Evaluation of on-line optical sensing techniques for monitoring curd moisture content and solids in whey during syneresis

This study focuses on the prediction ability of several optical sensing techniques, namely single wavelength (980 nm), broad spectrum and colour coordinates, for monitoring key syneresis indices during cheese manufacture. Three series of trials were undertaken in which milk gel was cut and stirred in an 11 L cheese vat. Three full factorial designs were employed with experimental variables consisting of: (i) three curd stirring speeds and three cutting programmes; (ii) three milk fat levels and three gel firmness levels at cutting; and (iii) two milk protein levels and three fat:protein ratio levels in the respective experiments. Models developed using the range of techniques investigated demonstrated that an on-line visible–NIR sensor was able to predict curd moisture content. However, the broad spectrum technique was the only one capable of predicting whey solids. The findings show that on-line sensing techniques can significantly improve the control of curd moisture content in cheese factories, across the range of experimental variables used in this study.     

Effects of Somatic Cell Counts and Milk Composition on the Coagulating Properties of Milk

Forty-two Holstein cows were selected to provide monthly milk samples with varying SCC for 1 yr. Coagulating properties of samples measured as rennet clotting time, rate of curd firming, and curd firmness at cutting were determined by a formagraph. Milk samples were analyzed for fat, protein, lactose, total solids, casein, individual caseins, urea, SCC, and pH. Least squares analyses of data, after adjustments were made for the effect of milk composition, indicated that elevated SCC were associated with a significant increase in rennet clotting time and slower rate of curd firming. An increase of SCC from 100,000 to 500,000 SCC/ml resulted in an increase of approximately 2.1 and 2.2% in RCT and K20, respectively. A further increase of SCC to above 1,000,000/ml resulted in an overall increase of 20.7 and 13.84% in RCT and K20, respectively. Regression analyses indicated that K20 was decreased by 5.42 min and curd firmness at cutting was increased by 12.92 mm for every percentage in milk casein. Rennet clotting time, rate of curd firming, and curd firmness at cutting were increased by 3.52, 3.41, min and decreased by 9.45 mm, respectively, for every unit increase in milk pH.     

Effects of Milk Composition and Genetic Polymorphism on Coagulation Properties of Milk

Milk samples from 31 Holstein cows of different phenotypes for β-casein, κ-casein, and β-lactoglobulin were collected monthly over the entire lactation. These samples were analyzed for total solids, fat, protein, casein fractions, lactose, urea, citric acid, somatic cell count, and pH. Rennet clotting time, rate of firming, and curd firmness as measured by a Formagraph were not significantly influenced by phenotypes for β-casein and κ-casein. Phenotype AA for β-lactoglobulin gave the best clotting time (3.91 min) and firmness of curd (36.30 mm) when compared with AB and BB phenotypes. Relative percentages of the different caseins and α-lactalbumin affected significantly rate of firming and curd firmness at cutting. Amount of κ-casein in milk was the most significant factor that affected curd firmness with a coefficient of regression of 15.96.     

Effect of Curd Healing Time on Stirred Curd Cheese Yield

Cheese was manufactured with variable heal times to determine the effect of curd healing time on stirred curd cheese yield. A randomized complete block design with three treatments (vat healing times from cut to cook) was replicated six and four times in studies 1 and 2, respectively, for a total of 30 vats of stirred curd cheese. In study 1, heal times of 15, 22, and 29 min were used in manufacturing cheese. Curd was not healed or healed 15 or 30 min in study 2. Cooking curd immediately after cutting resulted in significantly lower moisture content in cheese, lower raw cheese yields, and higher fat loss into whey. Healing cheese curd 15 min or longer decreased syneresis, resulting in higher moisture cheese and increased raw cheese yield. Heal time extended to 30 min resulted in a significantly smaller loss of fat into whey. Healing time had a significant effect on moisture retention, fat loss, and raw cheese yield.     

