All language subtitles for Inside.The.Factory.S01E02.Chocolate.1080p.PMTP.WEB-DL.AAC2.0.H264-BTN_track3_[eng]

We are, without doubt, a
nation of chocolate lovers.

We eat, each of us, on average,

this much chocolate every year.

That's a whopping 266
bars each.

And the British love affair
with chocolate begins here,

Liverpool Port.

Around 70,000 tons
of cocoa beans arrive

into the UK every year.

They're trucked to
factories all over Britain

and then used to feed
our insatiable sweet tooth.

But how do you produce
chocolate on this scale?

Whoa!

We've come to one of the
World's largest chocolate makers

to find out.

I'm Gregg Wallace.

I love chocolate.

And I've been given
exclusive access

to this giant factory
in York...

Oh my word!

...to reveal how they make over
7-million bars in one day.

How much of a chocolate
geek have you become?

Well, if I went on Mastermind,

I reckon I could get
through that quite easy.

I'm Cherry Healey,

and I'm gonna get hands-on
on a production line

in Derbyshire.

What is this?

Willie Wonka contraption.

[Gregg] And historian
Ruth Goodman will delve

into the factory archives,

looking at chocolate's
magic decade.

Isn't it lovely?

[Gregg] From bean to bar,

we're going to follow
the amazing journey

of one of our best
selling chocolates.

You'll never look at a chocolate
bar the same way again.

This is the incredible
story of the factories

that feed Britain.

This is the Nestle
factory in York.

It's one of the largest
chocolate manufacturers

in the world.

800 production staff
work around the clock

to produce millions
of bars a day,

which goes to every corner
of the UK and Ireland.

On this site, we'll see
how raw cocoa beans arrive

by truck and leave
just 24 hours later

as chocolate bars ready
for the supermarket.

And tonight, I'll be following
the journey of the Kit Kat.

This is one of the most popular
chocolate bars in the world.

We eat 1 billion of these
every year in the UK alone.

That's a staggering 1,900
every single minute.

But whether you like
your chocolate dark,

milk, or white, it all
starts with the cocoa bean.

Every day, 120
tons of them arrive

at the bean-processing plant
to start the production.

I'm going to roll up my sleeves

and help cocoa bean
expert Steve Calpin

unload his latest delivery.

Do you know how many
beans are on this truck?

I've never actually
counted them,

but I think there'll
be about 28 ton.

Just short of 30 ton?

Just short of 30 ton.

[Gregg excitingly screams]

That's an avalanche of beans.

In just 24 hours,

these beans will undergo an
incredible transformation

and leave York as
finished chocolate bars.

But their journey began
thousands of miles away.

[energetic music]

90% of British
chocolate begins life

as cocoa beans in West Africa.

The main harvest of pods from
cocoa trees happens in March.

Once the beans have
been collected,

they're dried
in the African sun

and then packed and
shipped to the UK.

[Gregg laughs]

It looks like a handful
of grubby pebbles.

[Steve] Yeah.

So this has literally
been transported straight

from the Ivory Coast?

Straight from the Ivory Coast.

And these are dried by the road,

so they've got
bits of grit in it.

They've got bits of grit.

Dirt.

Yup.

We've had shoes, snakes.

-Really?
-Yup.

Now the beans begin on
a non-stop, 3-hour ride.

The aim is to crack
their hard outer shell

and release the
cocoa rich center.

Come on.

But first, they
need to be cleaned.

Specially-sized holes on a
metal plate allow the beans

to fall through but capture

larger pieces of rubbish
on top.

It separates all the
string and bits of rubbish.

I get it.

The beans you want drop
through,

but anything bigger stays.

-And that's the way.
-Brilliant.

But it's not just grit and
rubbish

that have hitched a ride

over from Africa with
the beans.

Sometimes there's treasure.

I tend to get coins.

Get yourself a drink.

Thanks, mate.

Where do I have to go?

-To the Ivory Coast to buy one?
-The Ivory Coast, yeah.

[Gregg] Next up
is the de-shelling.

What happens here,

we have a series of rollers
in this machine here,

and as the beans go through it,

it crushes them and takes
the shell off the nib.

