Brad Leone Goes to Tillamook

good old Oregon weather out here tell you what wouldn't want it any other way are you rolling on sound right just talking hey guys I'm Bradley honey and we're here beautiful Oregon we're gonna meet up the folks from the Tillamook Creamery see how they make cheddar see how they make ice cream [Music] place production huh hey I was going good Liam Woolston very nice to meet you man so what are you what do you do here so look I'm a cheese maker born and raised in Tomah we're a farmer owned co-op 111 years old we make cheese butter ice cream yogurt sour cream all the did good dairy products yeah so see you got a cooking bat we bring in about 1.7 million pounds of milk a day and within 24 hours that's turned into cheese we don't actually fully pasteurize our milk so is you're not killing everything kill the bad stuff but we want to let some of the good stuff through that's I think that's an important part I'd imagine in getting like a good quality depth of flavor just like any food cheese start with the raw ingredient it has to be high quality if you're gonna make a hike right so like so after I see got your milk you got your quality milk how do we get from that to cheese we run that milk up here into the cooking vats and occu ate that with starter these are good bacteria that we're introducing lactic acid bacteria they take lactose and they chew it up and make it into lactic acid sure a fermentation process that's hanging this yeah we're adding 2 to 300 pounds of homegrown culture that we brought here so that's the inside of the business yep so this is the cheddar master so tell your master I don't think I'm quite there yet what the cheddar master is doing is making the perfect atmosphere within the curb to continue the fermentation process it's cool yeah if you're in achievement let's say we jump down into the the cheddar making process now let's do it yeah [Music] all right buddy here in the cheddar factory we're gonna go into the cheese department out on the floor and you look great by the office thank you almost didn't recognize ya doctor [Music] [Applause] [Music] so here we are in the Kirk phase soldiers well no yeah well this one's s raw milk at the start it's off of a fifty three thousand pound bath we're getting about five to six thousand pounds of cheese oh I'm the rest this way all right so should it be this yep we finished cooking in the bat we're ready to separate the curds away and drain the whey off right send the curd down into the chattering process so here we're pumping over into a big trough here and all that curd is coming over onto a screen and the way is going out and it's going in a pan and basically draining out Wow very cool well here we've got all our individual curds those are buttons oh wow pretty cool they're much liquid still in there right yeah it's so tempting to bite this I know have you eaten that oh yeah thanks good we can't do it right now okay fair enough agitate ER so here we've gone over the drain belt we've stirred out some of the moisture we're just lighting it Matt together watch your head it's one big mat of cheese by now looks so different yeah it's cutting into those little fingerling signs curds right the salt Lance's here going back and forth so that's spraying salt onto it you can see once we've salted them there's a heck of a skin on their egg that's upright yep oh wow don't eat it no I know what a process yeah this is ready to be pressed speaking of pressing that's what we got here yeah man we come out of the curd distributor or you move the curd with vacuum up you never get clogged oh yeah yeah and we go into a series of pipes that are pulled by vacuum we go into what we call cheese towers so we fill that column from from the bottom all the way up that 16 feet with cheddar curd that's just filled solid that's build solid Wow so down at the bottom we have a big platform that comes up and their guillotine step block off and pushes it out from there they get palletized and they go to age in our warehouse we want to get them down under 55 degrees just in this warehouse here it's about 35 million pounds just aging here I think on site we have about 50 55 altogether as it ages well I'm sure it's just developing flavor absolutely at about 70 days two months down the line that's gonna go into our so what happens after you're done how's it go from here into the finished product so at 70 days we run through sensory right what is what is the sensory sensory is the evaluation of the cheese all visual aroma flavor we do laps doing this nope these are people this is a whole team we have sounds like a pretty pretty important and skillful job yep so I'm gonna actually hand you off to Sam all right put me to work she's gonna let you taste some cheese and put you to work awesome thanks man Yeah