Processed Cheese and Analogues E-Book

A. Y. Tamime

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Serie: Society of Dairy Technology Series
• Sprache: Englisch

Seitenzahl: 744

Veröffentlichungsjahr: 2011

Beschreibung

Part of the Society of Dairy Technology Series, this book deals with a commercially significant sector of dairy science. The book includes chapters on legislation, functionality of ingredients, processing plants and equipment, manufacturing best practice, packaging, and quality control. The chapters are authored by an international team of experts. This book is an essential resource for manufacturers and users of processed and analogue cheese products internationally; dairy scientists in industry and research; and advanced food science students with an interest in dairy science.

Leseprobe

Table of Contents

Series Page

Title Page

Copyright

Preface to the Technical Series

Preface

Contributors

Chapter 1: Processed Cheese and Analogues: An Overview

1.1 Historical Background

1.2 Diversity of Products

1.3 Patterns of Production

1.4 Principles of Manufacturing Stages

1.5 Conclusions

References

Chapter 2: Current Legislation on Processed Cheese and Related Products

2.1 Introduction and Background

2.2 Definitions and Standards of Identity

2.3 Summary and Conclusions

2.4 Acknowledgements

References

Chapter 3: Effects of Natural Cheese Characteristics and Processing Conditions on Rheology and Texture: The Functionality of Cheese Components in the Manufacture of Processed Cheese

3.1 Definition of Processed Cheese Products: An Introduction

3.2 Overview of Manufacture

3.3 Microstructure of PCPs

3.4 Principles of Processed Cheese Manufacture

3.5 Effects of Natural Cheese Characteristics on PCPs

3.6 Effects of Processing Conditions

3.7 Conclusions

References

Chapter 4: Functionality of Ingredients: Emulsifying Salts

4.1 Introduction

4.2 Main Types of Emulsifying Salts

4.3 Properties and Roles of Emulsifying Salts Used in Processed Cheese

4.4 Selection of Emulsifying Salt

4.5 Conclusion

References

Chapter 5: Flavours and Flavourants, Colours and Pigment

5.1 Introduction

5.2 Types of Processed Cheese

5.3 Raw Material

5.4 Flavour

5.5 Colours

5.6 Sensory Attributes of Processed Cheese

5.7 Conclusion

References

Chapter 6: Manufacturing Practices of Processed Cheese

6.1 Introduction

6.2 Some Historical Background

6.3 Processed Cheese and Products

6.4 Key Steps in Processing

6.5 Changes in Processed Cheese During Its Shelf-Life

6.6 Conclusions

References

Chapter 7: Processed Cheese Plants and Equipment: A Practical Overview

7.1 Introduction

7.2 Unit Operations

7.3 Processing Plant for the Manufacture of Processed Cheese Slices

7.4 Conclusions

Chapter 8: Packaging Materials and Equipment

8.1 Introduction

8.2 Packaging Materials

8.3 Packaging Equipment

8.4 Conclusion

References

Chapter 9: Production of Analogue Cheeses

9.1 Introduction

9.2 Definition and Legislation

9.3 Applications and Advantages of Analogue Cheese Products

9.4 Manufacture of Analogue Cheese

9.5 Factors Influencing Analogue Cheese Functionality

9.6 Developments in Analogue Cheese

9.7 Future of Analogue Cheese

References

Chapter 10: Quality Control in Processed Cheese Manufacture

10.1 Introduction

10.2 HACCP

10.3 Examination of Raw Materials

10.4 Analysis of Chemical Composition

10.5 Microbiological Quality and Safety of the Product

10.6 Assessment of Physical Characteristics

10.7 Assessment of the Microstructure

10.8 Sensory Profiling of Processed Cheese

10.9 Conclusions

10.10 Acknowledgements

References

Appendix: Example of a Product Quality Information as a Result of Using a HACCP System

Color Plates

Index

The Society of Dairy Technology (SDT) has joined with Wiley-Blackwell to produce a series of technical dairy-related handbooks providing an invaluable resource for all those involved in the dairy industry, from practitioners to technologists, working in both traditional and modern large-scale dairy operations. For information regarding the SDT, please contact Maurice Walton, Executive Director, Society of Dairy Technology, PO Box 12, Appleby in Westmorland, CA16 6YJ, UK. email: [email protected]

