Cheese Puffs: A Crunchy, Cheesy Snack Explained

Cheese puffs are a popular snack food made from corn and flavoured with cheese or cheese-flavoured additives. They are also known as cheese curls, cheese balls, cheesy puffs, corn cheese, and corn curls. The process of making cheese puffs starts with picking the right type of cornmeal, which should be finely textured with a low moisture content. The cornmeal is then cooked by continuously mixing it while applying a fine mist of hot water. Once the correct consistency is achieved, the mixture is processed by an extruding machine, which propels the cornmeal mixture using an auger or tapered screw. As the cornmeal exits the machine, it solidifies, expands, and puffs. The shape of the die used in the extruding machine determines the shape of the cheese puffs, which can be ball-shaped, curly, straight, or irregularly shaped.

Cheese puffs were invented by accident in the 1930s

Cheese puffs, also known as cheese curls, cheese balls, cheesy puffs, corn cheese, or corn curls, are a popular snack that was invented in the 1930s. The story of their invention is an interesting one, involving a happy accident and a creative thinker.

During the 1930s, the Flakall Corporation of Beloit, Wisconsin, was a producer of animal feed. They used a special grinder machine to turn corn into flakes, maximizing the amount of grain that could be turned into feed. However, this grinder would occasionally clog, and employees would have to put moistened corn through the machine to clear the jam. On one fateful day, the moistened corn came into contact with the heat of the machine, and instead of flaking, it puffed up.

Enter Edward Wilson, a forward-thinking employee at Flakall. He noticed these strings of puffed corn oozing from the flaking machines and saw potential. Wilson took the puffed corn, added seasoning, and created a tasty treat he called Korn Kurls. Thus, a new snack was born, and the world of food was forever changed.

The Flakall Corporation recognized the potential of this accidental invention and transitioned into the human food product industry. They changed their name to the Adams Corporation and commercialized the product, Korn Kurls, in 1946. However, they were not the only ones with claims to the cheese curl throne. Other companies, like the Elmer Candy Corporation, also developed similar products and disputed the invention of cheesy snacks.

The process of creating cheese puffs involves selecting the perfect type of cornmeal with a low moisture content to ensure a pleasant texture. The cornmeal is then cooked by continuously mixing it while applying a fine mist of hot water. The cooked cornmeal is then extruded through a die, causing it to solidify, expand, and puff. The die's shape determines the form of the cheese curls, which can be ball-shaped, curly, straight, or irregularly shaped.

They are made from corn and flavoured with cheese or cheese-flavoured additives

Cheese puffs are made from corn and flavoured with cheese or cheese-flavoured additives. The process of making cheese puffs starts with selecting the perfect type of cornmeal, which should have a fine texture and low moisture content (6-10%) to ensure a pleasant eating experience. The cornmeal is then cooked by continuously mixing it with a fine mist of hot water to ensure even cooking.

Once the desired consistency of the cooked cornmeal is achieved, it is processed by an extruding machine, which propels the cornmeal mixture through a die that forms the specific shape of the cheese puffs. The high pressure of the extruding machine causes the cornmeal to be in a liquid state, but as soon as it exits the machine, it solidifies, expands, and puffs up. The die used can create various shapes, including balls, curls, straight, or irregular shapes.

After the cheese puffs are extruded, they are still in a raw state and need to be dried. They are transported to a drying area, which consists of a series of ovens with different stations, including flavouring stations. During transport, any deformed, too small, or large particles are removed, leaving only the perfectly shaped pieces.

The entire process of creating cheese puffs in an industrial setting is closely monitored to ensure health and safety quality control, with a particular focus on the cornmeal's moisture and grit size. The basic ingredients of cheese puffs are cornmeal and water, but the process of creating them is complex, making it challenging for individuals to replicate at home.

The cornmeal must be finely textured with low moisture content

The cornmeal used in cheese puffs must be finely textured and have a low moisture content. This is because the texture and moisture content of the cornmeal directly impact the final product's texture and mouthfeel. Cornmeal that is too coarse or gritty will result in an unpleasant, undesirable mouthfeel. To ensure a fine texture, the cornmeal is ground and then tested for grit size. This is done through a process of sieving and weighing, where the grain remaining on the sieves is considered too coarse, and the amount of usable grain is calculated.

Moisture content is another critical factor in the cheese puff-making process. The cornmeal should have a moisture content of between 6-10%. Too much moisture will make the final product soggy, while too little moisture will result in light, long, straight puffs. To achieve the desired moisture content, the cornmeal is cooked by continuously mixing it while applying a fine mist of hot water. This method ensures even moisture distribution throughout the cornmeal structure.

The moisture content of the cornmeal also plays a crucial role in the extrusion process. When the cornmeal mixture is pushed through the extrusion chamber, it is subjected to high pressure and temperature, causing the moisture to turn into steam. This change in state from liquid to steam contributes to the expansion and puffing of the cornmeal dough as it moves through the die. Therefore, maintaining the correct moisture content is essential for achieving the desired puffed texture of cheese puffs.

The drying process further emphasizes the importance of moisture content. After extrusion, the cheese puffs are still moist and need to be dried. The moisture content at this stage affects the drying time and temperature required to achieve the final crispy texture. If the moisture content is too high, the drying process may take longer, or the temperature may need to be increased, potentially affecting the colour and flavour of the cheese puffs.

In summary, the fine texture and low moisture content of cornmeal are crucial in the production of cheese puffs. These factors impact the mouthfeel, shape, and texture of the final product, as well as the manufacturing process, particularly the extrusion and drying stages. By carefully controlling the texture and moisture content of the cornmeal, manufacturers can ensure the desired characteristics of cheese puffs are achieved.

The cooked cornmeal is then processed by an extruding machine

The collettes still contain between 6-10% water, and they are conveyed to the drying area. The drying area consists of a series of ovens with different stations, including flavouring stations. During transport, deformed or substandard collettes are separated, and only the perfect pieces are left on the conveyor. The extruded cheese curls can be seasoned with a mixture of oils, flavours, spices, and colours, which are sprayed on the curls as they tumble in a barrel. Once flavoured, the curls are dried and packaged. The oven temperature is carefully controlled to ensure the moisture is removed without darkening the collettes.

The drying area is where flavourings are added

The drying area is where the magic happens and the distinctive flavour of cheese puffs is added. At this stage, the cheese curls are still raw and moist, and need to be dried out. The drying area is not a single oven, but a series of them, with different stations in between. This is where the flavourings are added. The curls are conveyed continuously through the dryer, which is hot enough to remove the moisture but not to darken the cheese curl.

The flavour reel is a critical part of the process. Oils, flavours, spices and colour are mixed together in a tank and then sprayed onto the curls as they tumble in a barrel. This is how the cheese flavouring is added, as well as any other desired flavours and colours. The distinctive orange hue of cheese puffs is often achieved at this stage. The flavour reel process ensures an even coating of the flavourings and colourings.

The moisture content of the cornmeal is critical to the end product. Too much moisture will make the cheese puffs soggy, while too little will result in light, long, straight puffs. The moisture content of the cornmeal is tested before the cooking process, and the moisture level of the cheese curls is also monitored after they have been extruded and cut. The drying process is carefully managed to ensure the correct level of moisture is removed.

The drying process is also where any quality control measures are implemented. Deformed or imperfect cheese curls are removed, and only the perfect pieces continue on the conveyor to the drying ovens. The entire process of creating cheese puffs in an industrial environment is closely monitored to ensure health and safety quality control standards are met.

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