Note: Descriptions are shown in the official language in which they were submitted.
~ ~ ~ s ~
ecification:
The present invention relates to a novel ~ood product
and process of manu~acture thereof; and more specifically rela~es
to a simulated cheese resem~ling mozzarella cheese ha~ing dry
rennet casein as its principle protein ingredient J and a process
for commingling the ingredients and hydrating the dr.y rennet
casein.
Back~ nd of the In~ention
Cheese has traditionally and historically been manufactured
from the milk o~ cows, goats J sheep and other animals. Because
of dietary problems and also the cost of natural milk.there have
been many substitute products developed which resemble:cheese and
are known as cheese analogs, imitation cheese, filled cheese and
simulated cheese, and which use non-milk ingredients and/or
certain milk derivatlve or milk by-products. (Imitation cheese
utilizing at derived from a non-dairy source is sometimes
referred to as a "filled cheese".) Such products have b~en
developed using vegetable or animal fats.substituted for milk
fats, and/or vegetable or animal protein substituted for milk
protein. Qften the substituted ingredients have characteristic
flavors that are imparted -to khe simulated product and which are
not typical of the cheese being simulated. .In some instances
those characteristic flavors ha~e been overcome by the addition
of certain ingredients such as salt and artificial flavorings
including strong cheese flavor material.
However, where the cheese to be si~lulated normally has
a bland or mild flavor, such as mozzarella cheese, it has not
been effective to mas~ the characteris~ic flavors of substitute
ingredients. For example, there have been a number of simulated
cheeses which utilize either acid casein or a caseinate as all or
a major part of the protein sourceO U.S. patent No. 4,016,298 to
Kasik, et al. teaches the production of a "cheese extender" from
neutralized acid casein (about 25 percent of the ingredients)
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first mixed with a vegetable fat and then water and other ingre-
dients including salt, lactic acid and lipolyzed uils to resemble
mozzarella cheese. Also, U.S. patent'~o. 4,110,484 to Rule,
et al. teaches the production of an imitation cheese from dry
caseinates (about 25.5% of the ingredients) mixed with vegetable
oil and water, an acidulant (such as lactic acid) and flavorings
to resemble mozzarella cheese. It is notable that Rule, e-t al.
suggest the prior i.mitation cheeses have included about 15-33%
- protein ingredients (caseinates).
While these examples o~ prior art result in nutritious
products it is 'believed that their resemblance to mozzarella
cheese is mainly in the physical consistency of the product
rather than flavor which is noticeably affected by the typical
characteristics of acid cas~in (dependant on the acid used) and
caseinates (a gluey-casein flavor) and not completely overcome by
the added flavor ingredients. Indeed, the favor ingredients
themselves are not typical of the traditiona'l and desira'ble bland
flavor found in good mozzarella cheese.
Also, the acid casein and caseLnate in;~redient~ impart
other physical characteristics that are ~oreign to mozzarella
cheese and which may be undesirable where the product is employed
with other foods. For instance, mozzarella cheese is oten used
as a topping t~at melts smoothly while retaining i~s natural
light color w~en making pizza. However, imitation cheese employing
caseinates are found to have a tendency to puff and brown when
cooked on a pizza crust.
Moreover, the mechanical handling of caseinates poses
some problems as they tend to be very light and dusty (being less
dense than milk powder). Yet, both caseinates and acid casein
are relatively soluble in water when mixed in appropriate equip-
ment ancl, thereore, are easy to hydrate and mix with the other
ingredients required to make a simulated cheese.
Prior to the present invention dry rennet casein was
not regarded as a suitable protein source for simulated cheese
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because of an extreme difficulty in hydrating the material.Indeed, as disclosed in U S. patent No 4,096 7 586 to Badertscher,
et al. the preparation of no more than a 10% solution of rennet
casein iIl water requires hydration for;ten minutes and adjustment
of pX with addition of a citrate and phosphate solu~ilizing
agent. However, as noted before, imitation cheese requires
protein well in excess of that amount. Yet the known bland
flavor and low~cost of rennet casein would ma~e it an ingredient
of choice for simulated cheese. NevertheIess, prior to the
present invention it has not been known to so employ rennet
casein as a major protein source in such a food product. See
also Roeper J. "High-Calcium Phosphate Casein Products For Use In
Food Systems", New Zealand Journal of ~air~ Science~and ~echnology,
1~76.
