CA3138132A1

CA3138132A1 - Novel modular universal cheese making machine and method for making cheese with it

Info

Publication number: CA3138132A1
Application number: CA3138132A
Authority: CA
Inventors: Peter Dobreff; William Little
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-11-08
Filing date: 2021-11-08
Publication date: 2023-05-08

Abstract

This invention relates to milk pasteurizing machines, cheese curds making machines, cheese making machines, cheese molding machines, cheese cutting machines and methods for manufacturing of different kinds of cheese using these machines. More specifically the machine is a Novel Modular Universal Cheese making, molding and cutting machine, which can transform within its several modules raw milk to curds and then to any kind of the most common cheeses shaped to a desired form and ready for maturing or sale. Further, the invention is a universal cheese curds making machine, cheese making machine and cheese molding machine, which can be mounted either in a stationary position in a building, or in a standard 40 ft. high cube shipping container to create a mobile (transportable) cheese plant.

Description

DESCRIPTION OF THE INVENTION
NOVEL MODULAR UNIVERSAL
CHEESE MAKING MACHINE AND METHOD
FOR MAKING CHEESE WITH IT
SUMMARY
This invention relates to milk pasteurizing machines, cheese curds making machines, cheese making machines, cheese molding machines, cheese cutting machines and methods for manufacturing of different kinds of cheese using these machines. More specifically the Machine is a Novel Modular Universal Cheese making, molding and cutting machine, which can transform within its several modules raw milk to curds and then to any kind of the most common cheeses shaped to desired form and ready for maturing or sale.
Further, the invention is a universal cheese curds making machine, cheese making machine and cheese molding machine, which can be mounted either in a stationary position in a building, or in a standard 40 ft. high cube shipping container to create a mobile (transportable) cheese plant.
The Art of Cheese making was developed thousands of years ago in parallel with the domestication of milk producing animals. Today, there are thousands of styles and kinds of cheese. Almost every country in the world and the regions within a country have their own kinds of cheeses. In some countries the recipes of regional cheeses are guarded by country and local laws.
Cheese is a milk product. Production of cheese always includes the production of cheese curds from the milk, separation of cheese curds from the whey, pressing and shaping of cheese curds into molds to obtain the desired transportable shape and the stage of the aging of the cheese.
During the process salt is applied to the cheese at different stages of the process, depending on the cheese making recipe.
This invention provides the design of a Novel Universal Modular Cheese Making Machine which will produce within its modules any kind of the world's most popular cheeses to the point when the cheese is ready for aging. Two of the modules also provide a means for the production of extruded cheese products, while a separate module provides CIP/COP
capabilities. This invention also provides a Method of how to operate the Cheese machine to produce the desirable result ¨ tasty cheese.
Date recue /Date received 2021-11-08 Introduction Note: For simplicity hereafter we will use the abbreviation "Cheese Machine"
instead of Novel Modular Universal Cheese Making Machine.
Note: All designs follow the strict guidelines and requirements of numerous Canadian and USA
Food Safety Authorities and laws, as well as design guidelines of 3-A and EHEDG Standard Organizations.
Note: All materials and equipment used in the design of the Cheese Machine are food grade.
Specifically the bodies of the modules, main construction elements, along with the fittings, and accessories are made of stainless steel. All bearings, gaskets, motor units, sensors and electric .. and electronic control panels are made with food grade materials and approved for dairy manufacturing environments.
Background of the Invention Cheese is one of the world's most popular foods. All persons masterful in the art of cheese making know that it is produced in several steps: turning milk into cheese curds, shaping of the cheeses curds, and aging of the cheese product. The first cheese curds were made by mixing the contents of the stomach of a fresh killed suckling lamb with sheep's milk.
Soon after humans started mass producing cheese. The first cheeses were made (and in many cases are still produced today) by artisan cheese makers using simple vats and primitive tools.
With the growth of cheese demand, it became obvious that a process and methods for cheese-making had to be studied in depth and production had to be mechanized.
Today, there are thousands of patents related to cheese making. There are two groups of patents related to cheese making and the cheese industry.
The First group deals with the chemical and biochemical transformation of milk to cheese curds and cheese.
The Second group of patents deals with mechanical means and methods for making cheese curds and cheese.
The invention relates to this Second group.
Cheese curds making machines and cheese curds cutting knives are produced in various shapes and sizes.
Unlike in the patented designs, the artisan cheese maker uses a non-patented (often wooden) simple mechanical paddle to agitate the milk and the rennet. He then cuts the cheese curds with a non-patented simple knife by hand. He presses his cheese in a simple press or by adding a weight. Despite this simplicity, the artisan cheese maker often produces tastier and more valuable Date recue /Date received 2021-11-08 cheese products than complicated patented machines of famous food processing equipment companies.
In other words ¨ the patented cheese machines designs are becoming more and more complicated, without adding value for the money to the cheese makers and the consumers of the cheese.
However, the Artisan Cheese makers also has a problem¨ manufacturing process is labor intensive and not always cost effective. Thus, their cheeses are more expensive and they have difficulty competing against mechanically made cheeses. In addition and in order to satisfy growing demand for cheese, the Artisan cheese maker must mechanize the manufacturing process, without compromising the quality of the final product.
This NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE AND METHOD
provides a simple and cost effective solution to many of the problems encountered by small, medium and advanced-medium cheese makers, without affecting the quality of the cheese product.
Block Diagram, Analysis and Optimization During the process of designing this Cheese Machine, we analyzed the designs of existing cheese machines and apparatuses.
We came to the conclusion that the most advantageous design is one based on a modular principle.
We optimized the number of modules of the Cheese Machine that are required for cheese making.
We reduced the number of the modules, without reducing the number of cheese products that our Cheese Machine can make. The Cheese machine is a universal machine that can make almost any kind of cheese known to mankind.
We also wanted to design a Cheese Machine to be easily movable, if required.
We invented a mobile Cheese Machine which can be used either as a stationary machine ¨ in an existing building, or it can be used as a mobile cheese plant, when mounted in 40 foot standard high-cube shipping container, which can be transported everywhere.
Several Block diagrams and a General drawing give a better understanding of the organization of the modules of the Cheese Machine:
- FIG. 1 Block diagram of the normal processing route when manufacturing traditional soft cheeses, semi-hard cheeses, hard cheeses and brine aged cheeses - FIG.2 Block diagram of the normal processing path for making pasta filata cheeses and pasta filata cheese extrusions.
Date recue /Date received 2021-11-08 Note: For production of just pasta filata cheese, we do not require Module 400 and Module 500.
Only Module 200 ¨ the Cheese processing vat is required.
- FIG 3 Block diagram of the range of use of Module 600 ¨ Combined CIP and COP unit.
- FIG 4 General Drawing of the Cheese Machine when used in a Mobile Container Cheese Making plant.
THE CHEESE MACHINE consists of following modules:
Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7) The first step of any cheese making process is to make cheese curds. To the pasteurized milk are added bacterial starter cultures (in some cases funguses), rennet and after a specific time the result is a cheese curds mass. Entrapped in the cheese curds mass is a liquid called whey. The cheese curd mass is cut in order to expel the whey from the cheese curds, which are small pieces with a complex structure of coagulated milk proteins and milk fats.
Cheese curds making machines and cheese curds cutting knives come in all kinds of shapes and sizes, like in U58820224, U55985347, U54989504, U53541687, DE000002538530C2, W02017085211A1, US20140096688A1, U52009238, US3019527, US3019527, US2917827, U54938424, U55052290, U52008/0047442A1, US 2016/0316776 Al, U51695761, EP1084609A1, EP2418934B1, U52014/0096688A1.
In Module 100 ¨ Batch Pasteurizer and Cheese Vat, the raw milk is pasteurized, microbial cultures and rennet are introduced, curds are made, then cut and matured. The module allows for washing of the curds as some washed rind cheeses require (Gouda for example).
It is a CIP
enabled unit.
One of the novelties in this Module 100 are the cheese curds cutting knives.
They are of a unique yet simple design and do not require any welding to the frame of the machine. This will allow them to be changed when required. Further, the blades are positioned in a such a way, that they also agitate the cheese curds, so no additional agitation paddles are required as in other patented designs.
Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.!!) The next step in making cheese is the separation of the solid phase ¨ the cheese curds from the liquid phase ¨ the whey.
There are a number of inventions concerning separation of cheese curds from the cheese whey like EP1175826A2, U53193927, U54306493, U55669291, U52494637, U51046906, U52193462, U53292259.
Date recue /Date received 2021-11-08 In the specific case of production of Pasta-filata cheeses, the cheese curds are not only separated from the whey, but the cheese curds themselves are cooked and stretched. For example, the worlds most popular pasta filata cheese is Mozzarella (pizza cheese).
Production of this cheese requires first the production of curds, followed by drainage of the curds.
Then the production of the cheese mass undergoes specific steps ¨ cheddarization of the curds;
cutting of the cheese mass into pieces; cooking - plastification and stretching of the curds to form a "dough"; shaping of the plasticized and slowly flowing cheese mass into molds to desired shapes and sizes. Pizza cheese is a high demand product and as a result, there are many patents of machines which deal with kneading, stretching, (cooking) of mozzarella cheese curds, like US2017258031A1, US20120097048, W002072338A1, W02017157785A1, US20110045131A1, US20030200873A1, US8932657, US5873654, US5480666, DE102011086981A1, US2039162, US3961077.
In this invention, so designed Module 200 ¨ Curds Processing Vat, solves all of the problems regarding the separation of the cheese curds from the whey, the cheddarization of the cheese curds and the making of pasta filata cheeses. For the first time in the history of contemporary cheese making Module 200 combines many of the steps of the cheese making process in one single apparatus.
Further our Module 200 ¨ Curds Processing Vat is of a novel and original construction.
The Curds Processing Vat module performs the following functions:
First, Module 200, when connected to Module 100, catches all the fines (smallest curds particles), when cheese curds are washed in Module 100 in the case of washed rind cheeses.
There is no need for a complicated draining assembly as in many patented designs.
Second, when connected to Module 100, the Curds Processing Vat drains the cheese curds from the whey and catches all fines, thus increasing the cheese yield.
Third, the Curds Processing Vat Module 200 is designed to be used as a machine for cheddarization of cheese curds if the cheddarization step is required.
Forth, the Curds Processing Vat 200 feeds the next Module 300 ¨ the Cheese press with cheese curds for pressing and is intended to be to used as a screw press to press the cheese curds into cheese molds.
Fifth, when used as a stand alone unit, the Curds Processing Vat 200 can cook pasta filata type cheeses, or cheese dipping sauces.
Sixth, the Curds Processing Vat 200 is used to salt the curds when the cheese is being prepared for further processing and for mixing of salt with fresh curds. Usually common table salt is the sole cheese conservation agent. The addition of salt depends on the recipe ¨
some cheeses require a brine bath soaking, instead of salting.
Date recue /Date received 2021-11-08 Seventh, the Curds Processing Vat 200 can be used for making extruded cheese shapes such as cheese fingers, cheese sheets, spaghetti shaped cheese extrusions etc.
In other words the Curds Processing Vat 200 is a real "multi-tasking worker"
of novel construction. It is a CIP enabled unit.
Module 300 ¨ Cheese Press (FIG.12, FIG.13, FIG.14, FIG.15, FIG.16, FIG.17, FIG.18) When some of the water (whey) is drained from the cheese curds, the cheese curds are pressed into molds to form cheese wheels and even more water is expelled from them. In some soft and blue-veined cheese only gravity is required to press the cheese curds into the molds (without any other mechanical pressing assistance). The sizes of the cheeses vary from huge to miniature.
