Progress 10/01/01 to 09/30/07
Outputs
Control of syneresis is critical in order to control the moisture content of cheese, which has a tremendous impact on the quality attributes of cheese. Unfortunately, there are currently no technologies available for monitoring curd syneresis. Rather, syneresis is empirically controlled, all over the world, by processing for specific temperatures and times. A novel optical sensor technology that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat (note that curd moisture control requires control of milk coagulation, cutting time and syneresis) has been developed. 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.
Impacts
The technology makes use of 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. 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 efficienct 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 an engineering firm (ESEInc.) have expressed an interest in this technology for cheese manufacture. Two patent applications have been submitted on this sensor technology to control curd moisture content during syneresis in cheese making
Publications
- No publications reported this period
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Progress 01/01/06 to 12/31/06
Outputs
A novel optical sensor technology that is able to monitor both milk coagulation and curd syneresis in a stirred cheese vat has been developed. 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 ranging from 5-10% over the range of 50-90% curd moisture content. A backscatter array sensor that will have the ability to measure optical properties for a broad range of optically thick food products has been designed and is being fabricated.
Impacts
Cheese processing efficiency and product consistency could be improved if the coagulation process could be controlled accurately. In cheese manufacturing the current practice requires manual selection of coagulum cutting time based on subjective evaluation of curd texture. An optical sensor was developed to measure light backscatter during enzymatic coagulation. The sensor in combination with an algorithm to interpret the data has been shown to accurately predict cutting time and thus automate this step. The cutting time prediction technology has been commercially tested and is currently being used by three cheese plants. Our current research is focused on expanding the prediction technology for monitoring curd shrinkage during the cooking process. Commercial interest in controlling the coagulation process remains high as this step has a significant impact on product moisture content, quality, and processing efficiency. Cottage cheese and yogurt manufacturers have
also expressed an interest in using the technology. The intelligent transition sensor developed has a wide potential for application in the food industry as it will detect the transitions between optically dissimilar fluids.
Publications
- Castillo, M., Lucey, F. A., Wang, T., Payne, F. A. (2006). Effect of temperature and inoculum concentration on gel microstructure, permeability and syneresis kinetics. Cottage cheese-type gel. International Dairy Journal 16, 153-163.
- Castillo, M., Payne, F. A., Wang, T., Lucey, J. A. (2006). Effect of temperature and inoculum concentration on prediction of both gelation time and cutting time. Cottage cheese-type gel. International Dairy Journal 16, 147-152.
- Castillo, M., Lucey, J. A., Payne, F. A. (2006). The effect of temperature and inoculum concentration on rheological and light scatter properties of milk coagulated by a combination of bacterial fermentation and chymosin. Cottage cheese-type gels. International Dairy Journal 16, 131-146.
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Progress 01/01/05 to 12/31/05
Outputs
Prediction of gelation and cutting times in cottage cheese culture was tested. Light backscatter profile was used to explain a complex combination of casein micelle aggregation, curd firming and micelle demineralization. Increasing temperature or inoculum concentration resulted in faster network formation, which resulted in more viscous and less stiff gels. The second minimum of the backscatter profile second derivative and the rheological gelation time were highly correlated but not significantly different, suggesting that they both corresponded to the beginning of gel firming. A second generation calibration is proceeding with the use of quality measurements in the development of a calibration model. Research is continuing on the development of an intelligent transition sensor technology for use in the food industry to detect the interface between different products for automating valve actions. An embedded processor circuit was designed, fabricated, and tested. A
commercial test is being planned. A unique concept that combines ultrasonic concentration and angular light scatter technologies to measure the microbial concentration in water at very low concentrations was developed and is being tested. The system combines both ultrasonic concentration and angular light scatter for the detection of microorganisms at low concentration. Angular light scatter tests were conducted and showed that light intensity ratios were directly proportional to microbial concentrations.
Impacts
Cheese processing efficiency and product consistency could be improved if the coagulation process could be controlled accurately. In cheese manufacture the current practice requires manual selection of coagulum cutting time based on subjective evaluation of curd texture. An optical sensor was developed to measure light backscatter during enzymatic coagulation. The sensor in combination with an algorithm to interpret the data has been shown to accurately predict cutting time and thus automate this step. The cutting time prediction technology has been commercially tested and is currently being used by three cheese plants. Our currents research is focused on expanding the prediction technology for monitoring curd shrinkage during the cooking process. Commercial interest in controlling the coagulation process remains high as this step has a significant impact on product moisture content, quality and processing efficiency. Cottage cheese and yogurt manufacturers have also
expressed an interest in using the technology. The intelligent transition sensor developed has a wide potential for application in the food industry as it will detect the transitions between any to optically dissimilar fluids.
