1 00:00:01,070 --> 00:00:05,110 They say that breakfast is one of the most important meals of the day. 2 00:00:05,750 --> 00:00:06,750 Lovely stuff. 3 00:00:06,850 --> 00:00:07,850 Put it on myself. 4 00:00:07,950 --> 00:00:08,950 You haven't got a tab. 5 00:00:09,070 --> 00:00:10,070 That's what they all say. 6 00:00:11,990 --> 00:00:18,110 So when I'm working hard hosting the UK's premier factory -based TV show, I 7 00:00:18,110 --> 00:00:19,029 couldn't agree more. 8 00:00:19,030 --> 00:00:22,290 And this factory's massive, so I need to keep my strength up. 9 00:00:22,990 --> 00:00:25,270 Can someone throw us a couple of sausages on? 10 00:00:27,560 --> 00:00:34,220 In the UK, we crunch through, get this, a billion boxes of cereal every 11 00:00:34,220 --> 00:00:35,220 year. 12 00:00:35,620 --> 00:00:41,060 So luckily, I've come to one of Europe's biggest factories that's dedicated to 13 00:00:41,060 --> 00:00:42,060 making the stuff. 14 00:00:46,340 --> 00:00:48,280 Want to take a big bottle of milk? 15 00:00:49,860 --> 00:00:52,160 Everything here is supersized. 16 00:00:53,320 --> 00:00:56,160 Holy granola, that is big! 17 00:00:56,940 --> 00:00:58,380 With massive machines. 18 00:00:58,840 --> 00:01:00,000 Where is everybody? 19 00:01:00,440 --> 00:01:02,300 And an automated process. 20 00:01:03,400 --> 00:01:04,879 Well, there it gets out. 21 00:01:05,420 --> 00:01:07,280 Making multigrain cereal. 22 00:01:09,300 --> 00:01:14,960 And while I find out exactly what goes into your breakfast bowls, Cherry's 23 00:01:14,960 --> 00:01:18,500 the short straw because she's learning how to clean them. 24 00:01:19,400 --> 00:01:22,160 Oh, yeah, I'm getting down and dirty. 25 00:01:22,520 --> 00:01:24,000 No, no, no, no, no, no. 26 00:01:24,440 --> 00:01:29,920 discovering the do's and don'ts of dishwashers. You don't rinse. We don't 27 00:01:29,920 --> 00:01:30,920 plates. 28 00:01:31,280 --> 00:01:36,180 And historian Ruth Goodman is in search of the mum from Sheffield who 29 00:01:36,180 --> 00:01:37,980 revolutionised spoons. 30 00:01:40,180 --> 00:01:43,920 So he doesn't set out to make a better spoon. This is a man who wants to make a 31 00:01:43,920 --> 00:01:44,920 better gun. 32 00:01:48,560 --> 00:01:55,090 This... Factory produces 120 million boxes of cereal every year. 33 00:01:55,230 --> 00:02:00,670 And I'm going to show you how they make every single flake. This is Inside the 34 00:02:00,670 --> 00:02:01,670 Factory. 35 00:02:20,739 --> 00:02:21,960 Hygiene. Very important. 36 00:02:26,040 --> 00:02:27,040 Hygiene. Again. 37 00:02:28,840 --> 00:02:30,140 That's the wrong one. 38 00:02:30,940 --> 00:02:33,760 Where's the water? There it is. Whatever happens to just tap? 39 00:02:34,280 --> 00:02:35,440 Tap, you're turned on. 40 00:02:35,740 --> 00:02:36,740 Bit of salt. 41 00:02:37,120 --> 00:02:39,360 Lovely. Now it's all this. Look at that. 42 00:02:40,120 --> 00:02:42,280 That tap's now turned into an hand dryer. 43 00:02:42,900 --> 00:02:44,180 Well, it's time to be alive. 44 00:02:44,620 --> 00:02:47,720 And then we're going over this bit now. It's like Blackpool Funhouse. Here we 45 00:02:47,720 --> 00:02:48,720 go. 46 00:02:52,230 --> 00:02:55,070 And this is like council swimming baths when you're a kid. 47 00:02:55,370 --> 00:02:58,030 Get your feet in there with hot verrucas and saw nails. 48 00:02:58,810 --> 00:03:01,570 Bit more sanitiser. Give them a wipe. 49 00:03:02,010 --> 00:03:03,010 Through the thing. 50 00:03:03,450 --> 00:03:04,770 Absolutely spotless. 51 00:03:14,250 --> 00:03:17,370 This is the Kellogg's factory in Wrexham. 52 00:03:17,920 --> 00:03:21,520 And they've been making cereal here for almost half a century. 53 00:03:21,780 --> 00:03:23,560 That's a lot of balls of wrecking. 54 00:03:26,540 --> 00:03:33,120 This factory runs around the clock. 55 00:03:33,200 --> 00:03:35,240 A temple of high tech. 56 00:03:35,980 --> 00:03:41,200 Making many of the nation's favourite cereals like brown flakes and fruit and 57 00:03:41,200 --> 00:03:42,200 fibre. 58 00:03:44,810 --> 00:03:51,390 But today, I'm following Special K, and I'm learning how they create these 440 59 00:03:51,390 --> 00:03:53,910 -gram boxes. 60 00:03:54,150 --> 00:03:55,150 Come here. 61 00:03:59,490 --> 00:04:06,350 And to get my morning going, I'm 62 00:04:06,350 --> 00:04:10,230 trekking across this massive site to Ingredients Intake. 63 00:04:13,040 --> 00:04:15,280 Now, excuse all the belts and buckles. 64 00:04:17,180 --> 00:04:20,320 Here's Craig Williams, who's in charge to explain all. 65 00:04:23,260 --> 00:04:26,660 Morning, Craig. You all right, pal? Morning, Paddy. You OK? Yeah, yeah. 66 00:04:26,660 --> 00:04:31,060 am OK, but I've got to be honest. I've never started a show in this kind of get 67 00:04:31,060 --> 00:04:32,640 -up. It's a little bit Fifty Shades of Grey. 68 00:04:32,880 --> 00:04:33,880 What are we doing? 69 00:04:34,520 --> 00:04:38,440 Well, all will be revealed. So we put all our tankers in here, and this one 70 00:04:38,440 --> 00:04:39,440 contains rice. 71 00:04:40,120 --> 00:04:43,880 Which, for me, is a little bit strange because obviously there's certain 72 00:04:43,880 --> 00:04:48,320 that are just rice, but I didn't think this particular cereal would contain it. 73 00:04:48,820 --> 00:04:51,600 47 % of the flake is actually rice. 74 00:04:52,020 --> 00:04:53,020 Can I have a look? 75 00:04:53,120 --> 00:04:55,720 Yeah, that's why we're wearing these paddies. Let's go up and have a gander. 76 00:04:59,900 --> 00:05:02,420 Like Challenge Annika, this, innit? Are you on me bum? 77 00:05:05,740 --> 00:05:08,940 Right then, we'll connect one of these to the back of your harness so we don't 78 00:05:08,940 --> 00:05:11,320 lose you. Okay, yeah. When you're falling off the tanker. 79 00:05:12,560 --> 00:05:15,780 Turns out the harness isn't for fun, but for safety. 80 00:05:16,840 --> 00:05:19,120 It's like a seatbelt, isn't it? It gets you like that. 81 00:05:19,380 --> 00:05:20,380 Yeah, yeah, yeah. 82 00:05:20,420 --> 00:05:24,960 Because we're climbing on top of the tanker to take a sample of the rice 83 00:05:24,960 --> 00:05:25,960 delivery. 84 00:05:26,020 --> 00:05:27,980 Do you want to do it? Yeah, yeah, can do. 85 00:05:30,460 --> 00:05:31,820 Oh, that's a first for me. 86 00:05:32,140 --> 00:05:33,140 Give us one more. 87 00:05:34,480 --> 00:05:38,260 What kind of rice is that then? It's a type of rice, if you do much cooking at 88 00:05:38,260 --> 00:05:41,760 home, that you'd use in a risotto. We use that because it's high in starch. 89 00:05:42,020 --> 00:05:46,040 So once it's cooked, it gets like a sticky texture. Right. And it helps bond 90 00:05:46,040 --> 00:05:47,040 flake together. 91 00:05:47,260 --> 00:05:49,340 Right, so now we've took the sample. Yeah. 92 00:05:49,840 --> 00:05:50,980 We're going to give it to Paul. 93 00:05:51,300 --> 00:05:55,320 Okay, no problem. Okay. We'll do the relevant testing on it. Right. Make sure 94 00:05:55,320 --> 00:05:56,320 meets the right specification. 95 00:05:56,760 --> 00:05:57,760 Yeah. 96 00:05:58,860 --> 00:06:03,080 First off, Paul makes sure the rice is a mix of big and small grains. 97 00:06:03,520 --> 00:06:06,020 which will give texture to the finished flake. 98 00:06:09,540 --> 00:06:10,720 Oh, hang on. 99 00:06:11,300 --> 00:06:12,620 Looks like someone's pecking. 100 00:06:13,200 --> 00:06:14,240 It's OK, though. 101 00:06:14,540 --> 00:06:16,400 Apparently, it's part of the test. 102 00:06:16,940 --> 00:06:20,800 Paul's checking the rice hasn't picked up any nasty taste or smell. 103 00:06:21,940 --> 00:06:23,360 And the scores are in. 104 00:06:24,500 --> 00:06:25,500 How's it looking, Paul? 105 00:06:25,780 --> 00:06:26,840 Rice is all good, Paddy. 106 00:06:27,760 --> 00:06:29,240 Belting. So we can load it in now? 107 00:06:29,480 --> 00:06:30,740 Yeah, let's get it going. OK. 108 00:06:31,440 --> 00:06:32,440 Load it up! 109 00:06:43,120 --> 00:06:44,140 Start the clock. 110 00:06:44,400 --> 00:06:46,120 Breakfast is underway. 111 00:06:48,440 --> 00:06:55,260 To make 350 ,000 boxes of cereal every day, this massive 112 00:06:55,260 --> 00:07:00,520 factory has four 100 -tonne, 30 -metre -high silos. 113 00:07:02,080 --> 00:07:03,860 Just for the ride. 114 00:07:04,200 --> 00:07:07,580 And there's another three silos full of wheat. 115 00:07:09,900 --> 00:07:15,540 So, 47 % of our flake is made up by rice, and the others whole wheat. 116 00:07:15,780 --> 00:07:19,780 Around 37 % whole wheat. Well, I'm glad you said that, Craig, because through 117 00:07:19,780 --> 00:07:24,560 the magic of telly, I've sent Cherry down to the farm to find out exactly how 118 00:07:24,560 --> 00:07:25,560 it's harvested. 119 00:07:29,780 --> 00:07:35,820 The wheat for your cereal paddy needs dry weather to harvest, and the somewhat 120 00:07:35,820 --> 00:07:39,600 changeable British climate is making that... Tricky. 121 00:07:41,180 --> 00:07:45,200 It's been such a soggy summer. It's been raining what feels like non -stop. 122 00:07:45,640 --> 00:07:49,720 But I just had the call from Farmer Stephen to say he thinks it's dry enough 123 00:07:49,720 --> 00:07:50,720 harvest the wheat. 