Patent Application
20220087278
Not applicable.
Not applicable.
This application is a continuation-in-part of the co-pending application, U.S. patent application Ser. No. 16/683,678, filed Nov. 14, 2019, which is a continuation-in-part application claiming benefit of U.S. patent application Ser. No. 14/162,911, having the filing date of Jan. 24, 2014 and further claims benefit of the parent application, U.S. patent application Ser. No. 13/426,397, with the filing date of Mar. 21, 2012. and wherein this application claims priority to the parent filing date, Mar. 21, 2012. This application is copending with the above referenced existing live applications and conforms with filing requirements pursuant to 35 U.S.C. 120, 37 C.F.R. 1.53(b) and all other relevant law not otherwise referenced herein.
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark office, patent file or records, but otherwise reserves all copyright rights whatsoever.
The present inventive subject matter relates to the formation of cheese, particularly cheese of the pasta filata type.
According to artisanal hand crafted tradition, the making of pasta filata cheese must follow certain necessary steps to achieve its signature flavor and texture. Texture, in the pasta filata context, provides a tender bounce, elastic and layered quality. Ideal pasta filata texture reflects its physio-chemical composition achieved by proper chemical, heat and physical manipulation of nascent cheese protein and fibers. The ideal flavor of pasta filata cheese by artisanal standards is a sufficient and even salting of the cheese throughout its cross section, without over salting as it is a mild and creamy flavored white cheese with high fat content.
According to artisanal pasta filata cheese making standards, the curd must first reach an ideal pH level of 5.2. Through the development of acid, calcium is removed from the protein structures, allowing formation of the right kind of protein network to begin stretching. The curd is subsequently submersed in a high heat bath for stretching to develop longer strand protein relationships. The high heat bath also assists in partially pasteurizing the nascent cheese curd. The cheese curd must be kept in a heated state during the stretching process to maintain pliability and for protein strands to continue forming while stretched. Some novice techniques call for microwave heating of the curd, which unevenly heats the curd through its crossection. An alternative advanced technique suggested by this same inventor provides for heating of the curd through direct contact with electro conductive means, taking advantage of the curd's even distribution of salt and moisture throughout. The high heat and stretching process at this stage can potentially produce a variety of results depending on the amount of time in the heated state, the intensity of heat, and the presence or level of salt brine if immersed in hot water bath. Any of these in excess may lead to failed results with denatured or damaged protein strands, loss of fat content or over salting. Ultra-pasteurization is not suggested because over heating will cause natural denaturing of protein molecules and strands.
By traditional methods, stretching occurs when the curd is formed and in a heated pliable state. This is often achieved by submersion of the curd in a heated bath to maintain ideal core temperature. The method of heating the curd by submersion in a hot bath is an archaic method dating to its 14th century Roman origins. This is a simple but timelessly effective technique. By pulling the cheese to stretch in this heated state, oil is preserved in between the strands within protein pockets, giving the cheese is creamy flavor. Stretching of the curd pulls the strands away, creating longer thin strands with space and pockets therebetween which gives the cheese its tender texture. This process has carried on into modern artisanal cheese making methods for its tried and true results.
It is difficult to achieve the high quality standard of artisanal pasta filata cheese in mass manufacturing context due to high volume and time constraints. Natural cheese, particularly of the pasta filata family (including but not limited to mozzarella, provolone, or blends thereof) have plastic or elastic qualities that make it pliable for molding when heated (typically between 120° F. to 160° F. Pliability in this heated state prevents the cheese from being self supporting (independently hold its own weight and shape). For purposes of packaging cheese with a prescribed shape, specifically pasta filata type cheeses, it is necessary that the external layer of a block be sufficiently cool to hold its own shape and weight while the internal warmer portions be cool enough not to reheat and deform the external layer (otherwise known in the industry as “slumping”). This stage of cooling is called “setting”. Once a piece of cheese has set, it is able to independently maintain a prescribed shape (be “self supporting”) and hence be ready for packaging and shelving. In practice within the manufacturing industry, core setting temperatures for standard pasta filata type cheese have ranged from above 80° F. to below 55° F.
