Automated Cheese Cutting for Caciocavallo: Weighing, Centering and Radial Portioning

Cheese processors need portioning systems that can accommodate variation in product shape while producing repeatable retail or food-service portions. Caciocavallo and similarly shaped cheeses present a particular handling challenge: the product may have a rounded or tapered profile, and its center of mass and dimensions can vary. A useful automation concept combines integrated weighing, controlled rotary positioning and radial cutting. A complementary adaptive pneumatic gripper can hold, center and transfer cheese between stations. This article describes the engineering considerations for such a prototype-based solution. It does not imply that prototype testing is complete or that patent protection has been granted; the described gripper project is at prototype testing and adjustment stage, with an Italian patent application filed.

1. Cheese geometry and process variability

Caciocavallo is not always a perfectly uniform geometric body. Shape, neck profile, diameter, height, surface condition and mass can vary from piece to piece. Cheese firmness also changes with recipe, moisture, maturation and temperature. These variations affect how the product sits on a table, how securely it can be gripped and where the radial cutting center should be located.

A fixed fixture may work for a narrow product range but can become inefficient when dimensions vary. The machine concept should therefore define the allowable size envelope and the product features used for locating. The design should also consider whether the rind remains on the final portions and whether the product is cut at ambient, chilled or another controlled temperature.

2. Integrated weighing as a process input

Weighing the cheese before cutting provides an actual mass value for portion planning. If a target number of portions is selected, the controller can calculate an initial nominal mass per portion. However, equal mass does not automatically mean equal geometry or identical appearance. Shape and density distribution still matter, and the cutting plan may need to balance portion mass with the desired radial pattern.

The weighing station should be mechanically isolated from vibration and movement during measurement. The scale must be calibrated, the product must be fully supported and the system should account for tare and any fixture weight. Data should be associated with the correct product cycle so that the weight value is not accidentally assigned to the next cheese.

3. Rotary table and radial cutting

A rotary table can position the cheese relative to a cutting head and support a repeatable radial pattern. The table’s locating surface should resist slipping without damaging the rind. The rotational axis, product center and cutting path need to be aligned. If the cheese is off-center, nominally equal angular divisions can produce visibly unequal portions.

Even and odd portion counts

Radial portioning may require an even or odd number of portions. The controller should translate the selected count into angular positions and define the sequence of cuts. An even division may allow paired or opposing cuts, while an odd division requires a different sequence to maintain the intended geometry. The actual cut path must consider blade width, center loss, rind behavior and the product’s shape.

Centering before cutting

Centering is a critical step. The machine should establish a repeatable reference using the cheese geometry and a locating or gripping method. Where the product is irregular, a simple diameter measurement may not identify the true center. Trials should determine which reference points give the best portion symmetry and whether the controller needs a correction based on measured geometry.

4. Adaptive pneumatic gripper concept

A pneumatic gripper can provide controlled holding and transfer between weighing, positioning and cutting stations. An adaptive design aims to accommodate a range of cheese dimensions while applying sufficient force to prevent movement. Too little force can allow rotation or displacement; too much force can mark or deform the cheese. Contact surfaces should be shaped to distribute load and should be suitable for the food-processing environment.

The prototype gripper described for this application has been built and is undergoing testing and adjustment. A patent application has been filed in Italy. A patent application is not the same as an issued patent, and the final performance, operating envelope and intellectual-property status should be described accurately in technical and commercial materials.

5. Coordinating the process stations

A possible sequence is: identify the cheese, weigh it, transfer it with the gripper, center it on the rotary table, select the portion recipe, execute radial cuts and discharge the portions. Each transfer should be confirmed before the next station begins. Sensors can help verify product presence, gripper position, table state and cycle completion. Fault handling should prevent the system from cutting when the product is not correctly located.

The control system should retain the measured weight, recipe, selected portion count and cycle status. This data can support traceability and process improvement. It should not be treated as a substitute for the processor’s own quality checks or legal metrology requirements.

6. Cutting technology and blade selection

Cheese texture varies widely. Semi-hard and hard cheeses can require different cutting forces from soft or elastic varieties. Ultrasonic cutting may be evaluated for suitable cheese products where reducing drag or adhesion is beneficial, but the blade and cutting method must be selected for the specific cheese. A radial cutting machine may use a different motion and tooling arrangement from a straight-slicing system. Sample trials should examine edge condition, crumbling, deformation, rind separation and residue.

7. Hygienic design and food safety

Cheese fat and protein residues can accumulate on contact surfaces and mechanisms. Grippers, rotary tables, blade holders and product supports should be designed for inspection and cleaning. Pneumatic components should be arranged to minimize contamination risk, and lubricants or other materials near product zones should be appropriately controlled. The processor should validate cleaning procedures and verify that the equipment fits its sanitation program.

8. Prototype testing and acceptance criteria

Testing should include the expected range of cheese sizes, weights, shapes and firmness. Measure weighing repeatability, centering accuracy, gripper retention, transfer reliability, portion mass variation, radial symmetry, cut quality and cycle time. Test both even and odd portion counts. Include repeated cycles to identify drift, wear or product build-up that may not appear in a short demonstration.

Acceptance criteria should be defined jointly by engineering, production and quality teams. A prototype that performs well on one ideal sample may require further adjustment before it is suitable for a varied production environment.

Frequently asked questions

Why integrate weighing and cutting?

Actual mass can inform the portion plan and help the processor evaluate portion consistency, although shape and density variation still need consideration.

Can the system cut even and odd numbers of portions?

The rotary control concept can be designed for both. The sequence and centering accuracy must be validated for each pattern.

Is the adaptive gripper already a finished commercial product?

The described prototype is undergoing testing and adjustment. Its final specification and readiness should be confirmed through the project validation process.

Discuss automated cheese portioning

Cheersonic can review cheese samples, portion requirements, weighing accuracy, handling and line integration to define a suitable automation project. Explore our ultrasonic food cutting solutions.

Contact a Cheersonic representative and discuss our cutting solutions today.
Email: market2@cheersonic.com