124 00:07:51,560 --> 00:07:52,560 Fingers crossed. 125 00:07:53,620 --> 00:08:00,020 I'm in Northamptonshire meeting Stephen Evans, who runs a 1 ,600 -acre farm. 126 00:08:00,360 --> 00:08:02,080 Lovely to see you. Really nice to meet you. 127 00:08:02,940 --> 00:08:08,520 and grows 2 ,000 tonnes of wheat a year, half of which go to the cereal factory. 128 00:08:09,460 --> 00:08:12,820 And today, there's just one field left to harvest. 129 00:08:14,020 --> 00:08:15,840 Has the rain been a total pain? 130 00:08:16,180 --> 00:08:18,460 It's been a horrible year. It's made life very difficult. 131 00:08:18,780 --> 00:08:21,120 Why can't you harvest when it's just rained? 132 00:08:21,360 --> 00:08:23,740 The grain, if it's too wet, will go mouldy in the shed. 133 00:08:24,060 --> 00:08:25,840 How much money do you lose if that happens? 134 00:08:26,240 --> 00:08:30,040 It'll be tens of thousands across the farm, so we've invested everything. 135 00:08:30,780 --> 00:08:32,240 And we really need this. Oh, my gosh. 136 00:08:34,760 --> 00:08:40,740 More rain is on the horizon, but the last few sunny days means this 25 -acre 137 00:08:40,740 --> 00:08:43,360 field should be dry enough to harvest. 138 00:08:44,540 --> 00:08:47,720 We just need to do a moisture test and see if it's good to go. The stakes are 139 00:08:47,720 --> 00:08:48,659 really high. 140 00:08:48,660 --> 00:08:51,580 There's a lot riding on this. So this is our electronic moisture tester. 141 00:08:51,920 --> 00:08:54,700 So we need the moisture of this grain to be 15 or less. 142 00:08:54,960 --> 00:08:57,740 15 % moisture or less, or we're in trouble today. 143 00:08:58,000 --> 00:08:59,000 That's right. 144 00:09:01,960 --> 00:09:03,240 14 .9. 145 00:09:03,560 --> 00:09:04,560 So is it go time? 146 00:09:04,820 --> 00:09:05,820 I think we'd better go. 147 00:09:05,980 --> 00:09:11,820 With the weather forecast threatening, it's a race against time. But the 15 148 00:09:11,820 --> 00:09:14,280 combine harvester is ready for action. 149 00:09:18,460 --> 00:09:20,120 It's absolutely amazing. 150 00:09:21,460 --> 00:09:23,000 It's just the most... 151 00:09:26,510 --> 00:09:27,890 of a machine I've ever seen. 152 00:09:28,170 --> 00:09:29,470 Yeah, 10 metres wide. 153 00:09:29,710 --> 00:09:31,370 It's amazing what they're a process. 154 00:09:32,630 --> 00:09:37,890 I've seen a few farm machines in my time, but this one is on another level. 155 00:09:38,530 --> 00:09:45,310 To make sure the valuable crop is gathered 156 00:09:45,310 --> 00:09:50,390 before the rain comes, Stephen calls in another harvester from a neighbouring 157 00:09:50,390 --> 00:09:51,390 farm. 158 00:09:51,610 --> 00:09:54,230 Today, it's all hands on deck. 159 00:09:54,810 --> 00:09:56,770 There we are. Take a seat. Look at this. 160 00:09:57,630 --> 00:09:59,630 So we'll put the front header in gear. 161 00:10:01,590 --> 00:10:02,770 Look at those teeth. 162 00:10:03,170 --> 00:10:05,170 So that's the knife that will cut the crop. 163 00:10:05,630 --> 00:10:08,070 That is one hell of a knife. 164 00:10:08,410 --> 00:10:09,510 All right, here it goes. 165 00:10:09,950 --> 00:10:10,950 Whoa, look at that. 166 00:10:11,610 --> 00:10:12,610 So we're off. 167 00:10:14,470 --> 00:10:18,730 So this rotating wheel is then pulling it all in the body of the machine, which 168 00:10:18,730 --> 00:10:20,630 is like a mini factory back there. Oh, it is. 169 00:10:22,380 --> 00:10:27,240 A combine harvester gets its name because it combines the three stages of 170 00:10:27,240 --> 00:10:28,240 harvesting. 171 00:10:28,760 --> 00:10:32,800 First, reaping, where the front header cuts the stalks of wheat. 172 00:10:33,980 --> 00:10:38,120 Next, threshing, to shake the ears from the stalks. 173 00:10:38,660 --> 00:10:45,160 And finally, winnowing, to separate the wheat from the chaff, the unwanted husk. 174 00:10:46,100 --> 00:10:51,120 The straw and the chaff fly out the back to fertilise the field for next year. 175 00:10:52,460 --> 00:10:56,980 The grain which will be used for cereals is filling up the tank behind us. How 176 00:10:56,980 --> 00:10:59,260 much are you collecting in one go? 177 00:11:00,040 --> 00:11:05,240 This machine currently is doing about 30 tonnes per hour, so that's a lot of 178 00:11:05,240 --> 00:11:06,240 bowls of cereals. 179 00:11:07,340 --> 00:11:12,180 In fact, it's enough to produce nearly two million bowls of our cereals. 180 00:11:12,660 --> 00:11:18,400 And we've got two of these monster machines working flat out to get the 181 00:11:18,400 --> 00:11:19,400 finished. 182 00:11:19,820 --> 00:11:22,860 I hope Paddy appreciates how much work has gone into this. So do I. 183 00:11:26,280 --> 00:11:27,640 It's about time we emptied. 184 00:11:28,940 --> 00:11:33,240 Once the grain tank is full... Oh, here he comes. Here he is. There we go. 185 00:11:34,500 --> 00:11:36,180 Let's hope Frank is good at catching. 186 00:11:36,620 --> 00:11:38,980 It needs to be emptied as quickly as possible. 187 00:11:39,460 --> 00:11:42,200 And we don't need to pause the harvest to unload. 188 00:11:43,080 --> 00:11:44,740 You've absolutely nailed it. 189 00:11:44,980 --> 00:11:46,640 Because the trailer comes to us. 190 00:11:47,040 --> 00:11:50,000 It's like someone's just turned the tap on for Max. 191 00:11:52,300 --> 00:11:53,720 Let him go into the store. 192 00:11:54,000 --> 00:11:55,000 Off he goes. 193 00:11:56,880 --> 00:12:02,000 With two combine harvesters, it takes just an hour and a half to gather 90 194 00:12:02,000 --> 00:12:04,260 tonnes of wheat from this final field. 195 00:12:08,660 --> 00:12:15,340 We've dodged the rain, and the freshly harvested crop is taken to a dry barn. 196 00:12:17,550 --> 00:12:19,690 Is this everything done? Have you finished the harvest? 197 00:12:19,950 --> 00:12:21,390 We're finished now. We're over the line. 198 00:12:21,730 --> 00:12:24,530 It's such a relief. The weather won't affect us anymore. 199 00:12:26,510 --> 00:12:32,330 The wheat will be sent to the cereal factory to be transformed into 72 200 00:12:32,330 --> 00:12:34,410 servings of breakfast flakes. 201 00:12:34,910 --> 00:12:38,830 Paddy, I've got 800 tonnes of wheat for you. I hope it's enough. 202 00:12:49,580 --> 00:12:51,780 I think that should keep us ticking over, Cherry. 203 00:12:52,900 --> 00:12:56,580 Mind you, I'm still getting to grips with the size of this place. 204 00:12:57,420 --> 00:13:00,960 It's a whopping 52 ,000 square metres. 205 00:13:01,480 --> 00:13:07,060 And using the traditional TV measuring system, that's bigger than seven 206 00:13:07,060 --> 00:13:09,360 pitches. Feeling fitter already. 207 00:13:10,940 --> 00:13:12,640 I'm definitely getting my steps in. 208 00:13:14,280 --> 00:13:18,120 We've had to put a wide -angle lens on the drone just to get this shot. 209 00:13:19,340 --> 00:13:25,060 From the huge silos at intake, I'm following our rice and wheat to the mini 210 00:13:25,060 --> 00:13:31,000 silos, where I've been told to look out for factory food designer Lizzie 211 00:13:31,000 --> 00:13:32,000 Waiting. 212 00:13:32,880 --> 00:13:34,720 You all right, Lizzie? Hi, Paddy, how are you doing? 213 00:13:34,940 --> 00:13:35,899 Keeping busy? 214 00:13:35,900 --> 00:13:39,180 Oh, just about. I just did a rhyming thing, it's all right. Now, listen, for 215 00:13:39,180 --> 00:13:42,960 good licence fee paying people at home, what are we doing here? 216 00:13:43,400 --> 00:13:47,840 So, this room is where all of the grains come through after they've just been 217 00:13:47,840 --> 00:13:51,540 offloaded. So, above us are all the silos, and there's about 80 tonnes of 218 00:13:51,540 --> 00:13:53,540 ingredients that go into the multigrain cereal. 219 00:13:53,820 --> 00:13:56,880 So, we've got the rice that you've just seen. Yeah. We've got the wheat, and 220 00:13:56,880 --> 00:13:58,020 we've got two types of barley. 221 00:13:59,060 --> 00:14:02,840 So, this is the wheat, which is really important for the structure of the 222 00:14:02,860 --> 00:14:06,260 It holds it all together, but it's a whole grain, so it adds fibre. It's 223 00:14:06,260 --> 00:14:07,680 good for your heart and digestive system. 224 00:14:07,960 --> 00:14:08,679 Oh, OK. 225 00:14:08,680 --> 00:14:11,640 Now, that's definitely changed from when I saw it with cherry. 226 00:14:12,350 --> 00:14:13,370 What's been done to it? 227 00:14:13,610 --> 00:14:14,610 This is cracked wheat. 228 00:14:14,790 --> 00:14:18,150 It's been taken to a mill, and then it's been cleaned to get rid of any 229 00:14:18,150 --> 00:14:22,550 impurities, and then those kernels are moistened a little bit, and then they're 230 00:14:22,550 --> 00:14:23,550 just cracked a little bit. 231 00:14:24,250 --> 00:14:25,250 Random question. 232 00:14:25,670 --> 00:14:26,890 How do you clean wheat? 233 00:14:27,190 --> 00:14:30,230 Just with water and a bit of scrubbing colour. So it's just like how you clean 234 00:14:30,230 --> 00:14:33,510 yourself at home. You get in the bath, you have a little bit of a scrub. 