TECHNICAL FIELD

The invention is related to a cheese production method.

The invention is related to the automatic production method of SUZME (UF WHITE) cheese carried out without human attendance, which completes its ageing process inside the final consumer packet or package suitable for food products.

PRIOR ART

The consumer demand for white cheese has risen in the last decade and the requirement for reducing contamination risks during process approaches and the need for continuous production processes has increased world-wide.

The production of SUZME (UF white) cheese is based on the Danish method which comprises the application of salt parchment (membrane) following coagulation, and acidification inside the package.

SUZME (UF white) cheese is based on acidification and high concentration fundamentals; first of all the salting process is completed and later on, the Tetra Brik® filling and coagulation stages are completed.

In a publication of Danapark Flexibles A/S (https://www.schurflexibles.com/node/1424). the ultra filtered cheese production is described as follows:“First of all the cheese milk is filled into a container, and the container is left inside the coagulation tunnel for coagulation to be achieved, for 30-60 minutes. Following this, the container is returned to the production line. A salt parchment (membrane) is placed on the cheese such that it will be in direct contact with the cheese. Around 2-5g of salt is added onto the salt parchment (membrane) and following this the container is sealed with an impermeable lid and closed.” In said method, the addition of salt after the coagulation tunnel causes production and hygiene problems. In the application of salt parchment (membrane) a contamination risk occurs for the cheese due to the salt itself and the container ’as the milk retentate - which by definition doesn’t go through the UF membrane, shows a high pH range 6.45- 6.65 before the incubation stage - is directly in contact with the salt parchment and stays in contact with the same container for a few days up to a few weeks following the salting process, this may lead to microbiological contamination risks.

A problem that is frequently faced is that the cheese my show signs of texture problems and/or the cheese may soften due to the application of salt prior to coagulation during incubation.

Besides these, the method needs the usage of a sensitive conveyor system in order to prevent the wrong distribution of salt due to the vibration inside the container and therefore the investment costs for cheese production are increased.

The European Patent document with the application number EP1437047 describes a feta cheese production method that ages inside the consumer package. In this method a cutting process is carried out before ageing. Said cheese continues its ageing process inside the package following the cutting process. The cutting process leads to contamination risk. Besides this the method of the invention is related to products that are around 150, 200 and 250 grams. These gramages are high for single use products.

In the Netherlands Patent Office document with the application number NL7809104 a packaging method of feta cheese in brine has been described. In this method the smallest portion has been described as 200 grams. In this method, it is not possible for the cheese to be presented as single use portions without them being subjected to any kind of cutting process.

A cheese production method that enables the production of cheese from ultrafiltered milk has been described in the American Patent and Trademark Office (USPTO) numbered US 4205090A. The invention is related to a method directed to the processing of milk and milk products and especially a method that can enable to obtain enriched cheese milk or liquid retentate in order to convert said milk or milk products into cheese. In the Worldwide Intellectual Patent Office (WIPO) document numbered WO 20151 10123 A1 production of acidified white cheese has been described. The invention is related to a system and method for the production of acidified white cheese that has been filled into containers before the coagulation of the ultrafiltered retentate.

In the Worldwide Intellectual Patent Office (WIPO) document numbered WO

2008017309A1 cheese production carried out inside a container is described. The method subject to the invention is especially suitable to be applied in cases where the cheese is kept inside brine that is produced as a result of the mixture liquid separated from the concentration, for the production of cheese from milk using ultra filtration or recombination.

In the Worldwide Intellectual Patent Office (WIPO) document numbered WO

1993020704A1 a cheese production method is described. The invention is related to method provided to continuously produce cheese at a homogenous temperature by taking acidified, ultrafiltered-concentrated milk (retentate) as basis, where coloring and coagulation is carried out after the retentate is filled in to ready packages.

In the Worldwide Intellectual Patent Office (WIPO) document numbered WO

1991000690A1 describes a continuous production method of farmer’s cheese obtained from ultrafiltered milk. The cheese is acidified with cheese acids and is produced by adding rennet if desired.

The American Patent and Trademark Office (USPTO) document numbered US 4689234 describes a process for producing cheese. In this invention, the milk, is concentrated with ultra filtration and diafiltration in order to obtain the desired lactose buffer capacity. Following concentration, a starter culture producing lactic acid is incubated into the precipitate and the retentate is fermented inside a fermentation vessel and the desired final pH is generally obtained as 5.2.

