DRY BLEND FOR MAKING EXTENDED CHEESE PRODUCT

Abstract

Disclosed herein are dry blends used in the process of making extended cheese products with improved meltability and firmness profiles.

Claims

1.-27. (canceled)

28. A dry blend free of casein comprising: a. 40%-70% starch comprising one or more chosen from acetylated starch, hydroxypropyl phosphate starch, oxidized starch, and octenyl succinic anhydride starch; b. 3%-18% whey; and c. 5%-25% emulsifiers; wherein an analogue cheese, free of casein and formed from 8%-62% dry blend, 10-84% water, and 8-62% of a fat at between 45 ° F. and 160 ° F., is firm enough for shredding and slicing at 40 ° F., and is emulsion and color stable during processing and melting.

29. The dry blend of claim 28, wherein the starch comprises octenyl succinic anhydride starch and oxidized starch.

30. The dry blend of claim 28, further comprising up to 8% gums.

31. The dry blend of claim 28, comprising: a. 45%-65% starch comprising one or more chosen from acetylated starch, hydroxypropyl phosphate starch, oxidized starch, and octenyl succinic anhydride starch; b. 5%-16% whey; and c. 8%-22% emulsifiers.

32. The dry blend of claim 28, comprising: a. 50%-60% starch comprising one or more chosen from acetylated starch, hydroxypropyl phosphate starch, oxidized starch, and octenyl succinic anhydride starch; b. 13%-16% whey; c. 9%-20% emulsifiers; and d. 2%-6% gums.

33. The dry blend of claim 28, further comprising up to 5% of an acidulant.

34. The dry blend of claim 33, wherein the acidulant is chosen from acetic acid, citric acid, fumaric acid, lactic acid, malic acid, phosphoric acid, and tartaric acid.

35. The dry blend of claim 33, wherein the acidulant is chosen from citric acid, lactic acid, and acetic acid.

36. The dry blend of claim 28, further comprising a native food starch.

37. The dry blend of claim 28, wherein the emulsifier is chosen from alkaline sodium aluminum phosphate, sodium citrate, trisodium phosphate, and disodium phosphate.

38. The dry blend of claim 37 wherein at least half of the emulsifier is alkaline sodium aluminum phosphate.

39. The dry blend of claim 28, containing less than 10% water.

40. The dry blend of claim 39, containing less than 5% water.

41. A method of making an analogue cheese free of casein comprising: combining 8%-62% dry blend of claim 28, 8%-62% of a fat, and 10%-84% water to form a mixture; heating the mixture at between 45 ° F. and 160 ° F.; and cooling the mixture to provide an analogue cheese that is free of casein, firm enough for shredding and slicing at 40 ° F., and emulsion and color stable during processing and melting.

42. The method of claim 41 further comprising adding casein, cheese, cheese curds, or combinations thereof; cooking the mixture to at least 150-155 ° F.; and forming an extended cheese product.

43. The method of claim 42, further comprising after the cooking step, adding additional water and cooking the resulting mixture to 160-170 ° F.

44. An extended cheese product comprising the analogue cheese of claim 28 and cheese and/or cheese curds.

45. The extended cheese product of claim 44, wherein the cheese and/or cheese curds are chosen from cheddar, Monterey Jack, Colby, Swiss, Gouda, Manchego, and pepper jack.

46. The extended cheese product claim 44, wherein the cheese and/or cheese curds comprise between about 10% and about 50% by weight of the extended cheese product.

47. The extended cheese product claim 44, wherein the cheese and/or cheese curds comprise between about 30% and about 90% by weight of the extended cheese product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0067] FIG. 1 depicts one example of a general method for making a cheese product using a dry blend.

