Patent Application
20060286209
The present invention relates to cultured dairy products, particularly to cultured cream cheese products, and more particularly to cultured cream cheese compositions which are prepared without a whey-separation step and which have reduced levels of cultured dairy materials. The present invention also relates to methods of making such cultured dairy products.
Cream cheese is usually made by mixing sweet milk or skim milk with sweet cream to a desired fat content (usually about 10 to about 16 percent). The mixture is pasteurized, homogenized, and cooled to a setting temperature (typically about 62 to about 92° F.). It is then inoculated with lactic acid bacteria and incubated until sufficient acidity has developed to cause the separation of curd from whey. The coagulation process may, optionally, be aided by the addition of a small amount of rennet. After the curd is separated from whey (e.g., using a centrifugal separator; see, e.g., U.S. Pat. No. 2,387,276), stabilizers, salt, and other ingredients are added. Finally, the product is packaged and chilled. Many variations to this process have been introduced through the years (see, e.g., U.S. Pat. Nos. 5,656,320; 5,079,024; 5,180,604; 6,419,975; 6,406,736; 6,558,761; 6,416,797; and 4,597,971).
Since whey proteins have been found to have high nutritive value and generally are less expensive than casein proteins, more recent efforts have been made to improve the utilization and retention of whey proteins when making cream cheese. For example, U.S. Pat. No. 6,558,716 (May 6, 2003) provides a process for re-incorporating whey protein into curd post-whey-separation. While this produces a finished cheese product with enhanced levels of whey protein, there remains an inefficient yield loss because of the whey separation step and only a relatively small amount of whey protein is added back to the curd. Moreover, although the process of U.S. Pat. No. 6,558,716 provides a less acidic cheese (and, thus, more organoleptically pleasing), consistent pH levels are not obtained since the bacterial cultures, which are live microorganisms, continue acid production while the liquid dairy mix is being concentrated, giving an inconsistent acidity/pH in the final product. In commercial cream cheese production, the dairy mix is broken at a given pH (e.g., between 4.5 and 5.5). As dairy mix is drawn off for pasteurization, the pH continues to decrease. Pasteurization effectively kills the lactic acid bacteria. But between the time the first dairy mix from the vat is pasteurized and the last portion of the dairy mix from the vat is pasteurized, the pH of the dairy mix and the resultant curd may vary by up to about one half of a pH unit. So the product at the end of the vat is significantly more acidic than that at the beginning of the vat.
U.S. Pat. No. 6,406,736 (Jun. 18, 2002) addresses this problem of non-robust pH control by proposing direct acidification of a liquid dairy mix. While a curd can be made using direct acidification (even without the need for a whey separation step), the finished product lacks the desired organoleptic properties of high quality cream cheese prepared with live and active bacterial cultures which produce auxiliary compounds in the liquid dairy mix (i.e., diacetyl, acetoin, free fatty acids) that enhance the cream cheese.
Other efforts have been made to produce a cream cheese without a whey separation step, but utilizing a traditional lactic acid-producing bacterial culture rather than direct acidification. For example, U.S. Pat. No. 6,861,080 (Mar. 1, 2005), incorporated the total solids (including protein) into a dairy mixture which is then used to create an emulsion with reduced average fat particle size below 0.8 microns and high quality organoleptic properties. Producing a cheese of this sort, however, typically requires investment in specialized equipment for creating the emulsion (e.g., by high pressure homogenizer) and heat transfer equipment. Moreover, all of the dairy materials are blended together before culturing and there are no teachings for minimizing acidity in finished product or assuring robust pH control (i.e., controlling variation of the pH level within production runs).
Therefore, there remains a need for producing a natural cream cheese that is made using lactic acid-producing bacterial cultures, and yet delivers a consistent pH level with less undesirable acidity and therefore, a more organoleptically pleasing product. Additionally, there remains a need for a cream cheese-making process that provides for increased yields and efficiencies by facilitating increased incorporation of whey proteins without the need for a whey separation step, for specialized equipment for heating transfer, and/or for creating an emulsion with reduced average particle size. The present invention provides such improved process and cream cheese products.
