Note: Descriptions are shown in the official language in which they were submitted.
This invention relates to cheese-like products and to a method
for direct fabrication of such products.
Imitation cheese products have been produced from a variety of
protein sources such as cottage cheese curd, milk solids, skim milk solids
and the like. In many instances the above protein sources have been combined
with minor amounts of the cheese being simulated and act as an extender
therefor.
In recent years, alkali or alkaline earth metal caseinates, which
are valuable sources of protein, also have been used in the production of
process cheese products as is illustrated by United States Patent No.
3,922,374 to Bell et al. However, such caseinates sometimes possess an
objectionable odor and flavor which can override the intended flavor of the
produced food products.
Some relatively bland caseinates have been produced by heating a
casein solution with an alkali metal or an alkaline earth metal salt in a
manner which causes coagulation of the protein. The resulting coagulum is
separated fTom a continuous liquid phase, and, afteT washing, is a
substantially bland alkali or alkaline earth metal caseinate. Sodium
caseinate, calcium caseinate and sodium-calcium caseinate have been employed
heretofoTe for the production of simulated process cheese products.
Nevertheless, a number of problems are inherent in the use of such materials.
For example, in some instances sodium caseinate is unsatisfactory in
imitation cheese pToducts because such imitation cheese products have a
tendency toward burning and puffing if baked OT toasted, for example, on
pizzas OT on open-faced, toasted
B~ -2-
sandwiches ~o~eve~, caC--jn~tes are ofteo used as extenders in
simulated dairy products so that smaller amounts of the more
expensive natural ingredient can be utilized in the product.
Another drawback of caseinates is that they are rela-
tively expensive and t~nd to develop objectionable flavors and
odors.
Wet mass rennet casein (e.g., cottage cheese curd) has
also been used to manufacture cheese products; however, it is a
perishable item and suffers from the problems of spoilage, in-
convenient handling and storage.
German Patent Publication (Offenlegungsschrift) No.23 42 299 discloses a cheese processing additive that can con-
tain up to 20 weight percent of rennet casein and that can be
added to crude cheese in an amount sufficient to supply 1 to 3
weight percent of rennet casein. However, the rennet casein
content of this processing additive is low, and a very large
amount ofaphosphatesalt (33 tol00weight percent, based on weight
of rennet casein) is used to produce the additive.
Accordingly, there has been a longstanding need for
an inexpensive protein source which can be utilized as the
principal protein source to produce a satisfactory food product
and which can be used, if necessary, as the sole protein source
in a cheese analog or cheese-like product. It has now been
found that a non-cultured, cheese-like product can be prepared
using dry, particulate rennet casein as the principal, or sole,
protein source of the product, notwithstanding the known rela-
tively low solubility of rennet casein in aqueous systems.
Summary of the Invention
The present invention contemplates solvation of dry
particulate rennet casein in water in the presence of an edible
solvation agent to produce a paste-like mass of predetermined
--3--
consistency.
Accordingly, the invention provides a non-cultured, simulated food
product having generally the texture, body and taste characteristics of
cheese which is a substantially homogeneous mass comprising at least about 25
percent by weight previously dry but solvated edible rennet casein, an edible
solvation agent present in an amount of about 2 to about 12 percent by weight
of said rennet casein, water, a bland, edible lipid material selected from
the group consisting of oil and fat, and sufficient quantities of suitable
flavoring agents to impart the desired flavor.
The important factors for the direct fabrication of cheese analogs
according to the present process are the relative amounts of the dry rennet
casein, the solvation agent, and water. The manner in which these components
are combined to constitute the mixture that is subjected to the heat treatment
can be varied to provide various textures and products. The individual
components can be premixed, mixed in the cooker, or a combination of the
foregoing procedures can be utilized. The nature of the heat treatment and
agitation to which the foregoing components are subjected during processing
also have a bearing on the obtained product.
