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- ♪ MTV
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[bright upbeat music]
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♪
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- We eat more baked beans
in Britain
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than anywhere else on earth.
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- Every day, we consume
over two million cans of them.
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- That takes hundreds
of sacks of beans like this.
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- Tonight, we're going to tell
the truly extraordinary story
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behind an ordinary can of
beans.
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- By taking you inside
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the biggest food factory
in Europe!
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- I'm Gregg Wallace.
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That's a tin of beans, innit?
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And I'll be revealing
the secrets
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of this astonishing
production line.
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A billion beans
is gonna go through here,
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and the laser is gonna
look at every single bean!
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And the science
behind the magic.
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That is mega strong!
That's quite incredible.
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That is simply that
with ripples in it.
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Turning a humble little bean
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into one of the 300,000 tons of
baked beans we eat every year.
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Mate, what it takes to give us
beans on toast, eh?
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- [fire roars]
- [upbeat music]
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- I'm Cherry Healey.
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I'll show you
the incredible journey
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your recycled tin goes on
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in order to make it back
to your pantry.
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God, it's so hot.
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Bits of it are just falling off
as it rolls away.
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- Historian Ruth Goodman
discovers that
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tin food was once
a matter of life and death.
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- Malnutrition had killed
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more than half
of the British seamen.
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♪
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- Three million cans
of baked beans
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will roll out of this
one factory
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in the next 24 hours.
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- And this
is the incredible story
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of how they do it.
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- Welcome
to "Inside the Factory."
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- [bike wheel spins]
- [wrench clinks]
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[conveyor clicks along]
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[machine whirs]
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[chips crunch]
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[conveyor whirs]
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[cereal clatters]
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[words thud]
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- [upbeat music]
- [conveyor whirs]
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[upbeat music]
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This is the Heinz factory
in Wigan.
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It works around the clock
with 1,200 staff
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to make 200 different products,
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including spaghetti, soup,
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and its biggest seller,
baked beans.
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They come in all sorts
of varieties and containers
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like plastic resealable jars
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and individual portion pots
for the microwave.
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But tonight, we're making
the traditional best seller,
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baked beans in a can.
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♪
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Each bean will go
on an incredible
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mile and half journey
through this factory
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before they are packaged
and ready to head
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to your local supermarket
less 24 hours later.
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♪
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The factory in Wigan
is enormous,
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covering 54 acres,
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five times the size
of Wembley Stadium.
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It's the largest food
processing plant in Europe
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and the biggest baked bean
factory on the planet.
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Bringing in the beans
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is ingredients inspector,
John Brady.
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Right, John, that's it!
That's our load of beans, yeah?
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- Yep.
- First one of the morning?
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- Yep.
- Come on then.
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[grunts]
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How many of these come
in every day?
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- About 20.
- Right.
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I'll move to the back.
Come on then.
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Let's have a look at is.
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I did not expect that.
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I don't know why.
I just didn't expect that.
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How many of those big bags
on there?
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- 10 in total,
two ton in weight.
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- 10 two-ton bags of beans.
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Driver!
We're ready.
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- [upbeat music]
- [truck hums]
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Overseeing the arrival
of the beans
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is operations manager Gary
Dent.
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- We typically take in
12 to 14 containers a day.
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We'll do 50,000 ton a year.
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But when you consider
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we'll make over three million
cans of beans a day,
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that's why we need
so many beans.
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- Three million cans
of beans a day.
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- Oh yeah, easy. Yeah.
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- Three million cans
of beans rolling out of here?
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00:04:23,320 --> 00:04:25,040
- In 20, yes.
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- Forgive me, but what bean
is in a tin of beans?
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- That's them, Gregg,
the haricot beans.
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- I really love it that we eat
so many of these,
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yet we probably don't know
their name.
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00:04:35,680 --> 00:04:37,400
We probably don't know
what they are.
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- No.
These are haricot beans.
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- Haricot beans
start life in a pod.
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[soft bright music]
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They grow throughout
the summer months
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and left to dry on the plant.
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The beans I'm following
come from North America,
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where the climate provides
the perfect growing conditions.
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Every week, 1,000 tons of beans
are loaded into containers
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and shipped
to the Port of Liverpool.
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Then they're trucked the final
20 miles here to the factory.
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[truck hums]
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- So these little things.
- Yeah.
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- How long roughly before
they become a tin of beans?
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- You could see a finished tin
of beans within two hours.
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- I suppose
it is possible for me
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to see every single stage
of this process, isn't it?
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- It certainly is, Gregg.
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- Maybe taste a few at the end?
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- Oh, without doubt.
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[upbeat music]
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- The bags of beans are brought
out of their shipping
containers
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and into the factory
at bean intake.
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[timer beeping]
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This is where the baked bean
production line begins.
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In just 24 hours,
these beans could be in a can
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on a supermarket shelf.
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Each two-ton bag is carefully
positioned above a funnel.
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When the bag is opened,
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the beans drop onto an enclosed
conveyor that takes them
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00:05:56,320 --> 00:05:59,520
to the first stage
of processing.
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- Could I have a go at that?
- Certainly.
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- Don't go anywhere, Gary,
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'cause if it falls over,
I'm blaming you.
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[machinery whirs]
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Each bag contains
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nine and a half million
individual beans,
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enough to fill more
than 20,000 cans.
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♪
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- That's a lot of beans
to drop, Gregg.
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- Whoa.
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00:06:22,000 --> 00:06:23,640
That's a bit tense, that, Gary.
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- Yeah.
- All right, now pull that.
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- [dramatic music]
- [beans clatter]
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- There they go.
- Yay!
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[beans clatter]
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My dry beans are traveling
to the blanching room,
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which is 200 meters away
from the intake area,
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to prevent contamination
from the outside world.
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They move at five miles an hour
on an enclosed conveyor,
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and it takes five minutes
for the first beans to arrive.
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Here, there'll be rehydrated.
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- Okay, Gregg,
we're now gonna see
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how we rehydrate
our dried beans.
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What we've got here
is the dried beans
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that you loaded up for us
about five minutes ago.
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They've now reached
the blancher,
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00:07:08,200 --> 00:07:09,720
and this is where
we put the water
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back into that dry bean.
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[up-tempo music]
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- In the blanching process,
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they pass through two
85-degrees Celsius,
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steam-heated chambers,
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each soaking the beans
for 10 minutes.
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- Time and temperature are key
in rehydration process.
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♪
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- Blanching in steam
quickly softens the outside
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of the dry bean
and lets in water.
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- That's the before and after.
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- They've swollen up
incredibly.
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- Yeah.
- But not cooked.
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- Not cooked.
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If you want to try one, you
can,
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but they're certainly
not cooked.
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It's just got a bit of give,
but in the middle,
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it's as hard as, like,
an uncooked risotto.
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- Yeah.
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- I quite like 'em.
You got any salt?
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The rehydrated beans
are washed in warm water
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to get rid of any loose skins.
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- Finally, the laser
sorter actually
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00:08:03,440 --> 00:08:05,680
detects any discolored beans
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00:08:05,720 --> 00:08:08,120
and rejects them
with an air jet.
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- [Gregg laughs]
- Honestly, yeah.
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- Really?
- Yes.
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00:08:11,720 --> 00:08:13,960
- Really? Okay, go on then.
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- 20 years ago, there would be
people flicking the beans up
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00:08:17,440 --> 00:08:20,880
with spoons,
but now we use a laser sorter.
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[bright upbeat electronic
music]
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♪
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- There are two lasers,
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00:08:27,080 --> 00:08:28,920
one above and one below
the beans,
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that examine them
from every angle.
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00:08:33,360 --> 00:08:37,360
A laser spots a discolored bean
and fires an air jet
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00:08:37,400 --> 00:08:41,280
that knocks it off
the production line.
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00:08:41,320 --> 00:08:43,840
- The puffing noise that you
hear is the gun firing,
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00:08:43,880 --> 00:08:45,640
knocking the beans off.
201
00:08:45,680 --> 00:08:48,480
- Every one of those
little clicks is a jet of air?
202
00:08:48,520 --> 00:08:50,280
- Yeah, exactly.
- And a bean dying?
