Note: Descriptions are shown in the official language in which they were submitted.
DESCRIPTION OF THE INVENTION
NOVEL MODULAR UNIVERSAL
CHEESE MAKING MACHINE AND METHOD
FOR MAKING CHEESE WITH IT
SUMMARY
This invention relates to milk pasteurizing machines, cheese curds making
machines, cheese
making machines, cheese molding machines, cheese cutting machines and methods
for
manufacturing of different kinds of cheese using these machines. More
specifically the Machine
is a Novel Modular Universal Cheese making, molding and cutting machine, which
can
transform within its several modules raw milk to curds and then to any kind of
the most common
cheeses shaped to desired form and ready for maturing or sale.
Further, the invention is a universal cheese curds making machine, cheese
making machine and
cheese molding machine, which can be mounted either in a stationary position
in a building, or in
a standard 40 ft. high cube shipping container to create a mobile
(transportable) cheese plant.
The Art of Cheese making was developed thousands of years ago in parallel with
the
domestication of milk producing animals. Today, there are thousands of styles
and kinds of
cheese. Almost every country in the world and the regions within a country
have their own kinds
of cheeses. In some countries the recipes of regional cheeses are guarded by
country and local
laws.
Cheese is a milk product. Production of cheese always includes the production
of cheese curds
from the milk, separation of cheese curds from the whey, pressing and shaping
of cheese curds
into molds to obtain the desired transportable shape and the stage of the
aging of the cheese.
During the process salt is applied to the cheese at different stages of the
process, depending on
the cheese making recipe.
This invention provides the design of a Novel Universal Modular Cheese Making
Machine
which will produce within its modules any kind of the world's most popular
cheeses to the point
when the cheese is ready for aging. Two of the modules also provide a means
for the production
of extruded cheese products, while a separate module provides CIP/COP
capabilities. This
invention also provides a Method of how to operate the Cheese machine to
produce the desirable
result ¨ tasty cheese.
Date recue /Date received 2021-11-08
Introduction
Note: For simplicity hereafter we will use the abbreviation "Cheese Machine"
instead of Novel
Modular Universal Cheese Making Machine.
Note: All designs follow the strict guidelines and requirements of numerous
Canadian and USA
Food Safety Authorities and laws, as well as design guidelines of 3-A and
EHEDG Standard
Organizations.
Note: All materials and equipment used in the design of the Cheese Machine are
food grade.
Specifically the bodies of the modules, main construction elements, along with
the fittings, and
accessories are made of stainless steel. All bearings, gaskets, motor units,
sensors and electric
.. and electronic control panels are made with food grade materials and
approved for dairy
manufacturing environments.
Background of the Invention
Cheese is one of the world's most popular foods. All persons masterful in the
art of cheese
making know that it is produced in several steps: turning milk into cheese
curds, shaping of the
cheeses curds, and aging of the cheese product. The first cheese curds were
made by mixing the
contents of the stomach of a fresh killed suckling lamb with sheep's milk.
Soon after humans
started mass producing cheese. The first cheeses were made (and in many cases
are still
produced today) by artisan cheese makers using simple vats and primitive
tools.
With the growth of cheese demand, it became obvious that a process and methods
for cheese-
making had to be studied in depth and production had to be mechanized.
Today, there are thousands of patents related to cheese making. There are two
groups of patents
related to cheese making and the cheese industry.
The First group deals with the chemical and biochemical transformation of milk
to cheese curds
and cheese.
The Second group of patents deals with mechanical means and methods for making
cheese curds
and cheese.
The invention relates to this Second group.
Cheese curds making machines and cheese curds cutting knives are produced in
various shapes
and sizes.
Unlike in the patented designs, the artisan cheese maker uses a non-patented
(often wooden)
simple mechanical paddle to agitate the milk and the rennet. He then cuts the
cheese curds with a
non-patented simple knife by hand. He presses his cheese in a simple press or
by adding a
weight. Despite this simplicity, the artisan cheese maker often produces
tastier and more valuable
Date recue /Date received 2021-11-08
cheese products than complicated patented machines of famous food processing
equipment
companies.
In other words ¨ the patented cheese machines designs are becoming more and
more
complicated, without adding value for the money to the cheese makers and the
consumers of the
cheese.
However, the Artisan Cheese makers also has a problem¨ manufacturing process
is labor
intensive and not always cost effective. Thus, their cheeses are more
expensive and they have
difficulty competing against mechanically made cheeses. In addition and in
order to satisfy
growing demand for cheese, the Artisan cheese maker must mechanize the
manufacturing
process, without compromising the quality of the final product.
This NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE AND METHOD
provides a simple and cost effective solution to many of the problems
encountered by small,
medium and advanced-medium cheese makers, without affecting the quality of the
cheese
product.
Block Diagram, Analysis and Optimization
During the process of designing this Cheese Machine, we analyzed the designs
of existing cheese
machines and apparatuses.
We came to the conclusion that the most advantageous design is one based on a
modular
principle.
We optimized the number of modules of the Cheese Machine that are required for
cheese
making.
We reduced the number of the modules, without reducing the number of cheese
products that our
Cheese Machine can make. The Cheese machine is a universal machine that can
make almost
any kind of cheese known to mankind.
We also wanted to design a Cheese Machine to be easily movable, if required.
We invented a
mobile Cheese Machine which can be used either as a stationary machine ¨ in an
existing
building, or it can be used as a mobile cheese plant, when mounted in 40 foot
standard high-cube
shipping container, which can be transported everywhere.
Several Block diagrams and a General drawing give a better understanding of
the organization of
the modules of the Cheese Machine:
- FIG. 1 Block diagram of the normal processing route when manufacturing
traditional soft
cheeses, semi-hard cheeses, hard cheeses and brine aged cheeses
- FIG.2 Block diagram of the normal processing path for making pasta filata
cheeses and pasta
filata cheese extrusions.
Date recue /Date received 2021-11-08
Note: For production of just pasta filata cheese, we do not require Module 400
and Module 500.
Only Module 200 ¨ the Cheese processing vat is required.
- FIG 3 Block diagram of the range of use of Module 600 ¨ Combined CIP and
COP unit.
- FIG 4 General Drawing of the Cheese Machine when used in a Mobile
Container Cheese
Making plant.
THE CHEESE MACHINE consists of following modules:
Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7)
The first step of any cheese making process is to make cheese curds. To the
pasteurized milk are
added bacterial starter cultures (in some cases funguses), rennet and after a
specific time the
result is a cheese curds mass. Entrapped in the cheese curds mass is a liquid
called whey. The
cheese curd mass is cut in order to expel the whey from the cheese curds,
which are small pieces
with a complex structure of coagulated milk proteins and milk fats.
Cheese curds making machines and cheese curds cutting knives come in all kinds
of shapes and
sizes, like in U58820224, U55985347, U54989504, U53541687, DE000002538530C2,
W02017085211A1, US20140096688A1, U52009238, US3019527, US3019527, US2917827,
U54938424, U55052290, U52008/0047442A1, US 2016/0316776 Al, U51695761,
EP1084609A1, EP2418934B1, U52014/0096688A1.
In Module 100 ¨ Batch Pasteurizer and Cheese Vat, the raw milk is pasteurized,
microbial
cultures and rennet are introduced, curds are made, then cut and matured. The
module allows for
washing of the curds as some washed rind cheeses require (Gouda for example).
It is a CIP
enabled unit.
One of the novelties in this Module 100 are the cheese curds cutting knives.
They are of a
unique yet simple design and do not require any welding to the frame of the
machine. This will
allow them to be changed when required. Further, the blades are positioned in
a such a way, that
they also agitate the cheese curds, so no additional agitation paddles are
required as in other
patented designs.
Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.!!)
The next step in making cheese is the separation of the solid phase ¨ the
cheese curds from the
liquid phase ¨ the whey.
There are a number of inventions concerning separation of cheese curds from
the cheese whey
like EP1175826A2, U53193927, U54306493, U55669291, U52494637, U51046906,
U52193462, U53292259.
Date recue /Date received 2021-11-08
In the specific case of production of Pasta-filata cheeses, the cheese curds
are not only separated
from the whey, but the cheese curds themselves are cooked and stretched. For
example, the
worlds most popular pasta filata cheese is Mozzarella (pizza cheese).
Production of this cheese
requires first the production of curds, followed by drainage of the curds.
Then the production of
the cheese mass undergoes specific steps ¨ cheddarization of the curds;
cutting of the cheese
mass into pieces; cooking - plastification and stretching of the curds to form
a "dough"; shaping
of the plasticized and slowly flowing cheese mass into molds to desired shapes
and sizes. Pizza
cheese is a high demand product and as a result, there are many patents of
machines which deal
with kneading, stretching, (cooking) of mozzarella cheese curds, like
US2017258031A1,
US20120097048, W002072338A1, W02017157785A1, US20110045131A1,
US20030200873A1, US8932657, US5873654, US5480666, DE102011086981A1, US2039162,
US3961077.
In this invention, so designed Module 200 ¨ Curds Processing Vat, solves all
of the problems
regarding the separation of the cheese curds from the whey, the cheddarization
of the cheese
curds and the making of pasta filata cheeses. For the first time in the
history of contemporary
cheese making Module 200 combines many of the steps of the cheese making
process in one
single apparatus.
Further our Module 200 ¨ Curds Processing Vat is of a novel and original
construction.
The Curds Processing Vat module performs the following functions:
First, Module 200, when connected to Module 100, catches all the fines
(smallest curds
particles), when cheese curds are washed in Module 100 in the case of washed
rind cheeses.
There is no need for a complicated draining assembly as in many patented
designs.
Second, when connected to Module 100, the Curds Processing Vat drains the
cheese curds from
the whey and catches all fines, thus increasing the cheese yield.
Third, the Curds Processing Vat Module 200 is designed to be used as a machine
for
cheddarization of cheese curds if the cheddarization step is required.
Forth, the Curds Processing Vat 200 feeds the next Module 300 ¨ the Cheese
press with
cheese curds for pressing and is intended to be to used as a screw press to
press the cheese curds
into cheese molds.
Fifth, when used as a stand alone unit, the Curds Processing Vat 200 can cook
pasta filata type
cheeses, or cheese dipping sauces.
Sixth, the Curds Processing Vat 200 is used to salt the curds when the cheese
is being prepared
for further processing and for mixing of salt with fresh curds. Usually common
table salt is the
sole cheese conservation agent. The addition of salt depends on the recipe ¨
some cheeses
require a brine bath soaking, instead of salting.
Date recue /Date received 2021-11-08
Seventh, the Curds Processing Vat 200 can be used for making extruded cheese
shapes such as
cheese fingers, cheese sheets, spaghetti shaped cheese extrusions etc.
In other words the Curds Processing Vat 200 is a real "multi-tasking worker"
of novel
construction. It is a CIP enabled unit.
Module 300 ¨ Cheese Press (FIG.12, FIG.13, FIG.14, FIG.15, FIG.16, FIG.17,
FIG.18)
When some of the water (whey) is drained from the cheese curds, the cheese
curds are pressed
into molds to form cheese wheels and even more water is expelled from them. In
some soft and
blue-veined cheese only gravity is required to press the cheese curds into the
molds (without any
other mechanical pressing assistance). The sizes of the cheeses vary from huge
to miniature.
Accordingly, there are many inventions which deal with the shaping of cheese
curds into cheese
wheels like U53562910, U51492388,U53727308, U53765090, U55792500, US6403138,
US20160205962A1, U54045152, EP3241432A1, EP2782441B1, U52077644, US1450105,
U52019002, U52980542, U51796445, U52263851, U52642797, U53192626, U53199195,
U53295205, U53355805, U59567153, U55480666, U54664613.
Our Module 300 ¨ Cheese Press is of a completely novel design.
To our knowledge it is the first cheese press which provides the cheese-maker
with the means to
measure, control and change the value of the pressing force which is applied
to the cheese
curds, so all kinds of cheese can be pressed.
The Cheese Press is of a horizontal space-saving construction with the
following functions and
modes:
First, when attached to Module 200 ¨ Cheese Processing Vat, cheese curds enter
the Cheese
press Module 300 and there they are pressed into a cheese mold of desired
shape by the screw of
Module 200. The pressing force is fully adjustable and measurable.
Second, When the Cheese press ¨ Module 300 is used as a stand-alone unit, it
can press any
cheese curds into cheese wheels or cheese blocks . The pressing force is again
fully adjustable
and measurable.
The possibility-by-design to have two different modes of operation, makes
Module 300 ¨ the
Cheese press really unique compared to the other patented designs.
Module 400 ¨ Cheese conveyor and Module 500 ¨ Cheese Cutting table
(FIG.19, FIG.20, FIG.21, FIG.22, 2FIG.23)
When making cheese extruded products, Module 400- Cheese Conveyor and Module
500-
Cheese Cutting Table are connected together and they are positioned in front
of Module 200 ¨
Curds Processing Vat.
Date recue /Date received 2021-11-08
Module 400 ¨ Cheese conveyor is an ordinary conveyor which fulfills the
government sanitary
requirements. It is equipped with a water sprinkling system which sprays
cooling water over the
extruded cheese product to cool the product down.
