Systems and methods for making plant-based cheese: “plantly”
Systems and methods for preparing plant-based cheese comprise preparing a plant-based cheese mixture, transferring the plant-based to a heat exchanger, heat treating* and cooling the plant-based mixture, dynamically mixing additional ingredients, possible homogenizing the plant-based cheese mixture, and packaging the homogenized plant-based cheese product. In embodiments, heat treatment can occur between 85-95° C. and cooling occurs at 65-70° C. Homogenization can occur before or after heat treatment. A related cheese making apparatus is also disclosed.
1 . A method of making plant-based cheese, comprising:
preparing a plant-based cheese mixture comprising plant-based ingredients and at least one enzyme by mixing at an agitation rate between 700-800 rpm and emulsifying the plant-based ingredients and the enzyme at a temperature of <50° C. in a vacuum mixer;
pumping the plant-based cheese mixture into a heat exchanger for heating and cooling the plant-based cheese mixture;
heat exchanger heat treating the plant-based cheese mixture at a temperature sufficient to inactivate the at least one enzyme for a holding time;
homogenizing the plant-based cheese mixture after the heat exchanger heat treating and prior to cooling;
cooling the homogenized plant-based cheese mixture;
dynamically mixing additional ingredients using a mixer that can withstand viscosities up to 15000 cp into the cooled homogenized plant-based cheese mixture; and
packaging the homogenized plant-based cheese mixture, wherein the method is carried out under closed conditions until the packaging of the homogenized plant-based cheese mixture.
2 . The method of claim 1 , wherein the plant-based cheese mixture is dairy-free.
3 . The method of claim 1 , wherein the method does not require draining of waste.
4 . The method of claim 1 , wherein mixing comprises emulsifying for 10 minutes, hydrating the mixture for 30 minutes, and allowing enzyme action to occur for 60 minutes.
5 . The method of claim 1 , wherein heat treating occurs at 85-95° C.
6 . The method of claim 1 , wherein cooling occurs at 65-70° C.
7 . The method of claim 1 , wherein heat treating occurs at 85-95° C. for a holding time of 20 seconds, and cooling occurs at 70-80° C.
8 . The method of claim 1 , wherein the holding time for heat treating is 10-20 seconds.
9 . The method of claim 1 , wherein heat treating comprises stirring at approximately 750 rpm.
10 . The method of claim 1 , wherein the additional ingredients comprise at least one of: an acid, a plant-based bacterial culture, and a salt.
11 . The method of claim 10 , wherein dynamically mixing comprises first adding the starter or the acid, then adding the salt.
12 . The method of claim 1 , wherein the additional ingredients are added and mixed without exposure to atmosphere or humans.
13 . The method of claim 1 , wherein the packaging comprises filling in molds and wherein the filling occurs at <50° C.
14 . The method of claim 13 , wherein filling occurs at 38-45° C.
15 . The method of claim 1 , wherein a total production time is less than two hours.
16 . The method of claim 1 , further comprising transferring the plant-based cheese mixture to a thermostatic buffer tank maintained at 60-70° C.
17 . The method of claim 1 , wherein homogenization occurs in a single stage at a pressure of 50-60 bar.
18 . The method of claim 1 , wherein homogenization occurs at a working pressure of 50-200 bar, at a temperature of 70-80° C.
19 . The method of claim 1 , wherein the heat exchanger is a hygienic heat exchanger and/or a scraped surface heat exchanger.