Andy Montoya
Mozzarella is a semi-soft, non-aged cheese with a unique texture and taste. It is made using the 'pasta filata' or 'stretched-curd' method, which involves heating and acidifying milk, curdling it to form curds, and then stretching and shaping the curds. The process of making mozzarella in a factory typically involves standardising the fat-to-casein ratio of the milk, coagulating the milk to form curds, heating and stretching the curds, shaping the cheese, and then packaging it. The specific steps and equipment used may vary depending on the factory and the type of mozzarella being produced, such as traditional mozzarella, low-moisture mozzarella, or smoked mozzarella.
How Mozzarella Cheese is Made in a Factory
| Characteristics | Values |
|---|---|
| Milk Type | Cow's milk, Italian buffalo's milk, goat's milk, sheep's milk |
| Milk Treatment | Pasteurized |
| Coagulation | Coagulated to form curds |
| pH Level | 5.2 |
| Cutting | Curds cut into small pieces |
| Heating | Mixed with hot water (around 95°C) |
| Stretching | Curds stretched to form long ropes of cheese |
| Shaping | Molded into desired shape (balls, rolls, loaves) |
| Cooling | Immersed in cool water |
| Brining | Soaked in brine (salt and acid solution) |
| Packaging | Vacuum-sealed packages or governing liquid |
| Storage | Refrigerated |
| Shelf Life | Up to 6 weeks in chilled vacuum packs |
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What You'll Learn
Milk selection: cow, buffalo, goat or sheep
The type of milk used to make mozzarella cheese depends on the desired flavour and texture, as well as the region in which it is produced.
Cow's Milk
Cow's milk is the most common type of milk used in cheesemaking around the world. It is versatile and earthy, with grassy and sweet flavours depending on the cow's diet and breed. Cows produce a large volume of milk, about 12-20 gallons per day, but due to its high water content, not much cheese is derived from this milk. Cow's milk is used to make traditional mozzarella, as well as low-moisture part-skim mozzarella, which is widely used in the food service industry.
Buffalo's Milk
Mozzarella di bufala is a specific kind of mozzarella made in the Campania region of Italy using Italian buffalo milk. It is also produced in the provinces of Naples, Caserta, and Salerno, as bocconcini alla panna di bufala. Buffalo milk is significantly higher in fat and protein than cow's milk, and its flavour is influenced by the fodder consumed by the buffalo. Water buffalo produce a relatively small amount of milk, about 4-6 gallons per day.
Goat's Milk
Goat's milk has a very goaty smell and flavour, and the resulting cheese can be minerally, sour, tangy, and even a bit spicy. Goat's milk is very rich and high in nutrients, with about 2 gallons of milk produced per day. Mozzarella made from goat's milk is less common and there are few producers.
Sheep's Milk
Sheep's milk is yellow and creamy, with a slight shimmer due to its high protein and fat content. The resulting cheese is often slightly oily and golden in colour, with nutty, barnyard-like flavours and scents of dry grass. Sheep produce about 2 quarts of milk per animal, and due to its high fat and sugar content, more cheese can be made from sheep's milk than from cow's or goat's milk. Mozzarella pecorella is a type of mozzarella made from sheep's milk in Sardinia, Lazio, and Abruzzo.
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Pasteurisation and coagulation
Traditional mozzarella is made using pasteurized and standardized milk. Pasteurization is the process of heating milk to eliminate bacteria and other unwanted substances. This process extends the shelf life of the milk and the cheese made from it. In the context of mozzarella, pasteurization also influences the moisture content of the cheese. Higher pasteurization temperatures are used to increase moisture retention, which is particularly important when manufacturing low-fat mozzarella cheese.
The pasteurized milk is then coagulated to form curds. Coagulation is the process of thickening the milk and forming curds by adding an enzyme or an acid to the milk. The two basic ways to make mozzarella are direct acidification of the milk to form the curds or the culture/rennet method. In the direct acidification method, more acid is slowly added to the milk to prevent localized coagulation. In the culture/rennet method, the milk is cultured with starter cultures before coagulation. After coagulation, the curds are cut into small pieces and mixed with hot water.
The curds are then stretched and "strung" or "spun" until long ropes of cheese form. This process is called the pasta filata method, which means "spun paste" or "stretched curd" in Italian. The stretching causes a significant rearrangement in the curd structure, creating mozzarella's unique textural and melting characteristics. The curds are then formed into balls by machine or by hand and are then tossed into cold water to maintain their shape while they cool.
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Curd cutting and cooking
The curd-cutting and cooking process is a critical step in the manufacture of mozzarella cheese. The size of the curds and the degree of heating will determine how much whey is expelled, which will significantly impact the final cheese. The cutting of the curds must be done uniformly: make several parallel cuts vertically, then several parallel cuts horizontally, creating a grid-like pattern. The number of knives used and the cooking temperature will also influence the size of the curd particles. Larger curd particles will retain more moisture during cooking, so a gentler, timed agitation is used to reduce the risk of curd shattering.
