UNIT 7 PRINCIPLE AND METHOD OF

MANUFACTURE OF
PASTEURIZED PROCESSED
CHEESE PRODUCTS (PCPS)
Structure
7.0 Objectives
7.1 Introduction
7.2 Definition and composition of process
7.3 Ingrediants used other then cheese in pasteurized processed
7.4 Manufacture of processed cheese
• Selection of Natural cheese
• Trimming and Grinding
• Processing
• Cooking Teachnique
• Packaging

7.5 Storage of Packaged Processed Cheese

7.6 Defects in process cheese
• Spoilage of Process cheese
• Pinking of Processed cheese
• Browing of Processed cheese

7.7 Let Us Sum Up

7.8 Key Words
7.9 Some Useful Books
7.10 Answer to Check Your Progress

7.0 OBJECTIVES
After reading this unit you should be able to:
• Understand the development of pasteurized processed cheese products,
• Understand the definition and composition of pasteurized process cheese
products,
• Know the level of processed cheese products production,
• Describe the merits of PCPs,
• Know the ingredients used in the manufacture of PCPs,
• Understand the differences between processed cheese, processed cheese food
and processed cheese spread.
• Understand the manufacturing protocols and equipment,
• Understand the selection of natural cheeses for correct formulation,
43
Cheese • Understand the appropriate use of emulsifiers,
• Understand the method of manufacture of PCPs
• Understand the different methods of packaging and storage.
• Know the defects in PCPs.
• Know the spoilage of PCPs

7.1 INTRODUCTION
Pasteurized processed cheese products (PCPs) are cheese-based foods produced
by comminuting, blending and melting one or more natural cheeses and optional
ingredients into a smooth homogeneous blend with the aid of heat, mechanical shear
and (usually) emulsifying salts (ES). Optional ingredients which are determined by
the product type, include dairy ingredients, vegetables, meats, stabilizers, emulsifying
salts, flavours, colours, preservatives and water (Table 1).
Attempts to increase the shelf life of cheese during the early twentieth century were
inspired by the possibility of increased cheese trade, via the production of more
stable transportable products, and by the existence of heated cheese dishes such as
Swiss fondue and Kochkase. Many of the early approaches were unsuccessful, as
the heat treated cheese were unstable, as reflected by oiling off and moisture exudation
during cooling and storage. In 1911, the Swiss workers Gerber and Stettler produced
a stable, heat-treated stable Emmental cheese, known as Schachtelkase, by the
addition of a ‘melting salt’, sodium citrate, to the commuted cheese before processing
(i.e. heating and shearing). Subsequently it was found that other cheeses (e.g.
Cheddar) could also be processed to form stable products by the addition of other
‘melting salts’ (e.g. sodium phosphates) or blends of different emulsifying salts. The
‘melting salts’ were gradually referred to as emulsifying salts when their functions
became known, i. e. mediation of the processes of protein hydration and emulsification
of free fat during processing. Initial successes were followed by numerous patents
for different melting salt blends and later for inclusion of food ingredients other than
cheese.
The basic aim of processing is to blend natural cheese, water, optional ingredients
and emulsifying salts and to pasteurize the mixture to obtain an end product which
has sufficient fluidity for convenient packaging and which possesses long keeping
qualities. It is believed that the popularity of processed cheese products is based on
its uniformity, mildness and good keeping quality.
In the year 2003, global production of PCPs is estimated at~1.5-1.8 MT per year,
equal to ~ 10-12% of natural cheese production. Moreover, production has been
steadily increasing at a rate comparable to that of natural cheese; indeed, the mean
annual growth rate (1.4%) in the 15 countries of the EU for the period 1995-99
was greater than that (0.6%) for natural cheese. Factors contributing to the continued
growth of the PCPs include:
• the application of heat during processing stabilizes the cheese system into a
physico-chemically and bacteriologically stable state enhancing the shelf life of
the product. This ensures conservation of precious milk solids during glut period
into a valuable form of process cheese. This product can be stored for months
or even years.
• their versatility as foods that offer wide variety in flavour, texture (e.g. elasticity,
44 firmness, spreadability, sliceability), cooking attributes (e.g. degrees of
 flowability, browning, viscosity), size and shape of final product, and overall Principle and Method of
Manufacture of Pasteurized
consumer appeal as made possible by differences in formulation and processing Processed Cheese Products
conditions, condiment addition and packaging technology. (PCPS)