Accordingly, it is an object of the present invention
to provide an improved simulated cheese, and a process for the
manufacture thereof, wherein dry rennet casein is the principle
protein ingredient.
It is another ob~ject of this invention to provide an
improved simulated cheese, and a process for the manufacture
thereof, wherein dry rennet casein is a source of protein in
excess of 10% of the weight of the ingredients of said product.
It is yet another object of this invention to provide
an i.mproved simulated mozzarella cheesel and a process for the
manufacture thereof, wherein dry rennet casein constitutes the
sole source of protein.
It is still another object of this in~ention to provide
an improved simulated mozzareIla cheese and a process or the
manufacture thereof, wherein dry rennet casein is incorporated as
the protein source in excess of 2Q% of the i.ngredients thereof.
A further object of the present invention i5 to provide
an improved process for the manufacture o~ simulated cheese
wherein dry rennet casein in excess of lOC/o of the cheese ingredients
is hydrated in water and mixed with a fat and other ingredients.
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It is a still further object o~ t~is lnvention to
provide a method for hydrating relatively greater amounts of dry
rennet casein in excess of 10% o the weight of the water in
which it is mixed.
In general, the present invention is an im~roved simulated
cheese.having in excess of about 15% protein ingredient and in
the range of about 15-33% of the.weight of the cheese pro*uct,
wherein dry rennet casein is the'principle.protein source in
excess of lOC/o of the product weight, preferably more than 15% and
most desirably about. 22~/o of t~e.product wei~ht. The remainder of
the product is made up of a~suitable oil or fat amounting to
about 12-35% of the product by weight, water~amounting to about
40-50% preferably.45-49% by weight, and minor amounts o~ sodium
citrate, lactic acid and other food additive:materials..including
salt. The improved product is achieved.by a novel process for
hydrating relatively la~ge amounts of dry.rennet casein and
mixing with the other ingredients wherein minor amounts.of sodium
citrate and lactic acid are first dissolved in t'he waker, the
rennet casein is then added in the presence o~ the oil or :Eat
ingredient and the mixture is agitated for several mi.nutes whi'le
heated. The remaLning :Lngredients are then added and mixed while
further heating the product; and the warm mixtu~e.is packaged and
cooled.
Further objects and advantages of the invention will
become clear from a reading of the following detailed description
o the invention.
Incorporation of.dry rennet casein as the major and
preferably sole protein ingredient in simulated cheese is highly
advantageous because of.the very bland flavor characteristic of
that material. Thus, nearly any type of cheese may be simulated
because the other principle ingredients, water and fa~, may
readily be obtained with very little if any flavor, and the
desired product flavor and cost may be constructed from re'latively
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smaller amounts of flavor contributing materials rather than
relatively larger amounts of flavor materials c~osen to suppress
.`. or mask the protein ingredient.
Simulated cheese of pH 5.1-6.0 and having the following
composition ranges may be produced:
Salt 0 to 2.5%
Moisture 40 to 60%
Fat 15 to 40%
Protein 15 to 33%
The protein range of the foregoing product will include
at least 10~/~ to 33~/O from remlet casein.and.the remainder not
exceeding 15% may be from other sources, such as calcium caseinate,
and sodium caseinate, and combinations:thereof, potas.sium caseinate,
magnesium caseinate,.lactic acid casein, and hydrochloric acid
casein. The fat component may be chosen from a variety of animal
and vegetable sources, and combinations thereof which are bland
in flavor and have a Wiley melting poi~t.of up to 135. The
melting point characteristic of the fat chosen will.affect the
relative softness or firmness of the resulting cheese. It :Ls
preferred that the fat be lar$ely a hydrogenated vege-table ~at
having a Wiley meltin~ point o 118-122, althou~h up to about 10%
of the fat may be from other sources including butter fat which
is sometimes desirable to impart flavor, texture, mouth feel and
melt control.