The cheese-like product of this invention is based on a substan-
tially homogeneous mass comprising at least about 25 percent by weight of
previously dry but solvated edible rennet casein as the principal protein
source, a solvation agent and water. A bland edible lipid material, i.e.,
an edible oil or fat, and a suitable flavoring agent (or agents) can be
present in quantities sufficient to impart to the product the characteristic
fat content and flavor of the desired cheese analog. A coloring agent
usually is also present. Salt and other protein constituents can be added
as desired.
In the process of this invention, the dry, particulate rennet
casein is solvated or hydrated at an elevated temperature with sufficient
3a water to produce a paste-like mass having no discernible unsolvated rennet
ar~7
-4-
casein particles present. The solvation is carried out with agitation in
the presence of a solvation agent and at a temperature of about 150F. to
about
' -4a-
3C0 F. F ~-?r~ / i a~ a,Q,lt 190?F to ab~ 2~ P Tl~e ~ n~
period during which solvation of the rennet casein is comple~ed
is about 30 seconds to about lO minutes, preferably about 2 to
about 4 minutes.
The produced cheese analog or non-dairy but cheese-
like product can be cast into loaves, sliced, or shaped into
other packaging configurations as desired.
Detailed Description of the Preferred Embodiments
More specifically, a non-cultured cheese analog embody-
ing this invention is a smooth, homogeneous plastic or non-plastic
mass wherein the principal, and in many instances the sole,
protein source for the cheese analog is previously dry but now
solvated edible rennet casein, present in an amount of at least
about 25 percent by weight of the total product. The rennet
casein content can be as high as about 65 percent by weight, or
higher, if desired, as long as the produced mass is substantially
homogeneous and no visually observable, discrete rennet casein
particles are present. Preferably the rennet casein content is
about 30 percent to about 45 percent by weight.
Rennet casein is a commercially available edible milk
protein product which contains more of the milk minerals than
does acid casein. Typically, edible rennet casein is isolated
by methods well known in the art from fresh pasteurized skim
milk of relatively low fat content by precipitation with a
rennet-type enzyme of the type used in cheesemaking. The pre-
cipitating enzyme can be of either animal or microbial origin.
The precipitated rennet casein is then washed, pressed, dried,
ground, sieved and blended to provide a substantially uniform,
particulate productO
It is preferred to use a dry, particulate rennet casein
having a lactose content of about O.l percent to about 0.3percent
--5--
by weight and havi~lg a p~ le s ' ~ appr~ximately 30 mesh.
Preferably, the ash cGnten-. of ~he dry, particulate rennet
casein that is used as the starting material is at least about
6 wt.-%, and more preferably about 7.5 wt.-%. One commercial
source of suitable dry, particulate, edible rennet casein is
New Zealand Milk Products, Inc., 6300 River Road, Rosemont,
Illinois. A typical batch of this particular edible rennet
casein has the following analysis:
wt.-%
Moisture 11.0
Protein (N x 6.38) 80.6
Milkfat 0.5
Lactose 0.1
Mineral salts (ash) 7.8
100.O
pH 7.1
Minerals and trace elements wt.-%
Calcium 2.7-3.0
Phosphorus 1.3-1.4
Magnesium 0.10-0.12
Sodium 0.01-0.05
Potassium 0.01-0.04
Iron 2-6 mg/kg
The term "solvated" as used herein and in the appended
claims characterizes previously dry, edible rennet casein that
has been hydrated at an elevated temperature and dispersed in an
aqueous system as a solution or a gel.
The dry rennet casein has a number of advantages as
the protein source. It is relatively inexpensive, and, because
of its dry form, can be stored for long periods of time without
,oil~* o ~jss o~ ~,avor which ~is a prc~hl~ wi~h _aseinates,
cott;~ge ul2ese ~urd, milk solids and other typ;cal protein com-
ponents of currently available process cheese products, many
of which cannot be used as the sole protein source. However,
heretofore it was no-~ known how to produce stable aqueous sys-
tems having a relatively high rennet casein content, i.e., a
rennet casein con-~ent in excess of about 20 weight percent.
