Methods and apparatus for the reduction of moisture variability in large cheese blocks

1. A process for making a block of cheese having reduced moisture variability, said process comprising providing a bulk container having a bottom and sidewalls; introducing cheese curd having an initial temperature of about 60 to 90° F. into the container to form a cheese curd block; pressing the cheese curd block to form a cheese block; controlled cooling of the cheese block to a final temperature of less than 45° F. over a total period of about 7 to about 13 days to form a final cheese block, wherein the controlled cooling is effective to provide a reduced moisture content variation between a geometric center and side edges of the final cheese block as compared to a similar cheese block cooled directly to 45° F. over the total period; wherein the final cheese block has a weight of at least about 500 pounds; wherein the controlled cooling comprises first cooling the cheese block at an intermediate temperature of about 10 to about 40° F. below the initial temperature and at least about 10° F. above the final temperature for a first cooling period of about 2 to about 5 days and then cooling the cheese block at the final temperature of less than about 45° F. for a second cooling period of about 5 to 7 days; and wherein the first and the second cooling periods are sufficient to cool the final cheese block to less than about 45° F.

2. The process of claim 1 , wherein the initial temperature is about 60 to about 90° F., wherein the intermediate temperature is about 15 to about 25° F. below the initial temperature, and wherein the first cooling period is about 3 to about 4 days.

3. The process of claim 2 , wherein the intermediate temperature is at least about 20° F. above the final temperature.

4. The process of claim 1 , wherein the cheese block has a diameter of about 24 to about 30 inches, and the cheese block has a moisture content variation of no greater than 2.0 percent between a location at a geometric center thereof and a side edge portion.

5. The process of claim 4 , wherein the moisture content variation is no more than 1.0 percent between the location at the geometric center and the side edge portion thereof.

6. The process of claim 4 , wherein the moisture content variation is no more than 0.5 percent between the location at the geometric center and the side edge portion thereof.

7. The process of claim 2 , wherein the cheese block has a diameter of about 24 to about 30 inches, and the cheese block has a moisture content variation of no greater than 2.0 percent between a location at a geometric center thereof and a side edge portion.

8. The process of claim 7 , wherein the moisture content variation is no more than 1.0 percent between the location at the geometric center and the side edge portion thereof.

9. The process of claim 7 , wherein the moisture content variation is no more than 0.5 percent between the location at the geometric center and the side edge portion thereof.

10. The process of claim 1 , wherein the final cheese block has a substantially symmetrical cross-sectional shape selected from the group consisting of square, rectangular, triangular, and circular and wherein the final cheese block is a cheese selected from the group consisting of Cheddar, Monterey Jack, and Colby.

11. The process of claim 2 , wherein the final cheese block has a substantially symmetrical cross-sectional shape selected from the group consisting of square, rectangular, triangular, and circular and wherein the final cheese block is a cheese selected from the group consisting of Cheddar, Monterey Jack, and Colby.