Reduced-fat cheddar cheese manufactured using a novel fat removal process

Normally, reduced-fat Cheddar cheese is made by removal of fat from milk prior to cheese making. Typical aged flavor may not develop when 50% reduced-fat Cheddar cheese is produced by this approach. Moreover, the texture of the reduced-fat cheeses produced by the current method may often be hard and rubbery. Previous researchers have demonstrated that aged Cheddar cheese flavor intensity resides in the water-soluble fraction. Therefore, we investigated the feasibility of fat removal after the aging of Cheddar cheese. We hypothesized the typical aged cheese flavor would remain with the cheese following fat removal. A physical process for the removal of fat from full-fat aged Cheddar cheese was developed. The efficiency of fat removal at various temperatures, gravitational forces, and for various durations of applied forces was determined. Temperature had the greatest effect on the removal of fat. Gravitational force and the duration of applied force were less important at higher temperatures. A positive linear relationship between temperature and fat removal was observed from 20 to 33 degrees C. Conditions of 30 degrees C and 23,500 x g for 5 min removed 50% of the fat. The removed fat had some aroma but little or no taste. The fatty acid composition, triglyceride molecular weight distribution, and melting profile of the fat retained in the reduced-fat cheeses were all consistent with a slight increase in the proportion of saturated fat relative to the full-fat cheeses. The process of fat removal decreased the grams of saturated fat per serving of cheese from 6.30 to 3.11 g. The flavor intensity of the reduced-fat cheeses were at least as intense as the full-fat cheeses.     

Determination of regional flavor differences in U.S. Cheddar cheeses aged for 6 mo or longer

ABSTRACT:  Cheddar cheese is a widely popular food in the United States. This product is produced in facilities across the United States and often marketed based on region of manufacture, implying that regional differences in flavor character of the cheese exist. This study was conducted to determine if regional differences in flavor exist in the aged U.S. Cheddar cheeses. Three times per year for 2 y, triplicate 18-kg blocks of Cheddar cheese (< 60 d old) were obtained from 19 manufacturing facilities located in 4 major cheese- producing regions/states: California, Northwest, Midwest, and Northeast. A trained sensory panel documented the flavor characteristics of cheeses after 6-, 9-, 12-, 18-, and 24-mo ripening at 7 °C. Regional differences were observed for specific flavors for cheeses manufactured in the Northwest, Midwest, and Northeast across ripening ( P < 0.05), but the specific flavors responsible for these effects were not consistent across ripening. Similarly, cheese make procedure effects were also observed for specific flavors across ripening ( P < 0.05), but these differences were also not consistent across ripening. The impact of region and cheese make procedure on flavor of the aged Cheddar cheeses was small in comparison to consistently documented, facility-specific flavor differences ( P < 0.0001). Flavor profiles of aged Cheddar cheeses were most strongly influenced by practices specific to manufacturing facility rather than region of manufacture.     

TEXTURE ANALYSIS OF CHEDDAR CHEESE MADE FROM ULTRAFILTERED MILK

The textural properties of Cheddar cheese made from ultrafiltered milk were assessed. Cheddar cheeses were prepared from 1.5- and 2.0-fold concentrated milk and ripened for three months. Textural characteristics of the UF cheeses were compared to control and commercial Cheddar cheeses by sensory and instrumental measures. The texture of cheese made from UF milk differed from the control commercial Cheddar cheeses. According to the trained sensory panel, the UF cheeses were harder and more rubbery, crumbly, chewy and grainy than the control and commercial Cheddar cheeses (P <0.01). The texture profile analysis (TPA), conducted using the Instron, did not correspond to the sensory measurements nor was it successful in discriminating among the cheese samples. Lack of agreement between the sensory and instrumental tests was attributed to differences in the testing conditions and procedures of the two methods. Instrumental tests should be validated against sensory measures in order to be useful as measures of palatability. Consumer preferences for the commercial, control and UF Cheddar cheeses were significantly different (P < 0.01), the UF cheeses being less preferred in terms of flavor, texture and overall acceptability.     