Accordingly, there are many inventions which deal with the shaping of cheese curds into cheese wheels like U53562910, U51492388,U53727308, U53765090, U55792500, US6403138, US20160205962A1, U54045152, EP3241432A1, EP2782441B1, U52077644, US1450105, U52019002, U52980542, U51796445, U52263851, U52642797, U53192626, U53199195, U53295205, U53355805, U59567153, U55480666, U54664613.
Our Module 300 ¨ Cheese Press is of a completely novel design.
To our knowledge it is the first cheese press which provides the cheese-maker with the means to measure, control and change the value of the pressing force which is applied to the cheese curds, so all kinds of cheese can be pressed.
The Cheese Press is of a horizontal space-saving construction with the following functions and modes:
First, when attached to Module 200 ¨ Cheese Processing Vat, cheese curds enter the Cheese press Module 300 and there they are pressed into a cheese mold of desired shape by the screw of Module 200. The pressing force is fully adjustable and measurable.
Second, When the Cheese press ¨ Module 300 is used as a stand-alone unit, it can press any cheese curds into cheese wheels or cheese blocks . The pressing force is again fully adjustable and measurable.
The possibility-by-design to have two different modes of operation, makes Module 300 ¨ the Cheese press really unique compared to the other patented designs.
Module 400 ¨ Cheese conveyor and Module 500 ¨ Cheese Cutting table (FIG.19, FIG.20, FIG.21, FIG.22, 2FIG.23) When making cheese extruded products, Module 400- Cheese Conveyor and Module Cheese Cutting Table are connected together and they are positioned in front of Module 200 ¨
Curds Processing Vat.
Date recue /Date received 2021-11-08 Module 400 ¨ Cheese conveyor is an ordinary conveyor which fulfills the government sanitary requirements. It is equipped with a water sprinkling system which sprays cooling water over the extruded cheese product to cool the product down.
Module 500 ¨ Cheese Cutting Table ¨ is of a novel design. It is easily adaptable to conveyors of various lengths and sizes.
Module 500 ¨ Cheese Cutting Table by design is unique, because it has two different modes.
The module has following functions and modes:
First, when Module 500 Cheese cutting table is connected to Cheese conveyor module 400 and Curds Processing Vat module 200, it is used to cut extruded and cooled cheese products to a desirable length before further processing or packaging. The speed of the cutting knife ¨ the length of the product is fully adjustable.
Second, when Module 500 ¨ the Cheese cutting table is used as a stand alone unit and equipped with an appropriate knife, it is used for the cutting of cheese wheels to wedges or other shapes.
Module 600 ¨ Combined Clean-In-Place (CIP) and Clean-Out-of-Place (COP) Unit (FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29) To our knowledge Module 600 ¨ CIP and COP unit is the First known CIP & COP
unit which aside of all sanitary requirements, is designed to fulfill all 3-A and EHEDG
designs guidelines.
Second unique feature of Module 600 ¨ CIP and COP unit is that the pump of the module can be used as a transfer pump for the daily operations in the dairy plant.
Third unique feature is that Module 600 ¨ CIP and COP unit is that the heat exchanger of the module can be used to make hot water for the daily operations of the dairy plant.
The purpose of Module 600 ¨ CIP & COP unit is to clean all modules of the Cheese machine, all parts and all accessories (such as hoses, fittings, cheese molds, etc.) which require sanitary cleaning ¨ Modules 100, 200, 300, 400, 500.
In addition as mentioned above, the design of the piping of Module 600 ¨ CIP &
COP unit allows for the pump, which is mounted on the unit to be used as a stand alone pump. The pump can also be used for various other purposes such as pumping whey, water, or pumping curds ¨ for example, when modules of the Cheese Machine have been retrofitted to existing cheese plants, or cheese vats supplied by other companies.
Accessories to the Machine (FIG.30) In addition to the modules of the machine, we have several useful accessories which facilitate the cheese manufacturing process. These accessories include a Process Dripping pan trolley, a Cheddarization table and Extrusion end caps.
Date recue /Date received 2021-11-08 Following is a detailed description of the Modules of the NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE
(aka: the Cheese Machine) Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7) The Batch Pasteurizer and Cheese Vat is a semi-cylindrical stainless steel Vessel 101,FIG.5, which is mounted on four welded adjustable legs 102, FIG.5. The legs 102, are welded in such a way, that when the vessel 101 is in a horizontal position, it is inclined at a 3 degrees angle as required by law.
The vessel 101 has a jacket 116, FIG.6 which is separated into two sections.
The jacket 116 provides a means for heating and pasteurization of the milk in the vat (also heating of the cheese curds) either with hot water or low pressure steam. Hot water or steam is supplied to each of the sections of the jacket 116 through two hot water (steam) inlets with flanges 107, FIG.5, FIG.6.
After heating the vessel 101, the cooled water (or the steam condensate) leaves the jacket 116, through two outlets with flanges 108, FIG.5. The hot water (low pressure steam) jacket 116 has insulation. The insulation is covered with a stainless steel sheet metal insulation cover 123, FIG.6.
The vessel 101 has a fully removable free ¨ standing reinforced stainless steel cover 114, FIG.5.
The cover 114 has two symmetrical covered manholes 115, FIG.5.
The reinforcements of the cover 114 are designed in a way, which allows for the cover 114 to be used as a convenient main platform for attaching pieces of hardware necessary for normal operation of Module 100. Such approach simplifies manufacturing of Module 100.
To the cover 114 are attached following pieces of hardware:
- Thermometer for measuring the temperature of the milk (cheese curds) 103, FIG.5 (required by law);
- Thermometer for measuring the temperature of the subspace between milk surface and cover of the vessel 104, FIG.5 (required by law);
- Two steam generators (or steam filters as the case may be) 106, FIG.5 for supplying steam to heat the subspace between the milk surface and the cover of the vessel (required by law);
- One central mounted wash ball with rotating jets 112, FIG.5, FIG.6. It allows for the CIP
cleaning of Module 100;
- Two milk inlets with sanitary clamp flanges 113, FIG.5, which allow for milk to be loaded into the vessel 101 from the milk supply truck (or the milk supply line).
To the front of the Batch pasteurizer and Cheese Vat is mounted a bi-directional gear motor 109, FIG.5 which rotates the curds cutting knives of the unit. All parameters of the gear motor 109 Date recue /Date received 2021-11-08 are appropriate for cutting and mixing cheese curds. The direction of rotation and the rotary speed of the gear motor 109 are fully adjustable.
The control box 105, FIG.5, controls not only the working parameters of the motor 109, FIG.5, but also the complete pasteurization process, and includes a temperature recording device which records the readings of the thermometers 103 and 104 FIG.5, as required by law.
Also in front of the Batch pasteurizer and Cheese Vat are mounted two none-drip milk valves 110 and 111, FIG.5.
The main milk valve 110, FIG.5, as the names states, is used for the complete evacuation of the vessel 101 and evacuation of the cheese curds from Module 100 to Module 200 ¨
Curds Processing Vat, when they are ready for further processing, with the help of a flexible food grade hose (not shown on the design drawings for greater clarity). The main milk valve 110, FIG.5, is also used during the CIP cleaning procedure, when connected with a flexible food grade hose (not shown) to Module 600 ¨ Combined CIP and COP Unit.
The auxiliary milk valve 111, FIG.5, has several important functions:
- First, the auxiliary milk valve 111, FIG.5 is used to remove part of the whey immediately, before the evacuation of the main mass of the cheese curds from Module 100 with the help of a detachable food grade hose (not shown). Since the cheese curds tend to settle to the bottom of the cheese vat, it is a standard procedure for the cheese makers to drain part of the whey before evacuation of the main mass of curds from the vat.
Previous patented cheese vat designs for that reason are equipped with special and complicated whey draining mechanisms for catching "fines" ¨ smallest cheese curds particles with size under 0.1mm.
Our design doesn't require such a complicated mechanism, because all fines are caught by the design within Module 200 ¨ Curds Processing Vat. This way, Our design is simpler than previous arts.
- Second, the auxiliary milk valve 111, FIG.5 is used for draining part of the whey (as described above) in the case of the production of so called "washed curds" cheeses such as Gouda. The Gouda cheese making recipe requires draining of a portion of the whey, and the replacement of the drained amount of whey with fresh water and the washing the curds to remove part of the lactic acid from the cheese (removal of a part of the sharp cheese taste and bringing some mildness to the cheese).
At the heart of the cheese curd cutting mechanism of Module 100¨ Batch Pasteurizer and Cheese Vat (FIG.6,FIG.7) is mounted the Main Axle of the cheese curds cutting assembly 122, FIG.6, FIG.7. To the Main Axle 122, are attached two sub-axles:
Date recue /Date received 2021-11-08 - The Back sub-axle 117, FIG.6, FIG.7 is a solid piece of stainless steel, and has grooves 118, FIG.6, FIG.7 cut into it. The Back sub-axle 117, FIG.6, FIG.7, is supported by a food grade plastic sliding bearing 119, FIG.6, which is fully submerged in the vat. Hence the grooves 118, FIG.6, FIG.7 allow for CIP washing of the sub-axle and bearing itself ¨ there are no "washing dead spots". This submerged bearing design, also allows for the simplification of the design of the vat, since there is no need for mechanical seals on the back side of the cheese curds cutting Main axle 122.
- The Front sub-axle 120, FIG.6, FIG.7, is made from a solid piece of stainless steel and is attached to the Main axle 122, FIG.6, FIG.7. However in this case there are no cut grooves in its to body. The Front sub axle 120, FIG.6, FIG.7 is supported by the bearings of the gear motor 109, FIG.5. Two food grade polymer lip seals 121 FIG.6 (or food grade mechanical seals, as the case may be), seal the vat interior from the vat exterior.
The cheese knives supporting frames 124, FIG.7 are welded to the Main axle of the cheese curds cutting assembly 122, FIG.6, FIG.7 with the help of two rings. In the steel frames are cut symmetrical channel slots 126, FIG.7, which end with holes cut into the metal.
The channel slots 126 are cut at an angle (at the range of 5 to 15 degrees) into the frame 124.
The cheese knives 125, FIG.7 are laser cut from stainless steel sheet metal with appropriate thickness. One of the longitudinal edges of cheese knives 125 is sharp ¨ for cutting of the cheese curds, while the other longitudinal edge is blunt for mixing of the cheese curds.
When mounted to the frame 124, all of the sharp edges of the cheese knives 125, point in one direction.
The cheese knifes 125, FIG.7 are designed to be wide enough so two knife holding holes 127, FIG.7 can be drilled into each of them, without compromising the mechanical strength of the knives.
To mount the cheese knife 125, FIG.7 into the frame, we slide each knife 125 into the symmetrical slots 126, FIG.7. Then we slide through the holes on the frame 124 and through the holes 127 on each knife, the two knife fixing bolts 129, FIG.7, and tighten the knife fixing bolts to the frame 124 with the help of the two knife fixing nuts 128, FIG.7.
Since the channel slots 126, FIG.7 are cut into the frame 124 at an angle, the cheese knives 125, also sit at an angle relative to the frame 124 in the channel slots 126 (see FIG.7). So when the cheese knives rotate, they not only cut the cheese curds, but also mix the cheese curds ¨ acting as paddles. It should be noted that the cheese knives are kept in place only by the two knife fixing bolts 129, FIG.7 and by the two knife fixing nuts 128, FIG.7 ¨ there is no welding, or any other fixing or attaching elements, etc. It should be noted that all mechanical fits of the symmetrical channel slots 126, FIG.7, of the cheese knives 125, FIG.7, of the knife holes 127, FIG.7 and of Date recue /Date received 2021-11-08 the knife fixing bolts 129, FIG.7 are clearance fits - so the cheese knives 125, FIG.7 can move several millimeters in each direction when mounted to the frame 124. This feature is especially important for the CIP cleaning of the cheese vat.
An advantage of the design is that at the beginning of the curds cutting process, and because of the rheological properties of the cheese curds, the knife fixing bolts 129, FIG.7 also act as cheese cutting knives. This cutting action plus the cutting action of the cheese knives 125, FIG.7 allows for a better cutting of the cheese curds mass to cheese curds. When the cheese curds become small enough, the knife fixing bolts 129, will not cut the cheese curds any further ¨ the cheese curds will just slide over the bolts. This is an advantage in the late stages of the curds to cutting process and the maturing of the cheese curds in the vat.
It is our belief that the design of the cheese curds cutting knives assembly is the simplest and the most advanced of all patented designs for such knives and assemblies in entire world. There are many known patented designs of curds cutting assemblies. Before This invention, known patented designs of curds cutting knives and described in EP2418934B1 and US