The present invention provides cultured dairy products and especially cultured cream cheese products which are prepared without a whey-separation step. The present invention also provides methods of preparing such cultured dairy and/or cream cheese products wherein a considerable quantity of non-cultured dairy material (generally greater than about 60 percent, and preferably about 70 to about 80 percent, of the total dairy protein) is added to a cultured dairy mix and subsequently functionalized (e.g., using high temperature and high shear conditions) to offer a finished cheese product with similar organoleptic properties and increased levels of whey protein compared to conventionally made cream cheese products. Since a whey separation step is not used, it is more cost efficient. Since a significant proportion of protein and dairy solids are added after culturing, the product can be made in continuous production without specialized heat transfer equipment, and ultimately offers a finished product with a more consistent pH level and less undesirable acidity, thereby providing a product with more desirable flavor profile.
The present invention provides a process for the manufacture of cultured dairy product containing cultured and non-cultured dairy ingredients, said process comprising
(1) providing a first mixture of dairy ingredients having a first amount of dairy protein;
(2) homogenizing and pasteurizing the first mixture to form a homogenized and pasteurized first mixture;
(3) cooling the homogenized and pasteurized first mixture to about 68 to about 104° F. to form a cooled first mixture;
(4) adding a lactic acid-producing bacterial culture to the cooled first mixture, after cooling to form a culture-containing first mixture;
(5) culturing the culture-containing first mixture at a temperature and for a time sufficient to obtain a pH-stable cultured first mixture, wherein the stable pH is in the range of about 3.5 to about 5.5 (preferably about 4.0 to about 4.5);
(6) providing a second mixture of dairy ingredients having a second amount of dairy protein, salts, and gums;
(7) adding the second mixture to the pH-stable cultured first mixture to form a third mixture; and
(8) heating and homogenizing the third mixture at a temperature and for a time sufficient to obtain a cultured dairy product containing cultured and non-cultured dairy ingredients, having a total amount of dairy protein;
wherein the first amount of dairy protein is about 10 to about 40 percent and the second amount of dairy protein is about 60 to about 90 percent, based on the total amount of dairy protein, wherein the cultured dairy product has a whey protein to casein ratio of greater than about 60:40, and wherein the process does not include a whey-separation step.
The present invention provides a cultured dairy composition containing cultured and non-cultured dairy ingredients, said composition comprising
(1) a first mixture containing cultured dairy ingredients, wherein the first mixture contains a first amount of cultured dairy protein, wherein the culturing of the first mixture is effected using a lactic acid-producing bacterial culture to obtain a stable pH in the range of about 3.5 to about 5.5 for the first mixture (preferably about 4.0 to about 4.5), and wherein the first mixture is prepared without using a whey-separation step;
(2) a second mixture containing uncultured dairy ingredients, salts, and gums, wherein the second mixture contains a second amount of uncultured dairy protein;
wherein the first mixture and second mixture are combined and then heated and homogenized at a temperature and for a time sufficient to obtain a cultured dairy composition containing cultured and non-cultured dairy ingredients, having a total amount of dairy protein;
wherein the first amount of cultured dairy protein is about 10 to about 40 percent and the second amount of uncultured dairy protein is about 60 to about 90 percent, based on the total amount of dairy protein, wherein the cultured dairy composition has a whey protein to casein ratio of greater than about 60:40. Preferably, the cultured dairy composition is a cultured cream cheese composition containing about 20 to about 30 percent cultured dairy protein and about 70 to about 80 percent uncultured dairy protein, based on the total amount of dairy protein, and has a whey protein to casein ratio of about 75:25 to about 85:15. The dairy protein in the second mixture generally includes, but is not limited to, whey protein. Preferably, the dairy protein in the second mixture consists of about 80 to 100 percent whey protein, based on total protein therein.
As indicated in
The first mixture is then cultured at a temperature of about 68 to about 104° F. and for a time sufficient to obtain a stable pH of about 3.5 to about 5.5 (preferably about 4.0 to about 4.5) using conventional lactic acid bacterial cultures and culturing conditions. The lactic acid culture used is not particularly limited. For example, it may be selected from the group consisting of Lactobacillus bulgaricus, Lactobacillus lactis, Lactobacillus helveticus, Lactobacillus delbrueckii subsp. lactis, Streptococcus thermophilus, Lactococcus lactis subsp. lactis, Lactococcus lactis subsp. cremoris, Lactococcus lactis subsp. lactis biovar diacetylactis, Leuconostoc lactis, Leuconostoc mesenteroides subsp. cremoris, Pediococcus pentosaceus, and Lactobacillus casei, and mixtures thereof. Preferably, the cultures are direct vat set (DVS) cultures. Such cultures are generally added to the fermentation mixture at a level of about 0.01 to about 1 percent, particularly about 0.05 to about 0.5 percent. Generally a stable pH within the desired range is obtained within about 10 to about 16 hours.