DETAILED DESCRIPTION

[0068] A “cheese analogue” as used herein refers generally to a cheese in which at least one milk fat and/or protein source has been replaced with a source that is not native to milk. The basic ingredients for a cheese analogue are usually water, casein, a fat/oil and a sequestering agent. Cheese analogues are typically categorized as dairy (all fats and proteins come from dairy sources), partial dairy (some fats and proteins come from dairy sources, while other have been replaced with non-dairy fats and proteins), or nondairy (all fats and proteins come from non-dairy sources). They can also be classified as being an imitation cheese or a substitute cheese. Imitation cheese is a substitute for and resembles another cheese but is nutritionally inferior to that cheese. A cheese substitute, on the other hand, resembles another cheese but is not nutritionally inferior to that cheese.

[0069] An “extended cheese product” is a food product based on a natural cheese, but wherein filler material has been added to the natural cheese to extend the mass and volume while maintaining or improving the physical properties of the natural cheese (i.e. meltability, stretchability, browning, elasticity, free oil formation, etc.). Extended cheese products are a type of cheese analogue.

[0070] A “pre-filled cheese extender package” is a package containing the dry blend that includes all the ingredients needed for a user to create an extended cheese product, such as, but not limited to, starches, gums, acidulants, whey, casein, emulsifiers, salts, and gelatin. These ingredients have been homogenously blended before being packaged.

[0071] Processed cheese has several technical advantages over unprocessed cheese, including extended shelf-life, resistance to separation when cooked, and uniformity of product. Its production also enjoys significant economic advantages over traditional cheese-making processes, most often through the ability to incorporate any of a wide variety of less expensive ingredients.

[0072] Emulsifiers are used to provide a uniform structure during the melting process. The essential role of the emulsifying agents in the manufacturing of processed cheese is to supplement the emulsifying capability of cheese proteins. This is accomplished by removing calcium from the proteins; peptizing, solubilizing and dispersion of the proteins; hydrating and swelling of the proteins; emulsifying of fat and stabilizing of the emulsion and by forming an appropriate structure after cooling. The use of emulsifiers in processed cheese results in cheese that melts smoothly when cooked. With prolonged heating, unprocessed cheese will separate into a molten protein gel and liquid fat; processed cheese will not separate in this manner. The emulsifiers, typically alkaline sodium aluminum phosphate, disodium phosphate duohydrate and sodium citrate, or other sodium or potassium phosphate, tartrate, or citrate salts, reduce the tendency for tiny fat globules in the cheese to coalesce and pool on the surface of the molten cheese.

[0073] A number of different types of starches can be incorporated into the dry blend. Suitable starches include vegetable starches (e.g., potato starch, arrowroot starch, pea starch, and tapioca) and grain starches (e.g., corn starch, wheat starch, and rice starch). Specific examples of suitable corn starches include dent corn starch, waxy corn or maize starch, and high amylose corn starch. The starches can be used individually or in combination. As noted above, starches can advantageously be included in the slurry. In some applications, the starch is added as a powder or unheated solution.

[0074] The starch can be modified or native. Modified starches, also called starch derivatives, are prepared by physically, enzymatically, or chemically treating native starch, thereby changing the properties of the starch. Modified starches are used in practically all starch applications, such as in food products as a thickening agent, stabilizer or emulsifier. Modified food starches differ in their degree of cross-linking, type of chemical replacement, oxidation level, degree of molecular scission, and ratio of amylose to amylopectin.

[0075] Examples of suitable gums that can be incorporated include, but are not limited to, xanthan gum, guar gum, konjac flour and locust bean gum. Examples of suitable stabilizers include chondrus extract (carrageenan), pectin, gelatin, and agar. Their synergistic interaction improves the textural quality of foods. It imparts rich mouth feel without masking flavor, enhances moisture retention, prevents syneresis and ice crystal formation in frozen products and forms thermally reversible gels. Blends of Xanthan Gum, Locust Bean Gum and Guar Gum are commonly used in the production of extended cheese products.