their convenience of use in the food service sector, especially the fast food trade,
and the home because of their excellent (stability) preservation, consistent tailor-
made
• functionality (e.g. flowability), convenient portion size and packaging (e.g. as
slices for the beef burger and sandwiches trade)
• their popularity with children of different ages owing to their safe ingestable
consistency (for infants) and mild flavours, and their packaging (colour,
caricatures, strength, ease of opening, size) and shape (e.g. triangles, fingers,
cartoon characters).
• their nutritive value (e.g. as a source of calcium and protein) as a food for
children. Because of its digestibility and beneficial properties processed cheese
is suitable as a diet food.
• their relatively low cost compared to most natural cheeses, made possible by
the use of relatively cheap non-cheese solids (e.g. whey, skim milk powder),
lower-grade natural cheese, and offcuts.
• Manufacture of process cheese with the addition of other food types (meat,
sea-foods, mushrooms, vegetables, fruits, fruit juices, dietetic substances and
vitamins.
• Manufacture of dried cheese from plain or seasoned processed cheese to be
used for sprinkling on soups, pasta or to be reconverted into spread by the
addition of water.
• Manufacture of dried cheese from plain or seasoned processed cheese for the
preparation of bakery goods, e.g. cheese flavoured biscuits.
• developments in manufacturing technology, emulsifying salt blends and functional
dairy ingredients which facilitate the manufacture of consistent quality products
with customized attributes.

7.2 DEFINITION AND COMPOSITION OF

PROCESSED CHEESE
There are various types of PCPs, the type or category of which, and standards of
identity therefore, depend on the particular region where they are produced. In the
United States, the code of Federal Regulations defines four types of PCPs based on
permitted ingredients and composition (Table 7.1). The percentage of natural cheese
in PCPs ranges from a minimum of 51% in pasteurized processed cheese spreads
and foods to 95% in pasteurized processed cheese.

45
Cheese Table 7.1: Ingredient and compositional specifications for pasteurized
processed cheese products
Product Permitted Ingredients Compositional specifications
category
Moisture Fat FDM
(% w/w) (% w/w) (% w/w)
Pasteurized Cheese: cream, anhydrous <43 - >47
blended milk fat, dehydrated cream
cheese (in quantities such that the
fat derived from them is less
than 5% w/w in finished
product); water; salt, food-
grade colours, spices and
flavours; mould inhibitors
(sorbic acid, potassium/
sodium sorbate, and/or
sodium propionates) at
levels <0.2% w/w of
finished product)
Pasteurized As far pasteurized blended <43 - >47
processed cheese, but with the
cheese following extra optional
ingredients: emulsifying
salts (sodium phosphates,
sodium citrates; 3% w/w of
finished product), food-
grade organic acid (e.g.
lactic, acetic or citric) at
levels such that the pH of
the finished product is 5.3,
cooking temperature may
be65-72°C for 30 sec.
Pasteurized As for pasteurized processed <44 >23 -
processed cheese, but with the
cheese foods following extra optional
ingredients: dairy
ingredients (milk, skim
milk, buttermilk, cheese
whey, whey proteins – in
wet or dehydrated forms),
fruits, vegetables, meats, the
pH usually 5.4-5.6, but may
go to 5.2, cooking
temperature, 77 °C for 30
sec.
According to PFA standard Processed cheese means the product obtained by heating
cheese with permitted emulsifiers and / or stabilizers namely, citric acid, sodium
citrate, sodium salts of orthophosphoric acid and polyphosphoric acid (as linear
phosphate) with or without added condiments and acidifying agents, namely vinegar,
lactic acid, acetic acid, citric acid and phosphoric acid, processed cheese may contain
not more than 4.0 percent of anhydrous permitted emulsifiers and/ or stabilizers,
provided that the content of anhydrous inorganic agents shall in no case exceed 3.0
per cent of the finished product. It shall not contain more than 47.0 per cent moisture.
The milk fat content shall not be less than 40.0 per cent of the dry matter. Processed
cheese may contain 0.1 per cent sorbic acid or its sodium, potassium or calcium
salts (calculated as sorbic acid) or 0.1 per cent of nisin either singly or in combination.
46 It may contain calcium chloride (anhydrous) not exceeding 0.02 percent by weight.
 Principle and Method of
7.3 INGREDIENTS USED OTHER THAN CHEESE Manufacture of Pasteurized
Processed Cheese Products
IN PASTEURIZED PROCESSED CHEESE (PCPS)

Table 7.2: Ingredients, other than cheese used in pasteurized processed

cheese products
Ingredient Main function /effect Examples
type
Dairy
ingredients
Milk fat Gives desired composition, Butter, anhydrous milk fat
texture and meltability
characteristics.
Milk Gives desired compositional Casein, caseinates, whey
proteins specification proteins, milk ultrafiltrates,
Texture and meltability milk proteinates
characteristics: assist the
production of a
physicochemically stable
product.
Lactose Low-cost filler, may affect Whey powder
texture
Stabilizers Assist formation of a Emulsifying salts: sodium
physicochemically stable phosphates and sodium
product; give desired texture citrates; hydrocolloids: guar
and meltability characteristics gum, xanthan gum,
carrageenans
Acidifying Assist control of the pH of final Food-grade organic acids,
agents product e.g. lactic, acetic, citric,
phosphoric
Flavours Impart flavour, especially Enzyme-modified cheese,
where much young cheese is starter distillate, smoke
used extracts
Flavour Accentuate flavour Sodium chloride, yeast
enhancers extract
Sweetening Increase sweetness, especially Sucrose, dextrose, corn
agents in products targeted at young syrup, hydrolysed lactose
children
Colours Impart desired colour Annatto, paprika, artificial
colours
Preservatives Retard mould growth; prolongs Nisin, potassium sorbate,
shelf life calcium/sodium propionate
Condiments Impart variety to appearance, Sterile preparations of
texture and taste; give product meat, fish, vegetables, nuts
differentiation and/or fruits