Other volumes in the Society of Dairy Technology book series:

Probiotic Dairy Products (ISBN 978 1 4051 2124 8)

Fermented Milks (ISBN 978 0 6320 6458 8)

Brined Cheeses (ISBN 978 1 4051 2460 7)

Structure of Dairy Products (ISBN 978 1 4051 2975 6)

Cleaning-in-Place (ISBN 978 1 4051 5503 8)

Milk Processing and Quality Management (ISBN 978 1 4051 4530 5)

Dairy Fats and Related Products (ISBN 978 1 4051 5090 3)

Dairy Powders and Concentrated Products (ISBN 978 1 4051 5764 3)

Technology of Cheesemaking, 2nd edition (ISBN 978 1 4051 8298 0)

This edition first published 2011 © 2011 by Blackwell Publishing Ltd.

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Library of Congress Cataloging-in-Publication Data

Processed cheese and analogues / edited by A.Y. Tamime.

p. cm.—(Society of Dairy Technology series)

Includes bibliographical references and index.

ISBN 978-1-4051-8642-1 (hardcover : alk. paper) 1. Processed cheese. I. Tamime, A.Y.

SF272.5.P76 2011

637′.358—dc22

2010052430

A catalogue record for this book is available from the British Library.

This book is published in the following electronic formats: ePDF [9781444341829]; Wiley Online Library [9781444341850]; ePub [9781444341836]; Mobi [9781444341843]

Preface to the Technical Series

For more than 60 years, the Society of Dairy Technology (SDT) has sought to provide education and training in the dairy field, disseminating knowledge and fostering personal development through symposia, conferences, residential courses, publications, and its journal, the International Journal of Dairy Technology (previously published as the Journal of the Society of Dairy Technology).

In recent years, there have been significant advances in our understanding of milk systems, probably the most complex natural food available to humans. At the same time, improvements in process technology have been accompanied by massive changes in the scale of many milk processing operations, and the manufacture a wide range of dairy and other related products.

The Society has embarked on a project with Wiley-Blackwell to produce a Technical Series of dairy-related books to provide an invaluable source of information for practising dairy scientists and technologists, covering the range from small enterprises to modern large-scale operations. This tenth volume in this series, on Processed Cheese and Analogues, provides a timely and comprehensive update of the principles and practices involved in the production of these products, from raw materials and processing technology to assurance of the quality of the final product. Processed cheese and its analogues have found many uses in both domestic consumption and in the catering and fast food sectors, providing functional properties beyond those that can normally be achieved with traditional cheeses.

Andrew Wilbey

Chairman of the Publications Committee, SDT

Preface

There is a wide range of processed cheese products, i.e. natural products made from blending different cheeses to form a range of solid and spreadable products, and cheese analogues (made not from cheese, but from dairy and non-dairy ingredients) available to the food market worldwide. Some of these products are extensively used in the fast food/catering chains (e.g. as ‘shredded’ cheeses), and are of increasing economic value in the industrialised and developing countries.

The purpose of this book, which is written by a team of international scientists, is to review the latest scientific developments in this field. The authors, who are all specialists in these products, have been chosen from around the world. The scientific aspects reviewed in this publication include (a) the functionality of ingredients, including the natural cheeses, emulsifying salts, stabilisers, flavourings and colourings, (b) the interactions between natural cheese and processing conditions in developing the rheology and final texture of the product, (c) current processing equipment and manufacturing practices, (d) the current statutory regulations (national and international) of these products because an appreciable percentage of the internationally traded ‘natural’ cheese includes processed cheese varieties and (e) quality assurance of processed cheese (in terms of chemical, physical and microbiological properties and sensory profiling) to ensure the safety of the product for the consumer.

Some key scientific aspects of processed cheese manufacture can be manipulated to control and maintain the consistency and quality of the final product, and coverage of this topic has produced some overlap with those sections dealing with, for example, the interaction of emulsifying salts with natural cheese components. I have felt justified in allowing this overlap because it emphasises the prime importance of the ingredients used during the preparation of the cheese blend including the effects of processing on the quality and consistency of processed cheese for the end-user.

There is no doubt that the book will have an international recognition by dairy technologists, students, researchers and processors, and will become an important component of the Technical Series promoted by the Society of Dairy Technology.