[0076] Acidulants are additives that give a sharp taste to foods by increasing the tartness or acidity. They also assist in the setting of gels and to act as preservatives. An acidulant (acidic agent) can be incorporated to adjust the pH of the finished cheese to a desired level. The acidity of the cheese can be controlled to help regulate the melt down characteristics of the finished cheese. Various acids can be employed; examples of suitable acids include, but are not limited to, acetic acid, citric acid, fumaric acid, lactic acid, malic acid, phosphoric acid, tartaric acid adipic acid, hydrochloric acid, glucano delta lactone, lactobionic acid or Genlac C, the latter being a blend of water, citric acid, lactic acid, acetic acid and artificial flavors. Acid is typically added to adjust the pH of the finished cheese to a pH from about 5-6 is reached, and more typically from pH 5.10-5.90.

[0077] A colorant can be incorporated into the soft or firm/semi-hard ripened or unripened blended cheese to adjust its natural color. This can be useful, for example, if consumers have a preference for a color other than the naturally-occurring color. Examples of suitable colorants include annatto, turmeric, titanium dioxide, and beta-carotene. Colorants may be of both the natural or artificial color. If one wished to color the cheese a red, an artificial color such as FD&C red # 40 can be used. Annatto imparts a yellowish color to cheese. The yellowish color often is preferred by consumers who perceive it to indicate a “richer” product upon cooking on a pizza. Colorants can be incorporated into the final soft or firm/semi-hard ripened or unripened blended cheese product by inclusion in the slurry. If added at the mixing stage, the colorant is generally sprayed onto the heated cheese mass as an unheated solution or dispersion in water. The amount of colorant added is typically in the range of about 0.01 to 0.02%, based on the weight of the finished cheese. Turmeric, if used, is generally added in an amount of about 0.01 to 0.001%. If annatto is added, it normally is added to about 0.1 to 0.2% by weight.

[0078] Various flavoring agents can also be incorporated into the cheese to tailor the flavor profile of the cheese to meet consumer preferences. Suitable flavors for mixing into the heated cheese include, for example, natural mozzarella flavor such as diacetyl and/or lipolyzed fat, or enzyme modified cheese for cheddar cheese. Flavoring agents can be incorporated into the final soft or firm/semi-hard ripened or unripened blended cheese product by incorporation into the heated slurry or by addition to the heated cheese mass as a dry powder, or more typically as part of an unheated aqueous solution. Flavoring agents are typically added in an amount such that the concentration in the final cheese product is within the range of about 0.01 to 5 wt. %. If incorporated into the slurry, the concentration of the flavoring agent in the slurry is generally is in the range of about 0.11-4.50 wt. %.

[0079] Non-dairy fat refers to various vegetable fats. These fats may be partially or fully hydrogenated, yielding a cheese product that is low in trans-fat. In an embodiment, the fat has a melting point close to that of butter fat, 93-103° F. Further, the fat may be blended with a liquid fat (oil) during the cheese making process.

[0080] Whey is the liquid remaining after milk has been curdled and strained. It is a by-product of the manufacture of cheese or casein and has several commercial uses. Sweet whey is manufactured during the making of rennet types of hard cheese like mozzarella, cheddar or Swiss cheese.

[0081] Cheese curds are an important step in the cheese making process. They are small chunks of cheese solids which have been separated from the natural whey present in milk, but not yet pressed into molds to make cheese. Different treatments of the curds yield different end cheeses, and the curds can also be eaten straight. The curdling process coagulates the solids in the milk, yielding cheese curds swimming in whey. The whey is drained from the curds, which may also be cut to facilitate drainage, and then the cheese curds can be salted, packed into molds, and turned into cheese.

[0082] Casein is the name for a family of related phosphoproteins (αS1, αS2, β, κ). These proteins are commonly found in mammalian milk, making up 80% of the proteins in cow milk and between 20% and 45% of the proteins in human milk. Casein has a wide variety of uses, from being a major component of cheese, to use as a food additive, to a binder for safety matches. As a food source, casein supplies amino acids; carbohydrates; and two inorganic elements, calcium and phosphorus. Casein contains a fairly high number of proline residues, which do not interact. There are also no disulfide bridges. As a result, it has relatively little tertiary structure. It is relatively hydrophobic, making it poorly soluble in water. It is found in milk as a suspension of particles called “casein micelles” which show only limited resemblance with surfactant-type micellae in a sense that the hydrophilic parts reside at the surface and they are spherical. However, in sharp contrast to surfactant micelles, the interior of a casein micelle is highly hydrated. The caseins in the micelles are held together by calcium ions and hydrophobic interactions. Types of casein commonly used in cheese making comprise, but are not limited to, rennet casein, acid casein, calcium caseinate, sodium caseinate, and potassium caseinate.

