Sliced Cheese: A Step-By-Step Guide To Its Making

how is sliced cheese made

Sliced cheese, often referred to as American cheese, is a processed cheese product made by blending real cheese with other texture- and flavour-altering ingredients. The first commercially available, shelf-stable, sliced processed cheese was introduced in 1950 by Kraft Foods Inc. and has since become a staple in U.S. households, especially for cheeseburgers and grilled cheese sandwiches.

Characteristics Values
First Invented Switzerland, 1911
First Commercially Available US, 1950s
Typical Ingredients Cheese, vegetable oils, unfermented dairy ingredients, salt, food colouring, sugar, calcium phosphate, palm oil, water, whey powder, modified potato starch, milk proteins, emulsifying salts
Typical Characteristics Melts easily, cooks evenly, distributes/stretches smoothly, resists congealing
Typical Products Kraft Singles, Dairylea, The Laughing Cow, Provel, Cheez Whiz, Velveeta

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History of sliced cheese

The history of sliced cheese is deeply intertwined with the history of processed cheese, which is made from cheese mixed with an emulsifying agent (a calcium chelator) and other additional ingredients such as vegetable oils, unfermented dairy ingredients, salt, food colouring, or sugar. Processed cheese was first developed in Switzerland in 1911 by Walter Gerber and Fritz Stettler, who added sodium citrate to melted Emmentaler cheese. In 1916, Canadian-American businessman James L. Kraft applied for the first U.S. patent for a method of making processed cheese, and in the 1950s, Kraft introduced Kraft Deluxe, the first commercially packaged cheese slices.

During World War II, Kraft focused on producing pre-served butter spreads and canned cheese for the armed forces, and in 1947, they tested out their new cheese slices in Detroit. However, sales were disappointing as customers didn't realise that the cheese was pre-sliced. In 1956, Clearfield Cheese Co. introduced the first individually wrapped cheese slices in the US, and these became ubiquitous in US households, commonly used for cheeseburgers and grilled cheese sandwiches. In 1965, Kraft Singles, as we know them today, began to appear in stores, and they remain one of America's favourite cheeses.

Processed cheese has several advantages over natural cheese, including a longer shelf life, resistance to separating when cooked (meltability), and a uniform look and physical behaviour. Its mass-produced nature also makes it much lower cost and enables industrial-scale production volumes, lower distribution costs, a steadier supply, and faster production time compared to traditional cheeses.

In the United Kingdom, processed cheese is typically sold in individually wrapped slices, often referred to as "singles", although the actual Kraft Singles product is not usually available in the UK. In the United States, the term "processed cheese" refers to products with the highest cheese content, while terms like "cheese food" or "cheese spread" refer to products with lower amounts of cheese. Due to the high proportion of additives, some products made in this way cannot legally be labelled as cheese in many countries, and competitors lobbied unsuccessfully to require processed cheese to be labelled as "embalmed cheese".

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How processed cheese is made

Processed cheese is made from a blend of different cheeses, most often Colby and cheddar, with additional ingredients such as vegetable oils, unfermented dairy, salt, food colouring, sugar, and preservatives. The first step in making processed cheese is to cut the selected blocks of cheese manually or mechanically into small slices suitable for the mincing machines. The slices are then shredded through special mincing machines into fine granules, which are then ground through roller mills to make them soft and smooth. The granules are then placed in a processing kettle and heated to a temperature of at least 75°C to ensure complete pasteurization. Agitation during processing is crucial for the complete emulsification of the cheese blend.

Processed cheese was first developed in Switzerland in 1911 when Walter Gerber and Fritz Stettler added sodium citrate to melted Emmentaler cheese, inspired by fondue and cheese sauces. They discovered that the emulsified cheese sauce could be re-cooled into a solid, resulting in a product with a longer shelf life. In 1916, Canadian-American James L. Kraft applied for the first U.S. patent for a method of making processed cheese, and Kraft Foods Inc. introduced the first commercially available, shelf-stable, sliced processed cheese in 1950.

The addition of a calcium-sequestering agent, commonly known as an "emulsifying salt," is a key step in the production of processed cheese. This agent prevents calcium from holding the casein network together, allowing smaller groups of linked casein molecules to mix into the fat when melted, resulting in a smooth and homogeneous texture. The high proportion of additives in processed cheese means that some products made in this way cannot be legally labelled as cheese in many countries.

Processed cheese is often sold in blocks or packs of individual slices, separated by wax paper or thin aluminium foil coated with a special lacquer. It has a distinct milder flavour profile than natural cheeses, making it appealing to consumers encountering cheese for the first time. It also has a longer shelf life due to its pasteurization, hot-filling, and packaging processes.