Additional minor amounts of calcium.sequestering agents,
preferably about 1.75% (ranging from 1.0-3%) hydrous sodium
citrate and about .26% (ranging from 0,0-0.5%) anhydrous citric
acid are used in the manufacturing procedure:and will be present
in the final product. Also, about 1.05% (ranging from 0.75~1.5%)
lactic acid is utilized to maintain pH 5.4-5.7. Other acidulents
as acetic acid, phosphoric acid, etc., and com~inations of acids
may be used for that purpose. Additional ingredients in minor
amounts, largely for taste.and preservative properties, may be
incorporated including lipolized cream, sorbic acid and, if
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desired, other commercially available arti~icial flavor vitamin
and mineral ~ortifiers.
Unlike the production of natural cheese, -the manufacture
of a simulated cheese need not involve the loss o~ liquids. That
is, there need not be an expression of whey or other liquid
during ormation of a curd. And there need not be any significant
time consuming ripening of the product. Instead, in the manuacture
of simulated cheese in accordance with the present invention,
substantially all of the ingredients including wa~er introduced
during the manufacturing process wil.l be retained in the final
product; and the product is immediately ready for consumption
after coolin8-
The manufacturing process is essentially one of mixingand cooking to produce a stable emulsion of the ingredients. The
formation of a water and oil or fat emulsion aided by food
emulsifiers has not been a problem. However, it has been necessary
to first solubilize the protein ingredient in the liquid phase
be~ore forming the emulsion. Thus, heretoore the protein ingre-
dient has been limited to those known to be highly solu~le or
easily dispersed and suspended in water~ ~ry relmet casein has
not heretoEore met that requirement. Moreover, i~ has been found
that the nature of the emulsion, possibly the degree to which the
casein is broken up and distributed, has a bearing on the texture
and body of the final product.
It has now been discovered that relatively great amounts
of dry rennet casein, in excess of 10% of the water phase, may be
hydrated and well dispersed by agitatin~ the mixture in the
presense of a minor amount of a calcium sequestering agent.
Sodium citrate is a sequestering agent of choice and is of additional
advantage as it remains present to later act as an emulsifying
agent. Hydration and dispersion of the dry rennet casein is
further enhanced by the addition of a small amount of citric acid
which has been ~o~nd, in combination with sodium citrate9 to
serve as a stronger sequestering agent than sodium citrate alone.
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3~
~iowever, the amount of citric acid ls cr~klcal ~o the ~e~ture of
the final simulated cheese product in that it'has also been found
that increased amo~lts of citric acid will reduce or eliminate
the chewy texture that is desired when simulating mozzarell~
cheese. As previously indicated the amount of sodium citrate
should range rom 1.0-3.0% and citric acid may range rom 0.0-
0.5% of the product mix.
Accordingly, the preferred procedure is to first introduce
a portion of the water into a mixing zone and dissolve therein
about 1.75% of sodium citrate (by weight ~ased on the total
product 'batch) along with about .26% an'hydrous citric acid (if
desired). The precise amounts of sodium citrate and citric acid
will largely depend on the texture desired in the end product and
should be established in trial batches. Also, absut 1.05% lactic
acid (88%) is added as an acidulent to obtain a p~l of about 5.5-
5.7 which will hinder bacteria growth (without the addition of
lactic acid the product would have a pH of about 6.5 which would
be conducive to bacteria growth).
More water is added and the dry rennet casein is added
while moderately agitating the mixture and blending is continued
or about five minutes or until. the casein is completely 'hydrated
and dispersed. The amount o water may be the balarlce of total
requirements or it may be somewhat less lf the produck is to be
subsequently heated by direct steam injection.
The hydrated rennet casein-water mixture is then cooked,
preferably by direct steam -injection to 165-170~.
Pre~erably the precedin~ steps are conducted in the
presence of most of the selected fat or oil ingredient. That is
prior to the in~roduction o dry rennet casein the fat or oil,
with the possible exception o a small amount o butterfat materials,
is placed in the mixing zone whereby during agitation of the
mixture and hydration of the casein an initial emulsion is formed
aided by the emulsifying properties o the sodium citrate and the
casein itself.
