Patent Application
20150250132
The present invention relates generally to cheese, and more particularly to methods for forming cheese shapes containing multiple different natural cheeses.
Natural cheese may be formed in blocks, which may then by cut into various shapes (e.g., slices, sticks, cubes, wedges, snacks, etc.). To make natural cheese blocks and shapes with more than one different type of natural cheese, e.g., Colby Jack cheese, etc., two different types of fresh natural cheese curds are prepared so that they are both ready at approximately the same time, with the curds being at approximately the same pH. The two different types of curds are then combined, formed into a block, cured, and cut into shapes.
The subject matter discussed in this background of the invention section should not be assumed to be prior art merely as a result of its mention in the background of the invention section. Similarly, a problem mentioned in the background of the invention section or associated with the subject matter of the background of the invention section should not be assumed to have been previously recognized in the prior art. The subject matter in the background of the invention section merely represents different approaches, which in and of themselves may also be inventions.
In one embodiment, a method of providing cheese shapes including two natural cheeses is provided. The method includes mixing pieces of a first cured natural cheese and curds of a second natural cheese. The method includes applying pressure to the mixture of the pieces of the first cured natural cheese and the curds of the second natural cheese to form a block. The method includes curing the block. The method includes cutting the block into shapes.
In another embodiment, a method of providing cheese shapes including three natural cheeses is provided. The method includes mixing pieces of a first cured natural cheese, pieces of a second cured natural cheese different than the first cured natural cheese, and pieces of a third cured natural cheese different than the first cured natural cheese and the second cured natural cheese. The method includes applying vacuum to the mixture of the pieces of the first cured natural cheese, the second cured natural cheese, and the third cured natural cheese. The method includes applying pressure to the mixture of the pieces of the first cured natural cheese, the second cured natural cheese, and the third cured natural cheese to form a block. The method includes curing the block. The method includes cutting the block into cheese shapes including the three natural cheeses.
In another embodiment, a method of providing cheese shapes including two natural cheeses is provided. The method includes making curds of a first natural cheese. The method includes mixing the curds of the first natural cheese with pieces of a second cured natural cheese. The method includes applying pressure to the mixture of the curds of the first natural cheese and the pieces of the second cured natural cheese to form a block. The method includes cutting the block into shapes including the two natural cheeses.
Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:
Generally, embodiments of methods for providing cheese shapes including multiple types of natural cheese are provided. When natural cheese blends are prepared by combining two different natural cheese curds, fresh curds of each of the two different natural cheeses to be combined are prepared so that the fresh curds of each are available at generally the same time, at generally the same pH level, etc. Fresh curd is generally produced from milk during the cheese making process and generally remains fresh for a period of approximately 24 hours or less. It may be difficult and/or impractical to prepare fresh curds of three or more different natural cheeses at a single cheese-making facility. Additionally, it may be difficult and/or impractical to prepare fresh curds of three or more fresh different natural cheeses such that they are available at generally the same time, at generally the same pH, etc., at some a single cheese making facility. Additionally, transporting different types of fresh curd from different locations while maintaining the fresh curds at acceptable conditions and within limited time to a single location to combine the different types to form a combination may be difficult and/or costly and/or impractical.
Embodiments of methods described below provide for forming cheese shapes with two or more (e.g., three, four, five, six, etc.) different types of natural cheese without having fresh curds of each of the different natural cheese types being provided at generally the same time, at generally the same pH level, etc.
For purposes of this disclosure, milk may include, for example, fresh liquid milk, milk protein concentrate, rehydrated nonfat dry milk powder, concentrated skim milk, filtered milk (for example, milk filtered to remove water and/or lactose), etc.
In step 26, rennet may be added to the milk and starter culture mixture and the mixture is coagulated. In step 28, the curd is formed and the whey is drained from the curd. This process results in the formation of fresh curd, which may be used in embodiments of methods described further below. The curd may be fresh curd of various types of cheese, e.g., Cheddar, Colby, Monterey Jack, Swiss, low moisture part skim (LMPS) Mozzarella, whole milk (W.M.) Mozzarella, Provolone, Parmesan, etc.
For purposes of this disclosure, natural cheese may be non-processed cheese. For example, processed cheese may be formed by heating cheese to a melting point and adding an emulsifier. Natural cheese may be cheese that is not formed by heating to a melting point and does not include an added emulsifier. Additionally, natural cheese may contain live bacteria, while processed cheese may not include live bacteria.