I recently conducted a theoretical transient heat transfer study based on standard cheese physical properties provided by the UW-Madison Diary Center, illustrating its cross sectional temperature profile after 10 minutes of cooling in salt brine solution. For a standard 4×4 inch six pound block of cheese submersed in 32° F. brine solution for 10 minutes, theoretical results reveal the outermost layer reaching an ambient temperature of 32° F. while the inner core temperature remains at approximately 140° F. These numbers reflect actual temperature ranges found in current manufacturing processes under similar conditions. The calculations were based on a 4×4 inch square six pound block of cheese with thermal conductivity of 0.332 W/mK and specific heat of 3 kJ/kgK, theoretically in direct contact with 32° F. brine solution for exactly 10 minutes.
In particular, the theoretical heat study revealed a temperature profile for seven external cross sectional layers (⅝ inch thick each) surrounding a thicker inner core of a 4×4 inch cheese block. The profile shows seven temperature ranges (rounded to the nearest degree) from inner core to outer surface on a per layer basis: 1) 140° F. to 125° F., 2) 125° F. to 109° F., 3) 109° F. to 94° F., 4) 94° F. to 78° F., 5) 78° F. to 63° F., 6) 63° F. to 47° F., 7) 47° F. to 32° F. The outside “skin” (according to the study, being the outermost layer in contact with the external environment) cools relatively quickly given greater surface area exposure to cooling agents. The skin is able to cool from an initial temperature of 140° F. to 32° F. within 10 minutes of submersion in 32° F. brine solution. The interior core, however, experiences negligible temperature change in the same period of time. Typically, the speed of cooling and setting is based in significant part by the thermal conductivity of the cheese, driving overall cooling time. According to this study, the cross sectional outer half of the 4×4 inch cheese mass reaches an average temperature of approximately 66° F. (rounded to the nearest degree) after 10 minutes of submersion in the 32° F. cooling medium while the inner half may require at least 4 to 5 hours or more to reach the same temperature.
Industry standards provide certain dimensional requirements for the manufacture of cheese blocks. One industry standard provides for a 20 pound block of cheese that is 20 inches long, 4.5 inches thick and 8 inches wide. Another standard sized loaf provides for a 5 pound block of cheese that is 4 inches wide, 4.5 inches thick, 10 inches long. Standard manufacturing techniques for the production of large pasta filata type cheese blocks require multiple steps in forming and cooling each block. Typically, these large blocks are shaped in molds and partially cooled to a desirable exterior temperature sufficient to hold shape in suspension. The blocks are then consolidated into a cold brine bath and buoyed through cooling bath channels for up to 12 hours.
This multi-step technique of separately forming and cooling the cheese blocks results in substantial loss of time and space as well as loss of inherent desirable qualities within the cheese. Extensive floor space is required to accommodate each separate step of the process. Extensive time (as long as 12 hours depending on the size of the block) is required to set the cheese in liquid cooling medium. The blocks quickly lose their shape when released too soon from their molds and allowed to travel unguided through brining channels. The extensive time submersed in brine solution results in substantial loss of butterfat, uneven salting of the cheese blocks, loss of shape from impact with other surfaces and increased risk of contamination.
The initial steps of forming cheese (stretching and shaping) in manufacture typically involves extrusion of a nascent cheese mass through a screw device, forcing them into molds. The extrusion method tends to excessively work the cheese, cutting into cheese fibers and internal pockets that naturally retain fat, moisture and flavor. This results in loss of flavor, change of texture and decrease in overall mass. The technique goes contrary to suggested methods for forming cheese by those in the art. The best method of stretching and separating cheese is by pulling rather than pushing and pinching rather than cutting, for reasons discussed above. Under current large scale manufacturing processes, the final product tends to be of inferior quality in moisture, flavor, and texture compared to artisanal style crafted pasta filata cheese.
Another disadvantage of current methods that use brine solution to work the cheese (to either heat or cool the cheese) is that the solution has the effect of washing the cheese. Whether the solution is sprayed over the cheese or that the cheese is immersed in solution, any material that is not otherwise integrated into the protein network of the cheese mass will be easily dislodged. This becomes a problematic scenario if foreign material is introduced and mixed into the cheese mass. The protein network of pasta filata cheeses, unlike processed cheese, are formed by strong hydrophobic protein to protein interactions that create hydrophobic protein latices. Once the latices are formed, it is difficult to reopen the bonds to allow new molecular connections without denaturing the entire cheese construct. For this reason, food particles that are introduced and mixed into pasta filata cheeses tend to be integrated between lattice structures and held together within the cheese mass by physical pressure and not by chemical bond. Composite pasta filata cheese products are not available in mass market primarily because current manufacturing processes that rely on brine solution for temperature control risks washing away food particles and resulting in frequent contamination of the brine solution. Current systems for manufacturing pasta filata cheese does not make it practical or feasible to produce composite pasta filata cheese products.
