Methods and Apparatus for the Reduction of Moisture Variability in Large Cheese Blocks

A process for making a block of cheese having reduced moisture variability, said process comprising providing a bulk container having a bottom and sidewalls;

• introducing cheese curd having an initial temperature of about 60 to 90° F. into the container to form a cheese curd block;
• pressing the cheese curd block to form a cheese block;
• controlled cooling of the cheese block to a final temperature of less than 45° F. over a total period of about 7 to about 13 days to form a final cheese block, wherein the controlled cooling is effective to provide a reduced moisture content variation between a geometric center and side edges of the final cheese block as compared to a similar cheese block cooled directly to 45° F. over the total period;
• wherein the final cheese block has a weight of at least about 500 pounds;
• wherein the controlled cooling comprises first cooling the cheese block at an intermediate temperature of about 10 to about 40° F. below the initial temperature and at least about 10° F. above the final temperature for a first cooling period of about 2 to about 5 days and then cooling the cheese block at the final temperature of less than about 45° F. for a second cooling period of about 5 to 7 days;
• and wherein the first and the second cooling periods are sufficient to cool the final cheese block to less than about 45° F.