Andy Montoya
Cheese crisps, also known as frico, are crunchy, lacy pieces of fried cheese that can be formed into bowls, chips, or crunchy garnishes. They are made by grating or shredding cheese, forming it into circles on a pan or baking sheet, and baking until stiff and airy. The simple recipe has an infinite flavor potential and a rich history. In factories, the process is similar, with whole cheeses grated and shreds distributed onto baking sheets in industrial ovens.
How are cheese crisps made in a factory?
| Characteristics | Values |
|---|---|
| Ingredients | Hard cheese such as Parmesan, Asiago, Manchego, or Cheddar |
| Shape | Thin, lacy wafers |
| Manufacturing Process | Whole cheeses are grated, shreds are distributed onto baking sheets, and heat is applied in industrial ovens |
| Flavor | Salty, tangy, savory |
| Texture | Crispy, crunchy |
| Form | Chips, bowls, or crunchy garnish |
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What You'll Learn
Industrial production methods
Grating or Shredding:
The process begins with whole cheeses, which are grated or shredded into fine or coarse pieces, depending on the desired texture and cooking method. Some brands may opt for a combination of fine and coarse shreds to create a varied texture.
Mixing and Flavouring:
The grated cheese can then be mixed with various ingredients to enhance flavour and texture. Some manufacturers choose to keep it simple, using only cheese, while others may add small amounts of grains or seeds, such as quinoa, oat bran, or rice, to create a unique flavour profile. Additionally, herbs, spices, or other savoury ingredients can be mixed in to create flavoured cheese crisps.
Shaping and Portioning:
The cheese mixture is then portioned out onto baking sheets or into skillets. For baking, rounded teaspoons of the mixture are dropped onto parchment paper-lined sheets, forming neat mounds. When using a skillet, the cheese is spread into thin, even circles, ensuring a uniform thickness to allow even cooking.
Cooking:
The cooking process involves applying heat to the cheese portions. In industrial settings, large ovens are used to bake the cheese until it is stiff, airy, and golden brown. The cooking time and temperature vary depending on the cheese variety and the desired crispness. Alternatively, skillets or fryers can be used to cook the cheese portions, creating a lacy, fried texture.
Cooling and Packaging:
After cooking, the cheese crisps are allowed to cool slightly before being loosened from the baking sheets or skillets with spatulas. They are then packaged for retail sale. The packaging process involves sealing the crisps in airtight containers or bags to maintain freshness and crispness.
Cheese crisps have gained popularity due to their simple yet versatile nature, high protein and low-carb content, and, of course, their cheesy flavour. Manufacturers have been cautious not to associate the product with specific diet trends, aiming for a stable hold in the market.
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Ingredients and flavouring
Cheese crisps are made from a variety of cheeses, including Parmesan, Asiago, Manchego, and cheddar. These cheeses are shredded, grated, or finely chopped and then baked until stiff and airy, with a lacy texture. The key to achieving the right crispness is to ensure that all the moisture is baked out of the cheese. This process also intensifies the flavour.
While some brands offer cheese crisps that contain only cheese, others include additional ingredients such as quinoa, oat bran, and rice. These added ingredients may provide a crunchier texture or enhance the flavour of the cheese crisps. However, the amount of these additional ingredients is usually minimal, as the primary focus of cheese crisps is the cheese itself.
When it comes to flavouring, cheese crisps offer a wide range of options. Herbs such as rosemary, thyme, and parsley can be added to provide a savoury flavour. For those who prefer a spicy kick, ingredients like garlic, chilli powder, or pepper flakes can be mixed into the cheese before baking. Other creative combinations include sun-dried tomatoes with thyme or dried apples with black pepper. These flavourings not only enhance the taste but also add sparks of colour to the cheese crisps.
The versatility of cheese crisps extends beyond their flavour; they can be served in various forms. Some people enjoy them as a standalone snack, similar to potato chips. Others might crumble them over a salad, use them as a dip, or even sandwich them with a savoury jam. Cheese crisps can also be formed into bowls or crunchy garnishes, adding a decorative touch to dishes.
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Preparation and cooking
Cheese crisps are made in factories by baking grated or shredded cheese in industrial ovens. The process is simple: cheese is grated, shreds are distributed onto baking sheets, and heat is applied. However, the specific temperatures and timings vary depending on the company and the type of cheese used.
To make cheese crisps, you need to start with shredded or grated cheese. You can use any hard cheese, such as Parmesan, Asiago, Manchego, or cheddar, as these varieties retain enough of their shape to create a "lacy" texture while still melting enough for the crisp to hold together. The authentic flavor of cheese crisps can be intensified by baking all the moisture out of the cheese.
