cut fat & improve yield in any cheese with nutrilac® ch-4560 · pdf fileit to be mixed...

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Arla Foods IngredientsBulletinArla Foods IngredientsBulletin

Cut fat & improve yield in any cheesewith Nutrilac® CH-4560

www.arlafoodsingredients.com

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Arla Foods IngredientsBulletin

Table of contentsNutrilac® CH-4560 for cheese production ..........................................................................................................................3

The challenge of low fat cheese .........................................................................................................................................4

Produce high quality low fat cheese...................................................................................................................................5

General features of Nutrilac® CH-4560 ..............................................................................................................................6

Specific features for the production of low fat cheeses .....................................................................................................7

The main properties of Nutrilac® CH-4560.........................................................................................................................8

Nutrilac® CH-4560 vs. other ingredients ..........................................................................................................................10

Case study ........................................................................................................................................................................12

How to use Nutrilac® CH-4560 .........................................................................................................................................13

Frequently asked questions ..............................................................................................................................................14

Cheese types & Nutrilac® usage .......................................................................................................................................15

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Nutrilac® CH-4560 for cheese productionWhether your demand is to improve the characteristics of your low fat cheese, or yield improvement of your full fat cheese, Nutrilac® CH-4560 is the perfect choice.

Superior low fat cheese qualityConsumer trends show that there is an increasing demand for low fat alternative dairy products, with the low fat cheese segment having enormous potential for growth.

Cheese is the dairy product that contains the highest fat content aside from butter, and this makes it an obvi-ous target for the development of reduced or low fat alternatives. However, reproducing low fat cheese, can prove to be extremely difficult for cheese producers.

What you get using Nutrilac® CH-4560 to make low fat cheese〉 Reduces your standard product fat content by up

to 10%〉 Reduce raw material cost by up to 4%〉 Creates a more appetising and natural coloured low fat cheese〉 Increases the water content with up to 3%

Improve yield in full fat cheese up to 18%The challange of increasing yields whilst maintaining the quality and characteristics of your cheese products is one faced by most cheese producers.

With Nutrilac® CH-4560s unique formula, it is possible to increase the yield by 5-18% without resulting in to soft textures. At the same time this makes the production more efficient, and reduces the raw material cost significantly.

What you get using Nutrilac® CH-4560 to improve yield in full fat cheese〉 Increase yield by up to 18%〉 Reduce raw material cost by up to 4%〉 Significantly improved efficiency of the production line

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The challenge of low fat cheese

Fat contributes significantly to the desired structure and characteristics of full fat cheeses; by applying taste, smooth structure, desirable mouth feel, and meltdown. With a reduced fat content, these characteristics are less significant, and the quality of the cheese is compro-mised.

Lowering the fat content of a cheese presents cheese makers with a number of challenges that need to be overcome:

〉 Hard and rubbery texture〉 10-30% lower yield than full fat version〉 Longer maturing period, in order to obtain the

desired texture〉 Unappealing transparent appearance

In a full fat cheese the fat globules interfere with the casein network, preventing the casein from dominating the final cheese texture, and creating a more flexible and smooth cheese matrix.

Full fat vs. reduced fat GoudaThe ratio between fat and protein in a 28% full gouda is 1:1, compared to fat and protein ratio of 1:1.8 in a 15% reduced fat gouda.

Full fat Gouda (28%) Reduced fat Gouda (15%)

ProteinFatSalt & AshesWater

25%

28%

27%

15%

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Why not produce high quality low fat cheese?

At Arla Foods Ingredients we have expertise in produc-ing specialised milk and whey protein solutions, that utilise the functional benefits from all milk protein fractions. This includes highly specialised whey protein concentrate, that is able to integrate with the casein network, and significantly influence cheese quality.The key to producing premium reduced fat cheeses, is to find a fat substitute that can:

〉 Interrupt the dominant casein network, in the same way as milk fat does

〉 Bind water better than casein, in order to increase the water/protein ratio

〉 Imitate the role of fat globules in the mouth, when consuming the cheese

〉 Contribute to the flavour compounds in the same way as milk fat

Arla Foods Ingredients has developed a functional milk protein, which can help solve these challenges.This specialised product is called Nutrilac® CH-4560. There are two major benefits associated with Nutrilac® CH-4560 that can create value for your business:

1. It is possible to create a superior quality reduced fat alternative to your full fat cheeses

2. It can improve the quality and yield on any of your existing low fat cheeses

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General features of Nutrilac® CH-4560

Easy dissolvable spray dried powder with 45% protein〉 Feature: Nutrilac® CH-4560s special production

method results in a fast dispersible powder, allowing it to be mixed easily into milk or water.

