Andy Montoya
Cheese is made from milk, and the type of animal that produced the milk can affect the way a cheese looks, smells and tastes. In factories, milk is typically collected from cows, but it can also come from sheep, goats, horses, camels, water buffalo, reindeer, and even yaks. Once the milk arrives at the factory, it is clarified using a centrifuge to remove small particles and cells, and the milk fat content is adjusted depending on the type of cheese being made. For harder cheeses, the milk is then heated and bacteria are added to produce lactic acid, which causes the milk to curdle. The curds are then cut, scalded and stirred before being drained of the remaining liquid, whey. The curds are then salted and pressed into moulds.
How Cheese is Made in Factories
| Characteristics | Values |
|---|---|
| Milk Source | Cow, Goat, Sheep, Buffalo, Reindeer, Horse, Water Buffalo, or a blend of these milks |
| Milk Pasteurization | Some factories use pasteurized milk, while others use unpasteurized milk with natural bacteria |
| Milk Standardization | Milk may be standardized to optimize the protein-to-fat ratio for better yield and quality |
| Milk Processing | Milk is heated, and cultures and rennet are added to initiate the curdling process |
| Curdling | A coagulant is added to cause milk to curdle and separate into curds and whey |
| Cutting Curds | Curds are cut into small pieces using knives, wires, or ladles to release whey and form a mat |
| Draining Whey | Whey is drained, leaving a mat of curds, which are then cut into sections and stacked |
| Cheddaring | Curd mats are flipped periodically to expel more whey and continue fermentation to reach the desired pH level |
| Milling | Curd mats are cut into smaller pieces and salted |
| Molding | Curds are placed into molds, pressed, and salted again to form a homogeneous texture |
| Aging | Cheese is aged for a period, impacting its flavor, texture, and aroma |
| Preservation | Cheese can be preserved through smoking, adding salt, or using preservatives and other additives |
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What You'll Learn
Milk preparation
Once the milk is selected and prepared, it is gently heated to separate it into curds and whey. This process can be done manually or with the help of machines. The curds are then cut into small pieces, releasing whey and affecting the moisture content of the final cheese. The smaller the curds, the more whey is released, resulting in a drier and harder cheese.
After cutting, the curds may be heated to separate them further from the whey. The whey is then drained, leaving behind a mat of curds. This mat is cut into sections and stacked, allowing the curds to "knit" together and form a tighter structure. This process, known as "cheddaring," is crucial in developing the final taste and texture of the cheese.
The next step in milk preparation is acidification. Cultures, called starter cultures or lactic acid bacteria (LAB), are added to the milk to initiate fermentation and increase acidity. These bacteria feed on lactose, producing lactic acid, which gives the cheese its characteristic flavour and texture. The specific cultures chosen depend on the desired characteristics of the cheese.
In addition to the starter cultures, coagulants such as rennet may be added to aid in the coagulation process. Rennet is an enzyme that causes the milk proteins to join together and form a firm curd. The amount of rennet and the speed of coagulation can be adjusted to create different styles of cheese.
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Acidifying the milk
The bacteria cultures used in this step are called lactic acid bacteria (LAB) as they primarily feed on lactose, the sugar present in milk, and produce lactic acid as a byproduct. This metabolic process of converting lactose into lactic acid is essential for the curdling of milk. The specific cultures chosen for this process contribute to the distinct flavour and textural characteristics of the final cheese product.
During the acidification process, the milk is gently warmed, and these selected bacteria are introduced. The bacteria work to ripen the milk, playing a vital role in determining the quality, flavour, body, and safety of the cheese. The amount and type of bacteria added, as well as the speed of acidification, will influence the style and characteristics of the resulting cheese.
For harder cheeses, a drier curd is desired, which is achieved by increasing the acidity of the milk. This is done by adjusting the amount of bacteria and altering the speed of the acidification process. The cheesemaker closely monitors the acidity and temperature of the milk during this step to ensure the desired outcome.
The acidification process is a delicate balance, as the bacteria not only contribute to the flavour and texture of the cheese but also help prevent the growth of spoilage organisms and pathogens. This step sets the foundation for the rest of the cheese-making process, emphasising the art and science behind the craft of cheesemaking.
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Curdling the milk
To begin the curdling process, milk is gently heated to a temperature approximating the body temperature of the animal from which the milk originated. This gentle heating initiates the separation of milk into curds and whey, with curds being the solid or gel-like substance and whey being the remaining liquid. The milk is then inoculated with lactic-acid-producing bacteria, which are essential for triggering curdling. These bacteria convert lactose (milk sugars) into lactic acid, causing a decrease in pH. This chemical change prompts the milk to curdle, and the specific bacteria used can significantly impact the final cheese's taste and smell.