Impact of fat reduction on flavor and flavor chemistry of Cheddar cheeses

A current industry goal is to produce a 75 to 80% fat-reduced Cheddar cheese that is tasty and appealing to consumers. Despite previous studies on reduced-fat cheese, information is critically lacking in understanding the flavor and flavor chemistry of reduced-fat and nonfat Cheddar cheeses and how it differs from its full-fat counterpart. The objective of this study was to document and compare flavor development in cheeses with different fat contents so as to quantitatively characterize how flavor and flavor development in Cheddar cheese are altered with fat reduction. Cheddar cheeses with 50% reduced-fat cheese (RFC) and low-fat cheese containing 6% fat (LFC) along with 2 full-fat cheeses (FFC) were manufactured in duplicate. Cheeses were ripened at 8°C and samples were taken following 2 wk and 3, 6, and 9 mo for sensory and instrumental volatile analyses. A trained sensory panel (n = 10 panelists) documented flavor attributes of cheeses. Volatile compounds were extracted by solid-phase microextraction or solvent-assisted flavor evaporation followed by separation and identification using gas chromatography-mass spectrometry and gas chromatography-olfactometry. Selected compounds were quantified using external standard curves. Sensory properties of cheeses were distinct initially but more differences were documented as cheeses aged. By 9 mo, LFC and RFC displayed distinct burnt/rosy flavors that were not present in FFC. Sulfur flavor was also lower in LFC compared with other cheeses. Forty aroma-active compounds were characterized in the cheeses by headspace or solvent extraction followed by gas chromatography-olfactometry. Compounds were largely not distinct between the cheeses at each time point, but concentration differences were evident. Higher concentrations of furanones (furaneol, homofuraneol, sotolon), phenylethanal, 1-octen-3-one, and free fatty acids, and lower concentrations of lactones were present in LFC compared with FFC after 9 mo of ripening. These results confirm that flavor differences documented between full-fat and reduced-fat cheeses are not due solely to differences in matrix and flavor release but also to distinct differences in ripening biochemistry, which leads to an imbalance of many flavor-contributing compounds.     

Enhanced nutty flavor formation in cheddar cheese made with a malty Lactococcus lactis adjunct culture

Nutty flavor in Cheddar cheese is desirable, and recent research demonstrated that 2- and 3-methyl butanal and 2-methyl propanal were primary sources of nutty flavors in Cheddar. Because malty strains of Lac-tococcus lactis (formerly Streptococcus lactis var. malti-genes) are characterized by the efficient production of these and other Strecker aldehydes during growth, this study investigated the influence of a malty L. lactis adjunct culture on nutty flavor development in Cheddar cheese. Cheeses made with different adjunct levels (0, 10⁴ cfu/mL, and 10⁵ cfu/mL) were ripened at 5 or 13°C and analyzed after 1 wk, 4 mo, and 8 mo by a combination of instrumental and sensory methods to characterize nutty flavor development. Cheeses ripened at 13°C developed aged flavors (brothy, sulfur, and nutty fla-vors) more rapidly than cheeses held at 5°C. Additionally, cheeses made with the adjunct culture showed more rapid and more intense nutty flavor development than control cheeses. Cheeses that had higher intensities of nutty flavors also had a higher concentration of 2/3-methyl butanal and 2-methyl propanal compared with control cheeses, which again confirmed that these compounds are a source of nutty flavor in Cheddar cheese. Results from this study provide a simple methodology for cheese manufacturers to obtain consistent nutty flavor in Cheddar cheese.     