Al (Tetra Laval Holdings & Finance S.A).
Such previous designs have following issues:
- First they use long strip-like curds cutting knives; which because of the laws of the physics tend to buckle, so to prevent the buckling of the knives, they must add additional reinforcement strips perpendicular to the knives in order to prevent the buckling and the breaking of the knives, - Second, these long strip-like knives don't provide the agitation required for mixing of the cheese curds during the maturation process, so they add additional externally attached agitating paddles to their vats and knives assemblies, in order to agitate the cheese curds in their vats;
- Third, each of these long strip knives is attached with wires, pins and etc.
- minimum two pins for each knife.
- Forth, all of the above mentioned reinforcement requires some welding which makes the replacement of the curds cutting knives a difficult procedure.
In Our invention (unlike the above cited patents and designs) the curds knives 125 are much wider. We drill two holes 127 only in each knife, and use only two bolts 129, two nuts 128, and the channel slots 126 cut at an angle, to fix the knives to the frame. This simple design (in Our invention) doesn't require welding of the knives to the frame.
In addition, even if we scale up the size of our curds cutting knives and knives assembly to fit into a bigger cheese vat, our design will still be stronger that the designs in the cited patents.
Plus we do not require (in our design) additional agitating paddles or extra elements to prevent the buckling of the knives.
Date recue /Date received 2021-11-08 At the same time the quality of the cheese curds is the same, while the amount of undesirable cheese fines (the cheese particles under 0.1 mm) is minimized.
Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.!!) Module 200 ¨ Curds Processing Vat is of a unique construction and design. It is difficult to compare this module to any of the existing curds processing machines, because none of the existing machines have all the functionality and capabilities of Our module.
The overall dimensions of Module 200 ¨ Curds Processing Vat are such that it can slide completely and freely underneath the Module 100 ¨ Milk Pasteurization and Cheese vat.
Module 200 ¨ the Curds Processing Vat, has a stainless steel jacketed body 201, FIG.8, FIG.9, FIG.10.
The module has a vat cover 202, FIG.8, which can be rotated around the cover axle 203, FIG.8 and can then be opened and closed. On the vat cover 202, we have two covered manholes 204, FIG.8, which allow for observation of the inner workings of the machine and adding salt or other components to processed cheese curds and products, as required by the recipe.
An elbow connection 205, FIG.8, allows the module to be connected with a flexible food grade hose to the main valve 110, FIG.5 of Module 100 for the evacuation of the cheese curds for processing in module 200, or for draining whey from Module 100 to Module 200 through the auxiliary milk valve 111, FIG.5.
On the vat cover 202, is mounted a wash ball assembly 206, FIG.8, FIG.10 for the CIP cleaning of the vat. Three additional inlets 207, FIG.8 on the cover allow for the mounting of various devices ¨ depending on the preferences of the cheese maker.
Module 200 has two adjustable legs with hand-wheels 208, FIG.8 and four legs with caster wheels 209, FIG.8. The two front legs with caster wheels 209, FIG.8, FIG.10 are shorter than the two back legs. When Module 200 is in operation the two adjustable legs with hand-wheels 208, FIG.8, FIG.10 are engaged and the Module is in a horizontal position ¨
supported by the end tips of the two adjustable legs with hand-wheels 208 and the two longer back legs with caster wheels 209. When Module 200 has to be put in a position for moving or CIP cleaning, the two adjustable legs with hand-wheels 208 are disengaged and Module 200 is inclined at an angle of 3 degrees as per sanitary requirements for CIP cleaning.
At the front of the Module 200 and to the body of the vat 201 is welded a main vat flange 227, FIG.8, FIG.9. To the main vat flange 227 with bolts is attached a removable flange 228, FIG.8.
Functions of the removable flange 228 are two:
- First, to allow access to the inside of the Module for changes of the sliding bearings and mechanical work;
Date recue /Date received 2021-11-08 - Second, to support the module whey draining pipe 210, FIG.8, FIG.10.
The whey draining pipe 210 is a pipe with two flanges and a body with drilled patterned holes.
The whey draining pipe is attached to a flange welded to the removable flange 228, FIG.8 with the help of the sanitary clamp 215, FIG.8, and is closed from the other side with an end cap 213, FIG.8 held in place by the sanitary clamp 214, FIG.8.
The draining and filtering of the whey from the cheese curds is achieved by several layers of filtering media 211, FIG.8,FIG.10, wrapped around the whey draining pipe 210.
The filtering media can be made from the following materials - natural and synthetic fabrics (like cheese cloth), - polymer sheets with micro-perforations, - metal sheet with micro-perforations.
The Filtering media is secured over the pipe 210 with a filtering media clamp 212, FIG.8, FIG.10. When the filtering media is a metal sheet with micro-perforations, there is no need of the clamp 212, because the whey filtering metal sheet is directly welded to the whey draining pipe 210.
In the production of pasta filata kinds of cheeses, cheese extrusions, or for example cheese sauces, we don't need to drain whey from Module 200, so the perforated whey draining pipe 210, FIG.8,FIG.10, is removed entirely by disengaging the clamp 215, and is replaced by a normal-no holes-pipe of appropriate length with two flanges.
For heating of cheese curds which is required in production of pasta filata kinds of cheeses, production of cheese extrusions (or for example production of cheese sauces) the cheese maker has two options:
- One of the options is for the cheese maker to supply live steam or hot water with a flexible hose through one of the inlets on the cover 207, FIG.8.
- The Second (and less expensive) option for the cheese maker is to supply hot water (or low pressure steam) to the jacket 225, FIG.9 of the vat 201, which is covered with insulation and an insulation cover 226, FIG.9. The jacket is divided into two compartments and each of them has hot water (steam) inlets 223, FIG.9, and hot water (steam condensate) outlets 224, FIG.9.
For the draining of the cheese curds, extrusion and pressing of the cheese curds, and further processing of the cheese curds to pasta filata cheeses, or cheese sauces, Module 200 is equipped with two ribbon type screw conveyors (mixers) ¨ the top ribbon conveyor 217, FIG.9, FIG.10, FIG.11 and the bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11.
At the front of the bottom ribbon conveyor 218 is attached a full blade extrusion conveyor 240, FIG.9, FIG.10.
Date recue /Date received 2021-11-08 All conveyors are put in motion by two hi-directional gear motors 219, FIG.9, FIG.10. The direction of the rotation, and the rotary speed of the gear motors 219, as well as any other parameters of the module (as the case may be) are monitored and controlled via the control box 216, FIG.8, FIG.9. The control box 216 is supported by two groups of two control box supports .. 220, FIG.8, FIG.9, which allows for the control box to be mounted either to the right or the left side of Module 200.
The top ribbon conveyor 217, FIG.9, FIG.10, FIG.11, has two sub-axles attached to the main axle.
The back end sub-axle 238, FIG.!!, FIG.10, passes through two lip seals 239, FIG.10, which seal the interior of Module 200 from the exterior, and is supported by the bearings 234, FIG10, of the top gear motor 219.
The front end sub-axle 235, FIG.!!, FIG10 is supported by a food grade sliding bearing 236, FIG10. The bearing 236, itself is mounted in a bearing box inside a three prong star-shaped bearing support 221, FIG.9 welded to the body 201 of the module and to the flange 217. The bearing 236, the bearing box and the bearing support 221 are completely immersed inside the module 200. To allow for the CIP cleaning of the bearing on surfaces of the sub-axle 235 are cut grooves 237, FIG.!!. These grooves extend beyond the length of the bearing box and bearing support 221.
The bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11, has two sub-axles attached to the main axle.
The back end sub-axle 231, FIG.!!, FIG.10, passes through two lip seals 232, FIG.10, which seal the interior of Module 200 from the exterior, and is supported by the bearings 234, FIG10, of the bottom gear motor 219.
The front end sub-axle 245, FIG.!!, FIG10 is supported by a food grade sliding bearing 229, FIG10. The bearing 229, itself is mounted in a bearing box inside the three prong star-shaped bearing support 222, FIG.9 welded to the body 201 of the module and the main vat flange 227, FIG.9. The bearing 229, the bearing box and the bearing support 222 are completely immersed inside the module 200. To prevent accumulation of cheese curds residues and to allow for the better CIP cleaning of the bearing, on surface of sub-axle 245 are cut grooves 230, FIG.!!. The grooves which extend beyond the length of the bearing box and bearing support 222.
The front end sub-axle 245, FIG.!!, FIG10 is designed in a way, so that it can be attached with four bolts 242, FIG.10 the full blade extrusion conveyor 240, FIG.9, FIG.10.
The front side of the extrusion conveyor 240 is capped with a welded cap 243, FIG.10 which has threads and to which is screwed an end bolt 244, FIG.10. The four bolts 242 allow the extrusion conveyor 240 to be removed from the module and replaced with screw conveyors of different sizes and lengths, Date recue /Date received 2021-11-08 in case it is required by the cheese maker. The end bolt 244 allows for the attachment of blades to the end of the conveyor 240 (for example a blade for chopping cheddarized cheese curds), or when the conveyor 240 is cleaned, for thorough cleaning of its interior.
Module 300 - Cheese Press (FIG.12, FIG.13, FIG.14, FIG.15, FIG.16, FIG.17, FIG.18) Module 300 of the Cheese Machine is a horizontal type of multi-use cheese press, of a unique design and capabilities.
The body of the Module 300 has a front cheese press plate 301, FIG 12, FIG.13, FIG 14, and a back cheese plate 302, FIG12, FIG13, FIG 14. The plates are connected by two bottom composite beams 303, FIG 12, FIG.13, FIG 14, and two top composite beams 304, FIG 12, FIG.13, FIG 14. Each of the plates 301 and 302 has four laser cut holes 305, FIG.13 which are used to center the beams 303 and 304 during the manufacturing welding process (for better linearity of the steel frame). To each of the plates 301 and 304 are welded four mounting brackets 306, FIG 12, FIG.13, FIG 14. To the front plate 301 is welded a pipe with a flange 307, .. FIG.13, FIG 14, which allows for the connection of the whey draining pipe 210, FIG.8, FIG.10 of Module 200 - the Cheese processing Vat. The front end of the pipe 307 is reinforced by a reinforcement ring 308, FIG.13 welded to the pipe and to the plate 301. The back of the pipe 307 is welded to a machined cheese gate guide plate 310, FIG.13, which has a channel for guiding the cheese gate 318, FIG 12, FIG.14, FIG.16, FIG.17. The guide plate 310, FIG.13, also has two shoulders 309, FIG.13, with four threaded holes, to which a cheese mold plate 338, FIG.17 is secured by four bolts 337, FIG.17. The plate 338 has a laser cut hole in it for the cheese curds to be able to flow into the mold form 318, FIG17, and also has a cheese mold support and a holding ring 336, FIG.17.
The back plate 302, has a laser cut hole 311, FIG.13 for mounting of an electric cheese-press pressing cylinder 325, FIG. 12, FIG.17, FIG.18. The size and the ratings of the pressing force of the electric cylinder 325 are such, that when required, it can press even the hardest cheese varieties. The pressing force of the electric cylinder 325 is measured by an S-type load cell 326, FIG.14,FIG.17, FIG.18. To the front end of the load cell 326, is screwed-on a load platform 327, FIG.14,FIG.17, FIG.18 for a more even distribution of the pressing force during the cheese pressing process and for a more precise measurement of the pressing force.
Module 300 - the Cheese press is mounted on four adjustable height legs with caster wheels 312, FIG. 12, FIG.13, FIG.14. This allows for an easier connection of Module 200 and Module 300 and the better mobility of the cheese press.
Module 300 - Cheese press is equipped with several safety devices:
Date recue /Date received 2021-11-08 - The First safety device is a side metal screen 313, FIG.12, FIG.14, which is mounted on one side of the cheese press on four of the brackets 306, with the removable pins 314, FIG12, FIG14.
- The Second Safety device is the top free standing metal screen 315, FIG.12, FIG14 which fits into the grooves 316, FIG12 cut on the plates 301 and 302.
- The Third safety device is two light curtains 317, FIG12, FIG.14, which are mounted on an another set of four brackets 306, opposite to the metal screen 313. The light curtains make the interior of the cheese press only accessible from one direction ¨ through the light beams of the light curtains 317. Therefore, during a pressing operation, when these light beams are crossed by the operator hand or any object, the beams are breached and the light curtains send a signal to the Control Box 324, FIG12, FIG14 to bring the cheese press to a complete stop.
Since all brackets 306 are designed identical, the metal screen 313 and light curtains 317 can exchange their places, so the interior of the cheese press can be made accessible either from the right or the left side.
The Control Box 324, FIG12, FIG14 controls the work of the Module 300 and has the following functions:
- It receives signals from the load cell 326 and measures the values of the pressing force;
- It allows for the full adjustment of the pressing force of the electric pressing cylinder 325;
- It receives a signal when a body crosses the beams of the light curtains 317 and brings to a full stop Module 200 and Module 300;
- It allows for the manual reset of the light curtain 317 and for the manual re-start of Module 300, and allows for the manual reset of Module 200, when the module is connected via a Wi-Fi network or a cable to Module 200 (cables or Wi-Fi sender ¨ receiver are not shown on the drawings);
- It gives a visual and a sound signal when the preset value of cheese pressing force is reached;.
The safety light curtains 317 have two additional functions:
- First, the curtains will not allow Modules 200 and 300 to restart if the cheese gate 318 is not open ¨ in this case the cheese gate will be in the way of the light passing from one light curtain to the other light curtain;
- Second, when the operator reaches to move or adjust the cheese gate, his hand must cross the beams of the light curtains 317, thus bringing to a full stop Modules 300 and Module 200 (in case that the signals from Module 200 are connected to the signals of Module 300). This way, we do not require electronic limiting switches for the operation of the cheese gate 318. They can be replaced by the two limiting bolts 328, FIG 14 screwed-on one side of the cheese gate 318, and two limit bolts 329,FIG.14 screwed-on the other side of the cheese gate 318.
Date recue /Date received 2021-11-08 As described above, the cheese gate 318 slides between the two shoulders 309 of the guide plate 310, FIG.13. To support this sliding action, and in order to have tighter tolerances, the cheese gate is supported by two cheese gate support assemblies 319, FIG.12, FIG14, FIG.16.
Inside each assembly 319, are two stainless steel rollers 332, FIG.16, on which the cheese gate 318 is suspended.
The exact position of each roller 332 is adjusted with the help of the five food grade plastic washers 333, FIG.16. In addition, each cheese gate support assembly has two cheese gate food grade plastic wiper blades 335, FIG.16 which clean the cheese gate as it slides.
The rollers 332, the washers 333, and the wiper blades 335 are mounted to the frame of the cheese gate support assembly using removable pins 334, FIG.16 for easy disassembly and cleaning. Each cheese gate support assembly 319, has three holes 336, FIG16, for mounting the assemblies 319 to the front plate 301 with bolts.
In order to accommodate the cheese molds of different sizes and shapes (cylindrical, rectangular parallel-piped) Module 300 is equipped with two identical cheese mold support frames 320 and 322, FIG.12, FIG14, FIG.15 and two identical cheese mold support sub-frames 321 and 323, FIG.12, FIG14, FIG.15.
The cheese mold support frame 322, FIG15, is made from sheet metal, to which are welded two adjustable height sanitary bolts of specific shape and size. The sides of the mold support frame, as designed, must fit snugly onto the bottom beams 303.
The cheese mold support sub-frame 323, FIG.15, is a sheet metal part on the bottom of which are welded two rings.
