Progress 01/15/05 to 01/14/09
Outputs
OUTPUTS: The ultimate goal of this research project was to develop a syneresis sensor technology capable of controlling curd moisture content. To date all the proposed technologies have been evaluated. Results allowed us to develop an optical sensor technology that has the potential to provide control over milk gelation, and curd syneresis as well as prediction of cutting time, curd yield and whey fat loses in a stirred cheese vat using just a single sensor. This technology offers the potential for improving curd moisture control for high and low moisture cheeses. Thus, the main goal of the proposal has been fully and successfully accomplished. A secondary objective of the research project was to study the correlations between the optical parameters measured during coagulation and syneresis and to explore the potential for combined monitoring of coagulation and syneresis. Our results clearly demonstrate that several coagulation parameters obtained from the LFV sensor are significant predictors of curd moisture content during syneresis. Using a single sensor, the LFV syneresis sensor technology has the potential to provide milk coagulation, cutting time and curd moisture content control during syneresis. Thus, the secondary objective has also been accomplished. Refinement of this technology is progressing thanks to a renewal project initiated at the beginning of 2009, which will allow validation of the ability of the technology to control moisture content in cheese production. DEGREE OF ACCOMPLISHMENT FOR SPECIFIC GOALS Objective #1. Set up of a Lab. Sys. for testing syneresis sensors. Fully accomplished. Objective #2. Investigate light backscatter syneresis sensor. Fully accomplished. Objective #3. Investigate light extinction and transmission syneresis sensors. Fully accomplished. Objective #4. Develop the syneresis prediction algorithms. Fully accomplished. 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 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). A number of invited conferences/seminar has been delivered to difference audiences at the USDA director's meeting, IDF, 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). PARTICIPANTS: Nothing significant to report during this reporting period. TARGET AUDIENCES: Nothing significant to report during this reporting period. 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 has been developed (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 offer 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., 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. In press.
- 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. In press.
- 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. In press.
- 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.
- Everard, C. D., Fagan, C. C., ODonnell, C. P., OCallaghan, D. J., Castillo, M., Payne, F. A. 2007. Computer vision and colour measurement techniques for inline monitoring of cheese curd syneresis. Journal of Dairy Science. 90, 3162-3170.
- Payne, F. A., Castillo M. 2007. Light backscatter sensor applications in milk coagulation. In: Encyclopedia of Agricultural, Food, and Biological Engineering. Vol. 1, pp. 1-5. Heldman, D., Ed. Taylor & Francis Group, Boca Raton. ISBN: 978-0-8247-0937-2.
- 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. In press.
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Progress 01/15/07 to 01/14/08
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 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
- Fagan, C. C., Castillo, M., Payne, F. A., ODonnell, C. P., Leedy, M., OCallaghan, D. J. 2007. Novel on-line sensor technology for continuous monitoring of milk coagulation and whey separation in cheesemaking. Journal of Agricultural and Food Chemistry, 55 8836-8844.
- Fagan, C. C., Castillo, M., Payne, F. A., ODonnell, C. P., OCallaghan, D. J. 2008. Effect of Cutting Time, Temperature and Calcium on Curd Moisture, Whey Fat Loses and Curd Yield by Response Surface Methodology. Journal of Dairy Science. In press.
- Everard, C. D., OCallaghan, D. J., Fagan, C. C., ODonnell, C. P., Castillo, M., Payne, F. A. 2007. Computer vision and color measurement techniques for inline monitoring of cheese curd syneresis. Journal of Dairy Science. 90, 3162-3170.
- Fagan, C. C., Leedy., M., Castillo, M., Payne, F. A., ODonnell, C. P., OCallaghan, D. J. 2007. Development of a light scatter sensor technology for on-line monitoring of milk coagulation and whey separation. Journal of Food Engineering. 83, 61-67.
- Fagan, C. C., C.-J. Du, C.P. ODonnell, M. Castillo, C. D. Everard, D.J. OCallaghan, F.A. Payne 2008. Application Of Image Texture Analysis For Online Determination Of Curd Moisture And Whey Solids In A Laboratory Scale Stirred Cheese Vat. Journal of Food Science. Submitted.