[0083] Dry blend refers to the “dry” (i.e. less than 15% water) starting material one would use in make of extended cheese product. A dry blend is a homogenous mixture of the ingredients that may be sold as a pre-packaged mix to a cheese manufacturer or user. Normally water and some type of fat would be added to produce the extended cheese product. One could also add in a desired flavor to resemble the desired cheese taste.

[0084] The dry blend that is provide here for use in the extended cheese product is designed to improve: 1) melt and flow ability of the final cheese product, which is a measure of how well the cheese melts and flows into a homogenous mass, preferably with little or no individual shreds of cheese still detectable; 2) stretch, which is measure of the ability of the cheese to form interconnected strings when the heated cheese is pulled; 3) texture, which is a measure of chewiness and smoothness; 4) coloring, which is a measure of the actual color of the melted cheese; 5) blister characteristics, which may include size, color and extent of coverage; and/or 6) nutritional composition.

[0085] The dry blends described herein are manufactured it in one step by blending all the dry material contained in the formulas described herein in a double ribbon blender. These batches are blended during addition of the ingredients, and then blended an additional 10 minutes, or until a homogenous mixture is obtained, after all ingredients have been added. Optionally, a food grade oil can be sprayed on with the blender running, with an additional 10 minutes of blending, or until a homogenous mixture is obtained. The dry product obtained at the conclusion of the blending is packed and is ready to be packaged or used in the cheese making process.

Dry Blend Examples

[0086] Examples 1-16 are for making a dry blend for use in making an analogue cheese.