[Gregg] The nib in the center
of the bean is the holy grail

of chocolate making.

It contains all the
cocoa solids and fats

that are the basis
of chocolate.

There you are, Gregg.

-That's the nib?
-That's the nib.

[Gregg] The last remaining
shell pieces are vacuumed

off the nibs, and the
clean ones are fed

into 3 giant
ovens... and roasted.

The temperature of the
ovens is so critical

to the recipe, it's kept
a closely, guarded secret.

After an hour, the
roasted nibs are fed

into a giant food processor,

which transforms them
into a thick, brown liquid

called liquor.

The thing that's made it
liquid like that is the fat

that's come out of the nib.

The same way that oil
comes out of an olive,

your fat's coming out
of the chocolate nib?

That's correct.

Have you added anything
at all to this nib?

Just a bit of love and
care and attention.

We all need a bit of that, mate.

I know.

[guitar music]

[Gregg] 8 tons of cocoa
liquor is now piped

from the bean-processing plant
to the factory next door.

Here, they will turn
the bitter thick liquid

into hundreds of tons
of sweet milk chocolate.

First, it needs to be mixed
with the other ingredients.

Sean Konriko is the factory's
chocolate specialist

and has been the keeper of
recipes for over 38 years.

[Sean] All those stainless
steel vessels

contain our liquid ingredients.

So there's cocoa liquor,
cocoa butter, vegetable fat,

and then we take all
our dry ingredients.

So sugar, our new components
are all fed across

into this mixer.

[jumpy music]

[Gregg] The result is a course
chocolatey powder churned

out at a rate of 9 tons
an hour.

Conveyor belts drop
the mixed ingredients

into the top of a giant,
heated blender called a conche.

After cooking in the
conches for over 7 hours,

the liquid chocolate is
pumped out into giant vats.

And I cannot wait to taste it.

[Sean] Put your sample jar under
there and just unwind that.

Whoa, whoa, whoa, whoa, whoa.

[Gregg laughs]

-And here we are.
-[Sean] Here we are.

We've got 28 tons
of liquid chocolate

and a very happy, bald
television presenter.

Fantastic.

Do you sell it by the pint?

Unfortunately, we don't
sell it by the pint;

we sell it by the bar full.

[piano music]

[Gregg] They make 16 different
chocolate recipes here

at the factory, a different
one for each product.

But what I don't understand
is why do they bother?

Why not just get
one great recipe

and use it for all of them?

Vicky Geal is the Senior
Confectioner in charge

of developing new
flavors and product,

and she's gonna show me

why the chocolate
recipe is so important.

Kit Kat chocolate is designed
specifically for Kit Kat.

What I've done here is made some

with some different
chocolates to prove

that other chocolates
do not work.

What different chocolates?

The first one I've used a
standard Kit Kat chocolate.

The second one is
a Yorkie chocolate,

and the third one is a
competitor chocolate,

which I shall not name.

See which you think is the best.

[guitar music]

Well, I can't really taste
the chocolate on this one.

Let me try the middle one.

The chocolate's, um,
creamier, rounded, deeper.

Let me try the last one.

That's the Kit Kat.

That's the original Kit Kat.

That is the original Kit Kat.

The insides are exactly the
same on every product.

It's just the chocolate
that's changed.

You've made your point, Vicky.

-[Vicky] There you go.
-In a delightful way.

Let's have a hug.

So it turns out, even
without realizing it,

we consumers expect a
certain chocolate flavor

to be on a particular bar.

[machine beeping]

This 28 tons of melted
chocolate is all going

to end up making just one
kind of chocolate bar.

But Cherry's getting her
hands dirty in Derbyshire

to learn how you make
a chocolate box full

of many different varieties.

[joyful music]

[Cherry] I'm at Thornton's,

the largest chocolate
manufacturer in the country.

They've been making chocolates
for over a hundred years

and produced a colossal
25-million boxes every year.

Most of the chocolate
made at Thorntons ends up

in boxes like these,

and while your first
thought might be

to scramble for
your favorite one,

you might be surprised to
know how much work goes

into making each and every one.

