Cheddar Cheese:

Agricultural Processing Brochure

South African farmers facing current economic realities are

searching for new options to maintain and expand their
businesses. One of the many opportunities to grow markets,
turnover and profits is by adding value to farm produce.
Options need to be selected carefully based on sound
information and knowledge of the opportunities presenting
themselves taking into account the strengths and weaknesses
of individual farms.

Introduction:
Product group: Dairy products
Dairy milk is one of the most versatile products available to the
processor. Processing options include fermenting, concentrating,
drying, freezing and many more methods of preservation.
Processed dairy products are divided into five groups:

 Concentrated dairy  Liquid dairy products

products  Powdered dairy
 Cultured dairy products products
 Frozen dairy products

Cheddar is categorised
as a cultured dairy product.

Product description:
Cheddar
Cheese is defined as the product
obtained from coagulated milk
from which the whey has been
removed. The coagulum or curd
has undergone ripening to a
greater or lesser extent.

Cheddar Is classified as a high fat

hard cheese. Mature cheddar
has a minimum fat in dry matter
content of 45 % and a minimum
dry matter content of 64%.

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Storage of raw milk for processing
Milk is a highly perishable product that may turn sour if left at
room temperature. Milk is cooled to improve its quality and
stability. Milk leaves the cow at ± 37°C and must be cooled
within 3 hours to 4°C. During cold storage, the milk must be
stirred gently to prevent a cream layer from forming on top
(cream separation by gravity). Raw milk is thus kept in large
vertical tanks at the factory or processing plant, which is fitted
with one or more propeller agitator(s) until further processing
proceeds.

Milk preparation for the manufacturing of cheese

Clarification of milk
Clarification is the removal of solid impurities (dirt particles, white blood cells and cells of udder tissue) from
the milk, prior to further processing. Clarification is achieved through filtration.

Thermisation of milk (optional)

Thermisation is a sub-pasteurisation heat treatment used to treat raw milk at a dairy or processing plant if it
cannot be processed immediately. The milk is heated to 60 - 66 °C for 5 - 20 seconds in a plate heat
exchanger. This heat treatment destroys psychotropic bacteria, with the result that milk can be held at 4 °C
for 2 - 4 days without any significant spoilage organisms growing.

Fast Fresh milk should be Prior to separation the milk is

4 ºC 45 - 60 º C
cooled to: heated to:
facts:

Pre-heating of milk for

separation CC
skim milk by passing pre-heated
raw milk (45 – 60°C) through a
conventional or hermetic
C
as the percentage of fat in the
cheese's dry matter, which

cC
Prior to separation the milk is excludes the cheese's water

CcC
heated to 45 - 60 °C to ensure centrifugal separator.
content
effective separation of the skim
milk and cream phase. Heating Standardisation follows directly Homogenisation of milk for
also inactivates the enzyme after separation and involves
cheese (optional)
lipase that is responsible for the
development of rancidity in fats.
Pre-heating guarantees the CCC
adjusting the fat content of milk to
obtain a product with a defined,
guaranteed fat content. Cheese
CC
Homogenisation is the process
where the fat globules in the milk
are finely distributed to prevent
highest possible cream quality,

CCC CC
is mostly classified according to fat separation. Homogenisation is
i.e. the lowest amount of free fat accomplished by forcing the milk
its fat on dry basis. The dry
in skim milk. through a small opening at high
matter in cheese contains
proteins, butterfat, minerals, and velocity to cause disruption of the
Separation and large fat globules to form small,
standardisation of milk for lactose (milk sugar), although

CC C
stable fractions. Homogenisation
cheese little lactose survives fermentation is most effective when the milk is
Separation: The cream fraction of when the cheese is made. A slightly heated (60 - 70°C) and
cheese's fat content is expressed can be done partially or

CC
raw milk is separated from the

CCC
completely.

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Cheddar cheese process
1. Pasteurising the milk: Pasteurisation is a mild heat
treatment that destroys all vegetative pathogens and heat
sensitive enzymes so that the phosphatase test gives a
negative result. The milk is heated to 72°C, followed by
rapid cooling. Although cheese made from unpasteurized
milk is considered to have a better flavour and aroma,
cheese milk is pasteurised to eliminate microbial
competition for the starter culture and to prevent some
common defects during ripening. Various pasteurisation
methods are available, depending on the size of the
processing plant.