The resulting cultured mix is then blended with a second mixture containing additional, but uncultured, dairy ingredients, salts, gums, and, optionally, conventional cheese additives. These additional dairy ingredients included, for example, dry whey protein concentrate, liquid whey protein concentrate, whey protein isolate, liquid or dried sweet whey, liquid or dried acid whey, and the like, as well as mixtures thereof. Up to about 20 percent of the protein can be non-whey, milk protein (e.g., dry milk, milk solids, milk concentrates, and the like). The composition and the amounts of the various ingredients in the second mixture, and the amount of the second mixture added to the blended mixture, should be adjusted to provide a cream cheese product of the desired composition. Generally the amount of dairy protein provided by the first mixture (i.e., cultured) should be about 10 to about 40 percent of the final product and the amount of dairy protein provided by the second mixture (i.e., uncultured) should be about 60 to about 90 percent of the final product. Preferably, the final product should contain about 20 to about 30 percent of cultured dairy protein and about 70 to about 80 percent of uncultured dairy protein. Moreover, the final product generally contains about 0.5 to about 2 percent salt and about 0.2 to about 1 percent gums/stabilizers and preferably about 0.7 to about 1.3 percent salt and about 0.3 to about 0.7 percent gums/stabilizers. Thus, the second mixture should be adjusted to obtain sufficient uncultured dairy protein, salt, and gums/stabilizers to obtain these desired levels in the final product.
Suitable gums/stabilizers include those used in conventional cream cheese products. Examples of suitable gums/stabilizers include carob gum, tara gum, xanthan gum, locust bean gum, carrageenan, cellulose gum, maltodextrin, pectin, inulin, starch, gelatin, agar, and the like as well as mixtures thereof. Preferred gums/stabilizers include xanthan, locust bean gum, and guar gum. The terms “gum,” “stabilizer,” and “gum/stabilizer” are used interchangeably in the present specification. The second mixture may also optionally contain additional ingredients such as flavors, colorants, anti-microbial agents, and the like. Such optional ingredients may be added at other points in the process so long as they do not adversely effect the process or the resulting product.
The blend of the cultured mixture and the second mixture, which contains uncultured dairy protein, salt, and gums/stabilizers, is then subjected to a heat treatment and homogenization, in either order, to provide the desired product. In one operation, the mixture is homogenized in a high shear homogenizer. Preferably, the blend is homogenized at a pressure of about 500 to about 8,000 pounds per square inch (psi). More preferably, the blend is homogenized at a pressure of about 1,500 to about 6,000 psi, and most preferably at about 2,000 to about 4,000 psi. Homogenization provides reduced particle sizes in the mixture. It is preferred to attain a particle size less than about 2.5 microns, and more preferably, a particle size less than about 1.5 microns. Suitable homogenizers that may be employed for this purpose are well-known in the fields of dairy science and food chemistry.
The second operation to which the blend is subjected is a controlled treatment at an elevated temperature. In general, the blend is treated at from about 175 to about 215° F. for about 2 to about 60 minutes. Preferably, this treatment is at a temperature from about 180 to about 205° F. for about 5 to about 30 minutes. Various ways of conducting the controlled elevated temperature treatment are known to workers of skill in dairy science and food chemistry. Such methods include, for example, heating in a thermally jacketed batch vessel, or passage through a heat exchange tube in which the fluid velocity and the length of the tube establish the duration of the treatment. The preferred sequence of these operations is one in which the homogenization precedes the temperature treatment. The reverse sequence, however, also is found to work. In general, the homogenization and heat treatment can also be carried out at the same time, for example, by heating the blend before and/or during the homogenization. Alternatively, if one of these procedures is carried out first, the other can follow within an operationally convenient time. Although not wishing to be limited by theory, the combined heat and homogenization treatments are thought to denature and cross link the whey proteins from the second mixture, thereby building the desired texture.