TABLE-US-00001 Example 1 Example 2 Ingredients Weight % Weight % Acetylated Potato Starch 15 15 Corn Starch 10.05 10.05 Octenyl succinic anhydride (OSA) 6.25 6.25 Waxy Maize Starch Rice flour 20.5 20 Whey 14.6 14.6 Salt 5.5 5.5 Alkaline Sodium Aluminum Phosphate 13.8 13.8 Sodium Citrate 2.5 0 Disodium Phosphate-Duohydrate 2.5 0 Trisodium Phosphate 0 5.5 Sorbic Acid 1.2 1.2 Mineral Oil 0.75 0.75 Blend of Xanthan, Locust, and Guar Gums 4.35 4.35 Citric Acid 3 3 TOTAL INGREDIENTS 100 100 Example 3 Example 4 Ingredients Weight % Weight % Acetylated Potato Starch 40.125 39.54434 Hydroxypropyl Phosphate Potato Starch 10 9.764036 Octenyl succinic anhydride (OSA) 6.25 7.078926 Waxy Maize Starch Whey 14.6 14.25549 Salt 8.75 8.543531 Alkaline Sodium Aluminum Phosphate 9.375 7.729862 Sodium Citrate 1.25 2.441009 Disodium Phosphate-Duohydrate 1.25 0 Trisodium Phosphate 0 2.441009 Sorbic Acid 1.5 1.464605 Mineral Oil 0.75 0.732303 Blend of Xanthan, Locust, and Guar Gums 4.35 4.247356 Citric Acid 1.8 1.757526 TOTAL INGREDIENTS 100 100 Example 5 Example 6 Ingredients Weight % Weight % Acetylated Potato Starch 40.125 42 Hydroxypropyl Phosphate Potato Starch 10 10 Octenyl succinic anhydride (OSA) 6.25 6.25 Waxy Maize Starch Whey 14.6 14.6 Salt 8.75 8.75 Alkaline Sodium Aluminum Phosphate 9.375 6.25 Sodium Citrate 1.25 1.25 Disodium Phosphate-Duohydrate 1.25 2.5 Sorbic Acid 1.5 1.5 Mineral Oil 0.75 0.75 Blend of Xanthan, Locust, and Guar Gums 4.35 4.35 Citric Acid 1.8 1.8 TOTAL INGREDIENTS 100 100 Example 7 Example 8 Ingredients Weight % Weight % Acetylated Potato Starch 42 43.25 Hydroxypropyl Phosphate Potato Starch 10 10 Octenyl succinic anhydride (OSA) 6.25 6.25 Waxy Maize Starch Whey 14.6 14.6 Salt 8.75 8.75 Alkaline Sodium Aluminum Phosphate 6.25 6.25 Sodium Citrate 2.5 1.25 Disodium Phosphate-Duohydrate 1.25 1.25 Sorbic Acid 1.5 1.5 Mineral Oil 0.75 0.75 Blend of Xanthan, Locust, and Guar Gums 4.35 4.35 Citric Acid 1.8 1.8 TOTAL INGREDIENTS 100 100 Example 9 Example 10 Ingredients Weight % Weight % Acetylated Potato Starch 40.125 38.4 Hydroxypropyl Phosphate Potato Starch 10 10 Octenyl succinic anhydride (OSA) 6.25 6.25 Waxy Maize Starch Whey 14.6 14.6 Salt 8.75 8.75 Alkaline Sodium Aluminum Phosphate 9.375 11.1 Sodium Citrate 1.25 1.25 Disodium Phosphate-Duohydrate 1.25 1.25 Sorbic Acid 1.5 1.5 Mineral Oil 0.75 0.75 Blend of Xanthan, Locust, and Guar Gums 4.35 4.35 Citric Acid 1.8 1.8 TOTAL INGREDIENTS 100 100 Example 11 Example 12 Ingredients Weight % Weight % Acetylated Potato Starch 35.9 40.125 Hydroxypropyl Phosphate Potato Starch 10 10 Octenyl succinic anhydride (OSA) 6.25 6.25 Waxy Maize Starch Whey 14.6 14.6 Salt 8.75 8.75 Alkaline Sodium Aluminum Phosphate 11.1 9.375 Sodium Citrate 2.5 1.25 Disodium Phosphate-Duohydrate 2.5 1.25 Sorbic Acid 1.5 1.5 Mineral Oil 0.75 0.75 Blend of Xanthan, Locust, and Guar Gums 4.35 4.35 Citric Acid 1.8 1.8 TOTAL INGREDIENTS 100 100 Example 13 Ingredients Weight % Corn Starch 43.33 Hydroxypropyl Phosphate Potato Starch 7.35 Acid-treated Corn Starch 15.04 Whey 14.3 Salt 5.18 Alkaline Sodium Aluminum Phosphate 3.7 Sodium Citrate 3 Sorbic Acid 1.5 Mineral Oil 0.75 Blend of Xanthan, Locust, and Guar Gums 1.85 Trisodium Phosphate 4 TOTAL INGREDIENTS 100 Example 14 Ingredients Weight % Acid-treated Corn Starch 10.05 Octenyl succinic anhydride (OSA) 6.6 Waxy Maize Starch Rice flour 10.5 Whey 14.6 Salt 5.5 Gelatin 4 Alkaline Sodium Aluminum Phosphate 7.4 Sodium Citrate 2.5 Disodium Phosphate Duohydrate 2.5 Trisodium Phosphate 5 Combination of Oxidized and 22.4 Acetylated di-starch adipate Sorbic Acid 1.2 Mineral Oil 0.4 Blend of Xanthan, Locust, and Guar Gums 4.35 Citric Acid 3 TOTAL INGREDIENTS 100 Example 15 Example 16 Example 17 Ingredients Weight % Weight % Weight % Acid-treated Corn Starch 10.05 10.05 10.05 Hydroxypropyl Phosphate 10 10 10 Corn Starch Rice flour 10.5 10.5 10.5 Whey 9 5 5 Salt 5.5 5.5 5.5 Gelatin 4 4 4 Sodium Citrate 0 2.5 2.5 Disodium Phosphate 4 2.5 2.5 Duohydrate Trisodium Phosphate 6 5 5 Oxidized Potato Starch 35.2 38 38 Sorbic Acid 1 1.2 1.2 Mineral Oil 0.4 0.4 0.4 Blend of Xanthan, Locust, 2.35 2.35 2.35 and Guar Gums Citric Acid 2 3 3 TOTAL INGREDIENTS 100 100 100

