregate of from about 60 to about 99% by weight of microcrystalline cellulose and from about 40 to about 1 % by weight of a galactomannan gum;

C) at least one gelling hydrocolloid; and D) at least one cheese culture.

Quantities of components in the cheese formulation are as set forth above in the description of the process of the invention.

The process of the invention can be used to prepare any type of reduced fat or non-fat natural cheese, including cheddar cheese, blue cheese, Parmesan cheese, Romano cheese, Camembert cheese, Gouda cheese, Jack cheese, Muenster cheese, Colby cheese, and Mozzarella cheese.

The excellent organoleptic properties of the reduced fat and non-fat natural cheeses of the invention arise at least in part from the presence of the microparticulates, which have been found to disrupt the casein microstructure and hence significantly and unexpectedly enhance the texture of the natural cheese product, as well as its mouthfeel. The resulting porous casein microstructure is very similar to that observed in full-. fat cheese. In addition, the presence of the gelling polysaccharide is important. One or more carrageenans, alginates or other gelling hydrocolloids that produce a desirable alteration of the milk proteins, can be employed. The carrageenans, for instance, have been found to react with κ-casein micelles. The resulting carrageenan-casein complex also enhances the melting properties of the natural cheese since this complex is thermally-reversible.

Hence, the reduced fat natural cheese, as well as the non-fat natural cheese, of the invention is softer, with a more easily deformable texture, and with enhanced meltability compared to other reduced fat natural cheeses having the same or similar percentage fat reduction. A process cheese product may be made from a reduced fat, including a non-fat natural cheese of this invention, produced as described herein. The reduced fat (non-fat), pasteurized process cheese product can be made by mechanically reducing the reduced fat (non-fat) natural cheese to a uniform mixture of fine particles, and then dry blending with a blend of appropriate functional process cheese constituents, such as an emulsifying agent (sodium or potassium citrate, phosphate, pyrophosphate, aluminum phosphate, or tartrate, and other known emulsifying agents), a preservative (salt, sorbic acid), gelling agent (kappa, lambda, or iota carrageenan, alone or in combination; carob bean gum, gum karaya, gum tragacanth, guar gum, gelatin, cellulose gum, oat gum, algin, xanthan gum) , a protein source

(non-fat milk solids, sweet dairy whey), a sweetener (corn syrup, com syrup

solids, other common sweeteners, sugar, dextrose, corn sugar, glucose syrup, glucose syrup solids, maltose, malt syrup, and hydrolyzed lactose), moisture content control agent (water), and acidifying agent (lactic acid, acetic acid, citric acid, and phosphoric acid); and optionally, a preservative (the sodium or calcium salts of proprionic acid and sorbic acid, and nisin), a colorant (annatto seed extract or any other harmless artificial colorant), and a flavorant (any flavoring that simulates the taste of cheese of any age or variety). The resultant mixture is then pasteurized, preferably at a temperature greater than 73.9°C (165°F). The cheese when pasteurized is in a molten form that can be poured into a mold or into slice forming equipment, and cooled to provide a firm process cheese product that is sliceable at room temperature.

The finished pasteurized process cheese product conforms to the National Cheese Institute guidelines for pasteurized process cheese product. These guidelines do not expressly mention non-fat cheese, because non-fat cheese was not available at the time the guidelines were drafted; however, the cheese made according to this invention fits within the guidelines.

According to these guidelines the pasteurized process cheese product has more than 45% base cheese for certain cheese mixtures, more than 51 % base cheese for all others; not more than 3% emulsifying agents; not more than 0.8% gelling agent; a final product pH >4 between 44-60% moisture; 0.1 to 0.3% preservative. Protein can be added to modify the texture, form, and structure of the cheese. Process cheese which varies from these guidelines can also be made on the basis of the disclosure made herein. Broadly speaking, a process cheese product, whether or not it conforms to the published guidelines can be made using: at least 42% base cheese, preferably at least 45% base cheese, more preferably at least 51 % base cheese, most preferably 42 to 70% base cheese; 0.1 to 5% emulsifying agent, preferably 0.1 to 0.3% emulsifying agent, and most preferably 0.2 to 0.3 % emulsifying agent; 0.05 to 0.8 % gelling agent , preferably from 0.1 to 3% gelling agent, and most preferably from 0.2 to 0.3% gelling agent; from 0 to 6% preservative, preferably from 0.1 to 0.3% preservative, and most preferably from 0.2 to 0.3 % preservative; and from 40 to 70% total moisture, preferably from 40 to 60% total moisture. Typically, during the process of making the process

