Influence of UHT processing on the quality of full fat and reduced fat requeijão cremoso

Author(s)

Darlila Aparecida Gallina

• Document type: Doctoral Thesis
• Press: Campinas, SP.
• Institution: Universidade Estadual de Campinas (UNICAMP). Faculdade de Engenharia de Alimentos
• Defense date: 2005-10-21

Examining board members

Ariene Gimenes Fernandes Van Dender; Walkíria Hanada Viotto; Salvador Massaguer Roig; Izildinha Moreno; Mirna Lúcia Gigante; Helena Maria André Bolini

• Advisor: Ariene Gimenes Fernandes Van Dender

Abstract

This research study describes the optimization of the manufacturing process of UHT full fat requeijão cremoso (long-life) as well as the development of a process to manufacture reduced fat version of UHT requeijão cremoso (long-life), in a way such as to obtain final products with characteristics similar to those of traditional commercial requeijão cremoso produced with the normal heat treatment. The processed cheeses were all made from fresh curds obtained by direct acidification of heated skim milk. Milk cream, emulsifying salt and sodium chloride were added to the curds before initiating the melting process. In the case of the reduced fat versions, milk fat was partially replaced by a fat substitute (WPC 34). The final products were hot-filled into glass containers (full fat and reduced fat requeijão cremoso) or sterilized by UHT processing (143ºC/3-5 seconds) before being aseptically filled into 125 mL Tetra Pak packages (full fat UHT requeijão cremoso and reduced fat UHT requeijão cremoso). The processed cheeses were evaluated and compared for physical-chemical, microbiological, texture profile analysis (TPA) and sensory (acceptability, DQA, shelf life study) characteristics, protein electrophoretic profile, scanning electron microscopy (SEM) and color (instrumental). No statistically significant (p < 0,05) differences were found in the chemical composition of the requeijão cremoso types investigated (traditional heat and UHT processing). The traditional reduced fat and UHT reduced fat requeijão cremoso presented quite similar chemical compositions. During storage for 90 days at 5ºC, the pH value and lactose levels of the traditional and UHT full fat requeijão cremoso samples did not show any significant differences (p < 0,05). Lipids oxidation as measured by TBA method was found to be significantly higher in the samples of requeijão cremoso (glass containers) compared to UHT requeijão cremoso after 30, 60 and 90 days storage. No statistically significant (p < 0,05) differences were found in the TBA values of the full fat UHT requeijão cremoso (stored at 5 and 25ºC) during the180 days storage period studied, except after the 135 days. In addition to being of satisfactory microbiological quality and in compliance with all applicable standards, the glass-packed requeijão cremoso samples (full fat and reduced fat) did not present any microbiological changes after 90 days storage at 4-5ºC. The results of the incubation test clearly show that the long-life processed cheeses (UHT full fat and UHT reduced fat requeijão cremoso) were also considered microbiologically safe and fit for human consumption as they did not present bacterial growth, change of pH value and visual appearance after incubation at 35-37ºC for 7 days. The texture profile parameter values (firmness, adhesiveness, elasticity and cohesiveness) of the glass-packed full-fat requeijão cremoso samples were significantly (p < 0,05) different from those of the UHT full fat cheeses during 90 days at 5ºC. In general, no significant differences (p < 0,05) were found between texture profile attributes of UHT full fat and UHT reduced fat processed cheeses when stored at 5 and 25ºC. No significant changes in the color parameters values (L*, b*, IB) of the glass-packed full fat and reduced fat requeijão cremoso, and UHT full fat and UHT reduced fat requeijão cremoso were observed throughout 90 days storage at 5C. Also in the case of UHT full fat and UHT reduced fat requeijão samples stored at 5 and 25ºC, the color parameter values did not measurably change during 180 days storage. No statistically significant differences (p < 0,05) were detected as to interaction between the samples (full fat and UHT full fat requeijão cremoso) and the storage period investigated, thus the heat treatment to which the different RC types were exposed during the manufacturing process did not produce any significant differences in terms of pH value, lactose levels, texture profile parameter values and color parameters values during 90 days at 5ºC. No statistically significant differences (p < 0,05) were detected as to interaction between the samples and the storage period investigated relative to the color parameters values and the texture profile parameter values of