- Everard, C. D., OCallaghan, D. J., Mateo, M. J., ODonnell, C. P., Castillo, M., Payne, F. A. 2008. Effects of cutting intensity and stirring speed on syneresis and curd losses during cheese manufacture. Journal of Dairy Science. Submitted.
- Fagan, C. C., Castillo, M., ODonnell, C. P., OCallaghan, D. J., Payne, F. A. 2008. On-line prediction of cheese making indices using backscatter of near infrared light. International Dairy Journal, 18 120-128.
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Progress 01/15/06 to 01/15/07
Outputs
A unique large field of view optical sensor was designed, manufactured and a control test conducted. The sensor provides information about gel assembly and curd shrinkage kinetics required for curd moisture control. 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 was predicted with a SEP ranging from 5 to 10% over the range of 50 to 90% curd moisture content.
Impacts
This technology developed 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 have expressed an interest in this technology for cheese manufacture. Recently, the Intellectual Property Development Committee has decided to pursue appropriate protection of this novel technology to control curd moisture content during syneresis in cheese making. 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.
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 01/15/05 to 01/14/06
Outputs
A laboratory system with a seven-liter, temperature-controlled cheese vat was set up to test different syneresis sensors for monitoring both milk coagulation and syneresis. A consistent cutting and stirring system was developed to reproduce industrial cheese making conditions. A fiber optic backscatter sensor and a large field of view (LFV) light backscatter sensor were compared for simultaneous monitoring milk coagulation and gel syneresis under different coagulation conditions (temperature, calcium chloride concentration) and cutting times. A three-factor factorial, central composite rotatable design with two star points (alpha = 1.682) and six replicates of the central point was used. The first replication of the experiment (20 trials) was run to select the most suitable range for the experimental factors. After selection of the adequate levels for the experimental factors, the experiment was randomly replicated three more times (60 trials). This design allows for
the estimation of curvature and hence provides levels at which the independent variables will minimize or maximize a dependent variable (curd moisture content, curd yield, whey fat concentration, etc.). Preliminary results showed that the LFV sensor responded in a similar manner to the backscatter sensor during milk coagulation and with a much lower degree of scatter than the backscatter sensor (or the light extinction sensor) during syneresis. The LFV sensor signal increased sigmoidally during coagulation by 30%. After cutting, the signal of the LFV sensor was found to decrease logarithmically between 25% and 61%. It was also observed that this decreasing response during syneresis increased with increasing temperatures, suggesting that the LFV sensor might be sensitive to the changes in syneresis kinetics with temperature. Equations were developed for the prediction of the whey fat losses, the curd moisture content and yield. It was found that rheological properties of the curd at
cutting are dominant factors determining whey fat losses. Curd moisture content and yield were both predicted using one LFV parameter representing milk coagulation reactions (tmax) and a second LFV parameter representing the syneresis kinetics (DDS). The results of this study suggest a potential application for the LFV sensor for the monitoring of both coagulation and syneresis during cheese manufacture that could allow improving cheese making process control.
Impacts
Syneresis is one of the most significant steps of cheese manufacturing. 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 successful syneresis control technology would lead to improved consistency in curd moisture content, concentration of minerals and lactose and pH of curd before ripening. This will modulate the curing biochemical reactions allowing a better control of this operation, which will result not only in a decrease of food safety risks and economical impact due to cheese defects but also in improvement of the final cheese quality. Successful development of this sensor technology will have a large impact on cheese manufacturing worldwide in terms of production efficiency and product quality and consistency.
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.
- 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.
- Castillo, M. 2005. Cutting time prediction methods in cheese making. In: Encyclopedia of Agricultural, Food, and Biological Engineering. Dennis Heldman (Editor). Marcel Dekker, Inc. New York. ISBN: 0-8247-4266-4. Peer-reviewed digital encyclopedia.
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