Office europeen des brevets (fi) Publication number : 0 674 835 A1

@ EUROPEAN PATENT APPLICATION

@ Application number : 95302042.7 @ Int. CI.6: A23C 19/06, A23C 19/068

(g) Date of filing : 27.03.95

(30) Priority: 28.03.94 US 218519 @ Inventor: Meilleur, Rheal Philipe 37 Maple Street Ontario, KOC 1MO Ingleside (CA) @ Date of publication of application : 04.10.95 Bulletin 95/40 @) Representative : Eyles, Christopher Thomas W.P. THOMPSON & CO. (84) Designated Contracting States : Celcon House AT BE CH DE DK ES FR GB GR IE IT LI LU MC 289-293 High Holborn NL PT SE London WC1V 7HU (GB)

© Applicant : KRAFT FOODS, INC. 250 North Street White Plains New York 10625 (US)

(54) Manufacture of large blocks of pasta filata .

(57) A method is disclosed for manufacturing a block of pasta filata cheese of desired size and configuration, e.g., a 680-pound (308.44 kg.) block, from finished pieces of pasta filata of typical size which may be about five pounds (about 2.27 kg.) each. The method includes milling the finished pieces into shreds, filling the shreds into a cheese box to form a cheese mass, and while in the cheese box, applying pressure to the cheese mass, vacuuming and draining the cheese mass, and curing the cheese mass to form the desired block which can be used for a variety of end uses such as retail, slices, or food service.

<

CO 00

Field of the Invention large blocks of soft pasta filata cheese have not been obtainable. The present invention is directed to the manufac- Improved methods and apparatus for the manu- ture of uniformly shaped large blocks of pasta filata facture of large American type cheese blocks involv- cheese and more particularly to the manufacture of 5 ing the placement of fresh (uncured) curd into a large uniformly shaped large blocks of soft pasta filata container are disclosed in U.S. Patents 3,969,995 to cheese from a plurality of smallerfully finished pieces Krueger, et al., 4,049,838 to Krueger, et al., and of soft pasta filata cheese. Large uniformly shaped 4,234,615 to Krueger. These patents focus on the blocks of pasta filata cheese have the benefit of sim- draining of and the pressing of curd in a large plified handling by modern equipment as well as f lex- 10 container, preferably using drainer blades of a partic- ibility for further uses, including the preparation of re- ular design. The inventions focused primarily on large tail, slices, or food service portions of pasta filata sized blocks of American type natural cheese, such cheese. Also within the scope of the invention are as cheddar or Colby varieties of cheese. Although the smaller blocks of any desired size and shape which patents mention possible applicability to may be formed by the same process from fully finish- 15 cheese, in practice the disclosed invention has not ed pieces of soft pasta filata cheese. been attempted for the manufacture of mozzarella or other pasta filata cheese because of the require- Background of the Invention ments for working, stretching and molding while in a plastic condition that is necessary to obtain accept- The known as pasta filata (plastic curd) 20 able pasta filata cheese. The methods and apparatus are Italian-type cheeses characterized by the fact disclosed in the above-identified Krueger patents that, after the whey is drained off, the curd is im- have not been used for soft pasta filata cheeses such mersed in hot water or hot whey and is worked, as Italian mozzarella because the product is too hot stretched, and molded while it is in a plastic condition. for direct fill at a typical processing temperature of Pasta filata cheese can be divided into two distinct 25 about 63°C (145°F). The hot cheese would caramel- types, hard cheeses such as and cacioca- ize (turn brown). On the other hand, cooling of soft vallo which are salted and cured, i.e., ripened, for 2 to pasta filata cheese results in characteristics which 12 months, and soft or moist cheeses such as moz- are not suitable for direct fill. zarella and scamorze which are eaten fresh with little Another approach to the manufacture of large or no ripening. 30 cheese blocks is described in U.S. Patent 5,175,014. The present invention is directed to the soft pasta This patent discloses collating and consolidating suc- filata cheeses, principally mozzarella, and, as used cessive layers of fresh uncured cheese blocks. The herein, it is to be understood that the term pasta filata method disclosed in the '014 patent would not work is intended to be limited to the soft uncured type. The for the manufacture of large blocks of soft pasta filata traditional process for the manufacture of pasta filata 35 cheese for the same reasons explained above with re- cheese and several improvements are described in spect to the requirements for processing such U.S. Patent 4,898,745. This patent recognizes that cheese. considerable handworking is required in the manufac- While the methods of the above described pa- ture of pasta filata cheese curd and that the process tents may represent improvements in the convention- is complicated and subject to control problems. Be- 40 al method for the manufacture of pasta filata cheese cause of these difficulties, pasta filata cheese gener- or for the manufacture of large blocks of cheese gen- ally is produced in small pieces, generally irregular in erally, it would be desirable to provide a method for shape, of no more than about five pounds (2.27 kg.) making pasta filata-type cheeses in the form of a in weight. large uniformly shaped block. For many years, the cheese industry has sought 45 Accordingly, it is an object of the present inven- to be able to produce the various cheese varieties in tion to provide an improved method for making a large large uniformly sized blocks which can readily be han- uniformly shaped block of pasta filata cheese. It is an- dled by large and modern cheese factory and food other object of the present invention to provide a packaging equipment and yet retain the characteris- method for remolding a plurality of finished pieces of tics, e.g., appearance, texture and taste, of tradition- so pasta filata cheese into one or more blocks of desired ally prepared cheese. Large blocks of cheese can shape and size. It is a further object of the invention readily be divided and packaged in a wide variety of to provide a method for manufacturing a block of pas- sizes and shapes, for example, as smaller blocks for ta filata cheese that is simple and economical and individual consumers, as slices of varying thickness, which maximizes the flexibility of the end uses of the width, and length, or in large blocks for food service 55 cheese block. applications. While large blocks of American type cheese have been successfully produced for a num- ber of years, until the present invention, satisfactory 2 3 EP 0 674 835 A1 4

