Field of the invention

The present invention relates to cheese making. More particularly, the invention relates to a method of preparing processed cheese by using a dairy based emulsifier without emulsifying salts. The invention also relates to such an emulsifier, a process for its preparation and its use in the production of processed cheese.

Background of the invention

Processed cheese provides a commercially interesting product to cheesemaker. Processed cheese has some significant advantages over unprocessed cheese, such as an extended shelf life. Moreover, it is possible to use cheese cuttings produced in cheese packaging.

In conventional manufacturing processes of processed cheeses, natural cheese or natural cheeses of different types, ages and degrees on maturity are blended with emulsifying salts/melting salts, water and other dairy and non- dairy ingredients, cooked and cooled to provide a homogenous smooth mass of cheese. Emulsifying salts are necessary ingredients in the production of processed cheese to emulsify fat into water and to dissolve insoluble calcium of cheese to a soluble form when the cheese material is cooked. The traditional emulsifying agents are typically sodium salts of phosphorous acid.

The function of the emulsifying salts is based on their ability to replace calcium in insoluble calcium-paracaseinate by sodium and thereby improve the emulsification properties of casein in the preparation of processed cheese.

An increasing trend of avoiding additives in food products has prompted to prepare processed cheese without emulsifying salts. Indeed, there are processed cheeses where the traditional emulsifying salts are replaced by calcium-depleted milk protein concentrates. For example, EP 2027776 A1 discloses processed cheese without emulsifying salts, comprising calcium re- duced casein source in an amount of about 2.5 to about 20 percent (solid basis). WO 2010/140905 A1 discloses a method for preparing calcium fortified processed cheese without emulsifying salts, wherein a substantially insoluble calcium source is mixed with a dairy liquid composition comprising casein where at least part of its divalent ions is replaced with sodium or potassium ions. The composition is then cooked to obtain an emulsion and the cooked composition is cooled to obtain a processed cheese. WO 2008/079031 A2 discloses a calcium- and phosphate depleted milk protein concentrate useful in making processed cheese.

One problem of the prior art processed cheeses is that their organo- leptic properties are not flawless but there are significant defects especially in taste. Whey proteins included in the prior art processed cheeses cause cooked/burnt flavour in processed cheese subjected to high heat treatment.

Thus, there is a need for processed cheese with good organoleptic properties, such as taste and texture, without undesirable additives. Brief description of the invention

An aspect of the invention is to provide a method of preparing processed cheese, comprising the steps of:

- forming a mixture comprising natural cheese(s) and a dairy based Ca-depleted sodium caseinate emulsifier substantially free of whey proteins;

- heating the mixture to about 80°C to about 142°C under stirring until a homogenous mixture is formed;

- cooling the homogenous mixture to provide processed cheese. Another aspect of the invention is to provide a dairy based Ca- depleted sodium caseinate emulsifier substantially free of whey proteins.

Still another aspect of the invention is to provide a method of preparing a dairy based Ca-depleted sodium caseinate emulsifier substantially free of whey proteins, comprising subjecting a milk raw material to microfiltra- tion and calcium depletion to provide the dairy based Ca-depleted sodium caseinate emulsifier, and concentrating the emulsifier by evaporation to a total solids content of about 10% to about 100%.

A still further aspect of the invention is to provide a use of a dairy based Ca-depleted sodium caseinate emulsifier substantially free of whey proteins in the production of processed cheese.

A still further aspect of the invention is to provide processed cheese having a ratio of Ca/P of > about 1 .0 and a content of phosphorous of at most about 2500 mg/1000 g cheese.

