TRANSFERABLE TECHNOLOGIES

IN DAIRY PROCESSING

NATIONAL DAIRY RESEARCH INSTITUTE ( I. C. A. R. ) KARNAL-132001 (Haryana) ICAR

INDIA

Transferable Technologies In

Dairy Processing

NATIONAL

DAIRY RESEARCH INSTITUTE ( I. C. A. R. )

KARNAL-132001 (Haryana) INDIA

l e AR

The valuable contributions from scientists at this Institute in developing technologies and compiling the monograph deserve special appreciation. I wish to congratulate the NDRI Scientists ' who have developed and compiled the "Transferable Technologies in Dairy Processing".

1.5. 1993

Sd j (S.C. Sarma) DIRECTOR

ACK NOWJ.EDGE MENT

Concerted efforts of the staff and .tudents of the Dairy Processing group at the National Dairy Research Institute, Kamal have gone in to hring out this monograph on transferahle technologies in Dairy Processing. The Scientists, Ph.D. Scholars and M.Sc. students in the faculties of Dairy Technology, Dairy Engineeril1g, Dairy Chemistry, Dairy Microbiology, Animal Biochemistry have toiled hard to develop new technologies and consolidate these in the form of this monograph. However, due to paucity of space we regret not to include the names of all such persons who have contributed towards development of these technologies. Their contribution is duly acknowledged. The names of authors in each of the technology are of those scientists of National Dairy Research Institute who have made major contributions in developiog these technologies.

They are the contact scientists for the transfer of the res ..

pective technologies.

Sd/S. SINGH (Convenor)

CONTENTS Page No.

1.

Raw Milk Quality

1.0 1.1

Raw Milk Quality Lac[operoxidase thiocyanate (L.P.) system of milk preservation

2.

Gulabjamun mix powder

3 4 5

Rasogolla mix powder

6

Paneer and related products Innovations in pan eeT manufacture Cow milk paneer Low fat paneer

8 8

Khoa powder InSlant kulfi mix powder

Recombined milk paneer Filled milk paneer Vegetable paneer UF- Paneer

UP-Chhan. Long shelf-life paneer Ready to use paneer curry

9 9 11

12 \3

15 15 16 17

Cheese and Related Products

3.1 3.2 3.3 3.4 3.5 3.6 37

4.

2

Indigenous Dairy Products

2.1 2.2 2.3 2.4 2.5 2.5 1 2.5.2 25.3 2.5.4 2.5.5 2.56 2.57 2.5.8 2.5.9 2.5 10 3.

1

Dairy starter cultures Accelerated ripening of cheese G ouda cheese from buffalo milk Mozzarella cheese

UF Cheddar type cheese Goat milk Cheddar cheese Cheese spread

19 20 21 22 23 24 25

Fermented Milk Products

4.1 4.2

Misti dabi

Lassi

27 27

4.3 4.4 4.5 4.6 5.

33 33 33 34 34 35 37 38

Edible casein and caseinates Whey powder Whey protein concentrates Lactose Acido-whey

40 41 42 42 44

Dairy Equipments

7.1 7.2 7.3 8.

Infant food formulations Bitidus contaioig infant formula Low lactose infant formula Formula for pre-term infants Malted milk Low fat spread Low lactose milk Low lactose powder

Dairy By- products

6.1 6.2 6.3 6.4 6.5

7.

28 29 30 31

Formulated Foods

5.1 5.1.1 5.1.2 5.1.3 5.2 5.3 5.4 5.5 6.

Lassi powder Yoghurt Shrikhand UF-Shrikhand

Continuous butter meher Continuous ghee making machine Continuous khoa making machine

45 45 47

Quality Assurance

8.1 8.2 8.3 8.4

Test ing of formaldehyde preserved milk aDd milk products Milk pricing and SNF scale Rapid coliform test TDNase test

48 50 51 53

. . • ,,;

,'"

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1. Raw Milk Quality

2

1.1

Lactoperoxidase System for Preservation of Raw Milk Under Field Conditions B.N. Mathur. Vijay Gupta , D.K. Thompkinson and Sudhir Singh

Unsurmountable difficulties are experienced under the field conditions for

application of refrigeration for preservation of milk. due to : inadequacy of power supply; frequent break-down of power supply/voltage fluctuations; high cost of refrigeration equipment; and difficulties for repaIr of refrigeration equipmeots under rural conditions. Need for develo ping alternatives to refrigeration for milk preservation are therefore, obvious.

