Andy Montoya
Cheese curls, also known as cheese puffs, cheese balls, corn curls, or corn cheese, are a popular snack food made from corn and flavoured with cheese or cheese-flavoured additives. The basic ingredients of cheese curls are cornmeal and water, which are mixed together and put through an extruding machine to form their distinctive shape. They are then baked or fried and coated with a mixture of cheese or cheese-flavoured powders, oils, and spices.
| Characteristics | Values |
|---|---|
| Ingredients | Corn, cornmeal, water, oil, cheese, cheese powder, acid whey powder, artificial cheese flavor, salt, spices, disodium phosphate, autolyzed yeast extract, annato and turmeric extracts (color), lactic acid, citric acid, natural flavor |
| Manufacturing Process | Corn dough is pushed through a die using an extruder, baked, and then coated with oil and cheese powder |
| Texture | Crispy, crunchy, airy |
| Shape | Ball-shaped, curly, straight, irregularly shaped |
| Nutritional Value | High in calories and fat, low in fiber and protein |
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What You'll Learn
Cheese curls are made from cornmeal and water
Cheese curls are a popular snack food, especially in the US, where they are commonly given to children in their school lunches. They are made from a simple combination of cornmeal and water, although the process of creating them is quite complex.
The cornmeal used to make cheese curls must be very finely textured with a low moisture content of 6-10%. This is because too much moisture will cause the end product to become soggy. The cornmeal is mixed with water to form a dough, which is then put through an extruder machine. This machine uses heat, moisture, and pressure to work the dough, pushing it through a die to form its distinctive shape. The shape of the die will determine whether the cheese curls are ball-shaped, curly, straight, or irregularly shaped.
The uncooked cheese curls that come out of the die are called collettes. These collettes are then baked in a large oven, and it is at this stage that they begin to puff up. After baking, the collettes are sprayed with vegetable oil and coated with cheese powder, or a mixture of oils, flavours, spices, and colours. The additional layer of oil is important, as it helps the other flavourings to stick. The collettes are then dried, packaged, sealed, and stored for transport.
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They are then baked or fried
Once the collettes have been extruded and cut, they are still in a raw state and need to be cooked. Depending on the product, cheese curls are then baked or fried. Herr's Cheese Curls, for example, are baked, not fried, resulting in a lighter and fluffier texture.
The collettes are conveyed to the drying area, which consists of a series of ovens with different stations, including flavouring stations. During transport, deformed or imperfect collettes are separated, and only the perfect pieces are left on the conveyor.
The flavouring process involves tumbling the collettes in a rotating barrel while spraying them with a mixture of oils, flavours, spices, and colours. An additional layer of oil is necessary on the outside of the curls. The oils used can include palm olein oil, safflower oil, and sunflower oil. The flavours can include cheddar cheese, acid whey powder, artificial cheese flavour, and salt.
After drying and flavouring, the curls are packaged, sealed, and stored for transport. The drying process is carefully monitored to ensure the cheese curls are within health and safety quality control tolerances. The dryer is usually about 140° F (59.9° C), removing moisture without darkening the collette. The collettes typically take around five minutes to dry and are reduced to between 1-2% moisture.
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Flavourings are added after baking/frying
Cheese curls are made from cornmeal and water, but the process of creating them is quite complex. The cornmeal must be very finely textured with a low moisture content of 6-10% so that it is pleasant to eat. The cornmeal is then mixed with water to form a dough, which is put through an extruder machine. This machine uses heat, moisture, and pressure to work the dough, which is then pushed through a die to form its distinctive shape. The uncooked cheese curl that comes out of the die is called a collette.
The collettes are then baked in a large oven and sprayed with vegetable oil. At this stage, they are still in a fairly raw state and are conveyed to a drying area. It is after this stage that flavourings are added. The flavourings are added in a rotating barrel where the curls are tumbled while being sprayed with flavoured liquids. These liquids are a mixture of oils, flavours, spices, and colours. An additional layer of oil must be present on the outside of the curls.
The flavourings and drying process are carefully monitored to ensure health and safety quality control. After drying, the curls are packaged, sealed, and stored for transport. The entire process is very precise to ensure that the cheese curls are within the tolerances of health and safety quality control.
Some cheese curls are fried instead of baked, and the fried variety is dried after frying.
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The snacks are coated with cheese or cheese-flavoured powders
Cheese curls are made by coating corn curls with cheese or cheese-flavoured powders. The corn curls are made from cornmeal and water, with the addition of oil. The cornmeal is mixed with water to form a dough, which is then put through an extruder machine. The extruder uses heat, moisture, and pressure to form the dough into a specific shape, which can be ball-shaped, curly, straight, or irregularly shaped.
The corn curls are then flavoured with a mixture of oils, flavours, spices, and colours. This can be done by spraying the curls with flavoured liquids as they tumble in a rotating barrel, or by applying powders such as cheddar cheese powder, acid whey powder, artificial cheese flavour, and spices. The additional layer of oil is necessary for the curls to be packaged, sealed, and stored for transport.
The entire process of creating cheese curls is carefully monitored to ensure that all aspects of production adhere to health and safety quality control standards. The Adams Corporation was the first to mass-produce cheese curls in 1950, and they were called Korn Kurls. Today, cheese curls are a popular snack, especially among children, and are produced by companies such as Frito-Lay, which offers a variety of shapes and flavourings.
Some cheese curls are made with real cheese, such as Herr's Cheese Curls, which uses a special blend of natural cheddars. The cheese curls are baked, not fried, resulting in a light and fluffy texture. The process of creating cheese curls starts with selecting the perfect type of cornmeal, which should be finely textured and have a low moisture content to ensure a pleasant eating experience.
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They are packaged and sealed for transport
Once the cheese curls have been dried and flavoured, they are packaged and sealed for transport. This is a critical step in the process, as it ensures the product's quality and freshness during shipping and storage.
The packaging process involves placing the cheese curls into bags or containers that are appropriately sized for the intended market. For example, a large bag for family consumption or individual packs for on-the-go snacking. The packaging material, typically plastic or foil, is carefully selected to maintain the product's freshness and protect it from external elements like moisture and oxygen, which could compromise the texture and taste.
Sealing the package is a crucial step to prevent contamination and ensure the product's longevity. Various sealing techniques are employed, such as heat sealing or vacuum sealing, depending on the packaging material and product specifications. This process eliminates air from the package, creating an airtight environment that preserves the cheese curls' crispness and flavour.
Transportation considerations also come into play when sealing the packages. The packages must be sturdy enough to withstand the rigours of shipping, including stacking, vibrations during transit, and varying temperatures. Proper sealing ensures that the product remains intact and fresh, even when subjected to challenging transportation conditions.
Finally, the sealed packages are boxed or palletised for efficient transport to distribution centres or retail outlets. This step involves stacking and securing the packages to optimise space utilisation and ensure stability during transportation. From here, the cheese curls are shipped to their final destinations, ready to be enjoyed by consumers.
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Frequently asked questions
Cheese curls are made from cornmeal, water, oil, and cheese or cheese-flavored additives.
The process of making cheese curls involves mixing cornmeal with water to form a dough, which is then put through an extruder machine. The extruder uses heat, moisture, and pressure to work the dough, forcing it through a die to form its shape. The uncooked cheese curl that comes out of the die is called a collette, which is then baked in an oven. After baking, the collettes are sprayed with vegetable oil and dusted with cheese powder.
Some popular brands of cheese curls include Herr's Cheese Curls, Cheetos Puffs, and Frito-Lay.