The rings of the sub-frame 323 fit snugly onto the heads of the adjustable bolts of the frame 322.
By using the shape of the sub-frame 323, and by using the adjustable bolts of the frame 322, we can mount cheese molds of different sizes and shapes on the Module 300 ¨ the Cheese press. In order to do that, we also must change the mold plate 338, FIG.17, to a mold plate of appropriate size and shape, so the neck of the cheese mold 330, FIG.17, fits snugly into the cheese mold support and the holding ring 336, FIG.17.
To change the cheese molds:
- First the mold plate 338, FIG.17 is removed by releasing the four screws 337, FIG.17;
- Then the mold plate 338 is replaced with a new mold plate of a desired shape and size;
- Finally we attach the new mold plate in place using the four screws 337, FIG.17;.
Module 300 ¨ Cheese press has two modes of operation:
- The First mode, when Module 300 is attached to Module 200 ¨ Cheese Curds Processing Vat;
- And the Second mode, when Module 300 is operated as a stand alone unit.
When Module 300 is operated in tandem with Module 200 (FIG.317):
Date recue /Date received 2021-11-08 - the whey draining pipe 210, FIG.8, FIG.10 of Module 200 - the Cheese processing Vat, is connected to the pipe 307, FIG 12, FIG.13, FIG 14 of Module 300 Curds Processing Vat with a sanitary clamp.
-the neck of the cheese mold 330, FIG.17, fits into the cheese mold support and the holding ring 336, FIG.17.
- the back cover 331, FIG.17 of the cheese mold is put in place;
- the piston of the electric actuator 325, FIG.17 is extended so the load cell platform 327, FIG17, touches the back cover 331, FIG.17 of the cheese mold with a small constant force (for example 100N), and pushes the cheese mold 330, FIG.17 to stay tight to the face of the mold plate 318, FIG.17.
- then the cheese gate 318, FIG.17 is opened - the light curtains 317.FIG.12 are reset -the bottom gear motor 219, FIG10 is started and the direction of the extrusion is set in such a way that the ribbon screw conveyor 218, FIG10 and full blade screw conveyor 240, FIG 10 transfers curds to the cheese mold 330, FIG.17.
It must be noted that the bearings of the gear motor 219 are of such a design, that they can withstand the axial forces even when the screw conveyors 218 and 240 are pressing even the hardest pressed cheeses.
- the load cell 326, FIG17 reads the pressing force values, and when the pressing force reaches a preset value at the control box 324, FIG.12, the control box then informs the operator with a visual and/or sound signal for the event;
- then the operator closes the cheese gate 318, FIG.17 with his hand.
- this triggers the light curtains 317,FIG.12 to shut down Modules 200 and 300.
- then the piston actuator 325 is disengaged from pressing the mold back cover 331, and the cheese mold 330 is removed from the cheese press.
This cycle is repeated until all of the cheese curds in Module 200 are pressed into cheese wheels or blocks.
Module 300 - the Cheese press can also be used as a stand alone unit (FIG.18).
In this case an additional cheese mold plate 339, FIG.18 is attached to Module 300. The additional cheese mold plate 339 is designed to be supported by the two bottom composite beams 303, FIG 12, FIG.13, FIG 14 and the two top composite beams 304, FIG 12, FIG.13, FIG 14 and slides freely on them. At its front, the cheese mold plate 339, FIG.18, has a mold restriction ring, similar to the design of the mold restriction ring 336, FIG.17. The back of the additional cheese mold plate 339, FIG.18 is supported by the mold restriction ring 336, FIG.17 of plate 338, FIG.17.
Date recue /Date received 2021-11-08 To press a cheese wheel:
- the back cover 331, FIG.17 of the cheese mold 341, FIG.18 is put in place;
- the cheese mold 341, FIG.18 is filled with cheese curds;
- the whole assembly (the full cheese mold 341 plus the back cover 331) is placed on the sub-frames 321, 323, FIG.18 and pushed tightly to the face of the cheese mold plate 339, FIG.18;
- then a food grade plastic plug 340, FIG.18 is inserted into the back end of the cheese mold 339;
- the pressing force of the electric piston 325, FIG.18 is preset to the desired pressing value with the help of the control box 324;
- then , from the control box the piston of the electric cylinder 325, FIG.18 is activated. The piston of the electric cylinder 325, FIG.18 starts moving forward, while the face 327 of the load cell 326, FIG.18 pushes the plug 340 inside the mold 341, until the load cell measurement reaches the preset value of the pressing force;
- when this value is reached, the piston of the electric cylinder 325, stops moving forward, .. changes direction and retracts, releasing the cheese mold 341;
- then the operator removes the pressed cheese wheel from the machine;
- then the operator fills the mold with cheese curds and the pressing cycle starts again, until all the cheese curds are pressed into cheese wheels;
If during the pressing operation, any body part or foreign object crosses the beams of the light curtains 317, FIG.12, FIG,14, this event triggers an emergency complete stop of Module 300.
Then Module 300 must be reset manually to re-start the cheese pressing operation.
Also, it should be noted that the dimensions and the shape of additional cheese mold plates 339, FIG.18 must correspond to the dimensions and the shape of the cheese mold 341.
Module 400 ¨ Cheese conveyor and Module 500 ¨ Cheese Cutting table (FIG.19, FIG.20, FIG.21, FIG.22, FIG.23) The next two modules of the Cheese Machine are module 400 ¨ Cheese conveyor and Module 500 ¨ Cheese Cutting table.
Different cheese extrusion end caps such as 703,704,FIG.30 can be attached to the whey .. draining pipe 210, FIG.8, FIG.10, FIG.19. with the help of the sanitary clamp 214, FIG.8, FIG.10, FIG.19. The cheese extrusion end caps such as 703,705, FIG.30 allow for various cheese shapes to be extruded from Module 200 ¨ Curds Processing Vat, to Module 400 -the Cheese conveyor (FIG.19).
The purpose of Module 400 ¨ Cheese conveyor is to cool down the cheese extrusions, and transport them to Module 500 ¨ Cheese cutting table FIG.19.
Date recue /Date received 2021-11-08 The purpose of Module 500 ¨ Cheese cutting table is to cut the cheese extrusions to a desired length ¨ for example cheese bites, cheese fingers, cheese ropes etc.
Another purpose of module 500 ¨ Cheese cutting table FIG.23 is to be used as a stand alone unit and to cut the cheese wheels, or blocks, to a desired size and shape, when the module is detached from module 400.
To serve its purpose, Module 400 ¨ Cheese conveyor must be of an approved sanitary design for the cheese industry, must have an appropriate length for cooling of the cheese extrusion, and must be able to fit with Module 500.
In addition Module 400 ¨ the Cheese conveyor must have the following elements:
- a Belt restraining boards 401, FIG.19;
- a belt with a smooth surface 403, FIG.19;
- adjustable legs 402, FIG.19;
- a cooling water distribution header with spray nozzles 405, FIG.19;
- a cooling water drip pan 404, FIG.19;
- two Connector slots 406, FIG.19 which are welded to the belt restraining boards 401, FIG.19.
The slots 406 allow for Module 400 to be connected to Module 500 ¨ the Cheese cutting table.
Module 500 ¨ Cheese Cutting table (FIG.19, FIG.20, FIG.21, FIG.22, FIG.23) has a body made of two identical laser cut stainless steel body plates 501, FIG. 19, FIG.20, FIG.21.
The two body plates 501, FIG. 19, FIG.20, FIG.21 are welded together with the help of the horizontal frame beams 513, FIG 21 at the bottom of the body plates 501.
The frame is further strengthened structurally by the actuator holding rail beam 523, FIG.19, FIG.21, FIG.22, welded between the body plates 501.
The body plates 501, FIG. 19, FIG.20, FIG.21 have numerous cuts on them to accommodate various parts of the Cheese cutting table ¨ module 500.
.. In addition the body plates 501, FIG. 19, FIG.20, FIG.21 restrict access to the cheese cutting table from both sides of the table ¨ they act as a safety device.
Module 500 ¨ Cheese Cutting table is mounted on four adjustable height legs with caster wheels 502 FIG.19, FIG.20, FIG.21, FIG.23.
To attach Module 500 to the Module 400 ¨ the Cheese conveyor:
- the First step is to extend the two front legs 502 of Module 500 to an appropriate length, while the two back legs 502 of Module 500 are not extended. After this first step, Module 500 is inclined relative to Module 400.This allows for the discharge of the cheese extrusions.
- the Second step is to insert from both sides of the table two connecting rods 407 FIG.19, through two connecting holes 503 FIG.19, until they enter the two Connector slots 406, FIG.19.
Both the connector rods 407 and connector slots 406 have holes in them, through which are Date recue /Date received 2021-11-08 inserted the removable connecting pins 408 FIG.19. This creates a rigid connection between module 500 and module 400.
-the Third and final step is to engage the brakes on the wheels of the Module 400 and Module 500.
Such an elegant and simple design of the connection between Module 400 and Module 500 allows for the connection to the cheese cutting table of different models of cheese conveyors (with an appropriate width) from many manufacturers, as long as other design requirements, described above, for such a cheese conveyor are met.
To prevent accidental access to the cheese cutting table from the front of Module 500 and as a to safety device, at the front end of the Module 500 is mounted a Front safety screen 504, FIG.19, which is fixed to the body plates 501 with four removable Safety screen pins 505 FIG.19.
The only open access to the insides of the Cheese cutting table - Module 500 is from the back of the module.
To allow for a normal operation of Module 500 and at the same time prevent accidents, the only open access to the insides of Module 500 is restricted by the two light curtains 506 FIG.19, FIG.20. The curtains 506 will bring to a full emergency stop the Module 500, if it is in operation and a foreign object or body part breaks the light beams paths.
The Cheese knife 519 FIG.21, FIG.22, moves up and down with the help of a food grade electric actuator 507 FIG.19, FIG.20 of hygienic design.
When cutting cheese extrusions to a desired length the cheese knife 519 can make hundreds or even thousands of cuts per single batch. The cheese knife 519 always strikes in the same place and will always cut the cheese extrusion completely with a single clean cut.
In order to keep the cheese knife sharp and to extend its life a food grade plastic sacrificial cheese cutting strip 509 FIG.20, FIG.21 is required.
This cheese cutting strip 509 is mounted on a stainless steel support cutting strip 508 FIG.20, FIG.21, with the help of cheese cutting strip removable mounting pins 510 FIG.20. In order to prevent any bending issues when the Cheese knife 519 strikes the cheese cutting strip 509, a reinforcement support of the cutting strip 512 FIG. 21, is welded under the cutting strip 508 FIG.20, FIG.21.
To facilitate the movement of the cheese extrusions and extruded cheese cuts through the cheese cutting table Module 500, six rectangular slots 514, FIG.21 are cut into the body plates 501.
Into each of the six slots are inserted steel roller support rods 511 FIG.20, FIG.21 which have tubular bodies and square ends.
Date recue /Date received 2021-11-08 On each of the roller support rods 511 are mounted food grade plastic rollers 522 FIG.21. The rollers 522 rotate freely, but are restricted in their axial movement with the roller restrain rings 520 FIG.21 and the roller restraining pins 521 FIG.21.
In order to facilitate movement of the cheese extrusions which are coming from the cheese conveyor Module 400 through the knife, one of the roller support rods 511, FIG. 521 and one of the rollers 522, FIG.521 is mounted in front of the sacrificial cheese cutting strip 509 FIG.21.
This roller guides the cheese extrusion toward the cheese knife 519 for cutting.
There are three cheese knife 519 guiding rods. Only the central cheese knife guiding rod 515 FIG.21, FIG 22 is attached to the electric actuator 507, while the side cheese knife guiding rods 525 FIG.22 are sliding freely through the two side-rods guide bushings 526 FIG.22.
The purpose of the side guiding rods 526 is to add extra stability to the cheese knife 519 during the cutting action.
The central guide rod 515 ends with a central knife guide end bracket 516 FIG.21, FIG.22. The side cheese knife guide rods end with side knife guide end brackets 524 FIG.22. The cheese knife is sandwiched between these end brackets 516, 524 and the cheese knife holding plate 517 FIG.22. To attach the cheese knife 519 to the end brackets 516, 524, three cheese knife bolts and nuts 518, FIG.21 are used.
One of the novel features of the Cheese cutting table ¨ Module 500 is that it can be used not only for cutting cheese extrusions, but when disconnected from the Cheese conveyor ¨ Module 400, it can also be used as a stand-alone cheese cutting table for cutting cheese wheels or cheese blocks to desirable shapes.
When the cheese table is used as stand alone unit:
- first, all of four cheese cutting table legs 502,FIG.23 are adjusted to an equal height.
- the cheese wheel cutting table 527, FIG.23 is mounted with the help of the four cheese wheel cutting table guides 529 FIG.23, which fit into the holes of the four cheese wheel cutting table brackets 528, FIG.23 welded to the body of Module 500;
- the final step is to re-adjust through the control box 530, FIG.23 the speed and the length of the cheese knife stroke from a fast and short stroke mode, like when cutting cheese extrusions, to a long and slow cutting mode when cutting cheese wheels.
At all times, the control box 530 controls the work of the light curtains 506 and enables a reset when the cheese cutting table knife comes to an emergency full stop.
Another function of the control box 530 is to communicate with the Cheese conveyor ¨ Module 400 and Module 200 ¨ Curds Processing Vat and to bring them to a full stop when Module 500 stops (or when necessary).
Date recue /Date received 2021-11-08 Module 600 ¨ Combined CIP and COP Unit (FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29) All dairy equipment and dairy production areas must be maintained in a clean and sanitary condition, in order for the cheese maker to obtain a high quality product.
The purpose of Module 600 ¨ Combined CIP and COP unit is to provide ways for the cleaning of all dairy equipment and all dairy production areas in a single unit. In another embodiment of the invention, the purpose of Module 600 is to provide ways for transferring liquids and for heating of dairy process water if the dairy doesn't have a separate hot water boiler.
The Module Main CIP vessel 601 FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29 is used for several tasks:
- First, for the heating of the cleaning solutions for all tasks;
- Second, for the COP (Clean-Out-of-Place) washing of process hoses and long tubular elements;
- Third, for COP washing of small parts, fittings and cheese press forms;
- Forth, as a CIP (Clean-In-Place) supply unit for the automatic washing of Modules 100, 200 and 400;
- Fifth as a CIP supply unit for the manual gun washing of Modules 300, 500 and Module 600 itself;
- Sixth, as a cleaning solution supply unit for the manual gun washing of all dairy production areas.
The Module has a Clean water vessel 602 FIG.24, FIG.25, FIG.27, FIG.28, FIG.29, which as the name implies is used to provide clean rinsing water for all tasks which the Main vessel 601 FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29 fulfills.
In addition, the Clean water CIP vessel 602 can also be used to supply clean water for the hot water production for use in different dairy areas.
One of the design features of both vessels 601 and 602 is that their inner walls (as per sanitary design guidelines) are inclined at an angle of 3 degree toward the central channels 618 FIG.26 at the bottom of the vessels, which channels themselves are inclined 3 degree towards the outlets of the vessels. This allows for complete evacuation of any liquids from the vessels.
Module 600 is mounted on six CIP module wheels 603 FIG.24, FIG.25 and is mobile.
The main CIP vessel 601 and the clean water CIP vessel 602 have movable covers - main CIP
cover 605, FIG.24 and clean water CIP cover 604 FIG.24. Each cover has two gas springs 606 FIG.24 for easy lifting.
The necessary pressure for all cleaning operations and various other tasks is created by a hygienic CIP pump 607 FIG.24, FIG.25, FIG.27, FIG.28 with a variable speed motor of appropriate size. The necessary process heat for heating of all cleaning solutions, rinsing Date recue /Date received 2021-11-08 solutions and production of hot water is provided by an over-sized hygienic U-tube heat exchanger 609 FIG.24, FIG.25, FIG.27, FIG.28.
The heating agent for the exchanger 609 is a low pressure saturated steam which enters through the exchanger steam inlet 620 FIG.25, FIG.27 and the resulting steam condensate exits through the exchanger steam outlet 621 FIG.25.