New Technology Lactoperoxidase is one of the naturally occuriog anti-microb ial system of bovine milk which can be harnessed for effective preservation of raw milk

under ambient conditions suitable for field applications. lP system can be activated with exogenous doses of thiocyanate and hydrogen peroxide when dosed within 2- 3 hours of milk production . Milk can be kept in good condition upto 30 hr at 37°C. Technology available for production of tablels of thiocyanate and percarbonate for activation of LP system under field conditions. Comparative cost of preservation:

a) b)

Mechanical refrigeration-27 Pllitre. LP system-8 P/litre.

•

2. Indigenous Dairy Products

3

2.1

Khoa Powder O.S. Rajorbia

. Khoa cannot be stored for more than 5 days at room temperature without spoilage. At preseot, no preservative is legally permitted to be added to khoa. Many of the States and Union Territories ban its production during the 'summer mOltths when the demand for khoa is invariably at peak. Because of its bulkiness and demand in cities and towns the cost of packaging and transportation of khoa arc also high. The techoology developed for manufacture of khoa powder would help eliminating these problems. New Technology

Technology for khoa powder manufacture has been developed for three scales of production viz. tray method for rural applications, roHer process for small entrepreneurs and spray drying for large scale production. Tray drying involves the preparation of khoa by conventional method, communuting it to fine particle size and spreading it into shallow trays followed by drying under specified conditions. For roller aDd spray drying, standardized buffalo milk is vacuum conCf!ntrated to desired level and heated at predetermined temperature to accentuate heated flavour prior to drying. Antioxidant and free flowing agents are added to improve the chemical and physical properties of khoa powder. Product Yield

About 14 kg of khoa powder is obtained from 100 lit of standardized buffalo milk. 00 reconstitution with water, this will produce about 21 kg of khoa. Utilization of khoa powder

Khoa powder, Can be utilized directly for the preparation of burfi, milk-cake, kalakand and gulabjamun. The quality of sweets made from khoa powder is highly acceptable. Shelf life

Khoa powder containing 0.01% BHA and packaced nitrogen gas can be stored upto 10 months at 30'C.

10

tin container under

4 Cost

Rs. 40, 45 and 42 per kg respectively for tray, roller and spray processes during the year 1992. Benefits of the technology

Surplus milk during flush season can profitably be converted into khoa powder to meet the lean period demands. Sweets of uniform quality can be produced throughout the year. Storage at room temperature for a very long period. Offers great export potential.

2.2

Instant Kulfi-Mix-Powder G .S. Rajorhia

Kulfi is a very popular traditional frozen milk product of India . The chemical and organoleptic qualities of kulfi sold in market s vary to a great extent. Inferior microbial quality is another serious drawback of market kulfi. The existing small scale batch process of kulfi making is not suitable for industrial application. Despite all these deficiencies, kulfi is invariably sold at exorbitant price. A technology has been perfected in this Institute for the manufacture of kulfi mix powder by srray drying process. New Technology

Mix is formulated from milk fat, MSNF, sucrose and isabgol husk. The concentration of solids is adjusted in the mix and only 25% of tbe total sugar required added before drying. The mix is homogenized and heat treated in a tubular heat exchanger. The mix is spray dried. The remaining sugar in ground form is dry blended with tbe powder and packaged in the tin cans. The proximate chemical composition of kulfi mix powder is : fat 25.41% MSNF 36.98%, isabgoI0.46%, sugar 34 . 65~~ and moisture 2.52%. Shelf-Life

Tbe product has a sbelf-Iife of 7 montbs at 30·C in tin cans. The shelf-life can be extended upto 10 montbs with the addition of butyl.ted hydroxyanisole and nirrogen gas flushing.

