NTISthis.com

Evidence Guide: FDFCH4003A - Produce a range of rennet-coagulated cheeses

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

FDFCH4003A - Produce a range of rennet-coagulated cheeses

What evidence can you provide to prove your understanding of each of the following citeria?

Manage sanitation in artisan cheese making

  1. Container of starter culture is sanitised or pre-ripened under aseptic conditions before tipping the contents into the vat to reduce the risk of infection or contamination
  2. All surfaces are kept clean and sanitised, except for curing boards
  3. Stringent personal hygiene and quarantine procedures are applied as part of best manufacturing practice
  4. Multi-phase cleaning systems are applied to ensure sanitised surfaces and equipment
  5. Food safety related information is recorded, as required, including milk counts and cheese bacterial counts
Container of starter culture is sanitised or pre-ripened under aseptic conditions before tipping the contents into the vat to reduce the risk of infection or contamination

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

All surfaces are kept clean and sanitised, except for curing boards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Stringent personal hygiene and quarantine procedures are applied as part of best manufacturing practice

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Multi-phase cleaning systems are applied to ensure sanitised surfaces and equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Food safety related information is recorded, as required, including milk counts and cheese bacterial counts

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop and implement procedures to prepare milk for artisan cheese making

  1. Raw milk is sampled and composition and counts measured/analysed
  2. Clarification and standardisation procedures for raw milk are implemented
  3. Pasteurisation procedures for milk are carried out
  4. Raw milk area is maintained separate from pasteurised milk operations
Raw milk is sampled and composition and counts measured/analysed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clarification and standardisation procedures for raw milk are implemented

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pasteurisation procedures for milk are carried out

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Raw milk area is maintained separate from pasteurised milk operations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Mix ingredients in the vat for rennet-coagulated cheeses

  1. Colour is added to the milk to change the colour of the cheese, if required
  2. Mould spores are added for mould ripened cheeses, if required
  3. Adjunct cultures are added to influence the texture and flavour of the ripened cheese, if required
  4. Enzymes are added to alter the flavour profile of the ripened cheese, if required
  5. The milk is acidified with organic or inorganic acids before renneting, if required (e.g. direct acidified Mozzarella or Bocconcini)
  6. The milk is partly acidified with acid prior to adding culture to control the calcium phosphate level in the curd during cheese making, if required
  7. Cultures and rennet are added to milk and held at required temperature
  8. A log of pH and temperature is maintained
Colour is added to the milk to change the colour of the cheese, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Mould spores are added for mould ripened cheeses, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjunct cultures are added to influence the texture and flavour of the ripened cheese, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Enzymes are added to alter the flavour profile of the ripened cheese, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The milk is acidified with organic or inorganic acids before renneting, if required (e.g. direct acidified Mozzarella or Bocconcini)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The milk is partly acidified with acid prior to adding culture to control the calcium phosphate level in the curd during cheese making, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cultures and rennet are added to milk and held at required temperature

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

A log of pH and temperature is maintained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cut and handle the curd for rennet-coagulated cheeses

  1. Curd cutting is supervised to achieve optimal yield and the required moisture level in the cheese
  2. Agitation and temperature of the curd and whey is monitored
  3. The curd and whey is heated, if required, and checked for uneven or overheating, if heated
  4. The heating schedule is planned to ensure optimal syneresis
  5. Part of the whey is removed and replaced with water to wash lactose and lactic acid from the curd, if required
  6. For large and small eye cheeses (e.g. large eye type-Swiss and small eye type-Gouda) the curd is matted under the whey before the whey is removed to ensure proper eye development
  7. All or part of the whey is removed from the curds by draining it out of the vat
Curd cutting is supervised to achieve optimal yield and the required moisture level in the cheese

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Agitation and temperature of the curd and whey is monitored

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The curd and whey is heated, if required, and checked for uneven or overheating, if heated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The heating schedule is planned to ensure optimal syneresis

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Part of the whey is removed and replaced with water to wash lactose and lactic acid from the curd, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

For large and small eye cheeses (e.g. large eye type-Swiss and small eye type-Gouda) the curd is matted under the whey before the whey is removed to ensure proper eye development

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

All or part of the whey is removed from the curds by draining it out of the vat

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop and implement salting, curing and packaging procedures

  1. Procedures are implemented to prepare the curd for salting
  2. Salting treatments are applied to ensure salt profile effects are minimised in the finished product
  3. Dry salted stirred or milled curd particles are placed into moulds for pressing, if required
  4. Ripening procedures are carried out and the process is monitored
  5. Packaging is developed and applied for each cheese type
Procedures are implemented to prepare the curd for salting

