D.J. O’Callaghan

Effects of cutting intensity and stirring speed on syneresis and curd losses during cheese manufacture.

Recombined whole milk was renneted under constant conditions of pH, temperature, and added calcium, and the gel was cut at a constant firmness. The effects of cutting and stirring on syneresis and curd losses to whey were investigated during cheese making using a factorial design with 3 cutting modes designed to provide 3 different cutting intensity levels (i.e., total cutting revolutions), 3 levels of stirring speed, and 3 replications. These cutting intensities and stirring speeds were selected to give a wide range of curd grain sizes and curd shattering, respectively. Both factors affected curd losses, and correct selection of these factors is important in the cheesemaking industry. Decreased cutting intensity and increased stirring speed significantly increased the losses of fines and fat from the curd to the whey. Cutting intensities and stirring speeds in this study did not show significant effects on curd moisture content over the course of syneresis. Levels of total solids, fines, and fat in whey were shown to change significantly during syneresis. It is believed that larger curd particles resulting from low cutting intensities coupled with faster stirring speeds resulted in a higher degree of curd shattering during stirring, which caused significant curd losses.

Effect of increasing the protein-to-fat ratio and reducing fat content on the chemical and physical properties of processed cheese product.

Scientific studies indicate that the intake of dietary fat and saturated fats in the modern Western diet is excessive and contributes adversely to health, lifestyle, and longevity. In response, manufacturers of cheese and processed cheese products (PCP) are pursuing the development of products with reduced fat contents. The present study investigated the effect of altering the fat level (13.8, 18.2, 22.7, 27.9, and 32.5 g/100g) in PCP on their chemical and physical properties. The PCP were formulated in triplicate to different fat levels using Cheddar cheese, skim milk cheese, anhydrous milk fat, emulsifying salt (ES), NaCl, and water. The formulations were designed to give fixed moisture (~53 g/100g) and ES:protein ratio (0.105). The resultant PCP, and their water-soluble extracts (WSE), prepared from a macerated blend of PCP and water at a weight ratio of 1:2, were analyzed at 4d. Reducing the fat content significantly increased the firmness of the unheated PCP and reduced the flowability and maximum loss tangent (fluidity) of the melted PCP. These changes coincided with increases in the levels of total protein, water-soluble protein, water-insoluble protein, and water-soluble Ca, and a decrease in the molar ratio of water-soluble Ca to soluble P. However, both water-soluble Ca and water-soluble protein decreased when expressed as percentages of total protein and total Ca, respectively, in the PCP. The high level of protein was a major factor contributing to the deterioration in physical properties as the fat content of PCP was reduced. Diluting the protein content or reducing the potential of the protein to aggregate, and thereby form structures that contribute to rigidity, may provide a means for improving quality of reduced-fat PCP by using natural cheese with lower intact casein content and lower calcium:casein ratio, for example, or by decreasing the ratio of sodium phosphate to sodium citrate-based ES.

Validation of a curd-syneresis sensor over a range of milk composition and process parameters

An online visible-near-infrared sensor was used to monitor the course of syneresis during cheesemaking with the purpose of validating syneresis indices obtained using partial least squares, with cross-validation across a range of milk fat levels, gel firmness levels at cutting, curd cutting programs, stirring speeds, milk protein levels, and fat:protein ratio levels. Three series of trials were carried out in an 11-L cheese vat using recombined whole milk. Three factorial experimental designs were used, consisting of 1) 3 curd stirring speeds and 3 cutting programs; 2) 3 milk fat levels and 3 gel firmness levels at cutting; and 3) 2 milk protein levels and 3 fat:protein ratio levels, respectively. Milk was clotted under constant conditions in all experiments and the gel was cut according to the respective experimental design. Prediction models for production of whey and whey fat losses were developed in 2 of the experiments and validated in the other experiment. The best models gave standard error of prediction values of 6.6 g/100 g for yield of whey and 0.05 g/100 g for fat in whey, as compared with 4.4 and 0.013 g/100 g, respectively, for the calibration data sets. Robust models developed for predicting yield of whey and whey fat losses using a validation method have potential application in the cheese industry.

