Displaying items by tag: seal

    Saturday, 02 May 2020 01:11

    Dimensional Dramas of Cheese Making.

    It might be something that only hits the hobbyist cheese maker at the last possible minute. You spend hours, even days making one type of cheese, so you want to get the best 'bang for buck' ratio you can. Looking at all those huge 200Kg wheels of cheese waiting patiently to be cut up at the local delicatessen/cheese monger/fancy food establishment, a cheese making hobbyist might just think a seemingly simple little thought "I could go bigger too", and dream of somewhat more impressive 2Kg, or 5Kg, or even larger wheels.

    What a journey that innocuous thought has created....

    Dear reader, in this self-isolating time, I may have gone a little more nuts than is probably warranted. In the past two months, I've made:

    • 20L of milk into two small Parmesan wheels.
    • Another 20L of milk into Pepato, (one medium wheel)
    • 10L of milk into Swiss. (medium)
    • Another 20L into Parmesan. (one bigger wheel)
    • 20L into Jarlsberg (Two medium wheels)
    • 22L into Gruyere infused with black garlic. (an even bigger single wheel, weighing in at just under 2.9Kg).

    Looking at the general trends, I'm definitely getting bigger, and there are definite advantages:

    1. Making bigger batches means I can make twice, three times, even four times the amount of cheese with only modest amounts of extra time and effort (well... there's extra cleaning.. and a corresponding amount of time will be needed when brining, but not much else).
    2. Making bigger wheels are more space-efficient in the wine fridge.
    3. Bigger wheels may take longer to age or allow the cheeses to be aged longer, allowing greater flexibility on the consumption date.
    4. Surface problems like unwanted moulds are far less likely to reach the bulk of the cheese internally.
    5. It's generally harder to excessively dry a large wheel. This prevents cracking/crumbling... unless you put it in a dry environment for particularly long periods of time. Still not recommended though.

    However, there are down sides, which I've mentioned before in other articles. But the one that brings this particular blog post to life is the dimension of my last cheese. The 2.9Kg Gruyere.

    While I'd love to tell you that I love waxing my cheeses. The truth is that waxing only suits the harder cheeses. While Gruyere fits into this category, I used a particular recipe which incorporates "Propionic Shermanii" culture, the culture which creates the bubbles or "eyes" in Swiss style cheeses.

    Cheeses made with Propionic Shermanii will swell up during the first phase of the aging process. As such, wax is likely to crack and not work very well as a moisture and microbe barrier. To make matters a little more interesting, I've infused black garlic throughout the cheese, and during the pressing phase, this has breached the surface all over the place. In short, the rind has many breaches. To stop unwanted mould from growing, I need to basically spray the entire surface of the cheese with vinegar, remove as much air as possible from the surface, and seal it up while providing the cheese enough room to expand.

    It is for this reason, despite my general abhorrence toward the excessive use of plastic, that I break down and use vacuum sealed plastic for this sort of case. Ok, so that's the solution, why bring this up as a separate post?

    My larger wheel is too wide to fit in the standard 28cm wide roll of plastic that my Food Saver can handle. Interestingly, it's extremely difficult to get a wider vacuum seal bags/rolls. When the bag is wider, the length is often significantly shorter. So when you need something that's 35cm x 40cm... or more on each dimension, you're not going to find that outside of industrial machines. Even if you could, many of the commercial sized bags will only work on commercial machines. You see most home-sized vacuum sealers need a textured bag, and the commercial machines use smooth bags, and use other means (usually higher temperatures) to melt the bag closed.

    Ham's cheap-ish attempt at an improvised solution.

    At present the cheese is in a large, dry-curing bag that I'd normally use in my more meat-oriented endeavours, but I used a sous vide trick of submerging most of the bag (except a small opening in the zip lock seal) to use the water pressure to squeeze a decent amount of the air out. This was then sealed it up. However, I don't think this is going to work long term.

    The longer term, but still improvised solution:

    Now I could just buy an industrial sized machine, and buy the bags to fit. Obviously that would work, but that is a very expensive way to go. Some of these vacuum sealers cost thousands. I don't make enough large cheeses to justify that kind of expense, so my solution:

     

    Buy the home-sealer-friendly, but larger 45cm x 6M roll, and use my existing machine.

     

    Before you ask: "How will that fit in a 28cm wide Food Saver?" 

    Ham's plan to use a wide roll in a standard vacuum sealer

    By sticking 28cm or so in at a time. Using the vertical (grey) image, depicting a wide section of plastic roll. The procedure is as follows:

    By using the seal-only function (not vacuum then seal function) on the vacuum sealer:

    1. Sealing the corners somewhat diagonally. You may need to cut off the corners first (indicated in blue), so the machine will allow it.
    2. If the corner seals don't cross over in the middle, (like the top edge in the diagram) trimming the corners off (if not done already) and sealing the middle (like the bottom edge of the diagram) may be done.
    3. Put the large piece of meat/cheese/whatever inside the bag using the unsealed end now! (It won't go in afterwards).
    4. Seal the bottom corners, cutting off if needed. Important, leave a gap between the sealed corners for the final sealing (marked red on the image)
    5. Again, trim the bottom corners off (still marked blue) to allow the sealer to finish with a "suck and seal" as normal.

    Using the "vacuum then seal" function:

    1. Stick the (now skinny enough) unsealed end (still marked red) into the food saver, allow it to suck the air out, and then melt the final seal in place. All done!

    It's obviously a more involved process, but I think it'll work. I'm waiting for the delivery of the new rolls, and I'll update this when I give it a go.

     

     

     

     

     

     

     

     

    Post delivery update:

    Well it actually worked! However, I must warn you that this is a very fiddly way to do this. It took me nearly 20 minutes to convince the machine to do this. Oh, and you know how I put that step 3 in bold... Yeah I missed that the first time. The good news was that I remembered it as the very next seal was still hot, so I just peeled it back open.

    Here I'm about to do the final seal. (Open end is on the right) So this bag is upside-down, relative to my drawn diagram above. The bag looks like a really wonky heptagon in real life. At the left, you can see the cross over of seals that would be at the top of the diagram above. At the top-right, you can see the double seal where I undid and redid the seal there.
    Here's the final, vacuumed sealed roll. In this image, the last seal is at the left. I went around resealing with a second line of sealing, to be safe. It took a very long time to suck all the air out, perhaps leaving the opening a little wider would have facilitated that.

    So now you know how to seal a 450mm wide roll in a 280mm wide sealer. Sounds like a square peg really does fit in a round hole, doesn't it?

    In case you're wondering where I got the wider rolls from, (because I couldn't find it on eBay, or the usual haunts). I ordered them from from a Aussie supplier over in Western Australia called La-va. They sell higher-end vacuum sealers and accessories. You can find the link to the rolls here:

    https://la-va.com.au/product-page/e-vac-structured-standard-vacuum-seal-rolls/

    Note: Just remember that most household vacuum sealers need the textured/structured kind of bags. If they are just clear plastic, they are for commercial sealers, and won't work in your machine.

    Stay safe and have fun!

    Ham.

     

    Published in Cheese Making
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