Any fluid which enters and exits the heat exchanger 609, passes through a digital reading, measuring and recording CIP thermometer probe 612 FIG.25, FIG.28. We then know and record the temperature of the cleaning fluids when they leave Module 600, as required by law, which is especially important for the temperatures of the CIP and the COP cleaning solutions.
There is room for mounting a second CIP thermometer probe on the CIP return water line ¨
probe mounting well 645 FIG.29.
Another measurement device is a conductivity probe 613 FIG.25, FIG.29 which measures the conductivity of the returning solution when Module 600 operates in CIP mode.
Measurement of the conductivity is useful since we can re-use part of the CIP rinsing water as make-up water for next washing agent, instead of dumping all into the sewer. The above statement is true in condition, that the conductivity of rinsing water falls down under a certain conductivity value.
All measurements and recordings from the control devices and the control of the pump 607 are processed by a CIP central control unit 610 FIG.24, FIG.25, FIG.27, FIG.28.
This unit also sends back signals to the steam control valve in the steam boiler room (not shown), which controls the steam supply to the exchanger 609.
To prevent clogging and the build-up of residues in the heat exchanger 609 on the outlet line of the pump 607 is mounted a basket type removable and washable filter 608 FIG.24, FIG.25, FIG.27, FIG.28.
A feature which protect the inlet line of the pump 607 is a removable mesh type grid 619 FIG.26, FIG.27 mounted in both vats. Such an arrangement prevents any debris or metal objects from being sucked into the pump 607 and damaging the propeller.
The pump 607 is equipped with a number of inlet and outlet quick connect sanitary clamp valves. These valves allow for fluids to enter and exit Module 600 via different conduits and to fulfill all of the designated to the module tasks.
In addition, these valves allow the two most expensive pieces of equipment mounted on Module 600 ¨ the pump 607 and the heat exchanger 609, to be used to the full extent of their design capabilities.
In the First conduit, which we call the Pump transfer mode, all valves are closed except valve 622 (inlet to the pump 607) and valve 623 (outlet of the pump 607) FIG.28. In this case pump Date recue /Date received 2021-11-08 607 can be used as a simple transfer pump for daily operations of the dairy ¨
transferring milk, whey, water etc.
In the Second conduit, which we call Vessel 602 Filling mode, all valves are closed and the vessel 602 is filled with clean water from the feed water connection 646 FIG.29.
In the Third Conduit, which we call Vessel 602 draining mode all valves are closed except valve 624 FIG.28 which allows for the drainage of the vessel 602.
In the Forth conduit, which we call Clean water heating and rinse mode, vessel 602 is filled with water and all the valves are closed except valve 625 FIG.28. This supplies the inlet of the pump 607 with clean water. Then, if the pump is started, by opening the different valves on the outlet of the pump we can rinse with clean water any conduit of the Module 600 and any of the other modules of the universal machine.
A special case is when valve 625 FIG.28 on the inlet of the pump is open, and then we open in consecutive order valves 628 FIG.28 (or 629 FIG.28 ¨ filter 608 bypass valve) and valve 637 FIG.29 (or valve 639 FIG.29 as an alternative). In this case the clean water will flow from the vessel 602, through the pump 607, through the heat exchanger 609 where it will be heated, through the outlet line 633 FIG.28, FIG.29, through the valve 637,FIG.29 (or through the outlet line 634 FIG.28, FIG.29 and through the valve 639,FIG29 as an alternative).
The end result is that we have clean hot water, heated in the heat exchanger, which can be used for any purpose in the dairy plant.
Another special case is to use the same conduit as the conduit which we just described, but without any heating steam supplied to the heat exchanger, so we can send cold rinse water to any part of the dairy plant.
In both cases this clean water can be used for CIP or a manual gun rinsing of all modules of the cheese machine. Some rinses can be completed with cold water - this will save energy and energy costs.
In the Fifth conduit, which we call vessel 601 filling mode, vessel 601 is filled with water from the feed water connection 647 FIG.29 In Sixth conduit, which we call Vessel 601 draining mode, all valves are closed except valve 626 FIG.28 which allows for the draining of vessel 601.
In the Seventh conduit, which we call COP solution heating and cleaning of hoses and long tubular parts mode:
- vessel 601 is full of water and a washing agent is added, while all valves are closed.
- then we open valve 627 FIG.28, valve 628 FIG.28, valve 630 FIG.28 and valve 635 FIG.29.
This way we create a circulation of the washing solution from the bottom of the vessel 601, through the working pump 607, through the working filter 608, through the working heat Date recue /Date received 2021-11-08 exchanger 609, through the thermocouple 612, and back to the vessel through the hose washing nozzles 614 FIG.26.
To the nozzles 614, FIG.26 (with quick clamps) can be attached any hoses or long tubular parts for washing. If it is done, the washing solution will circulate through inside of the hoses and will clean the insides of the hoses.
Measurement and recording of the readings of the Thermocouple 612 allows for the control of the heating process. The washing solution is circulated through the nozzles 614 and is heated until it reaches the required (by law) temperature for COP cleaning of hoses, tubular parts and the manual gun cleaning of the modules of the Cheese machine.
to In the Eight conduit, which we call CIP cleaning mode, - First we use the loop of the Seventh conduit, till the washing solution reaches the required (by law) temperature for CIP cleaning or 10 to 15 degrees above that temperature.
Then we open valve 637 FIG. 29 (or as an alternative valve 639 FIG.29) and valve 643 FIG.29;
and we close valves 630 FIG.28 and 635 FIG.29.
In this case, the washing solution will flow through the working pump 607, through the filter 608, through the working heat exchanger 609, through the line 633 FIG.29 (line 63 FIG.29 as an alternative), through the valve 637 FIG. 29 (the valve 639 FIG.29 as an alternative), through a sanitary type hose (not shown), to the washing ball of module 100 or module 200.
On its way back from module 100 or module 200, the washing solution flows from the bottom of the modules 100 or 200 through a sanitary hose (not shown), through the quick clamp connection 640 FIG.29, through the conductivity meter 613 FIG.29, through the valve 643 FIG.29, through the return line 644 FIG.28, FIG.29, to the vessel 601 FIG.28.
When required by law wash times and temperatures inside module 100 (or module 200) are reached the spent washing solution is collected in vessel 601.
The Ninth conduit, which we call spent washing solution disposal, is actually the same as the Sixth conduit ¨ we can drain the vessel 601 to the sewer using valve 626 FIG.28.
However there is an important alternative for disposal of the spent washing solution. In this case, all valves are closed and only valve 627 FIG.28 and valve 623 FIG.28 are opened, while the pump 607 is working. In this case, we can transfer the spent washing solution to a different place for disposal through the valve 623 if we attach to the valve 623 a hose (not shown on the drawings).
In the Tenth conduit, which we call COP washing of fittings, small parts and cheese mold forms:
- First these parts are loaded into the vessel 601 Date recue /Date received 2021-11-08 - then the vessel 601 is filled with water and the washing agent is added, while all valves are closed - then we open valve 627 FIG.28, valve 628 FIG.28, valve 631 FIG.28 and valve 632 FIG.28.
- then the washing solution will circulate in a loop through the valve 627, through the working pump 607, through the valve 628, through the filter 608, though the working heat exchanger 609, through the valves 631 and 632, through the jet nozzles 616 FIG.26, FIG.27 to the vessel 601.
The jet nozzles 616 FIG.26 FIG.27 are arranged in two arrays.
One array is at the bottom part of the vessel 601 and the jet nozzles 616 FIG.26 FIG.27 are slightly inclined towards the top of the vessel 601, while the second array is at the top part of the vessel 601 and the jet nozzles 616 FIG.26 FIG.27 are slightly inclined towards the bottom of the vessel.
This arrangement of the nozzles 616 FIG.26 FIG.27 creates a powerful swirl circulation of the washing or rinsing solution in vessel 601.
Each jet nozzle 616 FIG.26 is attached with its threaded end to a jet nipple 617 FIG.26, SO
nozzles are replaceable.
Threaded jet nipples 617 FIG.26 are welded in an angle to the nipple support plate 615 FIG.24, FIG.26, which from its side is welded to the body of the vessel 601. Each plate 615 is covered with a jet array cover 611 FIG.24 welded to the body of the vessel 601.
- The disposal of the spent washing solution is by using the Ninth circuit described above.
Accessories to the Machine (FIG.30) Some of the most important accessories of the cheese machine are given on FIGURE 30.
They include Cheddarization table 702,FIG.30, which can be mounted directly over the Process dripping pan trolley 701,FIG.30.
As the name implies the cheddarization table 702 is used when the cheese maker wants to do cheddarization of the cheese without using Module 200 as cheddarization unit.
The process dripping pan trolley701 is used to collect dripping whey or other liquids when required.
The Process dripping trolley 701 slides completely under Module 300 -the Cheese press and the front end of the Module 200 ¨ the Curds Processing Vat.
The process dripping pan trolley has an outlet with a quick clamp connection, which when connected to a food grade sanitary hose (not shown) can be connected through the valve 622 FIG.28 of Module 600 ¨ the CIP and COP unit to the outlet of the pump 607 FIG.28 for transferring drained whey or other solutions to the sewer.
Date recue /Date received 2021-11-08 Another useful accessories are the Cheese extrusion end caps 703, 704 FIG.30, which when mounted to the end of Module 200 ¨ The curds processing Vat, can shape cheese to different extrusion shapes ¨ list of such end caps is not closed.
Following is a Detailed description of the METHOD OF MAKING CHEESE with the NOVEL MODULAR UNIVERSAL CHEESE MAKING MACHINE
There are many kinds of cheeses and the Novel Modular Universal Cheese Making Machine can make all of them, including the preliminary step of pasteurization of raw milk.
Many cheeses are similar to each other in the way that the steps in their manufacturing are the same. The differences between the kinds of cheeses, or even the cheeses of the same kind, usually depend upon the climate, geography, maturation conditions, variations in the cheese making recipe, introduction of additional steps in the cheese making process, variation of bacteria and fungus used as inoculation cultures and variations of the type of rennet used. The Cheese machine is a very flexible platform and the cheese masters have the ability to adjust the process parameters as desired. Here we give the steps and the method for the production of the most popular cheeses.
Pasteurization of Raw Milk ¨ Preliminary step Pasteurization of Raw milk is completed in Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7). Before the start of the pasteurization process, the batch pasteurizer is clean, dry and the main milk valve 110, FIG.5, as well as the auxiliary milk valve 111, FIG.5 are in a closed position.
The First step in the pasteurization process is to load the milk via a flexible hose into the vessel 101 from the milk supply truck (or the milk supply line) through one of two milk inlets 113, FIG.5.
Then we start the temperature recording device mounted inside the control box 105, FIG.5. The recording device records, as required by sanitary laws, readings of the thermometer for measuring the temperature of the milk (cheese curds) 103, FIG.5; and the readings of the thermometer for measuring the temperature of the subspace between the milk surface and the cover of the vessel 104, FIG.5.
The next step is to start the two steam generators 106, FIG.5 which heat with steam the subspace between the milk surface and the cover of the vessel to the temperature values required by the sanitary laws.
Date recue /Date received 2021-11-08 Then from the control box 105, FIG.5 we switch on the electric gear motor 109, FIG.5, which starts the rotary motion of the cheese cutting knives, and the speed of the knives is adjusted to several rpm per minute. The cheese knives assembly as a whole mixes the milk and provides for better heat exchange when the milk is heated.
Next, the two steam condensate (hot water) outlets 108, FIG.5 are opened to the inlet of the steam boiler (or hot water boiler not shown on the drawings);
Next, saturated low pressure steam (or hot water) is supplied from the outlet of the steam boiler (hot water boiler not shown on the drawings) to the jacket of Module 100 through the two inlets 107, FIG.5, FIG.6. The amount of supplied steam (hot water) is controlled by a control valve in boiler hose of the dairy plant, which receives control signals from a PLC
mounted inside the control box 105, FIG.5. The amount of the supplied heating steam (hot water) depends on the temperature of the milk as measured and sent from the thermometer for measuring the temperature of the milk 103, FIG.5 to the PLC.
When steam (or hot water) flows through the jacket 116, FIG.6, the milk is heated until it reaches the pasteurization temperature as required by law. Temperature and time are the critical factors required to achieve pasteurization. Failure to achieve pasteurization will result in a microbiological hazard in the dairy product.
The generally accepted pasteurization schedule for dairy products produced by batch pasteurization of milk-based products with fat content below 10% milk fat (fluid milk, goat milk, whey) is 72 C to 75 C with a holding time at that temperature for 30 minutes.
The temperature of the pasteurization process, the temperature of the subspace between the raw milk surface and the cover 114, FIG.5, and the time of each step of the pasteurization process, must be recorded continuously on a government approved device and the records maintained for prescribed number of years.
When the pasteurization temperature (72-75 C) is reached and the holding time at this temperature (30 minutes) is completed, the steam (hot water) supplied to the jacket of Module 100 is turned off, and the two steam generators 106, FIG.5 are shut off When the steam (hot water) to the jacket is tuned off, pasteurized milk will start to cool down.
Meanwhile the electric gear motor 109, FIG.5 is left to rotate and the cheese knives are mixing the milk. It ensures faster and more uniform cooling of the milk.
Inoculation and Curdling of the Cheese Inoculation of the milk is a process of adding mixtures of bacterial cultures, and in the case of making blue vein cheeses adding funguses, to pasteurized and cooled down milk from the previous step. The temperatures at which the milk is inoculated with bacterial cultures and kinds Date recue /Date received 2021-11-08 of bacteria which are added to the milk are beyond the scope of this patent, so they won't be discussed in detail. As a general example for two of the most widely used bacterial species - S.
thermophilus has an optimal growth temperature range of 35-42 C, and L. d.
bulgaricus has an optimal range of 43-46 C. So the inoculation is completed in these temperature ranges.
Bacterial cultures which are added to the milk use as an energy source the milk sugar lactose and transform it into lactic acid. This bio-process increases the acidity of the milk - the pH of the milk is going down. This leads to denaturation of the milk protein casein and thus the formation of two phases ¨ a liquid phase called whey and a solid phase called cheese curds.
Some time after inoculation of the milk with bacterial cultures, rennet is added. Rennet is a complex set of enzymes produced in the stomachs of ruminant mammals. The chymosin, the key component of the rennet, is a protease enzyme that curdles the protein casein of the milk. In addition to chymosin, rennet contains other enzymes, such as pepsin and lipase. One of the main actions of rennet is the protease chymosin cleaving of the kappa casein chain.
The casein is the main protein of milk. The cleavage causes the casein to bond to other cleaved casein molecules and to form a network. The caseine will cluster better in the presence of calcium and phosphate.
This is why salts of these elements are occasionally added to supplement the preexisting quantities of calcium and phosphorus in the milk. The solid truncated casein protein network traps other components of the milk, such as fats and minerals, to create cheese.