With reference to
Natural cured cheese formed by embodiments of the process described above may be used in embodiments of methods of providing cheese shapes including two natural cheeses as are described further below. In some embodiments, natural cheese does not include additives such as, e.g., an emulsifier, and may provide for better tasting, more organoleptically pleasing, more texturally pleasing, additive free natural cheese, which may be desirable.
With reference to
In another embodiment, the pieces are generally cube-shaped and have a length, width, and height each of between approximately ¼ inch and approximately ½ inch. In another embodiment, the pieces are generally cube-shaped and have a length, width, and height each of approximately ⅜ inch. In one embodiment, the pieces each have a length, a width, and a height, and the length, the width, and the height of each of the pieces are generally the same, e.g., on average the height is dimensioned generally similar to the length and generally similar to the width. In another embodiment, the block is shredded to form cheese shreds, e.g., with a cheese shredding machine such as, for example, a Model CCX-D shredder available from Urschel® Laboratories, Inc. or any other suitable cheese shredding machine.
In one embodiment, a cheese shred has a length, a width, and a height, with the length being generally greater than the width and height, e.g., in one embodiment, the length is at least two times greater than each of the width and the height, in another embodiment, the length is at least three times greater than each of the width and the height. Additionally, in one embodiment, a shred has a width that is greater than the height (but less than the length), e.g., in one embodiment the width is at least two times greater than the height, in another embodiment, the width is at least three times greater than the height, etc.
In another embodiment, the block is extruded to form the smaller pieces. In another embodiment, the block may be cut and/or diced into small, generally cube-shaped portions, e.g., 1/16 inch by 1/16 inch by 1/16 inch, etc. In another embodiment, the block may be torn into smaller pieces, e.g., by a crumbler, pin mill, etc. In other embodiments, other suitable
In one embodiment, the first block is not broken into smaller pieces by an extruder or an auger, which may have an effect on the structure of cheese, which in some embodiments may be undesirable, e.g., may result in cheese shapes with less desirable texture, etc., but is instead cut, which may allow the cheese pieces to retain their structure and which may result in cheese shapes with more desirable texture, etc.
In step 36, a block of a cured second natural cheese, e.g., a type of cheese different than the first natural cheese, is provided. In step 37, the second block is broken into smaller pieces. In one embodiment, the smaller pieces of the second block may be similarly sized, shaped, dimensioned, etc., as the smaller pieces of the first block and may be formed in the same manner or a different manner than the smaller pieces of the first block. In another embodiment, the smaller pieces of the second block may be dissimilarly sized, shaped, dimensioned, etc., than the smaller pieces of the first block.
In one embodiment, the first and second cured natural cheeses may be cheese formed such as, for example, by the process illustrated in
In step 38, the pieces of the first cheese and the pieces of the second cheese are blended and/or mixed together, e.g., in a tumble drum, etc. The ratio of the amount of the first cheese and the amount of the second cheese may vary. In various embodiments, the first cured natural cheese may be provided in amounts of any suitable ratio relative to the second cured natural cheese, e.g., 50% first cured natural cheese and 50% second cured natural cheese, 90% first cured natural cheese and 10% second cured natural cheese, etc. In one embodiment, no flow agent, e.g., cellulose, blend of potato starch and cellulose, cellulose and natamycin blend, blend of potato starch, cellulose, and natamycin, etc., is added to the blended and/or mixed cheeses. In one embodiment, the temperature of the blended and/or mixed pieces of the first and second cheeses is controlled and/or regulated to between approximately 60° Fahrenheit and approximately 70° Fahrenheit. In another embodiment, the temperature of the blended and/or mixed pieces of the first and second cheeses is controlled to approximately 65° Fahrenheit.
In step 40, the blended and/or mixed pieces of the first cheese and the second cheese are located in a press. In one embodiment, the press is a programmable tunnel press, such as those available from Johnson Industries International Inc.
In step 42, the pieces of the first and second cheeses are subjected to vacuum and pressure in the press to form the pieces into a block, e.g., a cohesive mass. In one embodiment, vacuum is first applied and then pressure is applied. In another embodiment, the vacuum and pressure are applied generally simultaneously. In another embodiment, pressure is applied and then vacuum is applied.
