Nonstarter lactic acid bacteria and aging temperature affect calcium lactate crystallization in cheddar cheese

Invited review: Crystals in cheese: More than a curiosity

Scientific interest in cheese crystals extends back more than a century. However, starting around the 1970s, industry interest, and interest on the part of cheese scientists, grew dramatically as changes in cheesemaking technology and market changes caused the presence of crystals in the marketplace to increase; advanced analytical capabilities enabled new crystalline species to be identified, their origins and causative factors to be elucidated, and their contributions to cheese texture to be better understood. It is now evident that a host of organic- and inorganic-based crystals occur in natural cheeses. Some crystals form preferentially at the surface of rindless or rinded cheeses, others in the irregular openings or spherical eyes that occur within the body of some cheeses, and still others embedded within the cheese matrix. It is also evident that crystals may profoundly influence cheese texture, both as a direct consequence of their abundance, size, shape, and hardness, and as an indirect result of cascading physiochemical events initiated by crystal formation. Consumer response to increased incidence of crystals in the marketplace has been mixed. On the one hand, surface crystals of calcium lactate pentahydrate on Cheddar cheese came to be viewed quite negatively in some markets, often being mistaken for mold growth and spoilage. This triggered industry concern and led to considerable research to determine the underlying causes and to develop strategies to limit or prevent calcium lactate pentahydrate formation. At the same time, other forms of crystallization increasingly came to be viewed as positive features in the growing market dedicated to artisanal and traditional cheeses, giving rise to a bifurcated consumer response to cheese crystals that is evident today. Traditional artisanal cheesemakers perhaps have the most to gain from advances in cheese-crystal research. Traditional artisanal cheeses rely heavily on stories that are weaved around their identity to create uniqueness and add value. A challenge and opportunity for these cheesemakers in the United States and globally will be to translate the fascinating science of their cheese crystals into engaging narratives that capture the imagination, add value to their cheese, and enhance the enjoyment of their cheese by consumers.

A 100-Year Review: Cheese production and quality

In the beginning, cheese making in the United States was all art, but embracing science and technology was necessary to make progress in producing a higher quality cheese. Traditional cheese making could not keep up with the demand for cheese, and the development of the factory system was necessary. Cheese quality suffered because of poor-quality milk, but 3 major innovations changed that: refrigeration, commercial starters, and the use of pasteurized milk for cheese making. Although by all accounts cold storage improved cheese quality, it was the improvement of milk quality, pasteurization of milk, and the use of reliable cultures for fermentation that had the biggest effect. Together with use of purified commercial cultures, pasteurization enabled cheese production to be conducted on a fixed time schedule. Fundamental research on the genetics of starter bacteria greatly increased the reliability of fermentation, which in turn made automation feasible. Demand for functionality, machinability, application in baking, and more emphasis on nutritional aspects (low fat and low sodium) of cheese took us back to the fundamental principles of cheese making and resulted in renewed vigor for scientific investigations into the chemical, microbiological, and enzymatic changes that occur during cheese making and ripening. As milk production increased, cheese factories needed to become more efficient. Membrane concentration and separation of milk offered a solution and greatly enhanced plant capacity. Full implementation of membrane processing and use of its full potential have yet to be achieved. Implementation of new technologies, the science of cheese making, and the development of further advances will require highly trained personnel at both the academic and industrial levels. This will be a great challenge to address and overcome.

Crystal fingerprinting: elucidating the crystals of Cheddar, Parmigiano-Reggiano, Gouda, and soft washed-rind cheeses using powder x-ray diffractometry

