Food products and systems and methods of making same
Food products and systems and methods for their production involve microfiltration (“MF”) of fluid skim to form a MF retentate, combining the MF retentate with cream and subjecting the combination to ultrafiltration (“UF”) to form a UF retentate. Prior to UF, the composition is formed of non-acidified components. Following UF, the UF retentate is acidified and forms a food product including a high solids content. The solids content may be further increased using evaporation. The resulting cheese or cheese base contains a lower whey protein ratio in a fat:casein:whey protein ratio compared to systems and methods that do not employ MF.
1. A method for the production of a food product, the method comprising:
subjecting skim milk to microfiltration to remove at least a portion of whey protein thereby forming a skim milk microfiltration retentate;
combining cream with the skim milk microfiltration retentate;
subjecting the combined cream and skim milk microfiltration retentate to ultrafiltration to remove moisture and increase total solids thereby forming an ultrafiltration retentate, wherein the ultrafiltration retentate contains at least about 1 wt % salt; and
maintaining a viscosity of the ultrafiltration retentate below 1000 cP for at least about 8 hours to form the food product.
2. The method of claim 1 , wherein the step of maintaining a viscosity of the ultrafiltration retentate below 1000 cP is by circulating the ultrafiltration retentate using one or more of pumping or sweeping.
3. The method of claim 2 , wherein circulating the ultrafiltration retentate is performed at a temperature of about 120° F. to about 160° F.
4. The method of claim 1 , wherein after the step of maintaining, further comprising adjusting the viscosity of the ultrafiltration retentate to a selected viscosity.
5. The method of claim 4 , wherein the step of adjusting is by homogenization.
6. The method of claim 4 , wherein after the step of adjusting the viscosity of the ultrafiltration retentate, further comprising subjecting the ultrafiltration retentate to evaporation.
7. The method of claim 6 , further comprising elevating a temperature of the ultrafiltration retentate during evaporation.
8. The method of claim 1 , further comprising:
reserving a portion of the microfiltration retentate prior to the step of combining; and
adding the reserved portion of the microfiltration retentate to the ultrafiltration retentate, thereby increasing moisture and protein in the ultrafiltration retentate.
9. The method of claim 1 , wherein prior to the step of subjecting to ultrafiltration, the combination of the cream and the skim milk microfiltration retentate is non-acidified.
10. The method of claim 1 , further comprising, prior to the step of combining, subjecting the microfiltration retentate to a second microfiltration at a second temperature different from the first, and wherein the second microfiltration removes beta casein.
11. The method of claim 1 , wherein, prior to the step of combining, the microfiltration retentate is cooled to a temperature of about 40° F. to 60° F. and subjected to microfiltration.
12. The method of claim 11 , wherein the microfiltration retentate is cooled to a temperature of about 40° F. to 60° F. for at least about 12 hours.
13. The method of claim 1 , wherein the microfiltration retentate comprises about 10 wt % to about 12 wt % total solids.
14. The method of claim 1 , wherein the microfiltration retentate comprises about 7.5 wt % to about 9 wt % protein.
15. The method of claim 1 , wherein the viscosity of the ultrafiltration retentate is maintained below 1000 cP for between about 8 hours and about 48 hours.
16. The method of claim 1 , wherein the ultrafiltration retentate comprises about 45 wt % to about 80 wt % total solids.