Say Cheese!

The enzyme activity of the rennet causes the milk to coagulate to a solid gel known as curd. The liquid whey is drained off. The curd is cut with special cutting tools into small cubes which are heated and stirred – this lets more liquid whey drain off. The combined effect of these three actions – growth of bacteria, stirring and heat treatment – results in separation of whey from the curd grains.

The curd pieces are then salted. Salting gives flavour, helps to expel more liquid, and slows down bacterial growth, allowing the cheese to ripen. The finished curd is placed in cheese moulds of metal, wood or plastic, which determine the shape of the finished cheese.

The cheese is pressed, either by its own weight or more commonly by applying pressure to the moulds. This is for 3 reasons; to assist final whey expulsion, to provide texture, to shape the cheese,

Treatment during curd making and pressing determines the characteristics of the cheese, such as texture. The actual flavour of the cheese is determined during the ripening of the cheese. After pressing, the curds are removed from the moulds and left to ripen for 8 – 12 months in a humid atmosphere.

We begin by adding the proper amount of starter culture (bacteria) to our milk and then leaving it to for 45 minutes to 1 hour. Then we add enough rennet to get a firmly set curd in 45 minutes to 1 hour Once the curd has set firm to our satisfaction, it is cut into 3/8-5/8" cubes Making Cheddar Cheese

We then stir slowly for several minutes until we note a slight firming of the curd… …then we begin heating very slowly to 39 0 C, firming the curd - stirring constantly until the curd is firm and dry enough for the next stage.

The curd is allowed to settle to the bottom of the vat and the acidity is checked... if it is correct then we begin to remove the whey to the curd level. The curd is then transferred to the draining Cloth.

It is wrapped to keep it warm, flipping it every min. Special care is made to keep it warm (32 – 35 0 C)

After min the curd consolidates into a firm block....at which point it is cut into 4" blocks.

It is turned over again at min intervals… …increasing the height of stacking to accelerate acid production.

After about 1 hour the curd strips flatten out...and upon breaking, show a very elongated curd structure with a tough, dry texture.

The curd is then broken or cut into small pieces and 2% salt is added in 3 phases. This takes about 30 min in total before hooping the curd. The curds are then transferred to a hoop and the cloth is folded in.

It is then ready to press.. The pressure is kept low to start..the whey runs clear and slowly...then in 30 min pressure is increased, then increased again in 1 hour. After 5-6 hrs the curd consolidates somewhat but still has some openness.

Pressing is continued with maximum pressure for the next 24 hours or so. This yields a very smooth and tight surface. The cheese is then bandaged. 2 circles of muslin are cut slightly bigger than the top of the cheese.

These are sanitised and soaked in warm water, then spread evenly over the surface and smoothed out from centre to edge. A light coat of lard or butter is then applied and worked into the cloth.. (this helps the bandage to stick)

The other end is then bandaged and it is pressed again for an hour or so at max pressure. The side is then finished in a similar manner to the top and it is put back to press overnight.

Upon removing from the press we have a cheddar cheese wrapped in cloth and ready to age for the next months. It is stored on a shelf at 12 0 C with 85% humidity, and turned once a day for the first 8-12 weeks. This bandage forms a fine surface for the ripening of the cheddar, and develops it's natural surface of mold and age.

After about 2-3 weeks the first natural molds begin to grow and spread over time.. at 2-3 months we begin turning it, but only 2 times each week. The mold eventually dries off as the moisture in the cheese decreases, leaving a rather rustic surface (after 8-12 months).