[0087] The dry blends disclosed herein can be made into extended cheese products via the following process. Melt the fat (milk or vegetable fat) and then add the dry blend, optionally add flavoring, and then add water, in that order, and blend for 5 minutes. Cook the mixture to about 150° F. Add cheese and/or cheese curd and cook the resulting mixture to 160° F-175° F. Form the extended cheese product and cool it. The extended cheese product can then be packaged and refrigerated. Once cool, the product may be shredded or sliced, if desired. The amount of natural cheese product used may vary, such as at least 45%, depending the on the desired product.

[0088] Alternatively, melt the fat (milk or vegetable fat) and then add the dry blend, optionally add flavoring, add approximately two-thirds of the water, then the cheese and/or cheese curds, and optionally, casein, and blend for 1 minute. Cook the mixture to 150° F-155° F. Add the remainder of the water and the acidulant and mix for 1 minute. Cook the resulting mixture to 160° F-170° F. Form the extended cheese product and cool it. The extended cheese product can then be packaged and refrigerated. Once cool, the product may be shredded or sliced, if desired. The amount of natural cheese product used may vary, such as at least 45%, depending the on the desired product.

[0089] Meltability is measured by cutting a disk of cheese of a specified size, and placing the disk in a glass Petri dish. A technician heats the Petri dish in an oven at an elevated temperature for a specified time (350° F. for seven minutes), then pulls the dish out and measures the diameter of the circle the melted cheese has formed.

[0090] Stretchability of cheese can be determined by adapting a texture-profile analyzer to pull strands of cheese upwards from a reservoir of melted cheese. Cheese is placed into a stainless steel cup and tempered in a water bath at varying elevated temperatures, such as 60, 70, 80, or 90° C., for a specified time period, such as 30 min, before analysis. The cup is then placed in a water-jacketed holder mounted on the base of the instrument. A three-pronged hook-shaped probe is lowered into the melted cheese and then pulled vertically until all cheese strands break or 30 cm is reached. This produces a stretch profile as the probe is lifted through the reservoir of melted cheese and then pulls strands of cheese upwards. An additional test for measuring the stretchability of cheese was developed by heating a specified amount of cheese on a thermostatically controlled hot plate, followed by measuring the distance between the hot plate and moveable stretching plate before the cheese strands are torn off.

[0091] Further, a subjective test for meltability and stretchability may be performed. The cheese is shredded and a predetermined amount, such as about 200 g, is placed on top of a pizza crust covered in pizza sauce. The resulting pizza is baked in an over, such as for 4-9 minutes at 500° F. The pizza is removed from the oven and allowed to cool, such as for 1 minute. A visual check is then performed to determine if the cheese melted. If so, the melting is checked for homogeneity of the melt and spreading. The melted cheese is stretched and subjective determinations about the stretchability can be made, such as long stretches and weak stretchability.

[0092] The above dry blends will provide an ingredient to be used in making extended cheese products with improved melting and stretching properties.

[0093] It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. The cheeses of the present invention may be made by the methods described herein, or by any other method that produces a finished cheese product having the same physical or chemical properties as the present cheeses. All publications, patents and patent applications cited herein are hereby incorporated by reference in their entirety for all purposes to the same extent as if each individual publication, patent or patent application were specifically and individually indicated to be so incorporated by reference.