Publications
- Wang, T., Lucey, J. A., Castillo, M., Payne, F. A. 2005. Predicting cottage cheese cutting time using a light backscatter sensor. Milchwissenschaft 60, 164-167.
- Castillo, M., Gonzalez, R., Payne, F. A., Laencina, J., Lopez, M. B. 2005. Optical monitoring of milk coagulation and inline cutting time prediction in Murcian al Vino cheese. Applied Engineering in Agriculture 21 465-471.
- Jordan, M. J., Kevin, L. Goodner, Castillo, M., Laencina, J. (2005). Comparison of two HS-SPME fibers for the detection of volatile chemical concentration changes due to industrial processing. Journal of the Science of Food and Agricultural 85 1065-1071.
- Castillo, M., Payne, F. A., Lopez, M. B., Ferrandini, E., Laencina, J. 2005. Optical sensor technology for measuring whey fat concentration in cheese making. Journal of Food Engineering 71, 354-360.
- Castillo, M., Payne, F. A., Lopez, M. B., Ferrandini, E., Laencina, J. 2005. Preliminary evaluation of an optical method for modeling the dilution of fat globules in whey during syneresis of cheese curd. Applied Engineering in Agriculture v21(2) pp 265-269.
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Progress 01/01/04 to 12/31/04
Outputs
Prediction of gelation and cutting times in cottage cheese culture was tested. Light backscatter profile was used to explain a complex combination of casein micelle aggregation, curd firming and micelle demineralization. Increasing temperature or inoculum concentration resulted in faster network formation, which resulted in more viscous and less stiff gels. The second minimum of the backscatter profile second derivative and the rheological gelation time were highly correlated but not significantly different, suggesting that they both corresponded to the beginning of gel firming. Research is continuing on the development of an intelligent transition sensor technology for use in the food industry to detect the interface between different products for automating valve actions. An embedded processor circuit was designed and fabricated for development of an intelligent transition sensor technology. Programming is proceeding. A unique concept that combines ultrasonic
concentration and angular light scatter technologies to measure the microbial concentration in water at very low concentrations was developed and is being tested. The system combines both ultrasonic concentration and angular light scatter for the detection of microorganisms at low concentration. Angular light scatter tests were conducted and showed that light intensity ratios were directly proportional to microbial concentrations.
Impacts
The development of an optical technology for monitoring and control of the coagulation process in cheese making will promote moisture consistency in the final cheese product. Control of curd moisture content would reduce the damage to cheese during ripening and improve its final quality. Commercial interest in controlling the coagulation process remains high as this step has a significant impact on product moisture content, quality and processing efficiency. Cottage cheese and yogurt manufacturers have also expressed an interest in using the technology. Development of a technology for measuring microbial populations at low concentrations in clean water will have an impact on water treatment facilities, food processing plants, and possibly hospitals and pharmaceutical companies with a means to measure and monitor their water quality. The intelligent transition sensor technology is bases on the detection of changes in optical transmission or backscatter and will have
versatility of functioning for all fluid transfer in pipelines in food processing plants. It is unique in that it will not require calibration between fluids which is a current problem with existing technology.
Publications
- No publications reported this period
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Progress 01/01/03 to 12/31/03
Outputs
A unique fiber optic sensor design was used to measure light extinction of homogenized and raw cream from 0 to 50% milk fat concentrations at 35, 45 and 55C. Light extinction was related to milk fat concentration with non linear model and had a standard error of 0.28% for homogenized and 0.21% for raw milk fat. Whey fat concentration was measured by a dual fiber optic spectrometer (300-1100 nm) using a sampling cell designed to measure light sidescatter and/or transmission at different distances. Whey samples (0-0.9% fat) were analyzed. Normalized spectral sidescatter and transmission response versus whey fat concentration followed a power function, which encouraged to the development of an on-line fiber optic sensor to measure low concentrations of fat in cheese whey. Industrial whey samples were obtained at different times after coagulum cutting and normalized spectral sidescatter response versus whey fat concentration was measured. Results confirmed that dispersion
of fat into the whey during syneresis followed a first order kinetic, which could be useful for on line control of curd moisture content.