A.Y. Tamime

Contributors

Editor

Dr A.Y. Tamime

24 Queens Terrace

Ayr KA7 1DX

UK

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Contributors

Dr M.A.E. Auty

Teagasc Food Research Centre

Moorepark

Fermoy

Co. Cork

Ireland

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E-mail: [email protected]

Professor E.M. Buys

Department of Food Science

University of Pretoria

Lynnwood Road

Pretoria 0002

South Africa

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Mr S. Dixon

215 Moss Bank Road

St Helens

Merseyside WA11 7NS

UK

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E-mail: [email protected] and [email protected]

Dr J. Domagala

University of Agriculture

Animal Products Technology Department

30–149 Krakow

Balicka 122

Poland

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Dr K.J. Domig

Department of Food Science and Technology

BOKU – University of Natural Resources and Life Sciences

Muthgasse 18

A-1190 Vienna

Austria

Tel. ++0043 (0)1 47654 6750

Fax ++0043 (0)1 47654 6751

E-mail: [email protected]

Dr E. Duggan

Food and Health Institute

UCD Agriculture and Food Science Centre

University College Dublin

Belfield

Dublin 4

Ireland

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Dr K. Dürrschmid

Department of Food Science and Technology

BOKU – University of Natural Resources and Life Sciences

Muthgasse 18

A-1190 Vienna

Austria

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Dr T.P. Guinee

Dairy Products Research Centre

Teagasc

Moorepark

Fermoy

Co. Cork

Ireland

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Dr M. Hickey

Derryreigh

Creggane

Charleville

Co. Cork

Ireland

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Dr A. Hill

University of Guelph

Department of Food Science

Guelph

Ontario N1G 2W1

Canada

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Mr S. Kaliappan

Frito-Lay R&D

7701 Legacy Drive

Plano, TX 75024-4099

USA

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Professor W. Kneifel

Department of Food Science and Technology

BOKU – University of Natural Resources and Life Sciences

Muthgasse 18

A-1190 Vienna

Austria

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Professor J.A. Lucey

University of Wisconsin-Madison

Department of Food Science

1605 Linden Drive

Madison, WI 53706-1565

USA

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Dr A. Maurer-Rothmann

Management Business Line Dairy

Business Unit Food

BK Giulini

Ladenburg

Germany

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Dr L. Metzger

Alfred Chair in Dairy Education

Dairy Science Department

South Dakota State University

Box 2104 Dairy-Microbiology Building

Brookings, SD 57007

USA

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Dr J.F. Mostert

Food Safety and Human Nutrition

ARC-Animal Production Institute

Private Bag X2

Irene 0062

South Africa

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Professor D.D. Muir

DD Muir Consultants

26 Pennyvenie Way

Girdle Toll

Irvine KA11 1QQ

UK

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Professor M. Nogueira de Oliveira

Universidade de São Paulo

Departamento de Tecnologia Bioquimico-Farmacêutica

Avenue Prof. Lineu Prestes 580, Bloco 16

Sao Paulo 05508-900

Brazil

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Dr N. Noronha

Food and Health Institute

UCD Agriculture and Food Science Centre

University College Dublin

Belfield

Dublin 4

Ireland

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Professor E.D. O'Riordan

UCD Agriculture and Food Science Centre

University College Dublin

Belfield

Dublin 4

Ireland

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Professor G. Osthoff

Department of Microbial Biochemical and Food Biotechnology

University of the Free State

PO Box 339

Bloemfontein 9300

South Africa

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Mr M. O'Sullivan

Food and Health Institute

UCD Agriculture and Food Science Centre

University College Dublin

Belfield

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Mr E. Slabber

Dairybelle

PO Box 744

Bloemfontein 9300

South Africa

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Dr A. Smith

University of Guelph

Analytical Microscopy

Department of Food Science

Guelph

Ontario N1G 2W1

Canada

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Professor Z. Ustunol

Michigan State University

Department of Food Science and Human Nutrition

2105 S. Anthony Hall

East Lansing, MI 48824

USA

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Dr M. Wszolek

University of Agriculture

Animal Products Technology Department

30–149 Krakow

Chapter 1

Processed Cheese and Analogues: An Overview

A.Y. Tamime

1.1 Historical Background

The production of processed cheese started in Europe, and could date to the mid-1890s. Natural cheeses have limited shelf-life and, depending on many factors (i.e. level of moisture content, sanitary conditions during the manufacturing stages and storage conditions of the product), this can range from a few weeks to a couple of years. It is possible to suggest that the idea of processed cheese originated from a desire to extend the shelf-life of natural cheese or to develop a new type of cheese which was milder in taste or more stable. Around the same period, commercial developments were made in Germany for the export of short shelf-life soft cheese, e.g. Camembert, Brie and Limburger, which was achieved by heating the cheeses in metal cans. Similar processing methods were also developed for Dutch cheeses, but the process was most successful in Switzerland by using sodium citrate (Berger et al., 1989).