Summary The temperature of the cheese mass is then quickly, over a period of a few days, cooled to a sub- Generally, the present invention is directed to a ambient temperature when it is held in a cooler until method for making a uniformly shaped block of pasta the cheese mass has reknitted into a solid block. The filata cheese from a plurality of finished pieces of the 5 resulting solid block of cheese is then removed from same. The term "finished" is used to denote a piece the container and delivered to a cutting station where of pasta filata cheese that is obtained from the pasta it is cut into preferred sizes for retail or food service filata cheesemaking process in completed orfinished usage. The invention permits the manufacture of a form, i.e., ready to be eaten or otherwise consumed. novel large block of pasta filata cheese having a The block product may be of large size and consider- 10 weight of at least several multiples of five pounds able weight, but the invention also permits the forma- (several multiples of 2.27 kg.). A variety of sizes and tion of blocks in a variety of sizes. In the method of shapes for the new block are possible. the invention, the finished pieces of pasta filata Preferably, for large scale operations involving a cheese are comminuted into shreds in a curd mill, and variety of further uses, the cheese box is of size to the comminuted cheese is placed in a container 15 permit formation of a 680-pound (308.44 kg.) block of where it is pressed, vacuumed, and drained. The cheese. The dimensions of the large block may be cheese is then held under cool conditions for a time about 22" by 28" by 28" (about 55.9 cm. by 71.1 cm. sufficient to cause the comminuted cheese to reknit by 71.1 cm.). About 136 small pieces or loaves of into a single block of cheese of desired size and con- cheese are required for the production of each 680- figuration. 20 pound (308.44 kg.) block, assuming that each small block weighs about five pounds (about 2.27 kg.) and Description of the Drawing further assuming that there are no significant losses of cheese, whey, or moisture. Additional small pieces The single FIGURE is a schematic flow diagram may be required if some of the pieces weigh less than depicting the practice of the present invention. 25 five pounds (2.27 kg.) and/or to make up for losses. Turning now to the single FIGURE, there is illu- Detailed Description of the Invention strated a flow chart for the manufacture of 680 pound (308.44 kg.) blocks of mozzarella cheese from fully The starting material for the method of the inven- cured five pound (2.27 kg.) loaves of mozzarella tion is finished pasta filata cheese which has been 30 cheese. The present invention is intended to be inte- made in the usual way and which has been formed grated with a mozzarella cheese making operation into pieces or loaves of the standard sizes, i.e., up to such that the finished mozzarella loaves exiting the about five pounds (about 2.27 kg.) in weight. A suffi- cheese making operation, which are typically at a cient number of the pieces of finished cheese are temperature of between about 60°C and 66°C, direct- comminuted, i.e., milled into shreds at a predeter- 35 ly enter the described block making process. mined temperature and filled into one or more open In one embodiment of the invention, finished five ended containers or cheese molds of a desired size pound (2.27 kg.) mozzarella loaves exiting the and shape. cheese making operation 10 at a temperature of be- The cheese shreds are subjected to an initial tween about 60°C and about 66°C are introduced into pressing step to consolidate shreds and initiate re- 40 a cooling tunnel 20 maintained at a temperature of be- knitting of the shreds into a single block of cheese. tween about 46°C and about 52°C for a period of be- The bottom of the container is closed by a removable tween about 35 minutes and about 40 minutes in or- perforated drain plate to permit the removal of any der that the loaves exiting the cooling tunnel will have whey that may have been expelled from the cured an internal temperature of about 49°C. If the temper- cheese as a result of the shredding step. The process- 45 ature of the mozzarella loaves introduced to the curd ed product is then exposed to a vacuum to remove mill exceeds 52°C, the cheese may caramelize (turn any air trapped in the container. Removal of air aids brown). If the temperature is below about 46°C, the in providing good body and texture to the finished cheese will not knit properly and the product will have cheese block. an open texture considered to be unacceptable. After vacuuming, pressure is once again applied so It is, of course, possible to allow the mozzarella to the cheese mass within the container, the container loaves to cool to ambient conditions prior to process- is closed and is held at subambient temperatures for ing in accordance with the present invention. This a time sufficient to permit the cheese mass to knit into might well be the case if the block making operation a solid unitary block. These steps are accomplished is located remotely from the loaf making operation. In by closing the top end of the container with a spring 55 such instances it will be necessary to heat the loaves loaded pressure plate, inverting the container, remov- to within the indicated temperature range of between ing the perforated drainer plate and closing the con- about 46°C and about 52°C prior to milling. The moz- tainer with a solid end plate. zarella loaves, at a temperature of between about 3 5 EP 0 674 835 A1 6