235 00:14:33,770 --> 00:14:34,489 Yeah, exactly. 236 00:14:34,490 --> 00:14:35,510 Just no shower gel. 237 00:14:36,130 --> 00:14:37,130 All right. 238 00:14:38,920 --> 00:14:43,460 The other two main ingredients are kibbled barley, which are crushed whole 239 00:14:43,460 --> 00:14:44,460 grains. 240 00:14:44,660 --> 00:14:48,160 Almost like tiny little stones, it's quite hard. 241 00:14:48,480 --> 00:14:51,420 And finer textured malted barley flour. 242 00:14:53,200 --> 00:14:58,880 From here, our cereals rush along pipes into one of four enormous cookers. 243 00:15:02,060 --> 00:15:04,920 Whoa, this is massive! 244 00:15:10,740 --> 00:15:13,280 Holy granola, that is big. 245 00:15:14,400 --> 00:15:15,400 So bad. 246 00:15:16,460 --> 00:15:18,120 Lizzie, quick question. 247 00:15:18,420 --> 00:15:20,700 14 cookers, massive room. 248 00:15:21,040 --> 00:15:22,040 Where is everyone? 249 00:15:22,800 --> 00:15:24,340 So these are quite self -sufficient. 250 00:15:24,620 --> 00:15:27,940 We've got them all pre -set to make sure that as one cook finishes, another 251 00:15:27,940 --> 00:15:31,380 one's still going, and there's a continuous feed of cereal going to the 252 00:15:31,380 --> 00:15:32,380 part of the post -it. 253 00:15:35,100 --> 00:15:38,680 In one cook, how much cereal is that? 254 00:15:39,550 --> 00:15:43,970 About 740 kilos. That's about 1 ,500 boxes of cereal. 255 00:15:44,470 --> 00:15:47,130 Or 24 ,500 bowls of cereal. 256 00:15:48,290 --> 00:15:51,170 Wowzers! So the cook is in three stages. 257 00:15:51,410 --> 00:15:54,030 For the first stage, you have the cookers rotating. 258 00:15:54,310 --> 00:15:58,030 So all the ingredients are mixed together and we add in lots of hot 259 00:16:01,250 --> 00:16:07,090 A jet of steam is blasted into the cooker at 125 degrees Celsius. 260 00:16:08,010 --> 00:16:11,470 adding moisture to the mix and starting the cooking process. 261 00:16:25,490 --> 00:16:29,090 It's very similar to if you were making a risotto at home. You have your stock 262 00:16:29,090 --> 00:16:32,850 and your rice. Right. You mix and heat it and it gets thicker and it starts to 263 00:16:32,850 --> 00:16:35,690 swell. That's the same process that we've got going on in here. 264 00:16:44,679 --> 00:16:49,060 So, when I'm looking at a cereal, it's very, very dry and flaky. 265 00:16:49,380 --> 00:16:53,000 Surely we don't want to be adding more moisture to it. You're not going to keep 266 00:16:53,000 --> 00:16:54,000 making it soggy. 267 00:16:54,240 --> 00:16:57,200 Well, actually, Paddy, we need to add even more moisture to it. 268 00:16:57,560 --> 00:17:02,200 So, at this stage, we actually add in about a third extra moisture. 269 00:17:02,460 --> 00:17:03,780 Oh, no, no, no. 270 00:17:04,170 --> 00:17:08,530 I'm not a medical person, but someone needs to drink more water. 271 00:17:09,650 --> 00:17:13,150 This is, in fact, the flavour solution we added after the pre -seed. 272 00:17:13,490 --> 00:17:16,790 So in here we have malt, we have sugar, salt and water. 273 00:17:17,210 --> 00:17:18,210 Can I smell that? 274 00:17:18,410 --> 00:17:19,410 Yes, you can smell it. 275 00:17:21,470 --> 00:17:25,250 It's almost like a sweet and sour smell, that. 276 00:17:26,450 --> 00:17:31,890 The flavouring is added to the cooker, which slowly revolves for an hour. 277 00:17:32,520 --> 00:17:35,240 mixing all the ingredients thoroughly as they cook. 278 00:17:39,020 --> 00:17:41,280 If we go around now, we can go and take a little look at it. 279 00:17:41,500 --> 00:17:43,060 Thought you'd never ask. Come on then. 280 00:17:47,480 --> 00:17:52,780 Three hours after the rice was delivered, our mix is cooked and we've 281 00:17:52,780 --> 00:17:55,360 first step towards breakfast cereal heaven. 282 00:17:57,020 --> 00:17:58,020 Beautiful. 283 00:17:58,880 --> 00:18:00,940 All of this has just been dumped out of that cooker. 284 00:18:01,500 --> 00:18:03,240 And it's coming along these Archimedes too. 285 00:18:03,680 --> 00:18:04,680 Jump. Yes. 286 00:18:04,940 --> 00:18:06,260 Play. Play. 287 00:18:06,560 --> 00:18:09,040 It's not the most romantic word, but we go with it. 288 00:18:10,400 --> 00:18:13,020 It's been lovingly placed into this Archimedes too. 289 00:18:14,720 --> 00:18:17,800 Still looks nothing like cereal that I recognise. 290 00:18:18,400 --> 00:18:21,440 No, so the most important part about this is it's now cooked. 291 00:18:21,680 --> 00:18:25,220 That means it's ready to get all that moisture back out. So we put it in and 292 00:18:25,220 --> 00:18:27,120 we need to take it back out again. It does smell lovely though. 293 00:18:27,360 --> 00:18:29,480 Yes, yes. That's all the cooked flavours coming through. 294 00:18:30,200 --> 00:18:32,860 So, to save your fingers, I've brought you some so you can have a little closer 295 00:18:32,860 --> 00:18:33,579 look at it. 296 00:18:33,580 --> 00:18:34,780 All right, that's that. 297 00:18:35,040 --> 00:18:36,300 That is that, yes. Oh, that is hot. 298 00:18:36,560 --> 00:18:37,560 Yes, yes. 299 00:18:37,900 --> 00:18:42,180 It's not very wet, but there's definitely still quite a bit of moisture 300 00:18:42,180 --> 00:18:45,520 there. It's all moist now, but the next thing you're supposed to do is try and 301 00:18:45,520 --> 00:18:48,020 get all that moisture out to get to that lovely crunchy cereal. 302 00:18:49,140 --> 00:18:52,340 I'd love to try that, but I'm missing one key ingredient. 303 00:18:53,920 --> 00:18:54,920 Spoons! 304 00:18:56,160 --> 00:19:01,960 And that, viewers, is my clever link... to everyone's favourite historian, Ruth 305 00:19:01,960 --> 00:19:05,780 Goodman. She's visiting somewhere that makes the best of them. 306 00:19:09,740 --> 00:19:11,920 Sheffield, the steel city. 307 00:19:14,260 --> 00:19:19,820 Fed by iron ore and coal mined from the Pennines, Sheffield metalworks put the 308 00:19:19,820 --> 00:19:20,820 city on the map. 309 00:19:21,240 --> 00:19:25,360 And they were particularly famous for their cutlery. 310 00:19:27,310 --> 00:19:32,410 But it's one very specific piece of cutlery that I'm in Sheffield to find 311 00:19:32,410 --> 00:19:33,410 about. 312 00:19:33,770 --> 00:19:38,450 Not just any old spoon, but the stainless steel spoon. 313 00:19:41,610 --> 00:19:47,830 I'm at the Kellam Island Museum, a historic industrial site, to meet 314 00:19:47,830 --> 00:19:50,110 industry and metalwork, Emma Paragreen. 315 00:19:52,120 --> 00:19:57,240 So Sheffield has a really long history of cutlery making, doesn't it? It does 316 00:19:57,240 --> 00:20:00,080 indeed. It goes right back to the 13th century. 317 00:20:00,380 --> 00:20:04,900 OK. And then Chaucer talks about a Sheffield swivel, which is an early 318 00:20:05,220 --> 00:20:08,120 OK. But where do spoons come into it? 319 00:20:08,780 --> 00:20:15,500 Spoons have been around for millennia. Spoons made in bone, wood, even glass 320 00:20:15,500 --> 00:20:20,760 ceramic. In terms of a metal spoon, we're talking really the Tudor period 321 00:20:20,760 --> 00:20:22,120 then into the Elizabethan age. 322 00:20:22,380 --> 00:20:23,740 And what sort of metal were they? 323 00:20:24,040 --> 00:20:25,460 A lot of them were pewter. 324 00:20:26,160 --> 00:20:27,700 It's quite heavy, though, isn't it? 325 00:20:28,100 --> 00:20:30,660 And, of course, you can pewter taste. 326 00:20:31,020 --> 00:20:35,600 Yeah, you can smell it, you can taste it. There'll be a lead content as well. 327 00:20:35,820 --> 00:20:37,180 Which is really poisonous. 328 00:20:37,600 --> 00:20:38,920 OK, I'll give you that back. 329 00:20:39,370 --> 00:20:41,350 So maybe silver is a better option. 330 00:20:41,610 --> 00:20:45,450 OK. This is going into the 17th, 18th century. 331 00:20:45,790 --> 00:20:47,570 So solid silver? Solid silver. 332 00:20:48,030 --> 00:20:51,850 It's not exactly going to be in your poor man's cupboard then, is it? No, so 333 00:20:51,850 --> 00:20:52,850 lot more expensive. 334 00:20:53,870 --> 00:20:56,770 You always know if you're eating off a silver spoon. You can taste it on the 335 00:20:56,770 --> 00:20:57,770 food. Yeah. 336 00:20:58,470 --> 00:21:03,190 The bad taste you get when eating off pewter or silver is due to the metal 337 00:21:03,190 --> 00:21:07,110 reacting with acid in the food and with our saliva. 338 00:21:08,300 --> 00:21:14,840 But steel, an alloy of iron, carbon, and other elements, had the potential to 339 00:21:14,840 --> 00:21:16,420 react in a different way. 340 00:21:17,460 --> 00:21:23,840 By the mid -19th century, Sheffield was producing 85 % of British steel for 341 00:21:23,840 --> 00:21:26,640 everything from knives and forks to railway tracks. 342 00:21:29,560 --> 00:21:35,620 But in 1913, just before the First World War, a revolution in cutlery 343 00:21:35,620 --> 00:21:36,620 production. 344 00:21:36,640 --> 00:21:38,540 came from a surprising source. 