right nice to meet you thanks for having me excited welcome to the sensory lab my name is Samantha Sheppard and I'm the sensory manager here at Tillamook County Creamery alright I work with a team of eight super tasters and collectively we have about 70 years of combined experience super tasters right you know 25% of people are just naturally born into that super taster realm that means you have really heightened senses we love to work with those people and then there's about 50% of the population who are solid average tasters which training they can get to that super taster realm I think I fall in the category of trainable average guy but after this you're probably gonna you know this is training today I'm gonna take you on a tasting journey of our delicious and fabulous cheese's our cheddar cheeses and all the way to our stirred curds with some flavor variety thrown in there and then I'm gonna have you plug and taste and evaluate cheese plugs the way our cheese graders do cheese but what's up are you ready to get started yeah we'll start there this is the medium extra-sharp 2014 6 year old cheese I can fit this in my carry-on I think let's get started sails gonna say what's this surgical gear you grab grab this is the Trier Trier careful it's charged I did these as this thing goes into the cheese I'm already asking myself House is gonna perform and manufacturing I feel yeah uh-huh and then [Music] always a fresh smell you gotta go for it man and then just pull it right up that was perfect it's kind of hard to put an exact finger on like what it smells like like cheddar almost has its own fragrance oh he correct me if I'm wrong oh you're right believe it or not our cheese graters they can smell if it's gonna be bitter or sour if it's gonna have problems this one smells perfect today's perfect of course the best part is to eat oh yeah as we move down in time oh yeah this guy is 20 months year old this falls into our extra-sharp category little firmer yeah harder to turn a little yeah smell it what do you think pungent in the best way Cheddar's like that cheddar flavor just got offensive perfect I couldn't of said it better myself just amazing get in there oh yeah oh you've done that before good plug top note cheddar sharp cheddar but it has that like a look it does have like a lack yes to it in a very nice way the fat really carries the flavor on your palate for a long day it's sharing the love so the sensory team grades every single vat of cheese that we produce one thing that we're looking for is that this cheese has the perfect quality and organoleptic allow into our Reserve Program so that's are much older cheese's this baby's been here aging out in our warehouse for six years so this cheese then goes into our Reserve Program which you can buy in the deli cases Oh at 38 years yeah we have like 2012 13 14 15 yep all right should I go first you should crit yeah you should honor oh that's pretty oh my god I mean it's firmer but it's so silky and creamy hey totally I find what tasting aged cheese they show up as extremely creamy we have a palette Wow right how do you guys choose what cheese becomes I think this is it when they cheese graters grade that cheese initially they only allow the best of the best cheese with that perfect sensory profile to go through to the makers Reserve Program I'm gonna pull you away from these gorgeous 40-pound blocks I just really wanted to open your palate up with a lot of things we have to offer so dig into the curd well that's dangerous I know I don't know I know this is our Kate Mears cheddar I like to have this with like a glass of scotch never talking oh yeah what we got here the Morningstar I wanted to put in front of you because it has a really unique flavor fruit but like slightly fermented fruit that you sprinkled salt on yes totally so now we kind of take you to the stirred curd look Oh Jack now is it two types of cheese together exactly okay can done pass me the smoked cheddar wins us a lot of awards there's two ways to smoked cheese one you can add in some artificial flavors which we do not do or you can cold smoke those pictures so it doesn't know exactly realize it's real this is a lot of fun Sam thank you it's so nice to have you off that ice cream laughter dise twist my arm [Music] right lucky Tillamook thank you nice to meet you what's your role here at tell them oh I am the current ice cream manager for ice cream manufacturing and packaging oh yes you could maybe uh show me some you know how you guys do it we can get you involved all right cool hey you get lost in this place huh yeah it's small but it kind of goes everywhere yeah like that all right so salute what kind of ice cream are we making today today we're making old-fashioned vanilla old-fashioned ammonia and we're at the stage right now and