Impacts
Cheese processing efficiency and product consistency could be improved if the coagulation process could be controlled accurately. In cheese manufacture the current practice requires manual selection of coagulum cutting time based on subjective evaluation of curd texture. An optical sensor was developed to measure light backscatter during enzymatic coagulation. The sensor in combination with an algorithm to interpret the data has been shown to accurately predict cutting time and thus automate this step. The cutting time prediction technology has been commercially tested and is currently being used by three cheese plants. Our currents research is focused on expanding the technology for monitoring curd shrinkage during the cooking process. The moisture content of cheese could be standardized if a sensor was capable of monitoring whey release from the curd. Control of curd moisture content would reduce the damage to cheese during ripening and improve its final quality.
Concepts for monitoring syneresis in a vat are being developed and tested. Commercial interest in controlling the coagulation process remains high as this step has a significant impact on product moisture content, quality and processing efficiency. Cottage cheese and yogurt manufacturers have also expressed an interest in using the technology.
Publications
- Danao, M. C. and F. A. Payne. 2003. Determining product transitions in a liquid piping system using a transmission sensor. Trans. of the ASAE 46(2):415-421.
- Castillo, M., Payne, F.A., Hicks, C.L., Laencina, J., Lopez, M.B. (2003). Modelling casein aggregation and curd firming in goats' milk from backscatter of infrared light. J. Dairy Res. 70 335 348.
- Castillo, M., Payne, F.A., Hicks, C.L., Laencina, J., Lopez, M.B. (2003). Effect of protein and temperature on cutting time prediction in goats' milk using an optical reflectance sensor. J. Dairy Res. 70 205 215.
- Qing, D. K., M. P. Menguc, F. Payne, M.G. Danao, 2003. Fluorescence correlation spectroscopy for detection of trace amount of biological agents, Applied Optics, Vol. 42, No:16, pp: 2987-2994.
- Castillo, M., Payne, F.A., Gonzalez, R., Lopez, M.B., Laencina, J. (2003). Determinacion on-line del tiempo de coagulacion en leche de cabra mediante dispersion de radiacion NIR. Anales de Veterinaria, 19: 23-36.
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Progress 01/01/02 to 12/31/02
Outputs
A fiber optic sensor was reported to measure fat in milk and cream based on attenuation of light at 470 nm. The objectives of this experiment were to confirm the linearity of the signal ratio with fat content using a prototype sensor and to determine the error associated with the different batches of cream collected from a dairy plant using non-homogenized milk and at two different fat content ranges, low (2 to 7%) and high (35 to 55%). A linear relationship between fat content and the signal ratio for both low and high fat tests was confirmed. However, a significant batch-to-batch variation was observed suggesting sensor, electronic, or product changes between batches. If the batch-to-batch variation is ignored, the sensor had a CV of 1.75 and 8.83% for the low fat and high fat tests respectively. Re-designing the sensor to eliminate scratches to the distal tip, placing all the electronics on a shielded printed circuit board, and revising the test protocol to reduce
product influences on the results may reduce the CV.
Impacts
This sensor technology capitalizes on the miniature size of optical fibers to measure the light extinction of foods containing a high concentration of light scattering particles. It is expected that this technology will provide the food industry with a precise measurement tool at a very economical cost.
Publications
- Crofcheck, C. L., F. A. Payne, C. L. Hicks, M. P. Menguc, and S. E. Nokes. 2002. Fiber optic sensor response to high levels of fat in cream. Trans. ASAE 45(1):171-178.
- O'Callaghan D.J., O'Donnell C.P. and Payne F.A. 2002. Review of systems for monitoring curd setting during cheese making. International Journal of Dairy Tech., 55(2) 65-74.
- Crofcheck, C.L., F.A. Payne, and Menguc, M.P. 2002. Characterization of milk properties using a radiative transfer model, Applied Optics, 41(10):2028.
- Crofcheck, C. L., Payne, F. A., Hicks, C. L., Menguc, M. P., and Nokes, S.E. 2002. Fiber optic sensor response to high levels of fat in cream. Trans. ASAE 45(1):171-176.
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