Check Your Progress 1

1. Define pasteurized processed cheese products?
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2 Name the optional ingredients used in the manufacture of PCPs.
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47
Cheese ...................................................................................................................
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3. Briefly describe the development of PCPs.
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4. Give the level of production of PCPs.
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5. Describe the factors responsible for steady growth of PCPs.
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6. Name the main types of PCPs.
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7. Give the major steps of manufacture of PCPs
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7.4 MANUFACTURE OF PROCESSED CHEESE

The manufacture of PCPs involves the following major steps:
1. Formulation, deciding on the different types and levels of ingredients to be
included.
2. Cleaning and comminution of the cheese
3. Blending with ES, water and optional ingredients
4. Processing (heating and shearing) of the blend
5. Homogenization of the molten blend (optional)
6. Hot packing and cooling.
i. Selection of Natural Cheese
Selection is determined chiefly, by type, age, acidity, flavour, body, texture and
48 composition of the lots of cheese available. Some successful operators make their
selections entirely on the basis of flavor, body and texture. The proper choice of the Principle and Method of
Manufacture of Pasteurized
cheese must establish uniformly desirable flavor, body, slicing properties and Processed Cheese Products
composition. These are attained by mixing many lots of cheese. (PCPS)

In practice any type of cheese without exception can be used. During the entire
history of processed cheese there remains scarcely a single type of cheese which
has not been investigated. In practice, for economic reasons, factory technique and
consistency in quality, cheese which is available in plentiful quantities giving little
difficulty in processing and little waste in cleaning is used. The most important types
are the hard and semi- hard types, such as, Cheddar, Gouda, Edam, Emmentaler,
and Provolone to mention but a few. Due to their relatively high dry matter content
and their high intact protein content as structure building matter, they guarantee to
the processed cheese the necessary stability. Amongst these types which are easy to
process and which cause few complications one can name Cheddar. For this reason,
Cheddar is the most widely used type of raw material for processing throughout the
world.
It is generally accepted that old cheese alone is not suitable for processing as it
results in a cheese having a loose and grainy texture, weak body, poor slicing
properties and being liable to fat separation. On the other hand, very young cheese
gives a viscous, glutenous mix while young cheese yields a stable emulsion having a
smooth texture, firm body and good slicing properties. Old cheese may be blended
in with the latter in small amounts to give added flavour to the product. Usually
approximately 75% of the blend consists of short held cheese (1-3 months) and the
rest consists of cheese 5-6 months old. It has been found that 15% current (tough)
cheese may be incorporated in batch taking care to avoid lumps in the finished
product, but acid current cheese should not be used as colour defects ranging from
straw to deep pink are then likely to occur. Acid cheese should be at least 8 weeks
old when used and it is best not to use over 12%. As regard flavour, cheese on the
acid side can be an asset. High acid cheese tends to produce grainy texture.
In a successful blending of a batch of cheese for processing it has been suggested
that at least three, and often up to a dozen, different kinds of bulk cheese may be
required. It was further recommended that the cheese should be of three different
stages of ripening:
1. Young cheese 25%, 1-3 month old to impart a cohesive quality to the product.
It must not have acid character.
2. Short held cheese 50%, from 3-4 months in age, the cheese must not have
rubbery texture, provides mellowness and flavor.
3. Aged cheese- aged 6 months or more- 25% provide flavor.
Thus, it can be seen that young cheese is used for its desirable body texture, and
slicing properties and older cheese is used to impart satisfactory flavor. Also, by
using a combination of young and old cheese, the average storage time necessary to
produce a desired flavor is less than when only medium ripened cheese is used. This
practice also caters for the early usage of young cheese of poor curing properties
before definite flavour defects are evident.
Many cheese unfit for retailing, i.e. with broken or damaged rinds or cheese invaded
by mould after sampling can be salvaged for processing. It has been reported that
up to 5% of inferior cheese may be blended with good cheese with no noticeable ill
effects, but that putrid cheese should never be used as even 1% in a blend is detectable
in the finished product.
49
Cheese ii. Trimming and Grinding
The first step after the cheese has been selected is to trim off all non- edible portions.
In processed cheese the trimming is not done as deeply as in case of natural table
purpose cheese. This is due to the following:
a) The surface layer is inferior in flavour, and may be unclean, and
b) Beyond this, additional rind may be removed because it is so firm and dry as to
be unpalatable.
In processing, only the first of these reasons applies, rind need not be discarded,
solely because it is too firm, because grinding and heating will remedy this condition.
The rind may be removed by knives. Another method is to soften the rind by
tempering.
a) Tempering: Cheese is held in the blending room until it approaches a
temperature of 15-21 °C. This may require 48-72 hrs. Warming the cheese in
the blending room softens it and facilitates the cleaning, cutting and grinding
operations. It has added advantage of reducing the amount of heat required to
bring the cheese to its final cooking temperature
b) Trimming: The first step in cleaning is the removal of paraffin and bandage.
The first rough cleaning removes most of the soiled areas on the surface of the
cheese. The cheeses are then moved to the next area, where all inedible portions
