The dairy industry between sustainability and 5.0: innovative strategies and life cycle assessments in the processing and packaging of stretched-curd cheeses

This doctoral thesis focuses on advancing food process engineering, particularly dairy plant design, integrating laboratory-scale experimentation while providing life cycle assessment (LCA) and industrial validation. The research aims to enhance cow's milk processing through systemic innovations within the dairy industry. Curd freezing is proposed as a technological solution to improve raw material management (addressing milk surplus) and ensure greater production flexibility. This study explored the effect of freezing curd, produced from raw milk (RM) and pasteurized milk (PM), subjected to blast chilling and packaged in air (A), 100% nitrogen (N), and vacuum (V), on the quality of mozzarella obtained after 30, 60, and 90 days of storage at -18°C. Furthermore, an LCA approach was conducted to assess the environmental impact of mozzarella production, accounting for different acidification methods, packaging systems, and shelf-life durations. This analysis led to the definition of mitigation and improvement strategies aimed at aligning curd management with environmental protection principles. A technology transfer phase was also implemented, validating these protocols on a pilot scale within an industrial dairy to ensure scalability and industrial profitability processes. The results confirm that combining curd freezing with optimized packaging systems is an effective strategy for reducing waste and enhancing supply chain sustainability. This approach provides small and medium-sized dairy enterprises with a scientifically validated protocol to improve both economic and environmental performance.