46°C and 52°C, most preferably at a temperature of cheese mass into a unitary block. It is desirable to between about 48°C and 50°C are milled into shreds continue pressure against the upper surface of the in a curd mill 30 which may be of conventional design. cheese mass during exposure to vacuum. A pressure The milling is essential because individual blocks of of between about 8 psi and about 12 psi (about 55.2 cheese of five pounds (2.27 kg.) each would not knit 5 kPa and about 82.7 kPa), preferably between about properly due to the smooth surfaces on the outside 9 psi and about 11 psi (about 62.1 kPa and about 75.8 of the blocks. In a typical curd mill the loaves of kPa) has been found to produce good results. cheese are formed into shreds approximately 3/4" by The cheese next proceeds to inverting station 70 3/4" (approximately 19.1 mm. by 19.1 mm.) and up to where the cheese mold box is inverted onto a ship- approximately 3-1/2" (approximately 88.9 mm.) long. to ping skid and the perforated drain plate is removed. Alternately, the loaves may be cut into shreds of dif- The cheese proceeds to closing station 80 where ferent dimensions so long as the shreds are of a size a pressure plate is installed and pressure is applied, that will reknit into a block during processing. e.g., with eight springs placed on the plate. A cover is The milled curds then are placed in an open end- installed, thereby pressing down the springs to apply ed container or cheese box which has a perforated 15 ressure during cure. These steps are further ex- drainer plate closing its lower end at cheese loading plained in the aforementioned U.S. Patent No. station 40. Preferably, the cheese box is the 680- 4,234,615. pound (308.44 kg.) size discussed herein, which is a At this stage in the process, the temperature at standard box size. Alternatively, the cheese box may the center of the 680 pound (308.44 kg.) cheese block be of any size and configuration desired. 20 is typically between about 40°C (104°F) and about The filata cheese box is then transferred to press 46°C (115°F) preferably between about 42°C (108°F) station 50. A cylinder actuated ram press plate is en- and about 45°C (113°F) and the temperature at the gaged with the exposed upper surface of the shred- surface of the cheese is between about 39°C (1 02°F) ded cheese mass held within the cheese box and the and about 45°C (113°F), preferably between about cylinder is actuated to apply a pressure of between 25 41 °C (106°F) and about 43°C (109°F). about 35 psi and about 45 psi (about 241.3 kPa and It has been determined that in order to obtain about 310.3 kPa), preferably between about 39 psi cheese from the 680 pound (308.44 kg.) block that is and about 41 psi (about 268.9 kPa and about 282.7 equal in quality to that of conventional pasta filata kPa) for a period of between about 110 minutes and cheese, the cheese block must be cooled in a chiller about 130 minutes. During the pressing operation, the 30 90 to a uniform temperature of less than 4.5°C (40°F) temperature of the cheese mass in the cheese box is in less than 1 0 days, preferably between about 8 and maintained above about 46°C. about 10 days and thereafter cured for a period of The pressing operation causes consolidation of time sufficient to permit the cheese mass to reknit the shredded cheese mass in the cheese and a reduc- into a unitary block. It is apparent that smaller blocks tion in the cheese mass void volume. This facilitates 35 may cool and cure more quickly. the commencement of reknitting of the cheese shreds After chilling, the cheese proceeds to cooler 100 into a large block. The provision of the perforated where it is cured for an adequate period of time to drainer plate at the lower end of the cheese box per- complete the knitting process. For 680 pound (308.44 mits draining of the small amount of whey, if any, that kg.) blocks, a curing temperature of between about may be present. 40 4.5°C (40°F) and about 6.5°C (44°F), preferably be- No special drainer blades, such as are used in the tween about 5.5°C (42°F) and about 6.0°C (43°F), process of U.S. Patent No. 4,049,838, are required in and a curing time of between about 3 weeks and the practice of the present invention because the about 6 weeks, preferably between about 3 weeks whey was separated during the manufacture of the and about 5 weeks provides a highly desirable prod- finished mozzarella loaves prior to milling. 45 uct. From the pressing station 50 the cheese box is Upon completion of curing the cheese block is re- transferred to vacuum station 60 where it is exposed moved from the cheese box and delivered to the to a vacuum environment of below about 28" Hg and cheese cutting lines 110 or to an appropriate storage preferably below about 29" Hg for a period of be- area. At the cutting lines, the block can be cut into va- tween about 80 minutes and about 100 minutes, pre- 50 rious retail packages, e.g. from 227 g. to 454 g. Alter- ferably between about 85 minutes and about 95 min- natively, the block can be sliced for retail or food ser- utes. Typically the cheese box is placed in a vacuum vice use. Bulk sizes also are available for food service chamber connected to a vacuum source. use, which may involve cutting the large block into Exposure of the cheese mass to vacuum causes smaller block sizes of up to about 40 pounds (about air entrained within the mass to be expelled therefrom 55 18.1 kg.). through the perforated drainer plate and around the The invention is particularly applicable to moz- periphery of the press plate. Removal of entrained air zarella cheese because of the large demand for moz- further facilitates and speeds up reknitting of the zarella cheese, for example, for use in pizza. The 4 7 EP 0 674 835 A1 8 availability of a large block, e.g., 680 pounds (308.44 cheese, comprising the steps of milling said fin- kg.), permits maximum flexibility in the further han- ished pieces into shreds, filling the shreds into a dling, packaging and processing of the cheese for a cheese box to form a cheese mass, and while in variety of end uses. said cheese box applying pressure to the cheese 5 mass, vacuuming the cheese mass, and curing EXAMPLE I the cheese mass to form said block.