The invention provides an economical and efficient method for preparing processed cheese with good organoleptic properties where an effective emulsification of natural cheese raw material without any fat/water separation during heating is achieved with the dairy based emulsifier of the invention. In addition, the invention provides a method to prepare processed cheese with favourable texture and good organoleptic properties, i.e. smooth and creamy texture, glossy appearance and more intense flavour of natural cheese raw material, without any off-tastes caused by additives or ingredients. Detailed description of the invention

In an aspect, the present invention provides a method of preparing processed cheese, comprising the steps of:

- forming a mixture comprising natural cheese(s) and a dairy based Ca-depleted sodium caseinate emulsifier substantially free of whey proteins;

- heating the mixture to about 80°C to about 142°C under stirring until a homogenous mixture is formed;

- cooling the homogenous mixture to provide processed cheese. In the present invention,

the term "substantially free of whey proteins" will be understood to mean that the ratio of casein to whey protein is more than about 95:5;

the term "natural cheese" will be understood to be natural cheese according to Codex Alimentarius definition. Natural cheese can be ripened or unripened soft, semi-hard, hard, or extra-hard product, in which the whey protein/casein ratio does not exceed that of milk;

the term "cheese" will be understood to also encompasses cheeselike products. In the cheese-like products, milk fat and/or protein is replaced by another suitable fat or protein, or both partly or completely. Typically, milk fat is replaced by vegetable fat, such as rapeseed oil, fractioned palm oil or coconut oil. Also, lard can be used for replacement of milk fat. Milk protein can be re- placed by vegetable protein, like soybean protein.

Natural cheese suitable for use in the method of the present invention includes, but are not limited to, ripened hard or semi-hard cheeses, including those defined in the Codex Standards, such as Edam, Emmental, Gouda, Havarti, Parmesan as well as several special cheese types, for example such known trademarks as Jarlsberg, Grana, Oltermanni, Turunmaa and Finlandia. Also, a blend of two of more natural cheese types can be used as a cheese raw material.

The amount of natural cheese(s) used in the production of the processed cheese is in the range of about 15 to about 35% by weight. In an em- bodiment, the amount is about 22 to about 30% by weight. The dairy based emulsifier is combined with natural cheese(s) in order to emulsify fat and casein into water. The emulsifier is added in an amount so as to provide a ratio of the emulsifier casein to cheese casein of about 0.4 to about 0.8. In an embodiment, the ratio is about 0.4.

If desired, an aqueous liquid can be added to the mixture of natural cheese(s) and the emulsifier. The aqueous liquid can be used to adjust the softness of the processed cheese. The more the liquid is added, the softer texture is provided. The liquid can be added in an amount up to about 15% based on total weight of cheese. The aqueous liquid can be selected among tap wa- ter and various process streams of dairy industry obtained from processes for separating milk components or preparing dairy products. Such process streams can be obtained, for example, from various permeates from membrane filtration processes of milk, such as ultrafiltration, nanofiltration and/or reverse osmosis.

Further ingredients may be added to the mixture of natural cheese(s) and the emulsifier so long as they do not adversely affect the organoleptic properties of the processed cheese to be prepared. Examples of such ingredients include, but are not limited to, salt, flavoring agents and preservatives.

If desired, the pH of the mixture of natural cheese and the emulsifier is adjusted to about 5.5 to about 6.0.

If desired, the fat content of the processed cheese is adjusted. The adjustment can be suitably carried out by means of butter, cream, butter oil and/or vegetable oil. The fat content can vary in the range from about 5% to about 35%.

If desired, the total solids content of the processed cheese is adjusted. The adjustment can be suitably carried out by means of skim milk powder, full fat milk powder, Ca-depleted milk powder, milk mineral powder, whey powder and/or demineralized whey powder. The total solids can vary in the range from about 20% to about 60%. In an embodiment, the total solids is in the range of about 40% to about 50%.

The mixture of natural cheese(s) and emulsifier is heated to a temperature ranging from about 80°C to about 142°C under stirring to provide a homogenous mixture. In an embodiment, the mixture is heated to a temperature of about 95°C to about 142°C. In an embodiment, the heat treatment is carried out for about 0.5 to about 10 minutes. In another embodiment, the heat treatment is carried out for about 5 minutes. If desired, the mixture is homogenized to enhance the emulsification of fat and casein.