Essential steps in the manufacture of processed cheese is melting and heating blends of natural cheeses (e.g. different types, varying degree of maturity, i.e. fresh/young or matured, and cheese ‘re-work’), the addition of emulsifying salts, agitation to produce a homogeneous mixture, followed by packaging and cooling or vice versa. The application of heat (i.e. indirect or direct steam injection) inactivates the starter culture organisms and other bacteria, including the enzymes present in natural cheeses, and produces a product with extended shelf-life. Although the casein in natural cheeses possesses certain emulsifying characteristics, the stability of processed cheese could not be achieved without the use of emulsifying salts, such as citrates and phosphates.

Commercial production of processed cheese started in earnest in Europe and the USA between 1910 and 1920. The production techniques were based on Cheddar and other cheese varieties, and used citrates or phosphates as the emulsifying salts. These early attempts to produce good-quality processed cheese were of limited success, but the process became widespread by the 1930s when the emulsifying salts (e.g. polyphosphates and other types) appeared on the market (Berger et al., 1989). In addition, other dairy and non-dairy ingredients could be added to the blend before processing, and the use of these ingredients is normally governed by statutory regulation within each country of manufacture.

Over the past few decades, many aspects of the manufacture of processed cheese have been reviewed by many authors (Jackson & Wearmouth, 1959; Price & Bush, 1974a,b; Shimp, 1985; Sachdeva et al., 1988; Marchesseau et al., 1997; Schar & Bosset, 2002; Abd El-Salam et al., 2005; Dimitreli & Thomareis, 2007; Kapoor & Metzger, 2008), and the same subject has been reviewed in different textbooks (Meyer, 1973; Thomas 1977; Guinee, 1987; Berger et al., 1989; , 1991; Merkenich et al., 1992a,b, 1994; & Kaláb, 1993; Kaláb, 1995; & , 1997; Kosikowski & Mistry, 1997; Zehren & Nusbaum, 2000; Guinee et al., 2004; Schrader & Hoffman, 2008; Adhikari et al., 2009; Bunka et al., 2009; Johnson et al., 2009). In addition, Mann (1969, 1970, 1974, 1975, 1978a,b, 1981, 1983a,b, 1986, 1987, 1990, 1993, 1995, 1997, 1999, 2003) has compiled several successively up-to-date international digests on processed cheese. Contrary to the current belief, processed cheese is made from good-quality natural cheeses (blends of fresh/young and matured) rather than degraded stock; however, these latter types of cheeses are only used in very small proportions, including re-work processed cheese. In addition, the processing equipment used during the manufacture of processed cheese is known as cooker or kettle (e.g. vertical or horizontal; see Chapter 6), and continuous or batch processes are also available on the market. Although the latter method of processing is more popular as it provides greater control of product quality and is more suitable for large-scale operations, the batch process may be still be favourable in small- and medium-sized production units or, alternatively, because the batch process was developed first – ‘old habits die hard’.

In contrast, ‘imitation’ processed cheese is made from mixtures of dairy and/or non-dairy proteins and fat/oils. Hence, it was suggested by Shaw (1984) that in response to increasing manufacturing costs of processed cheese, imitation products have been developed to meet demand in fast food outlets (e.g. pizza), by the catering trade, ready cooked foods, in formulated foods and in school lunch programmes (see also IDF, 1989; McCarthy, 1990; Mortensen, 1991; Engel, 1992; Lee et al., 1992; Song et al., 1992; Bachmann, 2001; Hoyer & Kirkeby, 2007).

It is evident that there are many similarities between the manufacture of processed cheese and analogues, and this chapter provides a general background to these products, their properties and the patterns of their consumption in some selected countries.