On the same family farm where it all started over three decades ago, our dedicated team are buzzing away from very early in the morning until tea time each day, fuelled by the passion (and proper Yorkshire Tea) to create world-class unique cheeses.
Read on to learn about the hard work, care, passion and attention to detail that go into each and every batch...
FILLING THE VATS WITH MILK: READY TO GO
We pasteurise the milk as it flows from our receiving tanks into the vats in our cheese rooms. This is vital to start the process off right. This kicks off at 5am everyday as we prepare our vats for the day's make.
CULTURING: CULTURE IS EVERYTHING
Starter cultures, brimming with beneficial bacteria, set the stage for the diverse array of flavours and textures to come. For our blue cheeses, we then add Penicillium Roqueforti at this stage too - the blue culture then lies in wait, until it's time to produce those striking blue veins and blooming rind.
COAGULATION: FORMING THE CURD
With the addition of an enzyme called rennet, the solids in the milk begin to come together and form to the consistency of a perfectly set yoghurt. We use a vegetarian rennet here.
CUTTING: A GENTLE, CRUCIAL STEP
Timing is everything when it comes to cutting the curds just right. Once the milk and ingredients have reached the ideal texture (akin to set yoghurt) we gently hand-cut the curds in the vat. This is a vital process and marks the beginning of the separation between curds and whey.
DRAINING: RELEASING THE WHEY
We need to time this bit perfectly too. When it's time to let the whey off, we embark on the vital process of draining which is letting most of the whey drain out of the vats and into our whey drain. The excess whey is taken away by a local farmer who uses it to make electricity via his anaerobic digester. Once the draining off is started, we have to move swiftly to the next step, ensuring the integrity of the curd as they begin their journey into the moulds
MOULDING UP: SHAPING EXCELLENCE
Guiding the curds into the moulds is a defining part of cheesemaking and here, gentleness is the most important part. Our vats are raised so that we can use gravity let the silky curd glide into the moulds, trying to keep the delicate cubes as in tact as possible.
THE FIRST TURN: TIME FOR ‘BRIAN’ TO STEP UP
The first turn is a pivotal moment in the cheese-making process. The curds in the mould gradually settle under their own weight, pushing out the whey and beginning to gain solidity in the moulds. As excess moisture drains away, we wait for the right moment to initiate the important first turn. Now this part of the process is much improved thanks to an ingenious bit of kit, a "turner" that we have named Brian after the famous Yorkshire chef :)
TURNING: STRIVING FOR BALANCE
Our cheeses retain moisture and so regularly turning each cheese is vital. By carefully rotating them, we ensure that the consistency throughout the cheese remains consistent. This is a vital part of the process as the cheese ripens, initially turning the cheeses daily and then transitioning to weekly turns.
GRADING: REACHING OPTIMAL FLAVOUR
Determining the perfect moment for each cheese to be deemed mature requires our skilled grading process. Just like fine wine, each batch develops uniquely, boasting its own nuances. It is our duty to make the call at the right moment to grade our cheeses and judge if they are ready for dispatch.