The homogenous mixture is then cooled to obtain processed cheese. The form of the processed cheese may range from firm block to cheese spread. Further, the processed cheese may be cheese dip, cheese sauce, cheese fondue, cheese wedges, cheese slices, shredded or grated cheese. The water content of the processed cheese typically ranges from about 40% to about 80%. In an embodiment, the water content ranges from about 50% to about 60%.

The method of the invention can be a batch or continuous process. The processed cheese prepared by the method of the invention has good organoleptic properties, such as flawless taste and texture. Moreover, the flavour of natural cheese(s) used and edible fat as a raw material may advantageously be retained or enhanced. The processed cheese can be provided as an easily spreadable or dippable form. Further, the processed cheese has a fa- vourable nutritional mineral content. Particularly, a favourable Ca/P ratio for the bones and teeth over about 1 .0 is obtained. By contrast, most of the traditional processed cheeses are made with sodium phosphate salts and therefore have a high phosphorous content of about > 6000 mg/1000 g, and a Ca/P ratio of < 1 .0. Surplus phosphate in diet impairs Ca ingestion, which may be related to osteoporosis. The amount of phosphorous of the processed cheese prepared by the method of the invention is of at most about 2500 mg/1000 g cheese.

The protein content of the processed cheese prepared by the method of the invention is in the range of about 10% to about 27%.

The salt content of the processed cheese prepared by the method of the invention is in the range of about 0.2% to about 2.5%. In an embodiment, the salt content is in the range of about 0.7% to about 1 .5%.

The lactose content of the processed cheese prepared by the method of the invention is in the range of about 0.01 % to about 4.0%. The lactose content of the cheese can be adjusted by the lactose content of the emulsifier.

In another aspect, the present invention provides a dairy based Ca- depleted sodium caseinate emulsifier substantially free of whey proteins.

In an embodiment, the ratio of casein to whey protein of the emulsifier is more than about 95:5. In another embodiment, the ratio is more than about 96:4.

The lactose content of the emulsifier is advantageously decreased.

Lactose can be removed in any manner known in the art including, but not lim- ited to, microfiltration, diafiltration, precipitation and enzymatic hydrolysis. Lactose can have an adverse effect on cheese quality, such as taste and appearance. Further, high lactose content can cause browning of the processed cheese through Maillard reaction during a heating step of the manufacturing process and storage at elevated temperatures. It is well known that browning has an adverse effect on taste and appearance of a dairy product. In an embodiment, the lactose content of the emulsifier of the invention is at most about 1 % by weight. In another embodiment, the lactose content is at most about 0.7% by weight. In a still further embodiment, the lactose content is at most about 0.01 % by weight.

In an embodiment, the Ca/protein ratio of the dairy based emulsifier is at most about 15 mg Ca/g protein. In another embodiment, the Ca/protein ratio is at most about 1 .5 Ca/g protein. In still another embodiment, the Ca/protein ratio is at most about 0.2 Ca/g protein.

In an embodiment, the total solids of the emulsifier is in the range of about 10% to about 100%. In another embodiment, the total solids is in the range of about 10% to about 30%. In a further embodiment, the total solids is about 12% to about 15%. In still further embodiment, the total solids is about 15 to about 20%. In still further embodiment, the total solids is more than about 90% when the emulsifier is in form of powder.

When the total solids is in the range of about 10% to about 30%, the protein content of the emulsifier typically ranges from about 8% to about 26%. When the total solids is more than about 90%, the protein content of the emulsifier typically ranges from about 80% to about 85%.

In a further aspect, the invention provides a method of preparing a dairy based Ca-depleted sodium caseinate emulsifier substantially free of whey proteins, comprising subjecting a milk raw material to microfiltration and calcium depletion to provide the dairy based Ca-depleted sodium caseinate emulsifier, and concentrating the emulsifier by evaporation to a total solids content of about 10% to about 100%.