of the cheese are scraped of or cut away.
c) Trimming losses: The amount of rind removed from a normal, undamaged
cheese is determined by the flavour and consistency of the rind itself. The surface
areas of cheese in storage absorbs odours from boxes and storage rooms, the
areas affected must be removed in cleaning. A critical operator assumes that
any portion of the surface that is not suitable for consumption in its natural state
is undesirable for processing. Damaged rinds, cracked surfaces containing mould
growth. Mouldy areas surrounding trier holes, spots damaged by box nails and
the like are entirely removed. Weight losses in cleaning may range from a few
ounces in current cheese to several pounds in an old cheese which may have
been damaged by excessive mould growth or other from rind injury. It is
minimized by flexible wrapping. The rind can also be softened by exposing the
cheese to steam for a short time and then removing the surface by scraping.
iii. Processing
Processing refers to the heat treatment of the blend, indirectly or by direct steam
injection, while constantly agitating. Processing has two main functions: 1) to kill
any potential pathogenic or spoilage microorganisms, and thereby extend the shelf
life of the product; 2) to facilitate physico-chemical and microstructural changes
which transform the blend to an end product with the desired characteristics and
physico-chemical stability.
The cheese is grinded directly into the cooker. For grinding it is usually necessary to
cut the cheese into strips 2-3 inches square. The order of addition of the ingredients
varies with plant practices, cooker type, overall plant design, and duration of cooking.
A typical order of addition is: ground cheese, a dry blend of emulsifying salts and
optional dairy ingredients (e.g. skim milk powder), water and flavours. When the
cooking time is relatively short, the ES may be dispersed in a portion of the water
added at the beginning of the processing. This approach minimizes the time required
50 for the ES to dissolve during cooking, increases the concentration of ES during early
cooking and thereby enhances the effectiveness of the ES in promoting the desired Principle and Method of
Manufacture of Pasteurized
physico-chemical changes in the blend. After the preset time, the remaining water Processed Cheese Products
may be added manually, delivered by metering pump, or drawn in by vacuum inside (PCPS)
the vessel. Flavours may be added later in the process to minimize the loss of
volatile flavour compounds.
Processing may be performed in batch cookers (e.g. Stephan, Damrow) or
continuous cookers (e.g. Kombinator, Votator) connected to water, steam and
vacuum. During processing, the ground cheese remains crumbly until a temperature
of about 49 °C is reached. Beyond this point the cheese becomes sticky, stringy
and plastic and may effectively retain (or reincorporate) the fat without the addition
of an emulsifying agent. In the early stages of heating there is usually some “oiling
off”, especially at temperatures where the fat is fluid and before the plastic condition
has been reached, i.e. between 35 and 49°C. If the conditions are correct, this free
fat will be reincorporated into the cheese by the stirring at temperatures beyond
49°C. Factors affecting fat separation are 1) age of cheese, 2) acidity, 3) water
content, 4) velocity of agitation.
The temperature-time treatment in batch processing varies (e.g.70-95°C for 4-5
min), depending on the formulation, extent of agitation, the desired product texture
and shelf-life characteristics. The bacteria in the vegetative state are killed by these
temperature treatments. However, a temperature >130 °C may be required to kill
some spores. A temperature of 140 °C can be achieved in continuous cookers by
virtue of their design, e.g. scraped surface tubular heat exchangers which maximize
the surface area of contact between the heating medium (e.g. steam, oil or hot
water) and the blend, and ensure sufficient agitation to prevent burn-on of the blend
on the heat transfer surface. In continuous cookers, the blend is, typically, heated to
140 °C for 5 s and then cooled to 70-95 °C by flash evaporation of moisture due to
a pressure drop, or by passing through scraped –surface tubuler coolers. The product
is then held at this temperature for 4-15 min to allow adequate time for interaction of
the different blend ingredients, the desired physico-chemical changes to occur and
the development of the desired textural characteristics. The blend thickens
progressively with holding time at 70-95 °C.
iv. Cooking Technique
The oldest method is heating in a steam jacketed kettle equipped with double action
agitators. Steam pressures up to 30lbs/ sq. inch may be used in the jacket. A
definite weight of the selected, ground cheese and the calculated and weighed amounts
of emulsifying salt and other ingredients are placed in the kettle. The required amount
of water and possibly cheese colour are added. Heating and agitation are preferably
started before the kettle is completely loaded. The water and emulsifying salts should
be present before the heating has progressed very far. The heating and stirring are
continued until a temperature of 75 °C is reached. At that stage there should be no
free fat and the hot cheese should be semi-fluid with quite a pronounced tendency to
draw string. As soon as this condition and the temperature of 75 °C have been
reached, the cheese may be discharged from the kettle for packaging. No holding is
necessary for the sake of pasteurization, since the packaged product will cool slowly
and will be within an effective pasteurizing range for some time.
v. Packaging
The cheese is packed as soon as possible after heating to avoid aerial contamination.
It has been reported that 18-21° C is the best temperature for the cooling room,
the packages should not be placed under refrigeration until they have attained these
temperatures. 51
Cheese The main requirements for packaging materials for process cheese are:
1) moisture retention,
2) impermeability to oxygen,
3) no off-flavour side effects, and
4) close adherence to the cheese
The following packaging materials were tried: tin, tin foil, cellulose films, glassine,
coated aluminium foil and laminates of aluminium foil and parchment paper. It has
been reported that tins and parchment paper impregnated with foil are the best.

