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Critical factors for evaluation of cheese yield performance and fat loss in large cheese factories
Our objectives were to develop a data analysis system that utilized existing data within a cheese factory to evaluate cheese yield performance and fat loss using yield formulae for cheddar and mozzarella cheese manufacturers, to determine the accuracy of input data, and determine the sensitivity of the performance evaluation results to uncertainty in the accuracy of input data. Daily cheese manufacturing and analysis data on an individual vat basis were collected (for 1 year) from cheddar and mozzarella cheese factories that each processed about 900,000 kg of milk per day. The source and quality of all input data was identified and evaluated during repeated site visits. Observed outcomes (based on data collected in the cheese plants) for cheese yield and fat recovery were found to be very sensitive to the quality of input data for milk weight, milk fat and protein in the vat, and the moisture, fat and salt content of the cheese.
Different types and placement of flow meters were evaluated. Milk analysis was done by mid-FTIR and cheese analysis was done with near-IR in both factories. Proficiency evaluations of the accuracy of milk and cheese analysis were conducted in comparison to physical and chemical reference methods. Observed bias differences in analytical results were used to establish ranges for sensitivity analyses. Cheese moisture and fat sensitivity analysis ranges were + 0.5% and salt was + 0.25% daily based on proficiency test results. This variation in moisture, fat, and salt uncertainty produced a deviation of (+) 450 kg cheese/day and 225 kg cheese/day for salt. It was clear that as cheese factories have increased greatly in weight of cheese produced per day, the uncertainty in sampling and analytical accuracy of milk and cheese analysis that was adequate previously, has a level of uncertainty that allows a large margin for error in controlling the financial performance of the business. A bias error in moisture with the factory laboratory being high by 0.5% moisture on Cheddar was equated to a missed opportunity in one year of 175,000 kg more cheese. It was concluded that given the impact on economic performance of the factory, better cheese sampling approaches and cheese analytical systems are needed to optimize and control the financial performance of the cheese manufacturing process.
Keywords: cheese yield, fat loss, cheese analysis