4. Additions to cheese milk: Calcium salt (calcium chloride or calcium phosphate) is added to assist
the curd formation (± 0,2 %) and ensure the formation of a good quality curd. Without it, the curd could
be too soft, while overdosing will make the coagulum too hard to cut. Nitrite (Saltpetre) is added to
inhibit butyric acid bacteria that cause fermentation problems. Colorants may be added to correct the
seasonal variations in the colour of milk. The added ingredients are blended with the milk to ensure
uniform distribution of all components.

5. Forming the curd:

 Bacterial culture is added to the milk in the vat at 29 °C to acidify the milk. The bacterial culture
introduces ‘good’ bacteria, which plays an important role throughout the manufacturing process.
The temperature creates ideal conditions for the bacteria to grow, and the acidic environment helps
prevent foreign bacterial contamination.
 Rennet is added to the milk when it reaches a certain pH. This causes casein protein in the milk to
coagulate and separate from the liquid whey.

Process overview

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4. Cutting the curd: When the coagulum is firm – it shows
a clean break when tested – cutting blades stir through
the coagulum to cut it into small pieces. Cutting the curd
allows more whey to escape and lowers the moisture
content of the final cheese. The cubes of curd and whey
are gently stirred to prevent lump formation. Some whey
may be removed at this stage.

5. Scalding of the cheddar cheese curd: Scalding is a

heat treatment given to cheese curds to regulate the
texture and acidification of the curd. Steam or hot water
(39 - 40°C) is pumped into the jacketed cheese vat
to cause slow heating of the curds and whey. Rapid heating should be avoided as it causes case
hardening of cheese curds. The increase in temperature accelerates the whey separation and further
reduces the moisture content of the curd.

6. Releasing the whey: Draining aims at removing excess free moisture from the product by gravitation
force to obtain partial drying of the product surface. The whey and curd have separated due to cutting,
stirring and scalding. The whey is now drained off.

7. Cheddaring of the curds: Cheddaring is the special type of manipulation of the curd to develop the
required texture in cheddar cheese. During this process the curd is manipulated to consolidate, fuse
and convert the curd from a rubbery mass to a firmer structure with the affinity to tear. The curd is cut
into blocks and stacked 2 or 3 blocks high and turned regularly (± 15 minutes). This ensures the
fusion of the curd particles. This process is allowed to continue until the titratable acidity is 0,65 - 0,75
% (pH 5,2 - 5,3).

Cheddaring is the special type of manipulation of the curd to develop the

required texture in cheddar cheese.

8. Milling of the compacted 10. Moulding and Pressing of mould growth during storage.
curds: The blocks of cheese curds: The curd Traditionally, the round
compacted curd are milled particles are filled into moulds shaped cheeses were
into "chips" prior to salting. that represent the desired wrapped in bandage pasted
final shape of the cheese with a flour water mixture
9. Salting of cheddar curds: where after it is usually containing preservatives
Approximately 2 % salt (NaCl) subjected to pressing. This (sorbate/pimaricin) or waxed
is added to the milled curd. final pressing process is by dipping the bandaged
Thorough mixing takes place necessary to provide the cheese into a bath of melted
to ensure uniform distribution. desired shape and texture wax to prevent mould growth.
The salt is then allowed to while expelling the remaining
dissolve completely before whey. Pressing lasts 24 - 36 12. Maturing of cheddar
the curd is further processed. hours. cheese: Cheddar is matured
Salt retards undesirable acid at 4 - 8°C and controlled
production during storage 11. Wrapping and waxing of humidity conditions. Mild
which facilitates curd fusion cheese: The pressed curd is cheddar is matured for 3 - 6
through solubilisation of the treated with a wax layer or months, while mature cheddar
proteins and improves the plastic wrapping to protect it is left for 6 - 12 months.
colour of the end product. against moisture loss and
10.
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Labelling of Cheddar cheese:
The wrapping is labelled/printed with the necessary information.

Labelling of cheese
Labelling in South Africa is controlled by legislation. Anyone who
wants to use the information provided in this document must
familiarise him/herself with all the applicable laws that apply to the
producing, processing, manufacturing and storage of the products
referred to in this document. Please also refer to the disclaimer on
the last page.