Effects of cutting intensity and stirring speed on syneresis and curd losses during cheese manufacture

Recombined whole milk was renneted under constant conditions of pH, temperature, and added calcium, and the gel was cut at a constant firmness. The effects of cutting and stirring on syneresis and curd losses to whey were investigated during cheese making using a factorial design with 3 cutting modes designed to provide 3 different cutting intensity levels (i.e., total cutting revolutions), 3 levels of stirring speed, and 3 replications. These cutting intensities and stirring speeds were selected to give a wide range of curd grain sizes and curd shattering, respectively. Both factors affected curd losses, and correct selection of these factors is important in the cheesemaking industry. Decreased cutting intensity and increased stirring speed significantly increased the losses of fines and fat from the curd to the whey. Cutting intensities and stirring speeds in this study did not show significant effects on curd moisture content over the course of syneresis. Levels of total solids, fines, and fat in whey were shown to change significantly during syneresis. It is believed that larger curd particles resulting from low cutting intensities coupled with faster stirring speeds resulted in a higher degree of curd shattering during stirring, which caused significant curd losses.     

Physical characteristics of set yoghurt made with altered casein to whey protein ratios and EPS-producing starter cultures at 9 and 14% total solids

This study investigated firmness and syneresis of set yoghurts made at the CN to WP ratios of 4:1, 3:1, 2:1 and 1:1 using non-EPS-, capsular EPS- and ropy EPS-producing starter cultures. The yoghurts were made at 9 and 14% (w/w) total solids. The total solids, total protein, the concentration of lactose and the ratios of CN to WP as well as the protein's profiles (native- polyacrylamide gel electrophoresis) in heated and unheated milk blends were investigated. The level of soluble denatured whey protein aggregates in heated milk was also determined. The concentration of EPS, firmness and level of spontaneous syneresis in set yoghurt were monitored weekly throughout 28 days of storage. The microstructure of the set yoghurt made with milk blends at the CN to WP ratio of 4:1 and using three types of starter cultures was carried out after 1 day of storage. There was no difference in the total solids, total protein and lactose concentration of liquid milk blends, except the CN to WP ratios. There was no difference in whey protein denaturation between milk blends. The level of soluble denatured whey protein aggregates in heated milk blends decreased with reducing CN to WP ratio. The firmness and the level of spontaneous syneresis in set yoghurts decreased as the CN to WP ratios were reduced. The use of EPS-producing starter cultures reduced firmness and syneresis and changed the protein matrix in the microstructure of set yoghurts made at 9% (w/w) total solids compared to the control products. These were not observed in set yoghurts made at 14% (w/w) total solids.     

Yield and functionality of Cheddar cheese as influenced by homogenization of cream

Cheese milk was standardized (casein-to-fat ratio of 0.7) by blending 0.64% fat milk and 35% fat cream. Cream was homogenized at 0/0 MPa (CO), 3.5/3.5 MPa (H05), 6.9/3.5 MPa (H10) or 10.4/3.5 MPa (H15). Cream homogenization did not influence rennet-clotting time, but it increased rate of curd firming and increased curd firmness of cheese milk. Moisture and salt in moisture phase of cheese increased with homogenization. Moisture (37%) and salt (1.5%) adjusted yield increased 1.42, 3.44 and 3.85% in H05, H10 and H15, respectively, over CO. Homogenized treatment cheeses melted faster with age. Free oil in 1 week old cheeses was lowest in H10 and highest in H05 and increased in all treatments with age. Cheese hardness was not influenced by homogenization but decreased with age. Cheeses with homogenized cream had improved body and texture and flavor. Cream homogenized at 6.9/3.5 MPa was optimal for enhancing Cheddar cheese yield and functionality.     