〉 Benefit: It is an important issue for the cheese maker that the powder is easy to handle, and this opens several possible ways of adding the powder to the cheese milk. Refer to the FAQs, or contact us for more details.

Renneting properties remain unaffected〉 Feature: An increase of the whey protein ratio often

results in a decrease of the cheese milk renneting properties. Nutrilac® CH-4560 alleviates this po-tential problem; the protein particles in Nutrilac® CH-4560 do not react with the casein micelles.

〉 Benefit: Nutrilac® CH-4560 does not influence the renneting properties of the cheese milk, and consequently ensures a good cheese process, with a strong cheese curd.

Milky flavour〉 Feature: It is very important that the flavour profile

of all ingredients used are fresh and milky, especially in the case of fresh cheese types. Nutrilac® CH-4560 contributes to the flavour in the same way as milk fat would.

〉 Benefit: As a result of the selected raw materials, Nutrilac® CH-4560 has a surprisingly milky taste.

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Specific features for……the production of low fat cheeses

Unique fat replacement properties〉 Feature: The structure of the proteins in Nutrilac®

CH-4560 makes this whey protein solution perfect for fat replacement purposes.

〉 Benefit: The protein particles imitate the removed fat globules, and ensure that cheese containing Nutrilac® CH-4560 has the same creaminess and texture (mouthfeel) as a full fat alternative. Pro-duction is standardised, ensuring the exact same product every time.

More appealing natural colour〉 Feature: Low fat cheeses tend to have a more grey

and transparent appearance as a consequence of lowering the fat level, but by adding Nutrilac® CH-4560 to the cheese milk this change in the cheese colour is much less apparent.

〉 Benefit: The proteins in Nutrilac® CH-4560 scatter light in the same way as milk fat globules would, creating a more natural cheese colour.

Less caking of cheese curd〉 Feature: Nutrilac® CH-4560 significantly reduces the

phenomenon of caking of the cheese curd inside the cheese vat, when producing low fat cheese.

〉 Benefit: The cheese grains do not clump together and stick to the agitators in the cheese vat as much, making it easier to empty the vat and helping improve the final structure of the cheese.

…yield improvement of full fat cheeses

Cost savings through improved water binding capacity 〉 Feature: The water binding capacity of Nutrilac®

CH-4560 protein particles are significantly higher than regular casein protein.

〉 Benefit: Nutrilac® CH-4560 makes it possible to increase the water content in cheese by up to 3%, without resulting in softer textures. This can increase yields by 5-18%, with a reduced raw material cost pr. kg cheese of 2-4%.

Cost savings through shorter ripening period〉 Feature: When adding Nutrilac® CH-4560 to your

cheese, the strong casein network is interrupted. This phenomenon makes the ripening process speed up, due to the fact that fewer protein bindings need to be cleaved in order to achieve the smoothness of the final product.

〉 Benefit: Nutrilac® CH-4560 reduces the ripening period as much as 1-3 weeks, which leads to an overall time shortening of the cheese production, giving rise to a cost saving based on optimised utilisation of storage facilities.

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The main properties of Nutrilac® CH-4560

Fat simulation/replacement The protein particles present in Nutrilac® CH-4560 are fully comparable to the particle sizes of milk fat globules. This means that Nutrilac® can reproduce a creamy and smooth texture to the cheese products it has been added, in the same way as milk fat globules.

It is important to note that the protein particles are not affected over the maturing period of the cheeses either. The enzymes present in the cheeses cannot break down the protein particles, even after long m aturing periods. The particles can be observed unchanged through a confocal microscopy; results of an examination of a 6 week old Danbo Cheese can be seen in the photos below:

It is easy to observe and compare the light green particles of Nutrilac® CH-4560, in the right-hand photo, that imitate the size and shape of the black fat globules.

Texture improvementEven if you only use low dosages of Nutrilac® (e.g. 3-5% of total cheese milk protein), significant changes in cheese texture will still occur. The reason for this is that each kg of Nutrilac® CH-4560 contains several billion protein particles, and they interrupt the strong casein network in the cheese. This makes the cheese matrix more flexible and smooth, in the same way as milk fat globules function, and creates a more desirable cheese texture.

In addition, the high water binding capacity of the protein particles also contributes to a more desirable softer texture. An optimisation of the Nutrilac® CH-4560 dosage can result in a 5-10% total fat reduction in most cheese types, without noticeable loss of smoothness.

Fat imitation by Nutrilac® CH-4560

Reference New formula

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Water binding capacity It is the protein in cheese that binds almost all of the water, and this means there is a direct link between the protein to water ratio and the consistency of the cheese.

Typically, the proteins present in cheese is casein, and it is the water to casein ratio that determines the final consistency. In most cheeses, this ratio is in the range from 1.6 – 2.0.