Crystals in cheese may be considered defects or positive features, depending on the variety and mode of production (industrial, artisanal). Powder x-ray diffractometry (PXRD) offers a simple means to identify and resolve complex combinations of crystals that contribute to cheese characteristics. The objective of the present research was to demonstrate the application of PXRD to study crystals from a range of different cheese types, specifically Cheddar, Parmigiano-Reggiano, Gouda, and soft washed-rind (smear ripened) cheeses. In studies of Parmigiano-Reggiano and long-aged Gouda, PXRD has confirmed that hard (crunchy) crystals that form abundantly within these cheeses consist of tyrosine. Furthermore, PXRD has tentatively identified the presence of an unusual form of crystalline leucine in large (up to 6 mm in diameter) spherical entities, or “pearls”, that occur abundantly in 2-year-old Parmigiano Reggiano and long-aged Gouda cheeses, and on the surface of rindless hard Italian-type cheese. Ongoing investigations into the nature of these “pearls” are providing new insight into the roles that crystals play in the visual appearance and texture of long-aged cheeses. Crystals also sometimes develop profusely in the eyes of long-aged Gouda, which have been shown by PXRD to consist of tyrosine and the aforementioned presumptive form of crystalline leucine. Finally, crystals have been shown by PXRD to form in the smears of soft washed-rind cheeses. These crystals may be associated in some cheeses with gritty mouth feel and with zonal body softening that occurs during ripening. Heightened interest in artisanal cheeses highlights the need to better understand crystals and their contributions to cheese characteristics.

Surface roughness and packaging tightness affect calcium lactate crystallization on Cheddar cheese

Calcium lactate crystals that sometimes form on Cheddar cheese surfaces are a significant expense to manufacturers. Researchers have identified several postmanufacture conditions such as storage temperature and packaging tightness that contribute to crystal formation. Anecdotal reports suggest that physical characteristics at the cheese surface, such as roughness, cracks, and irregularities, may also affect crystallization. The aim of this study was to evaluate the combined effects of surface roughness and packaging tightness on crystal formation in smoked Cheddar cheese. Four 20-mm-thick cross-section slices were cut perpendicular to the long axis of a retail block (~300g) of smoked Cheddar cheese using a wire cutting device. One cut surface of each slice was lightly etched with a cheese grater to create a rough, grooved surface; the opposite cut surface was left undisturbed (smooth). The 4 slices were vacuum packaged at 1, 10, 50, and 90kPa (very tight, moderately tight, loose, very loose, respectively) and stored at 1°C. Digital images were taken at 1, 4, and 8 wk following the first appearance of crystals. The area occupied by crystals and number of discrete crystal regions (DCR) were quantified by image analysis. The experiment was conducted in triplicate. Effects of storage time, packaging tightness, surface roughness, and their interactions were evaluated by repeated-measures ANOVA. Surface roughness, packaging tightness, storage time, and their 2-way interactions significantly affected crystal area and DCR number. Extremely heavy crystallization occurred on both rough and smooth surfaces when slices were packaged loosely or very loosely and on rough surfaces with moderately tight packaging. In contrast, the combination of rough surface plus very tight packaging resulted in dramatic decreases in crystal area and DCR number. The combination of smooth surface plus very tight packaging virtually eliminated crystal formation, presumably by eliminating available sites for nucleation. Cut-and-wrap operations may significantly influence the crystallization behavior of Cheddar cheeses that are saturated with respect to calcium lactate and thus predisposed to form crystals.

Nucleic acid-based approaches to investigate microbial-related cheese quality defects

The microbial profile of cheese is a primary determinant of cheese quality. Microorganisms can contribute to aroma and taste defects, form biogenic amines, cause gas and secondary fermentation defects, and can contribute to cheese pinking and mineral deposition issues. These defects may be as a result of seasonality and the variability in the composition of the milk supplied, variations in cheese processing parameters, as well as the nature and number of the non-starter microorganisms which come from the milk or other environmental sources. Such defects can be responsible for production and product recall costs and thus represent a significant economic burden for the dairy industry worldwide. Traditional non-molecular approaches are often considered biased and have inherently slow turnaround times. Molecular techniques can provide early and rapid detection of defects that result from the presence of specific spoilage microbes and, ultimately, assist in enhancing cheese quality and reducing costs. Here we review the DNA-based methods that are available to detect/quantify spoilage bacteria, and relevant metabolic pathways in cheeses and, in the process, highlight how these strategies can be employed to improve cheese quality and reduce the associated economic burden on cheese processors.