Validation of a curd-syneresis sensor over a range of milk composition and process parameters

An online visible-near-infrared sensor was used to monitor the course of syneresis during cheesemaking with the purpose of validating syneresis indices obtained using partial least squares, with cross-validation across a range of milk fat levels, gel firmness levels at cutting, curd cutting programs, stirring speeds, milk protein levels, and fat:protein ratio levels. Three series of trials were carried out in an 11-L cheese vat using recombined whole milk. Three factorial experimental designs were used, consisting of 1) 3 curd stirring speeds and 3 cutting programs; 2) 3 milk fat levels and 3 gel firmness levels at cutting; and 3) 2 milk protein levels and 3 fat:protein ratio levels, respectively. Milk was clotted under constant conditions in all experiments and the gel was cut according to the respective experimental design. Prediction models for production of whey and whey fat losses were developed in 2 of the experiments and validated in the other experiment. The best models gave standard error of prediction values of 6.6 g/100 g for yield of whey and 0.05 g/100 g for fat in whey, as compared with 4.4 and 0.013 g/100 g, respectively, for the calibration data sets. Robust models developed for predicting yield of whey and whey fat losses using a validation method have potential application in the cheese industry.     

Variation in Coagulation Properties of Milk from Individual Cows,

Milk samples from 50 Holstein cows were tested monthly for 10 mo for total protein, casein, fat, somatic cells, and pH. A Formagraph was used to measure chymosin coagulation properties. Significant variations in coagulation time and curd firmness were observed in relation to period of lactation, individual cows, and milk pH. A high negative correlation coefficient (?.86) was observed between coagulation time and curd firmness measured 30 min after addition of chymosin. The mean coagulation time generally increased as lactation progressed and milk yield decreased. Curd firmness was generally greatest in midlactation samples.Milk from 38% of the cows did not coagulate in 30 min 1 mo prior to their dry periods. The frequency of failure to coagulate was 68% in winter and 32% in fall. Milk pH was the most significant factor that affected coagulation time and curd firmness. Simulated cheese making procedures were utilized to estimate recovery of fat and protein in curd. Curd yield calculated from the recovery data ranged from 5.4 to 14% with a mean of 9.2%.     

Impact of ropy and capsular exopolysaccharide-producing strains of Lactococcus lactis subsp. cremoris on reduced-fat Cheddar cheese production and whey composition

Cheddar cheese mixed starter cultures containing exopolysaccharide (EPS)-producing strains of Lactococcus lactis subsp. cremoris (Lac. cremoris) were characterized and used for the production of reduced-fat Cheddar cheese (15% fat). The effects of ropy and capsular strains and their combination on cheese production and physical characteristics as well as composition of the resultant whey samples were investigated and compared with the impact of adding 0.2% (w/v) of lecithin, as a thickening agent, to cheese milk. Control cheese was made using EPS-non-producing Lac. cremoris. Cheeses made with capsular or ropy strains or their combination retained 3.6–4.8% more moisture and resulted in 0.29–1.19 kg/100 kg higher yield than control cheese. Lecithin also increased the moisture retention and cheese yield by 1.4% and 0.37%, respectively, over the control cheese. Lecithin addition also substantially increased viscosity, total solid content and concentrating time by ultra-filtration (UF) of the whey produced. Compared with lecithin addition, the application of EPS-producing strains increased the viscosity of the resultant whey slightly, while decreasing whey total solids, and prolonging the time required to concentrate whey samples by UF. The amount of EPS expelled in whey ranged from 31 to 53 mg L⁻¹. Retention of EPS-producing strains in cheese curd was remarkably higher than that of non-producing strains. These results indicate the capacity of EPS-producing Lac. cremoris for enhanced moisture retention in reduced-fat Cheddar cheese; these strains would be a promising alternative to commercial stabilizers.     

Development of a fermented goat's milk containing probiotic bacteria

A set-type fermented milk manufactured from goat's milk was developed. Optimal curd tension was achieved by supplementation of milk with skim milk powder and whey protein concentrate (WPC). Milk was fermented employing a commercial probiotic starter culture (ABT-2), which contained Streptococcus thermophilus ST-20Y, Lactobacillus acidophilus LA-5, and Bifidobacterium BB-12. Supplementation of milk with 3% WPC reduced fermentation time by 2 h due to the increase in viable counts of S. thermophilus and Bifidobacterium by 0.3 and 0.7 log units, respectively. Addition of WPC increased the protein content (1%) as well as potassium and magnesium content (0.3 and 0.02 g kg⁻¹, respectively). Increase of the protein content led to an increase in the apparent viscosity and gel firmness of the product, and at the same time whey syneresis was reduced. As a consequence, the product received a high score for appearance, taste, aroma, texture and overall acceptance.     