cheese product, 0 to 70 weight percent water, preferably 20 to 60 weight percent water, and most preferably 40 to 60 weight percent water, based on the weight of the ingredient mixture, will be added to produce a process cheese product having the desired moisture content, it being understood that the original base cheese has from 35 to 70 percent moisture.

In another embodiment, a reduced fat natural cheese can be made using microparticles, the aggregate of microcrystalline cellulose and a galactomannan, such as guar gum; no gelling polysaccharide, need be used. However, generally, the gelling polysaccharide, if used, will improve the organoleptic, and melt properties of the cheese.

Such a natural cheese, made without the gelling polysaccharide, generally has from 0.05 to 1.5%, preferably from 0.5 to 1.0 %, and most preferably from 0.75 to 1.25% by weight of microparticles consisting essentially of an aggregate of from 60 to 99%, preferably from 70 to 95% by weight of microcrystalline cellulose and from 40 to 1 %, preferably from 30 to 5% by weight of a galactomannan gum, based on the weight of the milk used to make the cheese.

A reduced fat process cheese product, including a non-fat process cheese product can be made using any reduced fat, and or non-fat, natural cheese produced product, described herein, or made according to any process described herein.

The invention is illustrated by the following examples.

EXAMPLES

Example 1

Manufacture of cheddar cheese having a fat content reduced by 67% compared to full-fat cheddar cheese.

1000 Lbs. (373.2 kg) of raw whole milk was obtained and its fat content reduced to 1 % butterfat. 2.2 Lbs. (0.82 kg) of a dry blend of 0.2 lbs. (0.075 kg) of i-carrageenan and 2.0 lbs. (0.75 kg) of spray-dried microparticles of microcrystalline cellulose and guar gum (85:15 weight ratio) (NOVAGEL® RCN-15, a product of FMC Corporation, Philadelphia, PA) was prepared and added with stirring to the reduced fat milk, together with 5 lbs. (1.87 kg) of non-fat dry milk. The resulting dispersion was pasteurized at a temperature of 180-185°F (82.2-85°C) for 16 seconds. 0.2 Lbs. (0.075 kg)

of calcium chloride was then added, followed by the addition of a cheese culture of Lactococcus lactis subsp. cremoris, strain SKII. 150 Ml of liquid single strength rennet was added and after the mixture stood for 35 minutes, the resulting coagulum (curd) was removed from the whey and cut into 1/4 inch (0.63 cm) cubes and heated for 4 minutes. The cubes were heated to 100°F (37.8°C) over a period of 30 minutes with agitation and held at 100°F (37.8°C) for 45 minutes. The cubes were allowed to settle and the whey drained off. The cubes were matted and cut into slabs, followed by cheddar flipping every 15 minutes. Milling at 0.45% - 0.50% titratable acidity was carried out, followed by the addition of 2 lbs. (0.75 kg) of salt. The cheese mixture was then hooped and pressed for 16 hours.

The resulting low fat cheddar cheese had a soft smooth texture, a uniform color, and a flavor and mouthfeel substantially indistinguishable from the full-fat cheddar cheese of Comparative Example 2 below.

Comparative Example 1

Reduced fat cheddar cheese without the addition of i-carraoeenan and sprav-dried microparticulates.

The process of Example 1 was repeated except that no ι ₇ carrageenan or spray-dried microparticulates were added.

The resulting low fat cheddar cheese had a firm texture and an unacceptable mouthfeel.

Comparative Example 2 Full-fat cheddar cheese.

A full-fat cheddar cheese was prepared according to the process of

Example 1 except that whole milk was used without any reduction in butterfat content, and without the addition of i-carrageenan and spray-dried microparticulates. This full-fat natural cheddar cheese had a soft smooth texture, uniform color and an excellent flavor and mouthfeel.

