What is the ideal relative humidity and temperature range for a kaşar maturation room?

Pre-packaging kaşar climate has two stages. Surface drying for rind formation typically runs at 12–16°C and 80–85% RH for about 3–7 days, depending on block size and recipe. Maturation typically runs at 10–14°C and 85–90% RH; its duration follows the recipe and is at least 120 days for "eski" (aged) kaşar. These rooms have dew points of roughly +7.6…+13.5°C. The chosen set-point should be held within ±1°C and ±3% RH; exact values are set by the product recipe.

Is a condensing (compressor-type) dehumidifier sufficient for a kaşar maturation room, or when is a silica gel rotor required?

The decision follows the room's dew point and temperature. Condensing units are efficient at dew points of +10°C and above; the practical lower limit is about +5°C dew point, and capacity and efficiency drop markedly once ambient falls below 15°C. Kaşar rooms have dew points of roughly +7.6…+13.5°C, while room temperature is mostly below 15°C. Condensing units are therefore strong on the fresh-air line, where warm outdoor air is pre-treated, and in surface-drying rooms close to 15°C. For maturation rooms running continuously below 15°C, a condensing unit with a verified low-temperature capacity curve should be compared on energy use with a TFT silica gel rotor or hybrid unit. Below a +5°C dew-point target, a silica gel rotor is required.

How is mold growth on the kaşar surface prevented, and what HVAC measures are required?

Mould develops where free surface water, stagnant air and a suitable temperature coincide. Because many Penicillium species grow down to a_w ≈ 0.80, RH control alone does not stop mould; it limits growth rate. Three HVAC measures stand out. First, keep maturation RH within the 85–90% band and prevent the product surface from cooling below the air's dew point; for example, air at 13°C / 90% RH has a dew point of ≈ +11.4°C, and condensation forms on any colder surface. Second, provide a uniform 0.2–0.4 m/s air velocity at shelf level to eliminate dead zones. Third, maintain hygienic room surfaces, at least F7 filtration and a regular wheel-turning routine. Optional UV-C in the return duct reduces spore load.

How is Listeria monocytogenes risk managed in the maturation room, and is positive pressure mandatory?

Listeria monocytogenes is a psychrotrophic pathogen that can grow at refrigeration temperatures and colonise cold, damp surfaces (drains, door thresholds, gulleys), so control in the maturation room is essential. The primary barrier is slight positive pressure: the room is held about +5…+10 Pa above the adjacent corridor so that air flows outward when the door opens. The second layer is hygienic sandwich panelling with radiused corners and sealed floor-wall joints. The third layer is fresh-air filtration: at least F7, F9 where the risk assessment calls for it. Condensate drains must be trapped and the drip pan made of stainless steel. Positive pressure is not a standalone solution, but it is an indispensable barrier.

How is weight loss (shrink) managed during kaşar maturation?

There is no single universal figure for acceptable shrink; the producer sets it according to block size, rinded or vacuum-packed ripening, duration and recipe. Shrink is fastest during surface drying in the first days and slows as maturation progresses. When RH falls below the band, shrink increases and the rind may crack; when it rises above the band, mould risk increases. RH should therefore be held in a narrow band (e.g. ±3% RH), and each plant should track its own shrink curve alongside its temperature-humidity records.

According to the Turkish Food Codex, what are the minimum maturation time and moisture content limits for kaşar?

The Turkish Food Codex Cheese Communiqué (No. 2015/6) defines kaşar as a pasta-filata cheese that may be marketed fresh or ripened; it sets no general minimum ripening time for kaşar. The term "eski" (aged) may be used for kaşar ripened for at least 120 days, and ripened cheese must state its ripening time on the label. Compositional criteria are given in the communiqué's annexes; current values should always be checked against the communiqué text in force. HVAC design aims to hold the dew-point and RH set-points that help the product meet these criteria.

How are air changes per hour (ACH) and fresh-air ratio determined for a maturation room?