U.S. Pat. No. 5,480,666 attempts to reduce cooling time by providing a method that takes advantage of surface area cooling and the cheese's inherent ability to fuse by lamination. Pasta filata type cheese is first texturized by auger mixing method, then pressed by rollers on a conveyor belt where flattened sheets are cooled directly with a liquid cooling medium. The wide surface area and thinner cross sectional dimensions of each sheet allows it to cool comparatively faster than a block of cheese of standard industry size. Once cooled, the sheets are sliced into ribbons, stacked and allowed to laminate (stacked and fused together into one continuous mass) to produce standard sized blocks. This patent may work fine for processed cheese but the elastic nature of pasta filata cheese is more difficult to manage by this simplistic method. The natural slumping of warm pasta filata type cheese requires cooling within a rigid mold to set the cheese to a defined shape. For this reason, the two-step process of cooling in molds and subsequently in brine baths remains the popular method in mass manufacturing.
U.S. Pat. No. 4,626,439 attempts to improve existing manufacture methods for shaping pasta filata type cheeses. Accordingly, a nascent cheese mass is extruded onto a conveyor belt and pressed by rollers into thin sheets. The sheets are kept warm to maintain pliability during the rolling process. The edges of the sheets are trimmed to desired dimensions and excess pieces are reused. The cheese is kept warm through trimming to preserve excess pieces for reuse. Cooling begins immediately after trimming to quickly set the cheese and to maintain the trimmed dimensions. This process acknowledges the slumping effect of pasta filata cheese and provides an alternative method for shaping. The cooling process in this patent involves immersion of trimmed sheets in cold brine solution. Once set, cheese sheets are ready for slicing, dicing, shredding or cookie cutting. This process does not provide for shaping by mold. There remains a problem of over processing from reuse of trimmed material and decreased flavor and moisture content from over brining.
U.S. Application No. 2009/0226580 A1 similarly extrudes a nascent cheese mass onto a conveyor surface where the mass is pressed and rolled into thin sheets. Alternatively, the sheets are cooled directly on the conveyor with super cooled air and a cooled conveyor surface. This eliminates the need for direct contact with a liquid cooling medium. Since the sheets are directed for immediate comminuting (cut into smaller shapes such as by slicing, dicing or shredding), shape is of no concern. Therefore, the initial step of partial cooling in molds is eliminated and the cooling process is sped up by taking full advantage of surface area cooling. As with the above patent no. '580, texturization by extrusion can overwork the cheese and compromise its quality. Exposure to the open-air environment to maximize surface area cooling increases risk of contamination. Lastly, this application does not contemplate actual shaping of the cheese, and therefore renders this application inapplicable to the manufacture of cheese blocks, sticks or other molded forms.
U.S. Pat. No. 4,665,811 provides a method and apparatus similarly as above for pressing a nascent cheese curd to a desired thickness. The purpose of which is to create wider surface area for quick cooling and for final shredding. As with other devices intended solely for comminuting, this device does not provide a method for molding the cheese to shape under careful cooling conditions. Nor does it provide a method for properly texturizing the cheese for a more thoughtful texture since the end purpose of this product is to be eaten in a shredded or heated molten state.
U.S. Pat. No. 4,288,465 provides an alternative method and device for producing pasta filata cheese, specifically narrow strips of cheese of the string cheese type. This method acknowledges the need to stretch the cheese under a certain continuous amount of tension to create longer fiber layers of classic string cheese product. To achieve a continuous stretching affect, this device provides a spool system for directing and winding the cheese throughout. One drawback of this device has to do with slumping effect of warm pasta filata cheese during the stretching phase. In order to properly stretch the nascent cheese mass for producing long fibers and layers, the cheese mass must be in a heated state of approximately 120-140 degrees throughout. In this state, the cheese may be stretched but with very little resisting force beyond its own weight. Therefore, when pulled across a length of space without a means for support, the cheese will naturally drag and slump by gravitational affect. The result of stretching the warm cheese over extensive open space is an uncontrolled variability in thickness and fiber formation along its length as affected by gravity and its own weight due to slumping. As with other spooling methods for creating tension, the slumping problem of this invention may be overcome by providing a greater speed for the front spool, but this could result in secondary problems of even texture control while not completely eliminating the problem of slumping near heated segments. There is also a likely chance of unspooling on portions of the strand affected by slumping. The device in this case does not provide a supporting means between the pipe outlet and the first spool to minimize slumping without reducing the tension effect of the spool. The cheese being concurrently stretched and cooled in this case, will further run into problems of tearing due to the tension exerted on cooled cheese fiber.