Over a thousand people work
in this Derbyshire factory,

and today I'm getting
stuck in, too.

You need to put four blocks in.

Operations Manager, Nathan
Worth, is teaching me

to make a Vanilla Truffle.

I don't think even I could
eat all this in a day.

I could easily.

The truffle begins with the
center made from chocolate,

sugar, and butter.

[Nathan] And now we'll
mix it for a few minutes.

[Cherry] Oh, wow.

A hundred kilos of filling
needs to be handfed

into the start of
the production line.

-Oh, look at that massive blob.
-That's it.

I think we're gonna lose
you in there in a minute.

[Cherry] Bye.

It's like Willie Wonka's
chocolate factory.

[Nathan] It's Willie Wonka
without the Oompa-Loompas

and the chocolate
vases, I'm afraid.

[Cherry] Then the mix is pulled
through a cutter,

slicing into more centers
than I've ever seen.

How many of these
are in one row?

So there's 16 rows on here.

-16 rows.
-And on this line,

on this product, we
run 62 rows a minute.

So an hour on here, we're making
55,000 chocolates an hour.

In a week, we could be
making up to 25 million.

That is a staggering
number of chocolates.

Yeah, and I think I
eat a large percentage

of those while I'm working.

I'm right there with you.

[Nathan giggles]

[Cherry] This center gets
individually drizzled

with a drink of chocolate.

[Nathan] This is an enrober.

Enrobing is where
we put a curtain

of chocolate over the centers.

So what we're doing is we're
drizzling the chocolate over,

so instead of molding it
as a lot of people do,

we're actually coating
it with chocolate.

[Cherry] Wow.

And the secret to
perfect chocolate

is a process called tempering.

So we take the
chocolate at 45 degrees,

cool that down to 25 degrees,

heat it back up to 30 degrees

to get the correct
crystal structure.

What would happen if
you didn't heat up

and cool the chocolate down?

What you'd find is
it'd start going white,

go a little bit greasy.

It wouldn't snap if it
was a bar of chocolate,

and it wouldn't eat nice.

So sometimes you'll see
chocolate that's gone

a little bit gray.

That doesn't mean
it's going moldy.

It just means the crystal
structure has broken down,

and it's not how
we want it to be.

[Cherry] Those gray bits are
still perfectly safe to eat,

but to keep their
chocolate looking its best,

all factories like this rely

on their giant
tempering machines.

[Nathan] In this kind of
machine here that's behind you,

it's the workhorse
of the factory,

but actually, nobody
ever really sees it.

Oh, no, it's the unsung
hero of your factory.

I appreciate you,
Turbo-- um, Temper.

[Nathan laughs]

I appreciate you.

Once the first milk chocolate
layer cools and sets,

it's ready for a smothering
of white chocolate.

The vibrating
conveyor belt shakes

off the excess
chocolate to make sure

each one weigh's
exactly the same.

Wow.

It's a river of chocolate.

But what comes next
is the real magic.

Every one of the truffles
is skillfully hand decorated

with not a machine in sight.

Oh, wow.

It really is done by hand.

[Nathan] No machinery
at this point.

And away you go.

Oh, that's really fun.

Oh, no, I messed it up.

[Worker] No, no, they're fine.

[Cherry] Uh, uh!

Got it.

Goes really quick.

-I missed one.
-No problem.

You're gonna have
to pick up my slack.

That's no problem at all.

Do you think that people
don't really appreciate

how much work goes into
a piece of chocolate?

I think when people bite them

'cause they don't realize
how much we do do here.

I think they probably think
there's a machine does this.

You know what I mean?

Yes.

Look at you go.

[worker laughs]

-I mean, you're a demon.
-Years of practice.

Years of practice.

How long have you
been doing this?

Well, I've worked
here for 21 years.

21 years.

So you're a pro?

I'd hope so by now.

Is it hard to be doing
this and not take one?

It's extremely hard, and
I'm a total chocoholic.

I love it.

[Cherry] One down, but they are
still 11 varieties short

of a chocolate box, so
the team keep on going.

I'm blown away by the effort

to hand decorate
the chocolates,

but I do worry for whoever
has to pack them into boxes.

It turns out this is one area
where even humans need a hand.