Circulation airflow is set by the target air velocity at shelf level rather than by a fixed air-change rate: a uniform 0.2–0.4 m/s around the product, no dead zones and no high-velocity air striking the rind directly. Variable-speed (VFD) fans let the airflow be tuned to this target. Fresh air should be kept to the minimum needed for CO2 and odour control and slight positive pressure, because in summer most of the moisture load comes from fresh air. For example, 0.5 air changes (192 m³/h) of fresh air in a 384 m³ room, brought from 30°C / 70% RH outdoors to a 12°C / 85% RH room condition, adds about 2.6 kg/h of moisture load.

Why must air velocity not exceed 0.5 m/s during the surface drying stage?

The goal of surface drying is to remove moisture migrating from the body to the surface evenly and form a uniform rind. When shelf-level air velocity exceeds about 0.5 m/s, surface drying outpaces internal diffusion; the outer layer shrinks while the body stays moist. The resulting stress causes fine "crazing" cracks, higher shrink and mould ingress during later maturation. The recommended design uses textile ducts or perforated ceiling diffusers for gentle supply, delivering a uniform 0.2–0.4 m/s at product level.

How is moisture load and dehumidifier capacity calculated for a 20 ton/month kaşar plant?

Example: 20 tons per month, 2 kg blocks, 90-day ripening per the recipe and three 384 m³ maturation rooms (≈ 20 tons of stock per room). Assuming an average daily weight loss of 0.1%, product evaporation is 20 kg/day per room; adding infiltration (≈ 2 kg/day) and personnel (0.8 kg/day) gives 22.8 kg/day, or ≈ 28.5 kg/day (≈ 1.2 kg/h) with a 25% safety margin. Fresh air of 192 m³/h per room, brought from 30°C / 70% RH to 12°C / 85% RH, adds ≈ 2.6 kg/h, i.e. ≈ 9.8 kg/h for three rooms with the 25% margin. If the fresh air is treated in a central condensing unit, this load is not assigned to the room units a second time. Because the room unit runs at 12°C, it is selected from its low-temperature capacity curve and compared on energy use with a silica gel rotor or hybrid option. Each plant should replace these assumptions with its own data.

What is the periodic maintenance frequency for dehumidifiers in a kaşar maturation room?

In a food-contact environment, maintenance is critical for both equipment life and hygiene. Following the maintenance table in the article, a typical schedule is: monthly, a visual check of filters and evaporator surface, a condensate flow check and a sensor data check; quarterly, filter cleaning/replacement, evaporator cleaning, trap cleaning, a sensor drift check and a visual check of the silica gel rotor; semi-annually, full filter replacement, a detailed evaporator wash, sensor calibration and a rotor performance test; annually, a leak test, certified sensor calibration and a rotor wash/seal check. Exact intervals follow the maintenance instructions of the unit manufacturer and the HACCP procedure of the plant; maintenance and calibration records are kept in the HACCP documentation. NKT provides technical service and spare-parts support for the units it supplies.

Technical Article46 min read

Cheese Maturation Process and the Importance of Humidity Control

Humidity and temperature control in kaşar cheese maturation rooms, surface drying (12–16°C / 80–85% RH), maturation (10–14°C / 85–90% RH), Listeria prevention and shrink management. Turkish Food Codex Cheese Communiqué framework, dew-point-based comparison of condensing, silica gel rotor and hybrid dehumidification, and a worked moisture-load example for a 20 ton/month plant.

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Related Glossary Terms

For deeper definitions of the technical concepts in this article, browse the related entries in the NKT Glossary:

Relative Humidity (RH)Moisture Load Dew Point Silica Gel Rotor (Desiccant Rotor)Condensation Dehumidification Reactivation (Regeneration)Evaporator Coil Adsorption Defrost Infiltration Capacitive Humidity Sensor Calibration HVAC (Heating, Ventilation & Air Conditioning)ACH (Air Changes per Hour)HEPA Filter (High-Efficiency Particulate Air)Steam Humidification Hygienic Steam HACCP (Hazard Analysis & Critical Control Points)Sorption (Adsorption + Absorption)Water Activity (aw)Case Hardening VFD (Variable Frequency Drive)Maturation Proteolysis Listeria monocytogenes FIFO (First In First Out)Humidification Capacity (kg/h)Silica (SiO₂)Condensate (Steam Condensation)Filtration (Water Filtration)Biofilm

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