Cheese puffs are created from cornmeal, cheese powder, seasonings, and vegetable oil. The production process involves large quantities of cornmeal, typically 2,000-pound bags, weighed and processed in silos. Moisture content, initially at 10%, needs to increase to 15-20% by adding water. Hydrated cornmeal is then extruded under high pressure to form individual puffs, which are baked to remove excess moisture and achieve the desired texture. This systematic approach ensures consistent flavor and texture across different brands.
The texture and density of each airy cheese puff all come down to one component: moisture. In order to make cheese puffs, cornmeal's natural 10% moisture level needs to be increased to between 15-20%.
Cornmeal gets hydrated, shaped, baked, and cheese-dusted. The hydrated, liquified cornmeal is forced through a heated extruder with intense pressure (300 pounds per square inch).
Those extruders are equipped with specialized nozzles that form the tubular shape of each individual, 1½-inch, par-cooked cheese puff.
To crisp 'em up, the moisture that was added earlier must be removed, which happens via baking in a large oven.
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