Characterization of calcium lactate crystals on cheddar cheese by image analysis

Previous research demonstrated that crystal coverage on the surface of Cheddar cheese can be quantitatively and nondestructively measured using image analysis of digital photographs of the cheese surface. The objective of the present study was to extend image analysis methodology to quantify and characterize additional features of visible crystals on cheese surfaces as they grow over time. A random weight (approximately 300 g) retail sample of naturally smoked Cheddar cheese exhibiting white surface crystals was obtained from a commercial source. The total area occupied by crystals and total number of discrete crystal regions on one of the surfaces (approximately 55 x 120 mm) was measured at 3-wk intervals for 30 wk using image analysis. In addition, 5 small (approximately 0.3 mm radius) individual crystals on that surface were chosen for observation over the 30-wk period. The crystals were evaluated for area, radius, and shape factor (circularity) every third week using image analysis. The total area occupied by crystals increased in a linear manner (R(2) = 0.95) from about 0.44 to 7.42% of the total cheese surface area over the 30-wk period. The total number of discrete crystal regions also increased but in a nonlinear manner that was best described by a quadratic relationship. Measurement of discrete crystal regions underestimated the true number of crystals present at the cheese surface due to merging of adjacent crystals as they grew and merged into a single crystal region over time. Throughout this period, the shapes of the 5 individual crystals closely approximated perfect circles, except when adjacent crystals merged to form a single irregular crystal region, and the area occupied by each of the 5 crystals increased in a near-linear manner (R(2) = 0.95). Image analysis approaches may be used to evaluate crystal formation and growth rates and morphology on cheese.

The Formation of Calcium Lactate Crystals is Responsible for Concentrated Acid Whey Thickening

The use of spray drying for dehydration of acid whey is generally limited by the appearance of uncontrolled thickening and solidifying of the whey mass during the lactose crystallization step. The origin of this physical change is still unknown and probably linked to complex interactions between physical properties and chemical composition of these products. To understand this phenomenon, we simulated the thickening of concentrated acid whey on a laboratory scale by measuring the flow resistance changes as a function of time and whey composition. The thickening process was characterized by an amplitude of torque and a lag time (induction time). Thickening of lactic acid whey concentrate occurred regardless of the presence of whey proteins or lactose crystals. Moreover, this work clearly demonstrated that the thickening process was due to the formation of filamentous structures corresponding to calcium lactate crystals and showed a large dependence on calcium and lactate contents, pH, and phosphate concentration.

Cheese pH, Protein Concentration, and Formation of Calcium Lactate Crystals

The occurrence of calcium lactate crystals (CLC) in hard cheeses is a continual expense to the cheese industry, as consumers fail to purchase cheeses with this quality defect. This research investigates the effects of the protein concentration of cheese milk and the pH of cheese on the occurrence of CLC. Atomic absorption spectroscopy was used to determine total and soluble calcium concentrations in skim milk (SM1, 8.7% total solids), and skim milk supplemented with nonfat dry milk (CSM1, 13.5% total solids). Calcium, phosphorus, lactic acid, and citrate were determined in cheeses made with skim milk (SM2, 3.14% protein), skim milk supplemented with ultrafiltered milk (CSM2, 6.80% protein), and nonfat dry milk (CSM3, 6.80% protein). Supplementation with nonfat dry milk increased the initial total calcium in CSM1 (210 mg/100 g of milk) by 52% compared with the total calcium in SM1 (138 mg/100 g of milk). At pH 5.4, soluble calcium concentrations in CSM1 were 68% greater than soluble calcium in SM1. In cheeses made from CSM2 and CSM3, total calcium was 26% greater than in cheeses made from SM2. As the pH of cheeses made from SM2 decreased from 5.4 to 5.1, the concentration of soluble calcium increased by 61.6%. In cheeses made from CSM2 and CSM3, the concentrations of soluble calcium increased by 41.4 and 45.5%, respectively. Calcium lactate crystals were observed in cheeses made from SM2 at and below pH 5.1, whereas CLC were observed in cheeses from CSM2 and CSM3 at and below pH 5.3. The increased presence of soluble calcium can potentially cause CLC to occur in cheese manufactured with increased concentrations of milk solids, particularly at and below pH 5.1.

