Source: UNIVERSITY OF KENTUCKY submitted to
SYNERESIS SENSOR TECHNOLOGY DEVELOPMENT FOR CURD MOISTURE CONTENT CONTROL. RENEWAL APPLICATION
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
TERMINATED
Funding Source
Reporting Frequency
Annual
Accession No.
0213482
Grant No.
2008-35503-18858
Project No.
KY0PAYNE1
Proposal No.
2007-02738
Multistate No.
(N/A)
Program Code
71.1
Project Start Date
Apr 1, 2008
Project End Date
Sep 30, 2009
Grant Year
2008
Project Director
Payne, F. A.
Recipient Organization
UNIVERSITY OF KENTUCKY
500 S LIMESTONE 109 KINKEAD HALL
LEXINGTON,KY 40526-0001
Performing Department
BIOSYSTEMS & AGRIC ENGINEERING
Non Technical Summary
The cheese making industry is a very important segment of the US agriculture (~30% of world cheese production). The extent of syneresis controls the moisture, mineral and lactose content of the curd which affects final cheese sensory attributes. Curd moisture control would improve cheeses consistency and quality. Unfortunately, there are currently no technologies available for monitoring curd syneresis. The goal of this project was to develop an optical sensor technology to monitor syneresis and control the curd moisture content. We have developed an optical sensor technology (during this project) that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat. The technology consists of a unique optical sensor, a specific light waveband which yields the kinetics of syneresis and regression models which predict cutting time, whey fat losses, cheese yield and curd moisture content as a function of time. This technology offers the potential for monitoring coagulation and syneresis using a single sensor, which would result in improved cheese manufacture process control, improved cheese quality, and reduced processing losses.
Animal Health Component
(N/A)
Research Effort Categories
Basic
(N/A)
Applied
50%
Developmental
50%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
5013430202050%
5013450202050%
Knowledge Area
501 - New and Improved Food Processing Technologies;

Subject Of Investigation
3450 - Milk; 3430 - Cheese;

Field Of Science
2020 - Engineering;
Goals / Objectives
A syneresis sensor technology was developed for curd moisture content control during our current NRI research project. The developed technology shows potential as a robust sensor technology for control of both cutting time and extent of syneresis in curd processing. Refinement of the technology is progressing; however, there is clearly a need to validate the technology. Validation of the ability of the technology to control moisture content in cheese production is the overall objective of this proposal for renewal of our NRI research project. The specific research objectives are as follows: 1.Evaluate the performance of the syneresis sensor technology over a range of cheese processing conditions. 2.Reduce the standard error of prediction for curd moisture content during syneresis with improvements in the sensor, optical parameters, and moisture prediction algorithms. 3.Determine the precision of moisture content control through validation testing. A secondary objective, easily implemented, is to improve and validate prediction algorithms to estimate other significant cheese making indexes such as cheese yield, fat losses, etc.
Project Methods
Objective 1. Evaluate the performance of the syneresis sensor Experiment one. The performance of the syneresis sensor will be evaluated at constant coagulation conditions and varying syneresis conditions. A factorial experiment with two factors (cutting mode and stirring speed), three levels and three replications will be conducted. Gel will be cut at constant firming. The optical response will be measured every 7 s to obtain the first order syneresis kinetic parameters. Samples of curd and whey will be removed from the vat for compositional analysis (curd moisture content and whey fat) at 10 min intervals. Final whey and curd yield, as well as final whey fat losses will also be determined. The goal will be to determine a model of independent optical parameters in addition to temperature and product characteristics to predict the curd moisture content as a function of syneresis processing time. Experiment two. A second randomized factorial design having two factors, three levels and three-replication will be conducted to evaluate the performance of the syneresis sensor under a wide range of rheological gel conditions indirectly affecting the kinetics of syneresis. Experimental factors will be milk fat concentration and gel strength. The rest of the experimental will be performed as described for experiment one. Objective 2. Reduce the standard error of prediction for curd moisture content during syneresis The current standard error of prediction (SEP) for curd moisture content as a function of time during syneresis is 5.25% curd moisture content over the range of 50 to 90% curd moisture content. We propose to reduce the SEP below 2.5% curd moisture content. Experimental data obtained from Objective 1 will be use to evaluate alternative signal processing and predictive methods to reduce the SEP for curd moisture content. Several approaches will be used: a) improving the signal processing method; b) identifying new, more efficient optical parameters; c) developing more suitable algorithms for curd moisture content prediction. Objective 3. Determine the precision of curd moisture content control through validation testing A three factors, three levels, and three replications validation test will be performed to evaluate the precision of curd moisture content prediction within a wide range of syneresis ratios induced by three different syneresis factors, fat + protein concentration, fat:protein ratio and temperature. The general experimental methodology will be as for experiment one. The experimental data obtained will be split in two sets. The first replication will be used as calibration set. The remaining two replications will be used as validation sets. Complementary objective. Improve and validate prediction algorithms to estimate other significant cheese making indexes Data collected during experiments one and two (objective one) will allow obtaining algorithms for prediction of the different processing indexes of significance for cheese making. Data from objective 3 will be utilized to validate the predictive algorithms and determine the accuracy of the prediction for the different cheese making indexes studied.