In one embodiment, the pieces are subjected to pressure and/or vacuum for between approximately 5 minutes and approximately 5 hours. In another embodiment, the pieces are subjected to pressure and/or vacuum for between approximately 10 minutes and approximately 1 hour. In another embodiment, the pieces are subjected to pressure and/or and vacuum for approximately 20 minutes.
In one embodiment, the mixed cheese pieces are subjected to a pressure of between approximately 10 pounds per square inch (PSI) and approximately 100 PSI, e.g., the pressure applied to the surface of the cheese mixture is between 10 PSI and 100 PSI. In another embodiment, the mixed cheese pieces are subjected to a pressure of between approximately 30 PSI and approximately 50 PSI. In another embodiment, the mixed cheese pieces are subjected to a pressure of approximately 40 PSI. In another embodiment, pressure of between 8 PSI and 16 PSI is applied to the surface of the mixture of cheese pieces.
In one embodiment, the mixed cheese pieces are subjected to a vacuum of between approximately 10 mm Hg and approximately 50 mm Hg. In another embodiment, the mixed cheese pieces are subjected to a vacuum of between approximately 20 mm Hg and approximately 40 mm Hg. In another embodiment, the mixed cheese pieces are subjected to a vacuum of approximately 30 mm Hg.
In step 44, the cheese block formed from the mixed cheese pieces in the press is removed from the press and cured. In one embodiment, the cheese block is vacuum packaged and cured. In one embodiment, the block is cured for between approximately 1 day and approximately 1 month. In another embodiment, the block is cured for between approximately 1 week and approximately 3 weeks. In another embodiment, the block is cured for approximately 2 weeks.
In step 46, the cured block containing the two natural cheeses is cut into shapes, e.g., slices, such as generally rectangular and/or square slices, wedges, sticks, cubes, snacks, etc. The cheese shapes containing the two different types of cured natural cheeses may then be packaged and sold.
While the embodiment of the method illustrated in
In another embodiment, a fourth type of cured natural cheese, different from the first, second, and third types of cheese, is provided, e.g., in a block, broken into smaller pieces, blended and/or mixed with the first, second, and third cheese pieces, pressed, and a resulting cheese shape is formed containing the first, second, third, and fourth natural cured cheeses.
In other embodiments, any other suitable numbers of types of cured natural cheeses may be used to produce cheese shapes containing all of the different types of natural cured cheeses according to the embodiment of the method described above.
The embodiment of the method illustrated in
Additionally, the method of
With reference to
In one embodiment, the fresh curd may be pressed in the tower and broken up by, e.g., a curd breaker, e.g., to control and/or reduce the moisture in the curd.
In step 50, the pressed fresh natural curd of the first cheese from the tower is broken into smaller pieces, e.g., by a curd breaker. The smaller pieces may be of similar size as the size of the original curd prior to pressing. In one embodiment, the pieces may be between one inch and two inches in length on average.
In step 52, pieces of a second natural cured cheese of a different type than the first cheese are provided. In one embodiment, the pieces may be shreds. In another embodiment, the pieces may be generally cube-shaped, such as those described above with regard to the previous embodiment. In other embodiments, the pieces may be any other suitable shape. The pieces of the second natural cured cheese are added to the fresh natural first cheese curds. In step 54, the fresh natural first cheese curds and the second natural cured cheese pieces are blended together, e.g., mixed, tumbled in a tumble drum, etc.
In step 56, the mixed first cheese curd and second cured cheese pieces are pressed together, e.g., pressure and vacuum are applied to the mixed curd and cheese pieces in a cheese mold, such as, for example, a cheese mold configured to produce approximately 40 lb. blocks of cheese, a cheese mold configured to produce approximately 640 lb. blocks of cheese, etc.
In one embodiment, the mixture remains in the cheese mold, e.g., the 40 lb. cheese mold, from between 2 hours to 24 hours. In another embodiment, the mixture remains in the cheese mold, e.g., the 640 lb. cheese mold, from between ten days to 10 months. Once in the cheese mold, e.g., the 40 lb. cheese mold, in one embodiment, the temperature of the environment in which the cheese is located is controlled from approximately 100° Fahrenheit down to approximately 60° Fahrenheit. In another embodiment, once in the cheese mold, e.g., the 640 lb. cheese mold, the temperature of the environment in which the cheese is located is controlled from approximately 100° Fahrenheit down to about 36° Fahrenheit. In one embodiment, in the cheese mold pressure between approximately 20 psi and approximately 100 psi is applied to the cheese mixture. In another embodiment, in the cheese mold, vacuum of between 29 inches of Mercury and 30 inches of Mercury is applied to the cheese mixture.