The addition of the rennet is complimentary to the acidic curdling of the milk due to lactic acid produced by the bacterial cultures. The main difference is that the rennet curdling produces a much firmer and stronger casein network (curds) than the acid curdling only.
This allows for firmer and better cheeses and a better expelling of the liquids (whey) from the cheese. Both ¨ the bacterial cultures curdling and the rennet curdling were used together long before the beginning of the recorded history.
During the inoculation process and adding the rennet to the milk, the electric gear motor 109, FIG.5 is allowed to rotate the cheese cutting knives and to mix the milk with the bacterial cultures and the rennet for a better distribution of the cultures and the rennet in the vat.
Shortly after adding the rennet the gear motor 109, FIG.5 is turned off and the bacterial cultures and the rennet are allowed to transform the milk into cheese curds and a watery liquid called whey.
Curds Processing - Cutting of the cheese curds, Scalding (Cooking) of the curds and Washing of the curds Final result of the Curdling of the milk is the settling of the milk into a very moist gel.
Date recue /Date received 2021-11-08 To remove the excessive moisture (whey) from the cheese, it must be cut into smaller pieces (cheese curds) and the cheese curds then go through the process of maturation which is obtained by heating of the cheese curds in the cheese vat and stirring them.
Cutting of the curdled milk to cheese curds, when combined with stirring and mild heating, increases the bondage between the cheese proteins in a single cheese curd, entraps inside the protein network fat globules from the milk and lactic bacteria from the starter culture and expels water from the single cheese curd.
Cutting of the Curds To cut the curdled milk into cheese curds the bi-directional gear motor 109,FIG.5 is tuned on and it rotates the main axle 122,FIG.6,FIG.7 to which are attached the cutting knives 125, FIG.7.
One of the longitudinal edges of the cheese knives 125, FIG.7 is sharp ¨ for cutting of the cheese curds, the other edges are blunt for mixing of the cheese curds.
The direction of rotation of the bi-directional gear motor 109,FIG.5 when cutting the cheese curds, is such that the sharp edges of the knives 125 cut the curdled milk to cheese curds and mildly mix them at around 7 to 10 rpm per minute.
Because the knives 125 are mounted on the cheese knives supporting frames 124, FIG.7 at a slight angle, any two consecutive cuts of cheese knives 125 never cut along the same path.
This approach to cutting of the cheese curds reduces the amount of the cheese fines ¨ cheese curds with size under 0.1mm. This prevents the loss of cheese product during the separation of the cheese curds from the whey.
Scalding (Cooking of the curds) .. When the Cheese maker decides that the cheese curds are of a sufficient size, he stops the bi-directional gear motor 109,FIG.5, changes the direction of the rotation of the gear motor 109,FIG.5 through the control box 105,FIG.5 and then restarts it. Thus, the blunt edges of the of cheese knives 125, FIG.7 will contact the cheese curds and will only stir them without cutting.
At the same time, some heating steam (hot water) is allowed into the jacket of the Cheese Vat through the two inlets 107, FIG.5, FIG.6 from the steam (hot water) boiler.
The steam (hot water) heats up the jacket, which heats up the whey and the cheese curds.
The duration of the heating and the heating temperature of the cheese curds depends on the cheese recipe and the decisions for the stirring and heating action exercised on the cheese curds are made by the Cheese maker.
Date recue /Date received 2021-11-08 Usually this scalding (cooking) of the cheese curds is done at 30-32 C for soft cheeses, at 33-35 C for semi-hard cheeses, at 38-40 C for hard cheeses, and at temperatures above 40 C for the cheeses that are considered to be cooked cheeses.
For many cheeses after this step, the cheese curds are ready for draining of the whey.
Washing of the Cheese curds ¨ optional step Some cheeses named washed (rinsed) curd cheeses such as Edam, Gouda, Colby and Monterey Jack, require the additional step of washing (rinsing) of the cheese curds. In general, the washing of the cheese curds removes some of the lactic acid from the cheese curds and gives the cheeses produced by this technology a milder and nuttier taste. The essence of the process of washing of the cheese curds is to cut and cook the cheese curds as described above. Then a portion of the whey from the cheese vat is drained, and replaced with fresh filtered water the steps for cooking of the cheese curds is repeated.
To do this, after the first cooking cycle, the bi-directional gear motor 109,FIG.5 is stopped and a portion of the whey is drained through the auxiliary milk vale 111, FIG.5, through a flexible hose (not shown), through the elbow connection 205, FIG.8, to the Curds processing vat ¨
Module 200. The density of the cheese curds is slightly higher that the density of the whey, so they tend to collect at the bottom of the Cheese vat, rather then at the top, the implication being that the drained whey is almost cleared of cheese curds. In addition, for the whey to leave the Curds processing vat ¨ Module 200, the whey must pass through the filtering media 211, FIG.8,FIG.10 so any escaped cheese curds will be caught (won't be lost with the whey) and can be further processed with the rest of the cheese curds.
After draining part of the whey, clean filtered water (satisfying sanitary requirements) is added to the Cheese vat ¨ Module 100, through one of the inlets 113, FIG.5.
Then the Scalding (Cooking) of the curds step as described above is repeated.
After the scalding operation, the cheese curds are ready for the draining of the whey before pressing them into cheese molds.
Separation of the Cheese curds from the whey Separation of the cheese curds from the whey is an essential step during the making of any kind of cheese. In the presented invention, the separation of the cheese curds from the whey is completed in the Cheese Processing Vat ¨ Module 200.
To separate the cheese curds from the whey:
- First we put in motion the top ribbon conveyor 217,FIG.10 by switching on (at the control box 216,FIG.8) the corresponding bi-directional gear motor 219, FIG.9, FIG.10.
From the control box 216,FIG.8 we also adjust the direction of the rotation of the top ribbon conveyor Date recue /Date received 2021-11-08 217,FIG.10 as clockwise. When any cheese curds come in contact with the top conveyor the cheese curds will be moved in a direction that is opposite to the place where the gear motor 219, FIG.9, FIG.10 is attached.
- The Second step is to put in motion the bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.!!, by switching it on at the control box 216,FIG.8 the corresponding bi-directional gear motor 219, FIG.9, FIG.10. From the control box 216,FIG.8 we adjust the direction of the rotation of the bottom ribbon conveyor 218,FIG.10 as counter-clockwise. When any cheese curds come in contact with the bottom conveyor they will be moved in a direction towards the place where the gear motor 219, FIG.9, FIG.10 is attached.
To the front of the bottom ribbon conveyor 218, FIG.9, FIG.10 is attached the full blade bottom extrusion conveyor 240, FIG.9, FIG.10. So both bottom conveyors will rotate together and in the same direction ¨ counter-clockwise.
- The third step is to visually inspect if the end cap 213, FIG.8,FIG.10 and the filtering media 211, FIG.8,FIG.10 are properly installed.
- The forth step (while the cheese knives 125, FIG.7 are still stirring the cheese curds) is to drain part of the whey which will flow through the auxiliary milk vale 111, FIG.5, through a flexible hose (not shown), though one of the connections 207, FIG.8, through the curds processing vat body 201, FIG.10, through the whey draining pipe 210, FIG.8, FIG.10, through the filtering media 211, FIG.8, FIG.10, to the process dripping pan trolley 701,FIG.30, from where the whey can be transferred either to the sewer or for ricotta (cottage cheese) production (when the dairy plant is equipped for this).
- The fifth step (while the cheese knives 125, FIG.7 are still stirring the cheese curds) is to open the main milk valve 110, FIG.5, and then a mixture of whey and curds will flow through the main milk valve 110, FIG.5, through a flexible hose (not shown), through the elbow connection 205, FIG.8, to the Curds processing vat ¨ Module 200.
The cheese curds at this stage are soft, but yet solid particles, so any curds which come in contact with the bottom ribbon conveyor 218,FIG.10, which rotates counter-clockwise, will be transferred inside the curds processing vat in a direction toward the gear motor 219, FIG.9, FIG.10. The full blade bottom extrusion conveyor 240, FIG.9, FIG.10 rotates counter-clockwise (in the same direction) as bottom ribbon conveyor 218,FIG.10, any the cheese curds which come in contact with this full blade conveyor 240, FIG.9, FIG.10, will also be transported away from the whey draining pipe 210, FIG.8, FIG.10. In other words, the full blade bottom extrusion conveyor 240, FIG.9, FIG.10 will clean and prevent inside clogging of the whey draining pipe 210, FIG.8 with cheese curds (FIG.10). However, when large amounts of cheese curds are transported in a direction toward the gear motor 219, FIG.9, FIG.10 (towards the back Date recue /Date received 2021-11-08 end of the Curd processing vat Module 200) these cheese curds will tend to squeeze each other and even overflow from the vat. At this point, the top ribbon conveyor 217,FIG.10 which rotates clockwise will moves part of the curds away from the back end of the curds processing vat module 200. Thus when the two ribbon conveyors rotate in opposite directions (top clockwise, .. bottom counter-clockwise) they will circulate the cheese curds inside the Curds processing vat Module 200.
Since the whey is a liquid, it will flow freely out of the curds processing vat module 200 through the whey draining pipe 210, FIG.8, FIG.10, through the filtering media 211, FIG.8,FIG.10, to the process dripping pan trolley 701,FIG.30, from where the whey can be transferred either to the sewage or for ricotta (cottage cheese) production, when the dairy plant has such capacities.
Pressing of the Cheese Curds into different cheeses shapes Once the main volume of whey is separated from the cheese curds, the next step is to press the cheese curds in order to remove even more whey from them. Usually this is done by pressing of the wet cheese curds into cheese molds. The cheese molds give the final shape of produced cheese ¨ usually a cheese wheel or a cheese block.
Depending of how much pressing force is applied and how much whey (moisture) is removed from the cheese curds, the cheeses are classified in several groups. Starting with the cheeses with the highest moisture and the minimum value of the pressing force applied, these cheese groups are soft cheeses (such as Brie), semi soft cheeses (such as Roquefort), hard cheeses (such as Cheddar) and very hard cheeses (such as Parmesan).
The pressing force applied to the cheese curds varies ¨ while for soft and semi-soft cheeses we have just gravity pressing by their own weight, for the other cheese groups the pressing force usually varies from 0.05 MPa to 0.2 MPa.
One of the advantages of the Cheese Machine is that with the help of the S-type load cell 326, FIG.14,FIG.17, FIG.18 and the electric pressing cylinder 325, FIG.
12, FIG.17, FIG.18, the cheese pressing force can be measured, can be changed and can be regulated depending on the cheese variety produced.
This allows for the Cheese Machine to press all kinds of cheeses and to be a universal cheese machine.
To press any kind of cheese (except for the soft and the semi-soft varieties), after draining of the main portion of the whey:
- the gear motors 219, FIG.9, FIG.10 of Module 200 are turned off, - the end cap 213, FIG.8 is removed;
Date recue /Date received 2021-11-08 - the whey draining pipe 210, FIG.8, FIG.10 is attached to the pipe 307, FIG.13, FIG 14 of Module 300 with the help of the sanitary clamp 214, FIG.8.
- the cheese gate 318, FIG.14, FIG 16 is opened by hand;
- an empty cheese mold 330, FIG.12, FIG.14, FIG.17 is placed on the cheese mold support sub-frames 321, 323, FIG.12,FIG14, FIG.15;
- the position of the cheese mold is adjusted with the help of the bolts of the cheese mold support frames 320, 322,FIG.12, FIG14, FIG.15 in such a way that the neck of the cheese mold 330, FIG.12, FIG.14, FIG.17 fits into cheese mold support and holding ring 336, FIG.17;
- the back cover 331, FIG.12, FIG.14, FIG.17 of the cheese mold is placed on the cheese mold back end;
- the piston of the electric actuator 325, FIG.17 is extended so the load cell platform 327, FIG17, FIG.14 touches the back cover 331, FIG.17 of the cheese mold with a small and constant force (for example 100N), and pushes the front end of the cheese mold 330, FIG.17 to stay tight to the face of the mold plate 338, FIG.17, FIG.12;
- then the light curtains 317.FIG.12, FIG.14 are reset;
- the top and the bottom gear motors 219, FIG10 are started;
- the direction of the rotation of the ribbon conveyors 217, 218 FIG.10 is set in extrusion mode at the control box 324, FIG.12. Thus the top ribbon conveyor 217,FIG.10 is set to rotate counter-clockwise. At the same time the ribbon screw conveyor 218, FIG10 and the full blade screw conveyor 240, FIG 10 are set to rotate clockwise so they transfer the cheese curds to the cheese mold 330, FIG.17. It must be noted, that the bearings of the gear motors 219, FIG10 are of such designs and dimensions, that they can withstand all of the axial forces which will occur, even when the screw conveyors 218 and 240 are pressing the hardest to press cheeses (such as Parmesan);.
- the load cell 326, FIG17, FIG.14 reads the pressing force value, and when the pressing force reaches a preset value in the control box 324, FIG.12, the control box signals the operator with a visual and sound signal,.
- Then the operator closes the cheese gate 318, FIG.17 with his hand. When the operator's hand crosses the beams of the light curtains 317,FIG.12, FIG.14 this movement sends a signal to the control box 324, FIG.12 and shuts down Modules 200 and 300;
- The piston actuator 325, FIG.17 is then disengaged from pressing the mold back cover 331, FIG.17, and the cheese mold 330, FIG.17 is removed from cheese press.
This cycle is repeated until all of the cheese curds in Module 200 are pressed into cheese wheels or blocks by Module 300.
Date recue /Date received 2021-11-08 Re-Pressing of the cheeses and Using of Module 300-Cheese press as a stand alone unit Some cheeses require re-pressing which is usually completed within a maximum of 12 hours after the initial pressing of the cheese. In addition some cheese makers may prefer to press their cheese by using Module 300 as a stand alone unit.
To press cheese in this case, Module 300 ¨ the cheese press is detached from any of the other modules of the Cheese machine.
To prepare the Cheese press ¨ Module 300 as a stand alone unit for pressing cheese, we mount the additional cheese mold plate 339, FIG.18 to Module 300.
The additional cheese mold plate 339, FIG.18 is of such dimensions and design, that it is supported and slides freely on the bottom composite beams 303, FIG12, FIG.13, FIG 14 and the top composite beams 304, FIG 12, FIG.13, FIG 14.
On its front, the cheese mold plate 339, FIG.18, has mold restriction ring, similar to the design of mold restriction ring 336, FIG.17. The back of the additional cheese mold plate 339, FIG.18 is supported by the mold restriction ring 336, FIG.17 of plate 338, FIG.17.
To press a cheese wheel:
- the back cover 331, FIG.17 of the cheese mold 341, FIG.18 is put on;
- then the cheese mold 341, FIG.18 is filled up with cheese curds;
- the whole assembly (the full cheese mold 341 plus the back cover 331) is put on the sub-frames 321, 323, FIG.18 and pushed tightly to the face of cheese mold plate 339, FIG.18;
- Then a food grade plastic plug 340, FIG.18 is inserted into the back end of the cheese mold 339, FIG.18;
- the pressing force of the electric piston 325, FIG.18 is preset to the desired value with the help of the control box 324;
- then the Module is started and the piston of the electric cylinder 325, FIG.18 starts moving forward;
- the face 327 of the load cell 326, FIG.18 pushes the plug 340 inside the mold 341, until the value of the pressing force measured by the load cell reaches the preset value of the pressing force. When this value is reached, the load cell 326, FIG.18 sends a signal to the control box 324 so the piston of the electric cylinder 325 will stop moving any further forward;
- then the piston of the electric cylinder 325, FIG.18 will automatically change direction of movement and will retract, thus releasing the cheese mold 341;
The operator removes the cheese mold (with the pressed cheese wheel in it) from the Cheese press ¨ Module 300, unloads the cheese wheel , fills again the mold 341 with cheese curds and starts the cycle again, until all the cheese curds are pressed into cheese wheels.