Effects of milk composition, stir-out time, and pressing duration on curd moisture and yield

A study was undertaken to investigate the effects of milk composition (i.e., protein level and protein:fat ratio), stir-out time, and pressing duration on curd moisture and yield. Milks of varying protein levels and protein:fat ratios were renneted under normal commercial conditions in a pilot-scale cheese vat. During the syneresis phase of cheese making, curd was removed at differing times, and curd moisture and yield were monitored over a 22-h pressing period. Curd moisture after pressing decreased with longer stir-out time and pressing duration, and an interactive effect was observed of stir-out time and pressing duration on curd moisture and yield. Milk total solids were shown to affect curd moisture after pressing, which has implications for milk standardization; that is, it indicates a need to standardize on a milk solids basis as well as on a protein:fat basis. In this study, a decreased protein:fat ratio was associated with increased total solids in milk and resulted in decreased curd moisture and increased curd yield after pressing. The variation in total solids of the milk explains the apparent contradiction between decreased curd moisture and increased curd yield. This study points to a role for process analytic technology in minimizing variation in cheese characteristics through better control of cheesemilk composition, in-vat process monitoring (coagulation and syneresis), and post-vat moisture reduction (curd pressing). Increased control of curd composition at draining would facilitate increased control of the final cheese grade and quality.

Effects of hydrolysis on solid-state relaxation and stickiness behavior of sodium caseinate-lactose powders

Hydrolyzed or nonhydrolyzed sodium caseinate-lactose dispersions were spray dried, at a protein: lactose ratio of 0.5, to examine the effects of protein hydrolysis on relaxation behavior and stickiness of model powders. Sodium caseinate (NC) used included a nonhydrolyzed control (DH 0) and 2 hydrolyzed variants (DH 8.3 and DH 15), where DH = degree of hydrolysis (%). Prior to spray drying, apparent viscosities of liquid feeds (at 70°C) at a shear rate of 20/s were 37.6, 3.14, and 3.19 mPa·s, respectively, for DH 0, DH 8, and DH 15 dispersions. Powders containing hydrolyzed casein were more susceptible to sticking than those containing intact NC. The former had also lower bulk densities and powder particle sizes. Scanning electron microscopy showed that hydrolyzed powders had thinner particle walls and were more friable than powders containing intact NC. Secondary structure of caseinates, determined by Fourier transform infrared spectroscopy, was affected by the relative humidity of storage and the presence of lactose as co-solvent rather than its physical state. Glass transition temperatures and lactose crystallization temperatures, determined by differential scanning calorimetry were not affected by caseinate hydrolysis, although the effects of protein hydrolysis on glass-rubber transitions (T(gr)) could be determined by thermo-mechanical analysis. Powders containing hydrolyzed NC had lower T(gr) values (~30°C) following storage at a higher subcrystallization relative humidity (33%) compared with powder with nonhydrolyzed NC (T(gr) value of ~40°C), an effect that reflects more extensive plasticization of powder matrices by moisture. Results support that sodium caseinate-lactose interactions were weak but that relaxation behavior, as determined by the susceptibility of powder to sticking, was affected by hydrolysis of sodium caseinate.

Preliminary evaluation of endogenous milk fluorophores as tracer molecules for curd syneresis

A front-face fluorescence spectroscopy probe was installed in the wall of a laboratory-scale cheese vat. Excitation and emission filters were chosen for the selective detection of vitamin A, tryptophan, and riboflavin fluorescence. The evolution of the fluorescence of each fluorophore during milk coagulation and syneresis was monitored to determine if they had the potential to act as intrinsic tracers of syneresis and also coagulation. The fluorescence profiles for 2 of the fluorophores during coagulation could be divided into 3 sections relating to enzymatic hydrolysis of κ-casein, aggregation of casein micelles, and crosslinking. A parameter relating to coagulation kinetics was derived from the tryptophan and riboflavin profiles but this was not possible for the vitamin A response. The study also indicated that tryptophan and riboflavin may act as tracer molecules for syneresis, but this was not shown for vitamin A. The evolution of tryptophan and riboflavin fluorescence during syneresis followed a first-order reaction and had strong relationships with curd moisture and whey total solids content (r=0.86-0.96). Simple 1- and 2-parameter models were developed to predict curd moisture content, curd yield, and whey total solids using parameters derived from the sensor profiles (standard error of prediction=0.0005-0.394%; R(2)=0.963-0.999). The results of this study highlight the potential of tryptophan and riboflavin to act as intrinsic tracer molecules for noninvasive inline monitoring of milk coagulation and curd syneresis. Further work is required to validate these findings under a wider range of processing conditions.