136 finished pieces of mozzarella cheese, each 2. A method according to claim 1, wherein the fin- piece weighing about 5 lbs. (about 2.27 kg.), prepared ished pieces have a weight of about 5 pounds by a conventional mozzarella make procedure are 10 (about 2.27 kg.) and the block has a weight of cooled from 145°F (62.8°C) to 120°F (48.9°C), using about 680 pounds (about 308.44 kg.). a cooling tunnel. The blocks of cheese are run through a curd mill cutting the blocks into small 3. A method according to claim 2, wherein the di- shreds which are of size about 22" x 28" x 28" (about mensions of the block are about 22" x 28" x 55.9 cm. x 71.1 cm. x 71.1 cm.). The milled curds are 15 28" (about 55.9 cm. x 71.1 cm. x 71.1 cm.). placed in a cheese mold box approximately 22" (55.9 cm.) wide and 28" (71.1 cm.) long and somewhat 4. A method according to any one of claims 1 to 3, more than 28" (71.1 cm.) deep. wherein the finished pieces are milled to a shred The cheese mold box containing the curds is size of approximately 3/4" by 3/4" (approximate- transferred to a press station where pressure is ap- 20 ly 19.1 mm. by 19.1 mm.) and up to approximately plied to the cheese curd using about 40 psi (about 3 and 1/2" (approximately 88.9 mm.) long. 275.8 kPa) in a 6" (15.24 cm.) cylinder, the pressure being spread across the top surface of the large block 5. A method according to any one of claims 1 to 4, through the use of a pressure plate. A perforated plate wherein the finished pieces are equilibrated to a placed in the bottom of the box allows for drainage of 25 temperature of about 120 degrees F. (about 48.9 excess whey. degrees C.) before milling. The cheese mold box is placed in a vacuum chamber for about 1-1/2 hours at a vacuum measur- 6. A method according to any one of claims 1 to 5, ing about 28" Hg. Pressure is applied to the cheese wherein the pressure applied is about 2 p.s.i. using 10 psi (68.9 kPa) in a 6" (15.24 cm.) cylinder, 30 (about 13.8 kPa) on the top surface of the cheese while the cheese is under vacuum. After the cheese mass for about 2 hours. has been pressed, vacuumed and drained, it is trans- ferred to an inverting station where the cheese mold 7. A method according to any one of claims 1 to 6, box is inverted onto a shipping skid and the perforat- wherein the vacuuming is performed in a vacuum ed drain plate is removed. 35 chamber for about 1 and 1/2 hours at full vacuum The cheese then is transferred to a closing sta- of at least about 28" Hg. tion where a pressure plate is installed and pressure is applied through the use of 8 springs placed on the 8. A method according to claim 7, wherein pressure plate. A cover is installed pressing down on the of about 1 0 p.s.i. (about 68.9 kPa) is applied to the springs to apply a pressure of about 500 psi (about 40 top surface of the cheese mass while under va- 3447.4 kPa). The cheese is then quickly cooled to a cuum. temperature of about -2°C (28°F) within a period of about 10 days, in a quick chiller. The cheese then is 9. A method according to any one of claims 1 to 8, cured at a temperature of 5.5°C (42°F) for four weeks. comprising additional steps after draining the The resulting finished product is a block of moz- 45 cheese mass, including inverting the cheese box zarella cheese having a weight of about 680 pounds and applying further pressure to the cheese (about 308.44 kg.) and having dimensions of about mass. 22" x 28" x 28" (about 55.9 cm. x 71.1 cm. x 71.1 cm.). The large block can be cut into various smaller 10. A method according to claim 9, comprising addi- size blocks or sliced into slices, without falling apart 50 tional steps after applying further pressure to the and without unsightly seam lines inside the large cheese mass, including cooling the cheese mass block. to a temperature below 40 degrees F. (4.4 de- grees C.) within a period of about 10 days or less, and curing the cheese mass at a cool tempera- Claims 55 ture for about 4 weeks.

