Snacks from Cheese

BACKGROUND OF THE INVENTION

[0001] The present invention relates to food products containing high levels of cheese.

BRIEF SUMMARY OF THE INVENTION

[0002] According to some embodiments of the present invention, a method for preparing a cheese snack includes (1) rotary molding a cheese to obtain a pre-formed cheese snack, and (2) heating the pre-formed cheese snack to obtain a cheese snack having a moisture content less than about 5%. In some embodiments, the pre-formed cheese snack may be heated by baking, frying and/or microwaving. In some

embodiments, the cheese snack comprises about 60 wt% to about 100 wt% real cheese, or about 65 wt% to about 95 wt% real cheese, based on the weight of the cheese snack.

[0003] According to some embodiments of the present invention, a method for preparing a cheese snack includes (1) rotary molding a cheese dough to obtain a preformed cheese snack, the cheese dough comprising about 5 wt% to about 95 wt% real cheese, based on the weight of the cheese dough; and (2) heating the pre-formed cheese snack to obtain a cheese snack having a moisture content of less than about 5%. In some embodiments, the pre-formed cheese snack may be heated by baking, frying and/or microwaving. In some embodiments, the cheese dough comprises about 65 wt% to about 95 wt% real cheese, based on the weight of the cheese snack.

[0004] According to some embodiments of the present invention, a method for preparing a cheese snack includes (1) preparing a cheese dough, the cheese dough comprising about 60 wt% to about 95 wt% real cheese, based on the weight of the cheese dough; (2) forming the cheese dough to prepare a pre-formed cheese snack; and (3) heating the pre-formed cheese snack to produce a cheese snack having a moisture content of less than about 5%. In some embodiments, forming the cheese dough includes rotary molding or sheeting. In some embodiments, the cheese dough comprises about 60 wt% to about 85 wt% real cheese, or about 65 wt% to about 85 wt% real cheese, based on the weight of the cheese dough. In some embodiment, the cheese snack comprises about 65 wt% to about 85 wt% real cheese, or about 65 wt% to about 85 wt% real cheese, based on the weight of the cheese snack.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0005] The foregoing summary, as well as the following detailed description of certain embodiments of a food product will be better understood when read in conjunction with the following exemplary embodiments, the appended drawing and the appendices.

[0006] Fig. 1 is a process flow diagram of an exemplary embodiment of the present invention.

[0007] Fig. 2 is a process flow diagram of an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0008] Methods and compositions of some embodiments of the present invention relate to crackers or snacks having a significant amount of cheese, which may be prepared using cracker processes. In some embodiments, snacks are prepared using cracker processes that are not commonly used to produce crackers containing as much cheese as formulations of some embodiments of the present invention. Methods and compositions of some embodiments of the present invention are related to crackers or snacks containing cheese which are formed by rotary molding.

[0009] Referring to Figure I, a cheese snack may be produced by preparing a cheese or a cheese blend 1 10. In some embodiments, the cheese or cheese blend includes real cheese in an amount from about 5 wt% to about 95 wt%. The cheese or cheese blend may then be formed into a desired shape by rotary molding 120. The molded cheese piece may then be heated 130, for example by baking, frying, or micro waving. The heated cheese snack may then be dried 140 before optionally applying seasoning or seasoning oils 150. In some embodiments, the prepared cheese snack may then be packaged and/or stored 160.

[0010] Referring to Figure 2, a cheese snack may be produced by preparing a dough 210 containing about 60 wt% to about 85 wt% real cheese. The dough may contain flours, leaveners, starches and/or other ingredients to produce the desired texture. The dough may then be formed 220, for example, by rotary molding or sheeting. The formed dough may then be heated 230, for example by baking or frying. The heated cheese snack may then be dried 240 before optionally applying seasoning or seasoning oils 250. In some embodiments, the prepared cheese snack may then be packaged and/or stored 260.

[0011] In some embodiments, the cheese snacks exhibit a crispy and/or crunchy texture. In some embodiments, the cheese snacks exhibit a puffed, airy and/or porous structure.

[0012] Cheese and Cheese Dough

[0013] Cheese snacks of some embodiments of the present invention may be produced from a cheese or a dough containing cheese, i.e. a cheese dough. A suitable cheese may include about 50 wt% to about 95 wt% real cheese; about 55 wt% to about 95 wt% real cheese, about 60 wt% to about 95 wt% real cheese; about 65 wt% to about 95 wt% real cheese; about 70 wt% to about 90 wt% real cheese; about 75 wt% to about 85 wt% real cheese; about 50 wt% real cheese; about 55 wt% real cheese; about 60 wt% real cheese; about 65 wt% real cheese; about 70 wt% real cheese; about 75 wt% real cheese; about 80 wt% real cheese; about 85 wt% real cheese; about 90 wt% real cheese; or about 95 wt% real cheese.

[0014] Real cheese, also referred to as natural cheese, may be defined as that which meets the definition and standard of identity for a particular type of cheese included in 21 C.F.R. Part 133. Real cheese content may be measured as the weight percentage of real cheese included as a component in a food composition.

