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Giving Cheddar its Crumble

Vacuum for the right texture

Sliced in a sandwich, grated on top of pizza, melted in a creamy sauce, or as a simple snack: Cheese has been a staple and favorite food for thousands of years. Starting at the dairy farm, the cheese industry uses vacuum pumps from Busch in a variety of ways – including in some less expected processes in forming and packaging.

Cheesemaking is an exercise in patience. A “young” cheese can be produced in just a few hours, but many varieties require longer and more labor-intensive processes or extra maturing time to reach the taste and texture they are famed for. Vacuum can help speed up certain stages and reduce the physical workload for cheesemakers. And, in mass production, it is an essential part of getting cheese from dairy to supermarket shelf.

Falling into the cheddaring tower

Cheddar, a bacteria-ripened hard cheese originally created in England, has a unique production method in the cheese world. Once the milk has separated into curds and whey, the whey is drained off, leaving just the curds behind. Then the “cheddaring” process begins. This squeezes out excess whey and gives the cheddar its distinctively dense and crumbly texture. The process can be done manually, by stacking blocks of cheese on top of each other, or vacuum can be used. Under vacuum, the curds are conveyed through a pipe to the top of a 10-meter tall cheddaring tower. They are then dropped in, using gravity and their own weight to form a dense, cylindrical mass. The tower is also kept under constant vacuum. This draws out residual whey and air and maintains constant curd density. It also helps with precision when it comes to packagin – the steady vacuum means there is less weight variation in each cheese block.

Vacuum packaged for freshness

Once the cheddar has gone through the final stages of production and aged appropriately, it is put into its packaging. Most cheddar is vacuum packaged, sometimes with modified atmosphere. For cheese in blocks, pure vacuum packaging is suitable. The cheese is inserted between two layers of plastic foil, the air is completely removed, and the packaging is sealed. For sliced or pre-grated cheese, modified atmosphere packaging (MAP) is better, as vacuum alone can make individual pieces stick together. Instead, the packaging is put under vacuum to remove the ambient air, then a new gas mixture is inserted to replace it. Certain mixtures will allow the cheese to continue maturing inside the packaging, developing even more flavor as time goes on, while others will halt the process, simply keeping the cheese fresh until the moment of enjoyment arrives.
Why are so many cheeses round?

Although we rarely purchase them that way in the supermarket, many varieties of cheese start out as part of an enormous wheel. The shape is not just down to tradition; there are also more practical reasons. At first, it was most likely because of the shape of the storage vessel that was available: The earliest traces of cheese, dating back to over 7,000 years ago, were found in round pottery bowls. However, even as humans experimented with different container shapes, cheese has remained resolutely round for different reasons throughout its creation process. When making cheese, cheesemakers discovered that although rectangular molds save valuable space, they are not as robust. There is also an effect during the maturing stage. Unlike a circle, a square or rectangular shape has corners and edges, which create weak points where microbes can penetrate. This can lead to over-ripening and the cheese going off more quickly. And then there is one more practical reason when it comes to transport: Round objects roll, making it easier to transport a large and heavy cheese from one place to another without additional equipment!