Neither enzymes nor microorganisms are employed in
the production of imitation, non-cultured, cheese-like products
of this invention, thus the present invention provides a rela-
tively simple, economical process of relatively short duration
to produce a superior non-cultured, non-dairy, cheese-like
product. The product of this invention can be made at a much
lower cost than currently available imitation cheese products.
Furthe:rmore, by direct processing, i.e., by the direct
conversion of dry~ particulate edible rennet casein according to
the method of this invention, a simulated non-cultured cheese-
like product which closely resembles a natural cheese in body,
texture and flavor characteristics can be obtained. Thus the
present invention has provided a relatively simple, but economical
and superior advance in the art of cheese analogs and their formu-
lation.
The lipid material, i.e., the fat or oil, portion of
the produced edible composition may be constituted by any edible
fat or oil having a clean, bland flavor and preferably melting
at a temperature of about 50F. to about 100F., more preferably
at about 90F. to about 95F. The solid fat index of the oil at
92F. preferably is less than about 6, and more preferably about
0. The preferred oils or fats for the present purposes are
animal fat such as milk fat, hydrogenated or partially hydro-
genated vegetable oils such as coconut oil~ corn oil, palm oil,
s
soybean oi]J -~o~t,insee~ 11, safflower o l or mixtures such as
soybean-cottonseed oil blends, and the like. The oil or ~at
portion constitutes at least about 7 percent by weight, usually
about 7 to about 55 percent by weight of the total product
composition, and preferably from about 20 to about 30 percent
by weight thereof, depending on the type of cheese analog that
is produced.
Edible solvation agents such as the phosphate or citrate
salts capable of sequestering the calcium present in the dry, par-
ticulate rennet casein are employed in amounts of about 2 to about12 percent by weight of the rennet casein present, depending on
the desired body and texture of the cheese-like product. However,
if the solvation agent content is less than about 2 percent,
incomplete solvation and excessive syneresis will occur. On the
other hand, a solvation agent content in excess of about 12 per-
cent by weight produces no additional benefits.
At a relatively high edible solvation agent content,
i.e., at about 8 to about 12 weight percent, based on the weight
of rennet casein present, solvation provides a homogeneous plas-
tic mass that has a smooth, uniform body like that of processcheese and is free flowing at elevated temperatures. At an
intermediate edible solvation agent content of about 4 to about
8 weight percent, based on the weight of rennet casein present,
a relatively long or semi-plastic body is obtained for the sol-
vated rennet casein mass. Similarly, at a relatively low solva-
tion agent content of about 2 to about 4 weight percent, based
on the weight of the rennet casein present, a relatively short
body, exhibiting some brittleness, is obtained.
Suitable phosphate-containing solvation agents include
edible salts such as the alkali metal phosphates, e.g., disodium
phosphate, trisodium phosphate, sodium hexametaphosphate, sodium
tripolyphosphate, tetrasodium phosphate, dipotassium phosphate,
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monosodium dipl!~sl;~,a,e, disodium d;~hosp~ate, t ~sodium diphos~-
phate, ~etrasodium diphosphate and ~Ihe llke, ~he sodium aluminum
phosphates, and mixtures thereof. A preferred phosphate-contain-
ing solvation agent for the production of simulated process cheese
is a mixture of trisodium phosphate and disodium phosphate in a
weight ratio of about 1:1.5, the mix~ure being present in an
amount of about 8 to about 12 percent by weight of rennet casein,
depending on the desired degree of plasticity for the body there-
of. Another preferred solvation agent is an autogeneous mixture
of an alkaline sodium aluminum phosphate having approximate
empirical formula NaBAl2(OH)2(PO4)4 with about 30 weight percent
of dibasic sodium phosphate. Suitable citrate-containing solva-
tion agents include, for example, monosodium citrate, disodium
citrate, trisodium citrate, and the like. Other solvation agents,
e.g., chelating agents, sequestrants, or the like, can also be
used.