203
00:08:50,320 --> 00:08:52,040
- Bean being rejected.
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00:08:52,080 --> 00:08:55,360
- A has-bean.
- A has-bean. Very good.
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00:08:55,400 --> 00:08:57,120
- Within the next
couple of hours,
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00:08:57,160 --> 00:09:01,440
these will be in a can ready
to head to a supermarket.
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00:09:04,040 --> 00:09:07,240
- [bright cheery music]
- [fork clinks]
208
00:09:07,280 --> 00:09:08,320
[fork clinks]
209
00:09:08,360 --> 00:09:10,320
- Mm.
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00:09:10,360 --> 00:09:13,040
This tin of baked beans
is about to go
211
00:09:13,080 --> 00:09:15,560
on an incredible journey.
212
00:09:15,600 --> 00:09:17,720
Not the beans,
I've just finished those,
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00:09:17,760 --> 00:09:20,040
but the tin itself
will go through
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00:09:20,080 --> 00:09:23,360
an extraordinary process
to end up back
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00:09:23,400 --> 00:09:25,720
in someone else's cupboard.
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00:09:25,760 --> 00:09:27,320
It all begins the moment
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00:09:27,360 --> 00:09:30,680
you throw it
in the recycling bin.
218
00:09:30,720 --> 00:09:32,600
[can thuds]
219
00:09:32,640 --> 00:09:34,240
Did I just get that in?
220
00:09:34,280 --> 00:09:36,120
In most major cities,
221
00:09:36,160 --> 00:09:39,360
you can throw all of your
recycling into one bag,
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00:09:39,400 --> 00:09:41,160
but how is it all sorted
to make sure
223
00:09:41,200 --> 00:09:44,760
that my tin can ends up
in the right place?
224
00:09:44,800 --> 00:09:48,000
You do it with one of these,
225
00:09:48,040 --> 00:09:50,720
what's lovingly
known as the MRF,
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00:09:50,760 --> 00:09:53,400
Materials Recovery Facility,
227
00:09:53,440 --> 00:09:57,480
and it's one of the largest
of its kind in the world.
228
00:09:57,520 --> 00:09:59,600
[up-tempo lively music]
229
00:09:59,640 --> 00:10:02,040
At this recycling center
in East London,
230
00:10:02,080 --> 00:10:07,440
their MRF sorts 520 truckloads
every week.
231
00:10:07,480 --> 00:10:10,320
My guide through it
all is David Rumble.
232
00:10:10,360 --> 00:10:14,080
Wow. That is a monster machine.
233
00:10:14,120 --> 00:10:16,880
It looks like teeth
grinding everything.
234
00:10:16,920 --> 00:10:18,800
What is this actually doing?
235
00:10:18,840 --> 00:10:21,480
- Well, this is actually
separating out
236
00:10:21,520 --> 00:10:25,520
into three different sizes,
very big,
237
00:10:25,560 --> 00:10:28,240
which just rolls over the top,
medium size,
238
00:10:28,280 --> 00:10:32,240
which is where steel can goes,
and then very small,
239
00:10:32,280 --> 00:10:36,720
which is broken glass
and shredded paper.
240
00:10:36,760 --> 00:10:38,440
There it goes, your can.
241
00:10:38,480 --> 00:10:40,160
- There it is. There it is.
- You see it there?
242
00:10:40,200 --> 00:10:42,840
- Once it's all separated
into different sizes,
243
00:10:42,880 --> 00:10:46,640
it moves on to be
sorted by shape.
244
00:10:46,680 --> 00:10:49,080
Flat objects like paper
and cardboard
245
00:10:49,120 --> 00:10:52,160
travel along
the top of the wheels
246
00:10:52,200 --> 00:10:54,960
while the rest,
including my can, drop through
247
00:10:55,000 --> 00:10:57,640
and are collected at the
bottom.
248
00:10:57,680 --> 00:10:59,720
So it's a matter
of surface area.
249
00:10:59,760 --> 00:11:01,040
- Absolutely, yes.
250
00:11:01,080 --> 00:11:04,200
- Surface area and physics.
251
00:11:04,240 --> 00:11:07,240
Now that it's been
sorted by size and shape,
252
00:11:07,280 --> 00:11:09,000
it needs some
high-tech equipment
253
00:11:09,040 --> 00:11:12,240
to separate it further.
254
00:11:12,280 --> 00:11:16,040
- This is the near-infrared
optical separator,
255
00:11:16,080 --> 00:11:21,080
and what this is doing is
taking plastic off of the belt.
256
00:11:21,120 --> 00:11:24,320
So we're actually
pulling out EET,
257
00:11:24,360 --> 00:11:27,600
which is the clear plastic
drinks bottles.
258
00:11:27,640 --> 00:11:29,960
- A sensor
in the separator detects
259
00:11:30,000 --> 00:11:32,200
how much light
is passing through
260
00:11:32,240 --> 00:11:35,160
or reflecting off
the different materials.
261
00:11:35,200 --> 00:11:37,440
So it can spot
the clear plastic bottles,
262
00:11:37,480 --> 00:11:39,920
and they get blown off the
belt.
263
00:11:39,960 --> 00:11:41,600
Can it really be that detailed
264
00:11:41,640 --> 00:11:43,760
that it can see
an individual bottle?
265
00:11:43,800 --> 00:11:46,080
- Absolutely.
266
00:11:46,120 --> 00:11:48,760
- Finally, my steel can
is picked up
267
00:11:48,800 --> 00:11:52,040
and separated from
the aluminum drinks cans.
268
00:11:52,080 --> 00:11:55,360
This is an electro magnet
that will lift the can
269
00:11:55,400 --> 00:11:58,200
off of the belt, move it over
above a beam,
270
00:11:58,240 --> 00:12:00,040
and then drop it off.
271
00:12:00,080 --> 00:12:02,760
- So once the tin has been
dropped by the magnet,
272
00:12:02,800 --> 00:12:04,000
where does it go then?
273
00:12:04,040 --> 00:12:06,080
- It goes to the bailer
274
00:12:06,120 --> 00:12:08,800
where we make it
into a big square bail
275
00:12:08,840 --> 00:12:11,240
with ferrous metal.
276
00:12:11,280 --> 00:12:14,960
- The bailing machine
crushes up to 40,000 tin cans
277
00:12:15,000 --> 00:12:18,960
into one single cube,
each weighing one ton.
278
00:12:19,000 --> 00:12:20,240
- [soft electronic music]
- [forklift hums]
279
00:12:20,280 --> 00:12:25,520
This one includes my can.
280
00:12:25,560 --> 00:12:27,520
- [machinery whirs]
- [cans clatter]
281
00:12:27,560 --> 00:12:30,560
[bright jaunty music]
282
00:12:30,600 --> 00:12:32,320
- Back at the factory,
283
00:12:32,360 --> 00:12:34,840
it's been 25 minutes since
my dry beans arrived,
284
00:12:34,880 --> 00:12:37,880
and now they've been
rehydrated.
285
00:12:37,920 --> 00:12:39,480
To make baked beans,
286
00:12:39,520 --> 00:12:42,520
every manufacturer
uses haricot beans,
287
00:12:42,560 --> 00:12:47,040
but they all create their
own particular tomato sauce.
288
00:12:48,360 --> 00:12:50,720
Here at Heinz,
their special ingredients
289
00:12:50,760 --> 00:12:55,720
are prepared
in the spice mixing area.
290
00:12:55,760 --> 00:12:58,760
The recipe
is classified information,
291
00:12:58,800 --> 00:13:00,800
and making sure
it stays that way
292
00:13:00,840 --> 00:13:04,160
is manufacturing coordinator
Paul Sherrington.
293
00:13:04,200 --> 00:13:06,880
- This is where we make up
the secret spices
294
00:13:06,920 --> 00:13:09,000
what makes the beans famous.
295
00:13:09,040 --> 00:13:10,440
- What do you mean
the secret spices?
296
00:13:10,480 --> 00:13:12,160
- Secret.
No one knows.
297
00:13:12,200 --> 00:13:13,680
Only two people in the world
know about these spices.
298
00:13:13,720 --> 00:13:15,040
- Who do you think you are,
James Bond?