The resulting cultured dairy or cream cheese product, which contains both cultured and uncultured dairy proteins, has a pH in the range of about 4.5 to about 5.5, and preferably, about 4.8 to about 5.2. Moreover, it has been found resulting cultured dairy or cream cheese product has a more consistent pH during its manufacture and contains less acidity than conventional cream cheese products. Generally, the present cultured dairy or cream cheese has a shelf life of about least about 9 months when packaged in a sealed container and stored under refrigeration conditions (i.e., about 45° F.). Moreover, the resulting cultured dairy or cream cheese product has a whey protein to casein ratio of about 60:40 to about 90:10, and preferably about 75:25 to about 85:15. Thus, the present cream cheese products contain significantly more whey protein than conventional cream cheese products, including the cream cheese products produced by the methods described in U.S. Pat. No. 6,558,716, which generally contain less than 45 percent whey protein based on total protein. Generally, the present cream cheese products provided by the present invention contain about 60 to about 90 percent whey protein, based on total protein content, and preferably about 75 to about 85 percent whey protein.
Other ingredients, including but not limited to, sweeteners, fruits, flavors, and other conventional additives may be added to the resulting cultured cream cheese products. The cultured dairy or cream cheese products may also be aerated to provide a low fat aerated dairy product having an overrun greater than about 5 percent, preferably greater than about 15 percent, and more preferably about 15 to 50 percent. By adding appropriate levels of sweeteners (i.e., to taste) and aerating, low fat aerated dairy products containing less than about 12 percent fat (preferably about 3 to about 9 percent fat), greater than about 5 percent protein (preferably about 6 to about 10 percent protein), and about 40 to 80 percent moisture (preferably about 60 to about 75 percent moisture) can be prepared. Such aerated dairy products have a fat to protein ratios of less than about 2.5 (preferably less than about 1.4), overrun values of at least about 5 percent (preferably greater than about 15 percent and more preferably about 15 to 50 percent), milk solids of at least 10 percent, and a foam strength of at least about 100 pascals.
Unless otherwise indicated, all percentages and ratios in the present specification are by weight based on the total weight of the final cream cheese product composition. All patent and publications cited in the present specification are hereby incorporated by reference in their entireties.
An inventive full-fat cream cheese was prepared using the general method illustrated in the process flow diagram (
The whey protein concentrate (WPC) was from Glanbia Nutritional, Inc. (Monroe, Wis.); the whey powder was from American Milk Producers, Inc. (Jim Falls, Wis.; and the stabilizer/gum was locust bean gum from Danisco USA, Inc. (New Century, Kans.). After all ingredients were added, the blend was held for 10 minutes at 180 to 185° F. and subsequently homogenized at 3000/500 psi (first and second stage). Product was collected and packaged.
The inventive cream cheese exhibited the following composition and physical properties compared to (1) a conventionally made, full-fat, soft spread cream cheese and (2) a cream cheese prepared using the process of example 2 of U.S. Pat. No. 6,558,716. In Table 1B (as well as in corresponding Tables 2C and 3C in Examples 2 and 3, respectively), total solids, total fat, total solids nonfat, and total protein are based on the finished cream cheese composition, whereas percentage solids uncultured, percentage fat uncultured, percentage solids nonfat uncultured, and percentage protein uncultured are based on the total solids, total fat, total solids nonfat, and total protein, respectively, of the finished cream cheese composition. For example, the inventive product contains 6.0 percent protein, and of this protein, 73.9 percent is uncultured (and, therefore, 26.1 percent is cultured).
The inventive process incorporates a preponderance of protein (i.e., about 74 percent of total protein) after the culturing step. This creates a finished cheese product with increased levels of whey protein, more consistent or robust pH level during commercial manufacture, and higher pH levels than conventional and previous efforts. The inventive product was judged to have good flavor and overall eating quality with reduced levels of undesirably acidity compared to conventional cream cheese. Moreover, the inventive process does not include a whey separation step and is therefore more efficient.
An inventive reduced-fat cream cheese was prepared using the general method illustrated in the process flow diagram (
The dairy mix was cultured until the pH level reached steady state (pH 4.17). After heating from about 61 to about 180° F., ingredient additions were made as shown in the following recipe (based on 100 lbs finished product).
