About 4,500liters of fresh milk are delivered daily from the surrounding Stein farms with the same amount again brought by tanker from more distant farms so that about 9,000liters of unpasteurised milk are processed daily. The milk is first sieved, tested and weighed. If the milk needs to be stored before the next process it is cooled and stored in large vats at 10 deg C / 50 deg F. The fat content of Appenzeller cheese is regulated to exactly 50% of the dry mass so some of the milk is skimmed in centrifuges. The skimmed and full cream milk then flows over a heat exchanger, where it is heated, into the so-called cheese kettle, which contains about 600liters of milk. The milk is constantly stirred as it is heated to a temperature of 32 deg C/ 90 deg F, at which it coagulates, and the rennet and the lactic acid bacteria (natural coagulants and fermentation additives) are added. The cheese then begins to ferment and after about 30-40minutes it coagulates to form curds, which are broken up with the cheese sieve. The resulting crumbs - small lumps the size of corn kernels - separate from the whey. After the initial process has finished the curds are gently heated and stirred constantly until the necessary thickness has been reached. During the next stage the lumpy mixture is siphoned up with the whey and poured into the pressing tub, where it is formed into blocks of cheese which are cut into pieces and shaped. The remaining whey is squeezed out of the fresh cheeses, which are turned several times. The whey is completely skimmed of cream, after it has passed over the heat exchanger and through the centrifuge, before it enters the whey tank. It still contains protein and minerals and provides a valuable source of nutrition for pigs. The temperature is regulated in the drying-room where the cheeses begin to form a crust. The salt dip promotes the formation of a perfect crust and determines the flavor and storage properties of the cheese. The cheese is allowed to ferment and ripen naturally in cellars with a temperature of 14-15 deg C / 57- 59 deg F and a relative humidity of over 90%. About five to seven weeks after manufacture the cheeses reach the retail trade, where they are stored and subjected to further quality controls relating to texture, hole formation, color, appearance and smell. The cheese-dealer regularly bastes the cheese with the so-called "Sulze" or "Schmiere", made from herbs and spices (a secret traditional recipe), which gives the "Appenzeller" its typical flavor and special aroma. After 3.5-5 months the cheese is ripe and ready for sale.
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