In step 58, the block of cheese formed in the mold containing the first and second natural cheeses is removed from the tower and cured. In one embodiment, a block of cheese formed in the 40 lb. mold is vacuum sealed in plastic and/or sealed in wood and located in a cooler in which the temperature is maintained between 36° Fahrenheit and 50° Fahrenheit to cure. In another embodiment, a block of cheese formed in the 640 lb. mold is located in a cooler in which the temperature is maintained between 36° Fahrenheit and 50° Fahrenheit to cure, e.g., the 640 lb. block may not be vacuum sealed in plastic. In various embodiments, a block of cheese may be allowed to cure from between 2 weeks to 10 months to 2 years.
In another embodiment, the block is cured for between approximately 1 week and approximately 3 weeks. In another embodiment, the block is cured for approximately 2 weeks. In step 60, the cured block containing two different natural cheeses is cut into shapes (e.g., slices, such as generally rectangular and/or square slices, sticks, wedges, cubes, snacks, etc.). The shapes may then be packaged and sold.
While the embodiment illustrated in
In another embodiment, a fourth type of cured natural cheese, different from the first, second, and third types of cheese, is provided, e.g., in a block, broken into smaller pieces, blended and/or mixed with the first fresh natural cheese curds, the second natural cured cheese pieces, and the third natural cured cheese pieces, pressed, and a resulting cheese shape is formed containing the first, second, third, and fourth natural cheeses.
In other embodiments, any other suitable numbers of types of cured natural cheeses may be used to produce cheese shapes containing all of the different types of natural cured cheeses according to the embodiment of the method described above.
The embodiment of the method illustrated in
With reference to
In step 66, the fresh natural curds of the first cheese and the pieces of the second cured natural cheese are blended and/or mixed together, e.g., mixed, tumbled in a tumble drum, etc.
In step 70, the mixture is placed in a mold and pressed into a block, e.g., pressure and vacuum are applied to the mixture. In one embodiment, pressure of between 20 PSI and 100 PSI is applied to the surface of the mixture in the mold. In one embodiment, vacuum of between approximately 29 inches of Mercury and approximately 30 inches of Mercury is applied to the mixture in the mold. In one embodiment, pressure and/or vacuum is applied to the mixture in the mold for between 30 minutes and 6 hours.
In step 72, the block of cheese formed in the press containing the first and second natural cheeses is removed from the press and cured. In one embodiment, a block of cheese formed in a 40 lb. mold is vacuum sealed in plastic and/or sealed in wood and located in a cooler in which the temperature is maintained between 36° Fahrenheit and 50° Fahrenheit to cure. In another embodiment, a block of cheese formed in a 640 lb. mold is located in a cooler in which the temperature is maintained between 36° Fahrenheit and 50° Fahrenheit to cure, e.g., the 640 lb. block may not be vacuum sealed in plastic. In various embodiments, a block of cheese may be allowed to cure from between 2 weeks to 10 months to 2 years. In another embodiment, the block is cured for between approximately 1 week and approximately 3 weeks. In another embodiment, the block is cured for approximately 2 weeks. In step 74, the cured block containing two different natural cheeses is cut into shapes (e.g., slices, such as generally rectangular and/or square slices, sticks, wedges, cubes, snacks, etc.). The shapes may then be packaged and sold.
While the embodiment illustrated in
In another embodiment, a fourth type of cured natural cheese, different from the first, second, and third types of cheese, is provided, e.g., in a block, broken into smaller pieces, blended and/or mixed with the first fresh natural cheese curds, the second natural cured cheese pieces, and the third natural cured cheese pieces, pressed, and a resulting cheese shape is formed containing the first, second, third, and fourth natural cheeses.
In other embodiments, any other suitable numbers of types of cured natural cheeses may be used to produce cheese shapes containing all of the different types of natural cured cheeses according to the embodiment of the method described above.
The embodiment of the method illustrated in
With reference to
It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.
In each of the embodiments of methods described above, the different cured natural cheeses and natural curds may be provided and combined in various different suitable amounts and/or ratios.
Embodiments of the methods described above may allow for creating cheese shapes containing cheeses of difference ages, subjected to different curing and/or aging processes, etc.
Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. The position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of some process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.