U.S. Pat. No. 5,948,459 provides an apparatus and method for forming and cooling flowable cheese matter by forcibly pushing cheese through a molding tube. Therein the cheese is internally cooled by a cooling mechanism externally communicating with the molding tube to selectively create a cooling gradient along the length of the molding tube. According to this invention, pasta filata cheese is moulded and cooled to set in a controlled manner without secondary brining. However, the cheese lacks sufficient and proper texturizing treatment. This device contemplates protein fiber formation primarily from auger and forced extrusion which unfortunately cuts into the natural fiber strands within the cheese mass, compacts the mass and squeezes out fact pockets inside the mass. This device mainly contemplates production of narrow strands of string cheese. Heavier and thicker blocks of cheese will have a difficult time maintain its place along the spool due to slumping affect while affected by greater compaction from its own mass and weight against the molding tube. Therefore, this device would be impractical for mass production of larger sized mozzarella cheese blocks due to compromised quality from increased force needed to push the thicker block through.
European patent application no. EP 0779032 provides for a process of making composite cheese product that incorporates foreign edible food particles homogenously into the final cheese product. This application refers to a method of making processed cheese, which is different in parameter from the process of making pasta filata cheese. The challenges however remain the same in terms of the negative effect of brine solution on retention of foreign food particles and the risk of contaminating the brine solution.
European patent application no. EP 0515318 provides a similar method of producing composite cheese product that incorporates foreign edible food particles during the lattice formation phase of pasta filata cheese manufacturing process. However, the foreign particles are added to the cheese curd as the curd is being heated in hot water. The process of incorporation is inefficient, requiring more frequent replacement of hot water to avoid cross contamination.
There remains a considerable need for inventive solutions that improves upon the quality and speed of cheese molding and manufacture and an ability to mass produce composite cheeses safely and efficiently. All patents and applications referred herein are incorporated by reference in their entirety. Furthermore, where a definition or use of a term in a reference, which is incorporated by reference herein is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
An inventive solution directed to the mass manufacturing of artisanal style pasta filata type cheese (including but not limited to mozzarella, provolone and blends thereof) by upholding traditional standards for quality texture, flavor and moisture. The apparatus and method of this invention providing a process whereby Step 1) cheese curd granules are obtained by method of acidifying milk protein, coagulating said acidified milk protein to form solid curd, separating said solid curd from liquid whey, Step 2) placing said cheese curd granules that have been separated from whey into a container, said container having ohmic heating mechanism with electrical voltage output and a temperature gauge, Step 3) contacting said cheese curd granules with said temperature gauge and said electrical output of said ohmic heating mechanism to heat said cheese curd granules, Step 4) mix said heated cheese curd granules to create longer protein fiber strand latices, Step 5) adding and mixing edible food particles into said heated cheese mass into a nascent homogenous composite form, Step 6) shut off voltage output to the cheese mass, Step 7) stretch, mold, and cool said nascent homogenous composite cheese mass through a fully enclosed space of a counter-rotating dual compression belt cheese processing device, Step 8) pull, stretch, mold, and cool said nascent homogenous composite cheese mass through said fully enclosed space of said counter-rotating dual compression belt cheese processing device to form a continuous ribbon of cooled and shaped composite pasta filata cheese, Step 9) separate said continuous ribbon of cooled and shaped composite pasta filata cheese that is released from said counter-rotating dual compression belt cheese processing device, Step 10) cut and prepare said continuous ribbon of cooled and shaped composite pasta filata cheese for immediate packaging or for immediate storage. The entire process of this invention allows for a completely dry method for mixing, seasoning and producing pasta filata cheese and forming a composite finished product without loose ingredients that is ready for immediate cutting and packaging.
Said ohmic heating mechanism having one or more electro-conductive heating element wherein said electro-conductive heating element is positionable within or proximate to said container. Said ohmic heating mechanism also providing a temperature gauge which may be interconnected with said electro-conductive heating element or separately operating autonomously. Said temperature gauge having a terminal end that is contactable with the container or the cheese curd held therein. The temperature gauge also connected to a digital device with a viewable window that presents a temperature in readable manner. In either manner of design or function, the temperature gauge preferably provides real time immediate temperature reading of the heated curd material that it is in contact with. The immediate temperature reading may be coordinated with proper adjustment of electrical voltage output to control the level of heat and speed of temperature change of the cheese mass.
