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Kashar cheese is in the group of semi-hard cheeses; It is a light yellowish color, thin crusted, semi-flexible and slightly salted cheese. Sheep, cow and goat milks can be used in the production of Kashar cheese by applying appropriate techniques. These cheeses are produced by boiling and kneading the curd created in the cheddar process tanks, after straining the curd in the curd straining drum or in the curdling vessel, and then resting it in the cheddar transport cars for a certain period of time.
What Machines / Workbenches Does the Cheese Cheese Production Line Consist Of?
1)Milk Pasteurization Machine
2) Cheese Process Tank
3) Curd Drum / Curd Cedaring Trough
4)Stainless Curing Trough
5) Cheddar Wet Boiling Machine / Cheddar Dry Boiling Machine
6) Cheddar Transfer Machine
7) Cheddar Weighing Machine
8) Cheese Carrier Trolley and Cheese Molds
How Is Cheddar Produced?
- The raw milk to be made into cheese is pasteurized by keeping it in a milk pasteurization machine at 72-74°C for 15 seconds or at 65°C for 30 minutes. The aim of the pasteurization process is to purify the milk from disease-causing microorganisms. Pasteurized milk is cooled to fermentation temperature at 32-34°C.
- Starter yeasts are added to the milk at the fermentation temperature taken from the milk pasteurization machine to the kashar process tank. It is matured by waiting for about 30 minutes. Starter cultures add the ability to form lactic acid to cheddar cheese.
- In the cheese process tank, rennet is added to the cheese, whose pH reaches the desired value, in order to gain the clotting feature.
- The formed clot is cut with the knives of the cheese process tank in 15-20 mm dimensions, and after resting for 5-10 minutes, cutting is continued until it reaches 6-7 mm.
- The cut particles are mixed gently in the cheese process tank automatically, allowing the pieces to remain in the air.
- Some of the whey that is released (30% of the milk amount in the tank) is discharged from the tank.
- The curd and whey remaining in the cheese process tank are mixed for about 10 more minutes and the tank is started to be heated with steam or hot water from the jacket. The temperature is increased to 36-38°C, increasing by 1°C every 3-4 minutes. With the increase in temperature, the walls of the curd grains harden and the separation of the whey becomes easier. Once the heating process is completed, the curd is mixed again to remove the whey.
- The curd that releases its water and hardens is taken from the kashar process tank to the machine where the curd will be filtered by a pump suitable for the curd. To strain the curd, curd battalions (internally filtered, externally filtered) can be used, as well as a cheddar cheddar vat.
-Quiner Straining Drum: A drum with holes of 1 mm diameter rotates continuously and the curd is passed through the drum and straining process takes place. During this process, the spirally produced pipe inside the drum allows the curd to move in the drum. Curds that have lost their water taken from the drum are kept in stainless steel boats until they reach the pH level suitable for boiling.
-Cedarlama Tub: In the Cedarlama vat, the curds are mixed and the whey is discharged. The whey separated from the curds by mixing is filtered by the perforated sheets on the bottom base and the corrugated base structure. The straining of the curd by mixing the curd gives a granular structure to the curd.
- Curds that are filtered and whose acidity reaches the desired value are sent to dry boiled or water boiled machines to be cooked.
- Cheddar Sauce Boiling Machine: There is a chopping part for the curd at the entrance of the machine, where the curd is divided into pieces in the form of leaves so that the curd can be boiled well. The curd, whose dimensions and shape are made to the desired shape, is mixed with hot salt water with the help of spirals and turned into dough. The scalding water is heated in the brine vessel by circulating steam in the serpentine pipes and feeds the spiral chamber with the hot water pump. While the curd is boiled with the spirals that we can control the speed and rotation directions from the PLC screen, the brine is discharged by using the automatically controlled strainer sheet with the piston to ensure the circulation of the brine. Curd mixed with spirals is passed through the press sheet and taken into the kneading chamber. Salt water is fed to the cheese evenly in the kneading chamber and the fibrous structure of the cheese is formed. When the kneading process reaches a sufficient level, the lid is opened and the dough comes out.
- Cheddar Dry Boiling Machine: The top cover is opened and the curds are filled into the dry blanching machine. Components such as dissolving salt in the recipe are added to the curd from the manhole cover. In the dry scalding machine, the cheddar is boiled directly and indirectly with the filtered steam. In order to obtain the desired cheddar dough, the spirals working independently of each other are controlled from the PLC screen. Parameters such as temperature and pressure in the machine can be followed and changed from the PLC screen. When the cheddar dough is ready, the front cover is opened with the help of pistons and the cheddar cheese in the dry scalding machine is emptied. After the cheddar cooking process is done, the dry scalding machine is automatically washed with the cip system.
- The paste cheese is transferred to the cheddar transfer machine. The transfer machine, the inner surface of which is covered with Teflon, is used to transfer the cheddar from machines that produce high-capacity products at one time, such as dry scalding machine, to another machine without manpower.
- The cheese, which comes to the cheese weighing machine with the cheese transfer machine, is weighted automatically and quickly with tubes controlled by pneumatic pistons, according to the weighting selection that can be adjusted from the PLC screen.
- Cheeses taken from the cheddar weighing machine are arranged in the cheese molds on the cheddar transport shelves. In order for the cheddar cheese to be shaped properly, they are turned inside out 5-6 times within 1-2 hours.
—- Fresh cheddar cheeses are kept in the yellowing room for 1 day.
—– Ripe cheddar cheeses are salted at 16-18°C and 85-90% relative humidity after they are taken out of the molds. On the first day, they are lined up side by side by sprinkling dry salt on the top and bottom. The next day, two molds are placed on top of each other and this process is repeated every day, until stacking of eight. Cheeses are wiped with potassium sorbate solution every few days to prevent mold formation on the surfaces. Generally, the cheese is salted for 20 days, but depending on the acidity and the freshness of the milk, the salting time may vary. Cheeses that have completed the salting and maturation processes are washed with brushes in pasteurized whey, after drying, they are matured by keeping them for 30-60 days.