345 00:21:39,880 --> 00:21:46,220 This gentleman, Harry, really, was looking for different alloys to make a 346 00:21:46,220 --> 00:21:47,900 barrel that wouldn't rust. 347 00:21:48,140 --> 00:21:52,440 So he doesn't set out to make a better spoon. This is a man who wants to make a 348 00:21:52,440 --> 00:21:53,119 better gun. 349 00:21:53,120 --> 00:21:54,120 Yes. 350 00:21:55,060 --> 00:21:59,680 In search of a metal that wouldn't rust or corrode, Harry began to experiment 351 00:21:59,680 --> 00:22:02,660 with steel alloys containing chromium. 352 00:22:03,280 --> 00:22:06,900 which has a high melting point, ideal for use in gun barrels. 353 00:22:10,520 --> 00:22:15,240 To find out more, we visited the factory of Sheffield cutlery makers, David 354 00:22:15,240 --> 00:22:17,740 Mellor, to look at some of Harry's experiments. 355 00:22:20,960 --> 00:22:25,940 So we've got some early samples of some of the tests that Harry Brilly had been 356 00:22:25,940 --> 00:22:27,660 working on with his gun barrel. 357 00:22:28,240 --> 00:22:31,340 And then he discovered that... 358 00:22:31,720 --> 00:22:34,160 Actually, this might be useful for something else. 359 00:22:37,600 --> 00:22:43,960 On the 13th of August, 1913, Harry discovered a form of steel that was not 360 00:22:43,960 --> 00:22:48,280 rustproof, but had another revolutionary property. 361 00:22:50,560 --> 00:22:57,520 So he discovered this rustless steel, stainless steel, and left it with 362 00:22:57,520 --> 00:22:58,580 no paste. 363 00:22:58,900 --> 00:22:59,900 Oh, really? 364 00:23:00,440 --> 00:23:04,520 No, so if you imagine, this is the first time that a metal hasn't really had 365 00:23:04,520 --> 00:23:05,520 that aftertaste. 366 00:23:05,660 --> 00:23:10,020 So out of rifle barrels comes cutlery. Yeah, definitely. 367 00:23:10,920 --> 00:23:17,020 Originally known as rustless steel, in 1921, Harry teamed up with a local firm 368 00:23:17,020 --> 00:23:22,040 to produce cutlery which they marketed as stainless steel. 369 00:23:22,440 --> 00:23:26,880 So this is a mass -market product. It's cheap in comparison to what went before. 370 00:23:27,260 --> 00:23:32,380 Yeah, very much so. And as it says on the box, Neither rust tarnishes nor 371 00:23:32,380 --> 00:23:38,300 stains. Cutlery made from this steel is unaffected by food acids and is, in 372 00:23:38,300 --> 00:23:42,840 consequence, a universal boon. A universal boon. 373 00:23:43,480 --> 00:23:44,480 Guaranteed. 374 00:23:49,760 --> 00:23:54,720 And here, at David Mellor, they've been making stainless steel spoons since the 375 00:23:54,720 --> 00:23:55,800 1960s. 376 00:23:56,620 --> 00:23:59,040 Today, David's son, Corin. 377 00:23:59,480 --> 00:24:06,120 is the company's creative director so what's so great about stainless steel 378 00:24:06,120 --> 00:24:12,340 spoons then it's indestructible it's incredibly resilient lasts forever 379 00:24:12,340 --> 00:24:17,620 and there is nothing really to substitute good old stainless steel i 380 00:24:17,620 --> 00:24:24,480 simply is the best material to make a spoon out of a hundred odd years on it's 381 00:24:24,480 --> 00:24:28,280 just part of life Absolutely part of life. It's there every morning for your 382 00:24:28,280 --> 00:24:29,940 cereal, isn't it? And you just use it. 383 00:24:37,100 --> 00:24:38,380 Spot on that, Ruth. 384 00:24:38,960 --> 00:24:43,740 Back at the factory, I'm making a cereal pit for the best of spoons. 385 00:24:45,480 --> 00:24:46,560 It's like the Beatles. 386 00:24:47,060 --> 00:24:48,720 What a beautiful day. 387 00:24:50,680 --> 00:24:52,560 I'm the king of all time. 388 00:24:53,380 --> 00:24:54,480 Don't be noisy. 389 00:25:00,629 --> 00:25:04,710 What we've got so far is nothing like Blake yet. 390 00:25:08,150 --> 00:25:12,290 So I'm in search of Head of Operations, Ian Selley. 391 00:25:13,070 --> 00:25:14,070 All right, Ian. 392 00:25:14,230 --> 00:25:15,970 How are you, Paddy? All right? OK, thanks. 393 00:25:16,310 --> 00:25:21,510 Ian, I tell you, everything in this factory is supersized. Yeah, it's a 394 00:25:21,510 --> 00:25:25,770 big plant. Oh, my word, is it? Now, I've just left Lizzie. 395 00:25:26,070 --> 00:25:30,170 All that cereal's not quite cereal. Yeah. It's still very moist. I believe 396 00:25:30,170 --> 00:25:34,110 you're the man to dry it out. I sure am, Paddy. So we've been through the 397 00:25:34,110 --> 00:25:35,110 cooking process. 398 00:25:35,210 --> 00:25:38,090 Everything that we're going to see in the next few stages is about how we're 399 00:25:38,090 --> 00:25:41,590 going to transform that into the crispy cereal that we know. OK. 400 00:25:42,890 --> 00:25:48,670 It starts with the granulator, a fierce -looking bit of kit which forces the 401 00:25:48,670 --> 00:25:50,090 mixture through a mesh. 402 00:25:50,770 --> 00:25:54,130 This essentially is a box now with a steel conveyor inside. 403 00:25:54,550 --> 00:25:58,870 Right. And it will hold roughly three cups at any one time, which is about two 404 00:25:58,870 --> 00:25:59,789 tonnes of food. 405 00:25:59,790 --> 00:26:03,750 My word. And we're just trying to break it up, trying to make it more even, more 406 00:26:03,750 --> 00:26:06,750 free -flowing, in order that we can take moisture out. Got it? 407 00:26:10,290 --> 00:26:11,450 And off we go. 408 00:26:12,060 --> 00:26:15,740 following the mix to a massive 30 -metre -long dryer. 409 00:26:16,600 --> 00:26:21,400 Keep going, Ian. Where the temperature reaches 100 degrees Celsius. 410 00:26:22,060 --> 00:26:27,540 As it travels along, the mix loses a third of its moisture, starting the 411 00:26:27,540 --> 00:26:30,260 transformation from soggy to crunchy. 412 00:26:30,720 --> 00:26:31,880 What have we got here, Ian? 413 00:26:32,160 --> 00:26:35,000 So, these are our pellet mills, Paddy, right? 414 00:26:35,320 --> 00:26:39,560 Yeah. And what you can see there is that's the cox mix coming down through 415 00:26:39,560 --> 00:26:43,850 tube. And we put it between two rollers. We're going to make little tiny dough 416 00:26:43,850 --> 00:26:44,850 balls with it. 417 00:26:47,970 --> 00:26:52,070 One of the metal rollers is covered in hundreds of dimples. 418 00:26:52,590 --> 00:26:54,550 It looks a bit like bubble wrap. 419 00:26:55,110 --> 00:27:00,010 When the cooked cereal passes between the rollers, the mix is pushed up into 420 00:27:00,010 --> 00:27:04,390 dimples, moulding it into little balls of dough called pellets. 421 00:27:06,350 --> 00:27:08,730 I can see the little balls are dropping here. 422 00:27:10,730 --> 00:27:12,210 Be heavy and hang on. 423 00:27:16,470 --> 00:27:20,190 Each pellet will eventually become one flake of cereal. 424 00:27:23,370 --> 00:27:25,450 So they've still got a little bit of moisture in them, yeah? 425 00:27:25,650 --> 00:27:29,250 They still need to hold quite a lot of moisture in order that we can get them 426 00:27:29,250 --> 00:27:31,310 form together now to make them little balls. 427 00:27:34,650 --> 00:27:37,710 These little pellets don't look like cereal flakes yet. 428 00:27:38,960 --> 00:27:41,440 But they look over the moon to be on their way. 429 00:27:42,560 --> 00:27:45,380 Oh, look at these cheeky little scamps. 430 00:27:46,940 --> 00:27:48,540 Having a right little bounce about. 431 00:27:49,480 --> 00:27:54,900 So at this point now, we've put the product through a mesh. 432 00:27:55,220 --> 00:27:59,540 So those that have made it into a pellet small enough, drop through that mesh. 433 00:28:12,750 --> 00:28:16,150 Those that don't make it through there, so you can see there are some lumps that 434 00:28:16,150 --> 00:28:19,590 go over the top and over the end, they return back into the process. 435 00:28:20,390 --> 00:28:24,730 How much is coming through here now, Ian? So each pellet mill, Paddy, 436 00:28:24,730 --> 00:28:28,190 about 48 ,000 pellets a minute. 437 00:28:28,590 --> 00:28:29,590 Wow. 438 00:28:31,690 --> 00:28:35,390 If we multiply that by the amount of pellet mills we've got on, that's 10. It 439 00:28:35,390 --> 00:28:38,590 equates to about 4 ,000 bowls of cereal a minute. 440 00:28:39,370 --> 00:28:44,360 Hey, sometimes when I'm doing this show, People tell me facts and figures. 441 00:28:44,660 --> 00:28:49,260 I can't get my head around it, and that's one of them. I mean, just how is 442 00:28:49,260 --> 00:28:50,260 even possible? 443 00:28:50,800 --> 00:28:52,160 It really is amazing. 444 00:28:53,340 --> 00:28:56,160 It really is amazing to see. 445 00:28:57,760 --> 00:28:59,780 Want to try one, Paddy? 446 00:29:01,160 --> 00:29:02,460 Absolutely. At this point. 447 00:29:03,240 --> 00:29:05,300 Oh, still very moist. 448 00:29:05,560 --> 00:29:07,340 Still very moist at this point. 449 00:29:09,540 --> 00:29:11,260 You've got to put a lot in your mouth. 450 00:29:11,920 --> 00:29:14,060 to get that cereal taste. 451 00:29:14,680 --> 00:29:16,920 It's chewy, but it's not unpleasant. 452 00:29:18,420 --> 00:29:21,920 But it's definitely not what I know that taste to be. 453 00:29:27,400 --> 00:29:32,560 After four and a half hours, we're leaving the pellets behind, and we've 454 00:29:32,560 --> 00:29:35,560 metres to cover to get to the plate making. 