In an embodiment of the invention, the milk raw material is first subjected to microfiltration (MF) to concentrate casein in the microfiltration retentate. Whey proteins and a part of lactose, milk minerals and water are passed to a microfiltration permeate. The microfiltration retentate is then subjected to calcium depletion to provide a Ca-depleted sodium caseinate emulsifier. In another embodiment, the milk raw material is first subjected to calcium depletion to provide Ca-depleted milk raw material. The Ca-depleted milk raw material is further subjected to microfiltration to provide a Ca-depleted sodium caseinate emulsifier as a microfiltration retentate.

In an embodiment, the method of the invention for preparing a dairy based Ca-depleted sodium caseinate emulsifier further comprises a pH adjustment step. The pH adjustment can be carried out at any stage of the method. In an embodiment, the pH is adjusted after calcium depletion. In another embodiment, the pH of the Ca-depleted sodium caseinate emulsifier is adjust- ed prior to evaporation in order to reduce the viscosity and to increase volatility of the emulsifier and thus to facilitate the concentration of the emulsifier. In an embodiment, the pH is adjusted to about 6.0. The pH adjustment can be suitably carried out, for example, by citric acid, hydrochloric acid, nitric acid, lactic acid or gluconodeltalactone.

The Ca-depleted sodium caseinate emulsifier is then concentrated by evaporation to provide a total solids content of about 10% to about 100% to the emulsifier. In an embodiment, the emulsifier is concentrated to a total solids content of about 10% to about 30%. In another embodiment, the emulsifier is concentrated to a total solids content of about 10% to about 15%. In a fur- ther embodiment, the emulsifier is concentrated to a total solids content of more than about 90%.

The concentration of the emulsifier can be further enhanced by spray drying. This is convenient particularly in cases where the emulsifier is concentrated to a higher total solids content.

In an embodiment, the Ca-depleted sodium caseinate emulsifier is subjected to an enzyme treatment by transglutaminase. In an embodiment, the enzyme treatment is carried out on the dairy based Ca-depleted sodium caseinate emulsifier prior to the evaporation step. In another embodiment, the enzyme treatment is carried out after the evaporation step. Enzymatic modifi- cation of the emulsifier enhances the concentration of the emulsifier. Typically, the enzyme treatment of the emulsifier and the subsequent evaporation of the enzyme-treated emulsifier provide a total solids content of about 15% to about 30% to the emulsifier.

In an embodiment, the dairy based emulsifier is concentrated to powder. Microfiltration of the milk raw material is performed in such a manner that the milk raw material is concentrated by a factor of 1 to 4.5 times by volume, preferably 3.5 to 4.5 times by volume. The concentration factor (cf=K) refers to the ratio of the volume of the liquid fed to the filtration to the retentate, and it is defined with the following formula: K = feed (L) / retentate (L) (L = volume).

The microfiltration is carried out typically at about 10°C to about

60°C.

The microfiltration may comprise a plurality of microfiltration steps. Different steps may comprise, for instance, changing of process conditions and/or filtration membranes. A variable condition may be, for instance, filtration temperature, filtration pressure, addition of diafiltration medium (diawater), and/or concentration factor of filtration. Conditions can be changed by one or more variables.

In an embodiment of the invention, microfiltration of the milk raw material is performed by means of one or more diafiltration (DF) steps to enhance the separation of the protein components. In the diafiltration steps, any material not substantially containing the substance that one wishes to remove from the retentate can be used as diawater.

In the present invention, the term "milk raw material" will be understood to be milk as such obtained from an animal, such as cow, sheep, goat, camel, mare or any other animal that producers milk suitable for human consumption, or pre-processed as desired to adjust protein, fat and/or lactose content to a desired level.

For example, the milk raw material can be standardized in respect of the fat content, and if desired, of the protein content in a manner generally known in the art. The fat content of the standardized milk is typically in the range of 0.05 to 10%, specifically 1 .0 to 3.0%. Further, the raw material can be pretreated in order to lower its microbial load in a manner generally known in the art. Pathogenic and spoilage microorganisms removal is generally carried out by physical separation such as microfiltration, bactofugation or a combination thereof.