[0015] The cheese employed in the present invention may be any one or more than one cheese blend, reduced fat cheese, processed cheese, processed cheese product, real or dairy cheese, such as Parmesan cheese, Romano cheese, Cheddar cheese, Swiss cheese, Muenster cheese, Mozzarella cheese, Monterrey Jack, Pepper Jack cheese, Provolone cheese, Asiago cheese, Fontina cheese, Gorgonzola cheese, Blue cheese, and the like and any combinations thereof. In some embodiments, real cheddar cheese is suitable for use in the present invention. In some embodiments, aged whole milk cheddar cheese is suitable for use in the present invention. In embodiments of the invention, the dairy cheese may have a moisture content below about 60 wt %. Examples of lower moisture content cheeses that may be used include Parmesan cheese and cheddar cheese. Examples of cheeses which may be employed include so-called natural and aged cheeses produced by treatment of a dairy liquid with a clotting agent such as rennet, or a cheese- making culture, or by developing acidity to the isoelectric point of the casein, or a combination thereof. An example of a suitable cheese may include the cheese disclosed in U.S. Patent Application Publication No. 20070154612.

[0016] A suitable cheese may include an aged whole milk cheddar cheese prepared from cow's milk and other ingredients allowed by standards of identity, to produce a finished cheese having the physical and chemical properties of a cheese produced by the cheddar process. In some embodiments, such cheese has a fat content of about 50 wt%, a moisture content of about 35% to about 37%, a pH of about 4.9 to about 5.2, and a salt content of about 1.4% to about 2%.

[0017] A suitable cheese may include a cheese blend prepared from reduced fat cheddar cheese, water, modified food starch, sodium phosphate, sodium

hexametaphosphate, salt, sodium alginate, sorbic acid, and coloring. In some

embodiments, such cheese has a moisture of about 45.5%, a fat content of about 17%, and a salt content of about 2.15%.

[0018] As known in the cheese making arts, the identity of the cheese product, and its characteristic flavor profile, texture and mouthfeel are governed by the particular cheese- making culture(s) or enzyme(s) chosen for the fermentation. The dairy liquid may be ripened by inoculating it with a starter culture (e.g., a lactic starter for cheddar cheese production) until a desired acidity is reached. The fermentation mixture can be provided by combining the ripened milk and rennet source, and fermenting the resulting mixture for a time and temperature sufficient to set the milk. The order of combination of these components can be varied. Following fermentation, the vitamin- fortified set milk can be processed in accordance with standard cheese making procedures used to remove whey by-product from the curd and form cheese product from the curd. For example, the set dairy liquid may be cut, cooked/heated, and whey is separated from the curd. After draining the whey, the curds may be subjected to cheddaring, milling, and salting. The salted curd can be hooped and pressed to remove additional whey. The desired flavor, aroma and texture of the cheese is obtained by ripening which involves holding the cheese over a period of time under controlled conditions (e.g., temperature, humidity). The term "ripening" is used herein synonymously with "curing" and "aging." The curd may be dressed, paraffin-coated, and/or packaged before ripening. After ripening, the cured cheese may be cut and directly used, or alternatively wrapped/packaged before use, in the methods of the present invention.

[0019] The cheese also may be commercially obtained, and in embodiments of the invention the cheese may be a full fat cheese, a reduced fat cheese or a low fat cheese. In embodiments of the invention, the cheese may be ground in conventional manner or otherwise formed into small particulates or large particulates, for admixing with the other dough ingredients.

[0020] The cheese may be included in a pre-formed cheese snack in an amount of about 5 wt% to about 100 wt% of the pre-formed cheese snack; about 10 wt% to about 100 wt% of the pre-formed cheese snack; about 15 wt% to about 100 wt% of the preformed cheese snack; about 20 wt% to about 100 wt% of the pre-formed cheese snack; about 25 wt% to about 100 wt% of the pre-formed cheese snack; about 30 wt% to about 100 wt% of the pre-formed cheese snack; about 35 wt% to about 100 wt% of the preformed cheese snack; about 40 wt% to about 100 wt% of the pre-formed cheese snack; about 50 wt% to about 100 wt% of the pre-formed cheese snack; about 55 wt% to about 100 wt% of the pre-formed cheese snack; about 60 wt% to about 100 wt% of the preformed cheese snack; about 65 wt% to about 100 wt% of the pre-formed cheese snack; about 60 wt% to about 95 wt% of the pre-formed cheese snack; about 60 wt% to about 90 wt% of the pre-formed cheese snack; about 60 wt% to about 85 wt% of the pre-formed cheese snack; about 60 wt% to about 80 wt% of the pre-formed cheese snack; about 65 wt% to about 95 wt% of the pre-formed cheese snack; about 65 wt% to about 95 wt% of the pre-formed cheese snack; about 65 wt% to about 90 wt% of the pre-formed cheese snack; about 65 wt% to about 85 wt% of the pre-formed cheese snack; about 65 wt% to about 80 wt% of the pre-formed cheese snack; about 5 wt% of the pre-formed cheese snack; about 10 wt% of the pre-formed cheese snack; about 15 wt% of the pre-formed cheese snack; about 20 wt% of the pre-formed cheese snack; about 25 wt% of the preformed cheese snack; about 30 wt% of the pre-formed cheese snack; about 35 wt% of the pre-formed cheese snack; about 40 wt% of the pre-formed cheese snack; about 45 wt% of the pre-formed cheese snack; about 50 wt% of the pre-formed cheese snack; about 55 wt% of the pre-formed cheese snack; about 60 wt% of the pre-formed cheese snack; about 65 wt% of the pre-formed cheese snack; about 70 wt% of the pre-formed cheese snack; about 75 wt% of the pre-formed cheese snack; about 80 wt% of the pre-formed cheese snack; about 85 wt% of the pre-formed cheese snack; about 90 wt% of the preformed cheese snack; about 95 wt% of the pre-formed cheese snack; or about 100 wt% of the pre-formed cheese snack.

