Processed Cheese and Analogues

Adnan Y. Tamime

• Publisher: Wiley-Blackwell
• Year: 2011
• Print ISBN: 9781405186421
• eBook ISBN: 9781444341836
• Edition: 1
• Topic: Technology & Engineering
• Subtopic: Food Science
• Index: Technology & Engineering

Part of the Society of Dairy Technology Series, this book deals witha commercially significant sector of dairy science. The book includes chapters on legislation, functionality of ingredients, processing plants and equipment, manufacturing best practice, packaging, and quality control. The chapters are authored by an international team of experts.

This book is an essential resource formanufacturers and users of processed and analogue cheese products internationally; dairy scientists in industry and research; and advanced food science students with an interest in dairy science.

Chapter 1

Processed Cheese and Analogues: An Overview

A.Y. Tamime

1.1 Historical Background

The production of processed cheese started in Europe, and could date to the mid-1890s. Natural cheeses have limited shelf-life and, depending on many factors (i.e. level of moisture content, sanitary conditions during the manufacturing stages and storage conditions of the product), this can range from a few weeks to a couple of years. It is possible to suggest that the idea of processed cheese originated from a desire to extend the shelf-life of natural cheese or to develop a new type of cheese which was milder in taste or more stable. Around the same period, commercial developments were made in Germany for the export of short shelf-life soft cheese, e.g. Camembert, Brie and Limburger, which was achieved by heating the cheeses in metal cans. Similar processing methods were also developed for Dutch cheeses, but the process was most successful in Switzerland by using sodium citrate (Berger et al., 1989).

Essential steps in the manufacture of processed cheese is melting and heating blends of natural cheeses (e.g. different types, varying degree of maturity, i.e. fresh/young or matured, and cheese ‘re-work’), the addition of emulsifying salts, agitation to produce a homogeneous mixture, followed by packaging and cooling or vice versa. The application of heat (i.e. indirect or direct steam injection) inactivates the starter culture organisms and other bacteria, including the enzymes present in natural cheeses, and produces a product with extended shelf-life. Although the casein in natural cheeses possesses certain emulsifying characteristics, the stability of processed cheese could not be achieved without the use of emulsifying salts, such as citrates and phosphates.

Commercial production of processed cheese started in earnest in Europe and the USA between 1910 and 1920. The production techniques were based on Cheddar and other cheese varieties, and used citrates or phosphates as the emulsifying salts. These early attempts to produce good-quality processed cheese were of limited success, but the process became widespread by the 1930s when the emulsifying salts (e.g. polyphosphates and other types) appeared on the market (Berger et al., 1989). In addition, other dairy and non-dairy ingredients could be added to the blend before processing, and the use of these ingredients is normally governed by statutory regulation within each country of manufacture.

Over the past few decades, many aspects of the manufacture of processed cheese have been reviewed by many authors (Jackson & Wearmouth, 1959; Price & Bush, 1974a,b; Shimp, 1985; Sachdeva et al., 1988; Marchesseau et al., 1997; Schar & Bosset, 2002; Abd El-Salam et al., 2005; Dimitreli & Thomareis, 2007; Kapoor & Metzger, 2008), and the same subject has been reviewed in different textbooks (Meyer, 1973; Thomas 1977; Guinee, 1987; Berger et al., 1989;

, 1991; Merkenich et al., 1992a,b, 1994;

& Kaláb, 1993; Kaláb, 1995;

&

, 1997; Kosikowski & Mistry, 1997; Zehren & Nusbaum, 2000; Guinee et al., 2004; Schrader & Hoffman, 2008; Adhikari et al., 2009; Bunka et al., 2009; Johnson et al., 2009). In addition, Mann (1969, 1970, 1974, 1975, 1978a,b, 1981, 1983a,b, 1986, 1987, 1990, 1993, 1995, 1997, 1999, 2003) has compiled several successively up-to-date international digests on processed cheese. Contrary to the current belief, processed cheese is made from good-quality natural cheeses (blends of fresh/young and matured) rather than degraded stock; however, these latter types of cheeses are only used in very small proportions, including re-work processed cheese. In addition, the processing equipment used during the manufacture of processed cheese is known as cooker or kettle (e.g. vertical or horizontal; see Chapter 6), and continuous or batch processes are also available on the market. Although the latter method of processing is more popular as it provides greater control of product quality and is more suitable for large-scale operations, the batch process may be still be favourable in small- and medium-sized production units or, alternatively, because the batch process was developed first – ‘old habits die hard’.

