Introduction
In hard cheese production, technological parameters inside the dairy facility usually receive the greatest attention. However, this case study demonstrates that quality issues can originate much earlier — at the raw milk level, influenced by cattle feeding practices.
The audit was conducted at a mid-sized dairy plant known for traditional kashkaval production, which began experiencing inconsistent texture, uneven ripening, and flavor variations.
Initial Problem
The company observed several recurring issues:
- reduced elasticity of the cheese
- micro-cracks during maturation
- flavor inconsistency between batches
Standard laboratory analyses showed normal fat, protein, and pH values, making root-cause identification difficult.
Audit Methodology
1. Production Process Review
All critical processing stages were evaluated:
- pasteurization
- coagulation
- curd stretching
- ripening conditions
No major technological deviations were detected.
2. Raw Milk Supply Analysis
The audit expanded upstream to dairy farms supplying the facility. Seasonal feeding changes were identified, including a mixed diet of fresh grass and hay during transitional grazing periods.
3. Impact on Protein Structure
Advanced analysis revealed subtle shifts in casein fractions. While insignificant for general dairy products, these changes affected the stretching behavior essential for kashkaval texture.
Practical Example (Anonymized)
One supplier farm introduced a diet combining fresh pasture grass with high-fiber hay. Although nutritionally balanced, the feeding strategy altered milk protein structure, leading to:
- reduced curd stretchability
- increased moisture loss during maturation
The audit recommended adjusting feed ratios during sensitive seasonal transitions.
Implemented Improvements
- collaboration with animal nutrition specialists
- expanded milk quality monitoring beyond basic parameters
- minor adjustments to stretching temperature and timing
Results After Three Months
- more consistent cheese texture
- reduced batch variability
- improved flavor stability
Conclusion
A comprehensive dairy process audit must extend beyond the production floor. Raw material variability, driven by feeding strategies and seasonal changes, can significantly influence the performance of traditional cheese technologies such as kashkaval production.