Processed Cheese Manufacturing: It’s Not All CHEESE!

Have you ever thought about how processed cheese is made? Is it all about converting milk to curds? For Walter Gelber, who tried to find a way to ease its shipping to warmer climates, processing Swiss cheese changed the game in a way that nowadays, in the U.S. alone, billions of pounds of processed cheese are consumed each year!

Unlike natural cheese, processed cheese is not made directly from milk. In fact, natural cheese is one of the main ingredients of the processed cheese-producing blend.

The basic process? Choose a base cheese and remove rinds, then grind them into smaller pieces. Now, it’s time to add water, emulsifiers and other additives and melt them together at medium heat, then agitate it constantly to prevent burning. Once the cheese paste gets ready, pour it into a suitable container, plastic wrap or bottle and let them cool until they form.

In this article, we’ll dive into the processed cheese world—whether basic materials, step-by-step cheese production, packaging, or tips related to QC. Follow us to figure out how magnificent it’s manufactured!

What Is Processed Cheese Made of? (Key Materials of Processed Cheese)

If you’re curious to know, what exactly is processed cheese made of, we’re considering you with elemental ingredients which professionally manufacture various types of cheese. According to BonAppetit, processed cheese is real cheese cut with other, non-cheese ingredients.

1. Base Cheeses

The quality and other crucial components of natural cheese affect the final result. Basically, the combination of several types of them is the best choice to reach the ideal flavor and texture.

2. Cheese Emulsification

emulsifying salts are also known as “melting salts” or “chelating salts”, to separate proteins and lipids and attain a homogeneous mixture; these salts function as glue to prepare a soft, uniform structure while helping melt-process and form the oil-in-water emulsion.

3. Water

It’s mainly used to balance the moisture of blending mixture and liquefy dry ingredients. The most important point about adding water is the combination ratio between oil and water base to achieve such a uniform and well-smoothed paste.

4. Fat

Normally, it comes from base cheese, cream, milk powder, or butter to improve the formation and dairy-based flavor. Cheese fat improves stability, smoothness, and thickness, while it tastes consistently cheesy!

5. Protein Sources

Adding whey (whether powder or liquid), caseinate, or skimmed milk powder to develop the cheese’s protein base and denaturation process is common in cheese-making. If you’re looking for a smooth, while tangy and sharp-tasted cheese, increase protein!

Additional Ingredients in a Complex Processed Cheese

There are several additional ingredients in processed cheese that improve its texture, flavor, or color, including:

• Stabilizers: Materials like carrageenan or guar gum, aid to customize flavors, ease cutting process, and prevent separation and improve spreadability and texture.
• Preservatives: usage of sorbic acid or so is often because of expanding the shelf life and texture consistency during consumption.
• Colorings: to achieve desired appearance in cheese, some natural or artificial colorings might be used. That deep orange tone of Cheddar or Colby, simply stems from natural annatto color!
• Seasoning: at this point, to enhance the taste and make the processed cheese more joyful, herbs, dried veggies, spices, dried meat or bacon, and any artificial flavor are going to be used!

Ingredient	Ratio (%)	Description
Base Cheeses	50-60%	Combination of natural cheeses for flavor and texture.
Cheese Emulsification	2-3%	Emulsifying salts to create a smooth, uniform structure.
Water	10-20%	Adjusts moisture and blends ingredients.
Fat	10-25%	From cheese, cream, milk powder, or butter for smoothness.
Protein Sources	5-10%	Whey, caseinate, or skimmed milk powder for texture.
Stabilizers	0.5-1%	Carrageenan, guar gum to improve texture and spreadability.
Preservatives	0.1-0.5%	Sorbic acid or similar to extend shelf life.
Colorings	0.01-0.1%	Natural or artificial, like annatto for color.
Seasoning	1-5%	Herbs, spices, dried veggies, or artificial flavors.

How to Prepare Processed Cheese from Scratch?

Now, we’ve got to the most technical part. Here are five major steps to manufacture processed cheese. It may not seem simple, but we all know about the final result, exactly when it comes to watching how the cheese melts in your cheese toastie!

