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and the moon from there

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Here in Britain,
we love our Italian food.

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And one of our best loved dishes
<font color="

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My favourite is tortellini.

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For me, it's ravioli
with Parmesan on top.

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In the UK, we spend around
£130 million

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on these Italian classics
every year.

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And to find out how
<font color="

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..we've come to a factory
that's been making it since 1929.

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Ow! Ow, ow!

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I'm Gregg Wallace...

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GREGG SCREAMS, LAUGHS

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..and tonight, I'm following
the production of stuffed pasta,

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from full-flavoured ingredients...

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<font color="
of shellfish, ever.

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..to speciality dough...

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It's much denser, much heavier.

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If I had to mix and knead this by
hand, I'd have forearms like Popeye.

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..to see how these
produce-packed parcels are formed.

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<font color="

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You clever boy.

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I'm Cherry Healey...

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DISCORDANT SQUEALING AND SCREECHING
Oh, God!

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..and I'll be orchestrating
an experiment

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to find out if sound can affect
our sense of taste.

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<font color="

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That is the sourest music
known to humankind.

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And historian Ruth Goodman is
investigating how Italian migrants

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helped to rebuild war-torn Britain.

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So why does Bedford have such
a large Italian community?

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<font color="

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A brick.

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500 million pasta parcels are made
in this factory every year.

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And we're going to reveal
just how they do it.

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Welcome to Inside The Factory.

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This is the Dell'Ugo factory
in Borehamwood,

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<font color="

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It's a family-run business
that's been making pasta

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for four generations.

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They make a range
of fresh egg pasta,

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from lasagne sheets
to spinach and ricotta tortellini.

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But I'm making one of their
<font color="

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the crab and crayfish raviolo.

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Raviolo are stuffed squares

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that are just a bit bigger
than their little cousins, ravioli.

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And to make the crab and crayfish
filling for our parcels,

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we need a selection of shellfish.

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<font color="
intake area...

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..to catch a delivery with factory
manager Cesar Da Rocha.

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Cesar!
Yes.

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Right, tell me,
what have you got on there?

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OK, so in here, we have our
<font color="

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We get delivered a pallet
every week.

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In each pallet,
we have about 50 cases. 480 kilos.

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Almost half a tonne?!
Yes.

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Of crayfish?
Yes, yes.

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Now, where do they come from?

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<font color="
they come from Denmark.

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From Denmark? Yeah.
Are they fresh? Are they frozen?

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They come in frozen.
You know what? Let me show you.

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Sure. Let me get them off
and show you.

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<font color="
delivery of crayfish...

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..production of my raviolo begins.

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So this is the crayfish tails
that we get delivered. Ah.

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You get the tai...
Ah, just the tails.

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Yes, just the tail. They come
<font color="

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I actually have some crayfish here.
I'm going to show you.

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Pretty little things, ain't they?
Yes.

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They're closely related to lobster.

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These ones,
they come from fresh water.

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<font color="
and lakes.

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In terms of flavour,
the flavour you get out of these

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is a combination of lobster,
crab, shrimp,

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maybe not as salty, a bit sweeter.

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And this delivery you've got here,

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<font color="
to make with it?

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Way over 200,000 individual raviolo.

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Very impressive.

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Cesar, thank you.

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Along with the crayfish, our pasta
parcels contain another shellfish,

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one of my favourites, crab.

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<font color="

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to find a catch of these
big-clawed crustaceans.

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This pretty seaside town
is a little gem.

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It's a favourite for
holidaying families,

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but it's also world-famous
for crab fishing.

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<font color="

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These days, we think of seafood
as being caught by huge trawlers,

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but here, the work is done
by small boats

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that land right on that beach there.

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And I'm waiting for one to return
any minute now.

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<font color="

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He's on his way.

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Norfolk's nutrient-rich waters
are home to Cromer crabs,

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prized for being flavoursome,
fragrant, and tender.

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John Davies began fishing for them
on his dad's boat 45 years ago.

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Hi, John.
<font color="

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Can I come aboard?
You are more than welcome.

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Just be careful.
I will.

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So this is what you were after.
Yeah.

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They're still alive.
I can't pick one out.

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<font color="
they'll only give you a little nip.

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What's so special about
a Cromer crab?

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I put it down to the chalk and the
flint seabed that they're on,

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and its lovely clean fresh water.

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<font color="

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compared to one that's come from
a muddy reservoir.

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Crabs often live under rocks
on the seabed,

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and can't be fished with nets,

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so instead, they're caught in traps.

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John uses traditional parlour pots,
<font color="

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and left on the seabed for a couple
of days to lure in the crabs.

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How many of these pots
do you have out there?

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How many do you pull up in a day?

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We put an awful lot of these
on the seabed.

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<font color="
out at the moment. Wow.

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And they'll be in what we call
shanks or lines of 25.

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That's sort of comfortable
for this boat to hold.

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So we haul 25 up and re-bait them,
stack them.

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<font color="
from 200 to 300 pots a day.

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To sustain the crab population,

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young ones measuring less than
11.5 centimetres

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are returned to the sea.

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Measure at the widest part,
from there to there,

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<font color="
our legal size.

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Today, John's crew have hauled
300 kilos of mature crab.

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To keep it as fresh as possible,
it's processed the same day

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just a mile down the road
at Jonas Seafood,

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<font color="

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Hi, Kevin. Lovely to meet you.
Hiya.

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I mean, there is crab everywhere.

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Every single surface, every box,
is just full of crab.

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Yeah, so today we're cooking
five tonne of crab,

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<font color="

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To process the crabs,
they're electrically stunned

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before passing through a cooker
where they're immersed in water

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at 98 degrees Celsius
for 25 minutes.

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What happens now these crabs
are all cooked?

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<font color="
this cooling belt.

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What would happen if you cooled
these crabs down

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really, really fast? You'd lose the
quality of the texture of the meat.

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It would become very runny. Oh.
<font color="

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That's absolutely not what you want.

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No, it wouldn't be the Cromer crab
that we sell.

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Once the crabs are cooled
to under 5 degrees Celsius,

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the meat is removed from the shell.

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It's a fiddly process
<font color="

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so 30 people tackle this painstaking
job, called picking,

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getting through 4,000 crabs a day.

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Do you need an extra pair of hands?

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Absolutely. Always.
All right. Put me to work.

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Tsarinka Ivanova has been here
<font color="

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Hello!
Hi.

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I hear you are the fastest picker
in the east of England.

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Will you teach me your ways?
Of course I will.

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OK. So we both have a crab.
What do we do now?

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<font color="
into pieces.

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First we take off the legs,

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then the claws and the bony abdomen.

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Oh, wow. Oh, that actually comes off
quite easily. Yes.

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It's a myth that some parts
of the crab are poisonous,

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<font color="
or gills,

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have a bitter, unpleasant taste.

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With the knife,
you can take out all the brown meat.

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The shell contains
mainly brown meat.

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The crab's equivalent to its liver,
it has a sweet taste.

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<font color="
meat is found in the legs and claws.

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So now... Yeah.
..we have to break the claw.

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With a knife.
OK.

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Smash it!
Smash it, yeah.

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Smash it!

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<font color="
of these normally?

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Five minutes.

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It's really fiddly, and you've got
to have such attention to detail.

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To get the very last bits
of meat from the legs,

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Kevin's company uses a machine.

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<font color="

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It's like a super-sized garlic press
squeezing out the final flakes.

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What it is,
it's a very powerful motor

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which is squeezing the legs
against a drum,

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which has had 1.6 millimetre holes
<font color="

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So anything under 1.6 millimetre,

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all the meat,
falls into the meat section.

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So meat that way,
shell down and out.

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Yeah. That's the plan.

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Get every last bit of meat
out of those crabs.

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<font color="
after they're brought ashore,

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Cromer crabs are cooked, picked,
packed, and frozen,

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ready to travel the 137 miles
to our factory.

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<font color="
Figaro here, Figaro there,

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Figaro up, Figaro down

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the lightning

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Here in Borehamwood...

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..crab from Cromer,
<font color="

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have been transported from intake
to the kitchen...

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..where I'm meeting director
and joint owner of the factory,

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Charlie Ugo.

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Ooh, lovely!

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<font color="
Good to meet you.

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Not often I actually get to chat

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with one of the owners
of the company. Indeed.

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Right, what have we got to do?

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So we're making our filling
<font color="

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Where do we start?
Start with the crab.

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We've got two types of crab meat.

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We've got our leg meat
and we've got our purse meat.

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Purse? If you look at a crab
from the top,

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<font color="
without the legs,

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looks a little bit like
a lady's purse.

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I've been in food for 30 years,
I've never heard it called a purse.

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Not everybody uses the brown meat.
Why do you combine the two?

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<font color="
flavour, it adds that fishiness,

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it adds the texture and the bite.

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But the brown meat actually adds
a sweet, delicate flavour.

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I find the brown actually better
flavour than the white. Absolutely.

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<font color="
in each batch?

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OK, so this batch we're doing today,
it's total 125 kilos of filling.

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That's 26 kilos of crab.

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That will make about 210 kilos
of finished raviolo,

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which is about 8,000, 8,500
<font color="

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So over here, Gregg, you'll see
we're preparing some of the herbs

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and other ingredients that add
a lot of flavour to the mix.

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Can I help? Please, Gregg. Is that
<font color="

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Because what you're doing here
is cooking. Absolutely.

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Just on a big scale.

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Parsley and coriander
are sent frozen from France

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and defrosted at the factory.

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<font color="
in Italian food. Correct.

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Parsley is west
and coriander is east, like Asian.

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Yep.
It's an unusual combination.

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What we've realised over the years,
Gregg, is that the English palate

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<font color="
from the Italian palate.

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And English people in general,
the Brits,

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love their own flavour profiles.

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Which is why they have pineapple
on pizza, right? Absolutely.

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The coriander and parsley,
<font color="

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flavours that we have,
allow us to cover

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all of the major five flavours.

246
00:14:15,720 --> 00:14:17,200
What's the five flavours?

247
00:14:17,200 --> 00:14:20,960
Salty, sweet, sour, bitter.

248
00:14:20,960 --> 00:14:23,000
What's the other one?
Umami.