299
00:13:15,080 --> 00:13:18,200
- Yes. [chuckles]
- Mate, get out of here!
300
00:13:18,240 --> 00:13:21,360
The ingredients are listed
on the label of a can of beans,
301
00:13:21,400 --> 00:13:24,400
but because no recipe
could be copyrighted,
302
00:13:24,440 --> 00:13:27,560
the exact proportions they use
are a trade secret
303
00:13:27,600 --> 00:13:32,400
known only by the head buyer
and the chief quality officer.
304
00:13:32,440 --> 00:13:38,520
The secret spice recipe has
stayed the same since 1896
305
00:13:38,560 --> 00:13:42,360
and is delivered to the factory
as three anonymous powder
mixes.
306
00:13:42,400 --> 00:13:45,400
- What are they?
- I don't know.
307
00:13:45,440 --> 00:13:46,480
You honestly don't know
what they are?
308
00:13:46,520 --> 00:13:47,760
- Honestly, I don't know.
309
00:13:47,800 --> 00:13:49,440
I can taste these,
though, can't I?
310
00:13:49,480 --> 00:13:51,160
- 'Cause I.
- Indeed, yes, yes.
311
00:13:51,200 --> 00:13:53,200
- I might be able to work out
what's in it.
312
00:13:53,240 --> 00:13:55,280
- But if you do that,
we'll have to kill ya.
313
00:13:55,320 --> 00:13:57,240
- Surely working out
314
00:13:57,280 --> 00:14:00,320
what's in the three different
mixes shouldn't be too hard.
315
00:14:00,360 --> 00:14:02,920
Oh!
316
00:14:02,960 --> 00:14:05,640
They're so strong.
317
00:14:05,680 --> 00:14:09,600
You got a salty one,
a pepper chili one,
318
00:14:09,640 --> 00:14:12,480
and a sweet garlicky one.
319
00:14:12,520 --> 00:14:15,800
Do you know what
I conclude from that?
320
00:14:15,840 --> 00:14:19,760
- I haven't got a clue.
- [laughs] Not at all.
321
00:14:19,800 --> 00:14:21,920
- Paul doesn't know
the exact ingredients,
322
00:14:21,960 --> 00:14:24,440
but he does know
how much of each mix
323
00:14:24,480 --> 00:14:27,200
to measure out
for our bag of spices.
324
00:14:27,240 --> 00:14:29,560
What quantity of tomato
are we gonna add this to?
325
00:14:29,600 --> 00:14:33,480
- We're gonna add it to a
batch, which is five ton in
weight.
326
00:14:33,520 --> 00:14:34,920
- And how many tins will
that make roughly?
327
00:14:34,960 --> 00:14:37,560
- Approximately 20,000.
328
00:14:37,600 --> 00:14:40,040
- 20,000 from this little bag?
- Yes.
329
00:14:40,080 --> 00:14:41,640
- No wonder
my lips were tingling.
330
00:14:41,680 --> 00:14:43,360
[bright jaunty music]
331
00:14:43,400 --> 00:14:46,600
I'm taking my bag
of secret spices next door
332
00:14:46,640 --> 00:14:48,640
to the sauce room
333
00:14:48,680 --> 00:14:51,160
where sauce operator
Peter Foster
334
00:14:51,200 --> 00:14:53,360
is ready to mix up a batch.
335
00:14:53,400 --> 00:14:54,760
- Hello, mate!
- Oh, hello, Gregg!
336
00:14:54,800 --> 00:14:56,160
Lovely to see ya.
337
00:14:56,200 --> 00:14:59,240
- I've got some spice.
- Right.
338
00:14:59,280 --> 00:15:02,200
- What is this room?
- It's the sauce room.
339
00:15:02,240 --> 00:15:03,760
- You control the spice.
340
00:15:03,800 --> 00:15:06,600
- Control the bulk,
the water, boilers.
341
00:15:06,640 --> 00:15:08,880
- You're the chef.
342
00:15:08,920 --> 00:15:11,120
- Well, you could say so.
343
00:15:11,160 --> 00:15:14,600
- Peter is in charge
of eight mixing bowls,
344
00:15:14,640 --> 00:15:18,680
each one holding enough sauce
for 20,000 tins of beans.
345
00:15:18,720 --> 00:15:21,080
♪
346
00:15:21,120 --> 00:15:23,320
- There's you're tomato puree.
- Oh!
347
00:15:23,360 --> 00:15:25,080
♪
348
00:15:25,120 --> 00:15:27,680
Then I add my bag of spices.
349
00:15:27,720 --> 00:15:31,320
This is just like adding
a stock cube at home.
350
00:15:31,360 --> 00:15:32,760
With a press of a button,
351
00:15:32,800 --> 00:15:36,360
Peter adds starch
to thicken the sauce.
352
00:15:36,400 --> 00:15:40,640
The sugar and salt are blown
through pipes into the mixer,
353
00:15:40,680 --> 00:15:43,400
then some vinegar, but they
won't tell me how much.
354
00:15:43,440 --> 00:15:45,320
It's a secret.
355
00:15:45,360 --> 00:15:50,160
And finally, it's all blended
in the giant food mixer.
356
00:15:50,200 --> 00:15:52,920
Don't you think it might be
a little bit too technical
357
00:15:52,960 --> 00:15:55,520
for an old-fashioned
tin of beans?
358
00:15:55,560 --> 00:15:58,920
- We make the best beans,
so that's what we do.
359
00:15:58,960 --> 00:16:02,320
- After 15 minutes,
the sauce is ready.
360
00:16:02,360 --> 00:16:05,400
♪
361
00:16:05,440 --> 00:16:06,760
That's a tin of beans, innit?
362
00:16:06,800 --> 00:16:09,120
- That's a tin of beans.
363
00:16:09,160 --> 00:16:12,440
- Our tomato sauce is on its
way to get mixed with the
beans.
364
00:16:12,480 --> 00:16:15,120
Next, we're gonna
need some cans.
365
00:16:15,160 --> 00:16:18,840
They can make up to four
million baked bean cans
366
00:16:18,880 --> 00:16:21,600
in this factory every day
and for that,
367
00:16:21,640 --> 00:16:23,160
you need a lot of steel.
368
00:16:23,200 --> 00:16:26,840
- [upbeat music]
- [vehicle rumbles]
369
00:16:26,880 --> 00:16:30,400
- I followed my old tin
can from the recycling plant
370
00:16:30,440 --> 00:16:34,920
to Tata Steel
in Port Talbot, Wales.
371
00:16:34,960 --> 00:16:39,000
This is the largest steel works
in the UK.
372
00:16:39,040 --> 00:16:41,760
In six hours,
my can will be part
373
00:16:41,800 --> 00:16:45,040
of a brand new sheet of steel.
374
00:16:45,080 --> 00:16:48,960
- [flames roar]
- [dramatic music]
375
00:16:49,000 --> 00:16:51,520
♪
376
00:16:51,560 --> 00:16:54,600
Here, scrap metal makes up
over a quarter
377
00:16:54,640 --> 00:16:56,160
of the finished steel.
378
00:16:56,200 --> 00:16:59,720
And so my old, recycled tin can
379
00:16:59,760 --> 00:17:04,840
is about to be combined
with this raw iron ore.
380
00:17:04,880 --> 00:17:06,560
[dramatic music]
381
00:17:06,600 --> 00:17:11,560
It's been mined from rocks
as far away as Australia.
382
00:17:11,600 --> 00:17:16,040
To make steel, the iron ore
is tipped into a blast furnace,
383
00:17:16,080 --> 00:17:18,960
mixed with a type
of coal called coke,
384
00:17:19,000 --> 00:17:22,640
and heated to over
2,000 degrees.
385
00:17:22,680 --> 00:17:26,080
The result is almost
pure molten iron,
386
00:17:26,120 --> 00:17:28,880
which is poured into
brick-lined steel vessels
387
00:17:28,920 --> 00:17:32,000
called torpedoes
and shunted across the yard
388
00:17:32,040 --> 00:17:36,200
to the most incredible place
I've ever set foot in.
389
00:17:36,240 --> 00:17:42,760
♪
390
00:17:42,800 --> 00:17:47,440
That is absolutely
unbelievable.