As mentioned in an article published by ScienceDirect, Processed cheese is made by heating natural cheese of different types, ages, and maturity, that is simple! But here are the steps:

1. Preparation and Pre-Processing Step

Firstly, we should choose such appropriate, natural cheeses that include various ranges of maturity levels. The choice of cheese can be based on our craved final product, younger cheese is better for creamier texture in light-flavored cheese and aged cheese perfectly empowers the sharp-flavored cheese.

Trimming: Right after you choose the natural cheese, it’s time to wash it and get rid of rinds or mold

Grinding: To achieve a consistent and uniform texture, cut the trimmed cheese blocks into small pieces, in large size factories it’s called quartering (because of cutting it into four pieces)

2. Mixing with Emulsifiers and Additional Ingredients

Once the cheese is trimmed and ground, the next step includes blending it with emulsifying salts, water and other added elements, such as cream or fat, colorings, flavorings, and stabilizers.

Pro Tips:

• Beyond The Smoothness: This step causes the cheese pieces to transform to such a uniform and homogeneous mixture by activating the salts.
• Suitable Mixer: High-shear mixers play a crucial role in this part of manufacturing, the more powerful they are, the smoother the oil-in-water texture gets!
• Importance of temperature control with SSHE: scraped surface heat exchanger works as a tool to control cooling and heating during blending process, especially for gluey textures like cheese; it doesn’t let them get thick and improves uniformity and consistency by playing with temperature!

3. Cooking and Melting Process

To complete the transformation and aid salts rebuild cheese structure, the blending should go into a heating and folding process till it gets liquified. This mixture is warmed to a specific temperature rate (normally between 70°C to 85°C) for three central reasons:

Melt processing of the cheese: Playing with temperature during 5-10 min parts creates that desirable uniform and homogeneous texture.

To activate emulsifying salts: ES works better in higher temperatures and this step is going to help crash protein and lipid structure, as the tempering part goes well!

Hygienic concerns: If the heating process goes to the right place, it’ll keep the microbiological safety by destroying the unhealthy microorganisms!

Agitation: While the mixture is heating, it should be constantly blended, this agitation helps to make sure that every part of the mixture gets the same temperature and avoids scorching, while preventing the shaping of the lumps and creating the smoothest texture ever

4. Formation Process

After cooking and blending parts, it’s time to pour the cheese mixture into each desirable type. Here are the most popular formats and their crucial properties, which must be considered.

Cheese blocks and slices: mainly are shaped by pouring the mixture into a stainless-steel container, after a cooling process which needs to be slowly, they’re cut into pieces.

Spreads and tubes: the melted paste is poured into a bottle or a plastic tube for creamy and soft products that should be cooled as fast as possible by passing a cold tunnel after getting packed to keep that magical spreading style!

Wrapped slices: in this type of formation, hot cheese mixture is added into a piece of plastic wrap and pressed evenly to get cool in a bath of ice water. Finally, it is cut into pieces to make separated cheese slices!

5. Cooling and Storage Conditions

As we slightly mentioned before, after formation, the cheese paste needs cold processing to get shaped, there are two major techniques that are used based on type of cheese:

Spread products: it is necessary to cool the mixture as fast as possible, this process is going to balance the protein structure of cheese, while keeping smoothness and softness too!

Cheese blocks: they may be sliced or grated, the cooling process should go slowly to achieve such thick and easy-to-slice by remaining a strong protein net!

Molding: after the cooling process, it can be poured into molds to create such magnificent blocks of cheese!

6. Final step: Cheese Packaging & Labeling

Vacuum-sealed plastic or semi-rigid film is the most used cheese packaging, which provides manufacturers with remaining flavor and moisture, while preventing microorganism’s growth. this method is fitted for block, sliced and chunk processed cheese. According to Cheese Guidance, the right packaging can even Prevent consumer waste on the cheese.

Shredded cheese: Stand-up pouches or zipper bags are suitable for grated or diced cheese, this procedure avoids entering oxygen or causing any spoilage or physical harm. Also, they can be shaped as many sizes that manufacturers desire!