The WPC and whey powder were the same as used in Example 1. The stabilizer/gum was a blend of about 80 percent locust bean gum (Danisco, USA, Inc., New Century, Kans.) and about 20 percent xanthan gum (CP Kelco, Chicago, Ill.). After all ingredients were added to the mix, the blend was held for 10 minutes at about 180 to about 185° F. and subsequently homogenized at 3000/500 psi (first and second stage). Product was collected and packaged.
The inventive cream cheese exhibited the following composition and properties compared to (1) conventionally made, light cream cheese and (2) a similar cream cheese prepared using the process of example 7 of U.S. Pat. No. 6,558,716.
As with the previous example, the inventive process incorporates a preponderance of protein after the culturing step. This creates a finished cheese product with increased levels of whey protein and more consistent or robust pH during commercial manufacture, and higher pH levels than conventional and previous efforts. The inventive product was judged to have good flavor and overall eating quality with reduced levels of undesirable acidity compared to conventional cream cheese. Moreover, the inventive process does not include a whey separation step and is therefore more efficient.
An inventive ultra-light cream cheese was prepared using the general method illustrated in the process flow diagram (
The dairy mix was cultured to a steady-state pH of 4.17. After heating from about 58 to about 180° F., ingredient additions were made as shown in the following recipe (based on 100 lbs finished product).
The WPC, whey powder, and stabilizer/gum blend were the same as used in Example 2. After all ingredients were added to the mix, the blend was held for 10 minutes at about 180 to about 185° F. and subsequently homogenized at 3000/500 psi (first and second stage). Product was collected out and packaged. The inventive cream cheese exhibited the following composition and properties.
As with the previous examples, the inventive process incorporates a preponderance of protein after the culturing step. This creates a finished cheese product with increased levels of whey protein and a robust, higher pH level as well as good flavor and overall eating quality. Moreover, the inventive process does not include a whey separation step and is therefore efficient. Although comparison products (i.e., conventional products and products prepared by the method of U.S. Pat. No. 6,558,716) were not evaluated, the properties of such comparison products are expected to be similar to the comparison products shown in Examples 1 and 2 (except for lower total fat levels).
An inventive low-fat, aerated, cultured dairy product was prepared by blending milk and cream to the composition shown in Table 4A.
The blended dairy mix was homogenized at 2500/500 psi (first and second stage), pasteurized (168° F. for 30-seconds), and cooled to about 72° F. Subsequently, the dairy mix was inoculated with 0.03% DVS lactic acid-producing bacterial cultures supplied by Chr. Hansen and allowed to incubate at 72° F. for 15 hours. When the pH reached a steady state of 4.35, the mix was heated to 180° F. and the following ingredient additions were made as shown in Table 4B.
The WPC (49.75% protein) was supplied by First District Association (Litchfield, Minn.). The stabilizer/gum used was a blend of about 77 percent locust bean gum (supplied by Danisco USA Inc.), about 15 percent xanthan (supplied by CP Kelco), and about 8 percent carrageenan (supplied by FMC Corp., Philadelphia, Pa.). After ingredients were added to the mix, the blend was held for 15 minutes at 180° F. and subsequently homogenized at 3000 psi (single stage). Then, the dairy product was heated to 188° F. via a triple-tube and held for 60 minutes in a Grohn kettle while maintaining product temperature of 175 to 180° F. Next, a portion of the cultured dairy product was mixed with additional ingredients as shown in the recipe in Table 4C.
The resulting product was cooled to approximately 36° F. using a scraped surface heat exchanger and whipped/aerated to approximately 20% overrun. Finished goods were collected in 8-oz cups, sealed, and placed into refrigerated (45° F.) storage. This product was held under refrigerated conditions (<45° F.) and monitored for 4 months with no degradation of air cell stability or apparent loss of overrun. The inventive product was evaluated and determined to have good flavor and overall eating quality throughout shelf life. A summary of the finished goods characteristics is summarized in Table 4D.
Foam strength was measured using a Haake model VT550 viscometer (Gebruder Haake GmbH, Karlsruhe, Germany) at a shear rate of 0.0236 sec−1 and a temperature of 45° F.
All references cited herein are fully incorporated by reference. Having now fully described the invention, it will be understood by those of skill in the art that the invention may be performed within a wide and equivalent range of conditions, parameters and the like, without effecting the spirit or scope of the invention or any embodiment thereof.