Module 500 ¨ Cheese Cutting Table ¨ is of a novel design. It is easily
adaptable to conveyors
of various lengths and sizes.
Module 500 ¨ Cheese Cutting Table by design is unique, because it has two
different modes.
The module has following functions and modes:
First, when Module 500 Cheese cutting table is connected to Cheese conveyor
module 400
and Curds Processing Vat module 200, it is used to cut extruded and cooled
cheese products to
a desirable length before further processing or packaging. The speed of the
cutting knife ¨ the
length of the product is fully adjustable.
Second, when Module 500 ¨ the Cheese cutting table is used as a stand alone
unit and
equipped with an appropriate knife, it is used for the cutting of cheese
wheels to wedges or other
shapes.
Module 600 ¨ Combined Clean-In-Place (CIP) and Clean-Out-of-Place (COP) Unit
(FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29)
To our knowledge Module 600 ¨ CIP and COP unit is the First known CIP & COP
unit which
aside of all sanitary requirements, is designed to fulfill all 3-A and EHEDG
designs guidelines.
Second unique feature of Module 600 ¨ CIP and COP unit is that the pump of the
module can
be used as a transfer pump for the daily operations in the dairy plant.
Third unique feature is that Module 600 ¨ CIP and COP unit is that the heat
exchanger of the
module can be used to make hot water for the daily operations of the dairy
plant.
The purpose of Module 600 ¨ CIP & COP unit is to clean all modules of the
Cheese machine,
all parts and all accessories (such as hoses, fittings, cheese molds, etc.)
which require sanitary
cleaning ¨ Modules 100, 200, 300, 400, 500.
In addition as mentioned above, the design of the piping of Module 600 ¨ CIP &
COP unit
allows for the pump, which is mounted on the unit to be used as a stand alone
pump. The pump
can also be used for various other purposes such as pumping whey, water, or
pumping curds ¨ for
example, when modules of the Cheese Machine have been retrofitted to existing
cheese plants, or
cheese vats supplied by other companies.
Accessories to the Machine (FIG.30)
In addition to the modules of the machine, we have several useful accessories
which facilitate the
cheese manufacturing process. These accessories include a Process Dripping pan
trolley, a
Cheddarization table and Extrusion end caps.
Date recue /Date received 2021-11-08
Following is a detailed description of the Modules
of the NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE
(aka: the Cheese Machine)
Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7)
The Batch Pasteurizer and Cheese Vat is a semi-cylindrical stainless steel
Vessel 101,FIG.5,
which is mounted on four welded adjustable legs 102, FIG.5. The legs 102, are
welded in such a
way, that when the vessel 101 is in a horizontal position, it is inclined at a
3 degrees angle as
required by law.
The vessel 101 has a jacket 116, FIG.6 which is separated into two sections.
The jacket 116
provides a means for heating and pasteurization of the milk in the vat (also
heating of the cheese
curds) either with hot water or low pressure steam. Hot water or steam is
supplied to each of the
sections of the jacket 116 through two hot water (steam) inlets with flanges
107, FIG.5, FIG.6.
After heating the vessel 101, the cooled water (or the steam condensate)
leaves the jacket 116,
through two outlets with flanges 108, FIG.5. The hot water (low pressure
steam) jacket 116 has
insulation. The insulation is covered with a stainless steel sheet metal
insulation cover 123,
FIG.6.
The vessel 101 has a fully removable free ¨ standing reinforced stainless
steel cover 114, FIG.5.
The cover 114 has two symmetrical covered manholes 115, FIG.5.
The reinforcements of the cover 114 are designed in a way, which allows for
the cover 114 to be
used as a convenient main platform for attaching pieces of hardware necessary
for normal
operation of Module 100. Such approach simplifies manufacturing of Module 100.
To the cover
114 are attached following pieces of hardware:
- Thermometer for measuring the temperature of the milk (cheese curds) 103,
FIG.5 (required by
law);
- Thermometer for measuring the temperature of the subspace between milk
surface and cover of
the vessel 104, FIG.5 (required by law);
- Two steam generators (or steam filters as the case may be) 106, FIG.5 for
supplying steam to
heat the subspace between the milk surface and the cover of the vessel
(required by law);
- One central mounted wash ball with rotating jets 112, FIG.5, FIG.6. It
allows for the CIP
cleaning of Module 100;
- Two milk inlets with sanitary clamp flanges 113, FIG.5, which allow for milk
to be loaded into
the vessel 101 from the milk supply truck (or the milk supply line).
To the front of the Batch pasteurizer and Cheese Vat is mounted a bi-
directional gear motor 109,
FIG.5 which rotates the curds cutting knives of the unit. All parameters of
the gear motor 109
Date recue /Date received 2021-11-08
are appropriate for cutting and mixing cheese curds. The direction of rotation
and the rotary
speed of the gear motor 109 are fully adjustable.
The control box 105, FIG.5, controls not only the working parameters of the
motor 109, FIG.5,
but also the complete pasteurization process, and includes a temperature
recording device
which records the readings of the thermometers 103 and 104 FIG.5, as required
by law.
Also in front of the Batch pasteurizer and Cheese Vat are mounted two none-
drip milk valves 110
and 111, FIG.5.
The main milk valve 110, FIG.5, as the names states, is used for the complete
evacuation of the
vessel 101 and evacuation of the cheese curds from Module 100 to Module 200 ¨
Curds
Processing Vat, when they are ready for further processing, with the help of a
flexible food grade
hose (not shown on the design drawings for greater clarity). The main milk
valve 110, FIG.5, is
also used during the CIP cleaning procedure, when connected with a flexible
food grade hose
(not shown) to Module 600 ¨ Combined CIP and COP Unit.
The auxiliary milk valve 111, FIG.5, has several important functions:
- First, the auxiliary milk valve 111, FIG.5 is used to remove part of the
whey immediately,
before the evacuation of the main mass of the cheese curds from Module 100
with the help of a
detachable food grade hose (not shown). Since the cheese curds tend to settle
to the bottom of the
cheese vat, it is a standard procedure for the cheese makers to drain part of
the whey before
evacuation of the main mass of curds from the vat.
Previous patented cheese vat designs for that reason are equipped with special
and complicated
whey draining mechanisms for catching "fines" ¨ smallest cheese curds
particles with size under
0.1mm.
Our design doesn't require such a complicated mechanism, because all fines are
caught by the
design within Module 200 ¨ Curds Processing Vat. This way, Our design is
simpler than
previous arts.
- Second, the auxiliary milk valve 111, FIG.5 is used for draining part of the
whey (as described
above) in the case of the production of so called "washed curds" cheeses such
as Gouda. The
Gouda cheese making recipe requires draining of a portion of the whey, and the
replacement of
the drained amount of whey with fresh water and the washing the curds to
remove part of the
lactic acid from the cheese (removal of a part of the sharp cheese taste and
bringing some
mildness to the cheese).
At the heart of the cheese curd cutting mechanism of Module 100¨ Batch
Pasteurizer and
Cheese Vat (FIG.6,FIG.7) is mounted the Main Axle of the cheese curds cutting
assembly 122,
FIG.6, FIG.7. To the Main Axle 122, are attached two sub-axles:
Date recue /Date received 2021-11-08
- The Back sub-axle 117, FIG.6, FIG.7 is a solid piece of stainless steel, and
has grooves 118,
FIG.6, FIG.7 cut into it. The Back sub-axle 117, FIG.6, FIG.7, is supported by
a food grade
plastic sliding bearing 119, FIG.6, which is fully submerged in the vat. Hence
the grooves 118,
FIG.6, FIG.7 allow for CIP washing of the sub-axle and bearing itself ¨ there
are no "washing
dead spots". This submerged bearing design, also allows for the simplification
of the design of
the vat, since there is no need for mechanical seals on the back side of the
cheese curds cutting
Main axle 122.
- The Front sub-axle 120, FIG.6, FIG.7, is made from a solid piece of
stainless steel and is
attached to the Main axle 122, FIG.6, FIG.7. However in this case there are no
cut grooves in its
to body. The Front sub axle 120, FIG.6, FIG.7 is supported by the bearings
of the gear motor 109,
FIG.5. Two food grade polymer lip seals 121 FIG.6 (or food grade mechanical
seals, as the case
may be), seal the vat interior from the vat exterior.
The cheese knives supporting frames 124, FIG.7 are welded to the Main axle of
the cheese curds
cutting assembly 122, FIG.6, FIG.7 with the help of two rings. In the steel
frames are cut
symmetrical channel slots 126, FIG.7, which end with holes cut into the metal.
The channel slots
126 are cut at an angle (at the range of 5 to 15 degrees) into the frame 124.
The cheese knives 125, FIG.7 are laser cut from stainless steel sheet metal
with appropriate
thickness. One of the longitudinal edges of cheese knives 125 is sharp ¨ for
cutting of the cheese
curds, while the other longitudinal edge is blunt for mixing of the cheese
curds.
When mounted to the frame 124, all of the sharp edges of the cheese knives
125, point in one
direction.
The cheese knifes 125, FIG.7 are designed to be wide enough so two knife
holding holes 127,
FIG.7 can be drilled into each of them, without compromising the mechanical
strength of the
knives.
To mount the cheese knife 125, FIG.7 into the frame, we slide each knife 125
into the
symmetrical slots 126, FIG.7. Then we slide through the holes on the frame 124
and through the
holes 127 on each knife, the two knife fixing bolts 129, FIG.7, and tighten
the knife fixing bolts
to the frame 124 with the help of the two knife fixing nuts 128, FIG.7.
Since the channel slots 126, FIG.7 are cut into the frame 124 at an angle, the
cheese knives 125,
also sit at an angle relative to the frame 124 in the channel slots 126 (see
FIG.7). So when the
cheese knives rotate, they not only cut the cheese curds, but also mix the
cheese curds ¨ acting as
paddles. It should be noted that the cheese knives are kept in place only by
the two knife fixing
bolts 129, FIG.7 and by the two knife fixing nuts 128, FIG.7 ¨ there is no
welding, or any other
fixing or attaching elements, etc. It should be noted that all mechanical fits
of the symmetrical
channel slots 126, FIG.7, of the cheese knives 125, FIG.7, of the knife holes
127, FIG.7 and of
Date recue /Date received 2021-11-08
the knife fixing bolts 129, FIG.7 are clearance fits - so the cheese knives
125, FIG.7 can move
several millimeters in each direction when mounted to the frame 124. This
feature is especially
important for the CIP cleaning of the cheese vat.
An advantage of the design is that at the beginning of the curds cutting
process, and because of
the rheological properties of the cheese curds, the knife fixing bolts 129,
FIG.7 also act as
cheese cutting knives. This cutting action plus the cutting action of the
cheese knives 125, FIG.7
allows for a better cutting of the cheese curds mass to cheese curds. When the
cheese curds
become small enough, the knife fixing bolts 129, will not cut the cheese curds
any further ¨ the
cheese curds will just slide over the bolts. This is an advantage in the late
stages of the curds
to cutting process and the maturing of the cheese curds in the vat.
It is our belief that the design of the cheese curds cutting knives assembly
is the simplest and the
most advanced of all patented designs for such knives and assemblies in entire
world. There are
many known patented designs of curds cutting assemblies. Before This
invention, known
patented designs of curds cutting knives and described in EP2418934B1 and US
2014/0096688
Al (Tetra Laval Holdings & Finance S.A).
Such previous designs have following issues:
- First they use long strip-like curds cutting knives; which because of the
laws of the physics tend
to buckle, so to prevent the buckling of the knives, they must add additional
reinforcement strips
perpendicular to the knives in order to prevent the buckling and the breaking
of the knives,
- Second, these long strip-like knives don't provide the agitation required
for mixing of the
cheese curds during the maturation process, so they add additional externally
attached agitating
paddles to their vats and knives assemblies, in order to agitate the cheese
curds in their vats;
- Third, each of these long strip knives is attached with wires, pins and etc.
- minimum two pins
for each knife.
- Forth, all of the above mentioned reinforcement requires some welding which
makes the
replacement of the curds cutting knives a difficult procedure.
In Our invention (unlike the above cited patents and designs) the curds knives
125 are much
wider. We drill two holes 127 only in each knife, and use only two bolts 129,
two nuts 128, and
the channel slots 126 cut at an angle, to fix the knives to the frame. This
simple design (in Our
invention) doesn't require welding of the knives to the frame.
In addition, even if we scale up the size of our curds cutting knives and
knives assembly to fit
into a bigger cheese vat, our design will still be stronger that the designs
in the cited patents.
Plus we do not require (in our design) additional agitating paddles or extra
elements to prevent
the buckling of the knives.
Date recue /Date received 2021-11-08
At the same time the quality of the cheese curds is the same, while the amount
of undesirable
cheese fines (the cheese particles under 0.1 mm) is minimized.
Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.!!)
Module 200 ¨ Curds Processing Vat is of a unique construction and design. It
is difficult to
compare this module to any of the existing curds processing machines, because
none of the
existing machines have all the functionality and capabilities of Our module.
The overall
dimensions of Module 200 ¨ Curds Processing Vat are such that it can slide
completely and
freely underneath the Module 100 ¨ Milk Pasteurization and Cheese vat.