Said electro-conductive element comprising a source of electrical current, a wire conduit connected to said source of electrical current, and an electro-conductive end that is contactable with said cheese curd granules within said container. Said electroconductive end may comprise any one or combination of a plate, screw auger, probe, wall panel, wire, or combinations thereof. The process involving the contact of nascent cheese curd granules with said electro-conductive element which releases electrical current throughout the cheese, resulting in heating of the cheese curd material. The heated cheese curd granules are mixed during this heated state. The level of heat is recorded by said temperature gauge and kept at an ideal temperature level between X and X by controlling the level, quantity, time, and or frequency of electrical current flowing through said cheese curd granules. The cheese curd granules are essentially heated and mixed to create new extensive and lengthier fiber lattice connections. It is during this phase of the cheese making process that new food ingredients may be added and physically mixed into the new lattice networks to form a homogenous composite nascent cheese mass.
The food ingredients are preferably granular in size and may be whole or partial shaped particles or in powder form. The food particles may comprise dry or dehydrated ingredients or have some hydration within their content. The food particles may further comprise natural cooked, uncooked, cured, picked, dried, or refined processed ingredients. The food particles however preferably not comprising raw meat. The food particles may further comprise a pasty consistency, whole particle consistency, or powder consistency. The food particles may be sweet, savory, bitter, or sour in taste to create a complex blend of flavor profile together with the pasta filata cheese it is held within. In fact, the flavor of the food particles may be of any flavor profile and may comprise more than one flavor profile as long as it may be combined and mixed into the cheese mass in homogenous form. More than one type of food particle ingredient of different flavor, texture, and size may be added and mixed into said nascent cheese mass during the cheese mass formation process at this stage. Bearing in mind that certain added food ingredients may have an inherent acidity which may cause the cheese curd to release or expel additional liquid whey, resulting in a tougher cheese texture. In these circumstances, additive modifying ingredients may be added to the mixture during the mixing process to counter balance and maintain ideal pH of the cheese mass.
Said additive ingredient is preferably edible, non-toxic, food grade material for purposes of controlling levels of acidity of the cheese mass. The additive ingredient may be powder, liquid, gel, gas, or paste consistency or form or any combination of these.
The foreign food ingredients may comprise any of the following without limitation: fruits, nuts, meats, grains, vegetables, plant material, herbs, spices, salts, sugars, starches, food coloring, fungi, and other edible food products and food additives that may be cooked, uncooked, cured, pickled, dried, or refined processed ingredients. The total mass of foreign food particles added to the cheese mass for homogenous mixing is preferably no greater than 65% of the cheese mass itself in order for the lattice structure of the cheese mass to hold the material together and maintain integrity of the physical structure of the composite combined material during and between its mixing, stretching, cooling, molding, cutting, and packaging phases of the entire process.
Upon attaining a homogenous mixture of the composite cheese mass material, the electrical current is terminated. The composite cheese mass is then transferred to a counter-rotating dual compression belt cheese processing device for stretching, molding, and cooling in a dry environment. Said counter-rotating dual compression belt cheese processing device comprising a counter rotating dual compression belt system for forming pasta filata cheese from a nascent heated cheese mass. Said counter rotating dual compression belt system comprising a first and second circular belt strap, each said circular belt strap having an internal flat surface and an external grooved surface. Said external grooved surface of said first circular belt strap oppositely facing and in compressed contact with said external grooved surface of said second circular belt strap to form a length of sealed and compressed hollow space there between. Each said two circular belt straps moving in counter-rotational direction of each other.
Each said circular belt strap comprising nonporous durable and flexible thermo conductive food grade material. The internal surface of each said circular belt strap being in contact with an enclosed cooling mechanism comprising an enclosed and sealed cooling block containing a continuous stream of cooling medium flowing therein to maintain its external surface in a continuously chilled condition. Each circular belt strap passing across the continuously chilled surface of said enclosed cooling block will be cooled by dry means of wicking action and heat transfer. Said first and second circular belt strap passing across the continuously chilled surface of said enclosed cooling block will be cooled by dry means of wicking action and heat transfer.