455 00:29:37,680 --> 00:29:38,820 And here we are. 456 00:29:40,400 --> 00:29:42,560 That looks a little bit more familiar now. 457 00:29:43,220 --> 00:29:44,240 Go on, Ian. 458 00:29:44,600 --> 00:29:45,700 Reveal the flake. 459 00:29:49,140 --> 00:29:53,940 It's like playing the tastiest tuppany nudger on the pier, as your 460 00:29:55,940 --> 00:29:58,280 We've only gone and won the flaky jackpot. 461 00:30:00,160 --> 00:30:04,420 Paddy, this is one of our flaky mills. This is very similar to a pellet mill, 462 00:30:04,480 --> 00:30:05,480 two steel rolls. 463 00:30:05,640 --> 00:30:07,360 Yeah. But without the dimpled... 464 00:30:07,720 --> 00:30:09,860 And as you can see there, that becomes the plate. 465 00:30:15,640 --> 00:30:19,520 Would you like to take a sample? Yes, sir. Okay. Pull the handle there and 466 00:30:19,520 --> 00:30:20,520 take a sample. 467 00:30:21,880 --> 00:30:22,880 My God. 468 00:30:24,000 --> 00:30:27,700 That's floppy. There's still a lot of moisture at this phase. Yeah. 469 00:30:28,740 --> 00:30:32,040 I thought they were going to come out totally solid and crispy. 470 00:30:32,500 --> 00:30:35,800 So at this point, we've taken out about 40 % moisture. 471 00:30:36,520 --> 00:30:39,820 There's still moisture in there, because if we dried it out completely at this 472 00:30:39,820 --> 00:30:42,580 point, we wouldn't be able to get it through that flaking mill. It would 473 00:30:42,580 --> 00:30:44,420 probably disintegrate into a powder. 474 00:30:45,340 --> 00:30:49,800 I don't know if it's a psychological thing, but because it's a bit more like 475 00:30:49,800 --> 00:30:52,200 flake, I'm getting the flavour a bit more now. 476 00:30:52,620 --> 00:30:53,620 Possibly, yeah. 477 00:30:54,740 --> 00:30:59,120 But seeing those floppy flakes makes me think of one of me pets here. 478 00:31:00,020 --> 00:31:02,460 Soggy bits of breakfast stuck on the dishes. 479 00:31:04,080 --> 00:31:05,860 It's the eternal debate. 480 00:31:06,580 --> 00:31:12,000 What's the best way to stack those dirty cereal bowls in your dishwasher and get 481 00:31:12,000 --> 00:31:13,080 them spotlessly clean? 482 00:31:13,320 --> 00:31:18,000 Well, luckily for us, Cherry Healy is about to give us the answer. 483 00:31:20,980 --> 00:31:24,880 And ever the professional, she's brought her own prop along. 484 00:31:25,760 --> 00:31:27,080 Looks heavy, that cherry. 485 00:31:28,490 --> 00:31:33,250 In most households, it would seem, there is one person who stacks the dishwasher 486 00:31:33,250 --> 00:31:36,150 with the precision of a Scandinavian architect. 487 00:31:36,670 --> 00:31:40,490 And there is another who takes more of a cram it in approach. 488 00:31:42,670 --> 00:31:47,250 So, I'm in Bristol to dish the dirt on this dish washing divide. 489 00:31:49,730 --> 00:31:53,130 Cut the roof first. No, do the plate. No, the plate. 490 00:31:54,080 --> 00:31:55,100 No, cutlery first. 491 00:31:55,540 --> 00:31:57,720 You are cutlery first, you are plate first. 492 00:31:58,440 --> 00:32:01,720 There's always an argument, isn't there? This is the wrong way. This is wrong 493 00:32:01,720 --> 00:32:03,820 because there should be no pots up there. 494 00:32:04,980 --> 00:32:07,620 Who is the stacker and who is the shover? 495 00:32:07,980 --> 00:32:11,040 I'm the stacker. Does he sometimes just shove the dishes in? Occasionally, and 496 00:32:11,040 --> 00:32:12,860 then I have to chase it out of the way to it. 497 00:32:15,440 --> 00:32:16,720 What do you think about this stacking? 498 00:32:16,940 --> 00:32:17,940 How does it make you feel? 499 00:32:18,280 --> 00:32:20,840 I'm tired of doing it. Looks like something I would do. 500 00:32:21,780 --> 00:32:23,020 That would drive me nuts. 501 00:32:23,680 --> 00:32:25,120 I would have to take it all out on research. 502 00:32:26,480 --> 00:32:29,020 It seems there's only one conclusion. 503 00:32:29,460 --> 00:32:31,480 Everyone thinks they're right. 504 00:32:32,660 --> 00:32:35,820 Time to clear it up once and for all. 505 00:32:37,580 --> 00:32:42,900 Back in my very own kitchen, my family's dirty breakfast bowls are waiting for 506 00:32:42,900 --> 00:32:43,980 some expert treatment. 507 00:32:44,640 --> 00:32:46,720 Hi, Andrew, I'm Terry. Nice to meet you. 508 00:32:46,920 --> 00:32:48,660 From Andrew Lockson. 509 00:32:49,100 --> 00:32:55,720 dishwasher guru and principal researcher at consumer organization which is there 510 00:32:55,720 --> 00:33:00,280 anything that causes more domestic arguments than stacking the dishwasher i 511 00:33:00,280 --> 00:33:03,720 would say no they cause a lot of arguments but hopefully we can settle a 512 00:33:03,720 --> 00:33:10,620 arguments today but before andrew gives me a master class in stacking i need 513 00:33:10,620 --> 00:33:12,540 to rinse my very dirty plates 514 00:33:13,860 --> 00:33:15,980 No, no, no, no, no, no, no. Oh, what? 515 00:33:16,380 --> 00:33:19,100 Jerry, Jerry, Jerry. Oh, it's gross, though. We don't. 516 00:33:19,660 --> 00:33:22,200 You don't rinse. We don't rinse plates. 517 00:33:22,800 --> 00:33:27,260 You can actually mess up how the machine works by doing it. Because on most 518 00:33:27,260 --> 00:33:30,700 machines' auto program, it has what's called a turbidity sensor. 519 00:33:31,400 --> 00:33:32,460 Turbidity sensor. 520 00:33:32,820 --> 00:33:37,780 It senses, in that pre -wash cycle, how cloudy the water is. And what it's 521 00:33:37,780 --> 00:33:40,360 looking for is how dirty your dishes are. 522 00:33:40,620 --> 00:33:43,980 So imagine if you cleaned all this stuff, put it all in, the machine's 523 00:33:43,980 --> 00:33:45,920 go, hold a minute, this is just clean dishes. 524 00:33:46,200 --> 00:33:48,000 I'll adjust the temperature and lower it accordingly. 525 00:33:48,340 --> 00:33:50,940 So if you want your dishes really clean... 526 00:33:51,610 --> 00:33:55,930 make sure they're dirty the dishwasher wants to clean let it 527 00:33:55,930 --> 00:34:02,890 instead of rinsing scrape leftovers into your 528 00:34:02,890 --> 00:34:09,530 food waste bins and regularly clean the dishwasher filter and when 529 00:34:09,530 --> 00:34:13,889 stacking face everything towards the center of the machine for the best 530 00:34:13,889 --> 00:34:19,820 performance as a rule of thumb Typically, if you eat out of it, it goes 531 00:34:19,820 --> 00:34:23,219 lower rack. If you drink out of it, it goes on the upper rack. Right. 532 00:34:23,659 --> 00:34:28,800 And make sure no items are touching, so the water can flow and wash effectively. 533 00:34:30,780 --> 00:34:36,060 Non -stick cookware, sharp knives and wood should never go in the dishwasher, 534 00:34:36,060 --> 00:34:38,580 high temperatures and water pressure could damage them. 535 00:34:39,960 --> 00:34:41,639 Oh my God, are you re -stacking? 536 00:34:42,040 --> 00:34:43,040 No. 537 00:34:44,080 --> 00:34:47,900 It's like a natural thing. Is it because some of them weren't quite even? 538 00:34:48,219 --> 00:34:52,540 Well, you know, I mean, it is my job, you know, to be a slight pedant. 539 00:34:54,659 --> 00:34:58,680 Particular placement might be important, but with his neck locked, Andrew's got 540 00:34:58,680 --> 00:34:59,680 his work cut out. 541 00:34:59,820 --> 00:35:01,560 These are two of the worst offenders. 542 00:35:02,180 --> 00:35:05,480 Cereal -based anything and scrambled eggs. 543 00:35:05,780 --> 00:35:10,480 Yeah, what you've got here is carbs, sugar and starch, and protein with the 544 00:35:10,580 --> 00:35:12,320 So take a bit more time to break down. 545 00:35:13,160 --> 00:35:18,340 When left behind, the starches and proteins on the bowls form bonds with 546 00:35:18,340 --> 00:35:19,900 other and start to harden. 547 00:35:20,180 --> 00:35:24,380 The longer the food sits, the more cement -like it becomes. 548 00:35:24,800 --> 00:35:28,460 By adding moisture, the dishwasher breaks these bonds. 549 00:35:29,300 --> 00:35:33,140 So what we want to do with this one is put it in the middle where the intensity 550 00:35:33,140 --> 00:35:33,979 is highest. 551 00:35:33,980 --> 00:35:35,900 I'll be stunned if that comes off. 552 00:35:37,100 --> 00:35:38,100 We'll see. 553 00:35:39,340 --> 00:35:41,800 Time to put Andrew's tip to the test. 554 00:35:42,600 --> 00:35:44,100 Right, in the tablet goes. 555 00:35:47,680 --> 00:35:52,600 A pre -wash sprays jets of cold water between the carefully spaced plates and 556 00:35:52,600 --> 00:35:56,400 cutlery, knocking off excess food before the main cycle begins. 557 00:36:00,060 --> 00:36:05,140 But perfect stacking is not the only thing required for my dishes to sparkle. 558 00:36:05,840 --> 00:36:07,460 What about tablets? Is that important? 559 00:36:07,960 --> 00:36:12,260 Absolutely, yeah. They are designed to break down all the dirt and the food 560 00:36:12,260 --> 00:36:14,200 waste and start the cleaning process. 561 00:36:15,280 --> 00:36:20,300 Most tablets contain enzymes, which attack protein -based foods like my 562 00:36:20,300 --> 00:36:24,280 scrambled egg, as well as the starchy residue of breakfast cereal. 563 00:36:26,120 --> 00:36:29,420 They also have something else in them, which is a surfactant. 