Module 200 ¨ the Curds Processing Vat, has a stainless steel jacketed body
201, FIG.8, FIG.9,
FIG.10.
The module has a vat cover 202, FIG.8, which can be rotated around the cover
axle 203, FIG.8
and can then be opened and closed. On the vat cover 202, we have two covered
manholes 204,
FIG.8, which allow for observation of the inner workings of the machine and
adding salt or other
components to processed cheese curds and products, as required by the recipe.
An elbow connection 205, FIG.8, allows the module to be connected with a
flexible food grade
hose to the main valve 110, FIG.5 of Module 100 for the evacuation of the
cheese curds for
processing in module 200, or for draining whey from Module 100 to Module 200
through the
auxiliary milk valve 111, FIG.5.
On the vat cover 202, is mounted a wash ball assembly 206, FIG.8, FIG.10 for
the CIP cleaning
of the vat. Three additional inlets 207, FIG.8 on the cover allow for the
mounting of various
devices ¨ depending on the preferences of the cheese maker.
Module 200 has two adjustable legs with hand-wheels 208, FIG.8 and four legs
with caster
wheels 209, FIG.8. The two front legs with caster wheels 209, FIG.8, FIG.10
are shorter than
the two back legs. When Module 200 is in operation the two adjustable legs
with hand-wheels
208, FIG.8, FIG.10 are engaged and the Module is in a horizontal position ¨
supported by the
end tips of the two adjustable legs with hand-wheels 208 and the two longer
back legs with
caster wheels 209. When Module 200 has to be put in a position for moving or
CIP cleaning, the
two adjustable legs with hand-wheels 208 are disengaged and Module 200 is
inclined at an angle
of 3 degrees as per sanitary requirements for CIP cleaning.
At the front of the Module 200 and to the body of the vat 201 is welded a main
vat flange 227,
FIG.8, FIG.9. To the main vat flange 227 with bolts is attached a removable
flange 228, FIG.8.
Functions of the removable flange 228 are two:
- First, to allow access to the inside of the Module for changes of the
sliding bearings and
mechanical work;
Date recue /Date received 2021-11-08
- Second, to support the module whey draining pipe 210, FIG.8, FIG.10.
The whey draining pipe 210 is a pipe with two flanges and a body with drilled
patterned holes.
The whey draining pipe is attached to a flange welded to the removable flange
228, FIG.8 with
the help of the sanitary clamp 215, FIG.8, and is closed from the other side
with an end cap 213,
FIG.8 held in place by the sanitary clamp 214, FIG.8.
The draining and filtering of the whey from the cheese curds is achieved by
several layers of
filtering media 211, FIG.8,FIG.10, wrapped around the whey draining pipe 210.
The filtering media can be made from the following materials
- natural and synthetic fabrics (like cheese cloth),
- polymer sheets with micro-perforations,
- metal sheet with micro-perforations.
The Filtering media is secured over the pipe 210 with a filtering media clamp
212, FIG.8,
FIG.10. When the filtering media is a metal sheet with micro-perforations,
there is no need of
the clamp 212, because the whey filtering metal sheet is directly welded to
the whey draining
pipe 210.
In the production of pasta filata kinds of cheeses, cheese extrusions, or for
example cheese
sauces, we don't need to drain whey from Module 200, so the perforated whey
draining pipe 210,
FIG.8,FIG.10, is removed entirely by disengaging the clamp 215, and is
replaced by a normal-
no holes-pipe of appropriate length with two flanges.
For heating of cheese curds which is required in production of pasta filata
kinds of cheeses,
production of cheese extrusions (or for example production of cheese sauces)
the cheese maker
has two options:
- One of the options is for the cheese maker to supply live steam or hot
water with a flexible hose
through one of the inlets on the cover 207, FIG.8.
- The Second (and less expensive) option for the cheese maker is to supply hot
water (or low
pressure steam) to the jacket 225, FIG.9 of the vat 201, which is covered with
insulation and an
insulation cover 226, FIG.9. The jacket is divided into two compartments and
each of them has
hot water (steam) inlets 223, FIG.9, and hot water (steam condensate) outlets
224, FIG.9.
For the draining of the cheese curds, extrusion and pressing of the cheese
curds, and further
processing of the cheese curds to pasta filata cheeses, or cheese sauces,
Module 200 is equipped
with two ribbon type screw conveyors (mixers) ¨ the top ribbon conveyor 217,
FIG.9, FIG.10,
FIG.11 and the bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11.
At the front of the bottom ribbon conveyor 218 is attached a full blade
extrusion conveyor 240,
FIG.9, FIG.10.
Date recue /Date received 2021-11-08
All conveyors are put in motion by two hi-directional gear motors 219, FIG.9,
FIG.10. The
direction of the rotation, and the rotary speed of the gear motors 219, as
well as any other
parameters of the module (as the case may be) are monitored and controlled via
the control box
216, FIG.8, FIG.9. The control box 216 is supported by two groups of two
control box supports
.. 220, FIG.8, FIG.9, which allows for the control box to be mounted either to
the right or the left
side of Module 200.
The top ribbon conveyor 217, FIG.9, FIG.10, FIG.11, has two sub-axles attached
to the main
axle.
The back end sub-axle 238, FIG.!!, FIG.10, passes through two lip seals 239,
FIG.10, which
seal the interior of Module 200 from the exterior, and is supported by the
bearings 234, FIG10,
of the top gear motor 219.
The front end sub-axle 235, FIG.!!, FIG10 is supported by a food grade sliding
bearing 236,
FIG10. The bearing 236, itself is mounted in a bearing box inside a three
prong star-shaped
bearing support 221, FIG.9 welded to the body 201 of the module and to the
flange 217. The
bearing 236, the bearing box and the bearing support 221 are completely
immersed inside the
module 200. To allow for the CIP cleaning of the bearing on surfaces of the
sub-axle 235 are cut
grooves 237, FIG.!!. These grooves extend beyond the length of the bearing box
and bearing
support 221.
The bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11, has two sub-axles
attached to the
main axle.
The back end sub-axle 231, FIG.!!, FIG.10, passes through two lip seals 232,
FIG.10, which
seal the interior of Module 200 from the exterior, and is supported by the
bearings 234, FIG10,
of the bottom gear motor 219.
The front end sub-axle 245, FIG.!!, FIG10 is supported by a food grade sliding
bearing 229,
FIG10. The bearing 229, itself is mounted in a bearing box inside the three
prong star-shaped
bearing support 222, FIG.9 welded to the body 201 of the module and the main
vat flange 227,
FIG.9. The bearing 229, the bearing box and the bearing support 222 are
completely immersed
inside the module 200. To prevent accumulation of cheese curds residues and to
allow for the
better CIP cleaning of the bearing, on surface of sub-axle 245 are cut grooves
230, FIG.!!. The
grooves which extend beyond the length of the bearing box and bearing support
222.
The front end sub-axle 245, FIG.!!, FIG10 is designed in a way, so that it can
be attached with
four bolts 242, FIG.10 the full blade extrusion conveyor 240, FIG.9, FIG.10.
The front side of
the extrusion conveyor 240 is capped with a welded cap 243, FIG.10 which has
threads and to
which is screwed an end bolt 244, FIG.10. The four bolts 242 allow the
extrusion conveyor 240
to be removed from the module and replaced with screw conveyors of different
sizes and lengths,
Date recue /Date received 2021-11-08
in case it is required by the cheese maker. The end bolt 244 allows for the
attachment of blades to
the end of the conveyor 240 (for example a blade for chopping cheddarized
cheese curds), or
when the conveyor 240 is cleaned, for thorough cleaning of its interior.
Module 300 - Cheese Press (FIG.12, FIG.13, FIG.14, FIG.15, FIG.16, FIG.17,
FIG.18)
Module 300 of the Cheese Machine is a horizontal type of multi-use cheese
press, of a unique
design and capabilities.
The body of the Module 300 has a front cheese press plate 301, FIG 12, FIG.13,
FIG 14, and a
back cheese plate 302, FIG12, FIG13, FIG 14. The plates are connected by two
bottom
composite beams 303, FIG 12, FIG.13, FIG 14, and two top composite beams 304,
FIG 12,
FIG.13, FIG 14. Each of the plates 301 and 302 has four laser cut holes 305,
FIG.13 which are
used to center the beams 303 and 304 during the manufacturing welding process
(for better
linearity of the steel frame). To each of the plates 301 and 304 are welded
four mounting
brackets 306, FIG 12, FIG.13, FIG 14. To the front plate 301 is welded a pipe
with a flange 307,
.. FIG.13, FIG 14, which allows for the connection of the whey draining pipe
210, FIG.8, FIG.10
of Module 200 - the Cheese processing Vat. The front end of the pipe 307 is
reinforced by a
reinforcement ring 308, FIG.13 welded to the pipe and to the plate 301. The
back of the pipe 307
is welded to a machined cheese gate guide plate 310, FIG.13, which has a
channel for guiding
the cheese gate 318, FIG 12, FIG.14, FIG.16, FIG.17. The guide plate 310,
FIG.13, also has
two shoulders 309, FIG.13, with four threaded holes, to which a cheese mold
plate 338, FIG.17
is secured by four bolts 337, FIG.17. The plate 338 has a laser cut hole in it
for the cheese curds
to be able to flow into the mold form 318, FIG17, and also has a cheese mold
support and a
holding ring 336, FIG.17.
The back plate 302, has a laser cut hole 311, FIG.13 for mounting of an
electric cheese-press
pressing cylinder 325, FIG. 12, FIG.17, FIG.18. The size and the ratings of
the pressing force of
the electric cylinder 325 are such, that when required, it can press even the
hardest cheese
varieties. The pressing force of the electric cylinder 325 is measured by an S-
type load cell 326,
FIG.14,FIG.17, FIG.18. To the front end of the load cell 326, is screwed-on a
load platform
327, FIG.14,FIG.17, FIG.18 for a more even distribution of the pressing force
during the cheese
pressing process and for a more precise measurement of the pressing force.
Module 300 - the Cheese press is mounted on four adjustable height legs with
caster wheels
312, FIG. 12, FIG.13, FIG.14. This allows for an easier connection of Module
200 and Module
300 and the better mobility of the cheese press.
Module 300 - Cheese press is equipped with several safety devices:
Date recue /Date received 2021-11-08
- The First safety device is a side metal screen 313, FIG.12, FIG.14, which
is mounted on one
side of the cheese press on four of the brackets 306, with the removable pins
314, FIG12,
FIG14.
- The Second Safety device is the top free standing metal screen 315,
FIG.12, FIG14 which fits
into the grooves 316, FIG12 cut on the plates 301 and 302.
- The Third safety device is two light curtains 317, FIG12, FIG.14, which
are mounted on an
another set of four brackets 306, opposite to the metal screen 313. The light
curtains make the
interior of the cheese press only accessible from one direction ¨ through the
light beams of the
light curtains 317. Therefore, during a pressing operation, when these light
beams are crossed by
the operator hand or any object, the beams are breached and the light curtains
send a signal to the
Control Box 324, FIG12, FIG14 to bring the cheese press to a complete stop.
Since all brackets 306 are designed identical, the metal screen 313 and light
curtains 317 can
exchange their places, so the interior of the cheese press can be made
accessible either from the
right or the left side.
The Control Box 324, FIG12, FIG14 controls the work of the Module 300 and has
the following
functions:
- It receives signals from the load cell 326 and measures the values of the
pressing force;
- It allows for the full adjustment of the pressing force of the electric
pressing cylinder 325;
- It receives a signal when a body crosses the beams of the light curtains
317 and brings to a full
stop Module 200 and Module 300;
- It allows for the manual reset of the light curtain 317 and for the
manual re-start of Module 300,
and allows for the manual reset of Module 200, when the module is connected
via a Wi-Fi
network or a cable to Module 200 (cables or Wi-Fi sender ¨ receiver are not
shown on the
drawings);
- It gives a visual and a sound signal when the preset value of cheese
pressing force is reached;.
The safety light curtains 317 have two additional functions:
- First, the curtains will not allow Modules 200 and 300 to restart if the
cheese gate 318 is not
open ¨ in this case the cheese gate will be in the way of the light passing
from one light curtain
to the other light curtain;
- Second, when the operator reaches to move or adjust the cheese gate, his
hand must cross the
beams of the light curtains 317, thus bringing to a full stop Modules 300 and
Module 200 (in
case that the signals from Module 200 are connected to the signals of Module
300). This way, we
do not require electronic limiting switches for the operation of the cheese
gate 318. They can be
replaced by the two limiting bolts 328, FIG 14 screwed-on one side of the
cheese gate 318, and
two limit bolts 329,FIG.14 screwed-on the other side of the cheese gate 318.
Date recue /Date received 2021-11-08
As described above, the cheese gate 318 slides between the two shoulders 309
of the guide plate
310, FIG.13. To support this sliding action, and in order to have tighter
tolerances, the cheese
gate is supported by two cheese gate support assemblies 319, FIG.12, FIG14,
FIG.16.
Inside each assembly 319, are two stainless steel rollers 332, FIG.16, on
which the cheese gate
318 is suspended.