our flavor tank where we're gonna be flavoring our base mix so vanilla yep yep this is a mix that's already been agent ready to go makes a good coffee braver - oh I fell my god like that yeah we're running right now about 48 to 50 cartons per minute on this filler a lot of ice cream yesterday where we going next after these are all filled up I noticed ice creams pretty soft so we have a spiral freezer can we go in there yeah we can go in all right it's cold is total the household right now it's about 20 below zero but the wind chill is about 50 53 below zero all right let's go check that out all right here we go here we go all right that whole des hommes it's like taking spring break in Fargo [Music] well tell you there huh yeah thanks again for showing me the ice cream production I mean pretty amazing setup you got here you know a lot that goes into it I'm always fascinated by the assembly lines of it you know the mechanics of it Luke thanks again man I'm pretty neat you yep all right well hey guys I'm Brad thank you for having me here and hi my name is Anna Angola an ice-cream scientist for Tillamook and I helped create all of our new flavors little terrible job it's awful yeah I'm usually just making a pint at a time so you can make you know cake batter base or you could do a like cream cheese frosting foam this get a small batch so we run through it make sure it's okay make sure the flavor is on point and then once that is given the approval we go into production and that's where Chloe does for Chloe kitchen huh so while you're tasting so tell me what you do Chloe well I evaluate every single run we make out at OMA what are some of the things you're looking for in a quality ice cream so for quality ice cream you want to make sure it's really smooth the ice crystals need to be like really tiny and that's gonna give you a really good mouthfeel you want a little bit of mouth coating from the fat and the ice cream and you should have a certain amount of cream in it the swirl is all throughout the container there's no air pocket it's just that nice smooth creamy beautiful ice cream it's all about consistency and how do you guys quality control that let me tell ya I've got one all right a little strawberry her little classic he's a hell of a night you got there we do a quick slice it was pretty straight yeah pop it open Oh beautiful so we just want a consistent color throughout and that little marbling you kind of see we actually like that no there quick slice Oh and that really you can see the quadrants just kind of what right that right oh we we will yeah one more cut this is where you take the bite Cheers yeah real pro you'll probably notice that it's not like a bright bubblegum buddy fake looking pink yeah oh I respect that how many different flavors you guys made look at this one okay yeah 31 flavors 31 flavors next flavor yep what's that Marion Barry and Miriam Marion Oh Marion yeah a variety of blackberry is designed by Oregon State University it's a little bit on the sweeter side versus tart sides Black Arts gonna be pretty pretty sour and tart oh yeah all right I'm gonna cut it you get a B+ on oh look at would you look at that boy that's pretty pretty we always joke it looks like a Rorschach drawing what do you see a bat a bat so what's next I cut this way oh heavens through consistent placement of the fruit yes I see salmon going up a river oh that's very good and this was the mud side was it yes sure good and this is the peanut butter right mm-hmm it's really cool to see you guys you know from the from the cheese from the making process of the quality control I did with Sam and then kind of like a similar approach with you guys just you know it was a different product yeah I just really learned a lot man you guys really care about what you're doing and then hey I'm gonna go ahead to the to the creamery and get like a proper cold yeah are you sure collar or wait for cone or thank you thank you again and everyone at Tillamook for showing me how they make their cheddar their ice cream the time and the effort that goes in to make that product was really kind of blew me away especially the cheddar and how it's a live culture and these enzymes that are carrying through and developing this flavor I also loved how the human element was a part of it and now in every step of the way people wasn't just you know a high-tech factory but there was people involved and everyone working together and I think that's something that could easily be skipped and I'm glad that they don't thanks again guys I hope you enjoyed bone up teeth you

Channel: Tillamook

Views: 602,531

Keywords: tillamook, tillamook cheese, tillamook ice cream, tillamook oregon, tillamook creamery, cheddar master

Id: krVAsI90ZsY

Length: 15min 22sec (922 seconds)

Published: Tue Mar 03 2020