Said first and second circular belt strap each rotatable in counter-rotational direction of each other wherein heated pasta filata cheese curd is receivable, pullable, and stretchable therethrough in compressed manner. The nascent composite cheese mass is pulled, stretched, molded, and cooled to form a continuous ribbon of cooled and shaped composite pasta filata cheese. The released ribbon of composite pasta filata cheese is ready for immediate cutting, packaging, and storage.
A preferred embodiment of this invention provides the above described steps wherein the method of heating is by a dry method wherein the curd is kept in a heated state with direct electric conduction (ohmic heating method), taking advantage of the ionic properties of salt throughout the cheese mass. This process is considered a dry heating method because it does not require submersion in a heated water bath. A dry method of heating allows for dry salting of the cheese at an earlier stage where the salt is able to impregnate and infuse into the cheese mass. Food additives and food particulates may further be added at this stage as the heated cheese curd is mixed to form the nascent dough body of the cheese with improved and elongated protein latices. A homogenized mixture is eventually attained through this method of dry heating and mixing. The cheese mass once texturized to an ideal level of consistency and homogeny is then removed and placed into a first open end of a counter-rotating dual compression belt system, directing the cheese towards its second open end by pulling action.
The counter-rotating dual compression belt system providing a hollow channel space for the nascent composite cheese mass to be engaged by the first end of the belt system, capturing and pulling the cheese mass through in a state of tension. The nascent composite cheese mass is preferably a sufficiently large volume and weight wherein its size and weight provide a slight resistance against the capture and pulling of the counter-rotating dual compression belt system. The elasticity of the cheese adding a slight additional resistance against the pulling but not by much. The slight resistance affect from the composition and size of the nascent composite cheese mass will provide the necessary level of tension throughout the pulling and molding process. The amount of tension not being too great to risk breaking of fiber strands or release of the composite material thereon in cooler segments of the cheese. Also, gravity will not be a factor that would otherwise risk uneven tension along different segments of the cheese, resulting in uneven thickness and texture since the cheese ribbon is supported throughout the entire length of the device which functions as a moving molding device. The further more fully formed cheese mass ribbon is pulled and stretched away from the nascent cheese mass body. Once engaged within the counter-rotating dual compression belt system, the initial segment of the cheese at the first opening end (the proximal end) of the belt system is in a heated state to maximize protein strand formation and layering. This typically follows the first 6 to 12 inches from the first opening end of the belt system. This initial portion of the counter-rotating dual belt device may be in a warmer state to maintain the cheese in pliable state. Alternatively, the internal cavity at this proximal end may be buffered with an insulating flap, keeping this initial segment of the belt temperature neutral if the entire section of belt is cold. By this method, the cheese stays warm and pliable through the initial proximal end of the counter-rotating dual compression belt device where the cheese experiences a compressed pulling effect for approximately 6 to 12 inches, aligning protein molecules into long layered strands. Once through this proximal segment of the device, the cheese is ready for molding and cooling to set.
At this second segment of the belt system, an external cooling channel should be attached to two opposing sides of the belt system to evenly cool the cheese held within while it passes through. The cooling system preferably comprising a cooling liquid channel system where liquid coolant is cycled through from an external temperature regulated source, pulling away heat from the belt system and replenishing with new chilled liquid to maintain a continual temperature, achieving a continual wicking effect. This cooling liquid channel system is staged along the length of the belt system in external contact and communication with the belt system to keep the cheese held within in continued cooling state without direct contact with the cheese material held within. The cooling system comprising an external container that holds a cooling medium in a continual cooled state. The manner of maintaining the liquid in a continual cooled or chilled state may be by external refrigeration means or alternatively by addition of ice or other colder material into the cooling medium itself. The cooling medium may comprise the form of a liquid, gas, solid, gel, or any combination of these. The temperature of the cooling medium may be monitored by a temperature gauge for manual efforts in managing the chill temperature or automatically by a refrigeration machine. The cooling medium is moved into and cycled through an enclosed cooling channel within said cooling system in a closed loop circular manner. Said cooling system being in physical contact with the belt system but having said cooling medium held within the enclosed cooling channels within, having no actual contact of the cooling medium with the belts. One or more of said cooling system, each forming an individual unit, may be positioned and in contact with one or more locations along the surface of either or each of said belts. The temperature of the coolant system unit may be set at desired level at each segment of the belt system such that the cheese cross section is completely surrounded by a constant temperature. Alternatively, the temperature of each cooling system unit of a plurality of cooling system unit may be set at different temperatures in order to create a gradually cooling environment. Maintaining the belt at a constantly cooler temperature than the internal space that holds said warm cheese mass helps improve efficiency in cooling because every segment of cheese is subject to a wicking effect by a continual temperature gradient.
