Experimental Emmental cheese was produced at pilot plant scale with varied process conditions, and the ripened cheeses were analysed in terms of thermo‐physical properties. The amount of propionic acid and the temperature at tan δmax ( loss factor) were significantly influenced by varied process parameters. Experimental cheeses were compared to commercial Emmental cheese by the application of principal component analysis. Commercial Emmental cheese was clearly discriminated from experimental Emmental cheese mainly due to the melting behaviour. The results allow the establishment of a small‐scale process for Emmental cheese production to promote product development on a time and cost‐saving level.