249
00:14:25,720 --> 00:14:28,520
The aim of any recipe
<font color="

250
00:14:28,520 --> 00:14:32,200
of these flavour combinations
to achieve the desired taste...

251
00:14:34,040 --> 00:14:37,440
..and umami is known
as the fifth flavour.

252
00:14:37,440 --> 00:14:39,080
It's intensely savoury.

253
00:14:40,240 --> 00:14:43,920
Imparted by glutamates, an amino
acid that occurs naturally

254
00:14:43,920 --> 00:14:46,200
<font color="
fish and vegetables...

255
00:14:47,520 --> 00:14:48,880
Whoa!

256
00:14:48,880 --> 00:14:50,440
..like chilli and garlic.

257
00:14:50,440 --> 00:14:52,080
What's next, Charlie?

258
00:14:52,080 --> 00:14:54,360
Next thing on the list, Gregg,
is mayonnaise.

259
00:14:56,360 --> 00:14:58,120
Mayo adds a creamy texture

260
00:14:58,120 --> 00:15:01,000
that helps to bind the rest
<font color="

261
00:15:02,440 --> 00:15:04,920
..before 300g of salt is added.

262
00:15:06,000 --> 00:15:09,000
With the herb mix ready,
it's the moment of truth...

263
00:15:09,000 --> 00:15:11,160
Right, now we're ready to mix,
Gregg.

264
00:15:11,160 --> 00:15:13,560
..bringing all the ingredients
together.

265
00:15:13,560 --> 00:15:15,640
This is our filling mixing system.

266
00:15:18,240 --> 00:15:21,800
<font color="
goes 20kg of crayfish...

267
00:15:24,240 --> 00:15:27,200
I've never seen this amount
of shellfish, ever.

268
00:15:27,200 --> 00:15:28,600
Ever, ever, ever.

269
00:15:30,000 --> 00:15:32,640
..26 kilos of crab meat...

270
00:15:32,640 --> 00:15:35,640
You can see the mixture there
of the brown and the white

271
00:15:35,640 --> 00:15:37,600
in different textures.

272
00:15:37,600 --> 00:15:41,720
<font color="
the same family as cod and haddock.

273
00:15:41,720 --> 00:15:45,240
It adds a fish stock flavour
and yet more texture.

274
00:15:47,520 --> 00:15:49,520
Shall I add my flavour mix now?

275
00:15:49,520 --> 00:15:51,440
Absolutely. It's time, Gregg.

276
00:15:51,440 --> 00:15:54,240
Once my carefully-weighed herb mix
goes in,

277
00:15:54,240 --> 00:15:57,760
<font color="
of their boiled shells,

278
00:15:57,760 --> 00:16:00,440
and lemon juice is spread
over the top.

279
00:16:01,840 --> 00:16:06,560
And that freshly-squeezed lemon
juice ever so slightly enhances

280
00:16:06,560 --> 00:16:10,400
the herbs as you're pouring it in,
very lightly acidifies them.

281
00:16:13,760 --> 00:16:16,560
<font color="

282
00:16:16,560 --> 00:16:20,040
We've got to rotate this,
mix it over in two directions.

283
00:16:20,040 --> 00:16:22,720
And it's really important we get
the time exactly right here.

284
00:16:22,720 --> 00:16:24,800
We need to make sure
it doesn't damage the texture.

285
00:16:24,800 --> 00:16:27,520
So I'm going to ask you
<font color="

286
00:16:27,520 --> 00:16:29,400
I have a little stopwatch here.

287
00:16:29,400 --> 00:16:31,720
I need you to mix one way
for 32 seconds

288
00:16:31,720 --> 00:16:34,160
and then the other way
for 32 seconds.

289
00:16:34,160 --> 00:16:36,160
Oh, properly precise.

290
00:16:36,160 --> 00:16:38,480
32 seconds in one direction.

291
00:16:41,240 --> 00:16:43,000
If we mix this too fast,

292
00:16:43,000 --> 00:16:46,480
<font color="
the fish and we'll lose our texture.

293
00:16:46,480 --> 00:16:47,840
Absolutely.

294
00:16:47,840 --> 00:16:50,720
If you do it for too long,
it will turn into a paste, a mush.

295
00:16:50,720 --> 00:16:53,600
So please make sure as soon as
we hit the 32 seconds

296
00:16:53,600 --> 00:16:55,480
that we stop this rotation.

297
00:16:56,880 --> 00:16:59,040
<font color="
direction. Yeah.

298
00:17:00,720 --> 00:17:02,720
Can't believe that is so precise.

299
00:17:02,720 --> 00:17:05,080
When have you ever read a cooking
instruction that says,

300
00:17:05,080 --> 00:17:07,880
"Blend for 32 seconds in one,
blend for 32 seconds in the other"?

301
00:17:09,640 --> 00:17:11,600
BEEP

302
00:17:09,640 --> 00:17:11,600
<font color="

303
00:17:12,920 --> 00:17:15,720
Having mixed for
the required 64 seconds,

304
00:17:15,720 --> 00:17:20,800
we add 15kg of salted butter,
melted at 40 degrees Celsius...

305
00:17:23,080 --> 00:17:24,800
Look at that.

306
00:17:24,800 --> 00:17:27,480
Oh-oh-oh!

307
00:17:27,480 --> 00:17:30,080
..before the final ingredient.

308
00:17:30,080 --> 00:17:33,760
Gregg, the last thing we need to do
<font color="

309
00:17:33,760 --> 00:17:36,360
Breadcrumbs. Absolutely.
Breadcrumbs.

310
00:17:36,360 --> 00:17:38,720
And they will soak up
any extra moisture.

311
00:17:40,880 --> 00:17:44,120
Mixed for precisely
one minute and 34 seconds,

312
00:17:44,120 --> 00:17:46,080
the filling is ready.

313
00:17:47,320 --> 00:17:50,560
<font color="
perfect for our filling, Gregg.

314
00:17:50,560 --> 00:17:53,800
How long did it take to perfect
this recipe and the stirring times?

315
00:17:53,800 --> 00:17:56,240
How long? It's taken
over 20 years, Gregg,

316
00:17:56,240 --> 00:17:58,400
to get this recipe
what it is today.

317
00:17:58,400 --> 00:18:01,040
<font color="
is the quality check.

318
00:18:01,040 --> 00:18:02,640
Really?
I'll leave it up to you.

319
00:18:02,640 --> 00:18:04,560
Do you want to give it a taste
for us, please?

320
00:18:04,560 --> 00:18:06,840
Let us know if it meets
the standards.

321
00:18:06,840 --> 00:18:08,840
Do you want to know whether
<font color="

322
00:18:08,840 --> 00:18:10,320
to a quarterfinal, do you?

323
00:18:17,640 --> 00:18:20,600
I've got a tiny little bit of lemon.
Yeah. Tiny little bit of salt.

324
00:18:20,600 --> 00:18:23,200
Tiny little bit of chilli,
tiny little bit of herbs. Good.

325
00:18:23,200 --> 00:18:25,840
But moreover, what I've got
<font color="

326
00:18:25,840 --> 00:18:27,720
Exactly what we're looking for,
Gregg.

327
00:18:27,720 --> 00:18:29,600
We could now take a big
ladle full of that

328
00:18:29,600 --> 00:18:32,200
and put it into a bucket of pasta.
Absolutely. We've got lunch!

329
00:18:32,200 --> 00:18:34,800
Absolutely. You can put it in
<font color="

330
00:18:34,800 --> 00:18:36,320
There's an idea.

331
00:18:36,320 --> 00:18:38,560
Have you got any brown bread
and butter? Of course.

332
00:18:38,560 --> 00:18:41,920
Let's go and have some.
Crab sandwiches. Got any chips?

333
00:18:45,400 --> 00:18:49,520
Two hours and 21 minutes after
our crayfish arrived at the factory,

334
00:18:49,520 --> 00:18:55,080
<font color="
filling is dropped into tubs

335
00:18:55,080 --> 00:18:58,480
and sent into the fridge
for 24 hours -

336
00:18:58,480 --> 00:19:01,920
a vital process that helps
to develop the flavours.

337
00:19:06,960 --> 00:19:11,600
Perfecting the flavour combinations
will ensure my pasta packs a punch.

338
00:19:11,600 --> 00:19:13,720
<font color="
how things taste,

339
00:19:13,720 --> 00:19:16,280
can our ears have an impact too?

340
00:19:16,280 --> 00:19:18,760
Cherry has been investigating.

341
00:19:21,680 --> 00:19:24,120
LIGHT EDM PLAYS

342
00:19:26,120 --> 00:19:29,840
There's something not quite right
about this restaurant.

343
00:19:32,160 --> 00:19:36,360
My eyes are saying
beautiful Italian food,

344
00:19:36,360 --> 00:19:40,320
<font color="
something very different.

345
00:19:41,640 --> 00:19:43,760
SWOONING ITALIAN—STYLE
SONG PLAYS

346
00:19:43,760 --> 00:19:46,040
Ah, that's better.

347
00:19:46,040 --> 00:19:49,520
So can sound affect
our sense of taste?

348
00:19:57,680 --> 00:20:01,920
To find out, I'm meeting
Professor Charles Spence,

349
00:20:01,920 --> 00:20:06,800
<font color="
from the University of Oxford.

350
00:20:08,000 --> 00:20:09,640
Charles, hello.
Hi there.

351
00:20:09,640 --> 00:20:13,040
So we're in a recording studio
because you're going to explain

352
00:20:13,040 --> 00:20:16,120
how taste and our hearing
are connected.

353
00:20:16,120 --> 00:20:18,840
The sounds of the environment
<font color="

354
00:20:18,840 --> 00:20:22,720
be it the background music, be it
soundscapes or the noise of nature,

355
00:20:22,720 --> 00:20:24,960
all of those affect
our taste perception.

356
00:20:24,960 --> 00:20:28,520
Do I really register that
in how I taste things?

357
00:20:28,520 --> 00:20:31,160
Perhaps the best thing to do
<font color="

358
00:20:31,160 --> 00:20:32,880
See you in a minute.
All right.

359
00:20:32,880 --> 00:20:36,240
Charles calls this theory
"sonic seasoning,"

360
00:20:36,240 --> 00:20:38,680
and to test it, he's brought along

361
00:20:38,680 --> 00:20:43,360
three quintessential Italian
food and drink items.