Water is present in an amount of at least about 35 to
about 300 percent, based on the amount of rennet casein present,
and generally constitutes about 30 to about 60 percent by weight
of the composition, depending upon the desired consistency.
Water can be added during the premixing and cooking stages of
the manufacturing process of this invention. The water that is
present serves a two-fold purpose, namely, solvation of the
rennet casein and control of consistency. If too much water is
added, the resulting solvated mass becomes too fluid and no
longer resembles the body of a cheese.
Starter distillate, an acidulant, and salt are gener-
ally added for flavoring. The normal pH for the product obtained
after cooking and without an acidulant pxesent is approximately
7, therefore, an acidulant such as lactic acid or the like is
used in flavoring the cheese-like product and at the same time
'
lowers the ~ e il ~rol3~1ct to a des;red pH Yalue o~ ahout
5.4 to about 6.5, for a process cheese-like product preferably
about 5.5 to about 5.8.
Since both dry, particulate rennet casein and edible
oils are bland in flavor, it is desirable to add a small amount
of a flavoring agent, such as starter distillate, natural cheese
flavors, or artificial cheese flavors. Starter distillate is a
standard commercial product which is widely used by dairy product
manufacturers to add flavor to butter, margarine and cheese, and
to fortify the flavor of cultured buttermilk and other dairy
products, and is equally well suited for use in the present
cheese-like compositions. Starter distillate is made by cultur-
ing a buttermilk starter to a rich flavor and aroma, and then
distilling the volatile flavor constituents therefrom with steam
and under very accurate controlled conditions. For the products
of the present invention using a standard commercially available
single-strength starter distillate as the principal flavoring
agent, the desired flavor effect is achieved when the flavoring
agent reaches a concentration of about 0.3 to about 0.5 percent
by weight, preferably about 0.35 to about 0.4 percent by weight
of the ultimate composition.
Alternatively, the chief component or components of
starter distillate may be added in their pure form. For example,
diacetyl (i.e., 2,3-butane-dione) is the chief flavor component
of starter distillate and may be added alone, or together with
the acidulant (e.g., lactic acid, citric acid, glucono-delta-
lactone, hydrochloric acid, or the like) to achieve a flavoring
agent concentration of from about 10 to about 1500 parts per
million parts of the ultimate product. Other flavoring and/or
acidifying agents that may be added are acetic acid, butyric
--10--
acid~ propionic aci~ 5 i.e.~ C,~8 carboxylic acids or
mixtures thereof. In addition, artificial flavoring agents
and/or spices may be used in appropriate amounts to supplement
or replace the starter distillate components entirely. However,
the preferred flavoring agent is starter distillate, which, in
combination with desired levels of salt and acidulant, impart a
pleasing flavor that closely approximates the flavor of cheese.
The method of making a simulated, non-cultured cheese-
like product directly from rennet casein according to the prac-
tice of this invention can include premixing of the dry rennetcasein, solvation agent, and water in an amount which constitutes
a major portion of the total water content of the ultimately pro-
duced product, with or without the lipid material or flavoring
agents present, or the ultimate food product constituents can be
mixed within the processing vessel. Thereafter, the produced
admixture, containing a portion of the remaining water, is
agitated and heated to a temperature of at least about 150F.
and up to about 300F., preferably about 190F. to about 205F.
at atmospheric pressure, and held at that temperature until the
rennet casein present is solvated and a smooth mass is achieved,
preferably for about 30 seconds to about 10 minutes, and more
preferably for about 2 to about 4 minutes. At temperatures
above the boiling point of water, processing can be carried
out in a suitable pressure vessel. The remainder of the water
to the admixture can be furnished via the steam and/or water
separately introduced into the cooker before or during the
cooking step, depending on the type of cooker that is being
used. The produced smooth mass containing solvated rennet
casein as the principal protein source is then formed into the
desired product shape. In instances where the cooking is done
by direct steam, the condensate obtained from the steam supplies
the water necessary to bring the water content of the ultimate
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~Z~5
;_roduct 'co the d~sired value. If indirect hea;-~}-,~- is used, more
water is added to the cooker during the cooking operation.