5 Cost of Production

The cost of production of kulfi mix powder at the prices of 1991 worked out to Rs. 4S per kg. Reconstitution of Kulfi Mix Powder into Kulfi

KuJfi mix powder can be instantly reconstituted and frozen to get kulfi of consistently good quality all the year round at an affordable price. It cnsures the production of pathogen-free frozen product.

2.3

Gulabjamuu Mix Powder G.S. Rajorhia and Dharam Pal

Traditionally gulabjamun is prepared by halwais from a mixture of khoa, bleached wheat Bour (ma ida ) and baking powder. Kboa has wide variations in the chemical composit ion , fl .. vour and texture. Market samples of khoa are also contaminated with micrubes. This affects the final quality of gulabJamun. The shelf life of traditionallY prepared gulabjamun hardly exceeds onc week at ambient temperature. Storage of gulabjamun in the refrigerated cabinets adversely affects its texture and eating quality. The instant gulabjamuD mix powder developed by NDRI would overcome these problems and offer several additional benefits. New Technology

Gulabjamun mix powder is formulated from skim milk powder, Vanaspati (ghee optional), maida: semol ina, baking powder and ground cardamon. Two different formulae have been developed separately for spray and roller dried skimmed milk. Essentia l equipment needed are ghee meher, dry blender weighing machine and a p~ ckaging unit. The product can be marketed in a metalized poly· ester PE laminate. Method of preparation of gulabjamun from the mix powder

The conditions of gulabjamun preparation such as dough making, deep fat frying and soaking of balls in sugar syrup were standardized for the gulabjamun

6 mIx powder. Addition of 50 ml (for spray) to 55 ml (for roller dried skimmed milk) wat« to 100 g mix powder, making of balls of 8-10 g, deep fat frying at I 25-130'C for 15 min and soaking in sugar syrup of 60% consistency at 60' C produces sweet with desired properties, one kg mix powder yields about 150 balls of average size (25 g each). Shelf life

I I

Gulabjamun mix powder packaged in metalized polyester. PE laminate without preservative remains fit for use upto eight months at 30°C.

I I

Costs

The cost of Gulabjamun mIX powder formulated from roller dried skim milk is estimated to be Rs. 36/kg whereas for spray based mix formulation slightly higher (Rs. 38/kg). The current retail prices for other market brands of tbe mix vary between Rs. 60 to 80 per kg. Additional benefits

Simple technology Convenience in use

Surplus skimmed milk powder cao be profitably utilized

2.4

Rasogolla Mix Powder Dharam Pal, G.S. Rajorhia, F.C. Garg and B.B. Verma

Rasogolla is a popular Indian milk based sweet usually prepared from cow

milk. ehhana is used as a base product, for this delicacy. The sbelf life of chhana does not e~ceed a few hours at room temperature. Stored chhana produces rasogolla with infaior sensory properties Moreover, fresh cow milk is not available at all times and everywhere in India. Tr.Jditional method of rasogolla making leads to lot of inconsistencies in textural quality, To overcome these limitations, an instant dried rasogol!a mix has been developed by the scientists of

Dairy Technology Division, NDRI, Karnal using the modern technologies.

7 New Technology Cow milk is ultra filtered under specified conditions of operation at predetermined temperature. The: retentate is spray dried using a standard technique. The dried reteolate is blended with the selected additives to produce the desired flavour and texture in the finished product. Technique of rasogolla making from dried mix

Equal quantity of water is added to the mix powder. Circular balls of about 6 g size are rolled out in a manner that no cracks appear on the surface. Balls ~re immersed and cooked in the boiling sugar s}'rup (60% consistency) for 15 min w.ith plenty of foam around the balls. In order to maintain the consistency of the syrup, drops of hot water are intermittantIy poured in the sugar syrup. The balls are then transferred into another hot s ugar syrup of 40% consistency.

Product yield The average yield of the mix powder from cow milk is 7 percent which will produce about 55 kg of sweet (drained weight). This IS 20% higher than that obtained by traditi onal method.

Shelf life Drioed rasogolla mix can be stored without spoilage for about five months at 30°C and for 10 months at SoC in sealed containers.