Progress 04/01/08 to 09/30/09

Outputs
OUTPUTS: The overall objective of this research project is validation of the ability of the developed syneresis sensor technology to control moisture content in cheese production. DEGREE OF ACCOMPLISHMENT FOR SPECIFIC GOALS. Objective #1. Evaluate the performance of the syneresis sensor technology under different processing conditions. Fully accomplished. A five-factor, fully randomized, fractional, factorial central composite design (CCD) was employed. The five factors selected as independent variables were coagulation temperature, milk pH, fat to protein ratio, calcium chloride, and cutting time. Three entire replications of this experiment were conducted. Two were used as calibration set while one was used as validation set. During the syneresis phase of cheese making, curd was removed at differing times post-cutting from the cheese-vat. A curd aliquot was used to measure curd moisture content and the remaining one was pressed (0.1 kg cm-2 of pressure during 3 h) for determination of pressed cheese moisture content. Objective #2. Reduce the standard error of prediction for curd moisture content during syneresis with improvements in the sensor, optical parameters, and moisture prediction algorithms. Currently in progress.. Objective #3. Determine the precision of moisture content control through validation testing. Currently in progress. Accomplishment of objectives 2 and 3 relays in detailed analysis of data obtained for objective #1. Part of the results obtained after data analysis constitutes the Master's thesis for a graduate student involved in the project (Tatiana Gravena Ferreira). DISSEMINATION OF RESULTS. Wide dissemination of results has been obtained through publication of results in peer-reviewed scientific journals of high standard, oral presentations and posters at international conference meetings (ADSA, IFT, ASABE, ICEF, IDF, CIHEAM, CIGR, ICDST, EFFOsT) and a lot of different local (Kentucky) and national conferences (Ireland, Spain and USA). Several invited conferences/seminar has been delivered to difference audiences at the IDF, ADSA, University of Tennessee, Cal Poly, University of Murcia (Spain), University College Dublin (Ireland) and Moorepark Food Research Centre (Teagasc, Ireland), Universitat Autonoma de Barcelona. Technical consulting has been provided to University of Murcia (Spain), University College Dublin (Ireland), Moorepark Food Research Centre (Teagasc, Ireland), and Central Quesera Montesinos (Spain). PATENTS. Syneresis sensor technology for curd moisture content control in cheese making. Authors: Payne, F. A., Castillo, M., Everard, C. D., Fagan, C. C., O'Donnell, C. P., O'Callaghan, D. J. Application #US2008268110-A1. A method for monitoring the syneresis reaction in cheese making using computer vision and color measurement. Authors: Castillo, M., Payne, F. A., Fagan, C. C., Everard, C. D., O'Donnell, C. P., O'Callaghan, D. J. Patent #7,880,881. PARTICIPANTS: The individuals participating in this project are as described in the initial project. Training and professional development is currently being provided by the project for a graduate student. Master's student Tatiana Gravena Ferreira was assisting with the experiments and is currently enrolled as graduate student at the BAE Department. Research has also been conducted in collaboration with the University of Murcia in Spain that has contributed to consolidate the research and expand the scientific results of the project. Our collaboration did not only involve the participation of the University of Murcia (Spain) but also of a goat cheese plant (Central Quesera Montesinos S.L.). A Spanish grant was obtained by the University of Murcia (US-$56,847) in collaboration with the mentioned cheese plant with the aim of adapting the syneresis sensor technology to goat cheese manufacture; Dr. Payne and Castillo provide senior scientific and technical assistance for this collaborative project. TARGET AUDIENCES: Not relevant to this project. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
A novel optical sensor technology that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat is being validated (note that curd moisture control requires control of milk coagulation, cutting time and syneresis). The new syneresis technology consists of a unique large field of view optical sensor that provides the information about gel assembly and curd shrinkage kinetics required for curd moisture control. Curd moisture as a function of processing time can be predicted with a SEP of 1.72% over the range of 50 to 90% curd moisture content. Thus, this technology could be used for manufacturing of low, medium and high moisture cheeses. From an applicative point of view this technology would provide more consistent and efficiency production capability. The technology also would save energy by avoiding unnecessary syneresis processing and allow cheese maker to shift curd size as milk solids change during the year. Further, real time action would be possible in order to obtain the desired curd moisture content if culture inhibition occurs due to bacteriophage or agglutination problems. This technology is considered to offers the potential for a comprehensive process control of cheese making in the vat and for predicting curd moisture. Several cheese making facilities (Brewster Cheese Inc., and Kraft Foods Inc.) and a food processing engineering firm (ESEInc.) have expressed an interest in testing the implementation of this technology for cheese manufacture.