If desired, the lactose content of the milk raw material liquid can be reduced. In an embodiment, lactose content is reduced enzymatically by add- ing a lactase to the raw material. Lactases typically used in the lactose hydrolysis of milk can be used. The lactose content can also be reduced by other suitable means generally known in the art, such as by means of membrane filtration, chromatography or precipitation. Various techniques can be combined in an appropriate manner. In an embodiment, a low-lactose raw material liquid is composed of various fractions obtained from membrane filtrations, such as microfiltration and ultrafiltration of milk, whereby the lactose and protein contents can appropriately be adjusted to a desired level. The low lactose raw material can then further be lactose hydrolyzed to provide a lactose-free raw material.

In the present invention, the milk raw material can thus be, for in- stance, full-fat (whole) milk, cream, low fat milk, skim milk, buttermilk, colostrum, low-lactose milk, lactose-free milk, reconstituted (recombined) milk made from caseinates, milk powder and water, or a combination thereof as such or as a concentrate and pre-treated as described above, such as heat-treated. The raw material can contain fat and/or protein of vegetable origin. In an em- bodiment of the invention, the milk raw material is skim milk.

The milk raw material, optionally standardized (fat, protein and/or lactose) and/or pretreated for microbial removal (microfiltration or bactofuga- tion), can be heat treated after calcium depletion or between microfiltration and calcium depletion. Examples of suitable heat treatments include pasteurization, high pasteurization, or heating at a temperature lower than the pasteurization temperature for a sufficiently long time. Specifically, UHT treatment (e.g. milk at 138°C, 2 to 4 s), ESL treatment (e.g. milk at 130°C, 1 to 2 s), pasteurization (e.g. milk at 72°C, 15 s), thermisation (e.g. at 65°C, 2 s to 3 min) and high pasteurization (95°C, 5 min) can be mentioned. The heat treatment can be either direct (vapor to milk, milk to vapor) or indirect (tube heat exchanger, plate heat exchanger, scraped-surface heat exchanger).

In the microfiltration, the ratio of casein to whey protein of the emul- sifier is adjusted to more than about 95:5, specifically more than about 96:4.

If desired, the lactose content of microfiltration retentate can be re- duced in a manner described above. In an embodiment, the lactose content of the emulsifier prepared by the method of the invention is at most about 1 % by weight. In another embodiment, the lactose content is at most about 0.7% by weight. In a still further embodiment, the lactose content is at most about 0.01 % by weight. The decreased amount of lactose of the emulsifier can be achieved by reducing the lactose content of the casein concentrate prior to evaporation. Lactose is efficiently removed, for example, using microfiltra- tion/diafiltration in which a liquid essentially free from lactose is used as dia- water. Lactose is also efficiently removed by an enzymatic lactose hydrolysis treatment.

The calcium depletion of the milk raw material is carried out in order to remove at least a portion of calcium of the material. The calcium removal can be realized in any manner known in the art.

In an embodiment of the invention, the calcium depletion is realized by ion exchange. The ion exchange of the milk raw material or of the microfil- tration retentate is realized to replace at least a portion of calcium ions pre- dominantly bound to the casein micelles by sodium ions. Ion exchange is performed in a conventional manner known to a person skilled in the art. The ion exchange can be carried out, for example, in manner described in WO 2007/026053.

The calcium depletion can also be realized such that the milk raw material is acidified and the acidified milk raw material is microfiltrated. A Ca- depleted sodium caseinate emulsifier is obtained as a microfiltration retentate.

In an embodiment, phosphate ions are not removed from the emulsifier.

In an aspect, the present invention provides a use of a dairy based emulsifier of the invention in the production of processed cheese. The emulsifier is used in an amount so as to provide a ratio of the emulsifier casein to cheese casein of about 0.4 to about 0.8, specifically about 0.4.

In a still further aspect, the invention provides processed cheese having a ratio of Ca/P of > about 1 .0 and a content of phosphorous of at most about 2500 mg/1000 g cheese.

The following examples are presented for further illustration of the invention without limiting the invention thereto.