391
00:17:47,480 --> 00:17:49,320
♪
392
00:17:49,360 --> 00:17:52,280
Here, my tin can, along with
the rest of the scrap metal,
393
00:17:52,320 --> 00:17:56,080
is being loaded
into a huge skip.
394
00:17:56,120 --> 00:17:59,400
Tim Rutter talks me
through the process.
395
00:17:59,440 --> 00:18:00,920
- Two things are gonna happen.
396
00:18:00,960 --> 00:18:03,320
Firstly, the scrap metal
is gonna come along
397
00:18:03,360 --> 00:18:06,200
and be charged into the mouth.
- Which is there?
398
00:18:06,240 --> 00:18:07,400
- Which is coming down
the bay as we speak.
399
00:18:07,440 --> 00:18:08,760
- So that's scrap metal,
400
00:18:08,800 --> 00:18:10,560
and how much scrap metal
is in there?
401
00:18:10,600 --> 00:18:12,960
So there's anywhere between
50 and 100 tons of scrap metal,
402
00:18:13,000 --> 00:18:14,880
so maybe the equivalent of up
403
00:18:14,920 --> 00:18:17,760
to two million steel cans will
be in that charging vessel.
404
00:18:17,800 --> 00:18:21,240
- Whoa, so my tin can could
potentially be in there,
405
00:18:21,280 --> 00:18:23,280
and that scrap metal is gonna
go
406
00:18:23,320 --> 00:18:28,720
into the mouth of the cauldron,
and what is over there?
407
00:18:28,760 --> 00:18:31,920
- So here you can see
the ladle full of molten iron.
408
00:18:31,960 --> 00:18:33,560
So we've just come
from the blast furnace
409
00:18:33,600 --> 00:18:35,200
where that's been made.
410
00:18:35,240 --> 00:18:37,360
It's now in a ladle,
and that's ready to charge
411
00:18:37,400 --> 00:18:39,880
on top of the scrap
in the steel-making vessel.
412
00:18:39,920 --> 00:18:41,280
- [dramatic whimsical music]
- [machine rumbles]
413
00:18:41,320 --> 00:18:44,000
- From behind the safety
of a concrete wall,
414
00:18:44,040 --> 00:18:47,680
we can watch the action.
415
00:18:47,720 --> 00:18:53,040
First, the scrap metal is
tipped into the 12-meter-high
cauldron.
416
00:18:53,080 --> 00:18:58,840
♪
417
00:19:00,360 --> 00:19:02,720
The whole building is shaking.
418
00:19:02,760 --> 00:19:05,400
♪
419
00:19:05,440 --> 00:19:10,280
Then, 300 tons of molten iron
is poured on top.
420
00:19:10,320 --> 00:19:11,600
♪
421
00:19:11,640 --> 00:19:13,320
Wow.
422
00:19:13,360 --> 00:19:15,840
♪
423
00:19:15,880 --> 00:19:21,320
Finally, pure oxygen is pumped
in at supersonic speed.
424
00:19:21,360 --> 00:19:23,480
[flames roar]
425
00:19:23,520 --> 00:19:27,040
Carbon and other impurities
turn into a gas,
426
00:19:27,080 --> 00:19:32,440
leaving behind the steel
we need to make cans.
427
00:19:32,480 --> 00:19:37,320
How many tins of baked beans
am I looking at right now?
428
00:19:37,360 --> 00:19:41,440
- If you estimate that we're
making about 320 tons of steel,
429
00:19:41,480 --> 00:19:45,000
then that maybe makes about,
let's say, eight million cans.
430
00:19:45,040 --> 00:19:47,680
- Eight million cans.
431
00:19:47,720 --> 00:19:50,160
[whimsical dramatic music]
432
00:19:50,200 --> 00:19:53,640
The new steel is poured
into a water-cooled mold
433
00:19:53,680 --> 00:19:55,440
to reduce the temperature
and turn it
434
00:19:55,480 --> 00:19:59,880
into a slab that weighs
around 30 tons.
435
00:19:59,920 --> 00:20:02,320
God, it's so hot
436
00:20:02,360 --> 00:20:05,760
that bits of it are just
falling off as in rolls away.
437
00:20:05,800 --> 00:20:11,040
That is absolutely amazing!
438
00:20:11,080 --> 00:20:14,200
Before the slab of steel can
be made into a baked bean can,
439
00:20:14,240 --> 00:20:16,360
it needs to be a lot thinner.
440
00:20:16,400 --> 00:20:19,840
So it enters this kilometer-
and-a-half-long hall
441
00:20:19,880 --> 00:20:21,760
to be compressed.
442
00:20:21,800 --> 00:20:23,960
♪
443
00:20:24,000 --> 00:20:26,360
It passes through
a series of rollers,
444
00:20:26,400 --> 00:20:29,640
exerting almost
4,000 tons of force,
445
00:20:29,680 --> 00:20:33,120
which make it longer
and thinner.
446
00:20:33,160 --> 00:20:37,120
Oh wow! So it's being rolled up
into a huge coil.
447
00:20:37,160 --> 00:20:40,680
You really feel
that intense heat.
448
00:20:40,720 --> 00:20:43,880
The steel is constantly
cooled with water,
449
00:20:43,920 --> 00:20:46,000
and it's at a temperature
450
00:20:46,040 --> 00:20:50,000
just low enough
to hold its shape.
451
00:20:50,040 --> 00:20:52,040
A second set
of rollers transforms
452
00:20:52,080 --> 00:20:54,080
60 meter-long coil
453
00:20:54,120 --> 00:20:57,360
into a kilometer-long
length of sheet steel.
454
00:20:57,400 --> 00:20:59,440
♪
455
00:20:59,480 --> 00:21:03,600
That sheet steel is moving
at an unbelievable speed.
456
00:21:03,640 --> 00:21:06,720
- 30 to 40 miles an hour.
457
00:21:06,760 --> 00:21:08,240
- Five minutes later,
458
00:21:08,280 --> 00:21:11,080
the steel is coiled up
for the last time.
459
00:21:11,120 --> 00:21:14,880
♪
460
00:21:14,920 --> 00:21:18,440
- It starts off with a slab
that's about ten meters long,
461
00:21:18,480 --> 00:21:20,160
and by the time
we squashed it down
462
00:21:20,200 --> 00:21:22,560
to two millimeters thick,
463
00:21:22,600 --> 00:21:25,640
that is about
one kilometer of steel.
464
00:21:25,680 --> 00:21:27,840
♪
465
00:21:27,880 --> 00:21:31,920
- Once it's rolled up into
that amazingly neat roll,
466
00:21:31,960 --> 00:21:33,880
where does it go next?
467
00:21:33,920 --> 00:21:35,520
- So the next place
for this coil to go
468
00:21:35,560 --> 00:21:37,640
will be our sister plant
in Trostre
469
00:21:37,680 --> 00:21:40,080
who's gonna cold roll it
to make it even thinner
470
00:21:40,120 --> 00:21:42,760
and coat it with tin
before they pass it on
471
00:21:42,800 --> 00:21:45,920
to Heinz, our customer,
to make baked bean cans.
472
00:21:45,960 --> 00:21:48,720
- So this product
is still steel,
473
00:21:48,760 --> 00:21:52,240
and later on,
it becomes a tin can.
474
00:21:52,280 --> 00:21:54,240
- Well, people call it
a tin can, but of course,
475
00:21:54,280 --> 00:21:57,640
it's a steel can that's got
a coating of tin on it.
476
00:21:57,680 --> 00:21:59,120
- It seems unfair.
477
00:21:59,160 --> 00:22:01,240
Okay, I'll call it
a steel can from now on.
478
00:22:01,280 --> 00:22:02,640
- Okay, excellent.
479
00:22:02,680 --> 00:22:04,720
[soft dramatic music]
480
00:22:04,760 --> 00:22:06,880
- Coating the steel can with
tin
481
00:22:06,920 --> 00:22:09,240
creates a barrier
to stop air, water,
482
00:22:09,280 --> 00:22:11,960
and beans touching
the surface of the steel.
483
00:22:12,000 --> 00:22:13,680
♪
484
00:22:13,720 --> 00:22:15,480
It prevents the can from
rusting
485
00:22:15,520 --> 00:22:17,880
and will protect
the beans inside.