The exact position of each roller 332 is adjusted with the help of the five
food grade plastic
washers 333, FIG.16. In addition, each cheese gate support assembly has two
cheese gate food
grade plastic wiper blades 335, FIG.16 which clean the cheese gate as it
slides.
The rollers 332, the washers 333, and the wiper blades 335 are mounted to the
frame of the
cheese gate support assembly using removable pins 334, FIG.16 for easy
disassembly and
cleaning. Each cheese gate support assembly 319, has three holes 336, FIG16,
for mounting the
assemblies 319 to the front plate 301 with bolts.
In order to accommodate the cheese molds of different sizes and shapes
(cylindrical, rectangular
parallel-piped) Module 300 is equipped with two identical cheese mold support
frames 320 and
322, FIG.12, FIG14, FIG.15 and two identical cheese mold support sub-frames
321 and 323,
FIG.12, FIG14, FIG.15.
The cheese mold support frame 322, FIG15, is made from sheet metal, to which
are welded two
adjustable height sanitary bolts of specific shape and size. The sides of the
mold support frame,
as designed, must fit snugly onto the bottom beams 303.
The cheese mold support sub-frame 323, FIG.15, is a sheet metal part on the
bottom of which
are welded two rings.
The rings of the sub-frame 323 fit snugly onto the heads of the adjustable
bolts of the frame 322.
By using the shape of the sub-frame 323, and by using the adjustable bolts of
the frame 322, we
can mount cheese molds of different sizes and shapes on the Module 300 ¨ the
Cheese press. In
order to do that, we also must change the mold plate 338, FIG.17, to a mold
plate of appropriate
size and shape, so the neck of the cheese mold 330, FIG.17, fits snugly into
the cheese mold
support and the holding ring 336, FIG.17.
To change the cheese molds:
- First the mold plate 338, FIG.17 is removed by releasing the four screws
337, FIG.17;
- Then the mold plate 338 is replaced with a new mold plate of a desired shape
and size;
- Finally we attach the new mold plate in place using the four screws 337,
FIG.17;.
Module 300 ¨ Cheese press has two modes of operation:
- The First mode, when Module 300 is attached to Module 200 ¨ Cheese Curds
Processing Vat;
- And the Second mode, when Module 300 is operated as a stand alone unit.
When Module 300 is operated in tandem with Module 200 (FIG.317):
Date recue /Date received 2021-11-08
- the whey draining pipe 210, FIG.8, FIG.10 of Module 200 - the Cheese
processing Vat, is
connected to the pipe 307, FIG 12, FIG.13, FIG 14 of Module 300 Curds
Processing Vat with a
sanitary clamp.
-the neck of the cheese mold 330, FIG.17, fits into the cheese mold support
and the holding ring
336, FIG.17.
- the back cover 331, FIG.17 of the cheese mold is put in place;
- the piston of the electric actuator 325, FIG.17 is extended so the load cell
platform 327,
FIG17, touches the back cover 331, FIG.17 of the cheese mold with a small
constant force (for
example 100N), and pushes the cheese mold 330, FIG.17 to stay tight to the
face of the mold
plate 318, FIG.17.
- then the cheese gate 318, FIG.17 is opened
- the light curtains 317.FIG.12 are reset
-the bottom gear motor 219, FIG10 is started and the direction of the
extrusion is set in such a
way that the ribbon screw conveyor 218, FIG10 and full blade screw conveyor
240, FIG 10
transfers curds to the cheese mold 330, FIG.17.
It must be noted that the bearings of the gear motor 219 are of such a design,
that they can
withstand the axial forces even when the screw conveyors 218 and 240 are
pressing even the
hardest pressed cheeses.
- the load cell 326, FIG17 reads the pressing force values, and when the
pressing force reaches a
preset value at the control box 324, FIG.12, the control box then informs the
operator with a
visual and/or sound signal for the event;
- then the operator closes the cheese gate 318, FIG.17 with his hand.
- this triggers the light curtains 317,FIG.12 to shut down Modules 200 and
300.
- then the piston actuator 325 is disengaged from pressing the mold back
cover 331, and the
cheese mold 330 is removed from the cheese press.
This cycle is repeated until all of the cheese curds in Module 200 are pressed
into cheese wheels
or blocks.
Module 300 - the Cheese press can also be used as a stand alone unit (FIG.18).
In this case an additional cheese mold plate 339, FIG.18 is attached to Module
300. The
additional cheese mold plate 339 is designed to be supported by the two bottom
composite
beams 303, FIG 12, FIG.13, FIG 14 and the two top composite beams 304, FIG 12,
FIG.13,
FIG 14 and slides freely on them. At its front, the cheese mold plate 339,
FIG.18, has a mold
restriction ring, similar to the design of the mold restriction ring 336,
FIG.17. The back of the
additional cheese mold plate 339, FIG.18 is supported by the mold restriction
ring 336, FIG.17
of plate 338, FIG.17.
Date recue /Date received 2021-11-08
To press a cheese wheel:
- the back cover 331, FIG.17 of the cheese mold 341, FIG.18 is put in
place;
- the cheese mold 341, FIG.18 is filled with cheese curds;
- the whole assembly (the full cheese mold 341 plus the back cover 331) is
placed on the sub-
frames 321, 323, FIG.18 and pushed tightly to the face of the cheese mold
plate 339, FIG.18;
- then a food grade plastic plug 340, FIG.18 is inserted into the back end
of the cheese mold
339;
- the pressing force of the electric piston 325, FIG.18 is preset to the
desired pressing value with
the help of the control box 324;
- then , from the control box the piston of the electric cylinder 325, FIG.18
is activated. The
piston of the electric cylinder 325, FIG.18 starts moving forward, while the
face 327 of the load
cell 326, FIG.18 pushes the plug 340 inside the mold 341, until the load cell
measurement
reaches the preset value of the pressing force;
- when this value is reached, the piston of the electric cylinder 325,
stops moving forward,
.. changes direction and retracts, releasing the cheese mold 341;
- then the operator removes the pressed cheese wheel from the machine;
- then the operator fills the mold with cheese curds and the pressing cycle
starts again, until all
the cheese curds are pressed into cheese wheels;
If during the pressing operation, any body part or foreign object crosses the
beams of the light
curtains 317, FIG.12, FIG,14, this event triggers an emergency complete stop
of Module 300.
Then Module 300 must be reset manually to re-start the cheese pressing
operation.
Also, it should be noted that the dimensions and the shape of additional
cheese mold plates 339,
FIG.18 must correspond to the dimensions and the shape of the cheese mold 341.
Module 400 ¨ Cheese conveyor and Module 500 ¨ Cheese Cutting table
(FIG.19, FIG.20, FIG.21, FIG.22, FIG.23)
The next two modules of the Cheese Machine are module 400 ¨ Cheese conveyor
and Module
500 ¨ Cheese Cutting table.
Different cheese extrusion end caps such as 703,704,FIG.30 can be attached to
the whey
.. draining pipe 210, FIG.8, FIG.10, FIG.19. with the help of the sanitary
clamp 214, FIG.8,
FIG.10, FIG.19. The cheese extrusion end caps such as 703,705, FIG.30 allow
for various
cheese shapes to be extruded from Module 200 ¨ Curds Processing Vat, to Module
400 -the
Cheese conveyor (FIG.19).
The purpose of Module 400 ¨ Cheese conveyor is to cool down the cheese
extrusions, and
transport them to Module 500 ¨ Cheese cutting table FIG.19.
Date recue /Date received 2021-11-08
The purpose of Module 500 ¨ Cheese cutting table is to cut the cheese
extrusions to a desired
length ¨ for example cheese bites, cheese fingers, cheese ropes etc.
Another purpose of module 500 ¨ Cheese cutting table FIG.23 is to be used as a
stand alone unit
and to cut the cheese wheels, or blocks, to a desired size and shape, when the
module is
detached from module 400.
To serve its purpose, Module 400 ¨ Cheese conveyor must be of an approved
sanitary design for
the cheese industry, must have an appropriate length for cooling of the cheese
extrusion, and
must be able to fit with Module 500.
In addition Module 400 ¨ the Cheese conveyor must have the following elements:
- a Belt restraining boards 401, FIG.19;
- a belt with a smooth surface 403, FIG.19;
- adjustable legs 402, FIG.19;
- a cooling water distribution header with spray nozzles 405, FIG.19;
- a cooling water drip pan 404, FIG.19;
- two Connector slots 406, FIG.19 which are welded to the belt restraining
boards 401, FIG.19.
The slots 406 allow for Module 400 to be connected to Module 500 ¨ the Cheese
cutting table.
Module 500 ¨ Cheese Cutting table (FIG.19, FIG.20, FIG.21, FIG.22, FIG.23) has
a body
made of two identical laser cut stainless steel body plates 501, FIG. 19,
FIG.20, FIG.21.
The two body plates 501, FIG. 19, FIG.20, FIG.21 are welded together with the
help of the
horizontal frame beams 513, FIG 21 at the bottom of the body plates 501.
The frame is further strengthened structurally by the actuator holding rail
beam 523, FIG.19,
FIG.21, FIG.22, welded between the body plates 501.
The body plates 501, FIG. 19, FIG.20, FIG.21 have numerous cuts on them to
accommodate
various parts of the Cheese cutting table ¨ module 500.
.. In addition the body plates 501, FIG. 19, FIG.20, FIG.21 restrict access to
the cheese cutting
table from both sides of the table ¨ they act as a safety device.
Module 500 ¨ Cheese Cutting table is mounted on four adjustable height legs
with caster
wheels 502 FIG.19, FIG.20, FIG.21, FIG.23.
To attach Module 500 to the Module 400 ¨ the Cheese conveyor:
- the First step is to extend the two front legs 502 of Module 500 to an
appropriate length, while
the two back legs 502 of Module 500 are not extended. After this first step,
Module 500 is
inclined relative to Module 400.This allows for the discharge of the cheese
extrusions.
- the Second step is to insert from both sides of the table two connecting
rods 407 FIG.19,
through two connecting holes 503 FIG.19, until they enter the two Connector
slots 406, FIG.19.
Both the connector rods 407 and connector slots 406 have holes in them,
through which are
Date recue /Date received 2021-11-08
inserted the removable connecting pins 408 FIG.19. This creates a rigid
connection between
module 500 and module 400.
-the Third and final step is to engage the brakes on the wheels of the Module
400 and Module
500.
Such an elegant and simple design of the connection between Module 400 and
Module 500
allows for the connection to the cheese cutting table of different models of
cheese conveyors
(with an appropriate width) from many manufacturers, as long as other design
requirements,
described above, for such a cheese conveyor are met.
To prevent accidental access to the cheese cutting table from the front of
Module 500 and as a
to safety device, at the front end of the Module 500 is mounted a Front
safety screen 504, FIG.19,
which is fixed to the body plates 501 with four removable Safety screen pins
505 FIG.19.
The only open access to the insides of the Cheese cutting table - Module 500
is from the back of
the module.
To allow for a normal operation of Module 500 and at the same time prevent
accidents, the only
open access to the insides of Module 500 is restricted by the two light
curtains 506 FIG.19,
FIG.20. The curtains 506 will bring to a full emergency stop the Module 500,
if it is in operation
and a foreign object or body part breaks the light beams paths.
The Cheese knife 519 FIG.21, FIG.22, moves up and down with the help of a food
grade
electric actuator 507 FIG.19, FIG.20 of hygienic design.
When cutting cheese extrusions to a desired length the cheese knife 519 can
make hundreds or
even thousands of cuts per single batch. The cheese knife 519 always strikes
in the same place
and will always cut the cheese extrusion completely with a single clean cut.
In order to keep the cheese knife sharp and to extend its life a food grade
plastic sacrificial
cheese cutting strip 509 FIG.20, FIG.21 is required.
This cheese cutting strip 509 is mounted on a stainless steel support cutting
strip 508 FIG.20,
FIG.21, with the help of cheese cutting strip removable mounting pins 510
FIG.20. In order to
prevent any bending issues when the Cheese knife 519 strikes the cheese
cutting strip 509, a
reinforcement support of the cutting strip 512 FIG. 21, is welded under the
cutting strip 508
FIG.20, FIG.21.
To facilitate the movement of the cheese extrusions and extruded cheese cuts
through the cheese
cutting table Module 500, six rectangular slots 514, FIG.21 are cut into the
body plates 501.
Into each of the six slots are inserted steel roller support rods 511 FIG.20,
FIG.21 which have
tubular bodies and square ends.
Date recue /Date received 2021-11-08
On each of the roller support rods 511 are mounted food grade plastic rollers
522 FIG.21. The
rollers 522 rotate freely, but are restricted in their axial movement with the
roller restrain rings
520 FIG.21 and the roller restraining pins 521 FIG.21.
In order to facilitate movement of the cheese extrusions which are coming from
the cheese
conveyor Module 400 through the knife, one of the roller support rods 511,
FIG. 521 and one of
the rollers 522, FIG.521 is mounted in front of the sacrificial cheese cutting
strip 509 FIG.21.
This roller guides the cheese extrusion toward the cheese knife 519 for
cutting.
There are three cheese knife 519 guiding rods. Only the central cheese knife
guiding rod 515
FIG.21, FIG 22 is attached to the electric actuator 507, while the side cheese
knife guiding rods
525 FIG.22 are sliding freely through the two side-rods guide bushings 526
FIG.22.