Examples

Example 1. Dairy based Ca-depleted sodium caseinate

Whole milk was skimmed and pasteurized at 73°C for 15 s. The resultant pasteurized skim milk was subjected to microfiltration (MF) and recirculated through membranes of a pore size 0.08 μιτι at a temperature of 13°C to concentrate casein in a MF retentate. Water, whey protein and part of the lactose and milk minerals passed through the membrane to a permeate. Concen- trated whey protein-free casein retentate having the total solids of 1 1 % was treated with cation exchange by using an ion exchange resin in sodium form. Ion exchange of the MF retentate gave a sodium caseinate. The sodium ca- seinate was practically fully Ca-depleted having 0.09 mg Ca/g protein compared to skim milk having 39 mg Ca/g protein. The sodium caseinate was final- ly evaporated with a concentration factor 1 .2 to the total solids of 13.6%. The composition of the sodium caseinate emulsifier prepared above is given in Table 1 below.

Table 1. Composition of the emulsifier of the invention

Example 2. Dairy based Ca-depleted sodium caseinate Whole milk was skimmed and pasteurized at 73°C for 15 s. The resultant pasteurized skim milk was subjected to microfiltration (MF) and recirculated through membranes of a pore size 0.08 μιτι at a temperature of 13°C to concentrate casein in a MF retentate. Water, whey protein and part of the lactose and milk minerals passed through the membrane to a permeate. Concen- trated whey protein-free casein retentate having the total solids of 1 1 % was treated with cation exchange by using an ion exchange resin in sodium form. Ion exchange of the MF retentate gave a sodium caseinate. The sodium caseinate was practically fully Ca-depleted having 0.09 mg Ca/g protein compared to skim milk having 39 mg Ca/g protein. The sodium caseinate was pH adjusted to pH of 6.0 by citric acid. The sodium caseinate was finally evaporated with a concentration factor 2.5 to the total solids of 28%. The composition of the sodium caseinate emulsifier prepared above is given in Table 2 below. Table 2. Composition of the emulsifier of the invention

Example 3. Dairy based Ca-depleted sodium caseinate

Whole milk was skimmed and pasteurized at 73°C for 15 s. The resultant pasteurized skim milk was subjected to microfiltration (MF) and recircu- lated through membranes of a pore size 0.08 μιτι at a temperature of 13°C to concentrate casein in a MF retentate. Concentrated whey protein-free casein retentate having the total solids of 1 1 % was treated with cation exchange by using an ion exchange resin in sodium form. Ion exchange of the MF retentate gave a sodium caseinate. The sodium caseinate was enzyme treated (trans- glutaminase 3 U/g protein, about 12 hours), heat treated at 95°C for 5 min, and finally evaporated to the total solids of 20%. The composition of the sodium caseinate emulsifier prepared above is given in Table 3 below.

Table 3. Composition of the emulsifier of the invention

Example 4. Powder form of dairy based Ca-depleted sodium caseinate Whole milk was skimmed and pasteurized at 73°C for 15 s. The resultant pasteurized skim milk was subjected to microfiltration (MF) and diafiltra- tion using tap water and recirculated through membranes of a pore size 0.08 μιτι at a temperature of 13°C to concentrate casein in a MF retentate. A lactase enzyme was added to the MF retentate. Lactose was thus removed by diafiltra- tion and enzymatic hydrolysis. Concentrated whey protein-free casein retentate having the total solids of 1 1 % was treated with cation exchange by using an ion exchange resin in sodium form. Ion exchange of the MF retentate gave a sodium caseinate. The sodium caseinate was pH adjusted to pH of 6.0 by citric acid, heat treated at 95°C for 5 min, and evaporated. Evaporated concentrate was spray dried to final composition. The composition of the sodium caseinate emulsifier prepared above is given in Table 4 below.

