Composition, Microstructure, and Surface Barrier Layer Development During Brine Salting

New Insights into Cheese Microstructure

Microscopy is often used to assist the development of cheese products, but manufacturers can benefit from a much broader application of these techniques to assess structure formation during processing and structural changes during storage. Microscopy can be used to benchmark processes, optimize process variables, and identify critical control points for process control. Microscopy can also assist the reverse engineering of desired product properties and help troubleshoot production problems to improve cheese quality. This approach can be extended using quantitative analysis, which enables further comparisons between structural features and functional measures used within industry, such as cheese meltability, shreddability, and stretchability, potentially allowing prediction and control of these properties. This review covers advances in the analysis of cheese microstructure, including new techniques, and outlines how these can be applied to understand and improve cheese manufacture.

Symposium review: The Mozzarella/pasta filata years: A tribute to David M. Barbano

In the decades that followed the end of World War II, Mozzarella cheesemaking in the United States grew steadily as the pizza restaurant established an ever-expanding footprint across America and beyond. By the 1980s, Mozzarella cheesemaking had attained unprecedented scales of production, yet even as new cheese plants were coming on line across the country and production capacities were reaching extraordinary levels, the scientific and technological knowledge base needed to standardize production schedules, control product quality, and maximize cheese yields and efficiency lagged far behind industry needs. It was within this historical context that David Barbano turned his systematic and meticulous research program toward the needs of the Mozzarella cheese industry during the 1980s. By the early 1990s, Barbano was leading a team of graduate students, post-docs, technical staff, and collaborators in a systematic evaluation of every step in the Mozzarella cheesemaking process. The end product of these studies was nothing less than the transformation of what had been (to a large degree) a poorly understood "black box" process into a precisely controlled make procedure that lent itself to precision tailoring of cheese functionality, tight control over manufacturing schedules and efficiency, and maximization of cheese yields. Barbano's international collaborators included research scientists from Italy, where Mozzarella originated. Working with them, Barbano led a systematic evaluation of the scientific and technological aspects of Ragusano cheese, a traditional Protected Designation of Origin pasta filata cheese from Sicily. In the process, Barbano's team demonstrated a new approach to traditional artisanal practices that merged both the art and science of cheesemaking, in effect combining the best of both worlds, toward the goal of sustaining traditional cheesemakers and the working landscapes that they support. Throughout all of these studies, Barbano's research led to innovations in cheesemaking technology (such as improved salting methods, preacidification treatments, and strategies to improve low-fat Mozzarella functionality) that have revolutionized the Mozzarella industry worldwide.

Interaction of Brine Concentration, Brine Temperature, and Presalting on Salt Penetration in Ragusano Cheese

Thirty-one 3.6-kg blocks of Ragusano cheese were made on each of 6 different days (in different weeks) starting with a different batch of milk on each day. On d 1, 3, and 5, the cheeses were not presalted and on d 2, 4, and 6, all cheeses were presalted (PS). One of the 31 blocks of cheese was selected at random for analysis before brine salting (i.e., on d 0). The remaining 30 blocks were randomly divided into 2 groups of 15 blocks each; one group was placed in 18% brine (18%B) and the other group was placed in saturated brine (SB). For the 15 blocks within each of the 2 brine concentrations (BC), 5 blocks were placed in a brine tank at 12 degrees C, 5 at 15 degrees C, and 5 at 18 degrees C, and submerged for 24 d. The research objective was to determine the combined impacts (i.e., interactions) of PS the curd before stretching, BC (SB vs. 18%B), and brine temperature (BT; 12, 15, and 18 degrees C) on salt uptake, moisture content, and yield of Ragusano cheese. Although BC, BT, and PS each had their own separate impacts on salt uptake, there was little interaction of these effects on salt uptake when they were used in combination. The PS most quickly delivered salt to the interior of the cheese and was the most effective approach to salting for controlling early gas formation. There were strong separate impacts of BC, BT, and PS on cheese moisture content, moisture loss, and net weight loss, with BC having the largest separate impact on these parameters. Reducing BT reduced salt content and increased moisture, but the effects were small. The more important effect of reduced BT was to reduce growth of gas forming bacteria. The 18%B produced higher moisture, and less moisture and weight loss than SB. The effect of interactions of BC, BT, and PS on moisture loss and net weight loss were small. To achieve the maximum benefit from the various approaches to salting for controlling early gas formation in Ragusano cheese, PS combined with slightly lower BT (i.e., 15 degrees C instead of 18 degrees C) should be used. Although using 18%B instead of SB did increase salt uptake, the point at which improved salt uptake occurred due to use of 18%B did not provide benefit in prevention of early gas formation, as reported separately. However, use of 18%B instead of SB provided a 9.98% increase in cheese yield due to reduced moisture loss during brining; this would be very attractive to cheese makers. The increase in yield needs to be balanced against the risk of growth of undesirable bacteria in the 18%B and the creation of another cheese quality defect.