For cheese analogs having a relatively high solvated
rennet casein content, i.e., above about 50 percent by weight of
the composition, it is preferable to add the dry rennet casein
to hot water gradually over a period of time.
Premixing of the aforementioned ingredients is not
always necessary, however. As pointed out hereinabove, all or a
portion of the ingredients can be blended together in the cooker,
if desired.
It is important to agitate the admixture of ingredients
during heating. Moreover, severity of agitation at processing
temperature can be used to further adjust the body of the ulti-
mately produced cheese analog. For instance, a relatively high
shear agitation is desirable for a plastic body such as that for
a process cheese analog. On the other hand, for a cheese analog
having a relatively short body, e.g., blue cheese or feta cheese,
less severe agitation is normally used.
The following examples further illustrate this inven-
tion.
EXAMPLE 1: Preparation of Non-Dairy Premix
Dry, particulate edible rennet casein (about 297.5
lbs.) was combined in a blender with trisodium phosphate (about
11 lbs., 10 oz.), disodium phosphate (about 17 lbs., 12 oz.),
salt (about 17 lbs., 6 oz.), process cheese color (carotenal No.
73; about 350 ml.), water (about 308 lbs., 8 oz.), coconut oil
(about 218 lbs.), lactic acid (about 12 lbs., 8 oz.; about 4625
ml.), starter distillate (about 3 lbs., 7 oz.; about 1544 ml.).
The premix ingredients were then mixed for about 3 minutes to
achieve a substantially uniform blend which can be used as a
premix for the manufacture of cheese-like products.
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EXAMPLE 2: ~repd~ n of Simula,'~d Non Cultwred
Process Cheese Product
An aliquot of pre-blended non-dairy premix (about 410
pounds) produced in accordance with the method of Example 1 was
fed into a Rietz direct steam cooker to which had been previously
added about 5 pounds of water. Steam feed to the cooker was
partially turned on before the non~dairy premix was fed into the
cooker. After the non-dairy premix was introduced into the
cooker, the entire steam feed that was available was fed into
the cooker. As soon as the mixture in the cooker began to back-
splash, the steam feed was cut to about one-half of the original
volumetric rate and the mixture was cooked at a temperature of
about 195F. The steam feed was then shut off and additional
water (about 7.5 lbs.) was stirred into the mixture in the cooker
together with sufficient acidulant to provide a pH of about 5.7
for the product. Thereafter, the cooked mixture was discharged
into a suitable finish processing apparatus for packaging of the
produced process cheese analog.
EXAMPLE 3: Preparation of Simulated
American Cheese Product
Dry, particulate edible rennet casein (about 220 lbs.),
sodium citrate (about 18 lbs.), trisodium phosphate (about 6
lbs.), salt (about 11.5 lbs.), and water (about 267 lbs.) were
placed in a blender and mixed at ambient conditions until a
substantially homogeneous blend was obtained. A mixture of
partially hydrogenated cottonseed oil and partially hydrogenated
soybean oil (about 160.5 lbs) was then stirred into the pre-
viously produced blend and thereafter citric acid (about 9.7
lbs.), carotenal No. 73 color (about 0.6 lbs.), starter distil-
late (about 2.5 lbs.), de-lactosed whey (about 1.9 lbs.), mustard
(about 1.9 lbs.), and a vitamin-mineral premix (Hoffman-LaRoche
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TSD 7267~ grdl.lsj were mixed iJltO the produced blend
and -,;~* mixing continued for about three minutes.