Example 2

Manufacture of Monterey cheese having reduced fat content. 1000 Lbs. (373.2 kg) of sweet, high quality whole milk is standardized to a 0.9% butterfat content. 2.2 Lbs. (0.82 kg) of a dry blend of 0.2 lbs.

(0.075 kg) of κ-carrageenan and 2.0 lbs. (0.75 kg) of spray-dried microparticles of microcrystalline cellulose and guar gum (85:15 weight ratio) (NOVAGEL® RCN-15, a product of FMC Corporation, Philadelphia, PA) is prepared and added with stirring to the reduced fat milk, together with 5 lbs. (1.87 kg) of non-fat dry milk. The resulting, dispersion is pasteurized at a temperature of 180°F (82.2°C) for 16 seconds. The milk dispersion is cooled to 90°F (32.2°C) and pumped into a cheese vat. 0.2 Lbs. (0.075 kg) of calcium chloride is then added, followed by the addition of 2.0% by weight of a mixture of equal parts of Lactobacillus casei and Lactobacillus helveticus. 25 Ml of annatto cheese color are added. 4.5 Oz. (0.10 kg) of single strength rennet extract, diluted 1 :40 with tap water, is added, and the milk dispersion is stirred for 5 minutes. The vat is then covered, and a curd forms in about 30 minutes.

The solid curd is cut with 5/8" (1.59 cm) wire knives. The cut curds are allowed to remain in the whey for about 5 minutes, with occasional agitation. The curd-whey mixture is then heated to 102°F (38.9°C) in about 30 minutes, using steam in the vat jacket, with continued gentle stirring to avoid matting. During the first 10 minutes of heating the temperature is raised only 2°F (1.1 °C). When the temperature of 102°F (38.9°C) is obtained, the curds are gently stirred until the titratable acidity of the whey has increased 0.02%. When the curd cubes are firm, with only a few showing soft centers, they are allowed to settle and pushed back gently with a rake through the whey to the end of the vat. The whey is drained through a metal sieve in the vat gate so that one inch of whey remains above the curds. Enough clean cold water is added to reduce the temperature of the curds to 86°F (30°C). The curds are allowed to soak at this temperature for 5 minutes, followed by draining of all of the watered whey through a metal sieve. The curd is next trenched in the vat. 2.5 Lbs. (0.93 kg) of salt is added per 100 lbs. (37.32 kg) of curd using 2 or 3 scattering applications. The dry curds are stirred for 30 minutes to incorporate the salt uniformly. The salted curds are then placed on previously sterilized muslin cloths, which are then gathered and tied with a string. Each bag is shaped by hand into a very firm, round ball. The bags are placed in a vertical plate press and light to medium pressure applied for 24 hours. The cloths are then removed from the round, flat cheese, and the cheese is then dried in a drying room at 70%

relative humidity at about 60°F (15.56°C). After drying, the cheese wheels are immersed in hot paraffin at 245°F (118.3°C) and stored.

Example 3 Manufacture of reduced fat Brick cheese.

1000 Lbs. (373.2 kg) of sweet, high quality whole milk is standardized to a 0.85% butterfat content. 2.2 Lbs. (0.82 kg) of a dry blend of 0.2 lbs. (0.075 kg) of κ-carrageenan and 2.0 lbs. (0.75 kg) of spray-dried microparticles of microcrystalline cellulose and guar gum (90:10 weight ratio) (NOVAGEL® RCN-10, a product of FMC Corporation, Philadelphia, PA) is prepared and added with stirring to the reduced fat milk, together with 5 lbs. (1.87 kg) of non-fat dry milk. The resulting dispersion is pasteurized at a temperature of 180°F (82.2°C) for 16 seconds. The milk dispersion is cooled to 90°F (32.2°C) and pumped into a cheese vat. 0.2 Lbs. (0.075 kg) of calcium chloride is then added, followed by the addition of 0.5% by weight of Streptococcus lactis. 25 Ml of beta carotene is added. 4.5 Oz. (0.10 kg) of single strength rennet extract, diluted 1:40 with tap water, is added, and the milk dispersion is stirred for 3 minutes. The vat is then covered, with a curd forming in about 30 minutes. The solid but slightly soft curd is cut with 5/8" (1.59 cm) wire knives.