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Salting treatments are applied to ensure salt profile effects are minimised in the finished product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dry salted stirred or milled curd particles are placed into moulds for pressing, if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ripening procedures are carried out and the process is monitored

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Packaging is developed and applied for each cheese type

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and adjust process control to produce cheese with consistent taste and quality

  1. The process objectives of rennet-coagulated cheese making are established
  2. Moisture control is achieved in the cheeses by the use of processing factors
  3. The rate and the amount of acid development is controlled
  4. Calcium phosphate levels are controlled to influence basic cheese structure
  5. Texture of the cheese is controlled by regulating pH, ripening agents, salt, moisture and fat
  6. Cheese flavour is controlled through choice of ingredients (milks, cultures, coagulating agents and salt) and pH levels
  7. Process control parameters are used to achieve optimal yield
  8. Aging of rennet-coagulated cheeses is applied to develop optimal flavour and texture
The process objectives of rennet-coagulated cheese making are established

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Moisture control is achieved in the cheeses by the use of processing factors

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The rate and the amount of acid development is controlled

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Calcium phosphate levels are controlled to influence basic cheese structure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Texture of the cheese is controlled by regulating pH, ripening agents, salt, moisture and fat

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cheese flavour is controlled through choice of ingredients (milks, cultures, coagulating agents and salt) and pH levels

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Process control parameters are used to achieve optimal yield

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Aging of rennet-coagulated cheeses is applied to develop optimal flavour and texture

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out sensory analysis and grading of artisan rennet-coagulated cheeses

  1. A range of flavours in cheese are identified
  2. Different textures of cheeses are recognised
  3. Cheese is assessed for evenness of colour and finish
  4. Organoleptic properties of rennet-coagulated cheeses are analysed to identify possible changes to process controls
A range of flavours in cheese are identified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Different textures of cheeses are recognised

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cheese is assessed for evenness of colour and finish

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Organoleptic properties of rennet-coagulated cheeses are analysed to identify possible changes to process controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Meet workplace requirements for food safety, quality and environmental management

  1. Food safety related information is recorded
  2. Records of cheese manufacture are maintained
  3. Health and safety and environmental protection procedures are developed through a risk management approach
  4. Waste is disposed of and environmental impacts reviewed for the cheese making operation
Food safety related information is recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Records of cheese manufacture are maintained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Health and safety and environmental protection procedures are developed through a risk management approach

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Waste is disposed of and environmental impacts reviewed for the cheese making operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to produce artisan rennet-coagulated cheeses to a commercial standard. Assessment cannot take place on fully integrated industrial equipment.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Critical aspects of assessment must include evidence of the ability to produce a range of rennet-coagulated cheeses including:

establishing procedures for:

sanitation, food safety, quality assurance and environmental management in rennet-coagulated cheese production

developing work instructions for:

preparing milk for cheese making

coagulating milk through renneting

ensuring a suitable rate of fermentation

carrying out manufacture and curing processes to optimal levels

packaging and labelling rennet-coagulated cheeses

carrying out sensory analysis of rennet-coagulated cheeses

reviewing process control based on sensory analysis and recovered yield.

Context of and specific resources for assessment

Assessment of performance requirements in this unit should be undertaken within the context of cheese production. Competency is demonstrated by performance of all stated criteria, including the critical aspects and knowledge and skills elaborated in the Evidence Guide, and within the scope as defined by the Range Statements applicable to the workplace environment.

Assessment must occur in a real or simulated workplace where the assessee has access to:

production process and related equipment, including vats, stainless steel wire knives and milling machines, manufacturers’ advice and product specifications

sampling and testing equipment and procedures

methods and related software systems, as required, for collecting data and calculating yields, efficiencies and material variances appropriate to the type of cheese and the production environment.

Method of assessment

The following assessment methods are suggested:

observation of candidate making rennet-coagulated cheeses

written and/or oral questioning to assess knowledge and understanding

workplace samples of rennet-coagulated cheeses with a documented history of process and a completed self-evaluation

composition analysis of milk and cheese samples

third-party supporting statement.

Guidance information for assessment

Evidence should be gathered over a period of time against a range of rennet-coagulated cheese products. Part of the evidence requirements for this unit requires that samples of at least three batches of rennet-coagulated cheeses be produced to a commercial standard, in a real or simulated environment. Students must be assessed on their ability to control all aspects of sanitation and materials storage and handling.