A team of lightening-fast
robots pack the chocolates

into trays.

The robots have laser-guided
eyes that can tell the shape

of each chocolate and where
it is on the conveyor belt.

They then rotate
the chocolates

to match them up exactly
with the shape in the trays.

This area last year did over
30-million finished boxes.

[Cherry] And they can do
it with absolute precision

over and over again.

Despite all the machinery
and high-tech robots,

it still takes over a
100 people to make a box

of chocolates like this one.

So think about that next
time you're squabbling

over who gets the last one.

[eerie music]

[Gregg] Back in York,

I've moved from the
chocolate factory

to wafers.

Wafer Line Manager, Mark
Barratt, has worked here

for over 20 years.

He used to make the
chocolate, but for him now,

the filling is more than just
the middle; it's everything.

What's better?
Chocolate or wafer?

-Wafer.
-Why?

That's the beginning of it.
That's the middle.

If you don't get that great
snap, you haven't got the bar.

Do you think you might
be turning into a bit

of a chocolate bar anorak, Mark?

I think I'm there; I've
been there a while.

What is the first step
to making a wafer?

So we start off making
a batter mix with flour

and water and a few
pretty special ingredients

that we like to keep to ourself.

[Gregg] Flour from giant
silos outside is fed

into the mixers.

These mixers work
around the clock,

producing 40 kilos of
batter every minute.

But mixing all
that is one thing.

How on earth are you
gonna bake it all?

You start by piping it

into a hundred hinged waffle
irons called carriers.

The top of the
carrier shoots down.

As it shoots down,
the batter spreads,

and it builds a rectangle.

-Gotcha
-Yeah.

[Gregg] Conveyor belts take
the squashed batter squares

directly into
100-foot long ovens.

After just two minutes
at 150 degrees,

the carriers leave
the ovens, open up,

and spit out rich,
golden wafers.

Oh!

There we are, popping out.

Mate, they're like carpet tiles,

or they're like lino tiles.

[Mark] Yeah.

Shall we have a look at one?

There you go.

It's like an enormous poppadom.

It doesn't seem that crispy.

No.

Sorry.

I'll clean it up.

To crisp up the wafers,

they're fed into a
cooling rack,

snaking 30 feet into
the air to save space,

over an arch on
the second floor,

then back down stairs.

After cooling, they come
down that ski slope,

come along here,

and then the filling is
spread on top of the sheet.

[Gregg] The sweet
filling is made

of coco liquor and sugar.

It's like a perfectly, precisely
buttered piece of toast.

That's right.

The same level all the
time, the same thickness.

[Gregg] Then, the machine
stacks on coated wafer

on top of another coated wafer.

Okay 1, 2 and then,
we've got some coming

over the top, which
haven't got filling on.

[Gregg] And the result,

every 5 seconds perfectly
lined up spare of two layers

of filling sandwiched
between 3 layers of wafer.

A team of robots then
stacks the wafers,

cuts them into blocks,

and then sends the block
to be covered in chocolate.

[birds chirping]

Historian Ruth
Goodman's been looking

at chocolate's magic decade.

[Ruth] One of the earliest
memories we probably all share

is visiting the sweet shop.

It's usually the first
time as children we get

to spend our own money.

[cash register dings]

But the chocolate bars
we buy today are likely

to be exactly the same as those

that our parents bought
or our grandparents,

even our great grandparents
when they were young.

They all originate in the
same amazing 10-year period.

Roald Dahl once likened it
as the chocolate equivalent

of the Italian
Renaissance for painting,

and that decade was the 1930s.

[classical music]

The 1930s witnessed
a huge social shift

in British society.

Improved working conditions
meant people had more time off.

And this new concept of
leisure time brought a shift

in buying habits.

Until now, chocolate had
been an expensive treat

for the wealthy and mostly only
bought on special occasions.

Suddenly, cheaper
manufacturing costs meant

it could be made for
a lot less.

90% of the country
could now afford

to buy chocolate regularly.

A new mass market
had been created

at the beginning of the decade,

and now it was up to the
chocolatiers to feed it.

Amongst the first of the
block was an American.