Publications

  • Everard, C., OCallaghan, D. J., Castillo, M., Payne, F. A., ODonnell, C. P. 2010. Effects of milk composition, curd draining time and pressing duration on cheese curd moisture and yield. Journal of Dairy Science. Submitted.


Progress 04/01/09 to 09/30/09

Outputs
OUTPUTS: The overall objective of this research project is validation of the ability of the developed syneresis sensor technology to control moisture content in cheese production. DEGREE OF ACCOMPLISHMENT FOR SPECIFIC GOALS. Objective #1. Evaluate the performance of the syneresis sensor technology under different processing conditions. Fully accomplished. A five-factor, fully randomized, fractional, factorial central composite design (CCD) was employed. The five factors selected as independent variables were coagulation temperature, milk pH, fat to protein ratio, calcium chloride, and cutting time. Three entire replications of this experiment were conducted. Two were used as calibration set while one was used as validation set. During the syneresis phase of cheese making, curd was removed at differing times post-cutting from the cheese-vat. A curd aliquot was used to measure curd moisture content and the remaining one was pressed (0.1 kg cm-2 of pressure during 3 h) for determination of pressed cheese moisture content. Objective #2. Reduce the standard error of prediction for curd moisture content during syneresis with improvements in the sensor, optical parameters, and moisture prediction algorithms. Currently in progress.. Objective #3. Determine the precision of moisture content control through validation testing. Currently in progress. Accomplishment of objectives 2 and 3 relays in detailed analysis of data obtained for objective #1. Part of the results obtained after data analysis will constitute the Master's thesis for a graduate student involved in the project (Tatiana Gravena Ferreira). DISSEMINATION OF RESULTS. Wide dissemination of results has been obtained through publication of results in peer-reviewed scientific journals of high standard, oral presentations and posters at international conference meetings (ADSA, IFT, ASABE, ICEF, IDF, CIHEAM, CIGR, ICDST, EFFOsT) and a lot of different local (Kentucky) and national conferences (Ireland, Spain and USA). Several invited conferences/seminar has been delivered to difference audiences at the IDF, ADSA, University of Tennessee, Cal Poly, University of Murcia (Spain), University College Dublin (Ireland) and Moorepark Food Research Centre (Teagasc, Ireland). Technical consulting has been provided to University of Murcia (Spain), University College Dublin (Ireland), Moorepark Food Research Centre (Teagasc, Ireland), and Central Quesera Montesinos (Spain). PATENTS. Syneresis sensor technology for curd moisture content control in cheese making. Authors: Payne, F. A., Castillo, M., Everard, C. D., Fagan, C. C., O'Donnell, C. P., O'Callaghan, D. J. Application #US2008268110-A1. A method for monitoring the syneresis reaction in cheese making using computer vision and color measurement. Authors: Castillo, M., Payne, F. A., Fagan, C. C., Everard, C. D., O'Donnell, C. P., O'Callaghan, D. J. Application #US2008270063-A1. PARTICIPANTS: The individuals participating in this project are as described in the initial project. Training and professional development is currently being provided by the project for a graduate student. Master's student Tatiana Gravena Ferreira has been assisting with the experiments and is currently enrolled as graduate student at the BAE Department. Research is also being conducted in collaboration with the University of Murcia in Spain that will contribute to consolidate the research and expand the scientific results of the project. Our collaboration does not only involve the participation of the University of Murcia (Spain) but also of a goat cheese plant (Central Quesera Montesinos S.L.). A Spanish grant was obtained by the University of Murcia (US-$56,847) in collaboration with the mentioned cheese plant with the aim of adapting the syneresis sensor technology to goat cheese manufacture; Dr. Payne and Castillo provide senior scientific and technical assistance for this collaborative project. TARGET AUDIENCES: Not relevant to this project. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
A novel optical sensor technology that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat is being validated (note that curd moisture control requires control of milk coagulation, cutting time and syneresis). The new syneresis technology consists of a unique large field of view optical sensor that provides the information about gel assembly and curd shrinkage kinetics required for curd moisture control. Curd moisture as a function of processing time can be predicted with a SEP of 1.72% over the range of 50 to 90% curd moisture content. Thus, this technology could be used for manufacturing of low, medium and high moisture cheeses. From an applicative point of view this technology would provide more consistent and efficiency production capability. The technology also would save energy by avoiding unnecessary syneresis processing and allow cheese maker to shift curd size as milk solids change during the year. Further, real time action would be possible in order to obtain the desired curd moisture content if culture inhibition occurs due to bacteriophage or agglutination problems. This technology is considered to offers the potential for a comprehensive process control of cheese making in the vat and for predicting curd moisture. Several cheese making facilities (Brewster Cheese Inc., and Kraft Foods Inc.) and a food processing engineering firm (ESEInc.) have expressed an interest in testing the implementation of this technology for cheese manufacture.

