In the present study, brewers spent grain (BSG) was used to supplement processed cheese ''Block''. The BSG was added to the formula by replacing Karish cheese with 10,20,30,40 and 50%. Proximate chemical composition of BSG was determined. The resultant processed cheese ''Block'' samples were evaluated chemically, microbiologically, rheologically and sensory fresh and stored at 4±1⁰C for 1, 2 and 3 month. Significant differences in chemical, microbiological, rheological and sensory evaluation have been shown by increasing the BSG level in processed cheese ''Block''. The addition of 50% BSG had the highest value of total solids, pH values, meltability, rheological properties and sensory evaluation but it had the lowest in titratable acidity and oil separation.