Application of salt whey in process cheese food made from Cheddar cheese containing exopolysaccharides

The objective of this work was to use salt whey in making process cheese food (PCF) from young (3-wk-old) Cheddar cheese. To maximize the level of salt whey in process cheese, low salt (0.6%) Cheddar cheese was used. Because salt reduction causes undesirable physiochemical changes during extended cheese ripening, young Cheddar cheese was used in making process cheese. An exopolysaccharide (EPS)-producing strain (JFR) and a non-EPS-producing culture (DVS) were applied in making Cheddar cheese. To obtain similar composition and pH in the EPS-positive and EPS-negative Cheddar cheeses, the cheese making protocol was modified in the latter cheese to increase its moisture content. No differences were seen in the proteolysis between EPS-positive and EPS-negative Cheddar cheeses. Cheddar cheese made with the EPS-producing strain was softer, and less gummy and chewy than that made with the EPS-negative culture. Three-week-old Cheddar cheese was shredded and stored frozen until used for PCF manufacture. Composition of Cheddar cheese was determined and used to formulate the corresponding PCF (EPS-positive PCF and EPS-negative PCF). The utilization of low salt Cheddar cheese allowed up to 13% of salt whey containing 9.1% salt to be used in process cheese making. The preblend was mixed in the rapid visco analyzer at 1,000 rpm and heated at 95°C for 3 min; then, the process cheese was transferred into copper cylinders, sealed, and kept at 4°C. Process cheese foods contained 43.28% moisture, 23.7% fat, 18.9% protein, and 2% salt. No difference in composition was seen between the EPS-positive and EPS-negative PCF. The texture profile analysis showed that EPS-positive PCF was softer, and less gummy and chewy than EPS-negative PCF. The end apparent viscosity and meltability were higher in EPS-positive PCF than in EPS-negative PCF, whereas emulsification time was shorter in the former cheese. Sensory evaluation indicated that salt whey at the level used in this study did not affect cheese flavor. In conclusion, process cheese, containing almost 13% salt whey, with improved textural and melting properties could be made from young EPS-positive Cheddar cheese.     

Reduced fat process cheese made from young reduced fat Cheddar cheese manufactured with exopolysaccharide-producing cultures

In a previous study, exopolysaccharide (EPS)-producing cultures improved textural and functional properties of reduced fat Cheddar cheese. Because base cheese has an impact on the characteristics of process cheese, we hypothesized that the use of EPS-producing cultures in making base reduced fat Cheddar cheese (BRFCC) would allow utilization of more young cheeses in making reduced fat process cheese. The objective of this study was to evaluate characteristics of reduced fat process cheese made from young BRFCC containing EPS as compared with those in cheese made from a 50/50 blend of young and aged EPS-negative cheeses. Reduced fat process cheeses were manufactured using young (2 d) or 1-mo-old EPS-positive or negative BRFCC. Moisture and fat of reduced fat process cheese were standardized to 49 and 21%, respectively. Enzyme modified cheese was incorporated to provide flavor of aged cheese. Exopolysaccharide-positive reduced fat process cheese was softer, less chewy and gummy, and exhibited lower viscoelastic moduli than the EPS-negative cheeses. The hardness, chewiness, and viscoelastic moduli were lower in reduced fat process cheeses made from 1-mo-old BRFCC than in the corresponding cheeses made from 2-d-old BRFCC. This could be because of more extensive proteolysis and lower pH in the former cheeses. Sensory scores for texture of EPS-positive reduced fat process cheeses were higher than those of the EPS-negative cheeses. Panelists did not detect differences in flavor between cheeses made with enzyme modified cheese and aged cheese. No correlations were found between the physical and melting properties of base cheese and process cheese.     

