Puffed Cheese Product and Method
Disclosed is a method for producing crispy, puffed cheese snacks made entirely of, or primarily of, cheese. The method uses a sequential process to produce cheese snacks with excellent taste, smoother surface and mouthfeel, delicate crunch, and minimal breakage during packaging and shipping. The method can also be used to produce cheese powders.
1 . A method for making puffed cheese snacks, the method comprising the steps of:
a) forming at least one cheese into cheese pieces having a thickness of from about 0.5 mm to about 3 inches;
b) dehydrating the cheese pieces to form cheese pieces having a water activity of from about 0.30 to about 0.95; and
c) heating the dehydrated cheese pieces using dielectric heating to produce puffing of the cheese pieces to form cheese puffs.
2 . The method of claim 1 wherein the step of dehydrating the cheese pieces produces cheese pieces with a moisture gradient decreasing from the inside to the outside of the cheese pieces and a resulting skin covering the surface of each cheese piece.
3 . The method of claim 1 wherein the step (b) of dehydrating the cheese pieces is performed as a two-stage process, with stage 1 being the formation of a skin to coat each cheese piece while lower temperatures are used to remove moisture and frequent handling prevents the cheese pieces from adhering to each other, and stage 2 being a further dehydration period at higher temperatures to achieve target moistures, water activities, and skin thicknesses.
4 . The method of claim 1 wherein the dielectric heating is microwave heating.
5 . The method of claim 1 wherein the dielectric heating is radio frequency heating.
6 . The method of claim 1 wherein the cheese pieces can comprise at least one shape selected from the group consisting of animal shapes, stars, shapes of commonly identifiable objects, cubes, cuboids, spheres, ellipsoids, cylinders, cones, triangular prisms, hexagonal prisms, triangular-based pyramids, hexagonal pyramids, pentagrammic prisms, icosahedrons, octahedrons, dodecahedrons, and combinations thereof.
7 . The method of claim 1 wherein the at least one cheese is selected from the group consisting of full, partial, and low-fat Cheddar, Colby, Monterrey Jack, Provolone, Mozzarella, Gouda, Swiss, Havarti, and combinations thereof.
8 . The method of claim 1 wherein the cheese puffs further comprise one or more inclusions.
9 . The method of claim 1 wherein the cheese puffs further comprise one or more coatings.
10 . The method of claim 1 wherein the at least one cheese is a cheese having no detectable residual sugar by 2 months of age and a reduced fat content with a targeted fat dry basis (FDB) of from about 5 to about 40%.
11 . The method of claim 1 wherein the step of milling the cheese puffs is added to produce cheese powder from the cheese puffs.
12 . A method for making puffed cheese snacks comprising the steps of
a) forming at least one cheese into cheese pieces having a thickness of from about 0.5 mm to about 3 inches;
b) dehydrating the cheese pieces by convection heating at a dehydration temperature of from about 65 to about 170 degrees Fahrenheit for a time period of from about 10 minutes to about 8 hours; and
c) puffing the dehydrated cheese pieces using dielectric heating to form cheese puffs.
13 . The method of claim 12 wherein the dehydration temperature is from about 80 degrees Fahrenheit to about 170 degrees Fahrenheit.
14 . The method of claim 12 wherein the dehydration temperature is from about 90 degrees Fahrenheit to about 150 degrees Fahrenheit.
15 . A method for making puffed cheese snacks comprising the steps of
a) forming at least one cheese into cheese pieces having a thickness of from about 0.5 mm to about 3 inches;
b) dehydrating the pieces of cheese by holding the cheese at room temperature for a time period of from about 4 hours to about 96 hours; and
c) heating the dehydrated cheese pieces using microwave heating to form cheese puffs.
16 . A puffed cheese product comprising at least about 50 percent natural cheese, the product having a water activity in the range of from about 0.15 to about 0.80 and a fat content with a targeted fat dry basis (FDB) of from about 5 to about 40%.