Granulated protein has potential to increase cottage cheese production

Cottage cheese manufacturers who are seeking to increase yield and strengthen curd properties yet be flexible enough to use skimmed milk as a raw material now have another weapon in their armoury with the announcement that DSM Food Specialties has a new application for its granulated protein hydrolysate MaxiCurd.

MaxiCurd achieves this improved yield by enabling manufacturers to use a higher pasteurisation temperature without comprising the desired quality and eating enjoyment of the cottage cheese. It works by binding with the whey protein-casein complexes during renneting to stabilise the curds and deliver a consistently firm, high-quality cottage cheese (Fig.1). Without MaxiCurd the curds are very weak, leading to excessive losses during handling and an overly soft texture in the final product.

Rutger van Rooijen, new business development manager DSM Food Specialties, comments, "The global economic downturn is putting manufacturers under huge pressure to improve productivity - the international cottage cheese sector is no exception. MaxiCurd is part of our cost savings ingredient solutions - a portfolio of ingredients brought together to meet the current need to balance commercial demands with product quality. Our new online resource, www.dsm-food-saving4u.com, allows manufacturers to evaluate how our ingredients can help maximise their profitability. With MaxiCurd they have the potential to increase cheese yield by as much as fourpercent."

He added: "Plus with the supply of fresh milk sometimes difficult, due to fluctuating cost or limited availability for example, MaxiCurd offers the ideal solution. Cottage cheese manufacturers are generally restricted to skimmed milk powder produced under low pasteurisation conditions and this can only be used at a limited ratio if the quality of the cottage cheese is to be maintained. Using MaxiCurd, however, restores the renneting properties of the skimmed milk powder, enabling the use of cheaper and more widely available skimmed milk powder at a higher ratio."

MaxiCurd is a ready to use, protein hydrolysate, specifically developed to improve curd strength and increase cheese yield in a range of cheeses. It only needs to be dissolved in water at 40°C in a 10 per cent solution, and is then ready to be added to the pasteurised cheese milk, just like rennet.

The company has also announced the launch of Tolerase, a food grade acid lactase specifically developed for use in dietary supplements. This acid lactase is a positive introduction for manufacturers looking to provide consumers with a solution for easy digestion of dairy products. Its suitability for tablet applications means those suffering from lactose intolerance or malabsorption can now enjoy dairy products as part of their daily lifestyles by simply adjusting the dosage to match their needs.

Obtained through the controlled fermentation of modified Aspergillus oryzae, Tolerase works by hydrolysing milk sugar; efficiently converting lactose into glucose and galactose. It effectively replaces the required lactase normally naturally present in the intestinal system, which is either absent or not fully available in those suffering from lactose intolerance. Tolerase is characterised by its ability to function at a low pH in solution - so controls the pH in the stomach - and continues to hydrolyse lactase and facilitate digestion.

As a granulate product, Tolerase offers the safest option for dietary supplement manufacturers by reducing the health risks associated with dust in the atmosphere. In addition, its smooth flowability reduces the use of glidants to improve efficiency.

Ardy van Erp, product manager dairy enzymes, DSM Food Specialties, said: "We have used our extensive lactase knowledge, gained through our Maxilact neutral lactase range, and drying experience to develop this exciting new enzyme, which offers important benefits to consumers as well as manufacturers. Consumers suffering from lactose malabsorption can now enjoy the benefits of dairy products in a useful on-the-go format."

"Tolerase fits perfectly within our lactase portfolio and ensures our customers benefit from a comprehensive range. Its launch demonstrates our commitment to using our specialist knowledge to bring innovative products to market which combine high performance with real commercial benefits - an approach our customers have come to expect from the market leader in enzyme technology and lactase systems."

"Plus, Tolerase can be used in combination with other synergistic ingredients, such as vitamins, to create a multi-functional supplement and so opens up further opportunities for its use."

Direct-to-the-vat cultures

Meanwhile Chr Hansen's Fresco series of direct-to-the-vat culture blends for cottage cheese is attracting an increasing number of North American cheese makers. They are all looking to achieve optimum consistency and increased yield.

Chr Hansen's Fresco series of cultures for cottage cheese has sparked the international switch from bulk starter production to cheese making using the direct vat set (DVS) technology. The Fresco series is successful in several markets but particularly in North America - the world's largest market for cottage cheese - producers of cottage cheese are converting.

The current economic downturn is only fortifying this trend. Up 10 per cent the past year, today 30 per cent of North American cottage cheese is made using the Fresco cultures. Chr. Hansen says it now leads the global direct-to-the-vat cottage cheese culture market.

Food and beverage industry observers agree that cutting costs is the top priority in 2009 for F&B companies. A survey conducted recently by business advisory firm Deloitte showed that 31 per cent of respondents have made cost reduction their number one issue this year.

Deloitte's report Food and Beverage 2012 - Ingredients for Success in Volatile Markets said despite the economic challenge, recent key trends such as convenience, good nutrition and health, packaging reduction, interest in provenance, environmental impact and ethical sourcing remain. However, affordability, perceived value and price will be relatively more important drivers of consumer choice for the foreseeable future.

"With the economy in a downturn, consumers are tightening their belts. This urges cheese manufacturers to seek out cost-efficient production methods that do not lead to compromises on taste," says Roy Riley, marketing director, food cultures & enzymes, Chr Hansen North America.

In the past year, the Fresco culture programme has experienced a global sales growth of 38 per cent while cottage cheese production continues to decline 1-2 per cent annually.

"The two primary drivers for the Fresco programme continue to be an increase in product consistency and yield. The Fresco cultures improve the cheesemake consistency and dependability which allows the manufacturer to process the cheese on time. This minimises labour overrun costs due to slow vats and keeps the production schedule on time throughout the day. Moreover, the Fresco programme has been proven to increase curd yield an average of 3.3 per cent per vat thus increasing plant throughput using the same labour and equipment costs," Riley explains.

The first generation of the Fresco concept was launched in 2001, the second in 2003. The third generation - Fresco 1000 - which contains six culture blends designed to be phage alternatives used in rotation was launched in 2004 and expanded with two cultures in 2006 and 2007. Chr Hansen expects to launch another three Fresco 1000 cultures mid 2009.

Cottage cheese accounts for approximately 700000 tonnes of the world's 18.2 million tonnes of cheese consumed in 2008. In North America cottage cheese makes up approximately 12 per cent of all cheese.

According to food and drink consultancy Zenith International, global demand for dairy products has risen by 15 per cent from 40.9 million tonnes in 2003 to an estimated 47 million tonnes in 2008. Cheese accounts for the largest segment of the dairy sector analysed by Zenith.

Recent Issues