362
00:20:43,360 --> 00:20:47,840
I am going to get you to taste
<font color="

363
00:20:47,840 --> 00:20:51,960
first in silence,
and then with a piece of music.

364
00:20:53,960 --> 00:20:56,040
First up is black coffee.

365
00:20:57,440 --> 00:20:59,320
So it's quite bitter.

366
00:20:59,320 --> 00:21:01,120
There's a little hint of sweetness.

367
00:21:01,120 --> 00:21:03,480
GENTLE, HIGH-PITCHED TWINKLY TUNE

368
00:21:03,480 --> 00:21:06,760
Then Charles plays a
<font color="

369
00:21:06,760 --> 00:21:09,480
that's supposed to stimulate
my brain.

370
00:21:11,960 --> 00:21:14,480
The insular cortex,
deep within the brain,

371
00:21:14,480 --> 00:21:17,480
is responsible for
our sense of taste.

372
00:21:17,480 --> 00:21:21,400
Specific regions of the insular
react to different tastes,

373
00:21:21,400 --> 00:21:23,000
<font color="

374
00:21:24,240 --> 00:21:27,600
But can a piece of music
also act as a taste trigger?

375
00:21:29,040 --> 00:21:31,240
It seems a bit sweeter.

376
00:21:31,240 --> 00:21:33,440
That's right.
Is that... Is that right?!

377
00:21:33,440 --> 00:21:34,640
CHARLES CHUCKLES

378
00:21:34,640 --> 00:21:36,920
So the first track there
was the sweet track,

379
00:21:36,920 --> 00:21:40,000
<font color="
showing that sweetness,

380
00:21:40,000 --> 00:21:43,000
people associate more with
high pitch than with low pitch.

381
00:21:43,000 --> 00:21:48,360
They associate it with instruments
like tinkling pianos, wind chimes.

382
00:21:48,360 --> 00:21:52,320
Now a silent glass of Pinot Grigio.

383
00:21:52,320 --> 00:21:55,800
It's a little bit sharp.
<font color="

384
00:21:55,800 --> 00:21:58,080
HIGH PITCHED, SHRILL,
DISCORDANT SQUEALS

385
00:21:58,080 --> 00:22:02,200
And with specially composed, er,
not sure I can call this...

386
00:22:02,200 --> 00:22:03,520
Ugh. Total... God!

387
00:22:03,520 --> 00:22:04,920
..music!

388
00:22:05,840 --> 00:22:08,760
Tastes a bit more sour or bitter.

389
00:22:08,760 --> 00:22:10,120
It was a bit more unpleasant.

390
00:22:10,120 --> 00:22:11,960
<font color="
of sonic seasoning.

391
00:22:11,960 --> 00:22:14,320
Again, high pitch, a bit like
the sweet soundscape,

392
00:22:14,320 --> 00:22:16,920
but in this case,
very sharp music instead.

393
00:22:16,920 --> 00:22:19,040
And that music track is, in fact,

394
00:22:19,040 --> 00:22:22,120
I think the sourest music
known to humankind.

395
00:22:22,120 --> 00:22:25,520
<font color="

396
00:22:27,080 --> 00:22:29,920
So quite spicy, mild?
Mild.

397
00:22:29,920 --> 00:22:33,640
So now I'm going to fade in
the next track.

398
00:22:35,120 --> 00:22:38,080
BASSY DANCE BEATS

399
00:22:39,920 --> 00:22:41,480
CHERRY COUGHS

400
00:22:43,520 --> 00:22:48,000
It definitely got spicier
and didn't taste very nice.

401
00:22:48,000 --> 00:22:50,440
<font color="
much higher in tempo,

402
00:22:50,440 --> 00:22:53,320
much more energetic
piece of music.

403
00:22:53,320 --> 00:22:57,040
Much in the same way that eating
a chilli may make you more aroused,

404
00:22:57,040 --> 00:22:58,840
more alert, more energetic.

405
00:22:59,960 --> 00:23:02,400
But knowing what the experiment
was about

406
00:23:02,400 --> 00:23:04,480
<font color="

407
00:23:04,480 --> 00:23:06,680
so we're setting up a second test...

408
00:23:07,960 --> 00:23:10,720
Hello? Can you hear me?
Yeah.

409
00:23:10,720 --> 00:23:12,880
..this time with ten guinea pigs

410
00:23:12,880 --> 00:23:16,960
who have no idea
what they're about to experience.

411
00:23:16,960 --> 00:23:21,240
We're giving each of them two
<font color="

412
00:23:21,240 --> 00:23:24,840
They have to tell us which
they think tastes sweeter.

413
00:23:26,080 --> 00:23:27,200
I'm ready.

414
00:23:27,200 --> 00:23:29,280
In fact, the chocolate is
exactly the same,

415
00:23:29,280 --> 00:23:32,960
but we're going to play
different music as they try it.

416
00:23:32,960 --> 00:23:34,600
First, a bitter track.

417
00:23:34,600 --> 00:23:36,000
<font color="

418
00:23:37,200 --> 00:23:40,200
REPETITIVE DEEP STACCATO BEATS

419
00:23:47,480 --> 00:23:49,480
OK, fading out.

420
00:23:51,000 --> 00:23:53,640
Then one of Charles' sweet tracks.

421
00:23:53,640 --> 00:23:56,440
LIGHT, GENTLE ORCHESTRAL TUNE

422
00:24:00,200 --> 00:24:03,280
Please could you show us
which chocolate you think

423
00:24:03,280 --> 00:24:04,680
was the sweeter chocolate?

424
00:24:04,680 --> 00:24:08,480
Two tasters realised
<font color="

425
00:24:08,480 --> 00:24:10,200
B.

426
00:24:10,200 --> 00:24:14,160
The other eight thought the second
chocolate tasted sweeter.

427
00:24:15,960 --> 00:24:19,640
How will they react when
they find out we've tricked them?

428
00:24:19,640 --> 00:24:21,520
They tasted really different.

429
00:24:21,520 --> 00:24:24,040
I'm a bit surprised.
It's crazy.

430
00:24:24,040 --> 00:24:27,360
<font color="

431
00:24:27,360 --> 00:24:30,520
So a great result
from our experiment,

432
00:24:30,520 --> 00:24:34,400
but does sonic seasoning have
a practical use?

433
00:24:34,400 --> 00:24:35,880
So the future of this theory

434
00:24:35,880 --> 00:24:38,440
is that it will influence what music
is played in restaurants.

435
00:24:38,440 --> 00:24:41,840
<font color="
in the Far East, in Beijing,

436
00:24:41,840 --> 00:24:45,440
where the management are actually
deliberately using sweet sounds

437
00:24:45,440 --> 00:24:48,840
all day long so that they can reduce
the sugar in their cakes and drinks,

438
00:24:48,840 --> 00:24:51,680
hopefully keep the experience
<font color="

439
00:24:51,680 --> 00:24:53,200
just the way they always like it,

440
00:24:53,200 --> 00:24:56,120
but with a little bit less of
the unhealthy stuff in there.

441
00:24:57,600 --> 00:25:01,520
So not only does sound contribute
to how we experience food,

442
00:25:01,520 --> 00:25:04,320
but it also has the potential
to help us follow

443
00:25:04,320 --> 00:25:06,440
<font color="

444
00:25:14,080 --> 00:25:15,480
Back in Borehamwood,

445
00:25:15,480 --> 00:25:18,320
our tasty filling has been maturing
for 24 hours,

446
00:25:18,320 --> 00:25:22,960
and now we're one day, two hours,
and 21 minutes into production.

447
00:25:28,120 --> 00:25:33,160
The sound of a factory hard at work
may not be ideal for eating pasta,

448
00:25:33,160 --> 00:25:35,200
<font color="

449
00:25:36,360 --> 00:25:38,400
So, down here, Gregg,

450
00:25:38,400 --> 00:25:41,080
this is my favourite part
of the factory.

451
00:25:42,920 --> 00:25:47,080
We're on our way to savour
the secrets of pasta production.

452
00:25:49,840 --> 00:25:54,440
This is the beginning of
our production line for raviolo.

453
00:25:54,440 --> 00:25:57,480
<font color="
is the first stage,

454
00:25:57,480 --> 00:26:00,080
where we're adding
the semolina flour.

455
00:26:00,080 --> 00:26:03,080
Yeah. What is semolina?

456
00:26:03,080 --> 00:26:06,560
It's flour made from durum wheat,
which is a different wheat strain

457
00:26:06,560 --> 00:26:10,120
to what the normal white soft flour
<font color="

458
00:26:10,120 --> 00:26:12,360
for bread and other things
in the UK.

459
00:26:12,360 --> 00:26:14,720
It has 30% more protein

460
00:26:14,720 --> 00:26:17,080
than you would expect
in your standard flours.

461
00:26:18,880 --> 00:26:22,600
When you mix flour and water, the
proteins within the flour combine

462
00:26:22,600 --> 00:26:26,000
<font color="
which turns it into dough.

463
00:26:26,000 --> 00:26:29,240
The more protein you have,
the more strands are formed,

464
00:26:29,240 --> 00:26:31,720
and the stronger your dough will be.

465
00:26:31,720 --> 00:26:36,800
And the factory needs a strong dough
to withstand the rigorous processes

466
00:26:36,800 --> 00:26:39,600
it puts it through to turn
<font color="

467
00:26:41,560 --> 00:26:44,080
You must go through
quite a few bags of semolina.

468
00:26:44,080 --> 00:26:46,000
I mean, how many do you use
on this line?

469
00:26:46,000 --> 00:26:47,880
So these are 25-kilo bags.

470
00:26:47,880 --> 00:26:51,760
We run through about six bags
an hour.

471
00:26:51,760 --> 00:26:53,320
What?!
Yeah.

472
00:26:53,320 --> 00:26:56,040
<font color="
is the factory going through?

473
00:26:56,040 --> 00:26:59,760
Every week, approximately
3,000 bags of semolina.

474
00:27:02,760 --> 00:27:06,000
As each bag is added,
the hopper vibrates,

475
00:27:06,000 --> 00:27:08,240
sending the semolina through a sieve

476
00:27:08,240 --> 00:27:10,880
before it's piped to the next stage
<font color="

477
00:27:13,880 --> 00:27:18,000
But to make fresh pasta dough,
there's another vital element.

