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Production process
The creams Virgilio uses in the production of butter are already pasteurised at the associated companies. Pasteurising cream as soon as it is produced allows preserving the maximum amount of quality characteristics. The creams are then collected and transported daily to Virgilio plants. On arrival the operators responsible for unloading will draw samples of the product to be sent to the laboratory to check the actual quality. Once the tests have been done the products are unloaded into refrigerated tanks (temperature not exceeding 6°C), when these are full the pasteurisation/uperisation process begins: this procedure entails warming the milk to a temperature exceeding 80 °C for a few seconds and then cooling it to 8-12 °C and storage in proper tanks called maturators. This process allows eliminating any residue bacteria. In the maturator, selected (live) lactic acid bacteria are added to the pasteurised cream, their metabolic activities lead to the production of NATURAL aromatic substances such as diacetyl (a substance responsible for the aroma of butter). Furthermore the presence of these bacteria (also called "dairy bacteria") permits a better storage of the product. The maturation phase lasts approximately 18-24 hours. Cream consists of water, fat globules, proteins, lactose and salts. The fat globules are each covered by a phospholipidic membrane that permits them to remain in a water emulsion. During the butter-making phase the cream is repeatedly beaten with a rotating device called a BEATER, causing the phospholipidic membranes to break and the triglycerides to exit (this is the actual FAT in the butter). The lean part, buttermilk is separated from the cream, and is removed from the butter-maker, the remaining butter will then continue the process in a different part of the machine where it will be kneaded to loose more humidity, until it reaches the limit of 16% water. At this point the butter is ready.
The three UHT products, cooking cream, whipping cream and milk have a similar production process: this entails the fresh milk being heated to 150°C for no less than one second 1 sec., followed by homogenisation, i.e. shattering the fat particles immersed in the water into smaller particles in order to slow down the resurfacing processes of the same particles. This is followed by cooling to a temperature less than 30°C and finally the storage. Naturally there are substantial differences in the times required, temperatures of the various phases and the homogenisation methods. All the UHT products are packaged in a sterile environment using proper packaging machines.
. How is a Consorzio Virgilio-quality cooking cream produced ?
The raw material used consists of 24% fatty substance. The cream to be used is initially heated: a steam jet at 180°C is introduced into the cream in order to increase the temperature until it reaches 150°C. In this way the product is cleansed from all bacteria that would hinder its storage. The steam remains in contact with the product for no less than 1 second. It is then removed and the cream is cooled to 86-87°C. At this temperature the cream is sent to the homogeniser where every particle of the product is thrust at high pressure through a microscopic hole. It is therefore divided into into four/six smaller particles in order to proportionally slow down the slow down the resurfacing processes of the fats (the resurfacing speed is proportionate to the diameter of the fat globules). A further cooling process follows to a temperature less than 30°C and lastly the product is stored at a controlled temperature (4-6°C).
. How is a Consorzio Virgilio-quality whipping cream produced?
Initially whipping cream consists of 35% fatty substance. a steam jet at 180°C is introduced into the cream in order to increase the temperature until it reaches 150°C. In this way the product is cleansed from all bacteria that would hinder its storage. The steam remains in contact with the product for no less than 1 second. It is then removed and the cream is cooled to 80-86°C. At this temperature the cream is sent to the homogeniser where every particle of the product is thrust at high pressure through a microscopic hole. It is therefore divided into into four/six smaller particles in order to proportionally slow down the slow down the resurfacing processes of the fats (the resurfacing speed is proportionate to the diameter of the fat globules). A further cooling process follows bringing the product to a temperature of 10-12°C and lastly the product is stored at a controlled temperature (0-6°C).
Grana Padano PDO is produced using raw cows’ milk, from no more than two milkings a day. Partially skimmed milk for natural skimming is transferred into traditional copper double-bottomed boilers large enough for the formation of a maximum of two wheels of cheese. Natural whey is added to the milk.
This starter consists of natural culture of milk bacteria that develop in the whey coming from the previous caseification. The inoculated milk is heated to 31-33°C, and veal rennet is added for coagulation.
The curds are broken and cooked at between 53 and 56°C while beaten. Once the heating process has ended the rennet granules fall to the bottom of the boiler where they gather and they are kept for 30-70 minutes under the whey at a temperature not exceed the one at the end of cooking.
The subsequent operations of removal and placing into moulds are mostly done manually as they once were, they are done according to strict schedules and times tht are well established. The caseos mass is allowed to rest on the bottom of the boiler for about 45-60 minutes, to become firm. When it is time to remove, the operators use a shovel and a cloth ("schiavino") to lift the mould from inside the boiler and divide it into two equal parts –two "twin shapes" -, each is wrapped in a hemp or jute cloth and placed on the dripper. At this point each new wheel is closed off by a bander "fascera", which holds it tight and it is kept pressed by a heavy disk in the same material, so that the whey can drain off and the cheese can keep its traditional round shape.