reduced fat and UHT reduced fat requeijão cremoso. No significant differences (p < 0,05) were found between the samples (stored at 5 and 25ºC) and the storage period, thus, storage temperatures did not significantly affect the TBA values, the color parameters values and the texture profile attributes of UHT full fat requeijão cremoso and UHT reduced fat requeijão cremoso during 180 days at 5 and 25ºC. Images generated by scanning electron microscopy (SEM) showed marked differences between the microstructure of glass-packed full fat and UHT full fat requeijão cremoso on one hand, and between the microstructure of glass-packed reduced fat and UHT reduced fat requeijão cremoso on the other. These differences are probably due to effects of the heat and mechanical treatments inherent to UHT processing. In spite of having similar chemical compositions, the differences in texture and microstructure of the UHT full fat and UHT reduced fat requeijão cremoso versions are desirable and necessary, not only to enable the product to be filled into the package, but also to facilitate its consumption. The electrophoretic profiles of the full fat requeijão cremoso versions (glass-packed and UHT-processed) exhibited fractions of ß-CN, as1-CN e ?-CN. In addition to these fractions, the electrophoretic profile of glass-packed full fat requeijão cremoso shows also the presence of the as1 - I CN fraction. There was no difference between the electrophoretic profiles of the proteins present in the glass-packed reduced fat requeijão cremoso and that of the UHT reduced fat product, both of which contained the ß-CN, as1-CN and ?-CN fractions. No perceptible changes were observed in the electrophoretic profiles of the glass-packed requeijão samples (full fat and reduced fat) during the 90-day storage period studied, nor in the profile of the UHT full fat and UHT reduced fat cheeses during 180 days storage, thereby indicating that none of the four requeijão cremoso types studied was affected by proteolysis or casein fraction breakdown with time. The results of sensory acceptability analysis showed that both the glass-packed and UHT full fat requeijão cremoso samples received a high percentage of good ratings for overall sensory acceptability. The consistency and spreadability attributes of the UHT full fat requeijão cremoso samples received high percentages of rejection compared to the other sample types, with consistency receiving the lowest scores of acceptability. On the other hand, the samples of glass-packed reduced fat requeijão cremoso and UHT reduced fat requeijão cremoso obtained good percentage ratings for overall acceptability and received higher ratings for this attribute as compared to 2 different brands of commercial reduced fat requeijão. As for consistency and spreadability, particularly the samples of glass-packed and UHT reduced fat cheese which obtained consistently higher ratings compared to all the other samples types analysed. As for the attribute taste, UHT reduced fat requeijão cremoso received the highest scores for acceptability. The results of quantitative descriptive analysis show that (5% error level), compared to the glasspacked full fat product, the UHT full fat requeijão cremoso presented a darker tone of creamy white color, less firm and more fluid consistency, smoother and more fluid cheese flow on bread, less mouthfeel & body and a more intense acidic note. These samples exhibited similar intensity of aroma and typical requeijão and milk cream taste, ripened cheese aroma and salty and bitter flavor notes. Compared to the glass-packed reduced fat requeijão, the UHT reduced fat requeijão cremoso samples were found to exhibit only less intense taste of typical requeijão (5% error level). Based on the results of the shelf-life study and considering the need for a safety margin that would guarantee the safety of the product, the following shelf life times are suggested: (1) UHT full fat requeijão cremoso (long-life): 6 months when stored under refrigeration at up to 10º C; 5 months when stored at up to 25º C and 2 months when stored at up to 35º C; (2) UHT reduced fat requeijão cremoso (long-life): 6 months when stored under refrigeration at up to 10º C; 4 months when stored at a temperature of 25º C and 2 months when stored at up to 35º C. The use of UHT processing in the manufacture of requeijão cremoso aims at extending the shelf life of the product as a result of both the higher efficiency of the UHT process as compared to the traditional heat treatment and the advantages of the aseptic package that not only eliminates the need of refrigeration but also facilitates handling throughout the distribution chain. Thus, this new technology provides a new and technically & economically feasible alternative for large-scale dairy plants (AU)