Cooling an Artisan Cheese Process at Scale

June 8, 2026

Maplebrook Farm × G&D Chillers

Maplebrook Farm is a Vermont-based artisan cheese producer known for its handcrafted mozzarella, made using old world techniques and 100% Vermont milk sourced from a local family farm. Every batch reflects a commitment to quality, texture, and consistency; values that sit at the heart of Maplebrook’s process.

This project highlights how industrial chillers can solve consistency and water efficiency challenges in artisan cheese production.

As Maplebrook scaled production to meet growing demand, maintaining that same level of consistency became increasingly dependent on precise temperature control. Cooling, once handled with a simple approach, evolved into a critical operational challenge.

The Cooling Challenge

Because Maplebrook’s mozzarella is hand stretched and produced in small batches, even small fluctuations in temperature could impact moisture content, texture, and overall product quality.

Their process required cooling approximately 900 pounds of fresh mozzarella from 130°F down to 40°F, six times per day, every 90 minutes. The cheese was cooled in a large open water bath measuring 20 feet long, 4 feet wide, and 2 feet deep.

Initially, the operation relied on city water for cooling, a method that introduced several issues:

Incoming water temperatures reached 70°F during summer months
Seasonal temperature swings made results unpredictable
High flow rates led to excessive water consumption
Inconsistent cooling affected repeatability and quality

As volumes increased, it became clear that the existing approach could no longer support Maplebrook’s standards or long term growth.

An Engineering First Approach

Rather than starting with equipment selection, the G&D Chillers team focused on understanding Maplebrook’s process.

“We didn’t want to just size a chiller, we needed to understand how the mozzarella was behaving thermally throughout the process,” said Paul Johnson, Director of Technology and R&D for G&D Chillers.

Through numerous conversations and collaborative problem solving sessions, G&D worked closely with Maplebrook to evaluate:

Batch size, frequency, and production timing
The thermal load of fresh mozzarella
Bath volume and turnover rate
Opportunities to reduce water usage while improving cooling efficiency

The core insight was straightforward yet impactful:

Cool the water first.

By using a chilled water system for food processing to bring incoming water below 40°F before it entered the cheese cooling bath, Maplebrook could achieve faster, more consistent cooling without changing their production workflow.

The G&D Chillers Solution

G&D Chillers engineered a chilled water system for food processing centered around a 15-ton industrial chiller and CWS (Chilled Water System), purpose-built for Maplebrook’s mozzarella cooling process.

The system now:

Delivers 38°F water consistently
Reduces required flow rates by approximately 50%
Supports reliable, repeatable cheese cooling
Minimizes water waste
Improves overall system reliability during peak production periods

Beyond supplying equipment, G&D provided hands-on engineering support, including system integration guidance and piping design—eliminating the need for an external process engineer.

Results That Matter

With the new cooling system in place, Maplebrook achieved tangible improvements:

More consistent cheese temperature and quality
Significant reductions in water usage
Increased confidence during summer production peaks
A cooling solution designed to scale with future growth

“Cold water is integral to our cheese-making process. The implementation of our G&D chiller has drastically improved both efficiency and consistency. Everyone we’ve worked with — from design and installation to post-installation support — has been fantastic.”

— Michelle Weber, Maplebrook Farm

Most importantly, the improved cooling consistency allowed Maplebrook to protect the integrity of its handcrafted process while supporting higher throughput and operational efficiency.

A Partnership, Not Just a Purchase

“This was really about working alongside Maplebrook to solve a process challenge, not just supplying equipment,” said Andy Backer, North America VP of Sales for G&D Chiller's.

For artisan food producers navigating complex process challenges, this consultative, engineering driven approach makes the difference.

Frequently Asked Questions

What temperature should mozzarella be cooled to after stretching?

Mozzarella is typically cooled to around 40°F to maintain proper texture, moisture balance, and food safety standards.

How do cheese producers improve cooling consistency?

By using a controlled chilled water system rather than relying on variable city water temperatures, processors can achieve more stable and repeatable results.