A new method for the production of low-fat Cheddar cheese.

Our objective was to develop an alternative process to produce low-fat Cheddar cheese (LFCC) by combining reduced-fat Cheddar cheese (RFCC) made by a fat-removal process with micellar casein concentrate (MCC) to try to achieve the texture and flavor characteristics of full-fat Cheddar cheese (FFCC). The production of LFCC was replicated 3 times. The MCC was produced by ultrafiltration of skim milk, followed by 3 stages of microfiltration, and the final MCC was spray dried. The LFCC was formulated to achieve 6% fat, 28% protein, and 1.2% salt by a combination of RFCC, MCC powder, salt, and water. The 6% fat target was selected to comply with the FDA standard for a low-fat label claim. The pH of the LFCC mixture was adjusted to 5.3 by lactic acid. Rennet was added to the LFCC mixture, followed by pressing and packaging. Chemical and sensory data were analyzed by ANOVA using the Proc GLM of SAS to determine if any differences in chemical composition and sensory properties were present among different cheeses. Descriptive sensory scores were used to construct a principal component analysis biplot to visualize flavor profile differences among cheeses. The LFCC had 83% less fat, 32% less sodium, and higher protein and moisture content than FFCC. When the cheese texture was evaluated in the context of a filled-gel model consisting of matrix and filler (100% minus percentage of matrix) the LFCC had lower filler volume than FFCC, yet the LFCC had a softer texture than FFCC. The LFCC contained some of the original FFCC cheese matrix that had been disrupted by the fat-removal process, and this original FFCC matrix was embedded in the new LFCC matrix formed by the action of rennet on casein from the continuous phase of hydrated MCC. Thus, the texture of the LFCC was desirable and was softer than the FFCC it was made from, whereas commercial RFCC (50 and 75% fat reduction) were firmer than the FFCC. The sulfur flavor in LFCC was closer to FFCC than commercial RFCC. The LFCC had bitter and grape-tortilla off-flavors that came from the dried MCC ingredient. The commercial RFCC and LFCC made in this study were missing the typical aged Cheddar character (catty, nutty, fruity, brothy, milk fat flavors) found in aged FFCC. Future work to improve the flavor of LFCC made by the process described in this study should include the addition of a flavoring ingredient (e.g., enzyme-modified cheese) to enhance the aged Cheddar flavors and mask undesirable flavors.