The cut curds are allowed to remain in the whey for about 10 minutes, with occasional gentle agitation. The curd-whey mixture is then slowly heated to 96°F (35.6°C) in about 30 minutes at a rate of 1°F (0.55°C) rise every 5 minutes, using steam in the vat jacket with continued gentle stirring to avoid matting. When the temperature of 96°F (35.6°C) is reached, the steam is turned off, and the curds are allowed to settle. The curds are next pushed back gently with a rake through the whey to the end of the vat. The whey is drained through a metal sieve in the vat gate so that one inch of whey remains above the curds. Enough clean cold water is added to reduce the temperature of the curds to 96°F (35.6°C). The curds are allowed to soak at this temperature for 15 minutes. The watered whey level is reduced by draining until one inch remains above the curd bed.

The curds are ladled from the vat and added to open-ended, rectangular, perforated metal forms which rest on heat-sterilized bamboo or nylon draining mats. A metal plate or follower is applied to the cheese surface, and a clean, glazed brick weight is placed on each plate. Every 30

minutes the weights and plates are removed, the rectangular forms are turned over, and the weights and plates reapplied to the upper surfaces of the cheese. After a total of four such turnings, the cheese is kept in the forms, weighted down with the plates and glazed bricks, overnight at about 75°F (23.9°C). The cheese curd blocks are removed from the forms with a spatula, and the blocks placed in 23% NaCI brine at 50°F (10°C) for 24 hours. Dry salt is then sprinkled on the surfaces of the floating cheese. The salted curd blocks are set on their edges or short widths on wooden shelves in a curing room. The wooden shelves are previously wiped with a nutrient broth suspension of B. linens. The curd blocks are arranged so that the flat side of each block touches its neighbor. The curing room is maintained at 60°F (15.6°C) and 95% relative humidity. Each day for 11 or 12 days the flat sides of the cheese blocks are wetted with 5% warm salt solution. The cheese blocks are then transferred to a cleaning area, the surfaces washed with warm dilute salt solution, and dried for 24 hours in a drying room maintained at 60°F (15.6°C) and 70% or lower relative humidity. The dried cheese is dipped in paraffin wax at 245°F (118.3°C) and stored.

Example 4

Preparation of reduced fat Edam-type cheese.

1000 Lbs. (373.2 kg) of sweet, high quality whole milk is standardized to 0.70% butterfat content. 2.2 Lbs. (0.82 kg) of a dry blend of 0.2 lbs. (0.075 kg) of κ-carrageenan and 2.0 lbs. (0.75 kg) of spray-dried microparticles of microcrystalline cellulose and guar gum (90:10 weight ratio) (NOVAGEL® RCN-10, a product of FMC Corporation, Philadelphia, PA) is prepared and added with stirring to the reduced fat milk, together with 5 lbs. (1.84 kg) of non-fat dry milk. The resulting dispersion is pasteurized at a temperature of 180°F (82.2°C) for 16 seconds. The milk dispersion is cooled to 90°F (32.2°C) and pumped into a cheese vat. 0.2 Lbs. (0.075 kg) of calcium chloride is then added, followed by the addition of 1.0% by weight of a mixture of equal parts of Lactococcus lactis subsp. cremoris, strain SKII and Lactococcus lactis subsp. diacetylactis, strain JVI. 80 Ml of beta carotene is added. 192 Ml of single strength rennet extract, diluted 1 :40 with tap water, is added, and the milk is stirred for 3 minutes. The vat is then covered, with a curd forming in about 15 minutes. The curd is