The purpose of the side guiding rods 526 is to add extra stability to the
cheese knife 519 during
the cutting action.
The central guide rod 515 ends with a central knife guide end bracket 516
FIG.21, FIG.22. The
side cheese knife guide rods end with side knife guide end brackets 524
FIG.22. The cheese
knife is sandwiched between these end brackets 516, 524 and the cheese knife
holding plate 517
FIG.22. To attach the cheese knife 519 to the end brackets 516, 524, three
cheese knife bolts and
nuts 518, FIG.21 are used.
One of the novel features of the Cheese cutting table ¨ Module 500 is that it
can be used not
only for cutting cheese extrusions, but when disconnected from the Cheese
conveyor ¨ Module
400, it can also be used as a stand-alone cheese cutting table for cutting
cheese wheels or cheese
blocks to desirable shapes.
When the cheese table is used as stand alone unit:
- first, all of four cheese cutting table legs 502,FIG.23 are adjusted to
an equal height.
- the cheese wheel cutting table 527, FIG.23 is mounted with the help of
the four cheese wheel
cutting table guides 529 FIG.23, which fit into the holes of the four cheese
wheel cutting table
brackets 528, FIG.23 welded to the body of Module 500;
- the final step is to re-adjust through the control box 530, FIG.23 the speed
and the length of the
cheese knife stroke from a fast and short stroke mode, like when cutting
cheese extrusions, to a
long and slow cutting mode when cutting cheese wheels.
At all times, the control box 530 controls the work of the light curtains 506
and enables a reset
when the cheese cutting table knife comes to an emergency full stop.
Another function of the control box 530 is to communicate with the Cheese
conveyor ¨ Module
400 and Module 200 ¨ Curds Processing Vat and to bring them to a full stop
when Module 500
stops (or when necessary).
Date recue /Date received 2021-11-08
Module 600 ¨ Combined CIP and COP Unit
(FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29)
All dairy equipment and dairy production areas must be maintained in a clean
and sanitary
condition, in order for the cheese maker to obtain a high quality product.
The purpose of Module 600 ¨ Combined CIP and COP unit is to provide ways for
the cleaning
of all dairy equipment and all dairy production areas in a single unit. In
another embodiment of
the invention, the purpose of Module 600 is to provide ways for transferring
liquids and for
heating of dairy process water if the dairy doesn't have a separate hot water
boiler.
The Module Main CIP vessel 601 FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29
is used
for several tasks:
- First, for the heating of the cleaning solutions for all tasks;
- Second, for the COP (Clean-Out-of-Place) washing of process hoses and
long tubular elements;
- Third, for COP washing of small parts, fittings and cheese press forms;
- Forth, as a CIP (Clean-In-Place) supply unit for the automatic washing of
Modules 100, 200
and 400;
- Fifth as a CIP supply unit for the manual gun washing of Modules 300, 500
and Module 600
itself;
- Sixth, as a cleaning solution supply unit for the manual gun washing of
all dairy production
areas.
The Module has a Clean water vessel 602 FIG.24, FIG.25, FIG.27, FIG.28,
FIG.29, which as
the name implies is used to provide clean rinsing water for all tasks which
the Main vessel 601
FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29 fulfills.
In addition, the Clean water CIP vessel 602 can also be used to supply clean
water for the hot
water production for use in different dairy areas.
One of the design features of both vessels 601 and 602 is that their inner
walls (as per sanitary
design guidelines) are inclined at an angle of 3 degree toward the central
channels 618 FIG.26
at the bottom of the vessels, which channels themselves are inclined 3 degree
towards the outlets
of the vessels. This allows for complete evacuation of any liquids from the
vessels.
Module 600 is mounted on six CIP module wheels 603 FIG.24, FIG.25 and is
mobile.
The main CIP vessel 601 and the clean water CIP vessel 602 have movable covers
- main CIP
cover 605, FIG.24 and clean water CIP cover 604 FIG.24. Each cover has two gas
springs 606
FIG.24 for easy lifting.
The necessary pressure for all cleaning operations and various other tasks is
created by a
hygienic CIP pump 607 FIG.24, FIG.25, FIG.27, FIG.28 with a variable speed
motor of
appropriate size. The necessary process heat for heating of all cleaning
solutions, rinsing
Date recue /Date received 2021-11-08
solutions and production of hot water is provided by an over-sized hygienic U-
tube heat
exchanger 609 FIG.24, FIG.25, FIG.27, FIG.28.
The heating agent for the exchanger 609 is a low pressure saturated steam
which enters through
the exchanger steam inlet 620 FIG.25, FIG.27 and the resulting steam
condensate exits through
the exchanger steam outlet 621 FIG.25.
Any fluid which enters and exits the heat exchanger 609, passes through a
digital reading,
measuring and recording CIP thermometer probe 612 FIG.25, FIG.28. We then know
and record
the temperature of the cleaning fluids when they leave Module 600, as required
by law, which is
especially important for the temperatures of the CIP and the COP cleaning
solutions.
There is room for mounting a second CIP thermometer probe on the CIP return
water line ¨
probe mounting well 645 FIG.29.
Another measurement device is a conductivity probe 613 FIG.25, FIG.29 which
measures the
conductivity of the returning solution when Module 600 operates in CIP mode.
Measurement of
the conductivity is useful since we can re-use part of the CIP rinsing water
as make-up water for
next washing agent, instead of dumping all into the sewer. The above statement
is true in
condition, that the conductivity of rinsing water falls down under a certain
conductivity value.
All measurements and recordings from the control devices and the control of
the pump 607 are
processed by a CIP central control unit 610 FIG.24, FIG.25, FIG.27, FIG.28.
This unit also
sends back signals to the steam control valve in the steam boiler room (not
shown), which
controls the steam supply to the exchanger 609.
To prevent clogging and the build-up of residues in the heat exchanger 609 on
the outlet line of
the pump 607 is mounted a basket type removable and washable filter 608
FIG.24, FIG.25,
FIG.27, FIG.28.
A feature which protect the inlet line of the pump 607 is a removable mesh
type grid 619
FIG.26, FIG.27 mounted in both vats. Such an arrangement prevents any debris
or metal objects
from being sucked into the pump 607 and damaging the propeller.
The pump 607 is equipped with a number of inlet and outlet quick connect
sanitary clamp
valves. These valves allow for fluids to enter and exit Module 600 via
different conduits and to
fulfill all of the designated to the module tasks.
In addition, these valves allow the two most expensive pieces of equipment
mounted on Module
600 ¨ the pump 607 and the heat exchanger 609, to be used to the full extent
of their design
capabilities.
In the First conduit, which we call the Pump transfer mode, all valves are
closed except valve
622 (inlet to the pump 607) and valve 623 (outlet of the pump 607) FIG.28. In
this case pump
Date recue /Date received 2021-11-08
607 can be used as a simple transfer pump for daily operations of the dairy ¨
transferring milk,
whey, water etc.
In the Second conduit, which we call Vessel 602 Filling mode, all valves are
closed and the
vessel 602 is filled with clean water from the feed water connection 646
FIG.29.
In the Third Conduit, which we call Vessel 602 draining mode all valves are
closed except
valve 624 FIG.28 which allows for the drainage of the vessel 602.
In the Forth conduit, which we call Clean water heating and rinse mode, vessel
602 is filled
with water and all the valves are closed except valve 625 FIG.28. This
supplies the inlet of the
pump 607 with clean water. Then, if the pump is started, by opening the
different valves on the
outlet of the pump we can rinse with clean water any conduit of the Module 600
and any of the
other modules of the universal machine.
A special case is when valve 625 FIG.28 on the inlet of the pump is open, and
then we open in
consecutive order valves 628 FIG.28 (or 629 FIG.28 ¨ filter 608 bypass valve)
and valve 637
FIG.29 (or valve 639 FIG.29 as an alternative). In this case the clean water
will flow from the
vessel 602, through the pump 607, through the heat exchanger 609 where it will
be heated,
through the outlet line 633 FIG.28, FIG.29, through the valve 637,FIG.29 (or
through the outlet
line 634 FIG.28, FIG.29 and through the valve 639,FIG29 as an alternative).
The end result is
that we have clean hot water, heated in the heat exchanger, which can be used
for any purpose in
the dairy plant.
Another special case is to use the same conduit as the conduit which we just
described, but
without any heating steam supplied to the heat exchanger, so we can send cold
rinse water to any
part of the dairy plant.
In both cases this clean water can be used for CIP or a manual gun rinsing of
all modules of the
cheese machine. Some rinses can be completed with cold water - this will save
energy and
energy costs.
In the Fifth conduit, which we call vessel 601 filling mode, vessel 601 is
filled with water from
the feed water connection 647 FIG.29
In Sixth conduit, which we call Vessel 601 draining mode, all valves are
closed except valve
626 FIG.28 which allows for the draining of vessel 601.
In the Seventh conduit, which we call COP solution heating and cleaning of
hoses and long
tubular parts mode:
- vessel 601 is full of water and a washing agent is added, while all
valves are closed.
- then we open valve 627 FIG.28, valve 628 FIG.28, valve 630 FIG.28 and
valve 635 FIG.29.
This way we create a circulation of the washing solution from the bottom of
the vessel 601,
through the working pump 607, through the working filter 608, through the
working heat
Date recue /Date received 2021-11-08
exchanger 609, through the thermocouple 612, and back to the vessel through
the hose washing
nozzles 614 FIG.26.
To the nozzles 614, FIG.26 (with quick clamps) can be attached any hoses or
long tubular parts
for washing. If it is done, the washing solution will circulate through inside
of the hoses and will
clean the insides of the hoses.
Measurement and recording of the readings of the Thermocouple 612 allows for
the control of
the heating process. The washing solution is circulated through the nozzles
614 and is heated
until it reaches the required (by law) temperature for COP cleaning of hoses,
tubular parts and
the manual gun cleaning of the modules of the Cheese machine.
to In the Eight conduit, which we call CIP cleaning mode,
- First we use the loop of the Seventh conduit, till the washing solution
reaches the required (by
law) temperature for CIP cleaning or 10 to 15 degrees above that temperature.
Then we open valve 637 FIG. 29 (or as an alternative valve 639 FIG.29) and
valve 643 FIG.29;
and we close valves 630 FIG.28 and 635 FIG.29.
In this case, the washing solution will flow through the working pump 607,
through the filter
608, through the working heat exchanger 609, through the line 633 FIG.29 (line
63 FIG.29 as an
alternative), through the valve 637 FIG. 29 (the valve 639 FIG.29 as an
alternative), through a
sanitary type hose (not shown), to the washing ball of module 100 or module
200.
On its way back from module 100 or module 200, the washing solution flows from
the bottom
of the modules 100 or 200 through a sanitary hose (not shown), through the
quick clamp
connection 640 FIG.29, through the conductivity meter 613 FIG.29, through the
valve 643
FIG.29, through the return line 644 FIG.28, FIG.29, to the vessel 601 FIG.28.
When required
by law wash times and temperatures inside module 100 (or module 200) are
reached the spent
washing solution is collected in vessel 601.
The Ninth conduit, which we call spent washing solution disposal, is actually
the same as the
Sixth conduit ¨ we can drain the vessel 601 to the sewer using valve 626
FIG.28.
However there is an important alternative for disposal of the spent washing
solution. In this case,
all valves are closed and only valve 627 FIG.28 and valve 623 FIG.28 are
opened, while the
pump 607 is working. In this case, we can transfer the spent washing solution
to a different
place for disposal through the valve 623 if we attach to the valve 623 a hose
(not shown on the
drawings).
In the Tenth conduit, which we call COP washing of fittings, small parts and
cheese mold
forms:
- First these parts are loaded into the vessel 601
Date recue /Date received 2021-11-08
- then the vessel 601 is filled with water and the washing agent is added,
while all valves are
closed
- then we open valve 627 FIG.28, valve 628 FIG.28, valve 631 FIG.28 and
valve 632 FIG.28.
- then the washing solution will circulate in a loop through the valve 627,
through the working
pump 607, through the valve 628, through the filter 608, though the working
heat exchanger 609,
through the valves 631 and 632, through the jet nozzles 616 FIG.26, FIG.27 to
the vessel 601.
The jet nozzles 616 FIG.26 FIG.27 are arranged in two arrays.
One array is at the bottom part of the vessel 601 and the jet nozzles 616
FIG.26 FIG.27 are
slightly inclined towards the top of the vessel 601, while the second array is
at the top part of the
vessel 601 and the jet nozzles 616 FIG.26 FIG.27 are slightly inclined towards
the bottom of the
vessel.
This arrangement of the nozzles 616 FIG.26 FIG.27 creates a powerful swirl
circulation of the
washing or rinsing solution in vessel 601.
Each jet nozzle 616 FIG.26 is attached with its threaded end to a jet nipple
617 FIG.26, SO
nozzles are replaceable.
Threaded jet nipples 617 FIG.26 are welded in an angle to the nipple support
plate 615 FIG.24,
FIG.26, which from its side is welded to the body of the vessel 601. Each
plate 615 is covered
with a jet array cover 611 FIG.24 welded to the body of the vessel 601.