In contrast, ‘imitation’ processed cheese is made from mixtures of dairy and/or non-dairy proteins and fat/oils. Hence, it was suggested by Shaw (1984) that in response to increasing manufacturing costs of processed cheese, imitation products have been developed to meet demand in fast food outlets (e.g. pizza), by the catering trade, ready cooked foods, in formulated foods and in school lunch programmes (see also IDF, 1989; McCarthy, 1990; Mortensen, 1991; Engel, 1992; Lee et al., 1992; Song et al., 1992; Bachmann, 2001; Hoyer & Kirkeby, 2007).

It is evident that there are many similarities between the manufacture of processed cheese and analogues, and this chapter provides a general background to these products, their properties and the patterns of their consumption in some selected countries.

1.2 Diversity of Products

1.2.1 Terminology and/or Nomenclature

The products of the preservative treatment of natural cheeses by the application of heat came to be known as processed cheese or processed cheese food; in some instances the word ‘process’ is used instead of ‘processed’. This product is manufactured in many countries, and numerous variants of this type of product have appeared on the market over the years with alternative names, such as ‘pasteurised’, ‘emulsified’, pasteurised blended, ‘American’, ‘cooked’ or ‘sterilised’ cheese (

& Kaláb, 1993; Guinee et al., 2004; see also Chapter 2).

Developed products, known as ‘imitation’ processed cheese, are widely produced, and are made from mixtures of dairy and/or non-dairy proteins and dairy fat or vegetable oil. These products are variously labelled as ‘analogues’, ‘analogs' imitation’, ‘substitute’, ‘artificial’, ‘extruded’, ‘synthetic’, ‘Tofu’ and/or ‘filled’ cheese (Shaw, 1984; IDF, 1989; McCarthy, 1990). The following references are recommended for further reading on different aspects on processed cheese analogues (Santos et al., 1989; Ahmed et al., 1995; El-Nour et al., 1996, 1998, 2001a,b; Hetzner & Richarts, 1996; Ennis & Mulvihill, 1997; Abou El-Nour et al., 1998, 2001; Muir et al., 1999; Tamime et al., 1999; Kaminarides & Stachtiaris, 2000; Mleko & Foegeding, 2000, 2001; Bachmann, 2001; Lobato-Calleros et al., 2001; Pereira et al., 2001; Abou El-Nour & Buchheim, 2002; Pereira et al., 2002; El-Nour, 2003; Gustaw Mleko, 2007). These types of product are reviewed in Chapter 9.

1.2.2 Classification

At present, there are many types of processed cheese made worldwide. Smith (1990) reported the classification of these products based on the FAO/WHO Food Standards Programme of the Codex Alimentarius Commission, and they are grouped into two different categories based on the physical characteristics of the product: processed cheese and spreadable processed cheese (for further details, refer to Chapter 2). The standard also details the following aspects.

• Permitted dairy and food additives/ingredients.
• Minimum processing temperature at 70°C for 30 s.
• The named variety of natural cheese to be used to describe the processed cheese type, and the blend being required to contain at least 70 g 100 g−1 of the cheese mentioned.
• The chemical composition of the product is expressed as dry matter content and percentage of fat-in-dry matter (FDM).
• Labelling information.

The main difference between processed cheese and processed cheese spread products proposed by Smith (199...

Table of contents

• Cover
• Series Page
• Title Page
• Copyright
• Preface to the Technical Series
• Preface
• Contributors
• Chapter 1: Processed Cheese and Analogues: An Overview
• Chapter 2: Current Legislation on Processed Cheese and Related Products
• Chapter 3: Effects of Natural Cheese Characteristics and Processing Conditions on Rheology and Texture: The Functionality of Cheese Components in the Manufacture of Processed Cheese
• Chapter 4: Functionality of Ingredients: Emulsifying Salts
• Chapter 5: Flavours and Flavourants, Colours and Pigment
• Chapter 6: Manufacturing Practices of Processed Cheese
• Chapter 7: Processed Cheese Plants and Equipment: A Practical Overview
• Chapter 8: Packaging Materials and Equipment
• Chapter 9: Production of Analogue Cheeses
• Chapter 10: Quality Control in Processed Cheese Manufacture
• Color Plates
• Index