The type of bacteria used in the starter culture blend varies depending on the desired cheese variety and production process. For example, Swiss cheese is made with bacteria that produce carbon dioxide when digesting lactose, resulting in the characteristic holes in the cheese. On the other hand, Limburger cheese, known for its strong odour, owes its smell to the same bacteria responsible for stinky feet, Brevibacterium linens.
In addition to the bacteria, an enzyme called rennet is typically added to assist with the curdling process. Rennet, derived from the fourth stomach of calves, contains proteolytic enzymes that promote coagulation. It helps to join up the proteins in the milk, allowing for complete coagulation and the formation of a firm curd. The interaction between the lactic acid and rennet is crucial, as the activity of rennet requires an acidic pH. Adjusting factors such as the amount of rennet, the speed of curd formation, and the acidity of the milk will influence the style of cheese that is ultimately produced.
After the curdling process, the curds are cut into chunks, with soft cheeses requiring larger pieces and hard cheeses being cut into smaller pieces. This cutting step can be performed manually or using specialised machines with sharp, multi-bladed wire knives. The curds may also be heated to accelerate the separation of curds and whey. The specific techniques employed during these steps can greatly impact the final texture and flavour of the cheese.
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Draining the whey
Cheddaring helps to expel more whey and allows the fermentation to continue until a pH of 5.1 to 5.5 is reached. The curd mats are cut into sections and piled on top of each other, then flipped periodically. This process helps the mats to "knit" together and form a tighter matted structure. For certain types of cheese, such as mozzarella, the curd is formed into loaves and then placed in a brine (saltwater solution).
The whey that is drained off during this process is a valuable source of protein and can be used in various ways. In the early days of large-scale cheese-making, whey was often fed back to the animals as a protein source. Today, it is marketed to companies that produce protein-enriched products. It can also be used in home projects such as lacto-fermentation, where it can be added to produce to speed up the fermentation process.
Additionally, whey can be used in cooking. It can be added to the soaking water of beans, used as a marinade for meat, or used to cook oatmeal, rice, or polenta. It can also be used as a substitute for buttermilk in recipes for pancakes, cornbread, scones, or bread. Whey can also be frozen for later use, although this is not suitable if one intends to make ricotta or a whey cheese from it.
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Aging the cheese
The ageing process is what gives cheese its unique flavour profile and texture. It is what differentiates fresh, cured, and aged cheese. Fresh cheeses are not aged and typically have a mild, soft, and creamy flavour. Cured or semi-soft cheeses have little to no rind and include Monterey Jack, Colby, and Havarti. Aged or hard cheeses, on the other hand, are cured and aged for extended periods, resulting in a firmer texture and more intense flavours.
Aging cheese occurs when bacterial culture is added to milk, creating lactic acid from lactose, which makes the milk sour. This process, known as affinage, can take anywhere from a few weeks to several months or even years. During the ageing process, cheese loses moisture, and enzymes and bacteria are allowed to develop. The temperature and humidity of the environment play a crucial role in influencing how quickly the cheese loses moisture. A consistent temperature and humidity are maintained in the location where the cheese is aged, often referred to as a cheese cave. The desired result of the ageing process will determine the specific methods used, such as surface-ripening washes or brines, or interior ripening by wrapping the exterior in cloth.
The length of the ageing process depends on the type of cheese. Softer cheeses like Muenster or mild cheddar have shorter ageing times, while semi-hard and hard cheeses like sharp cheddar or parmesan require longer ageing periods. The final taste of cheddar, for example, can range from mild with a buttery flavour to seriously sharp with a complex flavour and crumbly texture, depending on the ageing time.
The proper humidity in the cheese cave or container is usually maintained by the moisture within the cheese itself. If additional humidity is needed, this can be achieved by using a wet paper towel or a damp sponge placed in the container, or by using a shallow pan of water with a sterilized sponge. The size of the container is important, with a general rule of thumb being 40% cheese and 60% empty space.
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Frequently asked questions
The first step in making cheese is preparing the milk. Milk comes from animals such as cows, sheep, goats, and buffalo, and it can be pasteurized or raw.
The next step is to add bacteria culture to the milk so that it ferments and becomes more acidic.
After fermentation, the milk will curdle and form curds. The curds are then cut into small pieces to release the whey.
The curds are then processed by being stirred, cooked, and washed. They are then drained of the whey, leaving a mat of curds.
The flavour of the cheese is influenced by the type of bacteria culture used, the aging process, and the addition of salt or other ingredients.