Nonstarter lactic acid bacteria biofilms and calcium lactate crystals in Cheddar cheese

A sanitized cheese plant was swabbed for the presence of nonstarter lactic acid bacteria (NSLAB) biofilms. Swabs were analyzed to determine the sources and microorganisms responsible for contamination. In pilot plant experiments, cheese vats filled with standard cheese milk (lactose:protein = 1.47) and ultrafiltered cheese milk (lactose:protein = 1.23) were inoculated with Lactococcus lactis ssp. cremoris starter culture (8 log cfu/mL) with or without Lactobacillus curvatus or Pediococci acidilactici as adjunct cultures (2 log cfu/mL). Cheddar cheeses were aged at 7.2 or 10 degrees C for 168 d. The raw milk silo, ultrafiltration unit, cheddaring belt, and cheese tower had NSLAB biofilms ranging from 2 to 4 log cfu/100 cm2. The population of Lb. curvatus reached 8 log cfu/g, whereas P. acidilactici reached 7 log cfu/g of experimental Cheddar cheese in 14 d. Higher NSLAB counts were observed in the first 14 d of aging in cheese stored at 10 degrees C compared with that stored at 7.2 degrees C. However, microbial counts decreased more quickly in Cheddar cheeses aged at 10 degrees C compared with 7.2 degrees C after 28 d. In cheeses without specific adjunct cultures (Lb. curvatus or P. acidilactici), calcium lactate crystals were not observed within 168 d. However, crystals were observed after only 56 d in cheeses containing Lb. curvatus, which also had increased concentration of D(-)-lactic acid compared with control cheeses. Our research shows that low levels of contamination with certain NSLAB can result in calcium lactate crystals, regardless of lactose:protein ratio.

Development and Application of Image Analysis to Quantify Calcium Lactate Crystals on the Surface of Smoked Cheddar Cheese

Calcium lactate crystals that form white specks or haze on the surface of cheese constitute a significant quality problem for producers of Cheddar cheese. Subjective methods to evaluate crystal coverage of cheese surfaces have been reported previously, but objective methods are currently lacking. The objectives of this work were to develop and evaluate an objective method to measure the area occupied by calcium lactate crystals on surfaces of naturally smoked Cheddar cheese samples using digital photography and image analysis. Coefficients of variation ranged from 1.29 to 4.68% for 5 replicate analyses of 3 different cheese surfaces that ranged from approximately 2 to 49% of total surface area occupied by crystals. Thus, results showed a high degree of repeatability for the 3 cheese surfaces, which ranged from very slight and geometrically simple to very heavy and geometrically complex crystal coverage. The method underestimated total area occupied by crystals on the 3 surfaces by 0.24 to 4.83% unless the fainter crystal regions that went undetected during initial thresholding were manually segmented and quantified. The wet weight of crystal substance collected per unit of surface area from 20 different cheese samples increased exponentially as the percentage of total surface area occupied by crystals increased. These data were consistent with subjective observations that crystal regions appeared to grow vertically as well as horizontally as they expanded to occupy greater surface area. Image analysis was well suited for evaluating changes in crystal coverage during cheese aging because measurements were made nondestructively and with minimal disruption to the cheese. The area occupied by crystals on 6 different surfaces from 3 different cheese samples increased linearly (R2 = 0.94 to 0.99) during storage at 4 degrees C for up to 33 wk. However, the rates of increase differed significantly among the 3 cheese samples. Image analysis may serve as a useful tool to quantitatively evaluate the effects of factors such as cheese composition, packaging conditions and storage temperature on rate of crystal growth and time of crystal appearance during storage.

Compositional Factors Associated with Calcium Lactate Crystallization in Smoked Cheddar Cheese

Previous researchers have observed that surface crystals of calcium lactate sometimes develop on some Cheddar cheese samples but not on other samples produced from the same vat of milk. The causes of within-vat variation in crystallization behavior have not been identified. This study compared the compositions of naturally smoked Cheddar cheese samples that contained surface crystals with those of samples originating from the same vat that were crystal-free. Six pairs of retail samples (crystallized and noncrystallized) produced at the same cheese plant on different days were obtained from a commercial source. Cheese samples were 5 to 6 mo old at the time of collection. They were then stored for an additional 5 to 13 mo at 4 degrees C to ensure that the noncrystallized samples remained crystal-free. Then, the crystalline material was removed and collected from the surfaces of crystallized samples, weighed, and analyzed for total lactic acid, L(+) and D(-) lactic acid, Ca, P, NaCl, moisture, and crude protein. Crystallized and noncrystallized samples were then sectioned into 3 concentric subsamples (0 to 5 mm, 6 to 10 mm, and greater than 10 mm depth from the surface) and analyzed for moisture, NaCl, titratable acidity, L(+) and D(-) lactic acid, pH, and total and water-soluble calcium. The data were analyzed by ANOVA according to a repeated measures design with 2 within-subjects variables. The crystalline material contained 52.1% lactate, 8.1% Ca, 0.17% P, 28.5% water, and 8.9% crude protein on average. Both crystallized and noncrystallized cheese samples contained significant gradients of decreasing moisture from center to surface. Compared with noncrystallized samples, crystallized samples possessed significantly higher moisture, titratable acidity, L(+) lactate, and water soluble calcium, and significantly lower pH and NaCl content. The data suggest that formation of calcium lactate crystals may have been influenced by within-vat variation in salting efficacy in the following manner. Lower salt uptake by some of the cheese curd during salting may have created pockets of higher moisture and thus higher lactose within the final cheese. When cut into retail-sized chunks, the lower salt, higher moisture samples contained more lactic acid and thus lower cheese pH, which shifted calcium from the insoluble to the soluble state. Lactate and soluble calcium contents in these samples became further elevated at the cheese surface because of dehydration during smoking, possibly triggering the formation of calcium lactate crystals.