Other processing options – Cultured dairy products

Listed below are other processing options not covered in this report, but available from Eskom.
 Cultured (sour) cream is the product obtained from cream that has been inoculated with a starter
culture to allow for the development of lactic acid
and flavour compounds under controlled conditions.
 Cottage cheese is the product obtained from coagulating milk. It is a soft, not matured cheese and
contains about 80% moisture.
 Kefir is a smooth, viscous, fermented dairy drink with a fresh acidic taste and contains lactic acid,
alcohol (± 1%) and gas (carbon dioxide).
 Long life, set dessert is a cultured dairy product similar to yoghurt that has undergone a heat process
to extend the keeping quality. Set long life dessert is fermented in the final retail container and has a
gel-like a consistency. It may or may not be flavoured.
 Long life, stirred dessert is a cultured dairy product similar to yoghurt that has undergone a heat
treatment to extend the keeping quality. Stirred long life dessert is produced in large batches prior to
packaging in the final retail container.
 Maas (cultured milk) is manufactured by inoculating pasteurised milk with a specific bacterial culture.
The end product has a firm texture, no gas bubbles and no separation of whey from the coagulum. It
has pleasant sour taste with a slight bite/prickliness on the tongue.
 Processed cheese is made from a variety of natural cheeses that are ground and blended together
with emulsifying agents. Various other additives may also be added. The mixture is heated and
packaging in laminated films.
 Ricotta is a cheese prepared from whey. Ricotta is a low fat, soft cheese with a maximum fat in dry
matter content of 10% and a minimum dry matter of 20%.
 Set yoghurt is prepared from high or full fat pasteurised milk inoculated with a specific starter culture.
Fermentation takes place in the final retail container under controlled conditions. The yoghurt has a
firm, gel-like consistency and a clean surface is apparent when the yoghurt is cut.
 Stirred yoghurt is a fermented milk product with a thick, smooth consistency and may or may not be
flavoured. It is incubated in tanks, stirred, flavoured and cooled before packaging.
 Drinking yoghurt is essentially stirred yoghurt with a lower solids content and broken coagulum. It may
be pasteurised and/or aseptically packaged to extend the keeping quality.
 Feta is a pickled cheese with a clean, acidic salty taste. It is packaged in a brine solution to prevent
drying out and to preserve the cheese.
 Cheese spread is a blend of hard cheese with added emulsifying salts. The mixture undergoes a heat
treatment that increases the shelf life. Cheese spread has a relatively high moisture content (± 55 %)
and a pH of 5,7 - 6,3.
 Cultured buttermilk is the product obtained from milk that has been inoculated with a starter culture to
produce a viscous liquid with a mild lactic flavour. It is consumed as a refreshing drink or used as an
ingredient in various baked products.

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Energy Advisory Service
Eskom's role is to aid the client with basic information in the
decision-making process. Thereafter the Eskom Advisor will
fulfil the role of energy advisor as part of the team that the
farmer selects.

Optimise your energy use

Eskom’s Energy Advisors, in regions across South Africa,
offer advice to business customers on how to optimise their
energy use by:
 Understanding their energy needs
 Understanding their electrical systems and processes
 Investigating the latest technology and process
developments, including electric infrared heating and
drying systems
 Analysing how to reduce energy investment costs
 Optimising energy use patterns in order to grow businesses and industries

Call 08600 37566, leave your name and number and request that an Energy Advisor in your region
contacts you. Alternatively, email an enquiry to advisoryservice@[Link] .

Alternative funding:
Five alternative funding product offerings are available to help reduce your investment costs for new
agro-processing or agro-beneficiation business or expand/improve an existing agro-processing or agro-
beneficiation business.

For more info visit: [Link]

Literature sources
 Catsberg, C.M.E. & Kempen van Dommelen, G.J.M. 1990. Food Handbook. New York: Ellis
Horwood.
 Dairy Processing Handbook. 1995. Tetra Pak Processing Systems. Sweden.
 Early, R. 1992. The Technology of Dairy Products. London: Blackie.
 Fellows, P. 1988. Food Processing Technology: Principles and Practice. Chichester: Ellis Horwood,
Ltd.
 Lombard, S.H. 1975. Kaasvervaardiging. South African Journal of Dairy Technology, Vol. 7, No. 3,
pp.163 - 166.
 Robinson, R.K. 1994. Modern Dairy Technology. Vol 2. Advances in Milk Products. 2nd ed.
London: Chapman & Hall.
 Rosenthal, I. 1991. Milk and dairy products: properties and processing. Basel : VCH.
 South Africa - Agricultural Products Standards Act (No 119 of 1990) and regulations. Pretoria:
 Government Printers
 South African - Foodstuffs, Cosmetics and Disinfectant Act (no 54 of 1972) and regulations.
Johannesburg: Lex Patria
 Varnan, A.H. & Sutherland, J.P. 1994. Milk and Milk Products: Technology, chemistry and
microbiology. London: Chapman & Hall.

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 Disclaimer
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The aim of this document is solely to provide the reader with

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The reader should familiarise him/herself with all applicable laws that apply to the product growing,
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Issued by Integrated Demand Management

Date: November 2018

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