As a result, all of the problems mentioned above necessitate developments and novelties to be made to the prior art. OBJECT OF THE INVENTION

The present situation necessitates to solve the above mentioned problems and to provide a technological novelty in the related field.

The main object of the invention is to provide a cheese production method structure where the texture and taste of SUZME (UF White) cheese is produced without using a permeable or impermeable salt parchment (membrane). In otherwords, this new method eliminates the usage of salt parchment (membrane) for the salting process.

Another object of the invention is to enable a more flexible production process that is dependent on the application of dry salt such that it is in direct contact with the coagulated retentate or by carrying out liquid salting (brine) directly to the retentate.

Another object of the invention is to apply a controlled calcium increase process before the demineralization process due to salt addition (NaCI) and acidification in order to obtain the desired coagulation process inside the SUZME (UF white) cheese package. Coagulation can be completed by direct salting, a brine incubation system prior to coagulation, or adding dry salt onto the cheese following coagulation. In order to eliminate the unwanted effect (such as early softening of the cheese, uneven form or a longer fermentation process) of direct salt addition the synchronization of these process steps is very important. The synchronization of these sequences, enables the increase of mineralization balance and starter culture acidification performance before the coagulation and acidification kinetics are carried out which provides correct organoleptic product features.

Another object of the invention is to provide a production method of SUZME (UF white) cheese having a smooth structure which has completed its coagulation process inside the package.

Another object of the invention is to provide a production method of SUZME (UF white) cheese without the need to use salt parchment (membrane).

Another object of the invention is to provide an alternative solution to prevent possible contamination relating to the addition of dry salt. The present invention that is mentioned above and that meets all of the aims that shall be clearly understood by means of the detailed description below is a SUZME (UF white) cheese production method. Said method comprises the below mentioned steps: a) Continuously mixing the milk retentate and adding CaCte, b) Adding LAB (Lactic Acid Bacteria) starter culture to milk retentate and c) Adding salt directly to the milk retentate, without using salt membrane.

As a result the production of cheese with proper taste and texture, without the need to use salt parchment (membrane) has been enabled.

In a preferred embodiment of the invention, CaCte, is added respectively before and during the direct salting process in order to control the correct mineralization- demineralization dynamics of retentate milk.

In a preferred embodiment of the invention, said salt is incubated into the milk retentate as brine before the coagulation process. Therefore the need to carry out salting with a salt parchment later on, has been eliminated.

In a preferred embodiment of the invention, said salt is added to the milk retentate following coagulation, as dry salt. As a result he need to carry out salting with a salt parchment later on, has been eliminated.

In a preferred embodiment of the invention, the LAB starter culture is selected as a mesophylic- thermophylic type that is resistant to salt.

In a preferred embodiment of the invention, the addition of CaCI2 into concentrated retentate milk comprises direct salting prior to or after the coagulation and the incubation of a mixture that has been selected from special starter culture strains. As a result the salt parchment (membrane) usage and the addition of salt thereon carried out in the prior art, has been eliminated.

In a preferred embodiment of the invention, preferably comprises the phase of applying a coagulant to retentate milk, that is selected such as preferably a microbic coagulant (microbic coagulant, fpc= fermentation produced chymosin). Therefore the IMCU (International milk coagulation unit) dosage of the coagulant, is not modified and any kind of excessive dose is not needed in comparison to the preparation method of a standard SUZME (UF white) cheese.

A preferred embodiment of the invention comprises the aging of SUZME (UF white) cheese inside a container suitable for food products without the need to use a salt parchment (membrane) on the surface of the cheese. This allows carrying out an additional incubation process hygienically without being subjected to the risk of contamination from yeast or moulds that are connected to the salt parchment (membrane).

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the invention subject to the production method of SUZME (UF white) cheese has been described with illustrations in order to provide a clear understanding of the subject matter, which should not be deemed to limit the scope of the invention.

The subject matter of the invention is the production method of SUZME (UF white) cheese, which is acidified and incubated inside the final product package or container that is suitable for food products, wherein said production is carried out automatically without the need for human attendance; the method is distinguished in that it comprises the steps of: a) Continuously mixing the milk retentate and adding CaCte, b) Adding LAB (Lactic Acid Bacteria) starter culture to milk retentate and c) Adding salt directly to the milk retentate, without using salt membrane.

The milk retentate that has been mentioned is preferably obtained by means of the below steps; a) A filtration process applied for the milk,

b) Separation and fat standardization processes applied for milk, c) Ultrafiltration method.