- The disposal of the spent washing solution is by using the Ninth circuit
described above.
Accessories to the Machine (FIG.30)
Some of the most important accessories of the cheese machine are given on
FIGURE 30.
They include Cheddarization table 702,FIG.30, which can be mounted directly
over the Process
dripping pan trolley 701,FIG.30.
As the name implies the cheddarization table 702 is used when the cheese maker
wants to do
cheddarization of the cheese without using Module 200 as cheddarization unit.
The process dripping pan trolley701 is used to collect dripping whey or other
liquids when
required.
The Process dripping trolley 701 slides completely under Module 300 -the
Cheese press and the
front end of the Module 200 ¨ the Curds Processing Vat.
The process dripping pan trolley has an outlet with a quick clamp connection,
which when
connected to a food grade sanitary hose (not shown) can be connected through
the valve 622
FIG.28 of Module 600 ¨ the CIP and COP unit to the outlet of the pump 607
FIG.28 for
transferring drained whey or other solutions to the sewer.
Date recue /Date received 2021-11-08
Another useful accessories are the Cheese extrusion end caps 703, 704 FIG.30,
which when
mounted to the end of Module 200 ¨ The curds processing Vat, can shape cheese
to different
extrusion shapes ¨ list of such end caps is not closed.
Following is a Detailed description of the
METHOD OF MAKING CHEESE with
the NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE
There are many kinds of cheeses and the Novel Modular Universal Cheese Making
Machine can
make all of them, including the preliminary step of pasteurization of raw
milk.
Many cheeses are similar to each other in the way that the steps in their
manufacturing are the
same. The differences between the kinds of cheeses, or even the cheeses of the
same kind,
usually depend upon the climate, geography, maturation conditions, variations
in the cheese
making recipe, introduction of additional steps in the cheese making process,
variation of
bacteria and fungus used as inoculation cultures and variations of the type of
rennet used. The
Cheese machine is a very flexible platform and the cheese masters have the
ability to adjust the
process parameters as desired. Here we give the steps and the method for the
production of the
most popular cheeses.
Pasteurization of Raw Milk ¨ Preliminary step
Pasteurization of Raw milk is completed in Module 100 ¨ Batch Pasteurizer and
Cheese Vat
(FIG.5, FIG.6,FIG.7). Before the start of the pasteurization process, the
batch pasteurizer is
clean, dry and the main milk valve 110, FIG.5, as well as the auxiliary milk
valve 111, FIG.5 are
in a closed position.
The First step in the pasteurization process is to load the milk via a
flexible hose into the vessel
101 from the milk supply truck (or the milk supply line) through one of two
milk inlets 113,
FIG.5.
Then we start the temperature recording device mounted inside the control box
105, FIG.5. The
recording device records, as required by sanitary laws, readings of the
thermometer for
measuring the temperature of the milk (cheese curds) 103, FIG.5; and the
readings of the
thermometer for measuring the temperature of the subspace between the milk
surface and the
cover of the vessel 104, FIG.5.
The next step is to start the two steam generators 106, FIG.5 which heat with
steam the subspace
between the milk surface and the cover of the vessel to the temperature values
required by the
sanitary laws.
Date recue /Date received 2021-11-08
Then from the control box 105, FIG.5 we switch on the electric gear motor 109,
FIG.5, which
starts the rotary motion of the cheese cutting knives, and the speed of the
knives is adjusted to
several rpm per minute. The cheese knives assembly as a whole mixes the milk
and provides for
better heat exchange when the milk is heated.
Next, the two steam condensate (hot water) outlets 108, FIG.5 are opened to
the inlet of the
steam boiler (or hot water boiler not shown on the drawings);
Next, saturated low pressure steam (or hot water) is supplied from the outlet
of the steam boiler
(hot water boiler not shown on the drawings) to the jacket of Module 100
through the two inlets
107, FIG.5, FIG.6. The amount of supplied steam (hot water) is controlled by a
control valve in
boiler hose of the dairy plant, which receives control signals from a PLC
mounted inside the
control box 105, FIG.5. The amount of the supplied heating steam (hot water)
depends on the
temperature of the milk as measured and sent from the thermometer for
measuring the
temperature of the milk 103, FIG.5 to the PLC.
When steam (or hot water) flows through the jacket 116, FIG.6, the milk is
heated until it
reaches the pasteurization temperature as required by law. Temperature and
time are the critical
factors required to achieve pasteurization. Failure to achieve pasteurization
will result in a
microbiological hazard in the dairy product.
The generally accepted pasteurization schedule for dairy products produced by
batch
pasteurization of milk-based products with fat content below 10% milk fat
(fluid milk, goat milk,
whey) is 72 C to 75 C with a holding time at that temperature for 30 minutes.
The temperature
of the pasteurization process, the temperature of the subspace between the raw
milk surface and
the cover 114, FIG.5, and the time of each step of the pasteurization process,
must be recorded
continuously on a government approved device and the records maintained for
prescribed
number of years.
When the pasteurization temperature (72-75 C) is reached and the holding time
at this
temperature (30 minutes) is completed, the steam (hot water) supplied to the
jacket of Module
100 is turned off, and the two steam generators 106, FIG.5 are shut off When
the steam (hot
water) to the jacket is tuned off, pasteurized milk will start to cool down.
Meanwhile the electric
gear motor 109, FIG.5 is left to rotate and the cheese knives are mixing the
milk. It ensures
faster and more uniform cooling of the milk.
Inoculation and Curdling of the Cheese
Inoculation of the milk is a process of adding mixtures of bacterial cultures,
and in the case of
making blue vein cheeses adding funguses, to pasteurized and cooled down milk
from the
previous step. The temperatures at which the milk is inoculated with bacterial
cultures and kinds
Date recue /Date received 2021-11-08
of bacteria which are added to the milk are beyond the scope of this patent,
so they won't be
discussed in detail. As a general example for two of the most widely used
bacterial species - S.
thermophilus has an optimal growth temperature range of 35-42 C, and L. d.
bulgaricus has an
optimal range of 43-46 C. So the inoculation is completed in these
temperature ranges.
Bacterial cultures which are added to the milk use as an energy source the
milk sugar lactose and
transform it into lactic acid. This bio-process increases the acidity of the
milk - the pH of the
milk is going down. This leads to denaturation of the milk protein casein and
thus the formation
of two phases ¨ a liquid phase called whey and a solid phase called cheese
curds.
Some time after inoculation of the milk with bacterial cultures, rennet is
added. Rennet is a
complex set of enzymes produced in the stomachs of ruminant mammals. The
chymosin, the key
component of the rennet, is a protease enzyme that curdles the protein casein
of the milk. In
addition to chymosin, rennet contains other enzymes, such as pepsin and
lipase. One of the main
actions of rennet is the protease chymosin cleaving of the kappa casein chain.
The casein is the
main protein of milk. The cleavage causes the casein to bond to other cleaved
casein molecules
and to form a network. The caseine will cluster better in the presence of
calcium and phosphate.
This is why salts of these elements are occasionally added to supplement the
preexisting
quantities of calcium and phosphorus in the milk. The solid truncated casein
protein network
traps other components of the milk, such as fats and minerals, to create
cheese.
The addition of the rennet is complimentary to the acidic curdling of the milk
due to lactic acid
produced by the bacterial cultures. The main difference is that the rennet
curdling produces a
much firmer and stronger casein network (curds) than the acid curdling only.
This allows for
firmer and better cheeses and a better expelling of the liquids (whey) from
the cheese. Both ¨ the
bacterial cultures curdling and the rennet curdling were used together long
before the beginning
of the recorded history.
During the inoculation process and adding the rennet to the milk, the electric
gear motor 109,
FIG.5 is allowed to rotate the cheese cutting knives and to mix the milk with
the bacterial
cultures and the rennet for a better distribution of the cultures and the
rennet in the vat.
Shortly after adding the rennet the gear motor 109, FIG.5 is turned off and
the bacterial cultures
and the rennet are allowed to transform the milk into cheese curds and a
watery liquid called
whey.
Curds Processing - Cutting of the cheese curds, Scalding (Cooking) of the
curds and
Washing of the curds
Final result of the Curdling of the milk is the settling of the milk into a
very moist gel.
Date recue /Date received 2021-11-08
To remove the excessive moisture (whey) from the cheese, it must be cut into
smaller pieces
(cheese curds) and the cheese curds then go through the process of maturation
which is obtained
by heating of the cheese curds in the cheese vat and stirring them.
Cutting of the curdled milk to cheese curds, when combined with stirring and
mild heating,
increases the bondage between the cheese proteins in a single cheese curd,
entraps inside the
protein network fat globules from the milk and lactic bacteria from the
starter culture and expels
water from the single cheese curd.
Cutting of the Curds
To cut the curdled milk into cheese curds the bi-directional gear motor
109,FIG.5 is tuned on
and it rotates the main axle 122,FIG.6,FIG.7 to which are attached the cutting
knives 125,
FIG.7.
One of the longitudinal edges of the cheese knives 125, FIG.7 is sharp ¨ for
cutting of the cheese
curds, the other edges are blunt for mixing of the cheese curds.
The direction of rotation of the bi-directional gear motor 109,FIG.5 when
cutting the cheese
curds, is such that the sharp edges of the knives 125 cut the curdled milk to
cheese curds and
mildly mix them at around 7 to 10 rpm per minute.
Because the knives 125 are mounted on the cheese knives supporting frames 124,
FIG.7 at a
slight angle, any two consecutive cuts of cheese knives 125 never cut along
the same path.
This approach to cutting of the cheese curds reduces the amount of the cheese
fines ¨ cheese
curds with size under 0.1mm. This prevents the loss of cheese product during
the separation of
the cheese curds from the whey.
Scalding (Cooking of the curds)
.. When the Cheese maker decides that the cheese curds are of a sufficient
size, he stops the bi-
directional gear motor 109,FIG.5, changes the direction of the rotation of the
gear motor
109,FIG.5 through the control box 105,FIG.5 and then restarts it. Thus, the
blunt edges of the of
cheese knives 125, FIG.7 will contact the cheese curds and will only stir them
without cutting.
At the same time, some heating steam (hot water) is allowed into the jacket of
the Cheese Vat
through the two inlets 107, FIG.5, FIG.6 from the steam (hot water) boiler.
The steam (hot
water) heats up the jacket, which heats up the whey and the cheese curds.
The duration of the heating and the heating temperature of the cheese curds
depends on the
cheese recipe and the decisions for the stirring and heating action exercised
on the cheese curds
are made by the Cheese maker.
Date recue /Date received 2021-11-08
Usually this scalding (cooking) of the cheese curds is done at 30-32 C for
soft cheeses, at 33-35
C for semi-hard cheeses, at 38-40 C for hard cheeses, and at temperatures
above 40 C for the
cheeses that are considered to be cooked cheeses.
For many cheeses after this step, the cheese curds are ready for draining of
the whey.
Washing of the Cheese curds ¨ optional step
Some cheeses named washed (rinsed) curd cheeses such as Edam, Gouda, Colby and
Monterey
Jack, require the additional step of washing (rinsing) of the cheese curds. In
general, the washing
of the cheese curds removes some of the lactic acid from the cheese curds and
gives the cheeses
produced by this technology a milder and nuttier taste. The essence of the
process of washing of
the cheese curds is to cut and cook the cheese curds as described above. Then
a portion of the
whey from the cheese vat is drained, and replaced with fresh filtered water
the steps for cooking
of the cheese curds is repeated.
To do this, after the first cooking cycle, the bi-directional gear motor
109,FIG.5 is stopped and a
portion of the whey is drained through the auxiliary milk vale 111, FIG.5,
through a flexible
hose (not shown), through the elbow connection 205, FIG.8, to the Curds
processing vat ¨
Module 200. The density of the cheese curds is slightly higher that the
density of the whey, so
they tend to collect at the bottom of the Cheese vat, rather then at the top,
the implication being
that the drained whey is almost cleared of cheese curds. In addition, for the
whey to leave the
Curds processing vat ¨ Module 200, the whey must pass through the filtering
media 211,
FIG.8,FIG.10 so any escaped cheese curds will be caught (won't be lost with
the whey) and can
be further processed with the rest of the cheese curds.
After draining part of the whey, clean filtered water (satisfying sanitary
requirements) is added to
the Cheese vat ¨ Module 100, through one of the inlets 113, FIG.5.
Then the Scalding (Cooking) of the curds step as described above is repeated.
After the scalding operation, the cheese curds are ready for the draining of
the whey before
pressing them into cheese molds.
Separation of the Cheese curds from the whey
Separation of the cheese curds from the whey is an essential step during the
making of any kind
of cheese. In the presented invention, the separation of the cheese curds from
the whey is
completed in the Cheese Processing Vat ¨ Module 200.
To separate the cheese curds from the whey:
- First we put in motion the top ribbon conveyor 217,FIG.10 by switching on
(at the control box
216,FIG.8) the corresponding bi-directional gear motor 219, FIG.9, FIG.10.
From the control
box 216,FIG.8 we also adjust the direction of the rotation of the top ribbon
conveyor
Date recue /Date received 2021-11-08
217,FIG.10 as clockwise. When any cheese curds come in contact with the top
conveyor the
cheese curds will be moved in a direction that is opposite to the place where
the gear motor 219,
FIG.9, FIG.10 is attached.