486
00:22:17,920 --> 00:22:20,320
♪
487
00:22:20,360 --> 00:22:23,320
Finally, the coated steel
is cut into sheets
488
00:22:23,360 --> 00:22:26,280
and trucked off
to the factory in Wigan,
489
00:22:26,320 --> 00:22:27,760
where it could find its way
490
00:22:27,800 --> 00:22:31,160
to your kitchen cupboard
within a few days.
491
00:22:31,200 --> 00:22:34,480
So next time you open
your tin of beans,
492
00:22:34,520 --> 00:22:38,720
spare a thought for
the unbelievable engineering
493
00:22:38,760 --> 00:22:40,480
that's gone into making it.
494
00:22:40,520 --> 00:22:42,880
[fire rumbles]
495
00:22:47,040 --> 00:22:48,480
[water splashes]
496
00:22:48,520 --> 00:22:50,280
[dramatic music]
497
00:22:50,320 --> 00:22:53,000
- Back at the factory,
it's been 45 minutes
498
00:22:53,040 --> 00:22:56,040
since my dried
haricot beans arrived.
499
00:22:56,080 --> 00:22:59,000
They've been blanched
to rehydrate them,
500
00:22:59,040 --> 00:23:02,840
and my tomato sauce
has been mixed.
501
00:23:02,880 --> 00:23:07,000
Now I need something
to put it all in.
502
00:23:07,040 --> 00:23:12,240
Heinz have their own can-making
factory here on site.
503
00:23:12,280 --> 00:23:16,560
Every day, 168 tons
of steel arrives,
504
00:23:16,600 --> 00:23:21,760
enough to make more
than five million cans.
505
00:23:21,800 --> 00:23:25,440
The engineer in charge
is Darren Maloney.
506
00:23:25,480 --> 00:23:27,800
So we buy the sheet steel
in one-meter-square sheets,
507
00:23:27,840 --> 00:23:29,640
approximately.
508
00:23:29,680 --> 00:23:32,320
- The sheets of steel
are fed into a machine
509
00:23:32,360 --> 00:23:34,760
that cuts them into strips.
510
00:23:34,800 --> 00:23:37,880
- So we slit that way
into long strips.
511
00:23:37,920 --> 00:23:41,400
Then we slit it this way
into the final blank.
512
00:23:41,440 --> 00:23:44,720
- Wow!
- That's cut into 16 of those.
513
00:23:44,760 --> 00:23:46,280
- How many tins will
that now make?
514
00:23:46,320 --> 00:23:47,320
- Two.
515
00:23:47,360 --> 00:23:49,040
♪
516
00:23:49,080 --> 00:23:51,000
The transfer system
collects them,
517
00:23:51,040 --> 00:23:52,280
takes 'em to the
welding machine.
518
00:23:52,320 --> 00:23:54,720
- It's taking about 100 at
once!
519
00:23:54,760 --> 00:23:59,120
- It's taking more than 100.
It's taking 240 at a time.
520
00:23:59,160 --> 00:24:00,480
- It's like one of
those fun fair games...
521
00:24:00,520 --> 00:24:01,840
- The gripper.
522
00:24:01,880 --> 00:24:03,560
- where you have
to grab the toy.
523
00:24:03,600 --> 00:24:07,240
In a fraction of a second,
each steel strip is bent round
524
00:24:07,280 --> 00:24:09,720
to form a cylinder
with the edges overlapping
525
00:24:09,760 --> 00:24:12,600
by just half a millimeter.
526
00:24:12,640 --> 00:24:15,120
In a process called
resistance welding,
527
00:24:15,160 --> 00:24:17,520
two electrodes heat up
the steel edges,
528
00:24:17,560 --> 00:24:20,280
melting them
and joining them together.
529
00:24:20,320 --> 00:24:22,360
Heats it up, sticks it
together. - Yes.
530
00:24:22,400 --> 00:24:24,960
- It's now the right shape
for a can,
531
00:24:25,000 --> 00:24:26,720
but it's big enough to make
two.
532
00:24:26,760 --> 00:24:28,520
[upbeat music]
533
00:24:28,560 --> 00:24:31,280
So the cylinders travel
across the room on conveyors
534
00:24:31,320 --> 00:24:34,640
and into a machine
which finally turns into a can.
535
00:24:34,680 --> 00:24:37,640
- So this part
of the kit rotates.
536
00:24:37,680 --> 00:24:41,440
It basically splits it in two.
537
00:24:41,480 --> 00:24:43,440
- So go like that.
538
00:24:43,480 --> 00:24:44,760
- Yeah.
539
00:24:44,800 --> 00:24:46,640
- Rips it up.
540
00:24:46,680 --> 00:24:50,120
That doesn't seem anywhere as
strong as a finished tin can.
541
00:24:50,160 --> 00:24:52,440
I can't do that with
my can of beans.
542
00:24:52,480 --> 00:24:55,520
We put the ripples on the can
to make the can strong.
543
00:24:55,560 --> 00:24:57,200
If we didn't do that,
544
00:24:57,240 --> 00:24:58,760
you'd end up where the cans
would just squash.
545
00:24:58,800 --> 00:25:01,160
The ripples give it
the strength.
546
00:25:01,200 --> 00:25:04,360
- So the next machine
rotates the can around a mold
547
00:25:04,400 --> 00:25:07,880
that creates ripples
on its body.
548
00:25:07,920 --> 00:25:10,000
These help to keep the can
rigid
549
00:25:10,040 --> 00:25:13,480
to prevent it collapsing
under pressure.
550
00:25:13,520 --> 00:25:15,200
- You can feel the difference.
551
00:25:15,240 --> 00:25:17,960
- Yeah, that's sturdy.
That's quite incredible.
552
00:25:18,000 --> 00:25:19,640
That is simply
that with ripples in it.
553
00:25:19,680 --> 00:25:21,240
- Yes.
554
00:25:21,280 --> 00:25:23,000
- And then over there,
it's putting the tops on.
555
00:25:23,040 --> 00:25:26,680
- Yep. It's putting the tops
on the bottom of the can.
556
00:25:26,720 --> 00:25:30,120
- Circular steel can ends
arrive at the factory
ready-made.
557
00:25:30,160 --> 00:25:31,760
[machinery whirs]
558
00:25:31,800 --> 00:25:34,120
They're dropped on top
of one end of the can,
559
00:25:34,160 --> 00:25:37,480
and the ages are folded
over to make a seal.
560
00:25:37,520 --> 00:25:41,240
This happens over
1,000 times a minute,
561
00:25:41,280 --> 00:25:45,560
and now they're off
on their way to be filled.
562
00:25:45,600 --> 00:25:47,440
[dramatic music]
563
00:25:47,480 --> 00:25:49,320
- In the early 19th century,
564
00:25:49,360 --> 00:25:55,040
food preservation was
a matter of life and death.
565
00:25:55,080 --> 00:25:57,440
For all of the military might
of both the British
566
00:25:57,480 --> 00:26:01,320
and the French navies,
the question of food
567
00:26:01,360 --> 00:26:04,480
was playing on the minds
of the warring admirals.
568
00:26:04,520 --> 00:26:08,760
Malnutrition had killed more
than half of the British seamen
569
00:26:08,800 --> 00:26:10,840
in the previous
Seven Years' War,
570
00:26:10,880 --> 00:26:14,920
so solving this problem
was imperative.
571
00:26:14,960 --> 00:26:17,840
To find out what was going
wrong with the naval diet,
572
00:26:17,880 --> 00:26:21,840
I'm aboard the Gannett,
a Victorian naval ship,
573
00:26:21,880 --> 00:26:24,800
to meet historian
Alex Patterson.
574
00:26:24,840 --> 00:26:26,880
Could you tell me why on Earth
575
00:26:26,920 --> 00:26:28,760
were all his men
suffering malnutrition?
576
00:26:28,800 --> 00:26:31,560
Surely they loaded the ships up
with supplies before they left.
577
00:26:31,600 --> 00:26:35,440
- Fresh food stocks would dry,
spoil very quickly.