Costs The cost of rasogolia mix powder works out to Rs. 80/- kg in a plant of 2 ton capacity daily. Benefits oJ the Technology Economic use of seasonal and regional milk surpluses. Produces rasogolla of consistent quality at convenience of the users. Adaptable to medium and industrial scale dairy process"iog operations. Allows product diversification with manageable investments for improved productivity of the dairy industry, The product offers good export potential. •

2.5 2.5.1

Paneer and Related Products

Innovations of Paneer Manufacture S. Sacbdeva and S. Singh

Paneer is prepared by acid and beat coagulation of milk. It has traditionally beeD produced in . very small quantities by small dealers Of consumers themselves . Commercial production of paneer helps the dairies utilise the surplus milk during flush season and provides an outlet for the relatively inferior quality milk. The limitations of paneer production on a ·large scale arc: i) lack of improved technology of manufacture and ii) limited shelf life. New Technology Paneer Manufacture from Buffalo Milk

Certain simple modifications in paneer technology could prove to be of great value. The advantages gained through optimisation of processing parameters • are: iJ

Higher yield through greater total solids recovery and higber moisture retention. ii) Improved rheological characteristics by proper pH and temperature control. iii) Increased yield and improved rbeology achieved by incorporation of bydrocolloids. iv) Economised production through use of low cost, non-conventional coagulants. v) Savings in energy and water requirements. vi) SimpJified manufacturing technique makes the process more amenable to mechanisation. Enhancement of Shelf Life of Paneer

Paneer has a limited shelf life of 6 days under refrigeration and 1-2 days at room temperature. The spoilage in paneer starts at the surface by the formation of a greenish yellow slime wbich is accompanied by a putrid odour. The shelf life of paneer can be extended to more than a month under refrigeration by using safe antimicrobial substances in limited quantities and adequate packaging. Heat steri-

10 together with part of the moisture of serum of the original mi lk in which are CODtained lactose, whey proteins, soluble salts, vitamins and other milk components. It contains approximately 53-55 pereer.t moisture, 23-26 percent rae, 17-19 percent protein , 2-2.5 percent carbohydrate and 1.5-2.0 percent minerals . Paneer is characterized by typical mild acidic flavour with slightly sweet taste. It has firm, close, cohesive and spongy body and smoot h texture. The conventional paneer is quite rich in fat content which not only pushes up the price of paneer but also makes it uDsuita~Je to those consumers who arc conscious of high fat and want 10 have relativel y low fat paneer Since paneer is mostly used for cooking purposes, the relatively high level of fat may not be absolute requirement for an acceptable product. Further, utilization of substandard milk for paneer making would reduce the cost of production and thus make it easy to popularize in Indi a. A technOlogy has been developed for low fat paneer of acceptable quality. New Technology

The steps in new technology are: standardization of milk to low fat level, coagulation of milk at low temperature, fortification of milk with soy solids to improve its quality and further reduce its cost of production. Yield

The yie ld of low fat panee, is about 17-18 percent. Shelf Life

The product can be safely stored for a week at refrigeration. Benefits of the Technology

Low cost of paneer. Good for health conscious people Suitable avenue for substandard milk utilization Simple technology

II

2.5.4

Recombined Milk Paneer S. Singh, S.K. Kanawjia and S. Sachdeva

The shelf life of paneer is quite limited. It canDot be transported to long distances and unapproachable areas where milk production is inadequate. The demand of pa[]cer can not be met in big cities even at very high price. This probleftr bec0mes further serious during lean -season when milk production goes down. It causes Jot of inconvenience to the consumers particularly in marriage season. Consequently prices sboot up and consumers are at a great loss. With this view in mind. a suitable technology has been developed for the manu~ facture of paneer from recombined milk. New Technology

Recombined milk is prepared by blending skim milk powder with cream or cooking butter or butter oil and water. Recombined milk is homogenized and coagulated at relatively higher temperature with the addition of a suitable coagulant. Product Yield

The yield of paneer is about 22.0 percent. Shelf life

The shelf stability of recombined milk paneer under refrigeration is about 8 days. Benefits of the Technology

Product can be made available round the year. Demand of paneer can be met in unapproachable areas where milk production is inadequate. Paneer supply will be enbanced.