- The Second step is to put in motion the bottom ribbon conveyor 218,
FIG.9, FIG.10, FIG.!!,
by switching it on at the control box 216,FIG.8 the corresponding bi-
directional gear motor 219,
FIG.9, FIG.10. From the control box 216,FIG.8 we adjust the direction of the
rotation of the
bottom ribbon conveyor 218,FIG.10 as counter-clockwise. When any cheese curds
come in
contact with the bottom conveyor they will be moved in a direction towards the
place where the
gear motor 219, FIG.9, FIG.10 is attached.
To the front of the bottom ribbon conveyor 218, FIG.9, FIG.10 is attached the
full blade bottom
extrusion conveyor 240, FIG.9, FIG.10. So both bottom conveyors will rotate
together and in
the same direction ¨ counter-clockwise.
- The third step is to visually inspect if the end cap 213, FIG.8,FIG.10
and the filtering media
211, FIG.8,FIG.10 are properly installed.
- The forth step (while the cheese knives 125, FIG.7 are still stirring the
cheese curds) is to drain
part of the whey which will flow through the auxiliary milk vale 111, FIG.5,
through a flexible
hose (not shown), though one of the connections 207, FIG.8, through the curds
processing vat
body 201, FIG.10, through the whey draining pipe 210, FIG.8, FIG.10, through
the filtering
media 211, FIG.8, FIG.10, to the process dripping pan trolley 701,FIG.30, from
where the whey
can be transferred either to the sewer or for ricotta (cottage cheese)
production (when the dairy
plant is equipped for this).
- The fifth step (while the cheese knives 125, FIG.7 are still stirring the
cheese curds) is to open
the main milk valve 110, FIG.5, and then a mixture of whey and curds will flow
through the
main milk valve 110, FIG.5, through a flexible hose (not shown), through the
elbow connection
205, FIG.8, to the Curds processing vat ¨ Module 200.
The cheese curds at this stage are soft, but yet solid particles, so any curds
which come in contact
with the bottom ribbon conveyor 218,FIG.10, which rotates counter-clockwise,
will be
transferred inside the curds processing vat in a direction toward the gear
motor 219, FIG.9,
FIG.10. The full blade bottom extrusion conveyor 240, FIG.9, FIG.10 rotates
counter-
clockwise (in the same direction) as bottom ribbon conveyor 218,FIG.10, any
the cheese curds
which come in contact with this full blade conveyor 240, FIG.9, FIG.10, will
also be transported
away from the whey draining pipe 210, FIG.8, FIG.10. In other words, the full
blade bottom
extrusion conveyor 240, FIG.9, FIG.10 will clean and prevent inside clogging
of the whey
draining pipe 210, FIG.8 with cheese curds (FIG.10). However, when large
amounts of cheese
curds are transported in a direction toward the gear motor 219, FIG.9, FIG.10
(towards the back
Date recue /Date received 2021-11-08
end of the Curd processing vat Module 200) these cheese curds will tend to
squeeze each other
and even overflow from the vat. At this point, the top ribbon conveyor
217,FIG.10 which rotates
clockwise will moves part of the curds away from the back end of the curds
processing vat
module 200. Thus when the two ribbon conveyors rotate in opposite directions
(top clockwise,
.. bottom counter-clockwise) they will circulate the cheese curds inside the
Curds processing vat
Module 200.
Since the whey is a liquid, it will flow freely out of the curds processing
vat module 200 through
the whey draining pipe 210, FIG.8, FIG.10, through the filtering media 211,
FIG.8,FIG.10, to
the process dripping pan trolley 701,FIG.30, from where the whey can be
transferred either to
the sewage or for ricotta (cottage cheese) production, when the dairy plant
has such capacities.
Pressing of the Cheese Curds into different cheeses shapes
Once the main volume of whey is separated from the cheese curds, the next step
is to press the
cheese curds in order to remove even more whey from them. Usually this is done
by pressing of
the wet cheese curds into cheese molds. The cheese molds give the final shape
of produced
cheese ¨ usually a cheese wheel or a cheese block.
Depending of how much pressing force is applied and how much whey (moisture)
is removed
from the cheese curds, the cheeses are classified in several groups. Starting
with the cheeses with
the highest moisture and the minimum value of the pressing force applied,
these cheese groups
are soft cheeses (such as Brie), semi soft cheeses (such as Roquefort), hard
cheeses (such as
Cheddar) and very hard cheeses (such as Parmesan).
The pressing force applied to the cheese curds varies ¨ while for soft and
semi-soft cheeses we
have just gravity pressing by their own weight, for the other cheese groups
the pressing force
usually varies from 0.05 MPa to 0.2 MPa.
One of the advantages of the Cheese Machine is that with the help of the S-
type load
cell 326, FIG.14,FIG.17, FIG.18 and the electric pressing cylinder 325, FIG.
12, FIG.17,
FIG.18, the cheese pressing force can be measured, can be changed and can be
regulated
depending on the cheese variety produced.
This allows for the Cheese Machine to press all kinds of cheeses and to be a
universal cheese
machine.
To press any kind of cheese (except for the soft and the semi-soft varieties),
after draining of the
main portion of the whey:
- the gear motors 219, FIG.9, FIG.10 of Module 200 are turned off,
- the end cap 213, FIG.8 is removed;
Date recue /Date received 2021-11-08
- the whey draining pipe 210, FIG.8, FIG.10 is attached to the pipe 307,
FIG.13, FIG 14 of
Module 300 with the help of the sanitary clamp 214, FIG.8.
- the cheese gate 318, FIG.14, FIG 16 is opened by hand;
- an empty cheese mold 330, FIG.12, FIG.14, FIG.17 is placed on the cheese
mold support sub-
frames 321, 323, FIG.12,FIG14, FIG.15;
- the position of the cheese mold is adjusted with the help of the bolts of
the cheese mold support
frames 320, 322,FIG.12, FIG14, FIG.15 in such a way that the neck of the
cheese mold 330,
FIG.12, FIG.14, FIG.17 fits into cheese mold support and holding ring 336,
FIG.17;
- the back cover 331, FIG.12, FIG.14, FIG.17 of the cheese mold is placed on
the cheese mold
back end;
- the piston of the electric actuator 325, FIG.17 is extended so the load
cell platform 327,
FIG17, FIG.14 touches the back cover 331, FIG.17 of the cheese mold with a
small and
constant force (for example 100N), and pushes the front end of the cheese mold
330, FIG.17 to
stay tight to the face of the mold plate 338, FIG.17, FIG.12;
- then the light curtains 317.FIG.12, FIG.14 are reset;
- the top and the bottom gear motors 219, FIG10 are started;
- the direction of the rotation of the ribbon conveyors 217, 218 FIG.10 is
set in extrusion mode
at the control box 324, FIG.12. Thus the top ribbon conveyor 217,FIG.10 is set
to rotate
counter-clockwise. At the same time the ribbon screw conveyor 218, FIG10 and
the full blade
screw conveyor 240, FIG 10 are set to rotate clockwise so they transfer the
cheese curds to the
cheese mold 330, FIG.17. It must be noted, that the bearings of the gear
motors 219, FIG10 are
of such designs and dimensions, that they can withstand all of the axial
forces which will occur,
even when the screw conveyors 218 and 240 are pressing the hardest to press
cheeses (such as
Parmesan);.
- the load cell 326, FIG17, FIG.14 reads the pressing force value, and when
the pressing force
reaches a preset value in the control box 324, FIG.12, the control box signals
the operator with a
visual and sound signal,.
- Then the operator closes the cheese gate 318, FIG.17 with his hand. When
the operator's hand
crosses the beams of the light curtains 317,FIG.12, FIG.14 this movement sends
a signal to the
control box 324, FIG.12 and shuts down Modules 200 and 300;
- The piston actuator 325, FIG.17 is then disengaged from pressing the mold
back cover 331,
FIG.17, and the cheese mold 330, FIG.17 is removed from cheese press.
This cycle is repeated until all of the cheese curds in Module 200 are pressed
into cheese
wheels or blocks by Module 300.
Date recue /Date received 2021-11-08
Re-Pressing of the cheeses and Using of Module 300-Cheese press as a stand
alone unit
Some cheeses require re-pressing which is usually completed within a maximum
of 12 hours
after the initial pressing of the cheese. In addition some cheese makers may
prefer to press their
cheese by using Module 300 as a stand alone unit.
To press cheese in this case, Module 300 ¨ the cheese press is detached from
any of the other
modules of the Cheese machine.
To prepare the Cheese press ¨ Module 300 as a stand alone unit for pressing
cheese, we mount
the additional cheese mold plate 339, FIG.18 to Module 300.
The additional cheese mold plate 339, FIG.18 is of such dimensions and design,
that it is
supported and slides freely on the bottom composite beams 303, FIG12, FIG.13,
FIG 14 and the
top composite beams 304, FIG 12, FIG.13, FIG 14.
On its front, the cheese mold plate 339, FIG.18, has mold restriction ring,
similar to the design
of mold restriction ring 336, FIG.17. The back of the additional cheese mold
plate 339, FIG.18
is supported by the mold restriction ring 336, FIG.17 of plate 338, FIG.17.
To press a cheese wheel:
- the back cover 331, FIG.17 of the cheese mold 341, FIG.18 is put on;
- then the cheese mold 341, FIG.18 is filled up with cheese curds;
- the whole assembly (the full cheese mold 341 plus the back cover 331) is
put on the sub-frames
321, 323, FIG.18 and pushed tightly to the face of cheese mold plate 339,
FIG.18;
- Then a food grade plastic plug 340, FIG.18 is inserted into the back end of
the cheese mold
339, FIG.18;
- the pressing force of the electric piston 325, FIG.18 is preset to the
desired value with the help
of the control box 324;
- then the Module is started and the piston of the electric cylinder 325,
FIG.18 starts moving
forward;
- the face 327 of the load cell 326, FIG.18 pushes the plug 340 inside the
mold 341, until the
value of the pressing force measured by the load cell reaches the preset value
of the pressing
force. When this value is reached, the load cell 326, FIG.18 sends a signal to
the control box 324
so the piston of the electric cylinder 325 will stop moving any further
forward;
- then the piston of the electric cylinder 325, FIG.18 will automatically
change direction of
movement and will retract, thus releasing the cheese mold 341;
The operator removes the cheese mold (with the pressed cheese wheel in it)
from the Cheese
press ¨ Module 300, unloads the cheese wheel , fills again the mold 341 with
cheese curds and
starts the cycle again, until all the cheese curds are pressed into cheese
wheels.
Date recue /Date received 2021-11-08
If during the pressing operation, any object (or any body part of the
operator) crosses the light
beams of the light curtains 317, FIG12, FIG.14 the Cheese press ¨ Module 300
will come to a
complete stop, and must be reset manually to re-start the cheese pressing
operation.
The cheese plate 338 FIG. 17, the cheese plate 339 FIG.18 and the cheese molds
330, 341
FIF17, FIG 18 can be manufactured to different diameters and square shapes.
When manufacturing the cheese plate 339, FIG.19, it must be remembered that
the dimensions
of the cheese mold restriction ring of the cheese mold plate 339, FIG. 18 has
to accommodate
for the cheese mold 341 FIG.18 plus the back cover 331, FIG.17.
Pressing and Processing of soft and semi soft cheese varieties.
Making of soft and semi soft cheeses (with moisture content more than 40%)
doesn't require the
step of pressing of the cheese. For these cheeses, the pressing force is only
the gravity and the
weight of the cheese curds and the leftover whey.
For such soft and semi soft cheese, the cheese curds with the whey left-over
after the draining of
the cheese curds, are scooped and poured into the cheese molds. Then gravity
is allowed to fuse
the cheese curds and the whey in a loaf of a soft cheese, which is then
smeared with white
fungus (such as Penicillium camemberti in the case of Brie cheese), or the
cheese can be pierced
with needles to allow for aeration of the insides of the cheese and
development of blue veins by
the fungus culture added beforehand (such as Penicillium roqueforti in the
case of Silton cheese).
For this operation:
- after the draining of the cheese curds in Module 200, the ribbon
conveyors of this module are
left to rotate in the cheese curds mixing mode. The top ribbon ribbon conveyor
217,FIG.10
rotates clockwise. At the same time the ribbon screw conveyor 218, FIG10 and
the full blade
screw conveyor 240, FIG 10 rotate counter clockwise, so the curds are moving
and mixing
inside the body 201,FIG. 10 of Module 200 in a circular motion;
- at this stage and if salt (NaCl) is required, it can be added and mixed
with the cheese curds and
leftover whey from the two manholes 204, FIG.8;
- when the salt is thoroughly mixed with the cheese curds and the whey, the
two gear motors 219,
FIG.10 receive a signal from the control box 216, FIG.10 and all conveyors are
brought to a
stop;
- then the end cap 213, FIG.8 is removed;
- from the control box 216, FIG.10, the directions of the rotation of the
two gear motors 219,
FIG.10 are set to cheese curds extrusion mode. The top ribbon ribbon conveyor
217,FIG.10
will rotate counter ¨ clockwise, while the ribbon screw conveyor 218, FIG10
and full blade
Date recue /Date received 2021-11-08
screw conveyor 240, FIG 10 will rotate clockwise, so the curds will be coming
out of Module
200 through the end of the whey draining pipe 210, FIG.8, FIG.10;
- finally we start the two gear motors 219, FIG.10 and the cheese curds and
leftover whey are
extruded (poured) into a vessel from where they can be scooped and distributed
into cheese
molds designed for soft and semi-soft cheeses.