Table 4. Composition of the emulsifier of the invention

Example 5. Powder form of dairy based Ca-depleted sodium caseinate Whole milk was skimmed and pasteurized at 73°C for 15 s. Lactase enzyme was added to skim milk after cooling to 13 °C. The resultant pasteurized skim milk was subjected to microfiltration (MF) and diafiltration using tap water and recirculated through membranes of a pore size 0.08 μιτι at a temperature of 13°C to concentrate casein in a MF retentate. A lactase enzyme was added to the MF retentate. Lactose was thus removed by diafiltration and enzymatic hydrolysis. Concentrated whey protein-free casein retentate having the total solids of 1 1 % was treated with cation exchange by using an ion exchange resin in sodium form. Ion exchange of the MF retentate gave a sodium caseinate. The sodium caseinate was pH adjusted to pH of 6.0 by citric acid, heat treated at 95°C for 5 min, and evaporated. Evaporated concentrate was spray dried to final composition. The composition of the sodium caseinate emulsifier prepared above is given in Table 5 below. Table 5. Composition of the emulsifier of the invention

Example 6. Spreadable processed cheese

A spreadable processed cheese was prepared by using the emulsifier prepared in Example 1 so as to provide an emulsifier casein/cheese casein ratio of 0.4, total solids content of 46% and fat in dry matter of 60% to the processed cheese. The ingredients and the amounts thereof used in the preparation are given in Table 6. The ingredients were grinded and blended together prior to cooking. Processed cheese blend was cooked and stirred in a Stephan cooker (IMA-Stephan UMSK 24E). The blend was heated by direct steam in- jection. The blend was stirred for 5 min after reaching the final temperature of 95°C. A stable emulsion was formed when all ingredients were melted in the cooker. At this stage the processed cheese was in liquid form. After cooking, the processed cheese was packaged and transferred to a cold room (4°C). Spreadable texture was formed during the overnight stay in the cold room. The composition of the resultant processed cheese is given in Table 7.

Table 6.

Ingredient Amount (%)

Emulsifier of Example 1 32.7

Edam cheese 16.8

Emmental cheese 16.8

Butter 22.3

Water 8.5

Milk powder 2.0

Salt (NaCI) 0.9 Table 7. Composition of processed cheese of Example 6

The processed cheese of the invention had strong cheese taste and soft and pleasant mouth feel. Example 7. Spreadable processed cheese

A spreadable processed cheese was prepared by using the emulsifier prepared in Example 2 so as to provide an emulsifier casein/cheese casein ratio of 0.4, total solids content of 47% and fat in dry matter of 60% to the processed cheese. The processed cheese was prepared in the same manner as described in Example 6. The ingredients and the amounts thereof used in the preparation are given in Table 8. The composition of the resultant processed cheese is given in Table 9.

Table 8.

Ingredient Amount (%)

Emulsifier of Example 2 18.4

Edam cheese 19.6

Emmental cheese 19.6

Butter 21 .0

Water 20.5

Salt (NaCI) 0.9 Table 9. Composition of processed cheese of Example 7

Example 8. Spreadable processed cheese

A spreadable processed cheese was prepared by using the emulsi- fier prepared in Example 3 so as to provide an emulsifier casein/cheese casein ratio of 0.4, total solids content of 47% and fat in dry matter of 60% to the processed cheese. The processed cheese was prepared in the same manner as described in Example 6. The ingredients and the amounts thereof used in the preparation are given in Table 10. The composition of the resultant processed cheese is given in Table 1 1 .

Table 10.

Ingredient Amount (%)

Emulsifier of Example 3 25.7

Edam cheese 19.4

Emmental cheese 19.4

Butter 21 .4

Water 13.4

Salt (NaCI) 0.9 Table 11. Composition of processed cheese of Example 8

Example 9. Spreadable processed cheese

A spreadable processed cheese having an emulsifier casein/cheese casein ratio of 0.6, total solids content of 46% and fat in dry matter of 60% was prepared by using the emulsifier prepared in Example 3 in the same manner as described in Example 6 except for lower cheese content. The ingredients and the amounts thereof used in the preparation are given in Table 12 below. The composition of the resultant processed cheese is given in Table 13. Table 12.