[0021] In some embodiments, cheese, a cheese product, or processed cheese is blended with other ingredients to prepare a cheese dough. Any suitable ingredients may be included in a cheese dough of the present invention in order to achieve a desired texture and consistency of the dough as well as of the final product. In some

embodiments, a desired dough consistency is soft, pliable and/or moldable. In some embodiments, a desired finished product texture is crispy, crunchy, flaky, tender, and/or melt-in-mouth texture. Ingredients included in a cheese dough may include but are not limited to flours, leaveners, and starches.

[0022] The flour component or farinaceous materials which may be combined with the cheese in producing the doughs of the present invention may be, for example, comminuted cereal grain or edible seed or vegetable meal, derivatives thereof and/or mixtures thereof. Examples of the flour component or farinaceous materials which may be used include wheat flour, corn flour, corn masa flour, oat flour, barley flour, rye flour, rice flour, potato flour, sorghum flour, bean flour, tapioca flour, graham flour, or starches, such as corn starch, wheat starch, rice starch, potato starch, tapioca starch, physically and/or chemically modified flours or starches, such as pregelatinized starches, and mixtures thereof. The flour may be bleached or unbleached, and may be a whole grain flour, such as a whole wheat flour. In some embodiments, wheat flour or mixtures of wheat flour with other grain flours are preferred. In embodiments of the invention, the protein content of the at least one flour, such as wheat flour, may be less than about 10% by weight, based upon the weight of the at least one flour. Generally, high protein content flours, such as durum wheat may be used particularly where a hard, glassy texture is desired.

[0023] The total amount of the flour component used in the cheese dough of the present invention may range, for example, from about 10 wt% to about 80 wt%, or about 10 wt% to about 50 wt%, based upon the weight of the dough. Unless otherwise indicated, all weight percentages are based upon the total weight of all ingredients forming the doughs or formulations of the present invention, except for inclusions such as flavor chips, nuts, raisins, and the like. Thus, "the weight of the dough" does not include the weight of inclusions.

[0024] In some embodiments of the invention, the flour component may be replaced in whole or in part by conventional flour substitutes or bulking agents, such as a gelatinized starch-based bulking agent, or resistant starch ingredient, such as a resistant starch type III (RS III) ingredient, polydextrose, hollocellulose, hemi-cellulose, microcrystalline cellulose, mixtures thereof, and the like. Com bran, wheat bran, oat bran, rice bran, mixtures thereof and the like may also be substituted in whole or in part for the flour component to enhance color, or to affect texture.

[0025] The flour substitutes or bulking agents, or bran may be employed in amounts which do not adversely affect dough rheology, dough shape retention, and texture or cell structure of the baked or cooked products. In embodiments of the invention, the amount of the flour substitute or bulking agent, such as a gelatinized starch-based bulking agent, or the RS III ingredient, may generally be up to about 75% by weight, based upon the total weight of the gelatinized bulking agent and the flour component, such as conventional, ungelatinized wheat flour.

[0026] In embodiments of the invention, a pregelatinized waxy starch or

pregelatinized high amylopectin-content starch may be employed to enhance dough cohesiveness, extensibility, and extrudability or machinability, and a crispy, texture. Pregelatinized waxy starches or pregelatinized high amylopectin-content starches which may be used in the present invention include but are not limited to pregelatinized waxy maize starch, pregelatinized waxy rice starch, pregelatinized waxy barley starch, pregelatinized waxy sorghum starch, and mixtures thereof. An example of a suitable pregelatinized waxy starch is a non-modified waxy maize starch such as X-Pand'R-612 produced by A.E. Staley Manufacturing Company. In some embodiments, a preferred pregelatinized waxy maize starch is not chemically modified nor acid hydrolyzed. In some embodiments, a suitable pregelatinized waxy starch has a moisture content of less than or equal to about 6% by weight and a pH of about 5 to about 6. In some embodiments, the pregelatinized waxy starch may provide an initial thickening which may facilitate dough formation and avoid agglomeration and stickiness, followed by a significant loss in viscosity under moderate shear and temperature conditions to facilitate expansion during baking. Loss in viscosity may increase the rate of heat penetration under heating or baking conditions during moisture removal. In some embodiments, the viscosity of the pregelatinized waxy starch at 5% dry solids may be at least about 1000 cps at about 85°C, with the time required to reach peak viscosity at about 85°C being a maximum of about 3 minutes. In some embodiments, the particle size distribution of the pregelatinized waxy starch may be less than or equal to about 20% by weight passing through a 50-mesh screen and less than or equal to about 30% passing through a 200- mesh screen. In some embodiments, if the particle size is too small, the pregelatinized starch tends to hydrate predominately on the surface. Increasing the particle size of the pregelatinized waxy starch tends to increase its ability to form homogeneous dry blends and reduces its tendency to form lumps.