In 1932, the Mars Bar
caused quite a stir.

[jazz music]

A so-called combination bar,

it added a core to the
standard chunk of chocolate

that Britain was used to,

an American invention that
were considered low rent

and faddish by chocolate makers

on this side of the Atlantic.

And so began what had been
called the "Chocolate Wars."

Terry's gave us the
Chocolate Orange in 1932.

Rowntree's responded
with both the Aero

and the Kit Kat in 1935.

Cadbury's contribution
was the Whole Nut,

and Roses in 1938,

and Mars fought back with
the Milky Way and Maltesers.

Suddenly, the high street was
choc-a-block with chocolate.

Ooh!

Isn't it lovely?

[Ruth] Down through
the generations,

we are still remarkably
faithful

to these original
brands first invented

in the chocolate decade.

[Gregg] Here in York, we've got
bean to liquor to chocolate.

And now, the filled
wafers are arriving

in the final production
hall by the thousands.

In this final stage,
all the elements

of the chocolate bar
are put together.

Bill Ashley, Factory
Quality Manager, is going

to show me how.

You've seen how we make wafer,

and you've seen how
we make chocolate.

Well, this is the plant
where we put both wafer

and chocolate together.

So the chocolate gets
deposited into a mold.

You can see on the mold
here we have an impression

on the bottom of the mold,

so when the chocolate
gets deposited on there,

and the bar finally
gets de-molded,

you can see Kit Kat on the top.

Chocolate gets squirted in here?

-Yes.
-It's traveling along.

[Gregg] Then what happens?

[Bill] Then, we put the
wafer into the mold itself.

[Gregg] The filled
wafers are cut to size

and dropped into the molds
on top of the chocolate.

You can now see the chocolate
underneath the wafer.

I don't know how the chocolate
gets on top of the wafer.

[violin music]

This snack is gradually
coming together.

What's the next stage?

Okay, so now we put chocolate
on the back of the bar.

Chocolate comes down the
pipe, gets deposited here,

and then just gets
spread across the mold.

[Gregg] That's a beautiful
thing.

That's like a chocolate
tide crashing onto a beach.

That's right.

[Gregg] How come the chocolate
doesn't stick to the mold?

[Bill] Okay, well, that's the
next important process.

You just wanna take
hold of that mold.

Try and twist that.

-No.
-No, it's solid;

it's hard plastic.

If you look down here,

can you see how those
molds are being twisted

on either side?

[Gregg] That's very much how
we would get ice cubes

out of an ice cube mold.

Does it have to be
horrible pink color?

[Bill] It's pink so we
can differentiate

with the chocolate.

So they're cool by
now, aren't they?

They are, yes.

They're cool, and they're
solid at this stage.

Give me a mold--
I'll get them out.

While I'm helping to de-mold,

back at Thorntons in
Derbyshire,

Cherry is having a sugar rush.

[violin music]

[Cherry] Easter is second only
to Christmas

for chocolate sales,

and here at Thorntons,

they make over 9
million eggs each year.

They've been making Easter
eggs here since 1922,

but what I've
wanted to know ever

since I was a kid is how on
earth do they make them hollow?

What comes first?

The chicken or the egg?

Well, when it comes
to Easter eggs,

-it's actually the mold.
-Oh.

So what we do is we have a mold

that we're gonna
actually form the egg in.

[Cherry] Melted chocolate
is squirted inside one half

of the egg-shaped mold.

Then, decorations are added.

[Nathan] We'll then put a second
mold on top of the first.

We'll put that into
a magnetic frame,

and we'll put it onto
one of these machines

over here called The Spinner.

[Cherry] Wow.

So it's a chocolate
wall installation.

The molds are rotated
in every direction

to thoroughly coat the
inside with chocolate.

[Nathan] Because chocolate
keeps setting,

it'll steadily build
up a layer of chocolate

on the inside of that mold
so it's really nice and even.

It'll give you that
perfect, hollow shell.

[Cherry] As the chocolate
dries,

it sticks to the mold,
leaving a void in the middle.

So the machine mixes
it around and around...

-and around?
-[Nathan] Yeah.

And then, just let the
chocolate move to the edges.