Date recue /Date received 2021-11-08 If during the pressing operation, any object (or any body part of the operator) crosses the light beams of the light curtains 317, FIG12, FIG.14 the Cheese press ¨ Module 300 will come to a complete stop, and must be reset manually to re-start the cheese pressing operation.
The cheese plate 338 FIG. 17, the cheese plate 339 FIG.18 and the cheese molds 330, 341 FIF17, FIG 18 can be manufactured to different diameters and square shapes.
When manufacturing the cheese plate 339, FIG.19, it must be remembered that the dimensions of the cheese mold restriction ring of the cheese mold plate 339, FIG. 18 has to accommodate for the cheese mold 341 FIG.18 plus the back cover 331, FIG.17.
Pressing and Processing of soft and semi soft cheese varieties.
Making of soft and semi soft cheeses (with moisture content more than 40%) doesn't require the step of pressing of the cheese. For these cheeses, the pressing force is only the gravity and the weight of the cheese curds and the leftover whey.
For such soft and semi soft cheese, the cheese curds with the whey left-over after the draining of the cheese curds, are scooped and poured into the cheese molds. Then gravity is allowed to fuse the cheese curds and the whey in a loaf of a soft cheese, which is then smeared with white fungus (such as Penicillium camemberti in the case of Brie cheese), or the cheese can be pierced with needles to allow for aeration of the insides of the cheese and development of blue veins by the fungus culture added beforehand (such as Penicillium roqueforti in the case of Silton cheese).
For this operation:
- after the draining of the cheese curds in Module 200, the ribbon conveyors of this module are left to rotate in the cheese curds mixing mode. The top ribbon ribbon conveyor 217,FIG.10 rotates clockwise. At the same time the ribbon screw conveyor 218, FIG10 and the full blade screw conveyor 240, FIG 10 rotate counter clockwise, so the curds are moving and mixing inside the body 201,FIG. 10 of Module 200 in a circular motion;
- at this stage and if salt (NaCl) is required, it can be added and mixed with the cheese curds and leftover whey from the two manholes 204, FIG.8;
- when the salt is thoroughly mixed with the cheese curds and the whey, the two gear motors 219, FIG.10 receive a signal from the control box 216, FIG.10 and all conveyors are brought to a stop;
- then the end cap 213, FIG.8 is removed;
- from the control box 216, FIG.10, the directions of the rotation of the two gear motors 219, FIG.10 are set to cheese curds extrusion mode. The top ribbon ribbon conveyor 217,FIG.10 will rotate counter ¨ clockwise, while the ribbon screw conveyor 218, FIG10 and full blade Date recue /Date received 2021-11-08 screw conveyor 240, FIG 10 will rotate clockwise, so the curds will be coming out of Module 200 through the end of the whey draining pipe 210, FIG.8, FIG.10;
- finally we start the two gear motors 219, FIG.10 and the cheese curds and leftover whey are extruded (poured) into a vessel from where they can be scooped and distributed into cheese molds designed for soft and semi-soft cheeses.
Cheddarization of cheese curds Some varieties of hard cheeses (such as Cheddar) and pasta filata cheeses (such as Kashkaval), before pressing, must undergo the process of Cheddarization. The Cheddarization can be described as a process where the bacterial cultures added to the pasteurized milk are allowed to grow on leftover lactose in the partially drained cheese curds, until they increase the acidity of the cheese curds (decrease the pH of the cheese curds) to a set point.
Increased acidity of the cheese curds creates an environment which suppresses the growth of undesirable bacteria and thus increases the quality of the final cheese product and its shelf life.
During the cheddarization process, the cheese curds are usually stacked on piles and the piles of cheese curds are flipped which allows for even more whey to be drained from them.
Then the cheese curds are cut, salted with NaCl and pressed into cheese molds of the desired shape and weight.
This Cheese machine allows for the classic cheddarization process to be completed easily:
- first, the cheeses curds are lightly pressed as described above into cheese molds (Pressing of Cheese Curds into different cheeses shapes) - then the cheese curds are unloaded on the cheddarization table 702 FIG.30 for the classic cheddarization process to take place. The dripping whey is collected into the process trolley 701, FIG.30.
- after the end of the cheddarization process the cheese curds are cut, salted, mixed, pressed and re-pressed into cheese molds as described above (Re-Pressing of the cheeses and Using of Module 300-Cheese press as stand alone unit).
One of the advantages of Our Cheese machine is that it also allows for mechanization of the process of cheddarization of the cheese curds:
- when the cheese curds are drained, the ribbon conveyors of Module 200 ¨ the cheese processing vat are in cheese curds mixing mode. The top ribbon conveyor 217,FIG.10 rotates clockwise. At the same time ribbon screw conveyor 218, FIG10 and full blade screw conveyor 240, FIG 10 rotate counter clockwise, so the curds are moving and mixing inside the body 201,FIG. 10 of Module 200 in a circular motion. The created circular motion allows for more and more whey to be drained and for the cheese curds to become drier and drier;
Date recue /Date received 2021-11-08 - when the cheese curds reach a point when they are sufficiently dry for cheddarization, two gear motors 219, FIG.10 are turned off at the control box;
- this brings Module 200 to a stand still and the bacteria are allowed to decrease the acidity of the cheese curds;
- Instead of flipping the cheese curds by hand as in the classic cheddarization process, after a period of time the two gear motors 219, FIG.10 are restarted in cheese curds mixing mode.
This re-start mixes the cheese curds which is equal to the manual operation of flipping cheese curds by hand. This procedure can be repeated several times - until the acidity of the cheese curds reaches the desired value;
- When desired pH value is reached, salt (NaCl) is added and mixed with the cheese curds;
The cheddarized cheese curds are now ready, to be pressed (Pressing of Cheese Curds into different cheeses shapes) and re-pressed (Re-Pressing of the cheeses and Using of Module 300-Cheese press as stand alone unit) as described above.
An additional option is to attach a knife of appropriate dimensions (not shown) with the help of the end cap bolt 244, FIG 10, to the front end of the full blade screw conveyor 240, FIG 10. This will allow the automatic cutting of the cheddarized cheese curds when they are leaving Module 200 for pressing into cheese wheels in Module 300. In this optional case, there is no need for the manual cutting of the chedarrized cheese curds by hand or by an extra curds cutting machine as it is usually done in classic cheddarization process (before pressing the curds into cheese wheels).
Stretching of pasta filata cheeses A special category of cheeses are so called pasta filata cheeses (such as Mozzarella and Caciocavallo). Their recipes add the additional step of cooking (stretching) of the drained cheese curds in hot water or with steam. Salting of the pasta filata cheese is done during the cooking of the cheese curds. The advantage of the cooking step is that it almost sterilizes the cheese product, which when combined with the salting of the curds increases the shelf life of the cheese product (up to several years for some varieties). The effect of sterilization is further enhanced when combined with the process of cheddarization of the cheese curds, which the recipes of many varieties of pasta filata cheeses require as a preliminary step.
When cheese curds are cooked in small amounts of hot water or with small amounts of direct steam, the protein networks of the single cheese grains tend to intermingle, their shapes disappear and the cheese curds become one dough like mass which flows like very thick molasses. The newly formed protein networks in the cheese dough have much higher elasticity than the protein networks in the drained cheese curds. The mass is repeatedly stretched by the cheese makers using their hands, sticks or since 20th century specialized machines. The Date recue /Date received 2021-11-08 continuous stretching of the cheese mass creates fibrous structures which makes the cheese more firm, expels even more water from the cheese and gives the pasta filata cheese a desirable string texture.
When the cheese maker decides that the cooking and stretching of the cheese curds is completed, the cheese dough is poured into cheese molds, where it solidifies and is ready for aging.
One of the advantages of our Cheese machine is that, instead of using a specialized cheese stretching machines for making pasta filata cheeses, it allows the cheese maker to stretch (cook) such cheeses in Module 200 ¨ Cheese curds processing vat, thus decreases the cost of the cheese making and the capital spent for buying additional cheese making equipment.
To make a pasta filata cheese in Module 200 ¨ Cheese curds processing vat:
- we start the usual step (Separation of the Cheese curds from the whey) as described above;
- the next step, is to leave the cheese curds to undergo the process of cheddarization (described above in Cheddarization of cheese curds). Some pasta filata cheeses don't require this step;
- after the cheddarization, the cheese curds are ready for stretching;.
To stretch and cook the cheese curds into pasta filata cheese in Module 200 ¨
the Cheese curds processing vat:
- First, the two gear motors 219, FIG.10 are stopped and Module 200 is in stand still;
- the next step is to remove the end cap 213, FIG.8 and the whey draining pipe 210, FIG.8, FIG.10 by removing the sanitary clamps 213 and 215, FIG.8;
- then the whey draining pipe 210, FIG.8 is re-placed with a plain pipe (with no holes on it) of the same dimensions. The replacement pipe is re-attached to Module 200 ¨ the Cheese processing vat with the help of the sanitary clamp 215, FIG.8;
- the end cap 213, FIG.8 is re-attached to its position on the newly mounted plain pipe, with the help of the sanitary clamp 213, FIG.8;
- the directions of rotation of the two gear motors 219, FIG.10 are set to cheese curds mixing mode and the gear motors are switched on. The top ribbon conveyor 217,FIG.10 rotates clockwise. At the same time ribbon screw conveyor 218, FIG10 and full blade screw conveyor 240, FIG 10 rotate counter clockwise, so the curds are moving and mixing inside the body 201,FIG. 10 of Module 200 in a circular motion;.
- then a sufficient amount of hot water (live steam) is added to the vat 201, FIG.8 and steam or hot water is supplied to the to the jacket 225, FIG.9 of the vat 201, FIG.8, thus allowing for the heating of the cheese curds in the vat 201, FIG.8;
- at this time salt (NaCl) is added to the curds in the cheese vat 201, FIG.8 as required;
- Combined action of the hot water (live steam) added to the cheese curds, continuous mixing of the curds with the ribbon conveyors 217, 218, 240 FIG.10 and through the jacket heating of the Date recue /Date received 2021-11-08 curds, softens the cheese curds and soon a very high viscosity cheese mass is formed. The viscosity of he cheese mass depends on the temperature of the curds and the amount of hot water (live steam) directly added to the Vat 201, FIG.8, FIG.10;
- when the cheese maker decides that the cheese curds are sufficiently cooked and stretched, the two gear motors 219, FIG.10 are switched off and Module 200 is brought to a stand still;
- then the end cap 213, FIG.8 is taken off and in its place is put a cheese extrusion end cap like cheese extrusion end caps 703, 704 FIG. 30;
- after this step, the directions of the rotation of the two gear motors 219, FIG.10 are set to cheese curds extrusion mode via the control box 216, FIG.10, and the cheese motors are switched on. The top ribbon conveyor 217,FIG.10 will rotate counter ¨
clockwise, while the ribbon screw conveyor 218, FIG10 and full blade screw conveyor 240, FIG 10 will rotate clockwise.
- The cooked and stretched pasta filata cheese flows out of Module 200 and is poured into the cheese molds of desired size and shape, where it cools down and solidifies.
Making of extruded cheese products With the help of Module 200 and Modules 400 and 500, the Cheese machine can also make extruded cheese products.
To make extruded cheese products of a desired shape and size (such as pasta filata cheese fingers, cheese bites, cheese sheets etc.):
- First, we follow the exact same procedure for making cheese curds (Separation of the Cheese curds from the whey, Cheddarization of cheese curds),as described above;
- Second, we follow the exact same procedure for Stretching of pasta filata cheeses, as described above, except in the final step ¨ to turn on the two gear motors 219, FIG.10 and to set them to cheese curds extrusion mode;
- Before switching on the two gear motors 219, the front end of the Module 200 is aligned with the front end of Module 400 in such a way that when the pasta filata cheese flows through the end cap of the desired shape (such as the end caps on FIG.30) it drops on the belt with a smooth surface 403,FIG.19 of Module 400;
- At the same time, the front end of Module 500 is attached to the back end of Module 400 as shown on FIG.19;
- the next step is to turn on the cooling water to the distribution header with spray nozzles 405, FIG.19, so when a pasta filata cheese extrusion comes on the conveyor it will be cooled down before it is cut to the desired length;
Date recue /Date received 2021-11-08 - Next, an important step is to adjust at the control box 216, FIG.8, FIG.9 the rotations per minute (rpm) of the two gear motors 219, FIG.10.
The rotation speed will determine the amount of cheese extruded per minute.
The linear speed of the belt 403,FIG.19 of Module 400 is dependent on the amount of cheese extruded per minute;
- The linear speed of the belt 403 is adjusted at the control box 530, FIG.23 of Module 500 to a such a value that all of the cheese extruded on the conveyor can be cooled and solidified before it reaches the cheese knife 519 FIG.21, FIG.22;
- Also at the control box 530 is adjusted the time relay which controls the downward movements per minute of the electric actuator 507 FIG.19, FIG.20 (cuts per minute) in such a way that the knife 519 cuts the cheese extrusions to the desired length;
- Finally, after all of the above steps are completed, the cheese maker can switch on the two gear motors 219, FIG.10, and the cheese extrusion process will start.
The pasta filata cheese will be extruded to the desired shape from Module 200 over the conveyor belt of Module 400. The cheese extrusion(s) are cooled on the conveyor belt 403,FIG.19 by water coming from the header 405, FIG.19 and they will then be cut to the desired length by the cheese knife 519 FIG.21, FIG.22.
Making of additional cheese products, alternative cheese like products, and cheese extrusions from them It must be noted, that by varying the recipes (amount of water, adding emulsifiers, spices, dyes etc.), Module 200 can also be used for making of additional cheese products such as cheese sauces, multicolored cheeses, spiced cheeses etc.
The Cheese Machine can also be used to make alternative cheese like products, where the animal milk in real cheese is replaced by plant, algae, fungus or bacteria derived milk substitutes.
The general idea is to use the Modules of the Cheese Machine for making alternative cheese curds like products and then processing the alternative cheese curds like products as real animal milk cheese curds.
The same is valid for making of Novel extruded cheese products with the Cheese machine using Modules 200, 400 and 500. In such cases, cooling water may or may not be necessary at all times.
Salting of the Cheeses The salting of a number of cheese products (such as cheddar type cheeses, pasta -filata cheeses, etc.) was described above, when.
Date recue /Date received 2021-11-08 However it has to be noted that for many cheeses the salting is done by immersing the pressed cheese wheels into brine solutions for a prescribed period of time (as an example Parmigiano Reggiano cheese), or by keeping the pressed cheeses in a brine permanently (as an example Feta cheese). In these examples the cheese curds are pressed into the cheese molds without salting and put in brine following specific cheese recipes (see above Pressing of the Cheese Curds into different cheeses shapes, Re-Pressing of the cheeses and Using of Module 300-Cheese press as a stand alone unit).
In Conclusion, it has to be written that, We the Inventors believe that the so described designs of this Novel Modular Universal Cheese Making Machine and Method for the making cheeses with it, will give us the right to make the Patent claims in the Patent Claims Section of this Patent.
Date recue /Date received 2021-11-08