Once you have your shredded cheese, you can add other ingredients to enhance the flavor. For example, you can mix in herbs like rosemary, thyme, or parsley, or spices like garlic powder, chili powder, or black pepper. You can also get creative and experiment with different combinations of cheeses and additives.
After mixing the cheese with any desired additives, it's time to form the cheese into circles on a baking sheet. Place about 2 tablespoons of shredded cheese in even circles, leaving about 2 inches (5 cm) between each circle, as they will spread as the cheese melts. Avoid making dense mounds of cheese, which can prevent uniform crisping.
Finally, bake the cheese circles in the oven until they are stiff, airy, and golden brown. The baking time will vary depending on the type of cheese and additives used, but it typically takes around 8-10 minutes. Once they are cooled slightly, use a metal spatula to loosen them from the baking sheet.
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Cooling and packaging
Once the cheese crisps are baked and ready, they need to be cooled and packaged. The cooling process is important as it can affect the physical and rheological properties of the cheese crisp. The rate of cooling can impact the fat crystallization, incorporation of recombinant fat globules, and protein-protein interactions.
The cheese crisps are typically placed on a paper towel-lined cutting board or a cooling rack to cool. This allows the crisps to reach room temperature and prevents them from becoming too gooey. It is important not to over-bake the cheese crisps as they can develop an unpleasant charred flavor.
After cooling, the cheese crisps are packaged. In the early days of crisp manufacturing, crisps were sold in bulk from barrels or glass display cases, or supplied in tins. However, in 1927, Laura Scudder revolutionized the industry by introducing wax paper bags for her potato chips. The bags were sealed with glue and helped keep the crisps fresher for longer. This innovation, along with the development of cellophane packaging, enabled mass production and extended shelf life. Today, potato crisps are commonly sold in foil bags, while more premium products may be packaged in luxury display boxes.
Proper packaging ensures the cheese crisps remain fresh and protects them from external factors that could affect their quality. The packaging material, format, and shape can vary depending on the composition and processing conditions of the cheese crisps.
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History and origins
The history of crisps can be traced back to the nineteenth century when potatoes were first transformed into the crispy, salty snack that we know today. According to folklore, the chef George Crum created the first crisps in a fit of fury after a customer complained that his fried potatoes were too thick and mushy. Crum sliced the potatoes thinly, crisped them in oil, and seasoned them with salt. This simple act of culinary rebellion laid the foundation for the global crisp phenomenon.
Over the years, the crisp industry evolved and expanded, with manufacturers experimenting with new flavours, production methods, and packaging innovations. In the United Kingdom and Ireland, crisp brands such as Tayto, Seabrook, Tyrrells, and Walkers gained popularity and market share. The crisp sector also faced scrutiny for its environmental impact, particularly regarding packaging waste, leading to the development of more sustainable solutions.
Cheese crisps, in particular, have an interesting history that spans multiple continents. The concept of baking shredded cheese into crispy wafers, known as "frico," originated in northeastern Italy. Frugal Friulian home cooks would grate the rinds of their local Montasio cheese onto hot skillets, creating lacy cheese crisps. Over time, frico made its way into fine dining establishments and upscale bars, where it was used as a garnish or stylish nibble.
In the 1980s, pre-packaged frico, rebranded as "cheese crisps," began appearing in gourmet specialty shops. This marked the beginning of cheese crisps as a standalone snack food category. Brands such as Whisps, Parm Crisps, Just the Cheese, Moon Cheese, and Sonoma Creamery Crisps entered the market, offering high-protein, low-carb, gluten-free options with real cheese as the main ingredient.
Today, cheese crisps have established a strong foothold in the American market, with multiple brands vying for shelf space and annual sales approaching half a billion dollars. The success of cheese crisps lies not only in their flavour and texture but also in their perceived health benefits, with manufacturers promoting the high-protein and low-carb nature of their products.
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Frequently asked questions
Cheese crisps are made of cheese that has been baked or fried until crispy. Some common types of cheese used include Parmesan, Asiago, Manchego, and cheddar.
To make cheese crisps in a factory, whole cheeses are grated and the shreds are distributed onto baking sheets. Then, heat is applied in industrial ovens. The exact temperature and timing vary by company and cheese variety.
Popular brands of cheese crisps include Whisps, Parm Crisps, Just the Cheese, Moon Cheese, and Sonoma Creamery Crisps.