It's easier to put
it on a machine

than stand there for
15 minutes doing that.

[Cherry] Before the eggs
leave the factory...

Ah! Magic.

Nathan gives me one of
the 9 million to try.

That's pretty good.

That is hot off the press.

You can't get a fresher
Easter egg than that.

And it's definitely hollow.

Yeah, we've only got another
8 million 999,999 to go then.

[rock music]

[Gregg] Back here on the
production line in York,

the team are pumping out 3,000
2-fingered chocolate bars

every minute.

Before they're loaded on
trucks to come your way,

they need to be
wrapped and packed.

What are you doing?

You seem to be throwing
chocolates away.

We're picking off ones which
are not of a good standard.

Do you know they all look
exactly the same to me.

No, well, they don't to us.

What's wrong with that one?

Well, we can see the wafer,
so that's wafer reveal.

Apart from wafer reveal.

We have footballs
on the chocolate.

Also, the chocolate is not
as shiny as it normally is.

Mate, you're being
a little too fussy.

Look, I'm a customer.

-All right?
-[Julie giggles]

It doesn't bother me.

How much of a chocolate
geek have you become?

Well, if I went on Mastermind,

I reckon I could get
through that quite easy.

Specialist subject: the Kit Kat.

Yes.

What happens to all of the
ones you're throwing away?

They all go into rework
where they're used

for the fillings for
the wafers.

What's the filling
for the wafer?

Well, as you can see
here, we have a wafer--

Oh, in between the wafers?

Yes, that's right.

I saw that put on.

Right, okay.

Yeah, yeah, yeah, okay.

-Brilliant.
-Do you understand that?

-Brilliant.
-Right, good.

[Gregg] It is incredible
how many chocolate bars

are being produced here
with so few people.

As high tech as all this seems,

they've actually been
making chocolate here

for over 100 years,
but back then,

the factory floor would have
looked very, very different.

[jumpy music]

[Ruth] In the shadow of
the modern factory,

there's a monument to
chocolate-making past.

This is the old Rowntree's
factory in York.

It was acquired by Nestle
in the late 1980s,

and there was so much rich
history that they appointed

a dedicated Rowntree
Historian, Alex Hutchinson,

to preserve its
significant past.

I've been given
access to the old site

and its archives to discover
just why it's so special.

In comparison to other
factories at the time,

was this a good one, a bad one?

This was a good one;
this was a very good one.

Everybody wanted to
work for Rowntree's.

Very good pensions.

If you were ill,
there was a doctor.

If you need a dentist,
you'd see a dentist,

and they would look after you.

They would look after you
very, very well indeed.

[Ruth] The Rowntree's
were Quakers,

a religious society formed in
England in the 17th century.

The highly moral Quaker
grocers were trusted

to produce
unadulterated chocolate.

[train horn honks]

And so, a handful of
these Quaker families

became the top chocolate
makers in Britain.

Birmingham had Cadburys.

Bristol had Fry's, and
York had Rowntree's.

The Rowntree family are Quaker.

Do you think that
made a difference

to how they did business?

Very much so. They wanted to
treat their workers

like they were part
of their family.

They didn't want to view
them as cogs in a machine.

[Ruth] To improve
their workers' lives,

the Rowntree family
designed a factory

that was bright and airy
and chocked full of perks.

You've got your theater,
library, ballroom,

sports grounds and, of course,

there's a sick
pay, paid holiday.

[Ruth] And the wage packet
was quite healthy, too.

The welfare pioneered
in chocolate factories

was soon adopted across
Britain.

While the founding members

of the Rowntree family
may have passed on,

the community they created
lasted for generations.

[electronic music]

But by the late 1980s,

consumer demand for cheaper
chocolate saw the beginning

of the end for the old ways.

The more labor intensive
parts of the production lines

were replaced with
mechanized systems

and machines capable of
churning out chocolates

by the millions.

The way we make chocolate
may well have changed,

but the legacy of those early
chocolate makers lives on.

[machine beeping]

[Gregg] Here at Nestle,

we're 21 hours into the
chocolate-making process.

And we've already got millions
of chocolate bars ready

to be eaten.

