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Our Amish farmers are up before dawn to hand-milk their cows. The fresh milk is delivered in traditional milk cans to the Cheese House minutes after milking.
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The milk enters the receiving room by conveyor.
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The canisters are dumped by hand into scales where the milk is weighed. Each farmer’s milk is weighed separately to determine the volume of milk he contributed and how much he will be paid.
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We pasteurize approximately 44,000 lbs of milk per day. During this process, the milk is heated to a specific temperature in order to destroy any disease-producing bacteria. All of the milk is then tested for antibiotics, bacteria and butterfat to determine safety and quality prior to the actual cheese making. As the first vat is filled with milk, natural enzymes called rennet are added. Rennet aids in the coagulation of the milk—the separation of the curds from whey. If Colby or Yellow Cheddar is being made, natural annatto extract is added. Once the first vat is completely filled, the artisan cheese maker proceeds to the next vat to begin the same process. We typically process three vats of milk into cheese every day.
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Starter cultures are used to speed and control the process of curdling milk during cheese making, in part by converting lactose to lactic acid. Cultures typically include some critical amounts of lactic acid, bacterial or mold spores and enzymes. Our unique culture is the most protected and important part of our process; it is what creates the unique flavor and characteristics of our cheeses.
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After the rennet and culture are added, agitators run for three cycles, stirring the milk with the rennet and culture.
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After mixing, the vat is left undisturbed for the critical “set time”. During the set time there can be no air movement and the temperature and humidity must remain constant. The set time is approximately 30 minutes, after which the true artisan element of cheese making comes into play. The master cheese maker tests the cheese, judging for consistency and texture. Only when he judges the cheese to be ready, does it moves to the next step in the process.
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Once approved by the master cheese maker, cheese makers begin cutting the vat into curds. Shown here is the vertical, or lengthwise, cutting of the vat. Cutting too soon will produce a cheese that is too soft. Cutting too late will produce hard and dry curds.
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After the vertical cutting, the cheese is cut horizontally, across the vat. When the cutting is complete, the cheese is cooked for approximately 30 minutes. At this point the vat contains around 2,000 pounds of cheese curds floating in the whey. The curds and whey are agitated and the PH level rises.
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When the PH level tests high enough, all of the whey is pumped out of the vat.
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Salt is added to the curds that remain in the vat. Every 40 lb. block of cheese requires one pound of salt. Salt does more than simply add flavor to cheese. It is what stops the chemical process of increasing acidity and PH level increase. It is very difficult to create a low sodium cheese in the traditional artisan cheese making fashion.
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Each hoop is filled with 40 lbs of curds, two buckets full, and is pressed overnight. The following morning the pressed blocks are pulled from the hoops, weighing approximately 42 lbs. It takes 10 lbs. of milk to produce 1 lb. of cheese!
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Then the heavy work begins. It takes three strong cheese makers to scoop buckets of curds into 40lb block cheese hoops.
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The pressed cheese blocks are then sealed in plastic bag, boxed and moved to the cold room for aging. The aging time varies depending on the type of cheese. It can be anywhere from 30 days up to three full years for our very special Christmas Cheddar.
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After aging, the pressed blocks are moved into the cutting room for cutting and packaging. The cheese blocks are pushed through wire cheese cutters.
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Then the cut blocks are moved to the wrapping table to be packaged and labeled.
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The final step of our process is to deliver our delicious cheeses to you either directly through our web site or at your local store.
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laWe currently receive milk from approximately 97 Amish farmers who have an average of 6 to 15 cows per herd, which are milked twice daily by hand.
People have come to know us for our fresh curds, our excellent line of yellow and white cheddars and our broad selection of delicious and uniquely flavored cheese.
For the professional chef we also carry food service sizes, which are distributed through Carmela Specialty Foods.