478
00:27:19,520 --> 00:27:21,480
So this is our egg tank, Gregg.

479
00:27:21,480 --> 00:27:23,400
If we open it up
and have a quick look,

480
00:27:23,400 --> 00:27:28,480
you can see inside we've got our
golden liquid egg ready for the mix.

481
00:27:28,480 --> 00:27:31,720
<font color="
to the dough,

482
00:27:31,720 --> 00:27:35,280
which is really important
for the adhesion of the two sheets

483
00:27:35,280 --> 00:27:37,760
of pasta when you're
sticking them together.

484
00:27:37,760 --> 00:27:42,240
It adds a film over that really
does allow them to stick well.

485
00:27:42,240 --> 00:27:45,800
<font color="
pasta come direct to the factory

486
00:27:45,800 --> 00:27:47,360
in liquid form.

487
00:27:48,800 --> 00:27:52,000
We've got ten kilos
of pasteurised golden egg here.

488
00:27:52,000 --> 00:27:54,560
Isn't it ironic that
that top looks like a chicken?

489
00:27:54,560 --> 00:27:56,720
IMITATES CHICKEN SQUAWKS

490
00:27:56,720 --> 00:27:59,520
<font color="
that before. Have you not?

491
00:27:59,520 --> 00:28:02,200
I like this. It's kind of
bringing me out of my shell!

492
00:28:04,080 --> 00:28:07,520
Roughly per week, we'll go
through about 1,000 of those bags.

493
00:28:07,520 --> 00:28:09,520
Oh! Wow.

494
00:28:09,520 --> 00:28:11,200
How many kilos of eggs is that?

495
00:28:11,200 --> 00:28:12,920
<font color="

496
00:28:12,920 --> 00:28:15,600
That's a whole flock of chickens
just for our eggs.

497
00:28:15,600 --> 00:28:19,520
Does this yellow yolk also give
your pasta another golden hue? Yes.

498
00:28:19,520 --> 00:28:22,240
We actually feed the chickens
marigold petals...

499
00:28:22,240 --> 00:28:25,520
<font color="
Charlie, come on.

500
00:28:25,520 --> 00:28:28,480
So what it does, Gregg,
the bright yellow petals,

501
00:28:28,480 --> 00:28:31,880
they eat those, and their eggs
come out extra bright.

502
00:28:31,880 --> 00:28:34,200
If you have a look,
you'll see that's a lot more yellow,

503
00:28:34,200 --> 00:28:36,040
<font color="
than you would expect.

504
00:28:36,040 --> 00:28:37,960
Listen, son, look at me.
Is that true?

505
00:28:37,960 --> 00:28:40,360
Absolutely. Is that absolutely true?
Absolutely true.

506
00:28:41,680 --> 00:28:44,520
While egg is important
for making our fresh pasta,

507
00:28:44,520 --> 00:28:48,680
<font color="
is made by mixing just wheat

508
00:28:48,680 --> 00:28:52,280
and water and then evaporating
the water to leave a pasta

509
00:28:52,280 --> 00:28:54,320
that's 100% durum wheat.

510
00:28:56,400 --> 00:28:59,760
A lot of people think that fresh
pasta is superior to dried pasta.

511
00:28:59,760 --> 00:29:03,040
I just consider them as
<font color="

512
00:29:03,040 --> 00:29:04,920
Absolutely.
Very different products.

513
00:29:04,920 --> 00:29:10,720
So for me, dried pasta is there
to absorb really heavy, rich sauces.

514
00:29:10,720 --> 00:29:12,360
If you're having a filled pasta,

515
00:29:12,360 --> 00:29:14,600
you absolutely want it
to have egg in it.

516
00:29:14,600 --> 00:29:17,320
<font color="
and creates a nicer texture

517
00:29:17,320 --> 00:29:19,560
when you're actually biting through
the two layers.

518
00:29:21,360 --> 00:29:27,040
56 kilos of liquid egg,
along with 350 kilos of semolina,

519
00:29:27,040 --> 00:29:30,640
is pumped to a mixer
sitting above the production line.

520
00:29:30,640 --> 00:29:35,200
<font color="
everything comes together

521
00:29:35,200 --> 00:29:37,160
and goes into our mixer.

522
00:29:37,160 --> 00:29:42,880
Inside, metal paddles rotate
as the egg and semolina are dosed

523
00:29:42,880 --> 00:29:46,440
to an accuracy of
0.5 grams per kilogram

524
00:29:46,440 --> 00:29:51,120
before 70 litres of water is added
<font color="

525
00:29:51,120 --> 00:29:53,080
So this is our mix, right?
Yes.

526
00:29:53,080 --> 00:29:56,360
But that's not a finished dough,
is it? No, not at all.

527
00:29:56,360 --> 00:29:59,280
I have a little sample here
for us to have a look at.

528
00:29:59,280 --> 00:30:03,000
That is nothing like a dough
<font color="

529
00:30:03,000 --> 00:30:05,840
For a start, it's much denser,
much heavier,

530
00:30:05,840 --> 00:30:07,760
and it's also much drier.

531
00:30:07,760 --> 00:30:11,800
If I had to mix and knead this by
hand, I'd have forearms like Popeye.

532
00:30:11,800 --> 00:30:13,960
That's why you make it wetter
at home, generally.

533
00:30:13,960 --> 00:30:15,960
<font color="
of liquid

534
00:30:15,960 --> 00:30:17,720
to get the gluten proteins to bond.

535
00:30:17,720 --> 00:30:19,360
Ah!

536
00:30:19,360 --> 00:30:22,760
We make it wetter at home because we
simply wouldn't be able to knead it

537
00:30:22,760 --> 00:30:25,520
if it was that dense and strong.
Brilliant.

538
00:30:28,000 --> 00:30:31,360
The dough drops out of the mixer
<font color="

539
00:30:31,360 --> 00:30:35,200
machine which folds and kneads it
to make it stretchier.

540
00:30:36,280 --> 00:30:40,560
Then it passes through a set of
rollers and emerges as two separate,

541
00:30:40,560 --> 00:30:43,520
eight-millimetre thick,
continuous sheets.

542
00:30:46,040 --> 00:30:48,040
There it is, our sheets of pasta.

543
00:30:48,040 --> 00:30:51,040
<font color="
with your fingers

544
00:30:51,040 --> 00:30:54,000
and the heel of your palm...
Absolutely.

545
00:30:54,000 --> 00:30:55,920
..is happening inside that box.

546
00:30:55,920 --> 00:30:59,400
It gets folded over 52 times
like you would do by hand,

547
00:30:59,400 --> 00:31:01,800
just a lot more pressure
and a lot quicker.

548
00:31:01,800 --> 00:31:04,400
<font color="
AND the bottom. Yes, we do.

549
00:31:04,400 --> 00:31:06,320
I'm guessing you're going to
put them together

550
00:31:06,320 --> 00:31:07,760
with the filling in the middle.

551
00:31:07,760 --> 00:31:10,720
We put the filling in between and
adhere them together. Brilliant.

552
00:31:10,720 --> 00:31:12,760
<font color="
that is, though, mate.

553
00:31:12,760 --> 00:31:15,480
I mean, right now that looks
like underlay!

554
00:31:15,480 --> 00:31:18,560
If you try and turn it
straight into a really thin sheet,

555
00:31:18,560 --> 00:31:20,480
you're going to end up
with little holes

556
00:31:20,480 --> 00:31:22,520
or just thinner
<font color="

557
00:31:22,520 --> 00:31:25,000
It goes through a thinning section,

558
00:31:25,000 --> 00:31:27,760
through these two thick
steel rollers,

559
00:31:27,760 --> 00:31:31,920
that take it from 8mm
to about 3mm, then down to 0.6.

560
00:31:34,760 --> 00:31:37,440
While Charlie's pasta know-how
is impressive,

561
00:31:37,440 --> 00:31:39,480
the techniques they use here

562
00:31:39,480 --> 00:31:43,000
<font color="
pasta-making itself, Italy.

563
00:31:44,640 --> 00:31:47,920
And this knowledge has been passed
down through Charlie's family

564
00:31:47,920 --> 00:31:49,640
for generations.

565
00:31:49,640 --> 00:31:51,640
You make so many pastas here?

566
00:31:51,640 --> 00:31:54,320
Do you know when it started?
What's the history?

567
00:31:54,320 --> 00:31:57,800
<font color="
my great-grandfather, Luigi,

568
00:31:57,800 --> 00:32:02,440
left his home in Italy when he was
14 years old to come to the UK.

569
00:32:02,440 --> 00:32:04,760
He came over for finishing school,

570
00:32:04,760 --> 00:32:07,840
finished his education,
and then stayed in the UK

571
00:32:07,840 --> 00:32:10,360
working at a deli
<font color="

572
00:32:10,360 --> 00:32:15,440
So that's actually how the company
started officially in 1929,

573
00:32:15,440 --> 00:32:17,960
in Gerrard Street
in what is now Soho.

574
00:32:19,320 --> 00:32:22,360
So, Gregg, this is
my great-great-aunt

575
00:32:22,360 --> 00:32:26,240
making spaghetti back in
the early '30s.

576
00:32:26,240 --> 00:32:29,320
<font color="
in the window of the deli

577
00:32:29,320 --> 00:32:31,400
so that everyone walking by
could see,

578
00:32:31,400 --> 00:32:34,120
have a bit of interaction
with the public.

579
00:32:34,120 --> 00:32:37,520
Charlie, do you feel a link with
Luigi, your great-great-grandfather?

580
00:32:37,520 --> 00:32:40,280
<font color="
the tradition? Absolutely.

581
00:32:40,280 --> 00:32:43,120
Whilst I don't feel the same, Gregg,
I was not born in Italy,

582
00:32:43,120 --> 00:32:46,360
I was born in the UK,
I'm a British man.

583
00:32:46,360 --> 00:32:50,240
However, I feel very intricately
linked to the history

584
00:32:50,240 --> 00:32:53,080
<font color="
particularly around pasta

585
00:32:53,080 --> 00:32:55,680
and cuisine and Italian food
in the UK.

586
00:32:55,680 --> 00:32:58,640
That's fantastic.
Mate, what a heritage!