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The emulsifying process

In traditional cheese, individual fat globules are trapped within a network of casein, held together by calcium. When traditional cheese is heated for an extended period, the calcium holds the casein network together, leading to the formation of lumps composed of protein gel and liquid fat.

To create a smoother, more homogeneous product, processed cheese introduces a calcium-sequestering agent, commonly known as an "emulsifying salt." These salts, including sodium phosphate, potassium phosphate, tartrate, and citrate, prevent calcium from binding the casein molecules. As a result, smaller groups of linked casein molecules form, allowing them to mix more effectively with the fat. This results in the formation of microscopic droplets instead of large lumps, creating a uniform and creamy texture.

Additionally, the emulsifying process allows for the incorporation of various ingredients, such as vegetable oils, unfermented dairy, salt, food colouring, and sugar. These additional ingredients not only modify the flavour and texture of the cheese but also contribute to its overall stability and longevity.

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Packaging and presentation

The colour and design of the packaging also play a significant role in the presentation of sliced cheese. Bright, eye-catching colours are often used to attract attention on supermarket shelves, with red, yellow, and orange being common choices. Some brands may also use transparent packaging to showcase the cheese inside, particularly if it is a higher-quality product. Additionally, the country of origin or the specific type of cheese may be featured on the packaging to give consumers a sense of the cheese's authenticity or unique characteristics.

In terms of shape, the iconic triangle-shaped cheese slice, often individually wrapped in foil, has become synonymous with processed cheese. This shape not only makes the slices easy to stack and pack but also provides a unique and distinctive look. Other shapes include rectangular blocks or circles, depending on the brand and variety of cheese.

The branding and marketing of sliced cheese can also influence its packaging and presentation. For instance, some brands may use characters or mascots on the packaging to appeal to a younger demographic or create a sense of fun and approachability. Others may emphasise the convenience or versatility of their product, highlighting its suitability for various dishes and occasions.

Lastly, the nutritional information, ingredients, and potential allergens are crucial aspects of the packaging and presentation of sliced cheese. By law, manufacturers must disclose the contents of the product, allowing consumers to make informed choices. This information is typically presented in a tabular format on the back or side of the package, detailing calories, fat content, protein, and the presence of common allergens such as dairy or soy.

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Sliced cheese in the US

Sliced cheese is a staple in many households across the United States, with its unique place in American cuisine. The term "processed cheese" in the US refers to products with the highest cheese content, made from cheese, up to 5% milk fat, and other allowed additives. The first commercially available, shelf-stable, sliced processed cheese was introduced in 1950 by Kraft Foods Inc. and has since become a household staple.

The process of making sliced cheese involves a combination of real cheese and texture- and flavor-altering ingredients. Chunks of cheese, typically cheddar, Colby, or similar varieties, are melted down with a liquid and an emulsifying agent, such as sodium citrate, to prevent the cheese from separating. This mixture is then molded into bricks or slices and packaged. The addition of sodium citrate gives American cheese its characteristic creamy texture and low melting point, making it ideal for use in dishes like cheeseburgers, grilled cheese sandwiches, and macaroni and cheese.

American cheese, often sold as individually wrapped slices or singles, has been criticized for being full of chemicals and not real cheese. However, it is important to note that American cheese is made with a significant amount of milk and cheese, and its manufacturing process is regulated by the FDA to ensure food safety. The term pasteurized process American cheese is used when the product is made from more than one type of cheese.

In addition to its versatility in various dishes, American cheese is also valued for its consistent quality, affordable price, and long shelf life. The mass production of processed cheese has made it dramatically more affordable than conventional cheese, contributing to its widespread adoption in American households.

Frequently asked questions

Processed cheese is made by blending real cheese with texture- and flavor-altering ingredients. It is made with the goal of being meltable without the fat separating from the protein.

Processed cheese is made from cheese mixed with an emulsifying agent (a calcium chelator) and other ingredients, such as vegetable oils, unfermented dairy ingredients, salt, food coloring, or sugar.

Processed cheese is often sold in blocks and packs of individual slices, often separated by wax paper, or with each slice individually wrapped by machine.

Processed cheese is not the healthiest option. It is made with additives and artificial ingredients, and it is not 100% cheese. However, it is fine to consume processed cheese in moderation.

Processed cheese is convenient, affordable, and has a longer shelf life than traditional cheese. It also melts easily and has a consistent texture and flavor.

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