Nestled in the heart of the Swiss Alps, Emmental cheese factories have been churning out wheel after wheel of the iconic Swiss cheese we've all come to know and love. The rich, nutty aroma and the distinctive eye pattern make Emmental a global favorite, but what goes into making this famous cheese? Let's delve into the art and science behind Emmental cheese production.
Emmental's origins trace back to the Emme valley in Switzerland, where monks from the Benedictine monastery of Bellelay developed the recipe in the 13th century. The monks were skilled cheesemakers, and their secret recipe has been passed down through generations, resulting in the production of the largest wheel of cheese in the world, weighing up to 300 pounds.
Production Process
The journey of Emmental cheese begins with high-quality cow's milk, predominantly from Simmental cows, known for their rich, creamy milk. This milk is enriched with natural cheesemaking cultures, which give Emmental its distinctive flavor and aroma.
pasteurized and then heated to about 90ºF (32ºC). Upon reaching this temperature, a natural coagulant, usually rennet from calves' stomachs, is added to the milk, causing it to curdle and separate into solids (curds) and liquids (whey). This marks the first crucial step in the cheesemaking process.
Curd Cutting
Next, the now solidified curd is cut into small, rice-sized pieces using a metal tool. This process is called curd cutting and determines the size and moisture content of the final cheese. Smaller curd pieces retain more moisture, while larger ones expel more whey, leading to a drier, harder cheese.
Once the curds have been cut, they're left to sit for about 30 minutes, allowing them to release more whey and contract further into smaller, more solid pieces. This process helps to develop the cheese's unique texture and flavor.
Curd Cooking
After curd cutting, the mixture is gently heated to about 104ºF (40ºC). This is known as curd cooking and helps to firm up the curds, allowing them to release even more whey. The heat also activates the cheese cultures, promoting the development of the distinctive eyes and flavor that are characteristic of Emmental cheese.
The whey, which by now is full of proteins and other nutrients, is drained off and often used to make other cheeses or as animal feed, ensuring minimal waste in the cheesemaking process.
Molding and Aging
Once the curds have sufficiently drained, they areready for the next stage: molding. The curds are packed into large, round molds and pressed to form the iconic wheel shape of Emmental cheese.
After pressing, the cheese wheels are immersed in a brine bath to draw out additional whey and add flavor. They are then left to age, or affine, in a humidity-controlled environment. The aging process can take anywhere from 2 to 12 months, during which the cheese's flavor develops and its rind hardens.
Washover
During the aging process, each wheel undergoes a process called 'washover.' This involves rubbing the wheels with a brine solution, which not only adds flavor but also promotes the development of the distinctive eyes that give Emmental its unique appearance. The washover process is repeated multiple times over several weeks, with each wheel turning slowly to ensure even distribution of the brine.
The creation of the eyes is a result of the activities of bacteria that feed on lactose and release carbon dioxide, which bubbles out and forms the eyes. This demonstrates the symbiotic relationship between the bacteria and the cheesemaker, who nurtures and encourages their growth.
Identification and Branding
As the cheese ages, it's monitored regularly for quality and consistency. During this time, each wheel is identified and branded with a specific insignia, known as a 'poinçon.' This unique mark signifies that the cheese has been officially recognized as genuine Emmental and meets the strict quality standards set by the Swiss government.
The poinçon stamp is a symbol of pride for Swiss cheesemakers, as it guarantees the cheese's authenticity and ensures that it can be traded under the protected designation of origin (PDO) status.
Finally, once the aging process is complete, the cheese is ready for sale. Emmental cheese is enjoyed worldwide, from Swiss fondue to sandwiches and gratins, its versatile flavor and meltability making it a pantry staple.
But more than just a food, Emmental cheese is a testament to the power of tradition and craftsmanship. It's a living link to the past, a story of monks and monasteries, of cows and valleys, of culture and commerce. So the next time you slice off a piece of Emmental, remember the journey it has taken to reach your plate. And appreciate the artistry and care that goes into creating each delectable wheel.