Using Light Backscatter at 980 nm to Determine Curd Moisture Content at Various Milk Fat and Gel Firmness Levels in Cheese-making

Curd moisture control plays a fundamental role in determining the quality of the final cheese. A large field of view (LFV) light backscatter sensor at 980 nm was used as a rapid on-line method for monitoring curd moisture content changes during syneresis. Improving the control of curd moisture content during the cheese-making process may enhance product consistency and reduce the overall production cost. The objective of this study was to evaluate the influence of two experimental variables (i.e. fat and gel firmness at cutting) using light backscatter at 980 nm on syneresis and curd moisture content prediction. An experiment was conducted in which whole milk was recombined at three fat levels, clotted under constant conditions and the milk gel was cut at three gel firmness levels. The curd-whey mixture was stirred in the vat after gel cutting and the syneresis process was monitored using the LFV sensor which was installed in the cheese vat wall.

Effect of hydrolyzed whey protein on surface morphology, water sorption, and glass transition temperature of a model infant formula

Physical properties of spray-dried dairy powders depend on their composition and physical characteristics. This study investigated the effect of hydrolyzed whey protein on the microstructure and physical stability of dried model infant formula. Model infant formulas were produced containing either intact (DH 0) or hydrolyzed (DH 12) whey protein, where DH=degree of hydrolysis (%). Before spray drying, apparent viscosities of liquid feeds (at 55°C) at a shear rate of 500 s(-1) were 3.02 and 3.85 mPa·s for intact and hydrolyzed infant formulas, respectively. On reconstitution, powders with hydrolyzed whey protein had a significantly higher fat globule size and lower emulsion stability than intact whey protein powder. Lactose crystallization in powders occurred at higher relative humidity for hydrolyzed formula. The Guggenheim-Anderson-de Boer equation, fitted to sorption isotherms, showed increased monolayer moisture when intact protein was present. As expected, glass transition decreased significantly with increasing water content. Partial hydrolysis of whey protein in model infant formula resulted in altered powder particle surface morphology, lactose crystallization properties, and storage stability.

Chapter 6 – The Syneresis of Rennet-Coagulated Curd

Gels formed from milk by renneting or acidification under quiescent conditions may subsequently show syneresis, that is, expel liquid (whey), because the gel (curd) contracts. Under quiescent conditions, a rennet-induced milk gel may lose two-thirds of its volume, and up to 90%, or even more, if external pressure is applied. Often, syneresis is undesired, for example, during storage of products like yogurt, sour cream, cream cheese, or quark; hence, it is useful to know under what conditions syneresis can be (largely) prevented. In making cheese from renneted or acidified milk, syneresis is an essential step. Consequently, it is useful to understand and quantitatively describe syneresis as a function of milk properties and process conditions, particularly when new methods or process steps are introduced in cheesemaking.

Light Sidescatter Measurements of Cheese Whey

In cheese manufacture milk proteins called casein micelles are destabilized to form a gel, which is cut, resulting in syneresis i.e. the expulsion of whey from curd particles. Manufactures are concerned with controlling cheese yield which is dependent on two factors namely whey fat losses and curd moisture content. Monitoring whey fat changes during syneresis may provide valuable information which will assist in developing sensor technologies for controlling cheese yield. The objective of this study was to determine if light sidescatter measurements of whey may be used to determine whey fat content. A fully randomised two-factor (milk fat content, gel cutting firmness) three-level factorial experimental design was employed. Milk coagulation was carried out in an 11 l vat. The gel was cut at the firmness required using a rheometer running simultaneously with coagulation in the vat. During syneresis samples were removed from the vat, at 20 min intervals after cutting. A portion of each whey sample was analyzed for fat, while the remainder was placed in a specially designed temperature-controlled cell which allowed for the recording of sidescatter spectra (300–1100 nm) using a fiber optic spectrometer. Spectra were subjected to principal component analysis. The first two components (PC) explained 100% of the variance in the spectra, and showed that it was possible to discriminate between samples on the basis of milk fat content. A whey fat prediction model was developed using partial least squares regression. The model predicted whey fat content with a root mean square error of cross-validation of 0.047 g/100 ml over a range of 0.502 g/100 ml (R = 0.94) using two components. These results indicate that light sidescatter has potential to monitor whey fat content.