7.5 STORAGE OF PACKAGE PROCESSED

CHEESE
The finished, packaged processed cheese should be stored, as far as possible, at
temperatures between 5 and 10 °C. Once again it is necessary to emphasized that
the processed cheese must not be held at temperatures below 0°C, as freezing can
upset its structure. In addition, when the boxes are removed from the cold room,
condensation can occur quickly, leading to early spoilage.
When cooling has not been completed, quite often the processed cheese is exposed
for a time to temperatures above 20 °C in hot countries as high as 30 °C. This can
occur during transport or storage. There is unfortunately a prevailing belief that
processed cheese possesses an unlimited keeping quality it often happens that little
importance is attached to the storage of processed cheese at higher temperatures.
Is processed cheese really absolutely sterile? If a sterilizing process has been used
during manufacture, whether by means of a short period ultra high temperature
procedure or by means of an autoclave, one can assume that the final product is
sterile, so long as a very conscientious and painstakingly clean working operation
has been carried out. Unfortunately, the use of a short high temperature processing
machine is no guarantee for the production of sterile products. A large number of
processing factories still use conventional cookers reaching a temperature between
85 and 95 °C or perhaps slightly higher, so that the possibility of the presence of
Clostridia and, in addition, vegetative organisms must always be born into mind.
These organisms, including the Clostridia, will, of course, most certainly continue to
multiply and develop with lengthy storage at temperatures around 25-30 °C and
eventually cause spoilage and deterioration in the cheese. Therefore, one must
avoid storage of processed cheese for long periods at temperatures above 20 °C.
Storing sterile processed cheese at higher temperatures is also not advisable because
the protein structure and the flavour are detrimentally altered, even though no
bacteriological change takes place. In addition, certain defects, which are not evident
at normal cold storage, are intensified at temperatures around 30 °C. An example
of this is the occurrence of sandiness, which is mostly caused by the formation of
fine or course crystals of calcium diphosphate (calcium pyrophosphate). Regular
checks are made in most well organized factories by storing representative samples
of processed cheese at various temperatures for a certain length of time, e.g., at
10,20,30, and 37°C. From the results obtained after the organoleptic examination
of samples stored at 30 and 37 °C, conclusions can be drawn as to possible changes
in the products at a later date.

52
 Principle and Method of
7.6 DEFECTS IN PROCESSED CHEESE Manufacture of Pasteurized
Processed Cheese Products
Whosever takes the trouble to collect samples of processed cheese and processed (PCPS)