564 00:36:30,220 --> 00:36:34,420 It basically stops water from forming droplets and it makes it spread more 565 00:36:34,420 --> 00:36:35,420 easily. 566 00:36:35,670 --> 00:36:39,190 want to add detergent to have maximum coverage and the water is the vehicle to 567 00:36:39,190 --> 00:36:46,130 get that there another addition rinse aid disperses the water on the surface 568 00:36:46,130 --> 00:36:52,590 of the dishes helping them to dry at the end of the cycle and to run efficiently 569 00:36:52,590 --> 00:36:57,730 the special dishwasher salt softens the water preventing lime scale build up and 570 00:36:57,730 --> 00:36:59,390 those horrid white marks on glasses 571 00:37:02,140 --> 00:37:03,140 So annoying. 572 00:37:03,220 --> 00:37:05,480 Every household has a cloudy glass. 573 00:37:05,840 --> 00:37:08,020 Yeah. That would be because you've not kept up with your fault. 574 00:37:09,180 --> 00:37:13,880 And with the cycle over, it's time to see if my impeccably stacked dishwasher 575 00:37:13,880 --> 00:37:15,160 has done its job. 576 00:37:22,500 --> 00:37:23,500 No. 577 00:37:23,760 --> 00:37:24,760 No! 578 00:37:25,740 --> 00:37:27,540 It dealt with the cereal. 579 00:37:28,680 --> 00:37:32,280 Dealt with the egg. Even the egg. Even the egg. 580 00:37:33,040 --> 00:37:34,740 So the cutlery is sparkling. 581 00:37:35,340 --> 00:37:38,040 Yeah. So does that mean that stacking properly works? 582 00:37:38,360 --> 00:37:39,500 Yep. Don't pre -wash. 583 00:37:40,000 --> 00:37:43,840 Stack properly the first time and you'll get good results every time. 584 00:37:44,160 --> 00:37:48,200 I'm sorry I didn't wear sunglasses because that is some good -looking 585 00:37:50,120 --> 00:37:53,540 So we've learnt how to get the best out of our dishwasher. 586 00:37:54,060 --> 00:37:57,900 Now all that remains is the battle of whose turn it is. 587 00:37:58,230 --> 00:37:59,230 to empty it. 588 00:38:11,450 --> 00:38:15,770 Gonna take a big bottle of milk. 589 00:38:20,730 --> 00:38:26,550 Just like everything in this factory, we've now got super -sized balls of 590 00:38:26,550 --> 00:38:27,550 cereal. 591 00:38:27,630 --> 00:38:30,850 But these flakes are still missing that all -important crunch. 592 00:38:31,670 --> 00:38:33,530 So I'm on the hunt for Ian again. 593 00:38:34,690 --> 00:38:35,690 Is it that way? 594 00:38:36,850 --> 00:38:38,430 I'm not sure where I'm going from here now. 595 00:38:39,170 --> 00:38:43,470 I want to find out how flakes go from floppy to fabulous. 596 00:38:45,910 --> 00:38:46,910 There he is. 597 00:38:47,950 --> 00:38:49,370 Good to see you again, Ian. 598 00:38:49,590 --> 00:38:50,408 All right, pal. 599 00:38:50,410 --> 00:38:51,410 I'll tell you what. 600 00:38:52,450 --> 00:38:55,550 It's toasty here. Oh, it's really warm here. Heat coming off that. 601 00:38:56,750 --> 00:38:57,750 Flippin' heck! 602 00:38:59,150 --> 00:39:00,990 We've arrived at the toasting machine. 603 00:39:01,690 --> 00:39:02,910 That explains a lot. 604 00:39:03,130 --> 00:39:06,710 So this is the part where we generate the really crispy, crunchy flakes. 605 00:39:06,990 --> 00:39:10,690 Okay. So what you can see at the point coming up the end feed, we've still got 606 00:39:10,690 --> 00:39:13,830 the floppy flakes. Yeah, I can see some of them go over the side there. 607 00:39:14,050 --> 00:39:15,050 Yep. 608 00:39:15,550 --> 00:39:18,750 So there's still a significant amount of moisture in there. Yeah. What they're 609 00:39:18,750 --> 00:39:20,290 going to do now, they go into their toaster. 610 00:39:20,530 --> 00:39:24,850 Right. It's very similar to a toasting machine that you get in a hotel. 611 00:39:25,520 --> 00:39:28,340 If you think about one where you load the bread in the conveyor... I'm going 612 00:39:28,340 --> 00:39:31,280 say you might be wasting your money there, get a new machine. 613 00:39:31,640 --> 00:39:36,760 Because I have never used a hotel toaster. That toaster bread just comes 614 00:39:36,760 --> 00:39:38,940 warm. This is significantly different. 615 00:39:39,780 --> 00:39:44,020 What temperature is in there, Ian? So this is way in excess of 200 degrees. 616 00:39:44,320 --> 00:39:45,440 Oh, my word. That's proper. 617 00:39:46,400 --> 00:39:49,740 So we're now going to put these floppy flakes inside the oven. 618 00:39:51,260 --> 00:39:54,460 Inside there is a conveyor, but it's a vibrating conveyor. Yeah. 619 00:39:55,040 --> 00:39:58,860 And it's bouncing the flake up and down, and we're going to really reduce that 620 00:39:58,860 --> 00:39:59,860 moisture. 621 00:40:00,880 --> 00:40:06,960 The bouncing helps the evaporation process and stops them sticking 622 00:40:08,680 --> 00:40:09,680 Look at that. 623 00:40:15,720 --> 00:40:18,640 I've got to say, there's definitely a nicer colour now. 624 00:40:19,220 --> 00:40:22,520 What you're seeing now is 6 .3 tonnes an hour here. 625 00:40:22,880 --> 00:40:26,980 Wow. So that's equivalent to about 12 ,500 boxes an hour. 626 00:40:27,220 --> 00:40:28,520 It's bonkers, isn't it? 627 00:40:30,020 --> 00:40:35,100 You know, it's amazing to me the amount of stuff that's going out of factories 628 00:40:35,100 --> 00:40:40,640 every single day, the product, the ingredients, the work. It's mind 629 00:40:40,940 --> 00:40:44,260 Yeah. I'm getting them lovely aromas, Ian. 630 00:40:44,740 --> 00:40:48,400 So what's happening within there is something called the Maillard reaction. 631 00:40:49,480 --> 00:40:54,200 That's where you get a browning effect and it also really fetches out the 632 00:40:54,200 --> 00:40:55,200 and the flavours. 633 00:40:56,460 --> 00:41:02,220 It was French chemist Louis Mayard who discovered that heating amino acids and 634 00:41:02,220 --> 00:41:05,540 sugars gives cooked food that taste we love. 635 00:41:06,060 --> 00:41:11,980 We're talking barbecued meat, roasted coffee and, of course, the toasty 636 00:41:11,980 --> 00:41:12,980 of cereal. 637 00:41:13,520 --> 00:41:19,170 So when I'm on the beach in Tenerife on my sun lounger, I'm getting the Mayard 638 00:41:19,170 --> 00:41:21,050 effect. Probably, yeah. Oh. 639 00:41:22,690 --> 00:41:27,530 Also, what's happened through the toaster is we've enhanced the surface 640 00:41:27,530 --> 00:41:30,690 of it. You'll see where the rice grain has expanded. 641 00:41:30,990 --> 00:41:34,590 Yeah, and it's popped. See, the textures look much different. And that's the 642 00:41:34,590 --> 00:41:38,670 wheat, the kibble barley, the rice all coming together now. Now it'll be really 643 00:41:38,670 --> 00:41:43,250 crunchy. That's what we left moisture -wise. At this stage now, we've taken 644 00:41:43,250 --> 00:41:45,890 90 % of the moisture. 645 00:41:47,080 --> 00:41:49,640 Can I try one? You can? Or two? 646 00:41:52,300 --> 00:41:55,300 Extremely hot. My God, they're roasting. 647 00:41:56,480 --> 00:41:58,980 I mean, you would be hot, wouldn't you, if you'd come out of an oven, to be 648 00:41:58,980 --> 00:41:59,980 fair. Right. 649 00:42:00,160 --> 00:42:01,160 Right. 650 00:42:02,820 --> 00:42:03,820 Ah. 651 00:42:08,100 --> 00:42:10,540 Lovely bit of crunch there now, Ian. That's lovely. 652 00:42:13,130 --> 00:42:17,450 I'm just not quite getting the full flavour, Ian. There's just a summit 653 00:42:17,650 --> 00:42:21,050 though. Well, that's because, Paddy, we're going to add a little bit more 654 00:42:21,050 --> 00:42:24,010 flavour in in the next phase. OK. We have a coaching plan. 655 00:42:24,410 --> 00:42:25,410 Lead on, Ian. 656 00:42:27,370 --> 00:42:28,370 There you are. 657 00:42:28,650 --> 00:42:29,650 More for them. 658 00:42:30,130 --> 00:42:31,130 Very nice. 659 00:42:45,990 --> 00:42:52,010 The breakfast flakes travel on through the vast factory, up this spiral 660 00:42:52,010 --> 00:42:56,910 elevator, which uses vibration alone to jiggle them upwards. 661 00:42:58,730 --> 00:43:01,970 As they head towards the enormous coating drum. 662 00:43:11,980 --> 00:43:15,020 Oh my word, they are absolutely flying in. 663 00:43:15,520 --> 00:43:19,020 They're coming out of that tube so quick, they don't even look like plates 664 00:43:19,020 --> 00:43:19,779 they hit the drum. 665 00:43:19,780 --> 00:43:23,880 Believe it or not, we've actually put a little bit of moisture back in. Only a 666 00:43:23,880 --> 00:43:27,240 very, very low level. And so we've put the coating syrup on here. 667 00:43:27,620 --> 00:43:32,520 So that contains sugar, salt, water, and we've put some vitamins in at this 668 00:43:32,520 --> 00:43:33,520 point. 669 00:43:43,610 --> 00:43:48,490 Inside the drum, the sugary liquid is sprayed onto the flakes from above. 670 00:43:48,970 --> 00:43:53,410 And the drum keeps moving them so the syrup doesn't make them all clump 671 00:43:53,410 --> 00:43:54,410 together. 672 00:43:54,910 --> 00:43:59,890 Then after a trip through yet another dryer, my flakes emerge looking good 673 00:43:59,890 --> 00:44:00,890 enough to eat. 674 00:44:01,390 --> 00:44:02,390 Again. 