According to another embodiment, the nascent composite cheese mass is guided towards a series of narrow compressional channels of the counter-rotating dual compressional belt system. Each compression channel having an open first end (or alternatively referred to as its proximal end) for receiving and capturing the warm cheese mass and a second end (or alternatively referred to as its open distal end) for releasing the formed cheese ribbons. Each channel is enclosed on all sides other than the proximal and distal ends, forming a narrow internal compression channel. The internal compression channel may have any type of cross-sectional shape that enables a consistent shaping and molding effect while the cheese mass is gradually pulled through. The negative space may be narrow at one or more location along the length of each elongated channel to create pressure points for stretching the cheese as it passes. Preferably, a narrow tapering would exist at the starting proximate end of the belt system to produce an initial squeezing and pulling effect. The side walls of each elongated channel are thermally conductive. The difference in temperature between the external environment and the internal cavity defines a preferred thermal gradient. The thermally conductive side walls being in contact with the cheese on the inside and a cooling medium on the external side facilitate heat exchange between the walls in wicking manner. The composite cheese mass may avoid direct contact with the cooling medium in this particular scenario and thus stretching, molding, and cooling is achieved in a physically supportive dry environment.
Each belt of the two counter-rotating dual belt device comprising a circular loop of flexible thermo-conductive material, wrapping around at least two rotating drive mechanisms forming one half of a counter rotating dual belt drive system. Each belt is preferably comprised of a solid, durable (having minimal stretch), flexible, non-flaking food grade material for purposes of cheese molding and food handling. Each belt should hold its grip over the cheese through the entire length of the compression channel. The rate of speed of each rotating belt is adjustable by adjusting the rate of speed of the rotating drive mechanisms.
A cooling mechanism is in immediate contact with the channel's external side walls. The cooling mechanism comprising a cooling medium in the form of solid, liquid, gel or gas or any combination of these that is cycled through an enclosed and sealed thermal conductive container in a closed loop manner. Said thermal conductive container may comprise, but is not limited to, the following known devices or techniques such as grooved channeling panels, thermally conductive pipes or tubing that can facilitate heat transfer between its own wall and the walls of the elongated channels. The temperature of the cooling mechanism may be adjusted to be higher or lower than the temperature within the channel cavity. The cooling mechanism may comprise a single continuous piece or alternatively several sectional pieces that couple together along the length of the channel on the internal side of the channel wall. This essentially comprises the internal side of each closed loop belt that is in contact with the rotating drive mechanism and not in contact with the cheese mass.
Proper setting of the cheese ribbons will depend on period of exposure between the cheese surface and the cooling walls of the elongated channels. Setting time is further dependent on the temperature gradient between the cheese and the external environment and the amount of cheese surface area in contact with the cooling side walls. Ultimately, the rate of speed in which the cheese ribbons are pulled through relative to the length of each channel will determine the period of exposure. The channels may be adjusted in length and the rotating pulling belts may be adjusted for speed to establish a preferred period of exposure of the cheese to the cooling environment. Multiple cooling system units attached along segments of the compression channel renews the cold temperature within the internal cavity of the compression channel, managing a more efficient cooling effect over the surface area of the cheese for the length of the channel.
By pulling the warm cheese through the counter-rotating dual compression belt channels, the cheese is continuously and concurrently stretched, shaped, and cooled to set within the length of each enclosed channels in relatively short time. Having the cheese pulled through an enclosed and compressed space also holds added food particles in place within said cheese ribbons. As the ribbons are molded and cooled to set within the enclosed channels, the added foreign food particle ingredients become captured in place as well in the body of the finished product. No material is dislodged in this process. The continuous and concurrent nature of this technique allows for constant production of high quality cheese with minimal space requirement and without need for liquid. The ability to produce cheese free of liquid allows the cheese to be dry salted and for foreign ingredients to be added at the start of the process since there would not be a risk of dilution from submersion in hot water bath. The ability to avoid utilization of liquid cooling medium in direct contact with the cheese is a second necessary condition to enable dry salting and mixing of foreign ingredients to occur. The added ingredients would not risk being lost, diluted, or uneven penetration (in the case of salt) by avoiding submersion in an open bath environment. As such, a novel technique for high volume production of cheese of hand crafted quality is established herein.