578
00:26:35,480 --> 00:26:37,800
So you were left
with the bare bones,
579
00:26:37,840 --> 00:26:39,600
which was the dried
food products.
580
00:26:39,640 --> 00:26:42,160
Dried fruit products didn't
have that much nutrition in
them.
581
00:26:42,200 --> 00:26:44,560
Coupled with, you know,
lack of fresh water,
582
00:26:44,600 --> 00:26:46,880
the men weren't getting
what they needed.
583
00:26:46,920 --> 00:26:48,880
It wasn't a great diet
to be at sea
584
00:26:48,920 --> 00:26:51,160
four, five months at a time.
585
00:26:51,200 --> 00:26:54,600
- Away without vitamin C
for months,
586
00:26:54,640 --> 00:26:57,600
the sailors were prone
to diseases like scurvy,
587
00:26:57,640 --> 00:27:02,040
suffering muscle and joint
pain, red rashes, and swelling
gums.
588
00:27:02,080 --> 00:27:04,040
Do you think they were
actually going hungry,
589
00:27:04,080 --> 00:27:06,360
or is it the quality
of the nutrition
590
00:27:06,400 --> 00:27:07,760
that's the problem?
591
00:27:07,800 --> 00:27:09,240
- Potentially a bit of both,
actually.
592
00:27:09,280 --> 00:27:11,240
The quality of the nutrition
wasn't great.
593
00:27:11,280 --> 00:27:13,600
We know that,
and if foods spoiled quicker
594
00:27:13,640 --> 00:27:15,120
than they could've
controlled it,
595
00:27:15,160 --> 00:27:16,880
they would've had
to lessen the rations.
596
00:27:16,920 --> 00:27:20,040
So to be able to feed four
to 800 men on board
597
00:27:20,080 --> 00:27:23,880
was a huge feat that the
Navy really struggled with.
598
00:27:23,920 --> 00:27:25,600
- [soft pleasant music]
- [seagulls cawing]
599
00:27:25,640 --> 00:27:27,040
- Across the channel,
600
00:27:27,080 --> 00:27:29,360
the French Navy faced
the same problem.
601
00:27:29,400 --> 00:27:33,640
In 1795, they offered a cash
prize to the first person
602
00:27:33,680 --> 00:27:37,080
to find a new method
of food preservation.
603
00:27:37,120 --> 00:27:38,320
♪
604
00:27:38,360 --> 00:27:40,800
The winner was Nicholas Appert.
605
00:27:40,840 --> 00:27:44,480
He found that, by heating food
inside glass bottles
606
00:27:44,520 --> 00:27:48,560
and sealing them up with a plug
of cream cheese and slate lime,
607
00:27:48,600 --> 00:27:53,720
he could preserve food
almost indefinitely.
608
00:27:53,760 --> 00:27:55,920
The British quickly
jumped on the bandwagon,
609
00:27:55,960 --> 00:27:58,200
coming up with
their own version.
610
00:27:58,240 --> 00:28:00,520
Looking for
a less fragile material,
611
00:28:00,560 --> 00:28:05,560
they turned to their already
established industry, tinplate.
612
00:28:05,600 --> 00:28:10,360
Author John Nutting has made
a replica of their solution.
613
00:28:10,400 --> 00:28:12,920
Why change from
glass bottles to tin cans?
614
00:28:12,960 --> 00:28:14,600
- Well, glass bottles
were fragile,
615
00:28:14,640 --> 00:28:17,200
so you didn't want really
to have to use something
616
00:28:17,240 --> 00:28:19,560
which was not particularly
good at resisting knocks
617
00:28:19,600 --> 00:28:21,120
and bashes
and all the sort of things
618
00:28:21,160 --> 00:28:23,600
that would happen
to preserve foods on ships.
619
00:28:23,640 --> 00:28:25,360
[soft upbeat music]
620
00:28:25,400 --> 00:28:27,440
- The innovator who made
the first successful tin cans
621
00:28:27,480 --> 00:28:31,160
for preservation was a man
called Bryan Donkin.
622
00:28:31,200 --> 00:28:33,840
He set up the first tin
canning factory
623
00:28:33,880 --> 00:28:37,200
in the world in London,
624
00:28:37,240 --> 00:28:39,680
and the principles
of counting he pioneered
625
00:28:39,720 --> 00:28:42,040
are still the same today.
626
00:28:42,080 --> 00:28:45,280
So food goes in there.
627
00:28:45,320 --> 00:28:47,080
First, he filled
the can with food
628
00:28:47,120 --> 00:28:50,960
through a hole in the top.
629
00:28:51,000 --> 00:28:54,040
- So now what we have to do
is cover that hole--
630
00:28:54,080 --> 00:28:55,880
- Right.
- And solder that on.
631
00:28:55,920 --> 00:28:59,000
- Okie doke.
632
00:28:59,040 --> 00:29:03,200
Then added a lid with
a much smaller hole.
633
00:29:03,240 --> 00:29:05,600
So now we've got
everything closed except
634
00:29:05,640 --> 00:29:08,760
for one tiny little hole.
635
00:29:08,800 --> 00:29:10,680
When he cooked
the food inside the can,
636
00:29:10,720 --> 00:29:13,800
steam could escape
through the hole,
637
00:29:13,840 --> 00:29:15,960
but it was then sealed up,
638
00:29:16,000 --> 00:29:20,760
preserving the food
inside the can.
639
00:29:20,800 --> 00:29:24,400
And that's it. So now
the food in there is cooked.
640
00:29:24,440 --> 00:29:27,320
All the bacteria are killed,
and because it's now sealed,
641
00:29:27,360 --> 00:29:28,400
no new bacteria can get in.
642
00:29:28,440 --> 00:29:29,880
- Exactly, yes.
643
00:29:29,920 --> 00:29:32,040
And it's preserved
with all its nutritional
644
00:29:32,080 --> 00:29:34,080
and vitamin values intact.
645
00:29:34,120 --> 00:29:36,080
- That's the key part of it
646
00:29:36,120 --> 00:29:37,720
that your nutritional value
is completely preserved, yes.
647
00:29:37,760 --> 00:29:39,560
[bright upbeat music]
648
00:29:39,600 --> 00:29:42,480
- So the tin can was born.
649
00:29:42,520 --> 00:29:45,520
By 1818, Donkin's factory
was supplying the Navy
650
00:29:45,560 --> 00:29:48,520
with almost 24,000 cans a year,
651
00:29:48,560 --> 00:29:51,800
including soup,
meat, and vegetables,
652
00:29:51,840 --> 00:29:56,680
all rich in vitamins
and minerals.
653
00:29:56,720 --> 00:29:59,960
The nutrition of the British
seamen was hugely improved,
654
00:30:00,000 --> 00:30:04,560
and this humble invention
saved thousands of lives.
655
00:30:07,160 --> 00:30:09,120
- [upbeat music]
- [machinery whirs]
656
00:30:09,160 --> 00:30:11,880
- Back in Wigan,
my three vital ingredients
657
00:30:11,920 --> 00:30:13,920
are being brought together
for the first time
658
00:30:13,960 --> 00:30:16,560
in the filling hole.
659
00:30:16,600 --> 00:30:18,800
The beans and dropping
down from blanching,
660
00:30:18,840 --> 00:30:21,920
tomato sauce is coming
from the kitchen next door,
661
00:30:21,960 --> 00:30:24,160
and the cans are traveling
from can making
662
00:30:24,200 --> 00:30:26,840
on the other side of the site.
663
00:30:26,880 --> 00:30:31,040
I'm following them to meet
filling operator Jason Lowe.
664
00:30:31,080 --> 00:30:33,520
- This is the starts
the process, Gregg.
665
00:30:33,560 --> 00:30:35,720
We'll get the cans
from can making,
666
00:30:35,760 --> 00:30:37,320
they come down the gantry,
667
00:30:37,360 --> 00:30:40,840
and they go straight
into the bean end.
668
00:30:40,880 --> 00:30:43,640
- The blanched beans arrive
at the rotating bean head
669
00:30:43,680 --> 00:30:47,800
and fill up the small round
compartments on top.
670
00:30:47,840 --> 00:30:51,640
Then they drop into
the waiting cans below.