675 00:44:04,350 --> 00:44:05,610 There they are. 676 00:44:05,850 --> 00:44:09,330 Now straight away they're in. I can see that little bit of sheen on them. 677 00:44:09,800 --> 00:44:13,620 So that's the coating or the flavour that we've added. Yeah. Now we've been 678 00:44:13,620 --> 00:44:14,578 through the dryer. 679 00:44:14,580 --> 00:44:18,060 Now that's the final product in its final finished state. You know what I'm 680 00:44:18,060 --> 00:44:19,660 going to ask, don't you? I do, Paddy. 681 00:44:19,940 --> 00:44:22,600 Yeah, you scoop it there, Ian. Let's have a look. 682 00:44:23,340 --> 00:44:25,500 All right, here we go. Big moment. 683 00:44:28,520 --> 00:44:35,080 Oh, instantly I get that sweetness, which is amazing because if I'd have had 684 00:44:35,080 --> 00:44:37,920 that without trying it before, I wouldn't have recognised that. 685 00:44:38,730 --> 00:44:42,330 And at the end when you swallow it, it's still sort of there in your mouth. But 686 00:44:42,330 --> 00:44:45,530 yeah, it makes all the difference, that, doesn't it? We're really fetching the 687 00:44:45,530 --> 00:44:46,530 flavours out now. 688 00:44:46,970 --> 00:44:52,270 This is exactly what I recognise now. This is what I pour out the box, into 689 00:44:52,270 --> 00:44:54,350 bowl, splash your milk, job's a good 'un. 690 00:44:54,570 --> 00:44:56,110 So now they're ready to go off to packing. 691 00:44:56,750 --> 00:44:58,350 Which is where I'm heading, Ian. 692 00:44:58,760 --> 00:45:03,400 Me and you will have to say goodbye. I have absolutely loved having our all 693 00:45:03,400 --> 00:45:04,400 breakfast together. 694 00:45:04,580 --> 00:45:06,440 Put the handshake away. Go on. 695 00:45:06,860 --> 00:45:09,740 Thanks for looking after me today, Ian. Take care, pal. Take care. 696 00:45:11,680 --> 00:45:15,260 Of course, this lot would be nothing without one thing. 697 00:45:17,660 --> 00:45:18,660 Milk. 698 00:45:20,000 --> 00:45:23,000 Which brings us to Ruth, who's down on the farm. 699 00:45:26,410 --> 00:45:30,630 For centuries, our countryside has been blessed with miles of rolling pasture 700 00:45:30,630 --> 00:45:32,350 land and grazing cows. 701 00:45:33,250 --> 00:45:38,790 But much like today, the history of dairy farming has been a troubled one, 702 00:45:38,790 --> 00:45:43,930 farmers battle the challenges of wavering demand and falling prices for 703 00:45:43,930 --> 00:45:44,930 milk. 704 00:45:46,870 --> 00:45:53,050 Back in the 1930s, there was an organisation that set out to give 705 00:45:53,050 --> 00:45:54,070 better deal. 706 00:45:54,670 --> 00:45:59,450 And one of their aims was to get the British public to fall back in love with 707 00:45:59,450 --> 00:46:02,190 drinking a lot more milk. 708 00:46:03,110 --> 00:46:04,290 All right with you girls? 709 00:46:07,890 --> 00:46:09,230 Hello! Hi. 710 00:46:10,810 --> 00:46:14,410 Historian Amy Swainston knows a thing or two about the milk industry. 711 00:46:17,330 --> 00:46:18,530 They do look happy. 712 00:46:18,990 --> 00:46:19,990 Feel bad. 713 00:46:21,770 --> 00:46:27,190 I'm meeting her at this dairy farm in Dorset to find out why farmers needed 714 00:46:27,190 --> 00:46:28,530 100 years ago. 715 00:46:30,650 --> 00:46:35,110 So what was going on for dairy farmers in the 1920s then? 716 00:46:35,350 --> 00:46:40,710 Well, in the late 1800s, many farmers had turned to dairy as a way to make 717 00:46:40,710 --> 00:46:44,290 because it was seen as quite a stable product to sell. 718 00:46:44,570 --> 00:46:49,370 But by the 1920s, milk production far exceeded the demand for milk. 719 00:46:49,840 --> 00:46:51,040 So essentially there was a surplus. 720 00:46:51,380 --> 00:46:54,580 Exactly, just not enough people buying what they were making. 721 00:46:56,040 --> 00:47:01,540 As supply outstripped demand, most dairy farmers were struggling to get a fair 722 00:47:01,540 --> 00:47:02,700 deal for their milk. 723 00:47:03,820 --> 00:47:08,260 Farms were a lot smaller back then. You'd have about 14 cows in a herd, 724 00:47:08,260 --> 00:47:09,820 today it's about 200 to 300. 725 00:47:10,320 --> 00:47:15,260 They would sell their milk to the creameries, which were a lot bigger. 726 00:47:15,790 --> 00:47:19,670 So all these little tiny farmers have got to deal with this middleman. Yes, 727 00:47:19,670 --> 00:47:23,050 it's the creameries that would dictate the prices to the farmers. 728 00:47:23,950 --> 00:47:28,510 Across the country, creameries processed the milk and made butter and cheese. 729 00:47:29,530 --> 00:47:34,750 To fight their control over the market, the farmers decided to band together. 730 00:47:35,350 --> 00:47:41,170 The decision was taken in 1933 to set up a cooperative between farmers to help 731 00:47:41,170 --> 00:47:44,330 them to sell their milk at a reasonable price to buyers. 732 00:47:47,120 --> 00:47:50,680 They called themselves the Milk Marketing Board and they were a 733 00:47:50,680 --> 00:47:55,140 was run by farmers for farmers. So that instead of the power being with these 734 00:47:55,140 --> 00:48:00,200 middlemen, the power should actually sit with the producers, the farmers. Yeah, 735 00:48:00,280 --> 00:48:01,760 so that they could get a fair price. 736 00:48:03,260 --> 00:48:07,120 Farmers no longer had to accept the prices offered by the creamery. 737 00:48:07,690 --> 00:48:13,730 Instead, each month, the board set the price for the milk they supplied and 738 00:48:13,730 --> 00:48:16,790 paid the money straight back to the farms. 739 00:48:17,490 --> 00:48:19,390 We're in the heart of the action now. 740 00:48:21,990 --> 00:48:27,850 It ensured 70 ,000 farmers across the UK could maintain a steady income. 741 00:48:30,510 --> 00:48:35,790 And as well as negotiating a fair deal for farmers, the board was also 742 00:48:35,790 --> 00:48:37,010 responsible for... 743 00:48:37,310 --> 00:48:38,930 popularising dairy products. 744 00:48:40,870 --> 00:48:46,730 Over the following decades, their marketing team got busy, making milk not 745 00:48:46,730 --> 00:48:50,570 a favourite of children, but a drink that appealed to adults too. 746 00:48:51,810 --> 00:48:53,950 So here we've got a milk bar. 747 00:48:56,350 --> 00:49:00,170 The Milk Marketing Board opened up quite a few milk bars throughout the country 748 00:49:00,170 --> 00:49:05,880 and... you can see the photos of trying to persuade young women this is a trendy 749 00:49:05,880 --> 00:49:10,600 thing to do it's particularly young women isn't it beautifully dressed 750 00:49:10,600 --> 00:49:17,520 and they didn't stop there in 1958 they sponsored the tour of 751 00:49:17,520 --> 00:49:24,080 britain's cycle race renaming it the milk crane oh and we got 752 00:49:24,080 --> 00:49:25,600 footballers here as well yeah 753 00:49:27,080 --> 00:49:31,400 Really associating it with physical fitness, with youth vitality. 754 00:49:32,840 --> 00:49:37,040 And there were advertising campaigns that came along with this. So they were 755 00:49:37,040 --> 00:49:41,820 spending about 1 .7 million on marketing per year by the mid -60s, which is 756 00:49:41,820 --> 00:49:42,940 about 30 million today. 757 00:49:44,020 --> 00:49:46,060 The investment paid off. 758 00:49:46,720 --> 00:49:51,560 Throughout the 60s and 70s, the British public fell in love with milk. 759 00:49:53,260 --> 00:49:59,120 And by the early 1980s, as Football League Cup was rebranded the Milk Cup, 760 00:49:59,420 --> 00:50:05,500 annual sales of the white stuff peaked at nearly 13 billion litres, 761 00:50:05,720 --> 00:50:09,300 compared to 4 billion in the 1930s. 762 00:50:10,140 --> 00:50:11,500 But it didn't last. 763 00:50:14,440 --> 00:50:17,540 So there is no Milk Marketing Board anymore. 764 00:50:17,960 --> 00:50:19,000 What happened? 765 00:50:19,380 --> 00:50:24,180 Well, in 1994, the MMB is actually shut down for good by the government, and 766 00:50:24,180 --> 00:50:28,580 that's because the Milk Marketing Board has a monopoly over the dairy industry. 767 00:50:28,920 --> 00:50:29,920 Ah, yes. 768 00:50:30,220 --> 00:50:35,060 The government wanted to increase competition, but with the break -up of 769 00:50:35,060 --> 00:50:39,540 Milk Marketing Board, the farmers lost their power to set the best price. 770 00:50:40,520 --> 00:50:42,860 So from the mid-'90s... 771 00:50:43,120 --> 00:50:44,520 Dairy farmers were on their own. 772 00:50:44,740 --> 00:50:50,200 Yeah, so where before they'd had that assurance on prices, now there wasn't 773 00:50:51,420 --> 00:50:57,780 With retailers driving prices down and the costs of farming going up, many 774 00:50:57,780 --> 00:50:59,160 farms couldn't survive. 775 00:51:00,800 --> 00:51:06,560 So today we actually have around 10 ,000 dairy farms left, which is the lowest 776 00:51:06,560 --> 00:51:10,360 it's been in living memory. And now supermarkets are the main seller of 777 00:51:10,480 --> 00:51:12,420 Yeah, so all the power is with them. Yeah. 778 00:51:13,640 --> 00:51:18,880 The Milk Marketing Board had its detractors, but for 60 years it provided 779 00:51:18,880 --> 00:51:22,040 stability in an unstable industry. 