Ingredient Amount (%)

Emulsifier of Example 3 37.5

Edam cheese 12.8

Emmental cheese 12.8

Butter 24.9

Water 7.1

Skim milk powder 4.0

Salt (NaCI) 0.9 Table 13. Composition of processed cheese of Example 9

The processed cheese of the invention had strong cheese taste and soft and pleasant mouth feel. Example 10. Processed cheese slices

A processed cheese slice having the powder casein/cheese casein ratio of 0.7, total solids content of 45% and fat in dry matter of 45% was made by using the emulsifier in powder form of Example 4. Part of the water addition was cooked in a twin screw cooker (Karl Schnell) to 95°C. The emulsifier and salt were dissolved in hot water. Pre-ground cheese and butter were added to the cooker and cooked to 95°C by direct steam injection. Processed cheese was packed in plastic pouches and formed in flat slice. Cooled cheese slices detached easily from plastic pouches and had the same structure as processed cheese slices made with conventional melting salts.

The recipe of the processed cheese is shown in Table 14. The composition of the resultant processed cheese is given in Table 15.

Table 14. Recipe of the processed cheese

Ingredient Amount (%)

Emulsifier powder of 10

Example 4

Edam cheese 44.3

Lactose free butter 12

Water 33

Salt (NaCI) 0.5 Table 15. Composition of processed cheese of Example 10

The processed cheese slice of the invention had strong cheese taste and soft and pleasant mouth feel. Reference Example 1. Spreadable processed cheese made with Ca- reduced milk protein powder

A spreadable processed cheese having the powder casein/cheese casein ratio of 1 .1 , total solids content of 48% and fat in dry matter of 55% was made by using conventional Ca-reduced milk protein powder (Cegeprot MC-S, (Grunau lllertissen GmbH, Germany). The composition of the powder is given in Table 16. The recipe of the processed cheese is shown in Table 17. The milk protein powder and salt were first dissolved to warm (40°C) water. Only a partial dissolution was achieved, since an insoluble powder mat was formed on the surface of water. The aqueous suspension of the partly dissolved powder was mixed and heated to 80°C in a Stephan cooker (IMA-Stephan UMSK 24E). Cheese and butter were added and the resultant mixture was cooked at 95°C for 1 min to provide a homogenous mixture. The mixture was cooled to 4°C to provide processed cheese. The composition of the resultant processed cheese is given in Table 18. Table 16. Composition of the milk protein powder

Table 17. Recipe of the processed cheese

Table 18. Composition of processed cheese of Reference Example 1.

The processed cheese had burnt powdery taste.

Reference Example 2. Spreadable processed cheese made with Ca- reduced milk protein powder

A spreadable processed cheese having the powder casein/cheese casein ratio of 0.5, total solids content of 46% and fat in dry matter of 60% was made in the same manner as in Reference Example 1 except that different conventional Ca-reduced milk protein powder (Cegeprot MC-B, Griinau lllertis- sen GmbH, Germany) and the recipe were used. The composition of the powder is given in Table 19. The recipe of the processed cheese is shown in Table 20. The composition of the resultant processed cheese is given in Table 21 .

Table 19. Composition of the milk protein powder

Table 20. Recipe of the processed cheese

Table 21. Composition of processed cheese of Reference Example 2

The cheese stayed inhomogeneous after the cooking step and vig- orous mixing. Results from further tests showed that the Ca-depleted milk powder casein/cheese casein ratio had to be >1 .0 for successful emulsion formation. The processed cheese had burnt powdery taste.

The organoleptic properties of the processed cheese prepared with the emulsifier of the invention were superior compared to the processed cheeses of Reference Examples 1 and 2, prepared by using conventional ca- sein powders without traditional emulsifying salts, on one hand, and traditional processed cheese prepared by using traditional emulsifying salts, on the other hand. The processed cheese of the invention had strong cheese taste and soft and pleasant mouth feel.

The Examples show that the conventional milk protein powders are needed in higher amounts than the emulsifier of the invention in order to achieve good emulsification during the preparation of processed cheese. Further, in the present invention, higher amounts of cheese raw material can be used for the production of processed cheese compared to those prepared by using conventional milk protein powders.

It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.