Required Skills and Knowledge

Required skills include:

Ability to:

sample fresh milk and analyse results

prepare milk for cheese making

carry out standardisation and pasteurisation procedures

adjust milk to renneting temperature and monitor temperature

add optional additives to influence flavour, colour and texture during ripening

add starter for acidification by lactic acid or acid for direct or part acidified milk for cheese making

add rennet to promote coagulation

test readiness of curd for cutting

use stainless steel wire or nylon line knives to cut the curd into small particles

carry out agitation and optional cooking procedure

carry out cheese washing procedures

carry out drainage operation

carry out further curd treatment, depending on the cheese type

carry out salting process

manage process control for moisture, pH, calcium phosphate levels, microbiology, texture and flavour in rennet-coagulated cheese making

carry out sampling for chemical and microbiological testing of cheese

manage ripening process for rind cheeses, mould ripened cheeses and bacterial surface ripened cheeses for optimum quality

assess rennet-coagulated cheeses for organoleptic qualities

conduct tests for pH, moisture and salt levels in cheese

maintain records for cheese making

carry out packaging of cheese

use multi-phase cleaning systems

develop safe work practices and personal hygiene and sanitation procedures

maintain the viability and integrity of coagulating agents and microbial additives

calculate cheese yields

develop packaging and labelling for rennet-coagulated cheeses

comply with environmental requirements for a processing operation.

Required knowledge includes:

Knowledge of:

the main cheese types and the common processes for making different types of rennet-coagulated cheeses

the main components of milk and cheese (both curds and whey)

types and impact of inhibitory substances in milk, including bacteriophage

purpose and basic principles of cheese making

specifications of product at each stage of rennet-coagulated cheese making

milk characteristics and components important in cheese making

milk preparation for cheese making (standardisation and pasteurisation)

types of starters used and their role in the fermentation process

types of adjunct cultures and their role in the flavour and texture characteristics of the ripened cheese

use of additives to the milk for modifying the flavour, texture and colour of the ripened cheese

effect of milk characteristics on cheese processing performance

use of bacterial cultures and coagulating enzymes

moisture control in cheese making

processes of coagulation and syneresis and their role in rennet-coagulated cheese making

critical control points in the manufacture of each cheese type

principles of brine salting and maintenance of brine salting systems for brine salted cheeses

principles of dry salting for dry salted cheeses

effects of pH and temperature on cheese processing performance and product quality

lactic acid bacteria and their role in cheese making

microbial contaminants of cheese (lipolytic bacteria, yeasts, moulds, bacillus, listeria, E. coli, salmonella, coliforms and staphylococci) and their impact on cheese quality

sampling and testing procedures for microbes

yeasts and moulds and other microorganisms of significance in cheese making

contamination/food safety risks associated with the process and related control measures

techniques used to monitor the cheese making process, such as inspecting, measuring and testing

common causes of variation and corrective action required for each cheese making process

organoleptic properties and their relationship to process control and ingredients in cheese making

sampling procedures

contamination risk of inoculants and contaminants

food safety and quality assurance standards and procedures

yield efficiency

cleaning and sanitation procedures in line with Australian standards for cleaning in the dairy industry

routine maintenance procedures

product/batch changeover procedures

OHS hazards and controls

procedures for recording production and performance information

environmental issues and controls relevant to the process, including waste collection and handling procedures.

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Legislation

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, OHS, anti-discrimination and equal opportunity.

Policies and procedures

Work is carried out according to:

company procedures

regulatory and licensing requirements

legislative requirements

industrial awards and agreements.

Cheese tests

Cheese tests may include:

testing for pH levels, moisture levels, salt levels and fat and protein levels

microbiological testing

chemical testing

physical testing of cheese throughout production

testing for organoleptic properties.

Cheese types

Cheese types may include the range of rennet-coagulated cheeses including:

low heating temperature (<40°C) hard cheeses (e.g. Cheddar)

high temperature (>40°C) hard cheeses (e.g. Parmesan and Romano)

eye cheeses

mould ripened cheeses (e.g. Camembert and Blue)

bacterial surface ripened cheeses (e.g. Swiss Tilsit)

feta

past filata cheeses (e.g. Mozzarella).

Clarification procedures for raw milk

Clarification procedures for raw milk may include:

cloth filters

centrifugal clarifiers and separators

bactofugation

membrane (micro) filtration.

Milk standardisation requirements

Milk standardisation requirements may:

include standardisation of microflora, fat and protein, and casein/fat rations

require the addition of skim milk or skim milk solids, or the separation of cream.