The resulting admixture was then barreled off into
finished cook weight of about 450 lbs., ground, and fed into a
Rietz direct steam cooker. Steam was then fed into the cooker
until the cooker contents reached a temperature of about 195F.
Thereafter the cooker contents was turned for about three
minutes while being cooked at about this temperature.
The cooked contents of the Rietz direct steam cooker
was then extruded into individually wrapped slices and cooled
to ambient temperature. A simulated American cheese product
having a pH of about 5.5 to 5.6 was obtained.
EXAMPLE 4: An Edible Cheese Analog
To water (about 26.4 kg.) in a blender were added
disodium phosphate (about 2 kg.) and sodium chloride (about 4
kg.), and dissolved therein. Dry, particulate edible rennet
casein (about 30.8 kg.) was thereafter stirred into the result-
ing solution followed by vegetable oil (about 25 kg.), flavor-
ing agents, and glucono-delta-lactone (about 3 kg.). The
resulting admixture was then thoroughly agitated until substan-
tially homogeneous, fed to a direct steam cooker, and cooked
therein at about 170F. to about 180F. for about three minutes.
A smooth, fluid mass was obtained, which was then
filled into containers and rapidly cooled to ambient temperature.
The ultimately obtained edible product was cheese-like in ap-
pearance and taste, and exhibited a relatively short, somewhat
brittle body.
EXAMPLE 5: Preparation of Solvated Rennet_Casein
Dry, particulate edible rennet casein was admixed
with water and with disodium phosphate (DSP) as the solvation
agent'copr,iii~ J,:am batches that were individually pro-
cessed in a douhle boiler capable of heating the contents thereof
to a temperature of about 190F. to about 200F. (Runs A -C).
In Runs D-F a portion of the rennet casein was added gradually
during the course of heating to maximum temperature.
The boiler contents in each instance was then agitated
with a portable agitator having a variable speed drive. Each
batch was held at the maximum attainable boiler temperature for
about 2 to 3 minutes while being agitated and then cooled. All
batches were subjected to about the same degree of agitation.
The experimental results are compiled in Table I, below.
Table I
Ingredient, ~ ~ B C D E F
rennet casein 30 40 50 55 60 65
DSP 2.4 3.2 4 4.4 4.8 5.2
water 67.6 56.8 46 40.6 35.2 29.8
In all instances the obtained mass was completely homo-
geneous. As the rennet casein content was increased, the obtained
mass became more translucent and the flowability of the mass upon
cooling changed from that of a semi-solid paste to a hard mass.
EXAMPLE 6: Solvation of Rennet Casein at
Varying Solvation Agent Concentrations
Dry, particulate edible rennet casein was solvated in
a manner similar to Example 5 with varying amounts of disodium
phosphate (DSP) as the solvation agent. The body of the obtained
mass was ~valuated in the hot state in each instance. The exper-
imental resul~s are compiled in Table II, below.
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s
~abie II
Ingredient, ; G H I ~ K L
._ ~
rennet casein 25 25 25 25 25 25
water 74.5 74.25 7473.5 73 72
DSPl 0.5 0.75 1 1.5 2 3
DSP2 2 3 4 6 8 12
1 based on total weight of composition
2 based on weight of rennet casein
In Run G, the obtained mass had the appearance of fresh
curd; some particulate rennet casein was also observed to be pre-
sent.
In Run H, the mass had a smooth body with some stretchi-
ness.
In Run I, the mass had a stringy body.
In Run J, the mass exhibited a lower viscosity and less
stringiness than the mass of Run I.
In Run K, the mass was quite thin and had a plastic,
almost process cheese-like body with very little stringiness.
In Run L, the mass was very plastic and had a process
cheese-like body.
The foregoing specification and the examples are in-
tended as illustrative and are not to be taken as limiting.
Still other variations and modifications within the spirit and
scope of the present invention are possible and will readily
present themselves to one skilled in the art.
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