cheese spreads regularly from the normal marketing sources, and submit them to a
thorough organoleptic examination, would soon come, to the conclusion that with
the exception of the well known top quality products, many processed cheese products
found on the market are exceedingly inferior, with regard to consistency, structure,
and flavour. Three well known defects in texture can be established here, “over
creaming, stickiness and sandiness”. These defects, which are most certainly of a
physico- chemical nature can be observed today more frequently than bacteriological
defects, e.g., the dreaded “blowing” of processed cheese due to butyric acid bacilli
and other clostridia. With respect to flavour, other objectionable defects include
metallic, oily, cardboardy, soapy, bitter and indeed the frequent total absence of the
desired characteristic flavour. The causes of these defects can be many: unsuitable
raw material, additives of non- standard flavour, unsuitable seasoning, defective
dosage and a faulty processing technique. In this connection, poor flavour can occur
in the presence of an unsuitably high addition of whey concentrate.
During processing the, the blend thickens progressively with holding time in the
cooker. The thickening, frequently referred to as ‘creaming’ or ‘creaming effect’
may be attributed to ongoing interaction of the emulsifying salts with the casein and
with the consequent increases in para-casein hydration and degree of emulsification.
Both factors contribute to an increase in the apparent viscosity of the molten blend.
However, extending the holding time of the molten product at high temperature
results in a gradual dehydration of the dispersed sodium para-caseinate, an
occurrence which has the effect of imparting elasticity and firmness to the final product.
Indeed, prolonged holding results in excessive protein dehydration and aggregation,
and a concomitant destabilization of the emulsion, as reflected by the exudation of
‘beads’ of free oil on the surface of the product on cooling. This defect, known as
‘over-creaming’, is also accompanied by a tendency of the product to express some
free water in the cooker or on subsequent cooling.
The flavour defects can be overcome by means of extremely careful control during
the whole production run. This includes careful selection of raw materials, with regard
to flavour and processing properties, the correct use of emulsifying salts and attention
to all the features of procedure and critical examination of all finished products.
i. Spoilage of PCPs:
Processed cheese, cheese foods and cheese spreads constitute an important part of
the cheese products marketed. Normally they keep satisfactorily because of the
heat used in processing, acid and salt present, containers which prevent contamination
of the finished products, and perhaps other factors. However, spoilage sometimes
may occurs, it may involve microorganisms or chemical changes. Pasteurized
processed cheese products are not sterile, as the spore forming bacteria are not
destroyed by the heat used. Their growth is controlled by proper pH, salt and Eh
level.
Defects in the films used to line boxes or in jar seals may permit the entrance of
moulds which find the conditions suitable for growth. Such spoilage usually occurs
in only occasional package. Serious spoilage commonly involves heat resistant
bacteria which, because of some irregularity grow in the packaged products.
Extensive gas blowing may occur in pasteurized processed cheese products. This is
caused by Cl. sporogenes and related carbohydrate fermenting bacterial sps., but 53
fortunately, they cause no safety problem. To minimize such an unpleasant occurrence
Cheese as gas blowing, the basic natural cheese stock should not contain excessive numbers
of anaerobic spores, the pH of the finished processed cheese should fall between
5.6 to 5.8, and NaCl content between 2.5 to 3.5(6.0-7.5% NaCl in serum).
The instances of spoilage in process cheese by Cl. Sporogenes has been reported
which involved bleaching, development of softened and crumbled areas, and faecal
odour, in some areas there was a small dark slit which was considered to be due to
gas. The isolation of Cl. Sporogenes and Cl. perfringens from tinned processed
cheese which was gassy and had a putrid odour also has been reported. The
condition was observed only in cheese in which skim milk powder was added. The
same types of organisms were isolated from cheese containing no milk powder, but
they did not cause deterioration.
ii. Pinking of Processed Chees
Pinking is a colour defect in processed cheese. This defect is produced by
overheating the cheese in the cooker. Its chemical cause is not known, but annatto
colour break down during heating may cause this defect. Also in processed cheese
containing young natural cheese, the pink colour may result from the Maillard type
browning
iii. Browning
In case of processed cheese foods and spreads, the non-cheese dairy products
have lactose which causes browning. Bigger the container slower the cooling and
more is the browning. Kraft developed a new process to control this problem. The
cheese from the cooker runs out and flows on cold water and then strips and pieces
of cheese is made.
Check Your Progress - 2
1. Give the raw materials used in the processing of PCPs.
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2. What precaution should be taken in the selection of cheese for the manufacture
of PCPs?
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3. What do you understand by trimming of cheese?
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4. Describe in brief the processing of processed cheese.
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54
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5. Describe packaging and storage of PCPs Principle and Method of
Manufacture of Pasteurized
................................................................................................................... Processed Cheese Products
(PCPS)
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6. Name the common defects in processed cheese.
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7.7 LET US SUM UP