Raw milk that has not been processed is kept in containers and following this is transferred into raw milk balancing tanks. The Balancing tank enables the continuous flow of the production line of milk at a certain flow rate. The milk that hat has a certain flow rate, is subjected to a filtering process in order to eliminate harmful substances and particles. Following the filtering process, the milk is subjected to a separation process and the fat from milk is separated.

After the fat is separated, pasteurization is applied in order to eliminate microorganisms that are harmful to milk. The temperatures that are applied during this stage are between 68 to 78°C. Following pasteurization, preferably the milk is cooled in order to prevent bad taste.

The milk is re-heated for the ultra filtration process and it is prepared for ultra filtration. The filtrate that is named as“permeate” with ultra filtration separates the retentate milk from the milk concentrate. This permeate (filtered milk) comprises solubulized salts and lactose and acids. The milk retentate that comprises high value components is obtained following the process.

Following this, in order to prevent the separation of the retentate milk, water and fat components and for them to form two different layers, they are subjected to a homogenization phase. When milk is subjected to high pressure, the fat layer on it is taken off and the milk is mixed with water and this mixture that is called emulsion is formed such that it can remain more stable and concentrated.

The concentrated mixture, is subjected to Pasteurization again in order to eliminate a possible contamination threat. The temperature applied is 75-85°C. The concentrated mixture is transferred into the retentate preparation tank wherein the preparation process comprises the successive steps mentioned below.

During the filling of the retentate tank, calcium solution (CaCI2) is added into the tank such that it has a dosage level between 0.01 % and 0.50% by weight, preferably between 0.15% and 0.25% by weight by mixing and the mixture is homogenously distributing during this mixing process. CaCI2 is added prior to the direct salting process in order to provide the controlling of the correct mineralization - demineralization of retentate milk prior to the addition of salt or during the addition of salt respectively.

Following this LAB (lactic acid bacteria) starter cultures are added to the vessel. The selected cultures are preferably mesophylic-thermophylic types that are resistant to salt. The LAB starter cultures are selected from Lactococcuslactis subsp. lactis, Lactococcuslactis subsp. cremoris, Streptococcusthermophilus,

Lactobacillusdelbrueckii subsp. lactis and Lactobacillusdelbrueckii subsp. Bulgaricus or combinations thereof.

In a preferred embodiment of the invention the LAB starter culture is formed of Lc. lactis, St. thermophilus and Lb. bulgaricus.

The early addition of the mesophylic - thermophylic starter cultures have been developed in order to improve the UpH/dt activity in high protein, high salt medium. The addition process of adding a controlled LAB starter culture between +2 to +20°C degrees, preferably between +12°C degrees and +16°C degrees provides shorter incubation phase and controlled acidification kinetics even under direct salting conditions.

In a preferred embodiment of the invention the salt is incubated as brine into the milk retentate prior to coagulation. In this alternative, the final salt content is between 1.0%- 5.0%, preferably between 1 .50% to 2.20% by weight. A brine process is used to prevent the usage of dry salt in the processing area; brine is prepared preferably by microfiltration comprising pasteurization or with a serial pasteurization process in a double jacket vessel with a salt content between 15-28 Baume, preferably between 18.0 and 22 Baume.

Following said processes the following steps are applied, a) The coagulant is added to the incubated milk retentate, b) The containers are filled with the concentrated mixture, c) Coagulation is carried out between 20 to 40 minutes (preferably before cutting.

Although the mentioned containers are plastic containers that are suitable for food products, preferably they have a volume between 20-2200 ml.

In a preferred embodiment of the invention, the method comprises the steps of applying a selected coagulant (microbic coagulant, fpc=fermentation produced chymosin) such as a microbic coagulant into the retentate milk. This way the IMCU (International milk coagulation unit) dosage of the coagulation is not modified and any kind of excessive dosage is not needed in comparison to the standard SUZME (UF white) cheese preparation method.

In a preferred embodiment of the invention, preferably said salt is homogenously sprinkled onto the coagulated retentate surface as dry salt, following coagulation. Said dry salt is between 1 %-5%, preferably 1 ,5%-2,5% at the final stage. The dry salt is preferably NaCI. Dry salt addition is completed right after the coagulation (and cutting) processes. At this stage, the salt parchment membrane is taken out and salt addition is being carried out onto the surface of the cheese.

Finally the following method steps are carried out, a) The cheese is incubated at 28.0-32.0°C degrees in order to reach the desired pH,

b) Storing between the range of +4 to +8°C degrees and between 1 to 7 days.

When the containers are filled, the incubation process of white cheese is started. The entire incubation process is carried out inside the container.