Complete line of machinery for making cottage cheese

The industrial-scale production of cottage cheese presents technological challenges not found in other cheeses. Cottage cheese is a dairy product highly valued for its freshness, texture, and nutritional profile, but its quality depends entirely on a particularly fragile element: the curd grain. Keeping the curd grains intact during cutting, washing, cooling, draining, and mixing with the cream is what distinguishes a creamy, homogeneous product from one with broken curd grains and low yield.

This technical challenge comes at an opportune moment for the sector. As noted in the previous article on new trends in cottage cheese consumption, demand is rising alongside the “high-protein” and “clean label” trends. This growth is driven primarily by young, active consumers—or those focused on clean labels—who value its approximately 14 grams of protein per 100 grams and its minimal ingredient list: milk, cultures, rennet, and salt.

For dairy manufacturers, capitalizing on this opportunity means having a production line capable of large-scale production without compromising the quality of the curd.

The Industrial Process of Cottage Cheese

Automated cottage cheese production requires a precise sequence of technologically coordinated steps:

• Coagulation, cutting, and heating of the grain
• Draining, washing, and cooling
• Water separation
• Mixing with the cream
• Final packaging

The main objective of this production line is to ensure gentle handling of the curd. This preserves the uniformity of the curd grains and results in a final product with a creamy, homogeneous texture.

Machines for Cottage Cheese Production

CURDFRESH CTT Vessel: Coagulation, Cutting, and Gentle Heating

The CURDFRESH CTT is a specialized tank designed exclusively for the initial phase of the process and optimized to handle the curd with the utmost care.

• Precision Processing: It features an advanced longitudinal and transverse cutting system, along with gentle agitation that minimizes grain breakage.

• Process Control: Thanks to its enclosed design and precise temperature control, it ensures uniform cooking, guaranteeing product consistency and yield.
• Construction and Hygiene: Manufactured from stainless steel (AISI 304 or, optionally, AISI 316), it includes an integrated CIP cleaning system and centralized control via a PLC with a touchscreen.

• Tank Capacity Models:
  • CTT10: 10,000 L
  • CTT12: 12,000 L
  • CTT15: 15,000 L

WHEYLESS PLUS CTR Whey Separator and Cooling Tower

The WHEYLESS PLUS CTR whey separator combines three critical phases into a single unit: whey separation, washing, and three-stage curd cooling.

• Energy and Water Efficiency: It uses heat recovery systems that significantly reduce energy and water consumption.

• Grain Quality: It performs a continuous, gentle treatment without abrupt mechanical agitation, removing residual lactose and homogenizing the temperature without damaging the cheese’s structure.

• Range of models and capacities:

AQUALESS CTS Water Separator: Efficient Drainage of Wash Water

The AQUALESS CTS water separator removes excess water from the washing and cooling processes, leaving the curd ready for the addition of cream.

• Technical separation: Its optimized discharge pressure prevents product loss and grain breakage.

• Design and Integration: It features weight-controlled dosing, a compact design, and integration with CIP cleaning systems.

• Range of models and capacities:
  • CTS-02: 2,000 L/h
  • CTS-03: 3,000 L/h
  • CTS-04: 4,000 L/h
  • CTS-05: 5,000 L/h
  • CTS-06: 6,000 L/h
  • CTS-08: 8,000 L/h

CREAMER CTC Cream Mixer: Homogeneous mixing with dressing

The CREAMER CTC cream mixer performs the final mixing of cottage cheese with the sauce or dressing (cream, salt, and other ingredients).

• Careful mixing: Use specialized agitators that ensure even distribution of the dressing without altering the condition of the grain.

• Performance: Includes a complete emptying system to minimize product loss and automatic control via PLC.

• Capacity models:
  • CTC-40: 4,000 L
  • CTC-50: 5,000 L

Packaging and Heat Sealing

Once the mixing process is complete, the product is conveyed to the heat-sealing units, where the packaging is sealed to create a hygienic package that ensures the cheese’s shelf life and food safety.

To ensure a continuous and efficient flow, the capacities of the equipment must be perfectly synchronized from coagulation through final mixing.

Setup and Workflow Guide

To ensure there are no bottlenecks on the production floor, equipment is grouped into recommended configurations based on daily production volume:

• Standard Configuration (Lines from 10,000 L to 12,000 L):
  • Cuba CURDFRESH CTT10 or CTT12.
  • WHEYLESS CTR-02-100 or CTR-02-120 separator.
  • AQUALESS CTS-02 water separator (2,000 L/h).
  • CREAMER CTC-40 mixer.
• High-Volume Configuration (Lines of 15,000 L or more):
  • Cuba CURDFRESH CTT15.
  • WHEYLESS CTR-03-150 separator.
  • AQUALESS CTS-03 Water Separator (3,000 L/h).
  • CREAMER CTC-50 Mixer.

Comparison of Capacities and Models

To ensure a continuous and efficient flow, the capacities of the equipment must be perfectly synchronized from coagulation through final mixing.

More information about the cottage cheese production process.

Technological and Health Benefits

• Maximum Hygiene: All equipment is constructed of AISI 304/316 stainless steel and is fully compatible with CIP (Clean-In-Place) systems.

• Full automation and control: Touchscreens and PLC-based automation that allow for the precise recording, repetition, and control of thermal parameters and process times.

• Product Integrity: Every fluid transfer and mechanical agitation process is designed with gentle flow dynamics, eliminating waste caused by curd dust or misshapen grains.

Complete production line for making cottage cheese.

Are you interested in adding cottage cheese to your product lineup?

At Fibosa, we design and manufacture complete production lines for the industrial production of cottage cheese, focusing on automation and the extremely gentle handling of the curd to prevent the curds from breaking apart and maximize commercial yield.

The process ensures gentle handling of the curd, preserving the uniformity of the curd grains and resulting in a product with a creamy, uniform texture.

Contact Fibosa to begin defining your project based on your production needs.