If this limit is exceeded, the cheese will become too soft. This ratio can be increased to 5 – 6.2

with Nutrilac® CH-4560. The water binding capacity of our Nutrilac® CH-4560 protein particles are significantly higher than regular casein protein.

Colour modificationLow fat cheeses tend to have a grey and transparent appearance as a consequence of lowering the fat level. This is especially the case when lowering the fat level below 10% total fat.

By adding Nutrilac® CH-4560 to the cheese milk, this change in the cheese colour is much less apparent, as the proteins in Nutrilac® CH-4560 scatter the light in the same way as milk fat globules creating a more natural cheese colour.

Nutrilac® CH-4560

H2OH2O

H2O

H2OH2O

H2O

Casein

H2O

H2O

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Nutrilac® CH-4560 vs. other ingredients & process adjustments

Carbohydrate-based ingredientsFat replacement (fat mimetics) based on gums, starch-es, fibres, CMC/MCC etc., can be used in the manufac-turing of low fat cheese, with the aim of increasing the yield as well as creaminess.Compared to Nutrilac® CH-4560, there are a number of differences and disadvantages:

〉 It is a major step having to declare non-dairy, carbohydrate-based ingredients on a highly ranked dairy product such as cheese. Nutrilac® CH-4560 is a 100% natural milk protein.

〉 In today’s cheese industry, the value of the cheese whey is important, because the prices of whey protein products (WPC) have been increasing sig-nificantly over the years. With carbohydrate-based ingredients, part of the carbohydrates will end in the cheese whey during cheese processing. This means that the traces of carbohydrates in the whey will downgrade the value for WPC production.

〉 Carbohydrate-based ingredients decrease the melt-ability of the cheese. This is not the case when using Nutrilac® CH-4560, on the contrary it will improve the meltability in most cases.

〉 Several tests performed by Arla Foods Ingredients application experts show that both the impact on cheese yield and the structure smoothness are higher when using Nutrilac® CH-4560.

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Adjustment of cheese processing parametersSkilled cheese makers are able to improve the quality of low fat cheese, by adjusting specific parameters, such as; cooking temperature, stirring time and choice of starter cultures.

These adjustments mainly increase the water content in the cheese, making it more soft and pleasant to consume. However, even only small increases in the water content can e.g. easily make the cheese too soft to slice. Nutrilac® CH-4560 has several obvious advan-tages compared to this method:

〉 It is possible to increase the water content signifi-cantly by using Nutrilac® CH-4560, and without the cheese becoming too soft. This is because the water binding ability of Nutrilac® is 3 times greater than regular casein.

〉 Even the best cheese maker can not replace the functionality of milk fat globules in the cheese matrix by adjusting processing parameters alone. Nutrilac® CH-4560 is able to imitate the removed fat globules very efficiently.

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Case example

Quality and yield improvement in low fat Tilsit (13% fat)Low fat Tilsit (Havarti) is a perfect example to demon-strate the influence Nutrilac® CH-4560 has on yellow cheese.

Test formulasLight reference With Nutrilac® CH-4560

Skimmed milk 97.20% 93.05%

Cream (38%) 2.80% 3.10%

Nutrilac® CH-4560 0.50%

Water 3.35%

Total 100% 100%

Procedure〉 Mix Nutrilac® CH-4560 with water, in the ratio 1:6.7〉 Hydrate for 30-45 minutes〉 Add to the cheese milk prior to pasteurisation〉 Pasteurise the cheese milk at 72-74°C for 20-30 seconds〉 Follow same cheese making procedure as with the light reference

Results of YieldLight reference With Nutrilac® CH-4560

Cheese yield from 100 kg cheese milk

8.64 kg

9.78 kg

Yield increase 13.19%

Compositional values of cheesesLight reference With Nutrilac® CH-4560

Protein 31.5% 29.9%

Fat 13.0% 13.1%

Drymatter 47.9% 46.3%

Spiderweb scores 1-5

Transparancy

Hardness

MouthmeltElasticity

Bitterness

ReferenceWith Nutrilac® CH-4560

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How to use Nutrilac® CH-4560

The addition of Nutrilac® CH-4560 is recommended to be in the range of 0.3% to 1.0%, calculated on the total cheese milk volume.

When it comes to the addition methods, there are several options:

Mixing with water〉 A pre-mixture of 13% Nutrilac® CH-4560 and 87%

water is the optimal way to incorporate the func-tional milk proteins into the cheese milk.

〉 The mixture can be made by either a tri-blender system, or in a mixing tank.

〉 After a mixing time of approximately 10-15 minutes it is important to let the mixture hydrate for another 1 to 15 hours.

〉 If a high impact on the yield is desired, we recom-mend to make a long (+10 hours) hydration at cold conditions. This will improve the yield increase with 30% compared to the results of 1 hour hydration.