[0027] "Modified" in the starch industry is understood essentially as a regulatory adjective that means chemically modified, rather than physically treated. Gelatinization is a physical treatment, in which no chemical bonds are destroyed or created. Chemical modification does result in actual chemical changes in the starch molecules. There are many different types of chemical modifications, but the most common chemical modification of waxy maize starch is a cross-linking reaction. Waxy starches are described as having a "long" texture when they are cooked. If the cooked starch slurry is poured from a spoon, it has a mucous appearance. By cross-linking the starch, the texture is said to become "short" because when the cooked slurry is poured from a spoon the stream breaks before it finishes falling.

[0028] In some embodiments, a functionality of pregelatinized waxy maize starch for crispy coatings is to create films. To the extent that the starch is cross-linked (and to the extent that the starch contains amylose, as for normal pregelatinized corn starch), the film- form-forming functionality and expandability may be decreased. A pregelatinized waxy starch which is not chemically modified may provide superior functionality for film-forming and expansion to a crispy texture. A waxy starch may have a very high amylopectin content and a very low amylose content. Generally, the amylose content of a waxy starch is less than about 2% by weight. Amylose-containing starches may create a more leathery, crunchy texture. The addition of a pregelatinized waxy starch which is not chemically modified to, for example, wheat flour may provide superior film forming ability, expansion, and crispiness compared to use of a chemically-modified waxy maize starch or a pregelatinized chemically modified waxy starch.

[0029] In some embodiments, a suitable pregelatinized waxy starch has a high degree of starch gelatinization (as measured by differential scanning calorimetry (DSC)), so that it is more readily hydrated and more readily activated prior to heating. In some embodiments of the present invention, the starch granules of the pregelatinized starches may be at least about 90% gelatinized, at least about 95% gelatinized, or completely gelatinized.

[0030] The amount of the pregelatinized waxy starch which may be used in embodiments of the present invention may range up to about 10% by weight, for example, from about 0.5 wt% to about 5 wt% ,or from about 1 wt% to about 3 wt%, based upon the weight of the dough.

[0031] Process-compatible ingredients, which may be used to modify the texture and taste of the products produced in some embodiments of the present invention, may include sugars such as sucrose, fructose, lactose, dextrose, galactose, maltodextrins, corn syrup solids, hydrogenated starch hydrolysates, protein hydrolysates, glucose syrup, mixtures thereof, and the like. Reducing sugars, such as fructose, maltose, lactose, and dextrose, or mixtures of reducing sugars may be used to promote browning. Exemplary sources of fructose include invert syrup, high fructose corn syrup, molasses, brown sugar, maple syrup, mixtures thereof, and the like.

[0032] A texturing ingredient, such as sugar, may be admixed with the other ingredients in either solid or crystalline form, such as crystalline or granulated sucrose, granulated brown sugar, or crystalline fructose, or in liquid form, such as sucrose syrup or high fructose corn syrup. In embodiments of the invention, humectant sugars, such as high fructose corn syrup, maltose, sorbose, galactose, corn syrup, glucose syrup, invert syrup, honey, molasses, fructose, lactose, dextrose, and mixtures thereof may be used to soften the texture of the final product. [0033] In addition to the humectant sugars, other humectants, or aqueous solutions of humectants which are not sugars or possess a low degree of sweetness relative to sucrose, may also be employed in the cheese dough. For example, glycerol, sugar alcohols such as mannitol, maltitol, xylitol and sorbitol, and other polyols, may be used as humectants. Additional examples of humectant polyols (i.e. polyhydric alcohols) include glycols, for example propylene glycol, and hydrogenated glucose syrups. Other humectants include sugar esters, dextrins, hydrogenated starch hydrolysates, and other starch hydrolysis products.

[0034] In embodiments of the present invention, the total sugar solids content, or the texturizing ingredient content, of the cheese doughs of the present invention may range from zero up to about 50% by weight, based upon the weight of the cheese dough.