Another embodiment of this invention provides for a series of compression channels or chambers fluidly connected to the distal ends of the elongated channels described above. Ribbons of cooled and set cheese released from the elongated channels are guided towards the proximal ends of the compression channels by a guiding mechanism. Multiple cheese ribbons enter each compression channel where they are pulled through with a pulling mechanism and compressed to laminate at narrow portions within the internal cavity of each compression channel. The compression channels are completely enclosed on all sides, other than the proximal and distal ends, to form an internal cavity with a negative space of defined shape and dimension. The cross-sectional space of the internal cavity at one or more location being narrower than the perimeter of the several cheese strips combined for purpose of compression and lamination. The negative space within the compression channels is continuous from the proximal end to the distal end. Each compression channel having pulling mechanisms and cooling mechanisms of the same or similar construction and functionality as described above for the elongated channels. As described above for the elongated channels, the side walls of the compression channels may also be thermally conductive and in contact with a cooling mechanism on its external side. However, cooling may not be required at this stage of molding and its absence in the compression channels may be an alternate embodiment to this invention.
As the cheese ribbons are pulled through each compression channel, they are compressed and laminated together to form a larger ribbon of cheese with defined shape. The core temperature of the larger laminate ribbon is equivalent to or lower than the core temperature of the individual cheese ribbons released from the distal end of the elongated channels. As in the preliminary test discussed above, the core temperature of a standard sized block that is approximately 2 inches wide by 4 inches long, cooled at 54° F. along the length of the elongated channel may decrease to 83° F. or lower after release from the compression channels. This alternative embodiment is ideal for continuous production of industry standard large sized cheese products or blocks. Note that nearly any desirable cross-sectional shape and size may be achieved by the above described process of this invention.
Other features, advantages, and object of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
Reference will now be made in detail to exemplary aspects of the present invention which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
According to the embodiment of
The side walls 215 of each channel illustrated in
The side walls 215 of each elongated compression channel 203 have an internal side facing 216 the internal cavity 207 and an external side facing the external environment, opposite the internal cavity 207. The external side of the top side wall (not shown) of
The channel side walls may be further composed of either multiple serpentine channel panels (see
According to the preferred embodiment of
As stated above, the left 213 and right 214 side walls may themselves comprise each of the two counter-rotating dual compression belts which make up the pulling mechanism. Alternatively, the pulling mechanism may slidaby rest over any two opposing side wall of the four side walls, utilizing the side walls as guide and structural support. The preferred embodiment of
Yet another embodiment of the pulling means 401 may comprise two larger and thicker counter-rotating belts 402a,b, each counter-rotating belt 402a,b looped around a rotating cog element 403a,b at two opposing ends along a horizontal plane, each said belt 402a,b positioned over the other along a vertical plane such that the external surface of a top belt 404 faces the external surface of a bottom positioned belt 405. See
The rotating belts 223 in general should be thermally conductive. The belts 223 are in direct contact with the compression channels' 203 inside cavity wall 216 and the cheese mass 250, 251 and ribbons. As the cheese is pulled through the length of each channel cavity 207, filling said cavity 207, it is molded to the shape of the negative space. The belt 223 should hold its grip over the cheese mass 250 and ultimately the cheese ribbon 251 through the entire length of each channel 203. The belts 223 are preferably comprised of a solid, flexible, durable, non-stretching and non-flaking food grade material for purposes of cheese molding and food handling.
The distal ends 206 of the elongated compression channels 203 in the preferred embodiment of
Said foreign food ingredients may comprise any form of edible food grade material of a particulate size that may be incorporated into the cheese mass and held in place within and between the internal lattice network of said cheese mass as it is cooled to set. Said particles may be the size of powder, grains, or larger pellet sized pieces, lengths of strands, blocks, whole or smaller portions of greater sized ingredients, soft or hard in texture, smooth or rough in texture, having some or no moisture content, having any type of shape, and may have any type of flavor profile including without limited to sweet, sour, bitter, savory, salty, bland, aromatic, or combinations thereof.
Having fully described at least one embodiment of the present invention, other equivalent or alternative methods according to the present invention will be apparent to those skilled in the art. The invention has been described by way of summary, detailed description and illustration. The specific embodiments disclosed in the above drawings are not intended to be limiting.
Implementations of the present invention with various different configurations are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16683678 | Nov 2019 | US |
| Child | 17539208 | US |