Cheese spreads: For spreadable and soft cheeses, flexible barrier containers or bottles due to their ability to keep high-moisture quality and fresh-flavored taste away from any molding or microbial issues are the most common option in cheese packaging!

Light Warning: Labeling Properties!

Surely, most of us didn’t pay attention to labels, and following information, there are multiple options for labeling:

1. Firstly, it should be included with the cheese’s total weight on the front side of the packaging. (mention if its bottle weight is added or not)
2. Secondly, there is a nutrition fact panel which indicates key components as energy content (calories, protein, salt, fat and carbohydrates), micronutrients, daily recommended serving size, etc.
3. Lastly, the ingredients statement must be listed in this suggested order; most used ingredients like milk or base cheese type, emulsifiers, fat, protein, chemical items, and risky ingredients cause allergic reactions or against religious thoughts (as Halal foods)

Batch vs. Continuous Process in Cheese Production

Two different ways of processing cheese: which one is perfect for processed cheese? Batch processing refers to a certain amount of cheese made in a single row of production, in fact, once a process is completed the next batch begins, while in a continuous manufacturing process we face a non-ending process that goes without a specific beginning or endpoint.

Batch process is technically slower than continuous and can be profitable for limited processes and changing flavors, meanwhile continuous processes are able to manufacture huge amounts of cheese in an ongoing process and obviously include higher production output in less timing, so they are possibly perfect for industrial cheese makers.

Cheese Quality Control Considerations

If you thought our work was done after cheese packaging, you’re completely wrong! You must always be sharp on every probable spoilage risk during the cheese-making process. It means there are several parameters that should be measured continuously:

• Microbiological aspects: samples of the final result must be tested to make sure there are no threatening microorganisms for safe consumption.
• Sensory evaluation: this object evaluates how much the texture and flavor are near what they are supposed to be. A number of tools may be used to test how consistent are elasticity or meltability!
• pH level: it helps to check the structure, in fact, it’s all about the acidity level! The perfect pH level for Spreads is between 5.6 and 5.9, while for cheese blocks and slices goes at 5.4-5.6, the higher it gets, the weaker the texture becomes!
• Moisture and fat factors: fat improves creaminess and uniformity, consistency range for fat is between 20-30%. Humidity percentage keeps the softness of cheese, surely if it goes too high it causes a runny vibe!

Parameter	Description	Ideal Range
Microbiological Aspects	Ensures no harmful microorganisms are present for safe consumption.	Must be free of pathogens.
Sensory Evaluation	Assesses texture and flavor to match expected quality. Includes elasticity and meltability tests.	Should meet standard texture and taste profiles.
pH Level	Determines acidity, affecting structure and texture.	Spreads: 5.6 – 5.9 Blocks & Slices: 5.4 – 5.6
Moisture Content	Influences cheese softness; excess moisture leads to a runny texture.	Controlled to maintain firmness.
Fat Content	Enhances creaminess and uniformity.	20 – 30%

Processed Cheese Testing Methods

Rheological analysis basically checks if the cheese is too runny or thick in the melting process to achieve the perfect flow result on the consumer’s mouth! (Does it melt properly?)

Stability evaluations are here to aid us making sure it’ll survive in the fridge or warm rooms without changing its taste and appearance! (Does it stay the same under different temperatures?)

Cheese Pasteurization & Homogenization Processes

To make the cheese pasteurized, it should get heated till 129–149°C to kill all harmful bacteria such as E. coli, Salmonella or so (Source: Diary Processing Handbook). This process can be useful to reduce the risk of food-related illnesses, provide consumers access easily at most supermarkets and leave a longer shelf life, as we need nowadays.

To make specific cheese such as blue cheese or soft and white cheeses like cream cheese, this process may commonly use to homogenize milk that collocate lipid and protein together which shapes the spreadable and smooth cheese texture.

What Are the Best Conditions to Store Processed Cheese?