[0035] In some embodiments, the sugar solids may be replaced in whole or in part by a conventional sugar substitute or conventional bulking agent such as polydextrose, hollocellulose, hemi-cellulose, microcrystalline cellulose, mixtures thereof, and the like. Polydextrose may be a suitable sugar substitute or bulking agent for making reduced calorie products of the present invention. Exemplary replacement amounts may be at least about 25 wt%, for example at least about 40 wt%, from about 50 wt% to about 75 wt%, of the original sugar solids content. In some embodiments of the invention, the amount of the conventional sugar substitute, conventional bulking agent, or conventional flour substitute may be from about 10 wt% to about 35 wt%, or for example from about 15 wt% to about 25 wt%, based upon the weight of the dough.

[0036] The moisture contents of the cheese doughs of the present invention should be sufficient to provide the desired consistency to enable proper forming, molding, machining, and/or cutting of the dough. The total moisture content of the cheese doughs of the present invention will include any water included as a separately added ingredient, as well as the moisture provided by flour (which usually contains about 12% to about 14% by weight moisture), cheese, and the moisture content of other dough additives or ingredients included in the formulation, such as high fructose corn syrup, invert syrups, or other liquid humectants.

[0037] Oleaginous compositions which may be used to obtain the doughs and baked goods or fried products of the present invention may include any known shortening or fat blends or compositions useful for baking applications, and they may include conventional food-grade emulsifiers. Vegetable oils, lard, marine oils, and mixtures thereof, which are fractionated, partially hydrogenated, and/or interesterified, are exemplary of the shortenings or fats which may be suitable in some embodiments of the present invention. Edible reduced- or low-calorie, partially digestible or non-digestible fats, fat-substitutes, or synthetic fats, such as sucrose polyesters or triacyl glycerides, which are process- compatible may also be suitable in some embodiments. In some embodiments, mixtures of hard and soft fats or shortenings and oils may be used to achieve a desired consistency or melting profile in the oleaginous composition. Exemplary of the edible triglycerides which can be used to obtain the oleaginous compositions for use in some embodiments of the present invention include naturally occurring triglycerides derived from vegetable sources such as soybean oil, palm kernel oil, palm oil, rapeseed oil, safflower oil, sesame oil, sunflower seed oil, and mixtures thereof. Marine and animal oils such as sardine oil, menhaden oil, babassu oil, lard, and tallow may also be suitable. Synthetic triglycerides, as well as natural triglycerides of fatty acids, may also be used to obtain the oleaginous composition. Suitable fatty acids may have a chain length of from 8 to 24 carbon atoms. Solid or semi-solid shortenings or fats at room temperatures of, for example, from about 75°F to about 95°F may be used.

[0038] In some embodiments, little, if any shortening or fat, or oil is needed because the cheese provides lubricity. In some embodiments of the invention, the amount of oleaginous composition employed may generally range up to about 10 wt%, or for example from about 1 wt% to about 5wt%, based upon the weight of the dough.

[0039] Cheese snacks which may be produced in accordance with the present invention include reduced calorie baked goods which are also reduced fat, low fat or no- fat products. As used herein, a reduced-fat food product is a product having its fat content reduced by at least 25 wt% from the standard or conventional product. A low-fat product has a fat content of less than or equal to three grams of fat per reference amount or label serving. However, for small reference amounts (that is, reference amounts of 30 grams or less or two tablespoons or less), a low-fat product has a fat content of less than or equal to 3 grams per 50 grams of product. A no-fat or zero-fat product has a fat content of less than 0.5 grams of fat per reference amount and per label serving. For accompaniment crackers, such as a saltine cracker, the reference amount is 15 grams. For crackers used as snacks, the reference amount is 30 grams. Thus, the fat content of a low- fat cracker would therefore be less than or equal to 3 grams of fat per 50 grams or less than or equal to about 6 wt% fat, based upon the total weight of the final product. A no-fat accompaniment cracker would have a fat content of less than 0.5 grams per 15 grams or less than about 3.33 wt%, based upon the weight of the final product.

[0040] In addition to the foregoing, the cheese doughs of the invention may include other additives conventionally employed in crackers and cookies. Such additives may include, for example, milk by-products, egg or egg by-products, cocoa, vanilla or other flavorings, as well as inclusions such as nuts, raisins, coconut, flavored chips such as chocolate chips, butterscotch chips and caramel chips, herbs, fruits, vegetables, meat, meat analogues, and the like in exemplary amounts of up to about 15 wt%, based upon the weight of the dough.

[0041] In some embodiments, a suitable source of protein may be included in the cheese doughs of the present invention to promote Maillard browning. The source of protein may include non-fat dry milk, whey solids, dried or powdered eggs, mixtures thereof, and the like. The amount of the proteinaceous source may, for example, range up to about 5% by weight, based upon the weight of the cheese dough. In some embodiments,the cheese provides a sufficient amount of protein, and other sources of protein may not be needed.

[0042] In some embodiments, the cheese dough compositions of the present invention may contain up to about 5 wt% of a leavening system, based upon the weight of the dough. Examples of chemical leavening agents or pH-adjusting agents which may be used include but are not limited to alkaline materials and acidic materials such as sodium bicarbonate, ammonium bicarbonate, monocalcium acid phosphate anhydrous, monocalcium phosphate monobasic (monohydrate), sodium aluminum phosphate, sodium acid pyrophosphate, diammonium phosphate, tartaric acid, lactic acid, mixtures thereof, and the like. Yeast may be used alone or in combination with chemical leavening agents.