Afer about eight hours from the time it was "shaped", another plastic strip is inserted between the "fascera" and the side of the wheel, the branding shows in relief the seal of origin, i.e the four-leafed clover with the registration number of the dairy, the letters identifying the province and the month of production, it also has the small rhombus shapes which are the symbol of the Grana Padano PDO, distributed throughout the surface, so they are visible all over the rind. After about 24 hours the teflon strip is replaced by one in steel, with small holes and slightly rounded to allow the cheese to take on its final shape.
After 2 days from production the cheese that has now taken on its characteristic round shape, is immersed into a salt and water solution in order to salt it. The lengh of this operation varies and normally consists of 16 to 25 days, depending on the type of salt, the size of the wheel, the degree of saltiness required.
At the end of the salting process the wheels are placed in an environment which favours drying, before being taken to the warehouse for ageing.
Once they are removed from the water and salt the wheels are then transported to the "heat or drying chamber" where they will remain for a few hours to dry, they are then taken to their last resting area in the ageing warehouse: these rooms have a modern system for controlling temperature, humidity and airation as is necessary.
During the long ageing process Grana Padano undergoes a series of physical, chemical and microbiological changes that are reflected in its organoleptic characteristics. During this time the wheels are treated, cleaned and turned approximately once a fortnight. These operations were once done manually but now there are brushing machines and turning is automated.
At the right time the Grana Padano PDO wheels are examined using the traditional examination instruments – the "hammer", "needle" and "probe"- and if necessary for a more careful examination, they are cracked.
Source: www.granapadano.it
UHT Milk (Ultra High Temperature) is milk that undergoes treatment that completely eliminates all type of bacteria whether pathogenic or not. The fresh product arrives at Consorzio Latterie Virgilio directly from associated Dairies, it is then heated to 150°C for no less than 1 second. It then undergoes a homogenisation process where the fat particles immersed in the water are thrust by high pressure through microscopic pores. They are thus broken into smaller particles in order to proportionally slow down the speed with which the fat particles i.e. "the fat part" resurface (the resurfacing speed is proportional to the diameter of the fat globules). Then the milk is cooled to a temperature lower than 30°C and stored. UHT Milk is then packaged in an aseptic environment using suitable packaging machines.
How is a Consorzio Virgilio-quality mascarpone produced? The initial product is the cream from our dairies. This is heated to 90°C and acidised with the addition of citric acid. The pH passes from 6,7 (typical of milk) to approximately 5.9-6.0: in this way the proteins aggregate and the mascarpone separates from the "whey". The two substances are separated completely by means of ultrafiltration: the mix passes through a "filter" that separates the mascarpone from the permeate (what was once called whey). The mascarpone in this phase has a temperature of approximately 80-85°C that is maintained for the entire duration of packaging: this is in order to guarantee safety and hygiene along the entire production process. Lastly the product is stored in cells at a controlled temperature between 0°C and 6°C.
Milk from 270.000 cows milked twice a day is taken to the dairy within two hours from each milking. The milk is in its natural state, without the addition of additives and without having been treated.
Evening milk, partially skimmed due to the fat rising naturally, is mixed in copper boilers with the full cream milk from the following morning. Starter whey is added to the milk, a natural culture of lactic acid bacteria obtained from whey left over from the previous days' work. This results in coagulation at a temperature of 33-35°C for 10-12 minutes, in copper cone-shaped trunk boilers using only veal rennet. The curd is then broken into small granules of approximately 2-4 mm, called "spinatura". Cooking is an extemely delicate phase in which the cheese maker takes the temperature in a controlled and gradual manner from 33-35°C to 55°C in approximately 10 minutes. The heat causes the granules to lose water and fall to the bottom of the boiler where they are allowed to settle for 45-60 minutes, leading to a compact mass that is then transferred to the moulds for shaping (which lasts 2-3 days). Salting is done by immersing the wheels into salt water for 20-25 days, at a temperature of approximately 16°C. The wheels are then allowed to age for at least 12 months (for an average of 20-24 months) at a temperature of 18-20°C. At the end of the minimum ageing period each wheel is subjected to expert checks in order to assess appearance, structure and characteristics of the body.
Source: www.parmigiano-reggiano.it
Provolone is produced starting from raw milk, seeded with thermophile ferments with a high acidifying power, to obtain the progressive acidification of the milk and curd.
Coagulation at 37-39° C was practiced using veal rennet to produce sweet provolone and kid or lamb rennet for spicy provolone.
After reducing the curd to large clots the size of maize kernels, it was brought up to a temperature of 50-52° C until the correct consistency was reached. The paste was then subjected to pulling in hot water at 70° C and then moulding in special moulds. It was then cooled by introducing the cheeses into running water to cool down and become firm.
The salting phase now follows by immersion in tanks with water at a controlled degree of salinity, for a variable period in relation to the weight of the cheese.
The cheeses are finally hung up on special supports, in pairs or singly, depending on the formats, in a warehouse with controlled humidity for the seasoning phase which may be short, medium or long, depending on the taste characteristics and final scent of the cheese.
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