But before that can happen,
they need packing up.

In this factory 3
and a half million

of these chocolate bars need

to be individually
wrapped every day.

[electronic music]

First, it's the foil wrap,

and then the paper.

27 feet are used every second.

Then they're bundled
into multi-packs.

Ex-army man Scott Robinson

gives the bars one
last inspection

before they're packed into
boxes with military precision.

Why with all this machinery
are we packing them by hand?

Because we can actually...

You get a better quality finish.

People can see anything
that's gone wrong.

The machines can go.

You can have sensors,

but they won't feel or see
things that are not right.

-Can I have a go?
-[Scott] Yup, feel free.

Come on, down you come.
Here we go now. Lovely.

Like that?

-Fold it that way now.
-Ugh, quick, quick.

Push it through there.

That's it; nice and gently.
Make sure it's square.

I ain't got time to be gently.

It's not as easy as it looks.

Oh my god.

For crying out loud, we've got
an avalanche happening here.

-How many do you lift at a time?
-5.

What have you got?
Hands like a bear?

[Scott laughs]
I'm just lucky.

[Gregg] Oh, that's it; just dump
another load at the front.

Make it harder.

[Scott laughs]

[Gregg] This is actually
physically quite challenging.

[Scott] It is.

-Do you dream about it?
-Not anymore.

Stop 'em; they're
gonna roll off the end.

The box really slows you down.

So they've sold the
whole principal on this

on having a break, yet
me and you don't get one.

There's a bit of an irony there.

Don't you think so, Scott?

Yeah, you need it.

Panic's setting in here.

[Gregg Laughs]

You're gonna have to
come and help me, mate.

I can't get 'em
done quick enough.

-Look.
-Give it a go then.

I've tried me best, Scott.

Yeah, you've done well.

[Cherry] Chocolate has been
our favorite sweet treat

for over 200 years.

But it's not imported
chocolate we buy the most of.

The top 3 selling brands in
the UK: Dairy Milk, Kit Kat

and Snickers are
all made right here.

So what is it about
British chocolate

that we all find
so irresistible?

To find out, I've come to
meet Master Chocolatier,

Paul A Young.

He's won many awards
for making chocolates

with a uniquely British flavor.

I feel like I'm meeting
chocolate royalty.

You are definitely the most
qualified person to answer this.

Why do we love British
chocolate so much?

It makes us really happy.

-It does.
-It does.

It makes me so happy.

It's not just the
sugar; it's the feeling,

the texture, the
nostalgic reminiscence

of childhood of when
you first had it.

Hand anyone chocolate,
and they'll smile.

[Cherry] These days, we have
the choice of chocolate

from any country we like, but
yet we still choose British.

What is it about
foreign chocolate

that just doesn't
sit right with us?

[Paul] We are tuned to love
British chocolate

from being very young,
but there are chocolates

from all around the world:
America, Belgium, Switzerland,

Holland, France, you name it,

and it's all
specifically different

and tailored to the
pallet of the country.

[Cherry] So it seems we all
hanker after the chocolate

we ate as children.

But can we really
taste the difference

between British
and foreign brands?

Paul and I are going to put
the great British public

to the test.

We're going to take 4
different chocolates

from 4 different countries and
see which one people prefer.

But first, we need to
melt down the chocolates

and reset them in
a similar shape.

So they all look the same,

and no one will be able to
tell which one is which.

-They won't.
-Wha-ha-ha

It's a secret.

[Cherry] Milk chocolate is made
up of cocoa, sugar, and milk,

but the proportions
can vary according

to its country of origin.

[Paul] We've got 4 varieties
of milk chocolate.

So we've got Belgian,
American, British, and Swiss.

The Swiss is very, very
milky, incredibly smooth,

light color.

I think most people would say,

"That's a nice milky chocolate."

At the opposite end of the
spectrum is the American.

-Ugh!
-I mean it is.

This is probably the biggest
selling American chocolate.

So what is it that gives it

that "to be polite"
distinctive flavor and taste?

It's the milk crumb,

and they manipulate it
to create butyric acid.

That gives it the cheesy,
sour, really off smell

and taste to us, and did
you know that butyric acid

is a component of vomit?