The prediction of moisture sorption isotherms for dairy powders

Moisture sorption isotherms were measured for whey protein isolate, high micellar casein and a milk protein concentrate powder. No temperature dependence was observed over the temperature range of 4–37 °C. At 50 °C the powders absorbed less moisture than observed at the lower temperatures. These isotherms were used to predict the isotherms for freeze-dried amorphous lactose/casein/whey protein powders. An isotherm for micellar casein was predicted using a simple additive isotherm model and was used along with isotherms for whey protein and amorphous lactose to predict moisture sorption isotherms for commercial dairy powders. Predicted isotherms compared well with measured isotherms indicating that this simple additive isotherm model is suitable for predicting moisture sorption isotherms of dairy powders. Delayed lactose crystallisation was observed in lactose/whey protein powders when compared to lactose/casein powders over the same water activity range.     

Skim milk protein distribution as a result of very high hydrostatic pressure

This work studies the micellar size and the distribution of caseins, major and minor whey proteins in different fractions of skim milk treated up to 900 MPa for 5 min. Transmission electron microscopy showed that the smallest casein micelles were formed around 450 MPa with no variations at higher pressures. The changes found in micellar size correlated with the concentration of soluble casein, because treatments at 250 MPa significantly enhanced the level of non-sedimentable casein while, between 700 and 900 MPa, there were no further increases with respect to lower pressures. There was a severe β-lactoglobulin (β-Lg) denaturation at pressures ≥ 700 MPa, which reached 77–87%. α-Lactalbumin (α-La) was stable up to 550 MPa, but it denatured at higher pressures. The content of soluble lactoferrin (Lf) decreased with pressure, particularly from 550 to 800 MPa, while that of secretory IgA (sIgA) progressively decreased from 250 up to 700 MPa. Our results indicated that treatment of milk at very high pressures, from 700 to 900 MPa, did not reduce micellar size nor released more soluble casein with respect to treatments at lower pressures (250–550 MPa). However, these treatments led to a severe denaturation of the whey proteins, in particular of β-Lg and the minor proteins Lf and sIgA. The possibility of using high hydrostatic pressure to obtain a soluble milk fraction with a casein and whey protein composition similar to that of human milk is discussed.     

Influence of curd cutting programme and stirring speed on the prediction of syneresis indices in cheese-making using NIR light backscatter

An NIR reflectance sensor, with a large field of view and a fibre-optic connection to a spectrometer for measuring light backscatter at 980 nm, was used to monitor the syneresis process online during cheese-making with the goal of predicting syneresis indices (curd moisture content, yield of whey and fat losses to whey) over a range of curd cutting programmes and stirring speeds. A series of trials were carried out in an 11 L cheese vat using recombined whole milk. A factorial experimental design consisting of three curd stirring speeds and three cutting programmes, was undertaken. Milk was coagulated under constant conditions and the casein gel was cut when the elastic modulus reached 35 Pa. Among the syneresis indices investigated, the most accurate and most parsimonious multivariate model developed was for predicting yield of whey involving three terms, namely light backscatter, milk fat content and cutting intensity (R² = 0.83, SEy = 6.13 g/100 g), while the best simple model also predicted this syneresis index using the light backscatter alone (R² = 0.80, SEy = 6.53 g/100 g). In this model the main predictor was the light backscatter response from the NIR light back scatter sensor. The sensor also predicted curd moisture with a similar accuracy.     