587
00:33:04,720 --> 00:33:08,600
We know that migrants from Italy
have made a wonderful contribution

588
00:33:08,600 --> 00:33:10,000
to the British diet.

589
00:33:10,000 --> 00:33:13,120
<font color="
and pizza?

590
00:33:13,120 --> 00:33:16,320
But Ruth's been discovering
the lesser-known story

591
00:33:16,320 --> 00:33:20,640
of how Italians helped to build
modern Britain, literally.

592
00:33:26,280 --> 00:33:29,920
Many places in the UK
have thriving Italian communities.

593
00:33:32,480 --> 00:33:34,280
Ciao.
<font color="

594
00:33:34,280 --> 00:33:36,880
Can I have a double espresso,
please? Course you can.

595
00:33:36,880 --> 00:33:39,520
And the influence
of those sunny shores

596
00:33:39,520 --> 00:33:41,720
is evident on most high streets.

597
00:33:41,720 --> 00:33:44,240
But there's a contender
for the title

598
00:33:44,240 --> 00:33:46,480
<font color="

599
00:33:46,480 --> 00:33:48,960
that might come as a bit
of a surprise.

600
00:33:48,960 --> 00:33:51,200
Welcome to Bedford.

601
00:33:54,600 --> 00:33:58,080
To find out more about this
little Italy in the east of England,

602
00:33:58,080 --> 00:34:01,520
where one in five people
have Italian roots,

603
00:34:01,520 --> 00:34:03,920
<font color="

604
00:34:03,920 --> 00:34:06,040
ITALIAN NATIONAL ANTHEM PLAYS

605
00:34:06,040 --> 00:34:08,760
Hello!
Hello. Welcome to Bedford.

606
00:34:10,360 --> 00:34:14,720
So why does Bedford have
such a large Italian community?

607
00:34:14,720 --> 00:34:17,800
Well, Ruth, it's all about this.

608
00:34:17,800 --> 00:34:20,400
A brick?
A brick, yes.

609
00:34:20,400 --> 00:34:23,840
<font color="
as it is embossed on it.

610
00:34:23,840 --> 00:34:26,760
And it was made
by London Brick Company,

611
00:34:26,760 --> 00:34:29,640
a large brickworks
based in Bedfordshire.

612
00:34:29,640 --> 00:34:32,200
And they made millions of
these bricks.

613
00:34:33,960 --> 00:34:36,800
The Stewartby Brickworks,
<font color="

614
00:34:36,800 --> 00:34:40,600
was the centre of the UK's
brick-making industry

615
00:34:40,600 --> 00:34:42,520
for over half a century.

616
00:34:42,520 --> 00:34:45,400
Located just a few miles
south of Bedford,

617
00:34:45,400 --> 00:34:48,720
it took advantage of
huge clay deposits

618
00:34:48,720 --> 00:34:54,240
laid down over 150 million years
<font color="

619
00:34:54,240 --> 00:34:58,600
So we've got some pictures here
of the brickworks itself.

620
00:34:58,600 --> 00:35:00,240
Look at all those chimneys!
Yes.

621
00:35:00,240 --> 00:35:03,040
You really start to see the scale
of it, don't you, here,

622
00:35:03,040 --> 00:35:04,280
in these images?
Yes.

623
00:35:04,280 --> 00:35:08,600
<font color="
18 million bricks a week.

624
00:35:08,600 --> 00:35:10,000
A week?!
A week.

625
00:35:10,000 --> 00:35:14,920
And 20% of all of the bricks
that were being used to make houses

626
00:35:14,920 --> 00:35:17,040
were coming from Bedfordshire.

627
00:35:17,040 --> 00:35:19,480
For the whole of Britain?
For the whole of Britain.

628
00:35:19,480 --> 00:35:22,840
<font color="
of Britain after the war,

629
00:35:22,840 --> 00:35:26,200
and of course, in order to do that,
they needed manpower.

630
00:35:26,200 --> 00:35:28,440
That's where the Italians
got involved.

631
00:35:28,440 --> 00:35:32,440
So this is part, I suppose,
of a wider policy of

632
00:35:32,440 --> 00:35:35,560
<font color="
assistance to help rebuild Britain.

633
00:35:35,560 --> 00:35:40,120
So why was it Italy in particular
that the brickworks were looking?

634
00:35:40,120 --> 00:35:42,840
They were actually struggling
with unemployment, particularly

635
00:35:42,840 --> 00:35:45,760
in the southern part of Italy,
<font color="

636
00:35:45,760 --> 00:35:47,880
So offices were set up in Naples,

637
00:35:47,880 --> 00:35:50,800
and people would come from
the surrounding areas

638
00:35:50,800 --> 00:35:54,440
looking for four-year contracts
to work in the London Brick Company,

639
00:35:54,440 --> 00:35:56,800
making the bricks here in the UK.

640
00:35:56,800 --> 00:35:58,800
So how many people
<font color="

641
00:35:58,800 --> 00:36:02,600
Well, by 1960,
over about eight years,

642
00:36:02,600 --> 00:36:06,720
there was now 7,500 Italians
working in the brickworks

643
00:36:06,720 --> 00:36:08,000
in Bedfordshire.

644
00:36:09,760 --> 00:36:12,960
A huge number considering
the population of Bedford then

645
00:36:12,960 --> 00:36:14,920
was just 60,000.

646
00:36:17,600 --> 00:36:20,800
<font color="
for those early arrivals,

647
00:36:20,800 --> 00:36:22,960
I'm meeting Liberato Albanese.

648
00:36:22,960 --> 00:36:24,480
DOORBELL RINGS

649
00:36:24,480 --> 00:36:27,200
Hello. Hello!
I'm glad you made it!

650
00:36:27,200 --> 00:36:29,480
Come in, come in, come in.

651
00:36:31,480 --> 00:36:35,000
He came to the works as
<font color="

652
00:36:36,960 --> 00:36:39,880
..and his friend,
Salvatore Garganese...

653
00:36:39,880 --> 00:36:43,680
Hello. I'm Salvatore.
Salvatore. Or Sav for short.

654
00:36:45,360 --> 00:36:48,560
..whose family joined his father
here in 1960.

655
00:36:49,920 --> 00:36:51,840
Oh, look at these.
<font color="

656
00:36:51,840 --> 00:36:54,120
Yeah, it's all my family here.

657
00:36:54,120 --> 00:36:56,920
I am on top there, myself.

658
00:36:56,920 --> 00:36:58,480
As a young man.
Yeah.

659
00:36:58,480 --> 00:37:02,400
That one over there, all of these,
my brothers on top of there.

660
00:37:02,400 --> 00:37:03,840
I was 17.

661
00:37:03,840 --> 00:37:07,760
So why did you come to Britain
<font color="

662
00:37:07,760 --> 00:37:10,320
We are very poor people.
Yeah.

663
00:37:10,320 --> 00:37:14,760
We work on a farm, and we work
with the cows, with the sheep.

664
00:37:14,760 --> 00:37:16,560
No money there.

665
00:37:16,560 --> 00:37:18,840
How old were you, Salvatore,
when you arrived?

666
00:37:18,840 --> 00:37:20,120
I was ten years old.

667
00:37:20,120 --> 00:37:23,560
<font color="
ten-year-old coming to Britain?

668
00:37:23,560 --> 00:37:26,840
My first impression
when I came here - oh, my gosh!

669
00:37:28,040 --> 00:37:30,240
School dinners.

670
00:37:28,040 --> 00:37:30,240
RUTH LAUGHS

671
00:37:30,240 --> 00:37:34,520
The sort of food that was used to
the English school dinners they did,

672
00:37:34,520 --> 00:37:36,640
<font color="

673
00:37:40,640 --> 00:37:44,480
There are now more than
14,000 people in Bedford

674
00:37:44,480 --> 00:37:47,600
descended from that first generation
of arrivals.

675
00:37:47,600 --> 00:37:49,840
This footage of Italian men
in the brickworks

676
00:37:49,840 --> 00:37:51,840
was shot in the 1950s.

677
00:37:53,560 --> 00:37:56,760
That's it.
<font color="

678
00:37:56,760 --> 00:37:58,320
They used to do it by hand.

679
00:38:00,480 --> 00:38:01,920
My dad had the Lambretta.

680
00:38:01,920 --> 00:38:04,040
Looking at that guy
on that Lambretta,

681
00:38:04,040 --> 00:38:06,640
I wouldn't be surprised
if that was him.

682
00:38:06,640 --> 00:38:09,920
And this is obviously, they probably
<font color="

683
00:38:09,920 --> 00:38:12,000
Now we're going to fetch money now.

684
00:38:12,000 --> 00:38:15,320
FILM: Plenty of work means
plenty of money.

685
00:38:15,320 --> 00:38:18,360
Money to send home to their family
in Italy...

686
00:38:18,360 --> 00:38:20,080
Yeah. That's true.

687
00:38:21,720 --> 00:38:25,040
So what was the work like
at the brickyards?

688
00:38:25,040 --> 00:38:28,520
<font color="

689
00:38:28,520 --> 00:38:30,560
because I had a good job.

690
00:38:32,120 --> 00:38:35,720
But the other people -
very, very hard.

691
00:38:35,720 --> 00:38:39,200
They certainly did their fair share
for this town.

692
00:38:39,200 --> 00:38:42,680
Made life a lot easier
for my generation,

693
00:38:42,680 --> 00:38:46,120
<font color="
better for the next generation.

694
00:38:48,440 --> 00:38:51,800
The last of Bedford's brickworks
closed in 2008...

695
00:38:53,640 --> 00:38:57,200
..but the thriving
Italian community remains.

696
00:38:57,200 --> 00:38:59,920
And whilst they're running
very different businesses,

697
00:38:59,920 --> 00:39:03,400
<font color="
of how our European cousins

698
00:39:03,400 --> 00:39:05,280
helped to rebuild Britain.

699
00:39:16,600 --> 00:39:20,360
44 miles from Bedford,
at the factory in Borehamwood,

700
00:39:20,360 --> 00:39:22,800
the recipe they use
to make their pasta

701
00:39:22,800 --> 00:39:25,040
owes a lot to that Italian heritage.

702
00:39:31,080 --> 00:39:35,760
<font color="
kneaded and rolled,

703
00:39:35,760 --> 00:39:37,080
my two sheets of pasta

704
00:39:37,080 --> 00:39:39,840
are travelling along
the production line.