Pasteurized processed cheese products (PCPs) are cheese-based foods produced
by comminuting, blending and melting one or more natural cheeses and optional
ingredients into a smooth homogeneous blend with the aid of heat, mechanical shear
and (usually) emulsifying salts (ES). Optional ingredients which are determined by
the product type, include dairy ingredients, vegetables, meats, stabilizers, emulsifying
salts, flavours, colours, preservatives and water, etc.
Attempts to increase the shelf life of cheese during the early twentieth century were
inspired by the possibility of increased cheese trade, via the production of more
stable transportable products. Many of the early approaches were unsuccessful, as
the heat treated cheese were unstable, as reflected by oiling off and moisture exudation
during cooling and storage. In 1911, the Swiss workers Gerber and Stettler produced
a stable, heat-treated Emmental cheese, known as Schachtelkase, by the addition
of a ‘melting salt’, sodium citrate, to the commuted cheese before processing (i.e.
heating and shearing). Subsequently it was found that other cheeses (e.g. Cheddar)
could be also processed to form stable products by the addition of other ‘melting
salts’ (e.g. sodium phosphates) or blends of different emulsifying salts.
The basic aim of processing is to blend natural cheese, water, optional ingredients
and emulsifying salts and to pasteurize the mixture to obtain an end product which
has sufficient fluidity for convenient packaging and which possesses long keeping
qualities. It is believed that the popularity of processed cheese products is based on
its uniformity, mildness and good keeping quality.
There are various types of PCPs, the type or category of which, and standards of
identity therefor, depend on the particular region where they are produced. In the
United States, the code of Federal Regulations defines four types of PCPs based on
permitted ingredients and composition, viz. pasteurized blended cheese, pasteurized
processed cheese, pasteurized processed cheese food and pasteurized processed
cheese spread. The percentage of natural cheese in PCPs ranges from a minimum
of 51% in pasteurized processed cheese spreads and foods to 95% in pasteurized
processed cheese.
The manufacture of PCPs involves; formulation, deciding on the different types and
levels of ingredients to be included, cleaning and comminution of the cheese, blending
with ES, water and optional ingredients, processing (heating and shearing) of the
blend, homogenization of the molten blend (optional), hot packing and cooling.
Raw materials include cheese, emulsifying salts, water, and additives. Selection of
cheese is determined chiefly, by type, age, acidity, flavour, body, texture and 55
Cheese composition of the lots of cheese available. Some successful operators make their
selections entirely on the basis of flavor, body and texture. The proper choice of the
cheese must establish uniformly desirable flavor, body, slicing properties and
composition. These are attained by mixing many lots of cheese.
Processing refers to the heat treatment of the blend, indirectly or by direct steam
injection, while constantly agitating. Processing has two main functions: 1) to kill
any potential pathogenic or spoilage microorganisms, and thereby extend the shelf
life of the product; 2) to facilitate physico-chemical and microstructural changes
which transform the blend to an end product with the desired characteristics and
physico-chemical stability.
The cheese is grinded directly into the cooker. For grinding it is usually necessary to
cut the cheese into strips 2-3 inches square. The order of addition of the ingredients
varies with plant practices, cooker type, overall plant design, and duration of cooking.
A typical order of addition is: ground cheese, a dry blend of emulsifying salts and
optional dairy ingredients (e.g. skim milk powder), water and flavours. When the
cooking time is relatively short, the ES may be dispersed in a portion of the water
added at the beginning of the processing.
The temperature-time combination treatment in batch processing varies (e.g.70-
95°C for 4-5 min), depending on the formulation, extent of agitation, the desired
product texture and shelf-life characteristics. The bacteria in the vegetative state
are killed by these temperature treatments. However, a temperature >130 °C may
be required to kill some spores.
The oldest method is heating in a steam jacketed kettle equipped with double action
agitators. Steam pressures up to 30lbs/ sq. inch may be used in the jacket. A
definite weight of the selected, ground cheese and the calculated and weighed amounts
of emulsifying salt and other ingredients are placed in the kettle. The required amount
of water and possibly cheese colour are added. Heating and agitation are preferably
started before the kettle is completely loaded. The water and emulsifying salts should
be present before the heating has progressed very far. The heating and stirring are
continued until a temperature of 75 °C is reached. At that stage there should be no
free fat and the hot cheese should be semi-fluid with quite a pronounced tendency to
draw string. As soon as this condition and the temperature of 75 °C have been
reached, the cheese may be discharged from the kettle for packaging. No holding is
necessary for the sake of pasteurization, since the packaged product will cool slowly
and will be within an effective pasteurizing range for some time.
The cheese is packed as soon as possible after heating to avoid aerial contamination.
It has been reported that 18-21 °C is the best temperature for the cooling room,
the packages should not be placed under refrigeration until they have attained these
temperatures. The finished, packaged processed cheese should be stored, as far as
possible, at temperatures between 5 and 10 °C.
Three well known defects in texture can be established here, “over creaming,
stickiness and sandiness”. These defects, which are most certainly of a physico-
chemical nature can be observed today more frequently than bacteriological defects,
e.g., the dreaded “blowing” of processed cheese due to butyric acid bacilli and
other clostridia. With respect to flavour, other objectionable defects, include metallic,
oily, cardboardy, soapy, bitter and indeed the frequent total absence of the desired
characteristic flavour. The causes of these defects can be many: unsuitable raw
material, additives of non- standard flavour, unsuitable seasoning, defective dosage
and a faulty processing technique.
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Normally the PCPs keep satisfactorily because of the heat used in processing, acid Principle and Method of
Manufacture of Pasteurized
and salt present, containers which prevent contamination of the finished products, Processed Cheese Products
and perhaps other factors. However, spoilage sometimes occurs, it may involve (PCPS)
microorganisms or chemical changes. Pasteurized processed cheese products are
not sterile, as the spore forming bacteria are not destroyed by the heat used. Their
growth is controlled by proper pH, salt and Eh level. The spoilage of PCPs during
storage may be due to gas formation, pinking discolouration and browning.