12

2.5.5 Filled Milk Paneer S. Singh aDd S.K. Kanawjia

During flush season some times the dairy plants declare milk holidays.

This

results in a slump in sale price of milk Thus, tbe producers of milk suffer under such situations. The fat is normally recovered as cream which is subsequently converted ioto ghee but skim milk does not find proper use . In order to enhance

the profitability of milk, it is very important to make Ihe best use of valuable solids of skim milk. This can be done by developing filled milk paneer where vegetable oils/vanspati can be blended with skim milk . Quite a cceplable product could be manufactured using skim milk and vegetable oils/vanaspati. Paneer so developed contains 16-18 percent protein, 22- 23 percent vegetable fat and 55-56 percent moisture.

New Technology

The technology involves: blending of skim milk with vegetable oils/vanaspati and coagulation of milk with suitable coagulant at desired temperature. The resulting product is quite acceptable. Yield

The yield of filled milk paneer is about 20-22 percent. Shelf Stability

The shelf stability of filled milk paneer at refrigerated temperature is about 8 days. Shelf life of paneer could be further increased up to 40 days by using suitable packaging materials and employing proper packaging system. Benefits of the Technology

Relatively low cost of production. Better utilization of skim milk. Good for health conscious people. Technology

m~ets

the requirements of various income groups.

13

2.5.6 Vegetable Paneer S. Singh and S.K. K anawjia

Despite several efforts to increas e the milk production. the per capita availability of milk still remains less than the minimum nutritional requirement. As a result, thtre is a wide spread malnutrition in the poorer strata of our por.-ulation. There is a strong case for finding out relatively efficient and cheaper sources of nutrition which could produce products similar in their functional properties to those of dairy products. On the other hand , some people object to milk fat. Under the circumstances, utilization of solids from tbe vegetable sources (like soy· bean and grouodnut) offer great promise to boost paneer production on one band and to lower the cost of production on the other. From the economical stand point, i~ is cheaper and more efficient to produce vegetable food solids per unit of investment than animal food solids. Soybean and groundout bave greater potential to supply higb quality proteins and arc so amenable that variety of products can be developed with and without milk solids. New Technology Soy Paneer

Soy milk is prepared using standard method. Milk is heated to an optimum temperature and coagulation effected using suitable coagulants. The coagulum is kept at optimum temperature for some time till clean whey is visible. Then the curd is moulded and pressed with appropriate weight for standard time. The product could be used for preparation of various culinary dishes. The accep· tablityof soypaneer could be further enhanced by addition of caseinates. PaneeT contains 21-24% TS, 6.0-7.5% fat , 120-17.0% protein 1.2-1-6% carbohydrate and 0.7-0.9% miDeral. Yield

One kg soybean yields about 1.5 kg paneer.

Product Cost The cost of production is much cheaper than that of conventional paneer. The estimated cost of soypaneer is about Rs. ISjkg.

14 Shelf Life

The shelf life of soypaneer is about 5 days in refrigeration which could be increased to 20 days by employing suitable packaging melhod . Groundnut Paneer /

Groundnut milk is prepared from deski nned groundnut by grinding it in a mixer/micropulverizer followed by filtering. adjustment of pH with the addition of lime water prior to boiling. Groundnut milk is blended with skim milk. The mixture is heated to a desired temperature and then coagulation is affected by citric acid solution . Other steps are similar to tbat for co nventional paneer. Groundnut milk as such is Dot suitable for paneer making. It results in soft and fragile body and texture. During frying. disintegration and eros ion of surface particles from the cubes take place. This shows that graundnut p rotein has less resilience aDd resistance to shear properties thereby adversely affecting tbe quality of product. Addition of 50 per cent skim milk to the ground nut milk markedly improved the quality of paneer. Paneer contains 42 .5% TS, 15.0% fat, 23.0% protein, 2.7% Carbohydrates and 1.6% mineral. Its rheological characteristics are quite com para ble to milk paneer. Yield

The \ ield of paneer manufdctured from groundnut milk blended with equal amount of skim milk is about 17.0 per cent Product Cost

Tbe estimated cost of paneer is about Rs 20j kg. Shelf Life

The shelf stability of groundnut paneer is abo ut 6 days in refrigeration wh ich could be enhanced to 25 days by cbemical treatment and proper packaging system. Benefits of the Technology

Techn ology suits the requirements of poor segments of population and also diet et ic groups II is rela tivel y cheaper and superior to conventional paneer in terms of proteins and calorific value It co uld alleviate the problem of malnutrition It solves the seasonal imbalances of paneer requirements. Cost of production is about half of the convenlional paneer.