Formation of soluble protein complexes and yoghurt properties influenced by the addition of whey protein concentrate

The effects of whey protein concentrate (WPC) on the formation of soluble protein complexes and yoghurt texture were evaluated. Skim milk (SM) and skim milk enriched with 1% WPC (SM + 1%WPC) or 2% WPC (SM + 2%WPC) were left unheated or heated and then made into yoghurt gels. Yoghurt prepared from heated SM + 2%WPC had significantly higher storage modulus, water holding capacity and firmness values and a denser microstructure than those prepared only from skim milk. Electrophoretic analysis of the milk showed that the level of β-lactoglobulin and κ-casein in the serum phase increased with increasing WPC concentration, indicating that the content of disulfide-linked β-lactoglobulin and κ-casein was higher in SM + 2%WPC than in SM, suggesting that more soluble protein complexes had been formed. Consequently, yoghurt prepared from heated SM enriched with WPC may have more bonds and more protein complexes in the protein network than yoghurt prepared only from SM, thus resulting in firmer gels.Practical applicationsYoghurt, one of the most popular fermented milk products, is of high economic importance to the dairy industry worldwide. In particular, high-protein yoghurt, such as Greek-style or set-type yoghurt, has been driving its ongoing popularity over recent years. In current industrial production of high-protein yoghurt, protein fortification and heat treatment of milk are two of the most important processing parameters affecting yoghurt texture. Whey protein concentrate has been added to milk to reduce whey separation and to increase the firmness of the yoghurt. From a technological point of view, the interaction of the denatured whey proteins with casein micelles or with κ-casein in the serum phases is regarded as responsible for obtaining a good yoghurt structure. The present research has shown that it is possible to produce yoghurt with a range of textural properties by precisely controlling the rate of whey protein fortification during its manufacture. Therefore, this study provides a better understanding of the effect of WPC fortification and aims to extend this insight for the production of good-quality yoghurt.     

Effect of Fluorescent Light on Repartition of Riboflavin in Homogenized Milk

This study was designed to determine the effect of fluorescent light on riboflavin in homogenized milk and in the resulting fat, casein, and acid whey isolated therefrom. The major proportion (82%) of riboflavin in homogenized milk was associated with the acid whey fraction, about 15% with the casein phase and about 3% with the fat phase. Riboflavin loss due to light exposure (2150 lx for 48 h at 7 C) was greatest in the whey fraction. Further separation of the whey proteins by gel filtration on Sephadex G-75 superfine indicated that the riboflavin associated with the high molecular weight fraction decreased following exposure. In the whey fraction, 95% of the riboflavin was in the free form and not associated with the major whey proteins. The free riboflavin was most labile to light exposure.     

Genetic analysis of coagulation properties,curd firming modeling,milk yield,composition, and acidity in Sarda dairy sheep

Sheep milk is an important source of food, especially in Mediterranean countries, and is used in large part for cheese production. Milk technological traits are important for the sheep dairy industry, but research is lacking into the genetic variation of such traits. Therefore the aim of this study was to estimate the heritability of traditional milk coagulation properties and curd firmness modeled on time t (CF_t) parameters, and their genetic relationships with test-day milk yield, composition (fat, protein, and casein content), and acidity in Sarda dairy sheep. Milk samples from 1,121 Sarda ewes from 23 flocks were analyzed for 5 traditional coagulation properties by lactodynamographic tests conducted for up to 60 min: rennet coagulation time (min), curd-firming time (k₂₀, min), and 3 measures of curd firmness (a₃₀, a₄₅, and a₆₀, mm). The 240 curd firmness observations (1 every 15 s) from each milk sample were recorded, and 4 parameters for each individual sample equation were estimated: rennet coagulation time estimated from the equation (RCT_eq), the asymptotic potential curd firmness (CF_P), the curd firming instant rate constant (k_CF), and the syneresis instant rate constant (k_SR). Two other derived traits were also calculated (CF_max, the maximum curd firmness value; and t_max, the attainment time). Multivariate analyses using Bayesian methodology were performed to estimate the genetic relationships of milk coagulation properties and CF_t with the other traits; statistical inference was based on the marginal posterior distributions of the parameters of concern. The marginal posterior distribution of heritability estimates of milk yield (0.16 ± 0.07) and composition (0.21 ± 0.11 to 0.28 ± 0.10) of Sarda ewes was similar to those often obtained for bovine species. The heritability of rennet coagulation time as a single point trait was also similar to that frequently obtained for cow milk (0.19 ± 0.09), whereas the same trait calculated as an individual equation parameter exhibited larger genetic variation and a higher heritability estimate (0.32 ± 0.11). The other curd firming and syneresis traits, whether as traditional single point observations or as individual equation parameters and derived traits, were characterized by heritability estimates lower than for coagulation time and for the corresponding bovine milk traits (0.06 to 0.14). Phenotypic and additive genetic correlations among the 11 technological traits contribute to describing the interdependencies and meanings of different traits. The additive genetic relationships of these technological traits with the single test-day milk yield and composition were variable and showed milk yield to have unfavorable effects on all measures of curd firmness (a₃₀, a₄₅, a₆₀, CF_P, and CF_max) and t_max, but favorable effects on both instant rate constants (k_CF and k_SR). Milk fat content had a positive effect on curd firmness traits, especially on those obtained from CF_t equations, whereas the negative effects on both coagulation time traits were attributed to the milk protein and casein contents. Finally, in view of the estimated heritabilities and additive genetic correlations, enhancement of technological traits of sheep milk through selective breeding could be feasible in this population.     

