Abstract
A method for manufacturing composite pasta filata cheese without loss of material or excess debris. Said method is achievable by avoiding use of liquid to control the temperature of the cheese. This is referred to as a dry method of manufacturing pasta filata cheese. The dry method of manufacturing in this case utilizing ohmic heating mechanisms and counter-rotating dual compression belt system to maintain a dry heating and cooling environment. Foreign food particles may be added to the cheese at various stages of manufacturing before it is molded and cooled to set to form a homogenous composite pasta filata cheese mixture.
Claims
1. A method for forming composite pasta filata cheese by dry heat and dry cooling, said method comprising the following steps: obtain cheese curd granules by method of acidifying milk protein, coagulating said acidified milk protein to form solid curd, separating said solid curd from liquid whey, placing said cheese curd granules that have been separated from whey into a container, Said container having electro-conductive heating mechanism, said ohmic heating mechanism comprising one or more electro-conductive heating element positionable within or proximate to said container and a temperature gauge, each said electro-conductive heating element of said one or more electro-conductive heating element comprising a voltage output element and a grounding element, said grounding element is located within or proximate to said container, said voltage output 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 electro-conductive end comprising a plate, screw auger, probe, or combinations thereof, said temperature gauge is contactable with said cheese curd granules within said container to gauge the temperature of said cheese curd granules, contacting said cheese curd granules with said temperature gauge and said electro-conductive end of said voltage output element, heating said cheese curd granules by contact with electrical current that is released through said voltage output element, mixing said heated cheese curd granules, adding and mixing edible food particles into and with said heated cheese curd granules, continuing to mix said heated cheese curd granules with said edible food particles until a nascent homogenous composite cheese mass is formed, shut off said voltage output element, stretching, molding, and cooling said nascent homogenous composite cheese mass through a counter-rotating dual compression belt cheese processing device, 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 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, whereby 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 each rotatable in counter-rotational direction of each other wherein heated pasta filata cheese curd is receivable, pullable and stretchable therethrough in compressed manner, pulling, stretching, molding and cooling said nascent homogenous composite cheese mass to form a continuous ribbon of cooled and shaped composite pasta filata cheese, cutting and preparing said continuous ribbon of cooled and shaped composite pasta filata cheese for packaging.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1A is a plan view cross sectional thermal profile of a cheese block illustrating cooling efficiency problems within the current art.
[0046] FIG. 1B is a plan view cross sectional thermal profile of three laminated cheese ribbons in accordance with an embodiment of the present invention.
[0047] FIG. 2A is a plan view of the inventive subject matter in accordance with an embodiment of the present invention.
[0048] FIG. 2B is a plan view of a serpentine panel in accordance with an embodiment of the present invention.
[0049] FIG. 3 is an exploded three dimensional top and front side view of the compression channel in fluid connection with the distal ends of the elongated channels in accordance with an embodiment of the present invention.
[0050] FIG. 4 is an alternative embodiment of the counter-rotating dual compression belt cheese making device.
[0051] FIG. 5 is an exploded view of an alternative embodiment of this invention.
[0052] FIG. 6 is a diagram image of the method of making composite pasta filata cheese.
[0053] FIG. 7 is a partial view of the invention as disclosed herein.
[0054] FIG. 8 is a front view of the distal end of an alternative embodiment of said counter-rotating dual compression belt cheese making device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] 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.
[0056] FIG. 1A is an illustration of a theoretical transient heat transfer study of cheese illustrating a cross-sectional temperature profile for a standard 4×4 inch six pound block 100 of cheese submersed in 32° F. brine solution for 10 minutes. The calculations were based on thermal conductivity of 0.332 W/mK and specific heat of 3 kJ/kgK. 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 100. 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. (101), 2) 125° F. to 109° F. (102), 3) 109° F. to 94° F. (103), 4) 94° F. to 78° F. (104), 5) 78° F. to 63° F. (105), 6) 63° F. to 47° F. (106), 7) 47° F. to 32° F. (107). The outside “skin” 107 (according to the study, being the outermost layer in contact with the external environment) is able to cool from an initial temperature of 140° F. to 32° F. within 10 minutes of submersion in 32° F. brine solution while the inner cross-sectional half of the cheese block mass (illustrated by the dark line 108) requires at least 4 to 5 additional hours to cool to set. In contrast, FIG. 1B shows a cross sectional profile of three cheese ribbons 152 (each ⅝ inch by 4 inches in dimension) laminated together 150 to form a larger ribbon of approximately 2 inches wide by 4 inches long. The core temperature 151 of the larger ribbon 150 is equal to or lower than the core temperatures 153 of each single ribbon composites 152. For my preliminary study, when exposing the singular ribbons 152 of mozzarella cheese to a constant cooling temperature of 54° F. while being pulled through the elongated compression channels, the core temperature cooled to approximately 84° F. within minutes as it reached the proximate ends of the compression channels. The core temperature 151 of the final laminated block 150 was also approximately 84° F., ready for immediate packaging without need for further cooling.