705
00:39:41,040 --> 00:39:43,880
Now it's time to add
our fishy filling.

706
00:39:46,600 --> 00:39:49,920
OK, so here is where our filling
from earlier,

707
00:39:49,920 --> 00:39:52,120
<font color="

708
00:39:52,120 --> 00:39:55,080
What weight of filling do you have
for every raviolo?

709
00:39:55,080 --> 00:39:59,280
So every raviolo has approximately
15g of filling inside. Right.

710
00:39:59,280 --> 00:40:05,600
And every hour, we go through about
two of the batches we made earlier,

711
00:40:05,600 --> 00:40:09,680
<font color="
of filling an hour. Wow.

712
00:40:09,680 --> 00:40:14,480
So this pump will now pump our
filling into the production line

713
00:40:14,480 --> 00:40:16,640
and join the pasta from earlier.

714
00:40:19,240 --> 00:40:21,000
It's raviolo time.

715
00:40:22,200 --> 00:40:26,640
The two pasta sheets enter
a stuffed pasta forming machine,

716
00:40:26,640 --> 00:40:30,480
<font color="
is pumped in to meet them.

717
00:40:32,440 --> 00:40:35,760
Well, that, my friend,
is a lovely sight.

718
00:40:35,760 --> 00:40:38,040
Absolutely.
There we have filled raviolo.

719
00:40:39,160 --> 00:40:42,840
So what happens here,
we get our two sheets from before,

720
00:40:42,840 --> 00:40:46,520
<font color="
to 0.6 millimetres per sheet.

721
00:40:46,520 --> 00:40:51,680
Those two sheets come in a V-shape
together, and we have that filling,

722
00:40:51,680 --> 00:40:55,560
it's gone through that pump,
coming to a set of spines.

723
00:40:55,560 --> 00:41:01,280
Those spines go up and down
and actually inject a small quantity

724
00:41:01,280 --> 00:41:05,160
<font color="
sheets, at the correct position,

725
00:41:05,160 --> 00:41:06,600
for multiple passes.

726
00:41:09,400 --> 00:41:10,920
With the filling in the middle,

727
00:41:10,920 --> 00:41:13,960
the two pasta sheets are rolled
through steel moulds,

728
00:41:13,960 --> 00:41:17,640
which press them together,
cutting out the parcel shapes.

729
00:41:22,120 --> 00:41:24,840
<font color="
at home, I must admit.

730
00:41:24,840 --> 00:41:28,440
But you often water the edge
to make it stick. Do you do that?

731
00:41:28,440 --> 00:41:32,200
We don't. In the way that
we've created that lovely rich

732
00:41:32,200 --> 00:41:35,800
egg protein in the mix before,
the adhesion is ready,

733
00:41:35,800 --> 00:41:38,240
<font color="

734
00:41:38,240 --> 00:41:41,120
And it looks like little fork marks
around the edge.

735
00:41:41,120 --> 00:41:43,240
You're making it look home-made.
Exactly.

736
00:41:43,240 --> 00:41:45,760
And that's the whole point,
is to try and simulate what you do

737
00:41:45,760 --> 00:41:49,600
at home, Gregg, and also that each
<font color="

738
00:41:49,600 --> 00:41:52,360
to give you that more artisanal
feel. Rustica!

739
00:41:52,360 --> 00:41:55,720
You're making it look rustic.
You clever boy!

740
00:41:55,720 --> 00:41:57,320
Oh, I do like that.

741
00:41:57,320 --> 00:41:59,440
How fast are you making these?

742
00:41:59,440 --> 00:42:01,840
We make 280 a minute, approximately.

743
00:42:04,200 --> 00:42:06,880
<font color="
and formed,

744
00:42:06,880 --> 00:42:10,600
any excess pasta is reworked
back into the start

745
00:42:10,600 --> 00:42:12,960
of the pasta-making process.

746
00:42:12,960 --> 00:42:17,080
Then hundreds of stuffed raviolo
travel along a conveyor

747
00:42:17,080 --> 00:42:20,400
and into an intriguing looking
tunnel.

748
00:42:20,400 --> 00:42:22,840
<font color="
here we have the next stage,

749
00:42:22,840 --> 00:42:24,680
which is pasteurisation.

750
00:42:24,680 --> 00:42:26,520
Pasta-isation!

751
00:42:26,520 --> 00:42:28,360
Pasta-isation.

752
00:42:29,640 --> 00:42:33,320
Inside the tunnel,
the parcels are sprayed with steam

753
00:42:33,320 --> 00:42:36,400
that heats the core
to 85 degrees Celsius

754
00:42:36,400 --> 00:42:41,760
<font color="
a process known as pasteurisation.

755
00:42:41,760 --> 00:42:45,240
There are two major reasons
why we pasteurise pasta.

756
00:42:45,240 --> 00:42:49,720
So firstly, it's to kill microbial
activity inside the filling

757
00:42:49,720 --> 00:42:51,360
and on the pastry itself.

758
00:42:51,360 --> 00:42:55,280
We now have pasta
<font color="

759
00:42:55,280 --> 00:42:57,680
whereas obviously it would be about
one or two days

760
00:42:57,680 --> 00:42:59,560
before pasteurisation existed.

761
00:42:59,560 --> 00:43:03,440
So we've got to kill that microbial
activity so that when we then

762
00:43:03,440 --> 00:43:05,720
pack the product,
there's no risk of anything growing

763
00:43:05,720 --> 00:43:07,480
<font color="

764
00:43:07,480 --> 00:43:09,280
It's safe, this pasteurisation,

765
00:43:09,280 --> 00:43:11,560
but it also gives you
a bigger shelf life. Indeed.

766
00:43:11,560 --> 00:43:14,440
Without putting any chemicals in,
any preservatives. Absolutely.

767
00:43:14,440 --> 00:43:17,840
However, there is another
<font color="

768
00:43:17,840 --> 00:43:22,000
The gluten bonds that we created
while kneading

769
00:43:22,000 --> 00:43:25,400
still don't make the pasta
strong enough for all the travel

770
00:43:25,400 --> 00:43:28,240
and all of the processing
that it's going to go through.

771
00:43:28,240 --> 00:43:31,400
We can actually see one of the
<font color="

772
00:43:31,400 --> 00:43:33,800
It's filled, it's sealed,
it's formed,

773
00:43:33,800 --> 00:43:35,400
but it's weak. You stretch it a bit

774
00:43:35,400 --> 00:43:38,280
and you're going to damage the
pasta. It's going to fall apart.

775
00:43:38,280 --> 00:43:39,680
That's now ruined.

776
00:43:39,680 --> 00:43:42,200
So we need to do something
to protect it

777
00:43:42,200 --> 00:43:44,080
<font color="

778
00:43:44,080 --> 00:43:48,840
So the pasteurisation process
actually seals the outside

779
00:43:48,840 --> 00:43:52,760
of the pasta to ensure, number one,
that no filling seeps out,

780
00:43:52,760 --> 00:43:54,360
but also that it lasts.

781
00:43:56,320 --> 00:43:58,880
As the parcels travel
through the tunnel,

782
00:43:58,880 --> 00:44:03,040
<font color="
absorb water from the steam,

783
00:44:03,040 --> 00:44:05,080
causing them to form a gel.

784
00:44:07,720 --> 00:44:12,480
This gelatinisation sets
the gluten strands within the dough,

785
00:44:12,480 --> 00:44:16,240
holding them in place
and stabilising the pasta's shape.

786
00:44:18,280 --> 00:44:23,280
So this pasteurisation tunnel,
<font color="

787
00:44:23,280 --> 00:44:26,600
It's not warm. Oh, it is a little
bit. On the outside, it's insulated,

788
00:44:26,600 --> 00:44:29,720
but there's 95 degree-plus steam
inside there.

789
00:44:31,720 --> 00:44:33,680
Well, you can feel the heat.
Absolutely.

790
00:44:33,680 --> 00:44:35,960
And you can see the amount
<font color="

791
00:44:35,960 --> 00:44:37,440
on the outside of that.

792
00:44:37,440 --> 00:44:39,440
They almost look partly cooked.

793
00:44:39,440 --> 00:44:41,800
They're getting that kind of
wrinkly texture. Exactly.

794
00:44:41,800 --> 00:44:43,680
They're starting to partially cook.

795
00:44:43,680 --> 00:44:47,080
So we have achieved
core pasteurization temperature.

796
00:44:47,080 --> 00:44:50,200
<font color="
off of the belt here...

797
00:44:50,200 --> 00:44:52,200
Heat?
Heat. Very hot.

798
00:44:52,200 --> 00:44:54,440
So you can see it's much stronger.

799
00:44:54,440 --> 00:44:57,080
It doesn't fall apart
like it did before. Ah.

800
00:44:57,080 --> 00:44:59,840
However, there is a problem,

801
00:44:59,840 --> 00:45:01,720
<font color="

802
00:45:01,720 --> 00:45:04,360
So what I'll do -
I'll do that and you'll see...

803
00:45:05,520 --> 00:45:07,720
Can I have a go next?
Please, please... Of course.

804
00:45:07,720 --> 00:45:10,120
..can I have a go?
Please, please!

805
00:45:10,120 --> 00:45:12,320
Please. So if you grab one
<font color="

806
00:45:12,320 --> 00:45:13,760
It is hot. Be careful.

807
00:45:13,760 --> 00:45:16,280
And it sticks!

808
00:45:13,760 --> 00:45:16,280
GREGG SCREAMS, LAUGHS

809
00:45:16,280 --> 00:45:17,960
Wahey!
There we go.

810
00:45:17,960 --> 00:45:20,400
See? That sticks.
And that is a problem.

811
00:45:20,400 --> 00:45:21,720
GREGG LAUGHS

812
00:45:21,720 --> 00:45:23,920
<font color="
you'd do with spaghetti.

813
00:45:23,920 --> 00:45:26,080
The flick on the ceiling thing
is a real test.

814
00:45:26,080 --> 00:45:28,360
I've never flung spaghetti
in me life.

815
00:45:28,360 --> 00:45:31,000
You've got to.
It's the real way to check.