considerably softer than the curd of Cheddar cheese. The solid curd is cut with 5/8" (1.59 cm) wire knives. The cut curds are allowed to remain in the whey for about 5 minutes. The curd-whey mixture is then slowly heated to 95°F (35°C) in about 15 minutes, at a rate of 1.5°F (0.83°C) increase every minute. The curds are stirred at 95°F (35°C) until they firm up in body without getting rubbery (usually about 30 minutes). The whey is drained through a metal strainer fitted into the exit gate of the vat until the remaining whey is just at the upper level of the curd bed. The warm curds and whey are rapidly ladled into metal molds lined with cheesecloth which were previously warmed in hot water. The temperature is maintained above 86°F (30°C). The heavy top lids of the molds are fitted into position and allowed to press down on the curds to force out the whey. The molds are then placed under light pressure for 30 minutes. The balls of curd are removed from the forms, washed in sweet whey at 70°F (21.1°C), wrapped in cheesecloth and replaced in the molds. The curds are pressed for 8-12 hours at about 5-10 psi (3515-7031 kgm ² ) using weights. The cheese is removed from the molds and cloths and immersed in 23% saturated brine solution at about 50°F (10°C) for 8-10 days, with daily turning and sprinkling with coarse salt. The cheese is removed from the brine solution, washed, dried, and placed on clean wooden shelves or cradles in a room at 60°F (15.6°C) and 90% relative humidity. Each wheel of cheese is turned and lightly salted each day for two weeks and twice weekly thereafter for an additional three weeks. The cheese is then waxed and ripened.

Example 5

Preparation of Gouda-type reduced fat cheese.

The process of Example 4 is followed except for the following changes: The whole milk is set.

Flat wheel shapes rather than spherical shapes are formed. The curd is cut into small, wheat grain size pieces with 3/16" knives.

The curd is held in saturated brine for 2 days. The wheels of cheese are placed on cheese shelving, no salt is applied, but the wheels are turned and washed with a wet cloth daily. The cheese is ripened for 3 months at 59°F (15°C).

The ripened cheese is coated with a yellow or orange wax.

Example 6

Preparation of a fat-free Colby cheese:

1000 lbs. of a sweet, high quality, liquid, starting milk is standardized to <0.1 % butterfat with the addition of a dry blend 2.0 lbs. of microparticles of coprocessed microcrystalline cellulose and guar gum (85:15 weight ratio) having a particle size range of 10-60 microns (Novagel RCN 15, a product of FMC Corporation, Philadelphia, PA) and 0.5 lbs of κ-carrageenan is prepared and added with agitation to the starting milk, together with 5 lbs. of non fat dry milk. The resulting dispersion is pasteurized at a temperature of 72.2°C (162°F) for 16 seconds. The milk dispersion is cooled to 32.2°C (90°F) and pumped into a cheese vat. 0.2 lbs. of calcium chloride is then added, followed by 2.0% by weight addition of cheese culture Lactococcus lactis subsp. cremoris, strain SKII with Lactococcus lactis, subspecie diactylactis, strain JVI in a 10:1 ratio with 0.05% by weight of Lactobacillus casei cells. Four and one-half ounces of a single-strength rennet extract, diluted 1 :40 with tap water, is added and the milk dispersion is stirred for 5 minutes. The vat is then covered and the solid curd which forms in about 30 minutes, is cut using 3/8" wire knives. The cut curds are allowed to remain in the whey for about 5 minutes with occasional agitation. The curd whey mixture is then heated, with continuous stirring, to avoid matting using steam in the vat jacket, to 38.8°C (102°F) in about 30 minutes. During the first 10 minutes of heating, the temperature rises only 2 degrees. When the temperature reaches 38.8°C (102°F), the curds are gently stirred until the titratable acidity of the whey has increased 0.02%. When the curd cubes are firm with only a few showing soft centers, they are allowed to settle and pushed back by a rake to the end of the vat. The whey is drained at 0.14% titratable acidity to a point where only 1 in. of whey covers the curds. Enough clean, cold water is added to reduce the temperature of the curds to 21.1 °C (70°F) where they are allowed to soak for 10 minutes, followed by draining of all watered whey through a metal sieve. The curd is formed into trenches along the vat sides. Two pounds of salt is added per 1000 lbs. of milk during 3 scattering applications. The salted curds are then placed in fabric-lined, stainless steel boxes with collapsible ends that are placed in a horizontal hydraulic press (20 psi) for 16 hours. Upon removal from the press, the blocks of compressed curd are taken out of the steel boxes then

vacuum-sealed in plastic film wrap. The cheese is aged for 30-60 days at a storage temperature of 7.2-15.5°C (45-60°F).

