Cleaner label shelf life solution for shredded mozzarella cheese

Chapter 1 Production Stage

The production process of cultured shredded mozzarella involves several steps to transform milk into the final shredded product. Here’s a general overview of the process:

Milk Collection and Pasteurization→Acidification and Culturing→Coagulation→Cooking and Stirring→Draining and Stretching→Forming→Chilling and Shredding→Cooling→Shredding→Packaging

Chapter 2 Quality Control

Quality Control: Throughout the process, quality control checks ensure that the cheese meets safety and quality standards.

In the production of cultured shredded mozzarella cheese, several types of microbial contamination could occur, impacting safety and quality. Here are some common microbial contaminants and the associated risks:

1. Bacteria:

?? - Salmonella: This bacterium can cause foodborne illness with symptoms like nausea, vomiting, diarrhea, and fever. Contamination typically arises from improper handling or insufficient pasteurization.

?? - Listeria monocytogenes: Listeria can grow at refrigerator temperatures and may cause listeriosis, which can be severe, particularly in pregnant women, newborns, elderly individuals, and immunocompromised persons. It can be introduced from raw milk or cross-contamination.

?? - Escherichia coli (E. coli): Certain strains, like E. coli O157:H7, can cause gastrointestinal illness. Contamination might occur from raw milk or improper sanitation.

?? - Staphylococcus aureus: This bacterium can produce toxins that lead to food poisoning. Contamination may occur from improper handling or inadequate hygiene.

2. Yeasts and Molds:

?? - Yeasts: They can cause spoilage by producing off-flavors and altering the texture. They might grow if the cheese is not stored properly or if there is cross-contamination.

?? - Molds: Some molds can cause spoilage and unwanted changes in appearance or texture. In controlled environments, specific molds are used for cheese aging, but unintended molds may grow if hygiene is not maintained.

3. Pathogenic Microorganisms:

?? - Bacillus cereus: This bacterium can cause foodborne illness, with symptoms ranging from vomiting to diarrhea. It may grow in improperly stored cheese.

?? - Clostridium botulinum: Although rare in cheese, this bacterium produces a potent toxin. Contamination usually occurs in poorly preserved foods but is less common in shredded mozzarella due to its acidity.

4. Contamination Sources:

?? - Raw Milk: If pasteurization is not done correctly, pathogenic microorganisms present in raw milk may survive.

?? - Processing Environment: Cross-contamination from equipment, surfaces, or handlers can introduce harmful microbes.

?? - Storage Conditions: Improper cooling or refrigeration can allow bacteria and molds to proliferate.

Chapter 3 Prevention and Control Measures:

For traditional mozzarella cheese shreds, managing shelf life involves several key aspects:

1. Typical Preservatives and Their Uses

?Antioxidants: Vitamin C (ascorbic acid) and Vitamin E (tocopherol) are commonly used to prevent oxidation, which can spoil the cheese and reduce its shelf life.

?Preservatives: Potassium sorbate and sodium benzoate are common preservatives that inhibit the growth of bacteria and mold, extending the cheese’s freshness.

?Salt: Salt is added during cheese production to enhance flavor and also to suppress microbial growth, helping to prolong shelf life.

?Lactic Acid Bacteria: Some cheese products include beneficial bacteria to help maintain stability and safety during storage.

2. Existing Problems and Consumer Reactions

?Taste and Texture Changes: The addition of preservatives might affect the taste and texture of the cheese, making it different from freshly made mozzarella, which some consumers may find unappealing.

?Health Concerns: There are concerns about the potential health impacts of certain preservatives and additives, particularly among consumers who are sensitive to food additives.

?Allergic Reactions: Some individuals may have allergic reactions to specific preservatives or additives, which could impact their acceptance of the product.

?Preference for Natural Foods: Modern consumers often prefer natural and minimally processed foods. The use of preservatives and additives might not align with this preference, leading to reduced market acceptance.

Chapter 4 Cleaner label preservation solution

Buffered vinegar(natural vinegar base) and natamycin(natural mold inhibitor) can be used as cleaner-label preservatives in shredded mozzarella. Here’s how each of these works and their suitability:

Buffered Vinegar

Buffered vinegar typically consists of vinegar with added buffering agents to stabilize its pH. It can be used as a preservative in cheese production due to its acidic nature, which can inhibit microbial growth.

- Function: Buffered vinegar helps maintain a low pH environment, which can reduce the growth of some bacteria and molds.

- Benefits: As a natural product, buffered vinegar aligns with cleaner-label requirements and is perceived as a more natural alternative to synthetic preservatives.

- Considerations: Its effectiveness is limited to certain types of bacteria and molds. It may not be as effective against all pathogens and might impact the flavor profile of the cheese if not used in appropriate quantities.

Natamycin

Natamycin (also known as pimaricin) is an antifungal agent used to prevent mold growth on the surface of cheese.

- Function: Natamycin inhibits the growth of molds and yeasts, which is particularly useful in preventing spoilage and extending the shelf life of cheese.

- Benefits: It is effective at very low concentrations and does not significantly alter the taste or texture of the cheese. Natamycin is also considered to be a clean-label option because it is a natural antifungal compound.

- Considerations: While natamycin is effective against molds and yeasts, it does not address bacterial contamination. Therefore, it should be used in conjunction with other safety measures, such as proper pasteurization and sanitation.

Application in Mozzarella Production

- Buffered Vinegar: It can be added to the cheese or its environment to help manage pH and microbial growth. However, its use should be carefully controlled to avoid unwanted flavor changes.

- Natamycin: Typically applied as a surface treatment on the cheese. For shredded mozzarella, it would be mixed into the cheese before shredding or applied to the surface of cheese blocks before shredding.

Shredded cheese is very sensitive to fungal spoilage. Shredded cheese is produced as follows: Cheese, such as mozzarella, pizza cheese or cheddar cheese, is shredded and conveyed to a rotating drum. In the first part of the drum, an anti-caking agent, mainly cellulose (microcrystalline or powder), is metered into the cheese. At the end of the drum, a natamycin suspension is sprayed onto the shredded cheese. Nozzles spray the cheese with a fine spray or ~5 mist of the fungicide. Finally, the cheese is emptied onto a conveyor belt and transported to the filling equipment.

The natamycin suspension is prepared by mixing natamycin and water, usually in a ratio of 2-4 g natamycin to 1 liter of water. The suspension is stored in a liquid container. To prevent the suspension from settling, a small amount of the suspension, which is pumped under pressure to the nozzles, is recirculated into the liquid container via a jet agitator. Alternatively, to prevent settling, a stirring device can be used. To prevent fungal growth on shredded cheese, a natamycin concentration of 3-20 ppm, preferably 4-10 ppm, on the cheese is desirable. Typically, about 6 liters of natamycin suspension are sprayed onto 1000 kg of cheese. This treatment is generally effective in preventing fungal spoilage.

Until now, spraying natamycin onto cheese was considered the best way to achieve a uniform distribution of natamycin on shredded cheese. An anti-caking agent, such as cellulose, must be added to the shredded cheese before the natamycin is added, as cellulose forms a film around the cheese particles, which prevents the shredded cheese from clumping. The natamycin suspension is then added during the production process, which will adhere to the cellulose layer formed around the cheese particles, which is where fungal spoilage can occur. This production process prevents both the agglomeration of cheese particles and the growth of fungi on shredded cheese.

Both buffered vinegar and natamycin can be suitable cleaner-label preservatives for mozzarella cheese. Buffered vinegar helps with acidity control, while natamycin specifically targets mold and yeast growth. Their effectiveness depends on the specific application and combined with other food safety practices.

Thank you!