[0057] FIG. 2A is an illustration of an exemplary embodiment of the inventive subject matter 200. This embodiment having a receiving chamber 201 or a trough for receiving the nascent warm cheese 250, a series of three elongated compression channels 203 and several guiding means 204 located between the trough 201 and the proximal end 205 of said elongated compression channels. Alternate embodiments of the invention may have fewer or greater numbers of elongated compression channels within each series than is depicted herein. The image of the elongated compression channels 203 of FIG. 2A does not provide for an accurate depiction of length but suggests only a length sufficient to accomplish the purpose of said invention. The length of each compression channel 203 may be adjustable to the user's preference. Each elongated compression channel may comprise one single or multiple individual segments. Each individual segment having a set of two flexible thermo-conductive belt loops, each belt loop in contact with at least two rotating driving mechanisms such that the two belt loops counter rotate against each other, forming a compression cavity therebetween where cheese is captured, compressed and pulled through. The guiding means 204 may also vary in quantity, shape and positional placement, depending on the action it is intended to achieve. In the immediate embodiment of FIG. 2A, the guiding means 204 comprises a simple triangular shaped immobile wedge seated on the proximal side of the channel opening 205, for the purpose of guiding and portioning (via the sharper protruding edge) the nascent cheese mass 250 into the compression channel cavities 207. In contrast, the guiding means 208 located beyond the distal end 206 of said elongated compression channels 203 in the preferred embodiment of FIG. 2A having rounded edges and integrated together within the proximal end 209 of the compression channel 210 purely for the purpose of corralling and guiding the long cheese ribbons 251 released from the elongated compression channels 203 without causing dent to the final cheese shape.
[0058] According to the embodiment of FIG. 2A, each elongated compression channel 203 is open on the proximal end 205 to receive the cheese mass and the distal end 206 to release formed and cooled cheese ribbons 251. Each elongated channel 203 is covered on all other sides by contiguous side walls (referred to cumulatively as the side walls 215, shown in part herein the bottom 212, left 213 and right 214 sides, top side not shown) to form an enclosed narrow internal cavity 207. The enclosed narrow internal cavity comprises a negative space of defined cross sectional shape and surface area (not shown). According to the embodiment of FIG. 2A, the side walls may form a rectangular or square shaped negative space. Alternate embodiments of the elongated compression channels 203 may have narrow internal cavities 207 and negative spaces of nearly any cross-sectional shape. The narrow internal cavity 207 may be shaped to be narrower at certain locations along the length of the channels to create additional pressure points for stretching the cheese.
[0059] The side walls 215 of each channel illustrated in FIG. 2A includes a top (not shown), bottom 212, right 214 and left side 213 surfaces. The bottom side wall in this particular embodiment comprises a large flat surface 212 that seats the entire device, creating a tight sealed connection with the left 213 and right side 214 walls of the elongated compression channels (among other parts of the device), thus acting dually as the bottom side wall 212 to the channels of the device. Again, alternate embodiments of this invention may have just one continuous side wall, particularly if the internal cavity is circular or oval with no corners or angles. In the depicted embodiment of FIG. 2A, the top wall surface may be a simple flat top cover, such as but not limited to glass, food grade plastic, or food grade metal, forming a fluid connection with the channel's right 214 and left 213 side walls. The bottom side 212 wall may be a simple base surface composed of the same food grade material as the rest of the compression channel side walls 215, fluidly connected to the compression channel's left 213 and right 214 walls. The left 213 and right side 214 walls comprising each of the two counter-rotating dual compression belts. The material composition of the compression channel side walls 215 is preferably food grade, solid, nonporous and non-flaking. Further, one or more side walls 215 should be thermally conductive and have the same level of thermal conductivity as the cheese mass.
