The efficiency of Fibosa’s production lines in the manufacture of cheddar cheese

At FIBOSA we design and manufacture complete lines for the production of Cheddar cheese , adapted to the specific needs of each client. Our comprehensive solutions combine advanced automation, high production capacity and proprietary technology to guarantee efficient and reliable processes.

1. Preparation and Transfer

Production begins in the processing vats, where the curd is prepared. Once ready, transfer pumps are used to carry the product to the next phase of the continuous process.

2. Cheddarization (FIDDAR Cheddarizer)

This is the central stage where the texture of the curd is transformed through several automated processes:

• Draining and turning: A curd mattress is formed that passes through three initial drainage lines with automatic turning.
• Acidification and texturization: The product is acidified and acquires the characteristic texture of cheddar.
• Scarifying: A scarifying drum cuts the curd into small pieces called “chips”.
• Dry salting: Dry salt is applied with a subsequent agitation system to ensure uniformity.

3. Block Formation (Void Column)

The curd chips are introduced into the vacuum block forming column . The product is compacted as it descends through the column in a vacuum environment to obtain a homogeneous, air-free block.

4. Cutting and Bagging

• Cutting: A guillotine system divides the compacted cheese column into blocks of precise dimensions (such as 350×280 mm).
• Bagging: A pneumatic actuator or a bagging robot automatically inserts the block into its bag.

5. Completion of packaging

The process continues with packaging and sealing, followed by shrink wrapping to fit the packaging to the product. Finally, a blowing and sweeping process is performed to clean or dry the packages before leaving the line.

6. Storage and Maturation

The finished blocks are moved to storage areas, where they are kept for maturation, which can range from a few weeks to more than 12 months depending on the type of cheddar desired.

The entire line is coordinated by centralized control and includes CIP cleaning systems to guarantee maximum hygiene at each stage.

The FIDDAR automatic Cheddarizer from Fibosa

The process that gives the cheese its name is cheddarization, a dance of physical and chemical transformations. The heart of this process is the FIDDAR automatic cheddarizer , designed to manage the de-skimming, acidification, salting and texturizing of the curd in an uninterrupted manner, with capacities ranging from 1,000 to 10,000 kg/h (depending on the model).

Within the FIDDAR, the product advances along three fundamental drainage lines that define its technical architecture:

• Initial drainage and turning: Where the characteristic “curd mattress” is formed, and automatic turning.
• Cheddarization and cutting: The process of ripening the curd before passing through the scarifying drum that cuts it into “chips” .
• Finishing and output: The final stage where the product is added with salt, stabilized and ready for compaction.

The automatic cheddarizer integrates adjustable speed conveyor belts, curd turning and a dry salting system with subsequent agitation to improve salt uniformity and the behavior of the dough before shaping.

Its closed stainless steel structure guarantees hygiene and process control. It includes a CIP system and centralized control for automatic cleaning and safe operation. With a capacity of 1000 to 10000 kg/h continuously, it ensures efficiency, uniformity and easy integration into industrial cheddar cheese lines.

The Block-Forming Column in the Void: How “chips” become blocks

The Vacuum Block Forming Column (XC352806) forms compact blocks of cheddar cheese from the “chips” coming from the cheddarizer. The equipment, totally enclosed and made of food-grade stainless steel, includes vacuum control, smooth finish, perforations for quick cleaning and CIP system. It incorporates vacuum pumps, adjustable elevator and centralized control for integration with the production line. It has a serum tank with centrifugal pump for extraction and cleaning.

The efficiency of this column, with a production speed of up to 2 blocks per minute (dimensions of 350×280 mm) reflects its industrial power:

• Air consumption: 150 L/min.
• Water consumption: 140 L/h.
• Installed power: 25 kW.

The process ends with a high-precision guillotine-type cutting system using a pneumatic actuator that extracts the product without manual manipulation. It is then bagged and vacuum sealed.

The transformation of cheddar cheese manufacturing is a success story where technology—through automation and continuous work—has managed to elevate a traditional process to the category of a milestone in modern food engineering.

Thanks to our extensive experience in the cheese sector and deep applied knowledge, at Fibosa we design and manufacture flexible solutions for the production of Cheddar cheese , adapted to the needs of each client, with fully automated and high-capacity plant designs to guarantee process stability and product uniformity.

Contact us and we will help you define the ideal line according to your capacity and your plant integration requirements.

La entrada Cheddar cheese manufacturing: the FIDDAR Automatic Cheddarizer from Fibosa se publicó primero en .

It is a sheep cheese exported all over the world, with a large size, intense flavor and a long cheese ripening process that gives it unique characteristics.