Effect of zinc fortification on Cheddar cheese quality

Zinc-fortified Cheddar cheese containing 228 mg of zinc/kg of cheese was manufactured from milk that had 16 mg/kg food-grade zinc sulfate added. Cheeses were aged for 2 mo. Culture activity during cheese making and ripening, and compositional, chemical, texture, and sensory characteristics were compared with control cheese with no zinc sulfate added to the cheese milk. Compositional analysis included fat, protein, ash, moisture, zinc, and calcium determinations. The thiobarbituric acid (TBA) assay was conducted to determine lipid oxidation during aging. Texture was analyzed by a texture analyzer. An untrained consumer panel of 60 subjects evaluated the cheeses for hardness, off-flavors, appearance, and overall preference using a 9-point hedonic scale. Almost 100% of the zinc added to cheese milk was recovered in the zinc-fortified cheese. Zinc-fortified Cheddar cheese had 5 times more zinc compared with control cheese. Zinc-fortified cheese had higher protein and slightly higher fat and ash contents, whereas moisture was similar for both cheeses. Zinc fortification did not affect culture activity during cheese making or during the 2-mo aging period. The TBA value of control cheese was higher than that of zinc-fortified cheese at the end of ripening. Although zinc-fortified cheese was harder as determined by the texture analyzer, the untrained consumer panel did not detect differences in the sensory attributes and overall quality of the cheeses. Fortification of 16 mg/kg zinc sulfate in cheese milk is a suitable approach to fortifying Cheddar cheese without changing the quality of Cheddar cheese.     

Identification of aroma-active compounds in Cheddar cheese imparted by wood smoke

Cheddar cheese is the most popular cheese in the United States, and the demand for specialty categories of cheese, such as smoked cheese, are rising. The objective of this study was to characterize the flavor differences among Cheddar cheeses smoked with hickory, cherry, or apple woods, and to identify important aroma-active compounds contributing to these differences. First, the aroma-active compound profiles of hickory, cherry, and apple wood smokes were analyzed by solid-phase microextraction (SPME) gas chromatography-olfactometry (GCO) and gas chromatography-mass spectrometry (GC-MS). Subsequently, commercial Cheddar cheeses smoked with hickory, cherry, or apple woods, as well as an unsmoked control, were evaluated by a trained sensory panel and by SPME GCO and GC-MS to identify aroma-active compounds. Selected compounds were quantified with external standard curves. Seventy-eight aroma-active compounds were identified in wood smokes. Compounds included phenolics, carbonyls, and furans. The trained panel identified distinct sensory attributes and intensities among the 3 cheeses exposed to different wood smokes (P < 0.05). Hickory smoked cheeses had the highest intensities of flavors associated with characteristic “smokiness” including smoke aroma, overall smoke flavor intensity, and meaty, smoky flavor. Cherry wood smoked cheeses were distinguished by the presence of a fruity flavor. Apple wood smoked cheeses were characterized by the presence of a waxy, green flavor. Ninety-nine aroma-active compounds were identified in smoked cheeses. Phenol, guaiacol, 4-methylguaiacol, and syringol were identified as the most important compounds contributing to characteristic “smokiness.” Benzyl alcohol contributed to the fruity flavor in cherry wood smoked cheeses, and 2-methyl-2-butenal and 2-ethylfuran were responsible for the waxy, green flavor identified in apple wood smoked cheeses. These smoke flavor compounds, in addition to diacetyl and acetoin, were deemed important to the flavor of cheeses in this study. Results from this study identified volatile aroma-active compounds contributing to differences in sensory perception among Cheddar cheeses smoked with different wood sources.     

INSTRUMENTAL AND SENSORY TEXTURE ASSESSMENT AND FRACTURE MECHANISMS OF CHEDDAR AND CHESHIRE CHEESES

Textural attributes of Cheddar and Cheshire cheeses, falling within narrow compositional ranges, were assessed by sensory panels, and from force-compression curves generated by compression between two plates, and, for Cheddar cheese only, by penetrometry. Individual sensory measurements did not relate well to any instrumental one, and were better at discriminating between cheeses. Samples of each cheese variety were fractured in different ways and the fracture surfaces were examined in a scanning electron microscope. Fracture surfaces were formed by cutting directly through the matrix, tearing of the matrix along planes high in fat or cracking at grain boundaries. It is suggested that consideration of fracture mechanism may aid the selection and development of useful instrumental methods for texture assessment of cheese.     

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