Example 7 Preparation of a fat-free pasteurized process cheese product:

To make 1000 lbs. of fat-free pasteurized process cheese product, grind 510 lbs. of a Colby cheese, containing butterfat and ~ 56% moisture, made as described in Example 6, to produce a uniform mixture of fine particles. The cheese is added to a steam-injected lay-down cooker wherein it is moved from front to back in a circular motion by an auger agitator. A dry blend, comprised of 18 lbs. sodium citrate, 5 lbs disodium phosphate, 10 lbs salt, 1.5 lbs sorbic acid, 6 lbs κ-carrageenan, 47 lbs non¬ fat milk solids, 47 lbs sweet dairy whey and 15 lbs of corn syrup solids, is added to the cooker with about 210 lbs water (allowing for 10% additional water from condensate). Add 25 lbs of a 10% lactic acid solution. Add preservative, color and flavor as preferred. The mixture is heated to a sufficient temperature for pasteurization, 73.8-82.2°C (165-180°F), then filled into waxed paper-lined boxes or slice-forming equipment. The molten cheese then solidifies upon cooling. The process cheese, made by the above method, has a firm, sliceable structure at room temperature.

Shredded pieces maintain shape and do not remat under light pressure. The cheese melts into a uniform mass upon cooking at 232.2°C (450°F) for 5 minutes in a conventional oven.

Example 8

Preparation of a fat-free Colby cheese:

1000 lbs. of a sweet, high quality, liquid, starting milk is standardized to <0.1 % butterfat with the addition of a dry blend 2.0 lbs. of microparticles of a coprocessed microcrystalline cellulose and guar gum (85:15 weight ratio) having a particle size range of 10-60 microns (Novagel RCN 15, a product of FMC Corporation, Philadelphia, PA); then 0.25 lbs of one of gums shown in Table 1 is added with agitation to the starting milk, together with 5 lbs. of non fat dry milk. The resulting dispersion is pasteurized at a temperature of 72.2°C (162°F) for 16 seconds. The milk dispersion is cooled to 32.2°C (90°F) and pumped into a cheese vat. to which 0.2 lbs. of calcium chloride is then added, followed by 2.0% by weight addition of cheese culture

Lactococcus lactis subsp. cremoris, strain SKII with Lactococcus lactis, subspecie diactylactis, strain JVI in a 10:1 ratio with 0.05% by weight of Lactobacillus casei cells. Four and one-half ounces of a single-strength rennet extract, diluted 1 :40 with tap water, is added and the milk dispersion is stirred for 5 minutes. The vat is then covered and the solid curd which forms in about 30 minutes, is cut using 3/8" wire knives. The cut curds are allowed to remain in the whey for about 5 minutes with occasional agitation. The curd whey mixture is then heated, with continuous stirring, to avoid matting using steam in the vat jacket, to 38.8°C (102°F) in about 30 minutes. During the first 10 minutes of heating, the temperature rises only 2 degrees. When the temperature reaches 38.8°C (102°F), the curds are gently stirred until the titratable acidity of the whey has increased 0.02%. When the curd cubes are firm with only a few showing soft centers, they are allowed to settle and pushed back by a rake to the end of the vat. The whey is drained at 0.14% titratable acidity to a point where only 1 in. of whey covers the curds. Enough clean, cold water is added to reduce the temperature of the curds to 21.1°C (70°F) where they are allowed to soak for 10 minutes, followed by draining of all watered whey through a metal sieve. The curd is formed into trenches along the vat sides. Two pounds of salt is added per 1000 lbs. of milk during 3 scattering applications. The salted curds are then placed in fabric-lined, stainless steel boxes with collapsible ends that are placed in a horizontal hydraulic press (20 psi) for 16 hours. Upon removal from the press, the blocks of compressed curd are taken out of the steel boxes then vacuum-sealed in plastic film wrap. This cheese is aged for 30-60 days at a storage temperature of 7.2-15.5°C (45- 60°F).