671
00:30:51,680 --> 00:30:56,000
On average,
465 beans into every can.
672
00:30:56,040 --> 00:30:57,800
It all happens so fast,
673
00:30:57,840 --> 00:31:00,200
I'll just have to take
their word for it.
674
00:31:00,240 --> 00:31:02,600
So you don't add
the tomato sauce yet?
675
00:31:02,640 --> 00:31:05,960
- No, the tomato sauce
is in the next step.
676
00:31:06,000 --> 00:31:09,000
- Can I see the sauce go in?
- Yeah, of course you can.
677
00:31:09,040 --> 00:31:11,520
This is what we call
a sauce filler.
678
00:31:11,560 --> 00:31:14,360
Happens at a rapid pace,
my friend, doesn't it?
679
00:31:14,400 --> 00:31:17,360
Endless sauce being put on.
680
00:31:17,400 --> 00:31:20,320
The cans are passing
at such a rapid rate
681
00:31:20,360 --> 00:31:24,920
that the sauce has to be
squirted in at high pressure.
682
00:31:24,960 --> 00:31:27,240
- After the sauce, you've got
the beans in the can,
683
00:31:27,280 --> 00:31:30,280
the sauce in the can,
then it puts the lid on.
684
00:31:30,320 --> 00:31:31,640
[upbeat music]
685
00:31:31,680 --> 00:31:33,240
- Here in filling,
686
00:31:33,280 --> 00:31:37,480
the can ends are stacked
into a machine by hand.
687
00:31:37,520 --> 00:31:39,440
Whatever you do, don't drop it,
688
00:31:39,480 --> 00:31:41,640
or else you'll end up with
all them can ends everywhere.
689
00:31:41,680 --> 00:31:45,040
[machinery whirs]
690
00:31:45,080 --> 00:31:46,840
Yay!
691
00:31:46,880 --> 00:31:49,040
♪
692
00:31:49,080 --> 00:31:52,280
Finally, the cans are sealed.
693
00:31:52,320 --> 00:31:55,960
But I've just realized.
The beans haven't been cooked!
694
00:31:56,000 --> 00:31:57,760
They're not cooked yet,
are they?
695
00:31:57,800 --> 00:32:00,360
- No, them are not cooked yet.
Them beans are blanched.
696
00:32:00,400 --> 00:32:02,680
They get cooked further down.
697
00:32:02,720 --> 00:32:06,640
- Inside the tin?
- Inside the tin.
698
00:32:06,680 --> 00:32:09,600
The beans and the sauce are
cooked together in a sealed
tin?
699
00:32:09,640 --> 00:32:11,320
- Yes.
700
00:32:11,360 --> 00:32:13,280
- Does that sound right to you?
701
00:32:13,320 --> 00:32:15,000
- That's our process, Gregg.
702
00:32:15,040 --> 00:32:16,640
- Who knew that?
703
00:32:16,680 --> 00:32:19,080
No one would ever dream
that those beans
704
00:32:19,120 --> 00:32:22,360
go into that can uncooked.
705
00:32:22,400 --> 00:32:25,400
Cooking them once they're
in the can kills any bacteria
706
00:32:25,440 --> 00:32:28,920
that might be inside,
preserving the contents,
707
00:32:28,960 --> 00:32:30,880
and Cherry's been
finding out exactly
708
00:32:30,920 --> 00:32:33,840
how long tin food will last.
709
00:32:33,880 --> 00:32:37,480
[bright upbeat guitar music]
710
00:32:37,520 --> 00:32:39,920
- If you're anything like me,
tins are bought
711
00:32:39,960 --> 00:32:41,920
for a rainy day,
and then they end up
712
00:32:41,960 --> 00:32:44,000
at the back of the cupboard,
gathering dust.
713
00:32:44,040 --> 00:32:49,000
But how long can they sit
there and still okay to eat?
714
00:32:49,040 --> 00:32:51,760
If they're past
their best before date,
715
00:32:51,800 --> 00:32:54,560
they can still be used as long
as they're not dented,
716
00:32:54,600 --> 00:32:57,120
punctured, swollen, or rusty.
717
00:32:57,160 --> 00:33:01,840
But is canned food
as nutritious as fresh?
718
00:33:01,880 --> 00:33:03,840
To find out,
719
00:33:03,880 --> 00:33:05,360
I'm going to the Health
and Life Sciences Department
720
00:33:05,400 --> 00:33:07,960
at the University of Coventry.
721
00:33:08,000 --> 00:33:09,640
First, I've brought them
a tin of tomatoes
722
00:33:09,680 --> 00:33:12,800
14 months past
its best before date.
723
00:33:12,840 --> 00:33:15,440
Dietician Carla Phillips
is going to measure
724
00:33:15,480 --> 00:33:18,280
the amount of vitamin C
in the tinned tomatoes
725
00:33:18,320 --> 00:33:20,680
and compare that to fresh ones.
726
00:33:20,720 --> 00:33:22,000
- We've got some
fresh tomatoes here.
727
00:33:22,040 --> 00:33:24,000
So we need to blend them down,
728
00:33:24,040 --> 00:33:26,160
and then we can extract
the vitamin C.
729
00:33:26,200 --> 00:33:27,400
- Here we go.
730
00:33:27,440 --> 00:33:29,120
♪
731
00:33:29,160 --> 00:33:30,600
[laughs]
732
00:33:30,640 --> 00:33:33,000
Scientist Andrew Reed
puts our tinned
733
00:33:33,040 --> 00:33:36,400
and fresh samples
into a liquid chromatographer
734
00:33:36,440 --> 00:33:39,800
to separate and measure
that vitamin C levels.
735
00:33:39,840 --> 00:33:41,840
So the results show
that the fresh tomatoes
736
00:33:41,880 --> 00:33:43,960
that we bought today
have the same vitamin C level
737
00:33:44,000 --> 00:33:45,480
as the tinned tomatoes.
738
00:33:45,520 --> 00:33:48,240
- What?
I'm completely gobsmacked.
739
00:33:48,280 --> 00:33:49,960
- Well, we can explain
that because these
740
00:33:50,000 --> 00:33:52,120
would've been tinned
as soon as they were picked,
741
00:33:52,160 --> 00:33:55,400
and these fresh tomatoes
might have been hanging around
742
00:33:55,440 --> 00:33:58,440
in a warehouse before
they went to the supermarket,
743
00:33:58,480 --> 00:34:00,280
so the vitamin C content
will degrade
744
00:34:00,320 --> 00:34:01,880
from these fresh products.
745
00:34:01,920 --> 00:34:04,800
- So canning preserves
the nutrients,
746
00:34:04,840 --> 00:34:08,600
whereas in fresh food,
they continually degrade.
747
00:34:08,640 --> 00:34:11,880
Next, the lab has found
another can to test.
748
00:34:11,920 --> 00:34:14,040
It's slightly out of date.
749
00:34:14,080 --> 00:34:15,640
["Stayin' Alive" plays]
750
00:34:15,680 --> 00:34:18,400
- What?
- 45-year-old can of skippers.
751
00:34:18,440 --> 00:34:22,680
♪ Stayin' alive
752
00:34:22,720 --> 00:34:24,280
- Ooh, it comes with a key.
753
00:34:24,320 --> 00:34:26,120
- I think you put.
- Yeah.
754
00:34:26,160 --> 00:34:27,480
- That bit in there.
- I think so.
755
00:34:27,520 --> 00:34:29,720
- These fish haven't been
out of bed
756
00:34:29,760 --> 00:34:33,040
- for 45 years.
- I know. Absolutely.
757
00:34:33,080 --> 00:34:35,240
- Theoretically,
there's no limit
758
00:34:35,280 --> 00:34:38,840
on how long fish can be kept
nutritionally sound in a can.
759
00:34:38,880 --> 00:34:41,000
That is absolutely incredible.
760
00:34:41,040 --> 00:34:44,320
They look fresh,
they smell fresh.
761
00:34:44,360 --> 00:34:45,840
But what I would like to know
762
00:34:45,880 --> 00:34:48,480
is are there any hidden
microbes in them?
763
00:34:48,520 --> 00:34:50,760
- We shall find out.