One of the most important components of processed cheese is the way it’s created to stay healthy longer than natural cheese, right due to its homogenized aspect and added preservatives. Therefore, storing cheese between 2°C to 10°C avoids the growth of harmful bacteria and moderates stable smoothness, while freezing or keeping it at a warmer temperature for too long may change the proper cheese texture to such melted bland cheese.

Unlike natural cheese, processed cheese normally has a low humidity (between 40-60%), also due to its specialized packaging such as plastic or foil wrapped and vacuum-sealed, they prevent molding and drying out, so always keep them away from oxygen!

Common Challenges in Manufacturing Processed Cheese and Troubleshooting Ideas

As with all manufacturing processes, this kind of production creates several dilemmas, sometimes the texture turns too thick or gummy, the flavor vibes spoiled, or the emulsifiers don’t work properly. Here are some of these examples, including their solutions.

1. Cheese Emulsion’s Issues

Sometimes, the cheese mixture doesn’t get uniform and smooth, while water and oil phases are quite separated; this means emulsifying salts’ functions failed due to using too little amount or the wrong type of them instead. Setting the ES level and adding the right type of it to the base can be helpful in solving the problem.

Moreover, if the temperature goes too high or too low, it may cause leaking out of cheese’s fat or not activate the salts entirely. At this point, using such an appropriate mixer or heat exchanger will change the game!

2. Texture Defects

Most of the texture problems normally come from wrong base cheese choices, they may be too soft and creamy or such hard cheese as a rock, also if the grinding step isn’t complete the final result will be grainy and not smooth at all!

So, what should we do to prevent such issues? Firstly, choose the right cheese, based on your purpose, then grind them to smaller pieces or grate them, after that check pH level and adjust salts, temperature of mixer and agitation speed too!

3. Flavor Troubles

Does the cheese paste taste weird?! Sour, bitter or bland, what’s the matter? It may stem from an uneven combination of aged and fresh base cheese, high-temperature and risk of burning, or using too much preservatives or flavorings.

Therefore, balance the cheese base mixture to avoid a sharp-flavored taste, be careful about the freshness of sorbic acid and other chemical ingredients, also stirring continuously, and stick to the perfect temperature (70-85°C).

Latest Innovation and Industry Trends in Cheese Manufacturing

Recently, manufacturers have found that by reducing sodium and other additives or using calcium as a good replacement, processed cheese may convert to such healthier options to buy compared to high-fat natural cheese.

Moreover, health-conscious aspects caused by using natural emulsifiers that come from plant, animal, or microbial sources, such as lecithin, gellan gum, and xanthan gum, improve stability, smoothness, or moisture.

Sustainable and Eco-Friendly Processed Cheese?!

To decrease your cheesy footprint, find processed cheese which are made from alternative base cheese sources like sheep, goat, or buffalo, they cause fewer environmental impacts, in comparison to cow’s products.

Nowadays, eco-friendly brands utilize sustainable packaging and energy-efficient and automatic machines to reduce their carbon dioxide footprint!

Conclusion

There we are; manufacturing processed cheese is a glamorous complex; from natural cheese to quartering, mixing with water and playing such gluey role of emulsifying salts, and from stirring and heating patiently to cooling rapidly, each stage is essentially a game-changer to create such uniform, flavorful result that we are looking for. The more effectively you follow this journey, the easier the quality control step will go in the manufacturing process.

FAQs

1. Can I make processed cheese at home?

Of course, mix shredded cheddar cheese with a little water and let them melt in low-heat temperature, then stir it constantly to get such a uniform texture, finally pour it into a container or plastic wrap. Surely, it’s not as perfect as a factory-made one, but it’s homemade and delicious!

2. Is it necessary to add those chemical salts or flavors?

To achieve that smooth and creamy texture of blending such oily ingredients like cheese with water, you must add emulsifying salts to make it possible, also some of these artificial flavorings improve stability and shelf-life.

3. How should I store processed cheese to stay fresh?

The fridge is the best place to keep your cheese fresh and moist enough. Be careful about the temperature (4–8°C) and humidity (70–85%), also if it’s shredded, make sure that there is no way for oxygen and for blocks or slices, wrap them in plastic or foil to prevent fridge smell vibes!