816
00:45:31,000 --> 00:45:33,040
I know that starch
<font color="

817
00:45:33,040 --> 00:45:36,880
So that is now starch gelatinised,
complete pasteurization,

818
00:45:36,880 --> 00:45:40,120
but it's now too sticky to go round
the rest of the line.

819
00:45:40,120 --> 00:45:41,520
So what do you have to do?

820
00:45:41,520 --> 00:45:45,680
So what we do is we send it back
underneath the pasteurisation tunnel

821
00:45:45,680 --> 00:45:47,320
<font color="

822
00:45:47,320 --> 00:45:50,800
going through a drying section
of about 50 degrees,

823
00:45:50,800 --> 00:45:53,920
really dry heat.
All of the moisture is removed,

824
00:45:53,920 --> 00:45:57,440
and we can see that if we grab
one of these parcels here,

825
00:45:57,440 --> 00:46:00,960
there's almost no moisture on that,
<font color="

826
00:46:00,960 --> 00:46:02,560
It's much less sticky than it was

827
00:46:02,560 --> 00:46:04,680
coming out of that
tunnel pasteurization.

828
00:46:04,680 --> 00:46:06,200
Give it a flick at the wall.

829
00:46:07,800 --> 00:46:09,960
It doesn't stick any more.
We know it's dry.

830
00:46:09,960 --> 00:46:11,720
It's ready to be processed.

831
00:46:11,720 --> 00:46:14,800
<font color="
I've ever had in a factory.

832
00:46:17,680 --> 00:46:21,440
What I like about this procedure,
even though it's on a big scale,

833
00:46:21,440 --> 00:46:24,240
it always looks like dinner
all the way through.

834
00:46:25,440 --> 00:46:27,080
It just looks like cooking.

835
00:46:33,320 --> 00:46:37,880
My dry raviolo are transported
<font color="

836
00:46:37,880 --> 00:46:40,880
into a chiller where they're held
for 25 minutes.

837
00:46:42,880 --> 00:46:46,280
Inside, the parcels'
core temperature drops

838
00:46:46,280 --> 00:46:48,640
to below four degrees Celsius,

839
00:46:48,640 --> 00:46:51,960
helping to solidify
the gelatinised starch

840
00:46:51,960 --> 00:46:54,080
<font color="

841
00:46:56,160 --> 00:46:59,800
Gluten is vital for binding
our pasta dough together,

842
00:46:59,800 --> 00:47:05,600
but it's estimated that 8% of the
UK is intolerant or allergic to it.

843
00:47:05,600 --> 00:47:08,160
Ruth's been discovering
the surprising way

844
00:47:08,160 --> 00:47:11,000
that gluten-free products
<font color="

845
00:47:14,200 --> 00:47:18,160
Nowadays, there's a huge range
of gluten-free food,

846
00:47:18,160 --> 00:47:19,880
from pasta

847
00:47:19,880 --> 00:47:21,360
to cakes and bread.

848
00:47:22,840 --> 00:47:27,280
The products available today look
much like their wheat counterparts,

849
00:47:27,280 --> 00:47:29,200
but it wasn't always that way.

850
00:47:31,120 --> 00:47:33,360
<font color="

851
00:47:33,360 --> 00:47:37,120
a pioneer in bringing
gluten-free food to our shelves.

852
00:47:39,080 --> 00:47:42,560
Hello, Chris. Ruth, good to meet
you. Good to meet you, too.

853
00:47:42,560 --> 00:47:46,520
We've all heard of
a gluten-free diet these days,

854
00:47:46,520 --> 00:47:49,520
<font color="
to realise

855
00:47:49,520 --> 00:47:52,040
that gluten was a health issue?

856
00:47:52,040 --> 00:47:56,000
It goes back, really, to the 19th
century, when there was an awareness

857
00:47:56,000 --> 00:47:58,400
that some of the children
were not thriving.

858
00:47:58,400 --> 00:48:00,400
What do we mean by "not thriving"?

859
00:48:00,400 --> 00:48:03,120
<font color="
Feeling very lethargic.

860
00:48:03,120 --> 00:48:07,760
Literally 30% of children
with the problem didn't survive.

861
00:48:07,760 --> 00:48:10,280
I mean, that's...that's quite
staggering, isn't it?

862
00:48:10,280 --> 00:48:12,960
But what it actually was,
people were unclear.

863
00:48:14,400 --> 00:48:18,800
<font color="
disease, was first linked to diet

864
00:48:18,800 --> 00:48:23,000
by British doctor Samuel Gee
in 1887,

865
00:48:23,000 --> 00:48:28,120
but he wasn't able to establish
what food was causing the condition.

866
00:48:29,640 --> 00:48:34,600
Then, during World War II, severe
hunger caused by the Nazi occupation

867
00:48:34,600 --> 00:48:37,280
<font color="
prompted a paediatrician

868
00:48:37,280 --> 00:48:39,480
to make an important breakthrough.

869
00:48:39,480 --> 00:48:43,440
So in 1944-45,
there was a Nazi blockade.

870
00:48:43,440 --> 00:48:45,080
There was no bread getting through.

871
00:48:45,080 --> 00:48:48,360
And there was a children's doctor
called Dr Willem Dicke.

872
00:48:48,360 --> 00:48:51,120
<font color="
with coeliac disease.

873
00:48:51,120 --> 00:48:53,480
So, Ruth, you can see from these
photographs,

874
00:48:53,480 --> 00:48:56,240
clearly going hungry
during the famine. Yeah.

875
00:48:56,240 --> 00:48:58,480
And because they couldn't
give them any bread,

876
00:48:58,480 --> 00:49:00,760
<font color="
other products to eat,

877
00:49:00,760 --> 00:49:03,560
they suddenly found that
they started to thrive

878
00:49:03,560 --> 00:49:06,560
and they actually felt a lot better.

879
00:49:06,560 --> 00:49:09,400
And he then realised that it was
the gluten in the wheat

880
00:49:09,400 --> 00:49:10,840
that was causing the problem.

881
00:49:10,840 --> 00:49:13,760
<font color="
of someone with coeliac disease?

882
00:49:13,760 --> 00:49:17,280
There's a protein within gluten,
gliadin, that is triggering off

883
00:49:17,280 --> 00:49:20,960
this antibody, and that attacks
the gut lining.

884
00:49:20,960 --> 00:49:23,000
In a coeliac, if it goes untreated,

885
00:49:23,000 --> 00:49:26,600
the consequence of that is that,
<font color="

886
00:49:26,600 --> 00:49:29,080
everything just flows through.
So you're not absorbing...

887
00:49:29,080 --> 00:49:32,560
You can't absorb any goodness from
the rest of your food. Precisely.

888
00:49:32,560 --> 00:49:35,040
So you might be eating as much,
huge amounts, and basically

889
00:49:35,040 --> 00:49:37,520
<font color="
it's just passing through. Yeah.

890
00:49:37,520 --> 00:49:41,360
That's true. So is there a
difference, then, between coeliac

891
00:49:41,360 --> 00:49:43,640
and gluten intolerant?
Oh, yeah.

892
00:49:43,640 --> 00:49:48,320
A lot of people who feel they have
<font color="

893
00:49:48,320 --> 00:49:52,960
can moderate their intake
of gluten and feel OK.

894
00:49:52,960 --> 00:49:54,440
The big difference is,

895
00:49:54,440 --> 00:49:57,760
you can feel unwell,
but it's not life-threatening.

896
00:49:57,760 --> 00:50:00,480
It's not as acute
as coeliac disease.

897
00:50:01,920 --> 00:50:04,760
Gluten is found in grains
<font color="

898
00:50:04,760 --> 00:50:08,320
used to make many
of our everyday foods.

899
00:50:08,320 --> 00:50:11,480
The challenge was to find
alternatives for those who needed

900
00:50:11,480 --> 00:50:14,200
to exclude it from their diet,

901
00:50:14,200 --> 00:50:18,160
and the first gluten-free product
to emerge in Britain was bread.

902
00:50:20,040 --> 00:50:24,920
<font color="
oversees their gluten-free range.

903
00:50:27,080 --> 00:50:29,920
So the early '60s,
there was a small company

904
00:50:29,920 --> 00:50:34,280
producing gluten-free bread, and it
actually came in a tin. In a tin?

905
00:50:34,280 --> 00:50:37,960
Can you believe it? In a tin.
<font color="

906
00:50:37,960 --> 00:50:41,120
And that was the only gluten-free
bread that was available for anybody

907
00:50:41,120 --> 00:50:43,920
who was diagnosed with
coeliac disease.

908
00:50:43,920 --> 00:50:46,040
They were available on prescription.

909
00:50:46,040 --> 00:50:48,760
As a coeliac, you just cannot
<font color="

910
00:50:50,240 --> 00:50:53,720
Gluten-free bread relied
on wheat alternatives

911
00:50:53,720 --> 00:50:55,680
like rice and tapioca flour.

912
00:50:57,200 --> 00:51:01,160
And this was steamed in tins,
very much like a pudding.

913
00:51:02,400 --> 00:51:04,440
So is this very different

914
00:51:04,440 --> 00:51:07,280
from how we make
<font color="

915
00:51:07,280 --> 00:51:09,880
Oh, very different. We actually
managed to achieve a dough,

916
00:51:09,880 --> 00:51:11,240
a gluten-free dough.

917
00:51:11,240 --> 00:51:13,520
We're also using slightly
different ingredients.

918
00:51:13,520 --> 00:51:15,840
So, for example, we're using
psyllium... What's that?

919
00:51:15,840 --> 00:51:17,800
<font color="

920
00:51:17,800 --> 00:51:21,800
A lot of the food technologists
and innovation guys that work on

921
00:51:21,800 --> 00:51:25,080
our products say it's more like
chemistry than traditional baking.

922
00:51:28,400 --> 00:51:30,240
The moment of truth.

923
00:51:30,240 --> 00:51:33,840
So this is the 1960s
coeliac experience.

924
00:51:33,840 --> 00:51:35,760
<font color="
Do you want to press it out?

925
00:51:35,760 --> 00:51:37,280
Oh, yeah. There it goes.

926
00:51:37,280 --> 00:51:38,760
And then...

927
00:51:38,760 --> 00:51:41,720
Yeah. Keep going, keep going.
Whoa! There you go.

928
00:51:41,720 --> 00:51:43,920
Tinned bread.
What do you think of that, Ruth?