1 . A method for manufacturing a block of pasta filata 11. A method according to any one of claims 1 to10, cheese from one or more finished pieces of said comprising the steps of equilibrating the finished 5 9 EP 0 674 835 A1 10 pieces to a temperature of about 120 degrees F. (about 48.9 degrees C), milling the finished pieces into shreds, filling the shreds into a cheese box to form a cheese mass, and while in the cheese box, applying pressure to the cheese 5 mass, vacuuming the cheese mass, draining the cheese mass, inverting the cheese mass, apply- ing further pressure to the cheese mass, cooling the cheese mass to a temperature below about 40 degrees F. (about 4.4 degrees C.) within a per- 10 iod of about 10 days or less, and curing the cheese mass at a cool temperature for about 4 weeks to form the large block.

15

20

25

30

35

40

45

50

6 EP 0 674 835 A1

PASTA FILATA COOLING CHEESE MAKING TUNNEL PROCESS

10 20

VACUUM LOADING STATION STATION

60 40

INVERTING CLOSING CHILLER STATION STATION

70 80 90

RETAIL <-

SLICES CUTTING LINES FOOD SERVICE'

110

FIG. I EP 0 674 835 A1

European Patent EUROPEAN SEARCH REPORT Application Number Office EP 95 30 2042

DOCUMENTS CONSIDERED TO BE RELEVANT Category Citation of document with indication, where appropriate, Relevant CLASSIFICATION OF THE of relevant passages to daim APPLICATION (lnt.C1.6) X FR-A-2 260 293 (KRAFT G.M.B.H.) A23C19/06 * claims 1-8 * A23C19/068

X GB-A-2 074 435 ({JUTLAND INDUSTRIES) * claims 1-11 *

A WO-A-92 07472 (DI NASI A.) * page 5, line 3 - line 6; claims 1-3 *

A US-A-3 041 153 (B. ELDER ET AL.) * claims 1,10 *

A EP-A-0 069 282 (NATIONAL DAIRY ASSOCIATION OF NEW ZEALAND LTD) * claim 9 *

A,D US-A-4 234 615 (G. KRUEGER) * column 2, line 29-37 *

A DE-A-31 25 154 (ZITZKE & MASCHER GMBH) TECHNICAL FIELDS A FR-A-1 356 181 (NATIONAL DAIRY PRODUCTS SEARCHED (Int.C1.6) CO) A23C A01J

The present search report has been drawn up for all claims Place of March Me of canplettM of Ike learck ExanHer THE HAGUE 19 July 1995 Desmedt, G CATEGORY OF CITED DOCUMENTS T : theory or principle underlying the invention E : earlier patent document, but published on, or X : particularly relevant if taken alone after the filing date Y : particularly relevant if combined Kith another D : document cited in the application document of the same category L : document cited for other reasons A : technological background O : non-written disclosure & : member of the same patent family, corresponding P : intermediate document document

8