[0060] 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 FIG. 2A faces the top ambient environment. The external side of the bottom side wall 212 of FIG. 2 faces the bottom ambient environment, assuming the device is positioned above ground level. The external sides 217 of the right 214 and left 213 side walls of FIG. 2A faces a series of cooling mechanisms 218 that facilitate continuous flow of a cooling medium (not shown). The cooling mechanism 218 comprises a cooling block 219 of similar dimensions as the channel side walls 215, receiving water through a piping system (not shown) and facilitates a flow of cold medium therethrough in enclosed manner. The cold medium may comprise any combination of solid, liquid, gas, or gel or any combination of these elements. In the embodiment of FIG. 2A and the exploded view of 2B, the external side of the compression channel's left and right side walls 213, 214 further possess grooved serpentine channels 220. 504. The serpentine channels 220,504 are exposed on the external side facing the cooling block 219. When pressed against each other, the cooling block 219 and the serpentine channels 220, 504 of the channel's external side walls 213,214 form a water tight seal. Cold water received from a piping system through the cooling block is directed into one end 221 of the serpentine channels and out of the other end 222 of the serpentine channels where the water is recalibrated to the desired temperature at the originating source. The continuous flow of cooling medium against the compression channel side walls 213, 214 helps to maintain a constant temperature gradient for purposes of efficient cooling inside the channel cavity. The serpentine channels 220, 504 may alternatively be incorporated into a singular cooling block comprising inert thermo-conductive food grade material, wherein said serpentine channels in this case would be bored through the block or comprise piping system embedded within said singular cooling block. These alternative embodiments would achieve essential the same results, which is the facilitation of cold medium against the external surface 217 of the compression channel side walls 213, 214. The cooling mechanism 218 may alternatively comprise a series of tubing carrying chilled medium, where the tubing wall is in contact with the channel external side walls 217. In such instance, the tubing wall (not shown) should be highly thermal conductive to ensure optimum heat transfer between the chilling medium and channel's internal cavity 207 through two layers of walls (the tubing wall and the channel wall).
[0061] The channel side walls may be further composed of either multiple serpentine channel panels (see FIG. 2B) interconnected together 203 or simply one single panel of a desired length. In either case, the user should be able to vary the temperature settings at different locations along the channel length. The cooling mechanism 218 in generally should also be comprised of solid, nonporous, food grade material that is thermally conductive, preferably at the same level of thermal conductivity as the cheese mass.
[0062] According to the preferred embodiment of FIG. 2A, a cooling temperature gradient is created between the external side 217 and internal side 216 of each compression channel side wall. As the cheese 250 passes through the length of each compression channel's internal cavity 207, it is quickly cooled. Given the wide surface area of the cheese ribbons 251 that is in direct contact with the compression channel's cool internal walls 216, the external and internal cross sectional layers of the cheese ribbons 251 quickly cool to setting temperatures. The rate of cooling will depend on period of exposure of cheese ribbons of a given cross sectional size to a preferred temperature gradient. The period of exposure is further dependant on the rate of speed in which the cheese ribbon is pulled through each compression channel and the length of the compression channel itself. Thus the dimensions of the compression channels should be adjustable to accommodate and control cooling time.
[0063] 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 FIG. 2A depicts an internal cavity 207 in contact with a pulling mechanism that follows the length of each compression channel 203, moving continuously alongside the internal walls 216 from proximal end 205 to distal end 206. The pulling mechanism may comprise any known means for gripping onto soft pliable and elastic material of varying levels of moisture that is also large in mass and volume. The preferred pulling mechanism would be able to quickly grip onto a portion of said cheese mass and pull the mass directly into and through the length of each channel's internal cavity 207 from proximal end 205 to distal end 206. The pulling mechanism 223 of the preferred embodiment of FIG. 2A comprises one or more rotating belts 223 looped around each elongated channel 203 from proximal 205 to distal ends 206 through the internal cavities 207 of each channel. The belts of the pulling mechanism depicted in FIG. 2A are pulled forward from proximal 205 to distal end 206 in continuous motion by a cog belt system 224. The cog belt system comprises just one of many known and standard actuating means that can activate the pulling mechanism in the manner intended herein. In the device illustrated in FIG. 2A, SS belts 225 are looped over a series of cog wheels 226. Several of said cog 226 wheels strategically positioned at the proximal and distal ends of the elongated channels and compression channels where the rotating belts 223 of the pulling mechanism are dually looped around and below the SS belts 225. Rotation of a central cog wheel 227 (by hand lever 228 or motor drive, etc.) where the SS belts 225 converge results in rotation of the entire SS belt system 225, forcing directional movement of the cog wheels 226 and in turn, resulting in tandem rotation of the rotating belts 223 of the pulling mechanism. The actuating means may further control the rate of speed in which the pulling mechanism moves, controlling the degree of stretching at pressure points along the internal cavity 207 of the channels 203. 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.