15

2.5.7

UF-Paneer S. Sachdeva. R.S. Patel, S.K. Kanawjia, S. Singh and V K. Gupta

Membrane technology bas been used to a great advantage for the manufacture of paneer. Ultrafiltration. when employed for paneer manufacture offers the following advantages :i) access to mechanisation ii) uniformity of production iii) improved shelf life iv) increased yield v) nutritionally better product

New Technology The process involves standardisation and heating of milk followed by ultrafiltration (UF) whereby lactose, water and some minerals are removed. The concentrated mass is cooled, acidified and then filled into suitable containers. This is followed by texturisatioD using microwave technique .. The resulting product has typical characteristics of normal paneer. The process also helps in increasing the shelf lIfe of paneer. The process requires an imported UF-unit.

The yield is increased by about 25 per cent which is due to the retention of aood quality whey proteins and the Slightly increased moisture content.

2.5.8 UF-Chhana D.K. Sharma and S. Sachdeva

Chhana is made in India by traditional methods. The whey proteins are drained alongwith whey during these manufacturing processes . A new technology retains, tbe whey proteins in form of chhana. This became possible by the application of ultrafiltration (UF) technique for making skim milk retentate. The Dew method gives 18-20% extra yield as compared with conventional method. Chhana quality was comparable with traditional chhana.

16 New Technology

Fresh skim milk is concentrated using UF-mineral membrane module to recover whey proteins along with casein' as UF-retentate. Retentate so obtained i. diafiltered using same membrane module. Oiafiltered UF-retentate is added

with plast ic cream and is heated and . cidified to get proper body and texture of cbbana. The product is cooled to obtain comparable body and texture as of traditional chhana. Shelf-life of product is one week under refrigeration temperature (4°C). The process requires an imported UF-unit. The process has inherent advantages of higher product yield, nutritionallY better product; Jess pollution problem, easy automation and process control. new process has potential scope for industrial application.

The

2.5.9 Long Shelf Life Paneer B.N. Mathur, D.K. Thompkinson , Sudhir Singh

Introduction

The traditional technology is suitable for batch operations and handling of milk upto 5000-10000 litres in batches. The traditional technology has the following limitations :

Loss of nearly half of milk solids in whey; Loss of heat in whey; Recontamination of product after heat treatment;

Limited shelf life; Labour intensive;

Lack of packaging systems; Lack of quality assurance systems. New Technology

Salient features are as follows : Higher product yield Conventional process Innovative process

15-22% 35-40%

17 Whey solids retained in the product,

DO

problem of whey disposal.

Shelf life 3 months at 30·C. I.

Various unit operations• integrated Cuny with mechanised energy efficient equip: , • _

,"...

. ments:

.

•

'

.

Appropriate packaginz system;

Favourable consumer response; and Cost of manufacture:

Traditional pa~eer Long shelf life paneer

2.5.10

52 P/kg _ 33 P/kg

Paneer Curry G.R. Patil

A variety of cODvenience foods have hit the Indian market during this decade and won over the palate of millions of people with exotic tastes and attractive packages offering an effortless cODvenience in eating. Several processes arc in vogue for producing tbis type of foods, namely. heat sterilization, drying. frying, baking. fermentation e(C. These methods substantially alrer sensory and nutritional qualities of any product. The above processes are known to cause the loss of lysine ranging from 0 to 38%. When paneer is heat sterilized, it becomes brown and the chewiness shoots up from 115 mo. mm to 898 mn. mm which is 00 rubbery side of texture. Dried paneer has retarded reconstitution properties and its rheological properties can never be the same as that of fresh paneer. The marketing of the convenience foods can certelinl) be augmented if the above drawbacks are overcome. In this context, hurdle technology (HT) is fast gaining attention in food industry. In HT concept, parameters like heat, low temperature, pH, preservative, water activity, etc. are termed as "hurdles", because they are the hurdles in the way of microbial growth. In conventional preservation only one or two hurdles are used. Three or more hurdles have to be applied at a time so that each hurdle is applied at its minimum intensity to minimize the adverse effects on sensorial and nutritive value. This is the basic . principle behind developing the shelf-stable paneer curry.