[0043] In some embodiments, the cheese doughs of the present invention may include antimycotics or preservatives, such as calcium propionate, potassium sorbate, sorbic acid, fumaric acid, citric acid, and the like. Exemplary amounts may range up to about 1 wt% of the dough, to assure microbial shelf-stability.

[0044] In some embodiments, emulsifiers may be included in effective, emulsifying amounts in the cheese doughs of the present invention. Exemplary emulsifiers which may be used include but are not limited to mono- and di-glycerides, polyoxyethylene sorbitan fatty acid esters, lecithin, stearoyl lactylates, and mixtures thereof. Examples of the polyoxyethylene sorbitan fatty acid esters which may be suitable are water-soluble polysorbates such as polyoxyethylene (20) sorbitan monostearate (polysorbate 60), polyoxyethylene (20) sorbitan monooleate (polysorbate 80), and mixtures thereof.

Examples of natural lecithins which may be used include those derived from plants such as soybean, rapeseed, sunflower, or corn, and those derived from animal sources such as egg yolk. Examples of the stearoyl lactylates include alkali and alkaline-earth stearoyl lactylates such as sodium stearoyl lactylate, calcium stearoyl lactylate, and mixtures thereof. Exemplary amounts of the emulsifier which may be used range up to about 3 wt% of the dough.

[0045] In some embodiments, conventional snack-flavoring, -seasoning, and - coloring ingredients, odorants, condiments, confections, and mixtures thereof may be included in the cheese dough and/or topically applied after baking or frying of the cheese snack pieces. Examples of such ingredients which may be suitable include flavorings such as the savory flavors of barbecue, sour cream, chives, onion, garlic, butter, salt, vinegar, honey mustard, ranch, bacon, chicken, beef, cheese, and ham flavorings, the sweet flavors of cinnamon and sugar, peanut butter, banana nut, apple pie, honey graham, shortbread, butter toffee, cocoa crunch, chocolate chip, honey nut, oatmeal raisin, and vanilla crunch flavorings, cookie flavors, nuts and seeds, vanilla, and chocolate products, vegetable flakes and herb flakes such as pepper, basil, thyme, peppermint, tomato, and parsley flakes, condiment flakes, fruit flakes, spices, cheese powders such as cheddar cheese and Nacho cheese seasoning powders, and mixtures thereof.

[0046] The seasonings or flavorings may be applied by coating the fried or baked pieces with an oil-based binding composition, and then applying a powdered seasoning composition to the binder coated pieces. Use of an oil-based binding composition rather than a water-based binder avoids the need for subsequent drying to obtain a shelf-stable final cracker or snack product. In embodiments of the invention, the oil-based binding composition or oil slurry may be used in an amount of from about 2 wt% to about 8 wt%, or from about 4 wt% to about 6 wt%, based upon the total weight of the seasoned snack, when the snack is a fried snack. In baked varieties, the oil-based binding composition may be used in an amount up to about 20 wt%, or up to about 15 wt%, based upon the total weight of the seasoned snack. The powdered seasoning may be employed in an amount of from about 2wt% to about 15 wt%, or from about 4 wt% by weight to about 8 wt%, based upon the total weight of the seasoned snack.

[0047] Preparing a Cheese Snack

[0048] In some embodiments, cheese snacks of the present invention may be prepared from cheese with no additional ingredients. In some embodiments, cheese snacks of the present invention may be prepared by mixing ingredients which may include cheese, flour and water to obtain a cheese dough. Additional ingredients may be included in the cheese dough as described above, if desired. The dough may be prepared using conventional dough mixing equipment, such as an upright mixer or batch mixer. In some embodiments, mixing may be conducted at about 10 rpm to about 50 rpm, or about 20 lpm to about 40 rpm, for about 1 minute to about 10 minutes in order to obtain a homogenous dough.

[0049] In some embodiments, cheese snacks of the present invention may be prepared on conventional cracker equipment, such as sheeting using multi-reduction rolls or one set of two rolls. Sheeted cheese dough may be cut into desired shapes to obtain a pre- formed cheese snack.

[0050] In some embodiments, cheese may be rotary molded and/or sheeted to obtain a pre-formed cheese snack. In some embodiments, a suitable cheese exhibits desirable elasticity, tensile strength, and rheology for rotary molding and/or sheeting. In some embodiments, the ability to successfully process a cheese by rotary molding and/or sheeting is unexpected. In some embodiments, the ability of a cheese to exhibit desirable elasticity, tensile strength and rheology suitable for rotary molding and/or sheeting is unexpected.

