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Scaling up Halloumi/grilled cheese production to meet growing demand

Andreas Charalambous

Andreas Charalambous is technical manager at Cyprus-based Agathangelou, where he oversees project management, R&D, technical sales and after sales support. He also supervises the engineering, installation, commissioning and electrical teams. He contributes this column exclusively for Cheese Market News®.

As global demand for Halloumi and grilled cheese surges, cheese producers face the exciting yet challenging task of scaling up production. Meeting this growing demand requires not only increased output but also a commitment to maintaining quality, consistency and sustainability.

The popularity of Halloumi and grilled cheese is at an all-time high, driven by their unique taste, versatility and appeal across various cuisines. In the United States alone, consumer interest in these cheese products has seen significant annual growth. This upward trend highlights the need for producers to expand their operations without compromising on the artisanal quality that Halloumi and grilled cheese enthusiasts cherish.

• Traditional Halloumi-making process: Strengths and limitations

Traditional Halloumi production involves a precise sequence of steps. Milk is heated, followed by the addition of rennet to curdle it. The curds are then cut and cooked before being pressed to remove excess whey. A distinctive feature of Halloumi production is the subsequent cooking of the pressed curds in whey previously used to extract anari, a type of whey cheese. This process imparts

Halloumi’s unique character. The cheese is then folded, flavored with mint and salt, and finally brined.

The simplicity and authenticity of the traditional Halloumi-making process are among its greatest strengths.

With basic ingredients and tools, cheese producers can create Halloumi with distinctive texture and flavor. The process allows for flexibility in production, accommodating various shapes and sizes of Halloumi. Additionally, the natural properties of fresh milk contribute to the overall quality and safety of the cheese.

Traditional methods of making Halloumi and grilled cheese are rooted in time-honored techniques, but scaling these processes presents significant challenges. Batch heating can lead to inconsistencies in temperature control, affecting the final product quality. Manual addition of rennet and curd cutting can result in variations in texture and yield. The labor-intensive nature of pressing and folding curds not only involves high labor costs but also poses ergonomic risks and leads to inconsistent results. Moreover, the open environment typical of traditional setups increases the risk of contamination, further complicating efforts to scale up and necessitating rigorous cleaning protocols. These challenges underscore the need for modernization to enhance efficiency, consistency and safety in Halloumi and grilled cheese production.

• Why modernize? Benefits and innovations

Modernizing the production process is crucial to overcoming these challenges and meeting growing demand. Embracing advanced technologies and innovative practices can help cheese producers enhance efficiency, consistency and sustainability.

Innovative technologies significantly enhance efficiency and consistency in Halloumi production. Continuous processing equipment supports large-scale production, streamlining operations and reducing production time.

Automated dosing systems ensure precise rennet control, eliminating variations in texture and yield.

Automated pressing units maintain uniform moisture content, while advanced heating systems optimize curd cooking temperatures. Quality control tools such as pH meters and moisture analyzers monitor product quality, while specialized molds ensure consistent shape and hygiene. Additionally, weight control mold filling systems guarantee uniform product weight, improving overall consistency and quality.

• Beyond modernization: Infrastructure and workforce expansion

Scaling up production involves more than just adopting new technologies; it also requires expanding infrastructure and developing the workforce. Increasing the size or number of production facilities accommodates higher volumes, while hiring and training additional staff ensures they are skilled in both traditional methods and new technologies. This dual approach of infrastructure expansion and workforce development is crucial for managing increased production efficiently.

Efficient scaling up necessitates optimizing existing processes and effectively managing the supply chain.

Streamlining workflows and improving operational efficiency reduce waste and enhance productivity. Ensuring a steady supply of high-quality raw materials and managing logistics are essential for supporting larger production volumes. Additionally, maintaining high standards through robust quality control systems ensures product consistency and safety across increased volumes. Expanding into new markets and increasing distribution channels are critical for meeting growing consumer demand and achieving market success.

• Embracing sustainable practices

Sustainable practices are crucial for reducing the environmental footprint of Halloumi production while enhancing efficiency and cost-effectiveness. Modern technologies such as closed cleaning systems, energy-efficient equipment and whey heat recovery systems minimize resource consumption and environmental impact. Integrating these innovations not only benefits the environment but also improves product quality and market competitiveness, promoting a more resilient dairy industry for the future.

• Why seek expert advice?

Transitioning to modern production methods and scaling up can be complex, making expert advice essential.

Agathangelou offers tailored solutions and guidance to help cheese manufacturers navigate this transition smoothly. With advanced production lines and extensive industry knowledge, we empower producers to scale up efficiently, maintain high standards and meet the growing demand for Halloumi and grilled cheese.

Embracing modern technologies, expanding infrastructure, optimizing processes and implementing sustainable practices allow cheese producers to enhance operations, ensure consistent quality and contribute to a more resilient dairy industry. Together, we can shape the future of Halloumi and grilled cheese production, meeting consumer demands and setting new standards for excellence.

CMN

The views expressed by CMN’s guest columnists are their own opinions and do not necessarily reflect those of Cheese Market News®.

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