7.8 SOME USEFUL BOOKS

Davis J. G. 1965. Cheese, Vol. I, J&H Churchill Ltd., London.
Davis, J. G. 1965, Cheese, Vol. II, J &H, Churchill Ltd., London
Kosikowski,F. 1982. Cheese and Fermented Milk Foods 2nd edn., FV Kosikowski
and Associates, New Yark.
Meyer, A. 1973. Process Cheese Manufacture, Food Trade Press, London.
Roginski, H., Fuquay J. W. and Fox, P. F., 2003, Encyclopedia of Dairy Sciences,
Vol. I, Academic Press, An imprint of Elsevier Sciences, New Yark.
Scott, R. 1981 Cheesemaking Practice, AppliedScience Publishers Ltd., Essex,
England.
Vanslyke, L.L. and Price, W.V. 1952, Cheese, 2nd. Edn.Orange Judd Pub
Corp.Inc.,New York.

7.9 KEY WORDS

Emulsifiers : Substances promoting emulsification of fat
during cheese processing preventing fat
separation.
Stabilizers : Substances used for stabilizing the body,
texture and water retention in process
cheese.
Body : Body refers to the physical properties of
consistency. These properties include
firmness, cohesiveness elasticity and
plasticity.
Texture : Texture refers to the manner of union of
the particles of the particles of cheese.
‘Creaming’ or ‘creaming effect’ : The thickening of blend during cooking.
Bloating : Swelling of processed cheese tins due to
formation of gas.
Pinking : Pinking is a colour defect in processed
cheese
Browning : Browning is a colour defect of processed
cheese.

7.10 ANSWERS TO CHECK YOUR PROGRESS

Your answer should include following points:
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Cheese Check Your Progress 1
1. i. PCPs are cheese based food,
ii. PCPs are produced by comminuting, blending and melting one or more
natural cheeses and optional ingredients,
iii. Use of emulsifiers and
2. Dairy ingredients, vegetables, meats, stabilizers, emulsifying salts, flavours,
colours, preservatives and water.
3. i. Need to increase the shelf-life for increased cheese trade.
ii. Existence of heated cheese dishes such as Swiss fondue.
iii. Heat treated cheese unstable without emulsifying salts.
iv. In 1911,the Swiss workers produced stable cheese by adding melting
salts, viz. sodium citrate to the commuted cheese before processing.
4. i. The global production of PCPs estimated to be at about 1.5-1.8 Mt /
year.
ii. The production increasing @ 1.4% / year.
5. i. Versatility as foods that offer wide variety in flavour, texture, cooking
attributes, etc.
ii. Convenience of use.
iii. Popularity with children.
iv. Nutritive value.
v. Relative low cost;
vi. Developments in manufacturing technologies.
6. i. Pasteurized blended cheese,
ii. Pasteurized processed cheese,
iii. Pasteurized processed cheese food,
iv. Pasteurized processed cheese spread.
7. i. Formulation, deciding on the different types and levels of ingredients to
be included.
ii. Cleaning and comminution of the cheese
iii. Blending with ES, water and optional ingredients
iv. Processing (heating and shearing) of the blend
v. Homogenization of the molten blend (optional)
vi. Hot packing and cooling.
Check Your Progress 2
1. Cheese, emulsifying salts, water, and additives.
2. i. Type, age, acidity, flavour, body, texture and composition of the lots of
58 cheese available.
 ii. The proper choice of the cheese must establish uniformly desirable flavor, Principle and Method of
Manufacture of Pasteurized
body, slicing properties and composition. Processed Cheese Products
(PCPS)
3. i. Removal of paraffin and bandage.
ii. Removal of all inedible cheese.
4. i. Heat treatment
ii. Continuous agitation
iii. Destruction of pathogenic and spoilage microorganisms.
iv. To facilitate physicochemical and microstructural changes.
v. Cheese ground directly into the cooker.
vi. Addition of ES, optional ingredients, water and flavours.
vii. Heat treatment up to a temperature – time of 70-95 °C.
viii. Hot packaging.
5. i. Requirements of packaging materials.
ii. Commonly used packaging materials.
iii. Right temperature of cooling room and storage after packaging.
6. i. Defect related to consistency, structure and flavour.
ii. Over-creaming, stickiness, sandiness.
iii. Flavour defects, viz. metallic, oily, cardboardy, soapy, bitter.
iv. Gas formation (bloating).

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