Gas-Flushed Packaging Contributes to Calcium Lactate Crystals in Cheddar Cheese

Gas-flushed packaging is commonly used for cheese shreds and cubes to prevent aggregation and loss of individual identity. Appearance of a white haze on cubed cheese is unappealing to consumers, who may refrain from buying, resulting in lost revenue to manufacturers. The objective of this study was to determine whether gas flushing of Cheddar cheese contributes to the occurrence of calcium lactate crystals (CLC). Cheddar cheese was manufactured using standard methods, with addition of starter culture, annatto, and chymosin. Two different cheese milk compositions were used: standard (lactose:protein = 1.47, protein:fat = 0.90, lactose = 4.8%) and ultrafiltered (UF; lactose:protein = 1.23, protein:fat = 0.84, lactose = 4.8%), with or without adjunct Lactobacillus curvatus. Curds were milled when whey reached 0.45% titratable acidity, and pressed for 16 h. After aging at 7.2 degrees C for 6 mo, cheeses were cubed (1 x 1 x 4 cm) and either vacuum-packaged or gas-flushed with carbon dioxide, nitrogen, or a 50:50 mixture of carbon dioxide and nitrogen, then aged for an additional 3 mo. Heavy crystals were observed on surfaces of all cubed cheeses that were gas-flushed, but not on cheeses that were vacuum-packaged. Cheeses without Lb. curvatus exhibited L(+)-CLC on surfaces, whereas cheeses with Lb. curvatus exhibited racemic mixtures of L(+)/D(-)-CLC throughout the cheese matrices. The results show that gas flushing (regardless of gas composition), milk composition, and presence of nonstarter lactic acid bacteria, can contribute to the development of CLC on cheese surfaces. These findings stress the importance of packaging to cheese quality.

Enhanced Lactose Cheese Milk does not Guarantee Calcium Lactate Crystals in Finished Cheddar Cheese

Three experimental batches of Cheddar cheese were manufactured in duplicate, with standardization of the initial cheese-milk lactose content to high (5.24%), normal (4.72%, control), and low lactose (3.81%). After 35 d of aging at 4.4 degrees C, the cheeses were subjected to temperature abuse (24 h at 21 degrees C, unopened) and contamination (24 h at 21 degrees C, packages opened and cheeses contaminated with crystal-containing cheese). After aging for 167 d, residual cheese lactose (0.08 to 0.43%) and L(+)-lactate concentrations (1.37 to 1.60%) were high and D(-)-lactate concentrations were low (<0.03%) for all cheeses. No significant differences in lactose concentrations were attributable to temperature abuse or contamination. No significant differences in L(+)- or D(-)-lactate concentrations were attributable to temperature abuse. However, concentrations of L(+)-lactate were significantly lower and D(-)-lactate were significantly higher in contaminated cheeses than in control cheeses, indicating inoculation (at d 35) with heterofermentative nonstarter lactic acid bacteria able to racemize L(+)-lactate to D(-)-lactate. The fact that none of the cheeses exhibited crystals after 167 d demonstrates that high cheese milk or residual lactose concentrations do not guarantee crystal formation. Contamination with nonstarter lactic acid bacteria can significantly contribute to D(-)-lactate accumulation in cheese.