Pecorino Romano manufacturing process with Fibosa technology

Curdling Cuba

First, the milk is heated to coagulation temperature and the rennet is added. When the curd reaches the right consistency, cutting begins.

Agitation and cutting determine the grain size and, consequently, the yield, drainage and final texture of the cheese.

In addition, the progressive and homogeneous cutting ensures that there is no excessive breakage or loss of nutrients, a key step in the cheese making process.

Drainage and delivery to the dosing machine

The whey is then partially extracted from the curd and the mass is conveyed to the dosing machine.

Controlled whey drainage ensures that no textural defects appear and that the curd reaches the molds at the optimum moisture content, thus ensuring a higher quality of the final product.

Mold washing and molding

The plastic or stainless steel molds are then washed in Fibosa’s mold washing tunnel. They are then transferred to the dosing machine, which fills each mold with the dosed and preformed curd.

Automatic mold washing ensures hygiene and reuse of molds, while uniform dosing ensures better regularity of weight and shape, essential aspects in any cheese machinery line.

Mold turning

Subsequently, the molds are turned with the Fibosa mold turner. With each turning, the cheese continues to expel whey.

This uniform turning promotes symmetrical drainage, avoids deformation and ensures optimum internal baking of the dough.

Demolding and positioning of the belt

At the end of the turning cycle, the piece is demolded and a belt is manually placed on it to tighten the cheese and remove residual moisture.

The belt ensures the consolidation of the cylindrical shape, the uniformity of the crust and the stability of the garment before the final phase.

Maturation

Finally, the pieces are placed in the cheese ripening room, where, over the course of months, Pecorino Romano develops its characteristic flavor, aroma and texture.

The control of temperature, humidity and ventilation ensures uniform ripening, avoids alterations of the rind and offers a final product of the highest quality for the international market.

Learn about the manufacturing process in video

If you want to see how this manufacturing process works, Fibosa has released a video showing how its technology ensures the tradition and quality of Pecorino Romano. From washing to ripening, each phase integrates technological innovation with the authenticity of traditional methods, ensuring that the result is faithful to the essence of one of Italy’s most iconic cheeses.

Watch the video here: https://www.youtube.com/watch?v=TvaCZWrzeQM

La entrada Pecorino Romano: Italian tradition with Fibosa technology for the cheese industry se publicó primero en .

The revolution: the first automatic Fibosa dosing machine

In the 90s, FIBOSA revolutionized the cheese industry with the introduction of its first automatic dosing machine. This machine incorporated key innovations such as portioning with standard shapers, labor reduction and a significant increase in efficiency. In addition, it allowed a saving of space in the plant, continuous production and discharge of the vat by means of pumps. These improvements, together with an optimization of hygienic conditions, marked a before and after in the way of producing cheese on a large scale.

Evolution and technologies at the turn of the century: a new era of innovation

With the beginning of the 21st century, FIBOSA continued to lead innovation in the cheese sector, developing a range of dosing machines adapted to the specific needs of each type of production:

BASIC dispenser

The BASIC batcher, designed for open dough, was introduced in the first decade of the 2000s. This machine stands out for its precise portioning, thanks to shapers adjustable in height and diameter that are adjusted according to the customer’s preferences. In addition, it offered a homogeneous pre-press that ensured a better shape of the cheese, reducing the labor required and increasing efficiency. Other advantages include saving space in the plant, continuous production and exceptional adaptability, making it suitable for all kinds of cheese factories thanks to its high reliability and precision.

PLUS dispenser

In 2006, FIBOSA presented the PLUS dosing machine, designed to adapt to open, soft, semi-hard or hard cheeses. With this machine, designed for large or small productions with multiple formats, optimal hygienic conditions were significantly improved thanks to its totally closed design.

UNIVERSAL dispenser

The first UNIVERSAL dosing machines, manufactured in 2008, were designed to work with both open and closed pasta in the same machine. The evolutions of recent years have made it the most complete, compact and reinforced equipment that is currently manufactured, with the capacity to make large cheeses.

This model of machine stands out as the most advanced and versatile in its category, thanks to its ability to work with any type of pasta and format. In addition, it is suitable for both high and low productions, positioning itself as a high-performance technological solution for cheese factories of any size.

With these innovations, the automatic dosing machine has become an indisputable benchmark in the transformation of the cheese industry. Over the past 45 years, FIBOSA has developed advanced technological solutions that have contributed to improving the quality, productivity and efficiency of cheese manufacturing, consolidating itself as a leader in the sector on a global scale.

La entrada 45 years of history of the FIBOSA dosing machine se publicó primero en .