Ah, that's not okay.

It's not okay for me.

Do you think most
people would be able

to tell the difference between
these 4 types of chocolate?

I think I will,

and I think the British
chocolate will be

the most popular.

[Cherry] But will Paul
be right?

With all the chocolates
cleverly disguised,

we're taking to
the streets to see

if people really do
prefer British chocolate.

Hi, is there any way
that we could tempt you

to try some chocolate?

-Yeah?
-We're doing a taste test.

-Yeah, should we?
-Yes!

Do you wanna try some
before your main course?

[Cherry] First they try
the American version.

Um, no?

You don't like that?

-But there's an aftertaste.
-There is.

[Cherry] What is the
aftertaste?

Like off milk.

[Cherry] And it seems that
American chocolate isn't a hit

with British taste
buds anywhere we go.

I'm not particularly
impressed with that.

It's got this really
bitter taste to it.

It's actually a bit sicky.

It's too [indistinct]

It's not nice.

[Cherry] In fact, out of the 4:

American, British,
Belgian and Swiss,

it was the British chocolate
that came out the winner.

It's just a different texture.
It's creamier.

That's a bit more like

a bit more dairy milk
chocolate kind of taste.

It's nice.

[Cherry] From garages...
to hairdressers.

Creamier than the
first and second one.

Really smooth, really rich.

That's very creamy, I think.

[Man] Okay.

We have a winner on our hands.

-It is the British chocolate.
-Well done.

So obviously people still
love British chocolate,

but no one's picked American.

[Cherry] No one's
picked American.

We did find some people

who like American
chocolate: Americans.

[trumpet music]

Oh.

I'm gonna have to change
all of my answers.

That's definitely American.

That's my favorite.

It's just sort of
like bringing home

to you versus you
having to go home.

It doesn't taste fake to me,

and that's why I think
it's pretty great.

Whether we want a bar to treat
ourselves or as a comfort,

we know what we like,

and we like the familiar,

but it's those
childhood memories

that keep us Brits so loyal
to the chocolate that we love.

[piano music]

[Gregg] 22 hours after the
beans first came on site,

the wrapped chocolate bars
are now ready for customers.

A team of 30-foot high robots
now stack them onto pallets.

And conveyor belts take
them to a warehouse

to await distribution.

But, with 4 million chocolate
bars to deal with every day,

this is no ordinary warehouse.

Distribution Manager Sally
Wright has let me inside.

Oh my word!

Crying out loud.

I didn't realize this much
chocolate actually existed

in the world.

Good grief.

[Gregg laughs]

What do you call this place?

This is the Building.

-The Building?
-The Building.

[Gregg] Every single pallet
of chocolate is stored,

monitored, and moved by robots.

Once the stock's been
fed into the Building

by the conveyor belt,

the humans no longer have
any control

over what happens to it.

[Sally] We don't have human's
controlling it.

We don't have fork
truck drivers in here.

The Building knows where
all the empty spaces are,

where all the stock is.

When we have orders, it knows
where to go and get the stock.

When we have fresh
stock coming in,

it knows where to put it away.

It self controls.

The Building runs itself?

Pretty much so, yeah.

We watch over it with
a computer system,

but ultimately, it self manages.

[Gregg] From the moment
the chocolate comes

into the Building,

the 5 giant unnamed
cranes stack the pallets,

store them, and then send
them to the loading area

when the orders come in.

Do humans get in those?

The engineers do, yeah.

Could I have a ride
on one of them?

Yes, we can arrange that.

Whoa!

[Gregg laughs]

Whoa!

Whoa!

Whoa!

Will it stop before
the wall at the end?

It may do.

[Gregg laughs]

[rock music]

This is nuts.

All that to give
us a chocolate bar?

Yup.

It's a strange world.

It takes the building
just one week

to get through its entire
stock of chocolate.

Every day up to 60 trucks are
loaded from the dispatch hall

at this site

and leave York with
chocolate destined

for shops and supermarkets
all over the UK and Ireland.

The next time you open
a bar of chocolate,

just think it is
one very small part

of an enormous, global
chocolate empire.

Wow.