After the initial emulsion is raised to 165-170F. the
remaining ingredients, i~ any, such as sorbic acid, lipolized
cream, color, flavor vitamin and mineral supplements, but excluding
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136~B17
salt, are added and the mixture reheated to 165-170~F. during
further agitation.
Salt (sodium chloride) in an amount o~ about 1% to 2% is
blended into the emulsion last after reheating the mixture.
The sequence of this step may be related to ~he mixing and
cooking equipment employed and is significant to the ease
with which the product may be mixed during cooking. It has
been found that if salt is added earlier while using a Damrow
cooker (according to the following example) the product
becomes very heavy and difficult to mix during cooking.
(Damrow is believed to be the trade name and trademark of the
Damrow Co., division o~ DEC International, Inc., 196 Western
Avenue, Fondulac, Wisconsin 54935O~
The completed product is then formed in package shape
while plastic, and cooled to an internal temperature of about
45~F. in less than 24 hours and pre~erably as rapidly as
possible.
A speci~ic example of thls preferred production of a
simulated mozzarella cheese is as follow.s:
A Damrow horizontal cooker ~570 lb. capacity), was
prepared for operation and the ~ollowing qwantities of
ingredients assembled:
Ingredient Weight - lbs. % B~__ei~ht
Rennet Casein 120.00 22.27
- (New Zealand 30 mesh)
Water 215.75 37.86
Sodium Citrate, Hydrous lOoO0 1O75
Citric Acidl Anhydxous 1.50 .26
Lactic Acid (~8%) 6000 1~05
~0 Hydrogenated Vegetable Fat 1~0.00 24.56
(Swi~t Vream brand partially
hydrogenated so-ybean and
cottonseed oil - SWIFT and VREAM
were the trade name and trade
mark o~ Swift & ~ompany, 115 W.
Jackson Boulevard, Chicago,
Illinois 60604)
Plastic Cream 80V/o Butterfat17.00 ~ 9
(standardized product)
Lipolized Cream 5.50 .98
(Miles L 22 brand - believed to be
the trade name and trade mark of
Miles Laboratories, Inc.j
Biotechnology Group, Elkhart,
Indiana 4651~)
Sorbic Acid 1.00 .18
Salt 8.00 1.40
~rtificial Flavors .80 .14
Vitamin-Mineral Fortifier .41 .07
(Hoffman-LaRoche, Inc.
3~0 Kingsland Street 9 Nutley,
New Jersey 07110)
In addition to the foregoing materials 37-lbs. (6.5%)
of water in the ~orm of steam condensate (added to the batch
by direct steam injection heating~ is allowed for in calculating
the total batch.
The vegetable fat is in a plastic form and is first
added to the Damrow coo~er and the auger run at moderate
speed to seal the cooker discharge with -the at This has
been found helpful in preventing the formation ot casein
clumps at the discharge end of the cooker where auger agi.-
tation is poor.
About 12V/o (25 lb.) of the water is introduced into the
cooker and all of the sodium citrate, citric acid and lactic
acid is added and dissolved therein. The balance o~ the
liquid water is then added. The auger is operated a-t moderate
speed and all of the dry rennet casein is slowly added and
blended for about 5 minutes to full hydration. Steam is
injected while auger continues to run and until the mix
reaches 165-170F. Thereafter, the steam is turned o~ and
the sorbic acid, plastic creams, lipolized cream, color,
flavor and vitamin-mineral material.s are added while the
mass is agitated, and the mix~ure is reheated to 165-170F. by
_
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steam injection.
ThP salt is then blended into the mix. The warnt product
has a heavy bread dough like tex~ure and a rich cream color1
There are no signs of ~ree oil, yet the product will release
from ~he equipment easily.
The warm product is divided into blocks welghing about
; 5, 20 and 40 pounds and cooled to 45F. within 24 hours.
Obviously many modifications and variations of the
invention as hereinbefore set forth may be made without
depar~ing from the spirit and scope thereof, and, therefore,
only such limitations should be imposed as are indicated in
the appended claims~
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