18 New Technology

Formulation: The product consists of gravy and paneer. The water activity of gravy and paneer is reduced to 0.95 by using suitable humectants. pH is lowered to 5.0 by a proper admixing of dahi and skim milk powder. Initially, the gravy is prepared by using onions tomatoes , usual spices and condiments, humectants and potassium sorbate (0.1 %) Fried paneer cubes and the gravy are packed in tins or retort pouches and subjected to heat treatment of F-value 0.8. The packages are then cooled in tap water. The retort pouches need -to be dipped in scaldillg water for 5 minutes.hefore consuming the: pr,I..' duct. Composition

The overall composition of the product is : total solids, 40.27%. fal 24.99%, protein, 5.88% and ash 3.16%, carbohydrates and glycerol constitute 6.24% . Shelf Life

The product has a shelf-life of 31 days at 30' C aDd more thaD tbree months at J 5'C. Cost

At the product output rate of 87.6 tonnes per annum, the cost of production of 200 g of the product iD a retort pouch worked out to be Rs. J8.48. Facilities required

The product manufacture requires no other extra facilities than the ODes that already exist in dairy product manufacturing units.

•

3. Cheese and Related Products

3.1 Dairy Starter Cultures M.P. Tiwari

,=========================== Microbial starter cultures play an essential role in cheese and fermented milk industries. Their use helps preparing products with desired characteristics 10 respect ·o f body, texture, flavour and aroma. The National Centre of dairy cultures (NCDC), located at NDRI has more than 200 types of single and multiple strain cultures. Many of these have been isolated locally and quite a few have been obtained from other countries. An acceptable dairy starter strain produces acidity to the desired level and at predetermined rates, contributes to the characteristic body. texture, flavour aod aroma of the particular product. The NCDC has collected starter cultures for most varieties of cheese, e ,. Cheddar, Gouda, Parmesan, Emmental, Camembert, Roquefort etc. These are tested from time to time for their original performance. Efforts have been made to evolve blends for buffalo milk cheese. Some of these starters have been blended so that they reduce the ripening time by about onc month to 40 days. The NCDC has sufficient Dumber of cultures for cheese varieties cooked at high temperature. Then~ are special cultures which produce desirable types of eyes in cheese. The centre also has starters for such cheese varieties where no ripening i. required e.g. Cottage, and Mozzarella. The starter cultures arc available for vari· ous fungal ripened cheese varieties also. The NCDC has in its stocks starters for various fermented dairy products, c.g. dahi. lassi, butter milk, shrikhand, misti dahi, yoghurt, bulgarian milk acidophil us milk, kumiss, etc. Most of these cultures have been used on pilot plant scale. Vacuum sealed ampules of starters remain viable for about one-and-half months at ambient temperature and more than fifteen years at refrigeration tern· perature. The subsidised cost of the culture is Rs. 20/- per ampule when collected at Kamal and Rs. 30/-per ampule sent through registered post parcel against crossed Demand Draft in favour of ICAR unit, NDRI Kamal.

20 '- '--3:2- - A-ccelerated"Ripening of ' Cheese· S. Singh aDd S.K. KaDawjia

The traditional process of manufacturing ripened vanetles of cheeses like Cheddar, Gouda, etc takes longer time to yield a product ready for use. The long

time curing is cumbersome, labour intensive, energy consuming. aod expensive. This problem is furtber aggravated iD case of buffalo milk cbeddar cbee,e. To overcome these limitations, technologies have been developed to accelerate the ripening process of cheeses which provide savings in refrigeration and labour and contribute io releasi~g considerable ums of money v.:bich are otherwise tied up in cheese cold store.

s.

New Technology .