Pasteurisation methods

Pasteurisation methods may be:

batch or continuous.

Cheese inoculants

Cheese inoculants include:

the lactic acid bacteria which are added to the milk as a culture in inoculation.

Cheese additives

Cheese additives may be added to the milk after inoculation and include:

calcium chloride

nitrates

colour (e.g. Annatto is added to Cheddar style cheeses to make a more orange colour)

lipases

adjunct cultures (e.g. Propionibacteria added to milk for Swiss type cheeses results in the large eyes and characteristic flavour of these cheeses)

enzymes (e.g. the use of lipase in some Parmesan and Romano style cheeses).

Cheese adjuncts

Cheese adjuncts are microbial populations added to cheese in addition to the normal inoculants to:

provide consistency to flavour and texture

accelerate flavour development

produce specific attributes to meet market targets

Adjunct cultures are essential for the correct ripening of the cheese.

Rennets

Rennets may include:

enzymes (mostly chymosin) from animal stomachs

chymosin fermented by genetically modified organisms

enzymes from microbial or plant sources.

Key composition ratios of cheese

Key composition ratios of cheese include:

salt to moisture ratio (S/M)

moisture in the non fat substance (MNFS)

fat in the dry matter (FDM)

pH (acidity).

Process control parameters to optimise yield

Process control parameters to optimise yield include:

curd cutting and subsequent agitation

heating and cooking

high temperatures during pressing.

Principles of optimising yield

Principles of optimising yield include:

obtain highest MNFS with good quality

standardise milk (P/F) to obtain maximum value for milk components

minimise fat and protein losses in the whey.

Processing factors to achieve moisture control

Processing factors to achieve moisture control include:

cheese making time

curd particle size

cooking temperature.

Preparation of the curd

For Cheddar and pasta filata cheeses, the curd particles may be allowed to matt before cutting and stacking as loaves, or stirred to prevent the particles from matting before the addition of dry salt. The loaves of matted curd are milled into small pieces before salting. The milled or stirred curd particles may be washed before salting

For pasta filata cheeses, salted, part salted or unsalted curd is heated to ~60°C to plasticise the curd (typically by stretching in hot water or brine). The plasticised cheese is then moulded into its desired shape and the part salted or unsalted cheeses salted further in a brine solution

For opened textured cheeses (e.g. Feta, Parmesan, Havarti, and most blue mould ripened cheeses) well drained curd is generally transferred from the vat into moulds before optional pressing

Eye and open textured cheese types are generally pressed before salting

For surface ripened soft cheeses (mould and/or bacteria), curd and part of the whey is transferred into moulds to form the shape of the cheese before salting.

Ripening procedures

Ripening procedures include:

for most hard cheeses:

the cheese may be sealed and allowed to ripen under either temperature controlled conditions (for rindless cheeses) or allowed to ripen under temperature and humidity controlled conditions before the cheese is sealed (for rinded cheeses)

for white or blue mould ripened cheeses, soft bacterial surface ripened cheeses (e.g. Limburger) and hard bacterial surface ripened cheeses(e.g. Swiss Tilsit):

the cheeses are allowed to ripen under temperature and humidity controlled conditions before the cheese is generally packaged in aerobic packaging. Some blue mould cheese and bacterial surface ripened cheese styles may be sealed at some stage during ripening

feta cheeses:

are generally ripened in a salt brine.

Aging of hard cheeses

Aging of hard cheeses may be:

from one to two months to several years

Temperature must be monitored for rindless cheeses and temperature and humidity for rind, mould ripened and bacterial surface ripened cheeses.

Packaging

Packaging may include:

vacuum and/or gas flush in gas and moisture proof film

surface drying as a protective rind followed by waxing

oxygen permeable packaging for most mould and bacterial surface ripened cheese types.

Multi-phase cleaning systems

Multi-phase cleaning systems require:

cleaning with a chlorinated alkaline detergent with a chelator, followed by water and acid rinses.

Records of cheese manufacture

Records of cheese manufacture may include:

timing of operations

temperature logging

milk and curd pH profile

curd weight

milk composition

cheese microbial counts

hooped yield

curing and grading data.

Food safety related information

Food safety related information may include:

milk counts

cheese bacterial counts

manufacture and storage details.

Cleaning standards

Cleaning standards include:

AS 4709 - 2001 Guide to cleaning and sanitising of plant and equipment in the food industry

AS 1162 - 2000 Cleaning and sanitising dairy factory equipment

AS 2541 - 1998 Guide to the cleaning-in-place of dairy factory equipment.