[0064] 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 FIG. 4. The location by which the surfaces of said two belts face each other are in compressed contact with each other. The external surface of at least one or both of said belts having grooved space 802 along its each said length such that when the two external surfaces 803a,b are compressed together, an elongated channel 804 is formed therebetween along a horizontal plane. See FIG. 8. As the two belts counter-rotate at preferably the same speed with each other, the elongated channel has the effect of being moved forward as well. Said elongated channel having an open proximate side and open distal side. Said proximate side 406 comprising the location where the elongated channel is formed by the coming together of the external surfaces of the two belts. The distal side 407, 801 is where the external surfaces peal away from each other as a result of their counter-rotational action. Said nascent cheese mass is captured on the proximate side of the belt system and released on the distal side 801, 802 by the counter-rotational motion of the two belts. As illustrated in FIG. 5, the cooling blocks 501 of said cooling means is positionable in adjacent contact with the internal surface of each belt 502, 503 along the location where the two belts meet. As such, the cooling blocks are positioned either above or below the location where the nascent cheese mass would pass through the elongated channel space, wicking away heat by manner of thermo-conductive heat transfer between the temperature gradient within the elongated channels and the cooler temperature along the surface of the cooling blocks. The cooling blocks further having the added benefit of providing compression support overtop the contacting surfaces of each counter-rotating belt, helping to maintain the water tight seal of the elongated channel along its entire length.
[0065] 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.
[0066] The distal ends 206 of the elongated compression channels 203 in the preferred embodiment of FIG. 2A releases ribbons of cheese which are further directed into a second series of compression channels 210, for additional molding via pressing and lamination. The invention may alternatively provide for multiple compression channels 210 in fluid connection in order to achieve the particular manner of manufacture desired. The compression channel 210 of FIG. 2A has elongated guiding means 208 fluidly connected to its proximal end 209, guiding and directing multiple ribbons of cheese 251 towards a narrow compression channel 210. Since the ribbons 251 may have already been cooled to set by this stage, no further cooling may be required but cooling means may be added to the compression channels 210 in the same manner of construction as with the elongated compression channels 203, to achieve specific molding temperatures. The compression channels 210 are completely enclosed on all sides, other than the proximal 209 and distal ends 229, to form an internal cavity 230 with a negative space of defined shape and surface area (not shown). The cross sectional space (not shown) of the internal cavity 230 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 210 is continuous from the proximal end 209 to the distal end 229. Each compression channel 210 having pulling mechanisms 231 and cooling mechanisms 232 of the same or similar construction and functionality as described above for the elongated channels. In the preferred embodiment of FIG. 2A, the compression chamber side walls (referred to cumulatively as 235, comprising a bottom 212, left 234, right 233, and top not shown) should also be thermally conductive, preferably to the same level of the cheese ribbons. The actuating means for the compression channel 210 as depicted in FIG. 2A is coextensive with that of the elongated channels 203, activated by the same source through interconnected SS belts 225. However, the actuating means need not be coextensive between the two series of channels 203, 210.
[0067] FIG. 3 depicts an exploded view of an exemplary embodiment of the compression channel 300 where cheese ribbons 301 are released from the distal ends 306 of the elongated compression channels 302 pulled into the proximal end of the 303 compression channel 300 by a rotating belts 304 of a pulling mechanism, and are compressed and laminated together to form a larger ribbon 305 of cheese with defined shape. This preferred embodiment is ideal for producing continuous cheese ribbons easily cut to industry standard sized cheese blocks. However, nearly any desirable cross sectional shape and sized may be achieved through the combination of processes of the described invention.
[0068] FIG. 6 provides a linear diagram of a preferred method of making composite pasta filata cheese. That method is as follows: Step 1: the formation of pasta filata cheese curds whereby cheese curd granules are formed from acidifying milk protein, coagulating said acidified milk protein to form solid curd; Step 2: separating solid curd from liquid whey; Step 3: Placing said cheese curd 701 granules into a dry container 702 having electro-conductive heating mechanism 703 (See, FIG. 7); Step 4: Ohmically heat said cheese curd 701 with said electro-conductive heating mechanism 703 and mix said cheese curd to form a nascent cheese mass 705 (See, FIG. 7), Step 5: Add and mix foreign food ingredients 704 into said warm nascent cheese mass 705 (See, FIG. 7); Step 6: Continue mixing said foreign food ingredients 704 into said warm nascent cheese mass 705 until a homogenous composite mass is formed; Step 7: Turn off said electro-conductive heating mechanism; Step 8: Transfer said homogenous composite nascent cheese mass onto a proximal end of a counter-rotating dual compression belt cheese making device; Step 9: Pull, mold, and cool to set said homogenous composite nascent cheese mass through said counter-rotating dual compression belt cheese making device; Step 10: Release a cooled and molded to set ribbon of composite pasta filata cheese mass 804 (See, FIG. 8) from the distal end of said counter-rotating dual compression belt cheese making device 801; Step 11: Cut said cooled and molded to set ribbon of composite pasta filata cheese mass for immediate storage or packaging.
[0069] 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.
[0070] 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.
[0071] 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.