Cheddarization of cheese curds
Some varieties of hard cheeses (such as Cheddar) and pasta filata cheeses
(such as Kashkaval),
before pressing, must undergo the process of Cheddarization. The
Cheddarization can be
described as a process where the bacterial cultures added to the pasteurized
milk are allowed to
grow on leftover lactose in the partially drained cheese curds, until they
increase the acidity of
the cheese curds (decrease the pH of the cheese curds) to a set point.
Increased acidity of the cheese curds creates an environment which suppresses
the growth of
undesirable bacteria and thus increases the quality of the final cheese
product and its shelf life.
During the cheddarization process, the cheese curds are usually stacked on
piles and the piles of
cheese curds are flipped which allows for even more whey to be drained from
them.
Then the cheese curds are cut, salted with NaCl and pressed into cheese molds
of the desired
shape and weight.
This Cheese machine allows for the classic cheddarization process to be
completed easily:
- first, the cheeses curds are lightly pressed as described above into cheese
molds (Pressing of
Cheese Curds into different cheeses shapes)
- then the cheese curds are unloaded on the cheddarization table 702 FIG.30
for the classic
cheddarization process to take place. The dripping whey is collected into the
process trolley 701,
FIG.30.
- after the end of the cheddarization process the cheese curds are cut,
salted, mixed, pressed and
re-pressed into cheese molds as described above (Re-Pressing of the cheeses
and Using of
Module 300-Cheese press as stand alone unit).
One of the advantages of Our Cheese machine is that it also allows for
mechanization of the
process of cheddarization of the cheese curds:
- when the cheese curds are drained, the ribbon conveyors of Module 200 ¨ the
cheese
processing vat are in cheese curds mixing mode. The top ribbon conveyor
217,FIG.10 rotates
clockwise. At the same time ribbon screw conveyor 218, FIG10 and full blade
screw conveyor
240, FIG 10 rotate counter clockwise, so the curds are moving and mixing
inside the body
201,FIG. 10 of Module 200 in a circular motion. The created circular motion
allows for more
and more whey to be drained and for the cheese curds to become drier and
drier;
Date recue /Date received 2021-11-08
- when the cheese curds reach a point when they are sufficiently dry for
cheddarization, two gear
motors 219, FIG.10 are turned off at the control box;
- this brings Module 200 to a stand still and the bacteria are allowed to
decrease the acidity of the
cheese curds;
- Instead of flipping the cheese curds by hand as in the classic
cheddarization process, after a
period of time the two gear motors 219, FIG.10 are restarted in cheese curds
mixing mode.
This re-start mixes the cheese curds which is equal to the manual operation of
flipping cheese
curds by hand. This procedure can be repeated several times - until the
acidity of the cheese
curds reaches the desired value;
- When desired pH value is reached, salt (NaCl) is added and mixed with the
cheese curds;
The cheddarized cheese curds are now ready, to be pressed (Pressing of Cheese
Curds into
different cheeses shapes) and re-pressed (Re-Pressing of the cheeses and Using
of Module
300-Cheese press as stand alone unit) as described above.
An additional option is to attach a knife of appropriate dimensions (not
shown) with the help of
the end cap bolt 244, FIG 10, to the front end of the full blade screw
conveyor 240, FIG 10. This
will allow the automatic cutting of the cheddarized cheese curds when they are
leaving Module
200 for pressing into cheese wheels in Module 300. In this optional case,
there is no need for the
manual cutting of the chedarrized cheese curds by hand or by an extra curds
cutting machine as it
is usually done in classic cheddarization process (before pressing the curds
into cheese wheels).
Stretching of pasta filata cheeses
A special category of cheeses are so called pasta filata cheeses (such as
Mozzarella and
Caciocavallo). Their recipes add the additional step of cooking (stretching)
of the drained cheese
curds in hot water or with steam. Salting of the pasta filata cheese is done
during the cooking of
the cheese curds. The advantage of the cooking step is that it almost
sterilizes the cheese product,
which when combined with the salting of the curds increases the shelf life of
the cheese product
(up to several years for some varieties). The effect of sterilization is
further enhanced when
combined with the process of cheddarization of the cheese curds, which the
recipes of many
varieties of pasta filata cheeses require as a preliminary step.
When cheese curds are cooked in small amounts of hot water or with small
amounts of direct
steam, the protein networks of the single cheese grains tend to intermingle,
their shapes
disappear and the cheese curds become one dough like mass which flows like
very thick
molasses. The newly formed protein networks in the cheese dough have much
higher elasticity
than the protein networks in the drained cheese curds. The mass is repeatedly
stretched by the
cheese makers using their hands, sticks or since 20th century specialized
machines. The
Date recue /Date received 2021-11-08
continuous stretching of the cheese mass creates fibrous structures which
makes the cheese more
firm, expels even more water from the cheese and gives the pasta filata cheese
a desirable string
texture.
When the cheese maker decides that the cooking and stretching of the cheese
curds is completed,
the cheese dough is poured into cheese molds, where it solidifies and is ready
for aging.
One of the advantages of our Cheese machine is that, instead of using a
specialized cheese
stretching machines for making pasta filata cheeses, it allows the cheese
maker to stretch (cook)
such cheeses in Module 200 ¨ Cheese curds processing vat, thus decreases the
cost of the cheese
making and the capital spent for buying additional cheese making equipment.
To make a pasta filata cheese in Module 200 ¨ Cheese curds processing vat:
- we start the usual step (Separation of the Cheese curds from the whey) as
described above;
- the next step, is to leave the cheese curds to undergo the process of
cheddarization (described
above in Cheddarization of cheese curds). Some pasta filata cheeses don't
require this step;
- after the cheddarization, the cheese curds are ready for stretching;.
To stretch and cook the cheese curds into pasta filata cheese in Module 200 ¨
the Cheese
curds processing vat:
- First, the two gear motors 219, FIG.10 are stopped and Module 200 is in
stand still;
- the next step is to remove the end cap 213, FIG.8 and the whey draining
pipe 210, FIG.8,
FIG.10 by removing the sanitary clamps 213 and 215, FIG.8;
- then the whey draining pipe 210, FIG.8 is re-placed with a plain pipe (with
no holes on it) of
the same dimensions. The replacement pipe is re-attached to Module 200 ¨ the
Cheese
processing vat with the help of the sanitary clamp 215, FIG.8;
- the end cap 213, FIG.8 is re-attached to its position on the newly mounted
plain pipe, with the
help of the sanitary clamp 213, FIG.8;
- the directions of rotation of the two gear motors 219, FIG.10 are set to
cheese curds mixing
mode and the gear motors are switched on. The top ribbon conveyor 217,FIG.10
rotates
clockwise. At the same time ribbon screw conveyor 218, FIG10 and full blade
screw conveyor
240, FIG 10 rotate counter clockwise, so the curds are moving and mixing
inside the body
201,FIG. 10 of Module 200 in a circular motion;.
- then a sufficient amount of hot water (live steam) is added to the vat 201,
FIG.8 and steam or
hot water is supplied to the to the jacket 225, FIG.9 of the vat 201, FIG.8,
thus allowing for the
heating of the cheese curds in the vat 201, FIG.8;
- at this time salt (NaCl) is added to the curds in the cheese vat 201, FIG.8
as required;
- Combined action of the hot water (live steam) added to the cheese curds,
continuous mixing of
the curds with the ribbon conveyors 217, 218, 240 FIG.10 and through the
jacket heating of the
Date recue /Date received 2021-11-08
curds, softens the cheese curds and soon a very high viscosity cheese mass is
formed. The
viscosity of he cheese mass depends on the temperature of the curds and the
amount of hot water
(live steam) directly added to the Vat 201, FIG.8, FIG.10;
- when the cheese maker decides that the cheese curds are sufficiently cooked
and stretched, the
two gear motors 219, FIG.10 are switched off and Module 200 is brought to a
stand still;
- then the end cap 213, FIG.8 is taken off and in its place is put a cheese
extrusion end cap like
cheese extrusion end caps 703, 704 FIG. 30;
- after this step, the directions of the rotation of the two gear motors 219,
FIG.10 are set to
cheese curds extrusion mode via the control box 216, FIG.10, and the cheese
motors are
switched on. The top ribbon conveyor 217,FIG.10 will rotate counter ¨
clockwise, while the
ribbon screw conveyor 218, FIG10 and full blade screw conveyor 240, FIG 10
will rotate
clockwise.
- The cooked and stretched pasta filata cheese flows out of Module 200 and
is poured into the
cheese molds of desired size and shape, where it cools down and solidifies.
Making of extruded cheese products
With the help of Module 200 and Modules 400 and 500, the Cheese machine can
also make
extruded cheese products.
To make extruded cheese products of a desired shape and size (such as pasta
filata cheese
fingers, cheese bites, cheese sheets etc.):
- First, we follow the exact same procedure for making cheese curds
(Separation of the Cheese
curds from the whey, Cheddarization of cheese curds),as described above;
- Second, we follow the exact same procedure for Stretching of pasta filata
cheeses, as
described above, except in the final step ¨ to turn on the two gear motors
219, FIG.10 and to set
them to cheese curds extrusion mode;
- Before switching on the two gear motors 219, the front end of the Module 200
is aligned with
the front end of Module 400 in such a way that when the pasta filata cheese
flows through the
end cap of the desired shape (such as the end caps on FIG.30) it drops on the
belt with a smooth
surface 403,FIG.19 of Module 400;
- At the same time, the front end of Module 500 is attached to the back end of
Module 400 as
shown on FIG.19;
- the next step is to turn on the cooling water to the distribution header
with spray nozzles 405,
FIG.19, so when a pasta filata cheese extrusion comes on the conveyor it will
be cooled down
before it is cut to the desired length;
Date recue /Date received 2021-11-08
- Next, an important step is to adjust at the control box 216, FIG.8, FIG.9
the rotations per
minute (rpm) of the two gear motors 219, FIG.10.
The rotation speed will determine the amount of cheese extruded per minute.
The linear speed of the belt 403,FIG.19 of Module 400 is dependent on the
amount of cheese
extruded per minute;
- The linear speed of the belt 403 is adjusted at the control box 530,
FIG.23 of Module 500 to a
such a value that all of the cheese extruded on the conveyor can be cooled and
solidified before it
reaches the cheese knife 519 FIG.21, FIG.22;
- Also at the control box 530 is adjusted the time relay which controls the
downward movements
per minute of the electric actuator 507 FIG.19, FIG.20 (cuts per minute) in
such a way that the
knife 519 cuts the cheese extrusions to the desired length;
- Finally, after all of the above steps are completed, the cheese maker can
switch on the two gear
motors 219, FIG.10, and the cheese extrusion process will start.
The pasta filata cheese will be extruded to the desired shape from Module 200
over the
conveyor belt of Module 400. The cheese extrusion(s) are cooled on the
conveyor belt
403,FIG.19 by water coming from the header 405, FIG.19 and they will then be
cut to the
desired length by the cheese knife 519 FIG.21, FIG.22.
Making of additional cheese products, alternative cheese like products, and
cheese
extrusions from them
It must be noted, that by varying the recipes (amount of water, adding
emulsifiers, spices, dyes
etc.), Module 200 can also be used for making of additional cheese products
such as cheese
sauces, multicolored cheeses, spiced cheeses etc.
The Cheese Machine can also be used to make alternative cheese like products,
where the
animal milk in real cheese is replaced by plant, algae, fungus or bacteria
derived milk substitutes.
The general idea is to use the Modules of the Cheese Machine for making
alternative cheese
curds like products and then processing the alternative cheese curds like
products as real animal
milk cheese curds.
The same is valid for making of Novel extruded cheese products with the Cheese
machine
using Modules 200, 400 and 500. In such cases, cooling water may or may not be
necessary at
all times.
Salting of the Cheeses
The salting of a number of cheese products (such as cheddar type cheeses,
pasta -filata cheeses,
etc.) was described above, when.
Date recue /Date received 2021-11-08
However it has to be noted that for many cheeses the salting is done by
immersing the pressed
cheese wheels into brine solutions for a prescribed period of time (as an
example Parmigiano
Reggiano cheese), or by keeping the pressed cheeses in a brine permanently (as
an example Feta
cheese). In these examples the cheese curds are pressed into the cheese molds
without salting and
put in brine following specific cheese recipes (see above Pressing of the
Cheese Curds into
different cheeses shapes, Re-Pressing of the cheeses and Using of Module 300-
Cheese press
as a stand alone unit).
In Conclusion, it has to be written that,
We the Inventors believe that the so described designs of this Novel Modular
Universal
Cheese Making Machine and Method for the making cheeses with it, will give us
the right to
make the Patent claims in the Patent Claims Section of this Patent.
Date recue /Date received 2021-11-08