The curds are then heated to a temperature of 105°F. They should be stirred slowly as they warm, but it is important not to break them up too much. The curds will eventually clump together and separate from the whey. The cooking temperature can be increased to reduce moisture and create a firmer body of cheese. The cheese pH is critical at this stage, as it influences proteolysis, which is essential for developing the melt and flavour of mozzarella.
The curds are then removed from the heat and stirred gently for another 5 minutes. They are then scooped out with a slotted spoon and placed into a strainer to separate them from the whey. The curds are then placed into hot water, and the process of stretching and pulling the curd is repeated several times until a smooth, glossy ball is formed. This ball is then placed into cold water, and the process is repeated for the next batch.
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Shaping and moulding
To initiate the shaping process, the curds are immersed in hot water, typically around 95°C. This temperature threshold is essential for achieving the desired consistency of the curds. Once the curds reach the ideal smooth and elastic texture, they are ready for moulding. The moulding process can be done by hand or with the assistance of machinery, depending on the scale of production and the cheesemaker's preferences.
The curds are then formed into balls, the traditional shape for mozzarella. These balls are then quickly placed in cold water to help them retain their shape as they cool down. This rapid cooling step is crucial to prevent the cheese from becoming mushy or losing its desired texture. The size of the mozzarella balls can vary, ranging from 80 to 100 grams or even up to 1 kilogram for larger options.
While the spherical shape is the most common for mozzarella, other traditional shapes are also available, such as bocconcini (small balls), treccia (braided shape), and nodini (knot-shaped). These different shapes add variety to the presentation and usage of mozzarella in dishes. The shaped mozzarella is then salted, either by soaking it in brine (a solution of salt and acid) or by dry salting during the kneading process. This step not only enhances the flavour but also acts as a preservative, extending the shelf life of the cheese.
After shaping and moulding, the mozzarella is packaged. Fresh mozzarella is typically packaged dry in vacuum-sealed plastic or immersed in a governing liquid called "latte". It can be sold salted or unsalted, depending on the producer and market preferences. The packaging and preservation techniques help maintain the freshness and quality of the cheese during storage and transportation.
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Packaging and distribution
The packaging process for mozzarella cheese can vary depending on the specific requirements and preferences of the manufacturer. However, some common steps and considerations in the packaging process include:
- Standardization of cheese milk to a specific casein-to-fat ratio is important to increase yield and improve body and texture.
- The use of vacuum sealing or chilled brine solutions to extend the shelf life of the product. Mozzarella can keep for up to 6 weeks in chilled vacuum packs.
- The application of anti-caking agents to retard clumping and enhance the appearance of shredded mozzarella.
- The use of antimicrobial packaging systems, such as lemon extract combined with brine and a gel solution made of sodium alginate, to increase the shelf life of the product.
- The inclusion of liquid in the packaging to maintain the moisture content of the cheese.
- The use of polyethylene pouches for packaging unsalted cheese, which can extend the shelf life to 3 months when stored at 8-10°C.
Once packaged, the distribution of mozzarella cheese involves transporting the product from the factory to various distribution channels, such as grocery stores, specialty stores, and delis. The distribution process aims to ensure that the cheese reaches consumers in a timely and efficient manner while maintaining its quality and freshness.
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Frequently asked questions
The process of making mozzarella cheese in a factory involves three main stages: heating and acidifying the milk, curdling the milk to form curds, and stretching the curds and forming them into balls. The milk is heated and mixed with citric acid and rennet, and then coagulated to form curds. The curds are then cut into small pieces, mixed with hot water, and stretched until they form long ropes of cheese. The cheese is then shaped into balls, cooled, salted, and packaged.
Mozzarella cheese is traditionally made from the milk of water buffalo, specifically the Italian Mediterranean buffalo breed. However, most mozzarella cheese found in supermarkets is made from cow's milk due to the higher availability and lower cost of cow's milk. Sheep's milk mozzarella is also available in some areas, and a small number of producers make goat's milk mozzarella.
Fresh mozzarella is a semi-soft, non-aged cheese that is typically eaten fresh and has a mild, milky flavor. It is known for its soft, silky texture and is usually formed into balls. Shredded mozzarella, on the other hand, is typically aged and has a firmer texture, making it suitable for baking and melting on pizzas and other Italian dishes.
Fresh mozzarella has a very short shelf life and is typically consumed within a day of production. It can be stored in brine or whey for up to a week or packaged in vacuum-sealed plastic for a longer shelf life. Low-moisture mozzarella can be refrigerated for up to a month, while shredded low-moisture mozzarella may have a shelf life of up to six months.