Publications

  • Mateo, M. J., OCallaghan, D. J., Everard, C. D., Castillo, M., Payne, F. A., ODonnell, C. P. 2009.Validation of a curd-syneresis sensor over a range of milk composition and process parameters. Journal of Dairy Science. 92 5386-5395.
  • Mateo, M. J., OCallaghan, D. J., Everard, C. D., Castillo, M., Payne, F. A., ODonnell, C. P. 2009. Evaluation of online optical sensing techniques for monitoring curd moisture content and solids in whey during syneresis. Food Research International. 43 177-182.
  • Ferreira, T. G., Castillo, M., Payne, F. A., ODonnell, C. P., OCallaghan, D. J. 2010. A sensor technology for monitoring and controlling syneresis in cheese making. Submitted to 2010 ADSA annual meeting. Denver, Colorado,July 11-15 2010.


Progress 04/01/08 to 03/31/09

Outputs
OUTPUTS: Validation of the ability of the developed syneresis sensor technology to control moisture content in cheese production is the overall objective of this research project. DEGREE OF ACCOMPLISHMENT FOR SPECIFIC GOALS. Objective #1. Evaluate the performance of the syneresis sensor technology under different processing conditions. Fully accomplished. Previous experimental results strongly encouraged us to combine the two proposed experiments to accomplish this goal into a larger one with five experimental factors. The final selection of the factors studied was done under the insight of the newest experimental results to ensure that most important processing conditions affecting syneresis were evaluated consistently as part of the same experiment. A five-factor, fully randomized, fractional, factorial central composite design (CCD) was employed. The five factors selected as independent variables were coagulation temperature, milk pH, fat to protein ratio, calcium chloride, and cutting time. The CCD consisted of a 2k-1 factorial (k = 5) with 2k axial points and seven center points (33 runs). Three entire replications of this experiment were conducted. Two were used as calibration set while one was used as validation set. During the syneresis phase of cheese making, curd was removed at differing times post-cutting from the cheese-vat. A curd aliquot was used to measure curd moisture content and the remaining one was pressed (0.1 kg cm-2 of pressure during 3 h) for determination of pressed cheese moisture content. Objective #2. Reduce the standard error of prediction for curd moisture content during syneresis with improvements in the sensor, optical parameters, and moisture prediction algorithms. Currently in progress. Objective #3. Determine the precision of moisture content control through validation testing. Currently in progress. DISSEMINATION OF RESULTS. Wide dissemination of results has been obtained through publication of results in peer-reviewed scientific journals of high standard, oral presentations and posters at international conference meetings (ADSA, IFT, ASABE, ICEF, IDF, CIHEAM, CIGR, ICDST, EFFOsT) and a lot of different local (Kentucky) and national conferences (Ireland, Spain and USA). Several invited conferences/seminar has been delivered to difference audiences at the IDF, ADSA, University of Tennessee, Cal Poly, University of Murcia (Spain), University College Dublin (Ireland) and Moorepark Food Research Centre (Teagasc, Ireland). Technical consulting has been provided to University of Murcia (Spain), University College Dublin (Ireland), Moorepark Food Research Centre (Teagasc, Ireland), and Central Quesera Montesinos (Spain). PATENTS. Syneresis sensor technology for curd moisture content control in cheese making. Authors: Payne, F. A., Castillo, M., Everard, C. D., Fagan, C. C., O'Donnell, C. P., O'Callaghan, D. J. Application #US2008268110-A1. A method for monitoring the syneresis reaction in cheese making using computer vision and color measurement. Authors: Castillo, M., Payne, F. A., Fagan, C. C., Everard, C. D., O'Donnell, C. P., O'Callaghan, D. J. Application #US2008270063-A1. PARTICIPANTS: The individuals participating in this project are as described in the initial project. Training and professional development is currently being