780 00:51:23,580 --> 00:51:28,220 It was a sort of organisation of a different era, wasn't it? Quite 781 00:51:28,220 --> 00:51:32,380 at the time. Yeah, in many ways it seems that we need something similar today. 782 00:51:40,180 --> 00:51:42,800 Oh, send a bottle of milk my way, Ruth. 783 00:51:43,290 --> 00:51:45,150 I've got a lot of flakes to get through here. 784 00:51:49,910 --> 00:51:56,850 But you can't have breakfast cereal without a box to put 785 00:51:56,850 --> 00:51:57,850 it in. 786 00:51:59,210 --> 00:52:05,450 First, exactly 440 grams of cereal is weighed and dropped into a bag. 787 00:52:06,350 --> 00:52:11,670 They're sealed and fall onto a vibrating conveyor that shakes the contents flat. 788 00:52:17,430 --> 00:52:22,750 I'm meeting Project Lead Donna Jenkins to find out more about how the bags get 789 00:52:22,750 --> 00:52:23,750 into the boxes. 790 00:52:25,030 --> 00:52:27,570 Hi Paddy! How are you? Nice to meet you, you okay? 791 00:52:27,890 --> 00:52:28,890 Yeah, welcome to packing. 792 00:52:29,170 --> 00:52:31,030 So talk me through it, what's happening now? 793 00:52:31,250 --> 00:52:35,810 So we loaded the boxes onto the carter and it's got a conveyor mechanism and 794 00:52:35,810 --> 00:52:37,290 they work their way up the conveyor here. 795 00:52:37,550 --> 00:52:41,490 So each of those black boxes are pulled down by the suction cups and as you can 796 00:52:41,490 --> 00:52:45,370 see there's suction cups extracting them. Yeah. So they work their way into 797 00:52:45,370 --> 00:52:48,760 guide. And Brad Box is being pushed open. Really clever. 798 00:52:49,000 --> 00:52:50,000 Yeah, he's clever. 799 00:52:51,860 --> 00:52:58,820 Amazing. Someone has sat down and invented a machine that takes a flat box 800 00:52:58,820 --> 00:52:59,820 flips it up. 801 00:53:00,500 --> 00:53:03,420 Someone sat down and thought about that. That's bonkers. 802 00:53:04,300 --> 00:53:05,480 We'll work our way down. 803 00:53:05,840 --> 00:53:07,100 So what's happening now? 804 00:53:08,120 --> 00:53:10,980 Hold on. Don't worry, I know how to handle these situations. 805 00:53:11,660 --> 00:53:14,000 You're going to be impressed by this. Shut it! 806 00:53:16,740 --> 00:53:18,340 That's how you do it. And then resume. 807 00:53:20,060 --> 00:53:23,160 So we apply glue to the top and the bottom of the box. Right. 808 00:53:23,360 --> 00:53:24,700 We have what we call a pusher. 809 00:53:24,960 --> 00:53:29,320 It's getting the food. So it's pushing the food into the open box. I can see 810 00:53:29,340 --> 00:53:30,340 Yeah, I can see it. 811 00:53:31,240 --> 00:53:33,260 And it makes its way along the conveyor. 812 00:53:33,740 --> 00:53:35,600 It's now going to seal the boxes. 813 00:53:36,420 --> 00:53:37,420 So clever. 814 00:53:37,740 --> 00:53:38,740 It is. 815 00:53:45,290 --> 00:53:46,870 Don't use my fingers. 816 00:53:47,610 --> 00:53:49,270 Don't use my fingers. 817 00:53:50,070 --> 00:53:56,170 The machine turns out 150 boxes a minute. That's more than two a second. 818 00:53:59,850 --> 00:54:05,090 So what I've always wanted to know is, what's the K for on special K? 819 00:54:05,470 --> 00:54:07,490 Come on Paddy, tell us! 820 00:54:14,060 --> 00:54:15,060 Don't build me up. 821 00:54:15,260 --> 00:54:16,260 I'm embarrassed. 822 00:54:16,980 --> 00:54:18,080 Don't tell me! 823 00:54:21,780 --> 00:54:22,780 Come on. 824 00:54:22,900 --> 00:54:24,920 Don't pretend you knew that as well. 825 00:54:26,340 --> 00:54:31,720 Moving on, me and Donna are leaving packing and heading to distribution. 826 00:54:32,000 --> 00:54:35,140 And, you've guessed it, it's megathigh. 827 00:54:36,640 --> 00:54:41,040 This is like having a little stroll in the old breakfast cereal future. 828 00:54:45,160 --> 00:54:49,880 And I can see what looked like a load of dodgeums, but with no drivers. 829 00:54:50,840 --> 00:54:54,020 How many of these little rascals are here? Hey, get out. 830 00:54:54,940 --> 00:54:56,620 So we have 25 of these. 831 00:54:57,180 --> 00:55:00,960 They're called automated guided vehicles, Paddy. They just operate 832 00:55:01,140 --> 00:55:05,060 And what their job is, is that they take all the finished boxes, either into 833 00:55:05,060 --> 00:55:08,840 storage on site, or they load it onto the autobay, and it'll get fed onto a 834 00:55:08,840 --> 00:55:10,000 truck all by itself. 835 00:55:10,810 --> 00:55:13,930 Are you not worried about being taken out by one of these? They're everywhere. 836 00:55:14,570 --> 00:55:17,850 No, Paddy, they're actually really intelligent. If you look at the top, 837 00:55:17,850 --> 00:55:18,549 a scanner. 838 00:55:18,550 --> 00:55:22,130 Yeah. What that's doing is talking to a control system, which is in the heart of 839 00:55:22,130 --> 00:55:23,129 the warehouse here. 840 00:55:23,130 --> 00:55:24,130 All right, OK. 841 00:55:24,350 --> 00:55:27,570 They're actually that clever, it'll actually detect obstacles in front of 842 00:55:27,570 --> 00:55:28,570 and it'll stop. 843 00:55:28,590 --> 00:55:29,590 Shall we give it a go? 844 00:55:29,710 --> 00:55:30,830 Let's give it a go, yeah. 845 00:55:31,779 --> 00:55:35,800 What we've got here, is this a specialist robotics operator machine? 846 00:55:36,120 --> 00:55:40,160 No, bog standard blue carton. It's a blue box, all right. As good as any. 847 00:55:41,980 --> 00:55:44,180 Right, I'll give it a whirl. Here we go. 848 00:55:44,800 --> 00:55:46,220 So can you pop it on the floor there? 849 00:55:49,080 --> 00:55:50,080 Let's see. 850 00:55:52,440 --> 00:55:53,440 Oh! 851 00:55:54,620 --> 00:55:56,160 Right bumper, we like that. 852 00:55:56,460 --> 00:55:58,200 Yeah, it'll now detect if it's safe. 853 00:55:58,400 --> 00:56:00,360 Right. And then it'll start off again. Brilliant. 854 00:56:02,220 --> 00:56:04,320 Amazing. Very, very clever little things. 855 00:56:06,240 --> 00:56:09,480 It doesn't have to be a blue box. No. It could be any object. 856 00:56:09,740 --> 00:56:10,880 It could be you, Paddy. Wow. 857 00:56:11,780 --> 00:56:12,780 Here we are. 858 00:56:13,980 --> 00:56:15,460 Oh! Oh! 859 00:56:16,540 --> 00:56:20,760 That... That was that. Look at that. Look how close that were. 860 00:56:21,300 --> 00:56:23,960 But to be fair, I jumped out in front of it. I took it by surprise. 861 00:56:24,480 --> 00:56:24,959 Yeah, you did, yeah. 862 00:56:24,960 --> 00:56:28,900 It was just going about its everyday microchip business then and then. 863 00:56:29,160 --> 00:56:30,400 And it still kept you safe? 864 00:56:30,960 --> 00:56:31,960 Thank you. 865 00:56:33,460 --> 00:56:34,460 Off you go. 866 00:56:35,460 --> 00:56:36,460 Very clever. 867 00:56:50,440 --> 00:56:51,440 Amazing. 868 00:56:53,580 --> 00:56:54,660 That's fantastic. 869 00:56:55,020 --> 00:56:56,200 Go on, you little rascals. 870 00:56:57,080 --> 00:56:58,080 I love that. 871 00:57:00,460 --> 00:57:04,880 Oh, I could hang about here all day, but apparently we haven't finished filming 872 00:57:04,880 --> 00:57:05,880 yet. 873 00:57:06,400 --> 00:57:10,440 Don't worry about stopping in front of the camera, lads. Just mow them straight 874 00:57:10,440 --> 00:57:11,440 over. 875 00:57:14,800 --> 00:57:20,700 Seven hours after the delivery of rye, my boxes of cereal are about to leave 876 00:57:20,700 --> 00:57:21,700 factory. 877 00:57:22,500 --> 00:57:24,080 Well, there they are, there, Donna. 878 00:57:24,560 --> 00:57:27,960 We've got around about 19 ,000 finished boxes on there, Paddy. 879 00:57:28,340 --> 00:57:30,040 19 ,000 boxes. 19 ,000. 880 00:57:30,400 --> 00:57:31,400 A lot of cereal. 881 00:57:32,460 --> 00:57:35,800 And every day, 40 trucks leave the factory. 882 00:57:36,100 --> 00:57:39,100 So we best get this one loaded up and on its way. 883 00:57:41,240 --> 00:57:42,340 There they go. 884 00:57:43,180 --> 00:57:46,560 Families across the nation will be enjoying them very soon. 885 00:57:47,920 --> 00:57:52,060 All this talk of breakfast and cereals, you know what I'm in the mood for? 886 00:57:52,560 --> 00:57:53,560 Full English breakfast. 887 00:57:54,090 --> 00:57:55,490 Good girl. Come on, Donna. 888 00:57:59,710 --> 00:58:06,270 From the factory in Wrexham, cereal is sent to all corners of the country to 889 00:58:06,270 --> 00:58:09,350 fill the bowls of hungry souls the nation over. 890 00:58:10,750 --> 00:58:16,310 And 30 million boxes are exported from here right across Europe. 891 00:58:17,630 --> 00:58:18,830 Bon appétit. 892 00:58:22,860 --> 00:58:27,900 So there you go, we've finally got boxes of crunchy flakes without a drop of 893 00:58:27,900 --> 00:58:28,960 moisture inside. 894 00:58:29,520 --> 00:58:34,520 Well, not until they get in your breakfast bowl. Right, get me some milk. 895 00:58:36,010 --> 00:58:41,550 Shut the bedroom window in the morning. Global Glamazons runway ready on BBC3. 896 00:58:41,630 --> 00:58:45,550 Brand new RuPaul's Drag Race UK versus the world. 897 00:58:45,790 --> 00:58:51,150 A school in crisis on BBC1. Mr Rimmer makes a dramatic return. 898 00:58:51,550 --> 00:58:53,470 Waterloo Road is next. 899 00:58:54,430 --> 00:59:01,390 An alley cat chewing on dead meat in the 900 00:59:01,390 --> 00:59:02,390 morning.