Table 1

Skim milk Cheese with Various Hydrocolloids

Sample Variable Moisture Solids Yield H ₂ 0

% % % % Increase

Control None 54.3 45.7 7.2

B Sodium 55.84 44.16 7.7 2.8 Alginate

C Agar 55.17 44.83 7.6 1.6

D LM Pectin ¹ 55.15 44.85 7.4 1.7

E Konjac 55.22 44.78 7.5 1.6

¹ LM Pectin = Low methyl Pectin

The natural cheese made as described in this example, including the co-processed microcrystalline cellulose/guar control, are softer than any natural cheese made without these ingredients.

Example 9

Preparation of a fat-free Colby cheese:

1000 lbs. of a sweet, high quality, liquid, starting milk is standardized to <0.1 % butterfat with the addition of a dry blend 2.0 lbs. of microparticles of microcrystalline cellulose having a particle size range of 10-60 microns and 0.5 lbs of K-carrageenan is prepared and added with agitation to the starting milk, together with 5 lbs. of non fat dry milk. The resulting dispersion is pasteurized at a temperature of 72.2°C (162°F) for 16 seconds. The milk dispersion is cooled to 32.2°C (90°F) and pumped into a cheese vat. 0.2 lbs. of calcium chloride is then added, followed by 2.0% by weight addition of cheese culture Lactococcus lactis subsp. cremoris, strain SKII with Lactococcus lactis, subspecie diactylactis, strain JVI in a 10:1 ratio with 0.05% by weight of Lactobacillus casei cells. Four and one-half ounces of a single-strength rennet extract, diluted 1:40 with tap water, is added and the milk dispersion is stirred for 5 minutes. The vat is then covered and the solid curd which forms in about 30 minutes, is cut using 3/8" wire knives. The cut curds are allowed to remain in the whey for about 5 minutes with

occasional agitation. The curd whey mixture is then heated, with continuous stirring, to avoid matting using steam ^' in the vat jacket, to 38.8°C (102°F) in about 30 minutes. During the first 10 minutes of heating, the temperature rises only 2 degrees. When the temperature reaches 38.8°C (102°F), the curds are gently stirred until the titratable acidity of the whey has increased 0.02%. When the curd cubes are firm with only a few showing soft centers, they are allowed to settle and pushed back by a rake to the end of the vat. The whey is drained at 0.14% titratable acidity to a point where only 1 in. of whey covers the curds. Enough clean, cold water is added to reduce the temperature of the curds to 21.1 °C (70°F) where they are allowed to soak for 10 minutes, followed by draining of all watered whey through a metal sieve. The curd is formed into trenches along the vat sides. Two pounds of salt is added per 1000 lbs. of milk during 3 scattering applications. The salted curds are then placed in fabric-lined, stainless steel boxes with collapsible ends that are placed in a horizontal hydraulic press (20 psi) for 16 hours. Upon removal from the press, the blocks of compressed curd are taken out of the steel boxes then vacuum-sealed in plastic film wrap. The cheese is aged for 30-60 days at a storage temperature of 7.2-15.5°C (45-60°F).

Example 10

Preparation of a fat-free pasteurized process cheese product:

To make 1000 lbs. of fat-free pasteurized process cheese product, grind 510 lbs. of a Colby cheese, containing butterfat and ~ 56% moisture, made as described in Example 6, to produce a uniform mixture of fine particles. The cheese is added to a steam-injected lay-down cooker wherein it is moved from front to back in a circular motion by an auger agitator. A dry blend, comprised of 18 lbs. sodium citrate, 5 lbs disodium phosphate, 10 lbs salt, 1.5 lbs sorbic acid, 6 lbs -carrageenan, 47 lbs non- fat milk solids, 47 lbs sweet dairy whey and 15 lbs of corn syrup solids, is added to the cooker with about 210 lbs water (allowing for 10% additional water from condensate). Add 25 lbs of a 10% lactic acid solution. Add preservative, color and flavor as preferred. The mixture is heated to a sufficient temperature for pasteurization, 73.8-82.2°C (165-180°F), then filled into waxed paper-lined boxes or slice-forming equipment. The molten cheese then solidifies upon cooling. The process cheese, made by the

above method, has a firm, sliceable structure at room temperature. Shredded pieces maintain shape and do not remat under light pressure. The cheese melts into a uniform mass upon cooking at 232.2°C (450°F) for 5 minutes in a conventional oven.