Use of milk powders to manufacture panela cheese by a wheyless cheesemaking process

Manufacturing cheese using only milk powders (not liquid milk) and a wheyless process could be highly beneficial for developing nations, owing to the limited availability of fresh milk and the lack of proper whey handling equipment. A wheyless process, using milk powders, is very challenging for semihard cheeses because it requires the rehydration of milk powders to very high protein levels (≥20%). The solubility and rennet coagulation properties of a range of commercial high-protein milk powders were evaluated. Incomplete rehydration (and often gelation) was observed for the commercial milk powders at ≥15% total protein (most form sticky gels at 12.5% total protein). A modified micellar CN (MMC) powder was developed that was whey protein-depleted (by ∼4.5-fold compared with a milk protein concentrate 80, MPC80), using microfiltration, which could allow us to use high temperatures (if necessary) for rehydration purposes. To improve solubility, the MMC retentate was 40% calcium depleted (by acidifying the chilled microfiltration retentate to pH 5.7 and then performing UF and diafiltration). Lactose was added back (∼24%) and monovalent ions (generated by nanofiltration of UF permeate) to MMC before spray drying. A wheyless cheesemaking process was explored with several milk powders using panela cheese as a model system. Panela is a Hispanic-style fresh, soft, nonmelting cheese that uses few or no starters. Most commercial panela cheeses have a pH value of ∼6.3. Our goal was to investigate the effect of our experimental MMC, commercial micellar CN (MC) and commercial MPC70 at 2 pH levels (original and adjusted to pH 6.3) on the functionality of natural, wheyless panela cheeses manufactured in a high-shear, process cheese-type cooker. Wheyless cheeses were also compared with a control panela cheese that was made using fresh, whole milk that included a conventional whey-drainage step. Proteolysis, rheology, texture, and sensory attributes of cheese were monitored at 7, 21, and 45 d of refrigerated storage. The MMC powder could be readily rehydrated to ∼20% protein and had good rennet coagulation properties. In contrast, the commercial milk powders did not rehydrate well and had a sticky, doughy texture. Storage time had no effect on proteolysis (pH 4.6-soluble N) or hardness in our experimental wheyless cheeses. In contrast, the control panela was much harder but softened during storage, which coincided with an increase in proteolysis. Wheyless panela made from MPC70 had high levels of pH 4.6-soluble N even after only 7 d of storage, which was caused by the high concentration of whey proteins in this cheese (which are soluble at pH 4.6). Panela made from MMC exhibited more meltability, likely due to the reduced calcium content. Wheyless panela cheese made from commercial powders were associated with stale, cooked, and adhesive sensory attributes, and the wheyless panela made from MMC was associated with melting, browning and cohesive attributes. The wheyless recipe developed for this study using the MMC powder could be successfully used by cheese manufacturers to produce panela with good textural and sensory properties, as well as an extended performance shelf life.