A big advantage when mixing with water is that there are no changes necessary in the cheese making para-meters; the lactose level is correctly regulated by the described mixing ratio with water. Mixing with milkIt is also possible to premix Nutrilac® CH-4560 with a portion of the cheese milk. 〉 We recommend mixing up to 13% with a small por-

tion of the milk, let it hydrate and then blend it back into the full portion of cheese milk.

〉 Once again, the longer the hydration is made, the higher the yield increase.

When mixing with milk, it is necessary to take steps in the cheese making parameters to regulate the lactose level to ensure the cheese has the desired pH.〉 This is done by increasing the volume of hot pro-

cessing water that is added in the final processing steps.

〉 The amount of extra processing water is calculated by multiplying the amount of Nutrilac® CH-4560 by 6.7.

Example15.000 kg cheese milk with 0.5% Nutrilac® CH-4560 contains 75 kg Nutrilac.This means that (75 x 6,7)kg = 502.5kg extra processing water has to be added in the production process.

Pasteurising through Plate Heat ExchangerThe necessary pasteurisation of the cheese milk is the same as usual, regardless of whether the pre-mixture is based on water or milk. 〉 In most cases this is a pasteurisation at 72-74°C for

15-20 seconds performed via Plate Heat Exchanger (PHE).

〉 This can be done by mixing the premix into the cheese milk in the silo tank, or in-line dosage just prior to the milk-PHE.

〉 It is also a possibility to perform a single PHE-pasteurisation of the premix. For example via the pasteurised whey cream; pumping the pasteurised premix directly to the cheese vat at the same time as the cheese milk.

Pasteurising batch wiseIf PHE pasteurisation is not possible, it can be done per batch via a hot water jacket system. 〉 The recommended batch pasteurisation is at 65°C

for 30 minutes, followed by cooling to regular cheese milk temperature.

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Frequently asked questions

What are the optimal storage conditions?Nutrilac® CH-4560 is stable when stored at ambient temperature. The product has a minimum one year storage life if kept under the prescribed storage condi-tions. A cooler storage temperature will give an even longer shelf life. Is Nutrilac® CH-4560 easy to use?Yes. The special production method results in a fast dispersible powder, allowing Nutrilac® CH-4560 to easily dissolve in both water and milk. If resting longer than 30 minutes, you are required to stir the solution in order to ensure a homogeneous mix.

Does the addition of Nutrilac® CH-4560 change the protein breakdown during ripening?No. Unlike whey proteins in general, the protein particles from Nutrilac® CH-4560 do not influence the casein breakdown (soluble nitrogen). The protein particles are placed individually in the cheese matrix, and the ripening enzymes therefore have full access to perform the proteolysis of the caseins.

Will the cheese become more bitter from adding Nutrilac® CH-4560?No. Bitter taste in cheese is a result of a slow proteolysis of casein, creating long chained peptides with a bitter taste. Tests show that Nutrilac® CH-4560 does not slow the proteolysis.

Are you still allowed to label cheese products as “Cheese” after adding Nutrilac® CH-4560 to the cheese milk?Yes. In most cases. The codex says that you are allowed to use techniques that increase the whey protein level in cheese, as long as the whey protein level in raw milk is not exceeded!

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Cheese types & Nutrilac® usage

Cheese typeFat

reductionYield

increaseLowest total

fat levelRecommended dosage level*

Hard Cheese e.g. Emmenthal, Manchego, Cheddar ++ +++ 3% 0.15-0.8%

Semihard Cheese e.g. Gouda, Edam, Tilsit, Port Salut +++ +++ 5% 0.2-0.8%

Pasta Filatae.g. Mozzarella, Provolone, Kashkaval ++ ++ 11% 0.2-0.8%

Fresh Cheese e.g. Burgos, Minas, Panela, Cottage Cheese +++ +++ <5% 0.2-0.8%

Moulded Cheesee.g. Camembert, Blue Cheese +++ +++ 8% 0.2-0.6%

White Salted Cheesee.g. Feta, Bulgarian +++ ++ 5% 0.3-0.8%

*) Dosage based on the volume of cheese milk.

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All rights to the information contained herein belong to Arla Foods Ingredients P/S. The information is confidential and may not be disclosed to third parties orexploited by users without prior written consent. Statements contained herein donot constitute permission to infringe any patent or license rights. The informationcontained herein is reliable to the best of our knowledge. The details given areintended only as a source of information. Users should evaluate the products todetermine their suitability for the user’s own specific purposes and compliancewith relevant food legislation. No warranties, expressed or implied, are made.

Arla Foods Ingredients Group P/SSønderhøj 10-12 DK-8260 Viby JDenmarkTel. +45 89 38 10 00Fax +45 86 28 18 38Email: [email protected]

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