Claims

The Embodiments of the Invention in Which an Exclusive Property or Privilege is Claimed by the Inventors are Defined as Follows:

1. A Novel Modular. Universal Cheese Making Machine which has the following modules:
1.1. Module 100 ¨ Batch Pasteurizer and Cheese Vat;
1.2. Module 200 ¨ Curds Processing Vat;
1.2. Module 300 ¨ Cheese Press;
1.3. Module 400 ¨ Cheese conveyor;
1.4. Module 500 ¨ Cheese Cutting table;
1.5. Module 600 ¨ Combined CIP and COP Unit;
The Novel Modular. Universal Cheese Making Machine, or any combination of the above enumerated modules of the machine;
When these modules are used to manufacture cheese, cheese products or alternative cheese like products and when this Machine or the modules of this Machine are mounted in a stationary cheese plant, in a mobile cheese plant (such as a shipping container= plant), or when a single module or any combination of the above enumerated modules are retrofitted to an existing cheese plant.
The Method of Making cheese, cheese products, and cheese like products with this Machine.
The method for cleaning of the Modules of the Machine.

2. Module 100 ¨ Batch Pasteurizer and Cheese Vat (FIG.5, FIG.6,FIG.7) including in part the following components:
2.1. A main axle of the cheese curds cutting assembly 122, FIG.6, FIG.7;
2.2. A back sub-axle 117, FIG.6, FIG.7 with grooves 118, FIG.6, FIG.7;
2.3. A front sub-axle 120, FIG.6, FIG.7;
2.4. Cheese knives fixing bolts 129, FIG.7;
2.5. Cheese knives fixing nuts 128, FIG.7;
2.6. Cheese knives 125, FIG.7. Each knife 125 has two knife holes 127, FIG.7 drilled in it, so two cheese knife fixing bolts 129, FIG.7 can slide through them; Each knife has one longitudinal sharp edge for cutting the cheese curds and one longitudinal blunt edge for mixing the cheese curds.
Date recue / Date received 2021-11-08 2.7. Cheese knives supporting frames 124, FIG.7. Each frame 124, FIG.7 has two supporting rings welded to the main axle 122. Each frame has a number of symmetrical channel slots 126, FIG.7, which end with holes cut into the metal. The slots 126 are cut at an angle in the frame 124. Each frame 124 has four holes cut in it so the two knife fixing bolts 129, FIG.7 can slide through these holes. To mount a cheese knife 125, FIG.7 into the frame, each knife 125 slides into the symmetrical slots 126, FIG.7. Then two knife fixing bolts 129, FIG.7 slide through the holes on the frame 124 and the holes 127 of each knife, and the bolts 129 are tighten with the knife fixing bolts to the frame 124 with the help of two knife fixing nuts 128, FIG.7.
The whole Module 100 ¨ Batch Pasteurizer and Cheese Vat;
The designs of each of the enumerated above parts.
The method of pasteurizing milk and processing alternative cheese like liquids with the Module;
The method of cutting cheese curds, cheese like products curds, cheese products or alternative cheese like products with this Module.

3. Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.11) including in part the following components:
3.1. A main vat flange 227, FIG.8,FIG.9;
3.2. A removable flange 228, FIG.8.
3.3.A top ribbon conveyor 217, FIG.9, FIG.10,FIG.11. The top ribbon conveyor 217, FIG.9, FIG.10, FIG.11, has two sub-axles attached to the main axle. The back end sub-axle 238, FIG.11, FIG.10, passes trough the two lip seals 239, FIG.10, which seal the interior of Module 200 from the exterior, and is supported by the bearings 234, FIG10, of the top gear motor 219. The front end sub-axle 235, FIG.11, FIG10 is supported by the food grade sliding bearing 236, FIG10. The bearing 236, itself is mounted inside the bearing box, which is welded inside the three prong star-shaped bearing support 221, FIG.9. The star-shaped bearing support 221, FIG.9 is welded to the body 201 of the module and the flange 217. Since the baring 236, the bearing box and the bearing support 221 are completely immersed inside the module 200, to allow for CIP cleaning of the bearing, on the surface of the sub-axle 235 are cut grooves 237, FIG.11, which extend beyond the length of the bearing box and the bearing support 221.
3.4. A full blade extrusion conveyor 240, FIG.9, FIG.10. From the front side the extrusion conveyor is capped with the welded cap 243, FIG.10 which has threads to which is screwed the end bolt 244, FIG.10. The bolt 244 allows for the attachment of Date recue / Date received 2021-11-08 different blades to the end of the conveyor 240, or when the conveyor 240 is cleaned, for the cleaning of its interior.
3.5. A bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11. The bottom ribbon conveyor 218, FIG.9, FIG.10, FIG.11 has two sub-axles attached to the main axle. The back end sub-axle 231, FIG.11, FIG.10, passes through the two lip seals 232, FIG.10, which seal the interior of Module 200 from the exterior, and is supported by the bearings 234, FIG10, of the bottom gear motor 219. The front end sub-axle 245, FIG.11, is supported by the food grade sliding bearing 229, FIG10. The bearing 229, itself is mounted inside the bearing box. The bearing box is welded inside the three prong stu-ff) shaped bearing support 222, FIG.9, which itself is welded to the body 201 of the module and the flange 217. Since the baring 229, the bearing box and the bearing support 222 are completely immersed inside the module 200, to allow for CIP cleaning of the bearing, on the surface of sub-axle 245 are cut grooves 230, FIG.11, which extend beyond the length of the bearing box and the bearing support 222. Also, the front end sub-axle 245, FIG.11, FIG10 is designed in such a way, so to it can be attached with bolts 242, FIG.10 the extrusion conveyor 240, FIG.9, FIG.10.
3.6. A whey draining pipe 210, FIG.8, FIG.10. The whey draining pipe 210 is a pipe with two flanges and a body with drilled patterned holes. The whey draining pipe is attached to the flange 215 with the help of a sanitary clamp 215, FIG.8, and is closed from the other side with the end cap 213, FIG.8 and the sanitary clamp 214, FIG.8. The action of draining and filtering of the whey from the cheese curds is achieved by several layers of filtering media 211, FIG.8,FIG.10, wrapped around the whey draining pipe 210. The filtering media can be one of the following materials ¨ natural and synthetic fabrics (such as cheese cloth), different plastic sheets with micro-perforations, or metal sheets with micro-perforations. The filtering media 211 is secured over the pipe 210 with the filtering media clamp 212, FIG.8, FIG.10. When the filtering media 211 is made from a metal sheet with micro-perforations, there is no need for a clamp 212, because the metal whey filtering sheet is directly welded to the whey draining pipe 210.
The whole Module 200 ¨ Curds Processing Vat (FIG.8, FIG.9, FIG.10, FIG.11);
The designs of each of the enumerated above components of the Module.
The Method of processing curds and making cheese and cheese products with the Module.
The Method of processing the curds of alternative cheese like products, and making alternative cheese like products with the Module.
Date recue / Date received 2021-11-08

4. Module 300 - Cheese Press including in part the following components:
4.1. A front cheese press plate 301, FIG 12, FIG.13, FIG 14;
4.2. A back cheese plate 302, FIG12, FIG13, FIG 14;
4.3. The two bottom composite beams 303, FIG 12, FIG.13, FIG 14;
4.4. The two top composite stainless steel beams 304, FIG 12, FIG.13, FIG 14;
4.5. The four mounting brackets 306, FIG 12, FIG.13, FIG 14;
4.6. The pipe with single flange 307, FIG 12, FIG.13, FIG 14, which allows for the connection of the whey draining pipe 210, FIG.8, FIG.10 of Module 200 - the Cheese processing Vat;
4.7. A cheese gate guide plate 310, FIG.13;
4.8. A cheese mold plate 338, FIG.17;
4.9. A load platform 327, FIG.14,FIG.17, FIG.18;
4.10. A side metal screen 313, FIG.12, FIG.14;
4.11. A top free standing metal screen 315, FIG.12, FIG14;
4.12. A cheese gate 318, FIG 16;
4.13. Two cheese gate support assemblies 319, FIG.12, FIG14, FIG.16;
4.14. Two cheese mold support frames 320, 322, FIG.12, FIG14, FIG.15;
4.15. Two identical cheese mold support sub-frames 321, 323, FIG.12, FIG14, FIG.15;
The Whole Module 300 - Cheese Press;
The designs of each of the enumerated above components of the Module.
The Method of pressing cheese, cheese products and alternative cheese like products with the Module.
The Method of pressing and processing of alternative cheese like products with the Module.

5. Module 500 - Cheese Cutting table, including in part following components:
5.1. The two laser cut stainless steel body plates 501, FIG. 19, FIG.20, FIG.21;
5.2. The horizontal frame beams 513, FIG 21;
5.3. An actuator holding rail beam 523, FIG.19, FIG.21, FIG.22;
5.4. A front safety screen 504, FIG.19;
5.5. A cheese cutting knife 519 FIG.21, FIG.22;
5.6. A sacrificial cheese cutting strip 509 FIG.20, FIG.21 with a steel support cutting strip 508 FIG.20, FIG.21 and the reinforcement support of the cutting strip 512 FIG. 21;
5.7. The plastic rollers 522 FIG.521 with the steel roller support rods 511 FIG.20, FIG.21, the roller restrain rings 520 FIG.21 and the roller restrain pins 521 FIG.21;
Date recue / Date received 2021-11-08 5.8. A cheese knife 519 FIG.21, FIG.22 with a central cheese knife guiding rod FIG.21, FIG 22, and two side cheese knife guiding rods 525 FIG.22, three guide bushings 526 FIG.22, and a cheese knife holding plate 517 FIG.22;
5.9. A cheese wheel cutting table 527, FIG.23 with four cheese wheel cutting table guides 529 FIG.23 and four cheese wheel cutting table brackets 528, FIG.23;
The Whole Module 500 ¨ Cheese Cutting Table;
The designs of each of the enumerated above components of the Module.
The Method of cutting cheese and cheese products with the Module.
The Method of cutting alternative cheese like products with the Module.

6. Module 600 ¨ Combined CIP and COP Unit, including in part the following components:
6.1. A main CIP vessel 601 FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29;
6.2. A clean water vessel 602 FIG.24, FIG.25, FIG.26, FIG.27, FIG.28, FIG.29;
The Whole Module 600 ¨ Combined CIP and COP Unit;
The designs of each of the enumerated above components of the Module.
The Method for CIP and COP washing with the Module.
Date recue / Date received 2021-11-08