[0051] In some embodiments, a cheese dough may be rotary molded and/or sheeted to obtain a pre-formed cheese snack. Similarly, in some embodiments, a suitable cheese dough provides desirable elasticity, tensile strength and rheology for rotary molding and/or sheeting. For example, in some embodiments, the dough is formulated such that it is not too soft and is not too stiff or dry to be rotary molded and/or sheeted. The elasticity, tensile strength, and rheology necessary for rotary molding and/or sheeting may be unexpected for a dough that includes the amounts of cheese of some

embodiments of the present invention. The elasticity, tensile strength, and rheology necessary for rotary molding and/or sheeting may be unexpected for a dough that includes more than 60 wt% cheese, or more than 65 wt% cheese, based on the weight of the dough.

[0052] In some embodiments, a desired elasticity, tensile strength and/or rheology may be attained by controlling the moisture level in the dough. In some embodiments, dough has a moisture level of about 20% to about 60%; about 25% to about 55%; about 30% to about 50%; about 20%; about 25%; about 30%; about 35%; about 40%; about 45%; about 50%; about 55%; or about 60%. In some embodiments, the pre-formed cheese snacks may be topped with cheese or other seasoning before cooking.

[0053] The cut or formed pre-formed cheese snacks may be transported on a conventional conveyor belt to a conventional oven, such as a direct gas fired convection oven or band oven for baking into crispy or crunchy cheese crackers, or to a fryer for frying into crispy or crunchy fried snacks. The cheese snacks may be formulated to maintain their shape while cooking and/or resist scorching. A crispy texture exhibited by formulations of some embodiments may be unexpected for a formulation containing the amounts of cheese of such embodiments. A crispy texture exhibited by formulations of some embodiments may be unexpected for a formulation containing more than 60 wt% cheese, or more than 65 wt% cheese.

[0054] Conventional frying devices, such as conventional fryers, fryer/coolers, may be employed in processing of the shaped pre-formed cheese snacks. Fryers equipped with agitators, or stirring paddles are preferred for preventing sticking of the individual pre-formed cheese snacks during frying. In some embodiments of the invention, fryers may be equipped with product submersion means for continued, complete, more rapid frying. [0055] Frying temperatures and times may range from about 280°F to about 360°F for about 5 to about 20 minutes. While baking times and temperatures may vary for different cheese snack formulations, oven types, etc., in general, commercial cheese snack-baking times may range from about 1.5 minutes to about 15 minutes, or from about 2 minutes to about 4 minutes, and baking temperatures may range from about 200°F to about 600°F, or from about 200°F to about 475°F.

[0056] After baking, the pieces may be dried using conventional drying equipment such as a one pass belt dryer, a rotary dryer, or a multi-pass dryer/cooler. Exemplary drying temperatures may range from about 200°F to about 225°F, and exemplary drying times may range from about 4 minutes to about 10 minutes.

[0057] In some embodiments, pre-formed cheese snacks of the present invention may be cooked by microwaving. In some embodiments, the pre-formed cheese snacks are microwaved for about 0.5 minutes to about 2 minutes; about 0.5 minutes; about 1 minute; about 1.5 minutes; or about 2 minutes. In some embodiments, cheese snacks of the present invention are formulated to maintain their shape during microwaving.

[0058] The baking and drying, or frying substantially reduces the moisture content of the shaped cheese snacks so as to achieve a cracker or snack having a shelf- stable moisture content, such as less than about 6 wt%, for example, from about 0.25 wt% to about 4 wt%, based upon the weight of the cracker or snack. The baked or fried products of the present invention may have a relative vapor pressure ("water activity") of less than about 0.3, or less than about 0.2, for preservative free microbial shelf-stability. In some embodiments of the invention, upon baking or frying the cheese snack pieces may undergo substantial starch gelatinization, and the crackers or snacks of the present invention may have a degree of starch gelatinization of less than about 80%, as measured by Differential Scanning Calorimetry (DSC).

[0059] After baking and drying or after frying, the pieces may be topped with conventional seasonings and topping oil, using conventional seasoning application equipment such as a rotating drum.

[0060] The snack products of the present invention may be packaged in polyethylene foil lined bags with a nitrogen flush. The products may exhibit an extended shelf life of at least six months, preferably at least 12 months. [0061] Cheese Snacks

[0062] In some embodiments, cheese snacks of the present invention prepared from cheese alone are puffed, having an open and airy structure, a cheesy taste and a crispy, crunchy texture.

[0063] In some embodiments, cheese snacks of the present invention prepared from cheese dough possess a crunchy texture. In some embodiments, inclusion of a reduced fat cheese in cheese snacks of the present invention results in a more flaky and crispy- crunchy texture.