Effect of composition and antioxidants on the oxidative stability of fluid milk supplemented with an algae oil emulsion

The oxidative stability of an algal oil emulsion dispersed in water, or fluid milk of varying fat contents, was assessed from measurements of lipid hydroperoxide and propanal concentration. All of the milk samples, independent of their milk fat content, were stable compared to the aqueous samples. The extent of oxidation was unaffected when sodium azide (200 ppm) was added to inhibit microbial growth. Added iron (100 ppm) accelerated the oxidation rate in the aqueous samples, but had no effect on the milk samples. The antioxidant properties of milk were ascribed to the iron binding of casein. Added protein antioxidants (0.8 wt%) [i.e. sodium caseinate, whey protein isolate (WPI) and thermally denatured WPI] had minimal effects whereas EDTA and ascorbic acid (160 ppm) were effective antioxidants.     

Effect of cutting time, temperature, and calcium on curd moisture, whey fat losses, and curd yield by response surface methodology

Response surface methodology was used to study the effect of temperature, cutting time, and calcium chloride addition level on curd moisture content, whey fat losses, and curd yield. Coagulation and syneresis were continuously monitored using 2 optical sensors detecting light backscatter. The effect of the factors on the sensors’ response was also examined. Retention of fat during cheese making was found to be a function of cutting time and temperature, whereas curd yield was found to be a function of those 2 factors and the level of calcium chloride addition. The main effect of temperature on curd moisture was to increase the rate at which whey was expelled. Temperature and calcium chloride addition level were also found to affect the light backscatter profile during coagulation whereas the light backscatter profile during syneresis was a function of temperature and cutting time. The results of this study suggest that there is an optimum firmness at which the gel should be cut to achieve maximum retention of fat and an optimum curd moisture content to maximize product yield and quality. It was determined that to maximize curd yield and quality, it is necessary to maximize firmness while avoiding rapid coarsening of the gel network and microsyneresis. These results could contribute to the optimization of the cheese-making process.     

Visible-near infrared spectroscopy sensor for predicting curd and whey composition during cheese processing

The potential of visible-near infrared spectra, obtained using a light backscatter sensor, in conjunction with chemometrics, to predict curd moisture and whey fat content in a cheese vat was examined. A three-factor (renneting temperature, calcium chloride, cutting time), central composite design was carried out in triplicate. Spectra (300–1,100 nm) of the product in the cheese vat were captured during syneresis using a prototype light backscatter sensor. Stirring followed upon cutting the gel, and samples of curd and whey were removed at 10 min intervals and analyzed for curd moisture and whey fat content. Spectral data were used to develop models for predicting curd moisture and whey fat contents using partial least squares regression. Subjecting the spectral data set to Jack-knifing improved the accuracy of the models. The whey fat models (R = 0.91, 0.95) and curd moisture model (R = 0.86, 0.89) provided good and approximate predictions, respectively. Visible-near infrared spectroscopy was found to have potential for the prediction of important syneresis indices in stirred cheese vats.