The modifications in the manufacturing technique involve: standardization of buffalo milk, relatively. bigber .beat treatmeDt, additioD of bigber rate of starter culture and microbial rennet and cooking at lower temperature. The rate of ripening is accelerated . ~y sup.plementing the starter culture with adjunct bacteria , addition of exogenous free enzymes like lipase and protease, and microencapsulated enzymes aDd partial curiDg of cbeese at elevated temperature. SupplemeDtation of buffalo milk witb goat milk also improves tbe flavour, and body and texture developmeDt. Benefits of the Technology

Buffalo milk can be utilized for tbe manufacture of good quality cheddar cheese. Supplementation with goat milk elimiDates tbe iDbereDt drawbacks of buffalo milk cheese. Technology provides

a profitable outlet for goat milk

utilization.

It also solves tbe problem of mixed milk utilizatioD.

The ~ecbDology saves a considerable amout of labour, space, eDergy and curtails tbe amount of money tied up iD tbe cold store. It redeces the total ripening cost to about 20-27 per cent.

21

3.3 Gouda Cheese from Buffalo Milk S.K. Kanawjia, S. Singh and B. D. Tiwari

Gouda cheese is a quick ripening variety with relatively milder flavour which is expected to be liked by the cbeese loving clientele. It also forms a good raw material for processed cheese and reduces its cost. Traditionally Gouda cheese is manufactured from cow milk using calf rennet. However, in India it is the buffalo milk which constitutes the major share of the total milk production. As such buffalo milk is not suitable fl)T the manufacture of Gouda cheese as it yields a cheese with hard and crumbly body and flat flavour even after prolonged ripening. Besides, the import of calf rennet in cheese making is baDDed by the GovL of India. To overcome these limitations. technology has been developed to manufacture good quality Gouda cbeese from buffalo milk using microbial rennet. Further, the technology has also been standardized to accelerate dtvelopment of flavour and body and texture of Gouda cheese. New Technology

The method of manufacture of buffalo milk Gouda cheese involves standardization of milk to a suitable casein/fat ratio, application of relatively higher heat treatment, addition of optimum level of starter and use of lower cooking temperature. The flavour and body and texture development were further enhanced by adding starter adjuncts, modified starters, applications of exogenous enzymes and supplementation of buffalo milk with goat milk. Product Yield

The yield of cheese made from buffalo milk is considerably higher (14%) as compared to that of cow milk (12%). Benefits of the Technologl'

Buffalo milk could be satisfactorily utilized for Gouda cheese making. Ripening period could be reduced considerably. Gouda cheese could be utilized for lbe manufaclure of process chc:ese. Lowers the cost of production. Provides profi1able outlet for goat milk.

22 3.4

Mozzarella Cheese S K. Kanawj'a, S Singh and B.D. Tiwari

Mozzarella cheese is one variety of Ilnripent'd cheese. It is a soft and whIte cheese wh('lse melting and stretching properties arc highly sUitable for Pizza making. Altbough the demand for Mozzarella cheese in India is on the increase due (0 the proliferation of Pizza parlours and expansion of fast food chain3, there are no organised dairies engaged in its manufacture. The increasilrg d'e mand has generated a need for process and product ~tandardization. At present the main comtraint in the commercial exploitation appears to be the paucity of full understanding of the technical aspects in the manUfl/CIUre of the product. Technology has been sta ndardized to manufacture Mozzarella cheese of uniform c~lmposilional and functional properties by convenrional culture melhod. The total time required [Q manufacture Mozzarella cheese by this method was shortenc::d by using direct acid method. A method has also been developed to manufacture, Mozzarella cheese from buffalo milk admixed with goat milk. New Technology Mozzarella Cheese from Culture Method

Th e method of manufacture of Mozzarella cheese from buffalo milk invol ves standardlzdtion of milk at suitahle fat level, addition (If :l ppropri at e level of st::r'er culture, use of optimum level of microbial rennet, p.trtial dra ining of whey and stretching the curd at proper acidity. The cheese made with tlles'! combinations possessed excellent thvour, body and texture, stretching and melting properties. Mozzarella Cheese from Direct Acid Method

The technology involves standardization of buffalu milk, acidification with diluted acid at low lemperarure, u