[0064] Cheese snacks of the present invention may include cheese in an amount of about 5 wt% to about 100 wt% of the cheese snack; about 10 wt% to about 100 wt% of the cheese snack; about 15 wt% to about 100 wt% of the cheese snack; about 20 wt% to about 100 wt% of the cheese snack; about 25 wt% to about 100 wt% of the cheese snack; about 30 wt% to about 100 wt% of the cheese snack; about 35 wt% to about 100 wt% of the cheese snack; about 40 wt% to about 100 wt% of the cheese snack; about 50 wt% to about 100 wt% of the cheese snack; about 55 wt% to about 100 wt% of the cheese snack; about 60 wt% to about 100 wt% of the cheese snack; about 65 wt% to about 100 wt% of the cheese snack; about 60 wt% to about 95 wt% of the cheese snack; about 60 wt% to about 90 wt% of the cheese snack; about 60 wt% to about 85 wt% of the cheese snack; about 60 wt% to about 80 wt% of the cheese snack; about 65 wt% to about 95 wt% of the cheese snack; about 65 wt% to about 95 wt% of the cheese snack; about 65 wt% to about 90 wt% of the cheese snack; about 65 wt% to about 85 wt% of the cheese snack; about 65 wt% to about 80 wt% of the cheese snack; about 5 wt% of the cheese snack; about 10 wt% of the cheese snack; about 15 wt% of the cheese snack; about 20 wt% of the cheese snack; about 25 wt% of the cheese snack; about 30 wt% of the cheese snack; about 35 wt% of the cheese snack; about 40 wt% of the cheese snack; about 45 wt% of the cheese snack; about 50 wt% of the cheese snack; about 55 wt% of the cheese snack; about 60 wt% of the cheese snack; about 65 wt% of the cheese snack; about 70 wt% of the cheese snack; about 75 wt% of the cheese snack; about 80 wt% of the cheese snack; about 85 wt% of the cheese snack; about 90 wt% of the cheese snack; about 95 wt% of the cheese snack; or about 100 wt% of the cheese snack. [0065] The following examples, wherein all parts, percentages, and ratios are by weight, and all temperatures are in °F unless indicated to the contrary, illustrate some embodiments of the present invention:

[0066] Examples

[0067] Example 1 :

[0068] A cheese snack was prepared by rotary molding pasteurized cheddar cheese, which contained 80% real cheese, by itself. The molded cheddar cheese was then baked for 6 minutes in a 5 zone oven at the following temperatures:

[0069] The baked cheese snack contained 2% moisture, was puffed, and possessed an open and airy structure, cheesy taste, and a crispy, crunchy texture.

[0070] Example 2

[0071] A cheese snack was prepared according to the following formulation:

[0072] A mixture was prepared by mixing the ingredients of Stage 1 at 20 rpm for 1 minute. The ingredients of Stage 2 were then added and mixed at 40 rpm for 4-5 minute, to prepare a dough. The dough was rotary molded to form pre-formed cheese snacks. The snacks were then baked for 7.5 minutes in a 5 zone oven at the following

temperatures to produce a cheese snack with 2 % moisture: Zone 1 Zone 2 Zone 3 Zone 4 Zone 5

Top 425°F 465°F 490°F 430°F 280°F

Bottom 320°F 370°F 360°F 355°F 200°F

[0073] The baked cheese snack had a light, flaky and crispy texture.

[0074] Example 3:

[0075] A cheese snack was prepared according to the following formulation:

[0076] A mixture was prepared by mixing the ingredients of Stage 1 at 20 lpm for 1 minute. The ingredients of Stage 2 were then added and mixed at 40 rpm for 4-5 minute, to prepare a dough. The dough was rotary molded to form pre-formed cheese snacks. The snacks were then baked for 7.5 minutes in a 5 zone oven at the following

temperatures to produce a cheese snack with 2% moisture:

[0077] The baked cheese snack had a flaky and crunchy texture.

[0078] Example 4

[0079] A cheese snack was prepared according to the following formulation:

Ingredients Pounds Wt%

Wheat flour 20 36.87

[0080] The ingredients listed above were mixed to form a homogenous dough. The dough was then sheeted using a conventional sheeter and cut with a triangle cutter without docker pins to form pre-formed cheese snacks. The pre-formed cheese snacks were then baked in a direct gas-fired oven for 4 minutes at the following temperatures to produce a cheese snack with 2% moisture:

[0081] The cheese snacks produced a puffed texture and structure, which may be related to the selection of ingredients as listed above, including the reduced fat cheese.

[0082] Example 5

[0083] A cheese snack was prepared according to the following formulation:

[0084] The ingredients listed above were mixed to form a homogenous dough. The dough was then sheeted using a one-step two roll sheeter and cut to form pre-formed cheese snacks. The pre-formed cheese snacks were then baked in a jet zone/impingement oven for 1.7 minutes at the following temperatures to produce a cheese snack with 2% moisture:

[0085] The cheese snacks produced a chip-like texture and have grill marks due to the jet zone/impingement oven.

[0086] It will be appreciated by those skilled in the art that changes could be made to the exemplary embodiments shown and described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the exemplary embodiments shown and described, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the claims. For example, specific features of the exemplary embodiments may or may not be part of the claimed invention and features of the disclosed embodiments may be combined.

[0087] It is to be understood that at least some of the figures and descriptions of the invention have been simplified to focus on elements that are relevant for a clear understanding of the invention, while eliminating, for purposes of clarity, other elements that those of ordinary skill in the art will appreciate may also comprise a portion of the invention.