Microfiltration (MF) is a membrane process that can separate casein micelles from milk serum proteins (SP), mainly beta-lactoglobulin and alpha-lactalbumin. Our objective was to develop a multistage MF process to remove a high percentage of SP from skim milk while producing a low concentration factor retentate from microfiltration (RMF) with concentrations of soluble minerals, nonprotein nitrogen (NPN), and lactose similar to the original skim milk. The RMF could be blended with cream to standardize milk for traditional Cheddar cheese making. Permeate from ultrafiltration (PUF) obtained from the ultrafiltration (UF) of permeate from MF (PMF) of skim milk was successfully used as a diafiltrant to remove SP from skim milk before cheese making, while maintaining the concentration of lactose, NPN, and nonmicellar calcium. About 95% of the SP originally in skim milk was removed by combining one 3 x MF stage and two 3 x PUF diafiltration stages. The final 3 x RMF can be diluted with PUF to the desired concentration of casein for traditional cheese making. The PMF from the skim milk was concentrated in a UF system to yield an SP concentrate with protein content similar to a whey protein concentrate, but without residuals from cheese making (i.e., rennet, culture, color, and lactic acid) that can produce undesirable functional and sensory characteristics in whey products. Additional processing steps to this 3-stage MF process for SP removal are discussed to produce an MF skim retentate for a continuous cottage cheese manufacturing process.

Many consumers are concerned with fat intake. However, many reduced-fat foods, including reduced-fat cheese, lack robust flavors. The objectives of this study were to characterize the flavors found in full-fat cheese, cheese fat, and reduced-fat cheese made from aged Cheddar using a novel process to remove the fat (Nelson and Barbano, 2004). Two full-fat, aged cheeses (9 and 39 mo) were selected, and the fat was removed using the novel fat removal process. Full-fat cheeses, shredded and reformed full-fat cheeses, corresponding reduced-fat cheeses, and cheese fats were then analyzed using descriptive sensory and instrumental analysis followed by consumer acceptance testing. Cheeses were extracted with diethyl ether followed by isolation of volatile material by high vacuum distillation. Volatile extracts were analyzed using gas chromatography/ olfactometry with aroma extract dilution analysis. Selected compounds were quantified. The 39-mo cheese was characterized by fruity and sulfur notes, and the 9-mo-old cheese was characterized by a spicy/brothy flavor. Reduced-fat cheeses had similar flavor profiles with no difference in most sensory attributes to corresponding full-fat cheeses. Sensory profiles of the cheese fats were characterized by low intensities of the prominent flavors found in the full-fat cheeses. Instrumental analysis revealed similar trends. Consistent with sensory analysis, there were lower concentrations and log(3) flavor dilution factors for most compounds in the cheese fats compared with both the reduced- and full-fat cheeses, regardless of compound polarity. Consumers found the intensity of flavor in the reduced-fat cheese to be equal to the full-fat cheeses. This study demonstrated that when fat was removed from aged full-fat Cheddar cheese, most of the flavor and flavor compounds remained in the cheese and were not removed with the fat.

Normally, reduced-fat Cheddar cheese is made by removal of fat from milk prior to cheese making. Typical aged flavor may not develop when 50% reduced-fat Cheddar cheese is produced by this approach. Moreover, the texture of the reduced-fat cheeses produced by the current method may often be hard and rubbery. Previous researchers have demonstrated that aged Cheddar cheese flavor intensity resides in the water-soluble fraction. Therefore, we investigated the feasibility of fat removal after the aging of Cheddar cheese. We hypothesized the typical aged cheese flavor would remain with the cheese following fat removal. A physical process for the removal of fat from full-fat aged Cheddar cheese was developed. The efficiency of fat removal at various temperatures, gravitational forces, and for various durations of applied forces was determined. Temperature had the greatest effect on the removal of fat. Gravitational force and the duration of applied force were less important at higher temperatures. A positive linear relationship between temperature and fat removal was observed from 20 to 33 degrees C. Conditions of 30 degrees C and 23,500 x g for 5 min removed 50% of the fat. The removed fat had some aroma but little or no taste. The fatty acid composition, triglyceride molecular weight distribution, and melting profile of the fat retained in the reduced-fat cheeses were all consistent with a slight increase in the proportion of saturated fat relative to the full-fat cheeses. The process of fat removal decreased the grams of saturated fat per serving of cheese from 6.30 to 3.11 g. The flavor intensity of the reduced-fat cheeses were at least as intense as the full-fat cheeses.

Preacidification of milk for cheese making may have a beneficial impact on increasing proteolysis during cheese aging. Unlike other acids, CO(2) can easily be removed from whey. The objectives of this work were to determine the effect of milk preacidification on Cheddar cheese composition, the recovery of individual milk components, and yield. Carbon dioxide was injected inline after the cooling section of the pasteurizer. Cheeses with and without added CO(2) were made simultaneously from the same batch of milk. This procedure was replicated 3 times. Carbon dioxide in the cheese milk was about 1600 ppm, which resulted in a milk pH of about 5.9 at 31 degrees C. The starter culture and coagulant addition rates were the same for both the CO(2) treatment and the control. The whey pH at draining of the CO(2) treatment was lower than the control. Total make time was shorter for the CO(2) treatment compared with the control. Cheese manufactured from milk acidified with CO(2) retained less of the total calcium and fat than the control cheese. The higher fat loss was primarily in the whey at draining. Preacidification with CO(2) did not alter the crude protein recovery in the cheese. The CO(2) treatment resulted in a higher added salt recovery in the cheese and produced a cheese that contained too much salt. Considering the higher added salt retention, the salt application rate could be lowered to achieve a typical cheese salt content. Cheese yield efficiency of the CO(2) treated milk was 4.4% lower than the control due to fat loss. Future work will focus on modifying the make procedure to achieve a normal fat loss into the whey when CO(2) is added to milk.

Whey proteins in general and specifically beta-lactoglobulin, alpha-lactalbumin, and immunoglobulins have been thought to decrease proteolysis in cheeses manufactured from concentrated retentates from ultrafiltration. The proteins found in whey are called whey proteins and are called milk serum proteins (SP) when they are in milk. The experiment included 3 treatments; low milk SP (0.18%), control (0.52%), and high milk SP (0.63%), and was replicated 3 times. The standardized milk for cheese making of the low milk SP treatment contained more casein as a percentage of true protein and more calcium as a percentage of crude protein, whereas the nonprotein nitrogen and total calcium content was not different from the control and high SP treatments. The nonprotein nitrogen and total calcium content of the milks did not differ because of the process used to remove the milk SP from skim milk. The low milk SP milk contained less free fatty acids (FFA) than the control and high milk SP treatment; however, no differences in FFA content of the cheeses was detected. Approximately 40 to 45% of the FFA found in the milk before cheese making was lost into the whey during cheese making. Decreasing the milk SP content of milk by 65% and increasing the content by 21% did not significantly influence general Cheddar cheese composition. Higher fat recovery and cheese yield were detected in the low milk SP treatment cheeses. There was more proteolysis in the low milk SP cheese and this may be due to the lower concentration of undenatured beta-lactoglobulin, alpha-lactalbumin, and other high molecular weight SP retained in the cheeses made from milk with low milk SP content.