provided by the project for a graduate student. Master's student Tatiana Gravena Ferreira has been assisting with the experiments and is currently enrolled as graduate student at the BAE Department. Research is also being conducted in collaboration with the University of Murcia in Spain that will contribute to consolidate the research and expand the scientific results of the project. Our collaboration does not only involve the participation of the University of Murcia (Spain) but also of a goat cheese plant (Central Quesera Montesinos S.L.). A Spanish grant was obtained by the University of Murcia (US-$56,847) in collaboration with the mentioned cheese plant with the aim of adapting the syneresis sensor technology to goat cheese manufacture; Dr. Payne and Castillo provide senior scientific and technical assistance for this collaborative project. TARGET AUDIENCES: Not relevant to this project. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
A novel optical sensor technology that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat is being validated (note that curd moisture control requires control of milk coagulation, cutting time and syneresis). The new syneresis technology consists of a unique large field of view optical sensor that provides the information about gel assembly and curd shrinkage kinetics required for curd moisture control. Curd moisture as a function of processing time can be predicted with a SEP of 1.72% over the range of 50 to 90% curd moisture content. Thus, this technology could be used for manufacturing of low, medium and high moisture cheeses. From an applicative point of view this technology would provide more consistent and efficiency production capability. The technology also would save energy by avoiding unnecessary syneresis processing and allow cheese maker to shift curd size as milk solids change during the year. Further, real time action would be possible in order to obtain the desired curd moisture content if culture inhibition occurs due to bacteriophage or agglutination problems. This technology is considered to offers the potential for a comprehensive process control of cheese making in the vat and for predicting curd moisture. Several cheese making facilities (Brewster Cheese Inc., and Kraft Foods Inc.) and a food processing engineering firm (ESEInc.) have expressed an interest in testing the implementation of this technology for cheese manufacture.

Publications

  • Fagan, C. C., ODonnell, C. P., OCallaghan, D. J., Castillo, M., Payne, F. A. 2009. Visible-near infrared spectroscopy sensor for predicting curd and whey composition during cheese processing. Sensing and Instrumentation for Food Quality and Safety. 3, 62-69.
  • Mateo, M. J., D.J. OCallaghan, C. D. Everard, C. C. Fagan, C.P. ODonnell, M. Castillo, F. A. Payne. 2009. Influence of curd cutting programme and stirring speed on the prediction of syneresis indices in cheese-making using NIR light backscattering. LWT - Food Science and Technology. 42, 950-955.
  • Everard, C. D., OCallaghan, D. J., Mateo, M. J., ODonnell, C. P., Castillo, M., Payne, F. A. 2009. The use of colour parameters derived from an online fibre-optic sensor to monitor curd syneresis during cheesemaking. Journal of Food Engineering. 94, 1-6.
  • Talens, C., OCallaghan, D. J., Everard, C. D., Fagan, C. C., ODonnell, C. P., Castillo, M., Payne, F.A. 2009. Evaluation of an improved tracer method to monitor cheese curd syneresis at varying milk fat levels in a cheese vat. Milchwissenschaft. 64, 161-164.
  • Mateo, M. J., OCallaghan, D. J., Everard, C. D., Fagan, C. C., ODonnell, C. P., Castillo, M., Payne, F. A. 2009. Effect of milk fat concentration and gel firmness on syneresis during curd stirring in cheeses-making. International Dairy Journal, 19 264-268.
  • Mateo, M. J., OCallaghan, D. J., Everard, C. D., ODonnell, C. P., Fagan, C. C., Castillo, M., Payne, F. A. 2008. Prediction of syneresis indices using a LFV light backscatter sensor over a range of stirring speed and cutting intensity during cheese-making. Biosystems Engineering Research Review, 13, May 2008, 13-16.