929
00:51:43,920 --> 00:51:46,200
<font color="
it like bread?

930
00:51:46,200 --> 00:51:49,400
We... We could do that, but the
majority of people toast it

931
00:51:49,400 --> 00:51:52,720
before you eat it. It just makes it
a little bit more pleasant.

932
00:51:52,720 --> 00:51:55,080
In comparison to modern
gluten-free bread,

933
00:51:55,080 --> 00:51:57,840
<font color="
beast, isn't it?

934
00:51:57,840 --> 00:51:59,520
Yeah. I mean, talk about retro.

935
00:51:59,520 --> 00:52:03,160
I mean, this is just lightyears away
from where we are now.

936
00:52:05,240 --> 00:52:08,560
It wasn't until the 1980s
that new gluten-free products

937
00:52:08,560 --> 00:52:11,640
like pasta were also made available
<font color="

938
00:52:11,640 --> 00:52:15,080
and another decade before they
started appearing in grocery shops,

939
00:52:15,080 --> 00:52:18,560
setting the bar for a host
of modern day options

940
00:52:18,560 --> 00:52:21,000
available in supermarkets today.

941
00:52:22,480 --> 00:52:24,440
I'm just so proud of
where it's come to,

942
00:52:24,440 --> 00:52:26,200
<font color="

943
00:52:26,200 --> 00:52:28,280
and I think there's a lot more
we can do.

944
00:52:28,280 --> 00:52:31,440
And it all begins with a tin.
Doesn't it just?

945
00:52:40,840 --> 00:52:42,440
Back at the factory,

946
00:52:42,440 --> 00:52:45,840
they also make their own range
of gluten-free pasta,

947
00:52:45,840 --> 00:52:49,280
but my gluten option,
<font color="

948
00:52:49,280 --> 00:52:51,600
is still one of the most popular.

949
00:52:54,960 --> 00:52:58,560
It's been filled, pasteurised,
and cooled.

950
00:52:58,560 --> 00:53:01,280
Now my parcels are sent
from the fridges,

951
00:53:01,280 --> 00:53:03,640
along conveyors, to packing...

952
00:53:09,200 --> 00:53:12,120
..where I'm meeting Sheila Isnard.

953
00:53:12,120 --> 00:53:15,200
<font color="
Hello, Gregg.

954
00:53:15,200 --> 00:53:17,480
You've got some great
bits of machinery in here.

955
00:53:17,480 --> 00:53:18,800
Oh, I do indeed.

956
00:53:18,800 --> 00:53:21,480
Tell me about the packing process.
OK.

957
00:53:21,480 --> 00:53:24,240
So above us we have
a multihead weigher,

958
00:53:24,240 --> 00:53:27,800
also known as
<font color="

959
00:53:27,800 --> 00:53:30,880
So a multihead weigher
will receive all our raviolo

960
00:53:30,880 --> 00:53:32,720
from the cooling system.

961
00:53:32,720 --> 00:53:38,880
It will vibrate and gently spread
our raviolo across the 14 heads.

962
00:53:38,880 --> 00:53:41,480
Each head has an individual scale

963
00:53:41,480 --> 00:53:45,280
that will then weigh the raviolo
<font color="

964
00:53:48,120 --> 00:53:52,800
Once portioned, the raviolos
slide down a 1.5 metre chute

965
00:53:52,800 --> 00:53:55,320
into cardboard containers.

966
00:53:55,320 --> 00:53:59,040
So how many individual raviolo
do we get in the box?

967
00:53:59,040 --> 00:54:01,960
We get on average ten raviolos,

968
00:54:01,960 --> 00:54:04,440
but it's two portions.

969
00:54:04,440 --> 00:54:06,920
<font color="
are you making a day?

970
00:54:06,920 --> 00:54:08,320
A lot, Gregg.

971
00:54:08,320 --> 00:54:12,200
So per day, we produce
140,000 portions,

972
00:54:12,200 --> 00:54:16,920
and that is 1.4 million
of individual filled raviolo.

973
00:54:16,920 --> 00:54:21,000
There aren't that many red and white
checked tablecloths in Britain.

974
00:54:25,960 --> 00:54:30,160
<font color="
head towards a flow wrap packing

975
00:54:30,160 --> 00:54:33,880
machine, which covers the trays
with protective polyethylene

976
00:54:33,880 --> 00:54:38,440
packaging while injecting a mix
of carbon dioxide and nitrogen.

977
00:54:40,520 --> 00:54:45,000
This gas flushing is what we get
<font color="

978
00:54:45,000 --> 00:54:47,120
Correct.
That's the same thing.

979
00:54:47,120 --> 00:54:48,880
Exactly the same thing.
Yeah, yeah, yeah.

980
00:54:50,360 --> 00:54:53,400
By introducing nitrogen
into the packaging,

981
00:54:53,400 --> 00:54:55,840
it lowers oxygen levels inside.

982
00:54:55,840 --> 00:54:58,880
Without oxygen,
<font color="

983
00:54:58,880 --> 00:55:01,600
and the pasta stays fresher
for longer,

984
00:55:01,600 --> 00:55:05,440
while carbon dioxide helps
inhibit bacterial growth.

985
00:55:07,840 --> 00:55:09,560
Having already been pasteurised,

986
00:55:09,560 --> 00:55:14,040
it's an extra protection
against contamination,

987
00:55:14,040 --> 00:55:18,440
and, once refrigerated,
<font color="

988
00:55:18,440 --> 00:55:22,080
So our raviolo can be fresh
for up to 30 days.

989
00:55:22,080 --> 00:55:23,600
Wow!

990
00:55:23,600 --> 00:55:25,600
That's amazing, isn't it?
It's fantastic.

991
00:55:25,600 --> 00:55:29,560
You can get a fresh filled pasta
on a shelf for almost a month. Yes.

992
00:55:31,120 --> 00:55:34,640
<font color="
packed, gas flushed...

993
00:55:34,640 --> 00:55:36,720
Yeah?
..where does it then go?

994
00:55:36,720 --> 00:55:38,880
Then our raviolo is ready
for dispatch.

995
00:55:38,880 --> 00:55:42,120
And that's where I've got to go.
Fist bump. Thank you.

996
00:55:49,200 --> 00:55:52,680
Once the raviolo are packed,
<font color="

997
00:55:52,680 --> 00:55:56,160
They pass through a massive
warehouse capable of storing

998
00:55:56,160 --> 00:55:59,560
enough raviolo for two million
dinners...

999
00:56:01,640 --> 00:56:04,440
..before heading to Cesar
at dispatch.

1000
00:56:07,120 --> 00:56:08,880
Hello, my friend.

1001
00:56:08,880 --> 00:56:11,120
How many pallets on each truck?

1002
00:56:11,120 --> 00:56:13,960
<font color="
in each truck.

1003
00:56:13,960 --> 00:56:15,800
That's a fair old weight of pasta.

1004
00:56:15,800 --> 00:56:18,200
How many trucks are leaving here
every week?

1005
00:56:18,200 --> 00:56:20,880
With all different pasta types
that we have, around 80.

1006
00:56:20,880 --> 00:56:22,600
Really?
Yes.

1007
00:56:22,600 --> 00:56:26,320
<font color="
..you send out 80 trucks of pasta?

1008
00:56:26,320 --> 00:56:28,080
Yes, yes.

1009
00:56:28,080 --> 00:56:29,480
Wow.

1010
00:56:29,480 --> 00:56:31,520
So out of those 80 trucks
that leave here,

1011
00:56:31,520 --> 00:56:33,680
how many of those trucks
would you say is the raviolo?

1012
00:56:33,680 --> 00:56:36,760
<font color="
we would fill a couple of them,

1013
00:56:36,760 --> 00:56:39,320
two of them a week.
So how much is that, then?

1014
00:56:39,320 --> 00:56:42,120
Over 250,000 individual parcels.

1015
00:56:42,120 --> 00:56:44,800
It would be around 52,000 portions.

1016
00:56:44,800 --> 00:56:49,280
How do you explain
the British love of pasta?

1017
00:56:49,280 --> 00:56:52,000
<font color="

1018
00:56:52,000 --> 00:56:55,600
but it's also the combination
of ingredients that people get,

1019
00:56:55,600 --> 00:56:59,480
and the flavour. Of all the pastas,
why is that one the best seller?

1020
00:56:59,480 --> 00:57:03,960
People do look to get pasta
to a restaurant level, I think.

1021
00:57:03,960 --> 00:57:07,080
<font color="
Of course.

1022
00:57:07,080 --> 00:57:10,600
That's it, right?
Yeah. Loaded, ready to go.

1023
00:57:10,600 --> 00:57:13,160
That was a fascinating process.
You know that?

1024
00:57:15,200 --> 00:57:17,680
Do you like to cook pasta at home?
I do.

1025
00:57:22,840 --> 00:57:27,280
One day, five hours, and 16 minutes
<font color="

1026
00:57:29,600 --> 00:57:35,000
..my fresh crab and crayfish raviolo
are heading to shops - and bellies -

1027
00:57:35,000 --> 00:57:37,360
the length and breadth of the UK...

1028
00:57:39,240 --> 00:57:41,080
..with the people of Liverpool

1029
00:57:41,080 --> 00:57:43,400
putting away the most amount
of pasta.

1030
00:57:45,840 --> 00:57:48,720
Stuffed pasta looks like
<font color="

1031
00:57:48,720 --> 00:57:51,800
but actually there is
precision and skill

1032
00:57:51,800 --> 00:57:55,160
that goes into making
every little pasta parcel.

1033
00:57:57,880 --> 00:58:00,520
Personally, I'll always be grateful
to the Italians

1034
00:58:00,520 --> 00:58:04,000
that brought their wonderful food
<font color="

1035
00:58:07,560 --> 00:58:12,000
The factory has come a long way
from its first early assembly lines,

1036
00:58:12,000 --> 00:58:15,120
but how do we get from there
to here?

1037
00:58:17,040 --> 00:58:20,160
Explore the history and the future
of the factory

1038
00:58:20,160 --> 00:58:22,200
on an interactive timeline.

1039
00:58:22,200 --> 00:58:23,760
<font color="

1040
00:58:27,000 --> 00:58:29,880
..and follow the links
to the Open University.