764
00:34:50,800 --> 00:34:53,000
- To see if the fish
is still safe to eat,
765
00:34:53,040 --> 00:34:55,760
microbiologist
Dr. Daniel Hammond
766
00:34:55,800 --> 00:34:58,040
places samples on Petri dishes
767
00:34:58,080 --> 00:35:01,000
that need to be incubated
for microbe testing.
768
00:35:01,040 --> 00:35:04,600
The results will take five
days.
769
00:35:04,640 --> 00:35:07,440
As a dietician,
would you recommend cans?
770
00:35:07,480 --> 00:35:09,200
- Absolutely.
771
00:35:09,240 --> 00:35:10,120
They're a great way
of helping us to meet
772
00:35:10,160 --> 00:35:11,840
our nutritional requirements.
773
00:35:11,880 --> 00:35:13,200
You know, if we buy fresh fruit
and vegetables,
774
00:35:13,240 --> 00:35:14,800
then they can stay
in our fridge,
775
00:35:14,840 --> 00:35:16,480
and if we don't use them up
quick enough,
776
00:35:16,520 --> 00:35:19,400
then the nutrients
can become less over time.
777
00:35:19,440 --> 00:35:21,760
But tinned vegetables will
really keep the nutrition
778
00:35:21,800 --> 00:35:23,080
locked in for longer.
779
00:35:23,120 --> 00:35:26,000
- So fresh is wonderful
if eaten quickly,
780
00:35:26,040 --> 00:35:29,320
but cans are a fantastic way
of getting good food
781
00:35:29,360 --> 00:35:31,080
into our body very
conveniently.
782
00:35:31,120 --> 00:35:33,040
- Absolutely.
783
00:35:33,080 --> 00:35:34,120
["Stayin' Alive"]
784
00:35:34,160 --> 00:35:36,080
- And the old tin of skippers,
785
00:35:36,120 --> 00:35:39,000
after a sample was incubated
in a Petri dish for five days,
786
00:35:39,040 --> 00:35:42,080
it showed no signs
of bacterial growth.
787
00:35:42,120 --> 00:35:47,120
So remarkably, after 45 years,
the fish is fit to eat.
788
00:35:47,160 --> 00:35:51,360
♪ Ah, ah, ah, ah,
stayin' alive, stayin' alive ♪
789
00:35:51,400 --> 00:35:54,400
- But before you eat any food
from out of date cans,
790
00:35:54,440 --> 00:35:57,160
make sure the can is intact
and in good condition
791
00:35:57,200 --> 00:36:00,960
and the contents look
and smell okay.
792
00:36:01,000 --> 00:36:04,360
[machinery hisses and whirs]
793
00:36:04,400 --> 00:36:05,960
- [dramatic music]
- [timer beeps]
794
00:36:06,000 --> 00:36:08,040
- Back at the factory,
it's been 52 minutes
795
00:36:08,080 --> 00:36:11,440
since I released my beans
from the bag.
796
00:36:11,480 --> 00:36:14,840
They've already been blanched
and sealed inside the can.
797
00:36:14,880 --> 00:36:18,480
Now it's finally time
to cook them.
798
00:36:18,520 --> 00:36:23,000
[machinery hisses]
799
00:36:23,040 --> 00:36:25,600
Just like a household
pressure cooker,
800
00:36:25,640 --> 00:36:27,760
steam is used
to raise the pressure
801
00:36:27,800 --> 00:36:31,320
and the temperature inside
the cooking chamber.
802
00:36:31,360 --> 00:36:33,880
There are five chambers
in each cooker,
803
00:36:33,920 --> 00:36:37,600
and inside each one
is a giant corkscrew,
804
00:36:37,640 --> 00:36:39,720
which continuously turns,
805
00:36:39,760 --> 00:36:44,080
moving the cans from one end
of the chamber to the other.
806
00:36:44,120 --> 00:36:47,320
The movement mixes the beans
and sauce inside the can,
807
00:36:47,360 --> 00:36:50,640
and the heat from
the steam cooks them.
808
00:36:50,680 --> 00:36:52,280
Seven minutes later,
809
00:36:52,320 --> 00:36:54,840
they move on
to the next chamber.
810
00:36:54,880 --> 00:36:56,880
So what we do is we
send it up one way,
811
00:36:56,920 --> 00:36:59,080
transfer it, and send
it all the way back,
812
00:36:59,120 --> 00:37:02,200
transfer it again, send it
all the way back up this end.
813
00:37:02,240 --> 00:37:05,440
- Why don't you just make
a great, big pot of beans
814
00:37:05,480 --> 00:37:09,000
and sauce, cook it up,
stick it in a can?
815
00:37:09,040 --> 00:37:11,040
- Well, we can't guarantee
that there won't be bacteria
816
00:37:11,080 --> 00:37:13,080
in that product
when it cooked it up,
817
00:37:13,120 --> 00:37:15,080
and we're sealing
that bacteria in a can
818
00:37:15,120 --> 00:37:16,880
and close the spoiled product
or dangerous product
819
00:37:16,920 --> 00:37:19,880
on the other side
of the process.
820
00:37:19,920 --> 00:37:22,240
- 21 minutes
at a high temperature
821
00:37:22,280 --> 00:37:26,200
and pressure kills
any bacteria inside the can.
822
00:37:26,240 --> 00:37:28,360
That means the beans
will be good to eat
823
00:37:28,400 --> 00:37:31,720
for at least the next 16
months.
824
00:37:31,760 --> 00:37:33,960
That's why
it's perfectly preserved.
825
00:37:34,000 --> 00:37:36,200
That is the beauty of canning.
826
00:37:36,240 --> 00:37:37,960
- It controls bacteria.
827
00:37:38,000 --> 00:37:40,480
[dramatic music]
828
00:37:40,520 --> 00:37:44,840
So it turns out that baked
beans aren't actually baked
after all.
829
00:37:44,880 --> 00:37:48,080
They're cooked using steam.
830
00:37:48,120 --> 00:37:52,200
Mate, what it takes
to give us beans on toast, eh?
831
00:37:55,840 --> 00:37:56,840
- [timer beeps]
- [tense music]
832
00:37:56,880 --> 00:37:59,600
In just one hour and 27
minutes,
833
00:37:59,640 --> 00:38:03,040
my beans have been blanched,
laser checked,
834
00:38:03,080 --> 00:38:06,320
put in a can,
covered in tomato sauce,
835
00:38:06,360 --> 00:38:09,480
and sent spiraling through
a pressure cooker.
836
00:38:09,520 --> 00:38:12,320
They've been cooked
with the lid already sealed on,
837
00:38:12,360 --> 00:38:16,160
so every two hours,
a team of experts take a can
838
00:38:16,200 --> 00:38:18,360
off the production
line and taste it,
839
00:38:18,400 --> 00:38:20,040
checking the texture
of the beans
840
00:38:20,080 --> 00:38:22,400
and the flavor of the sauce.
841
00:38:22,440 --> 00:38:24,760
As soon as my beans
get the green light,
842
00:38:24,800 --> 00:38:27,360
it's time to put
a label on them.
843
00:38:27,400 --> 00:38:30,400
Today,
that's Hayley Wright's job.
844
00:38:30,440 --> 00:38:33,400
There's a hole in the wall
where the cooker is,
845
00:38:33,440 --> 00:38:34,680
and they come straight
through to you?
846
00:38:34,720 --> 00:38:37,120
- Yeah.
- How many?
847
00:38:37,160 --> 00:38:39,280
- We package over
three million a day.
848
00:38:39,320 --> 00:38:41,880
- These are still really warm.
- They are warm.
849
00:38:41,920 --> 00:38:43,280
These are straight
from the cooker.
850
00:38:43,320 --> 00:38:45,800
This is the way that
we normally label them.
851
00:38:45,840 --> 00:38:47,960
- A machine sprays each can
852
00:38:48,000 --> 00:38:51,200
with a mist of glue
and sticks on a label.
853
00:38:51,240 --> 00:38:53,560
It's all carefully monitored.
854
00:38:53,600 --> 00:38:54,720
- The light that
you can see shining
855
00:38:54,760 --> 00:38:56,080
is actually a camera.
856
00:38:56,120 --> 00:38:57,560
That is taking a photograph
857
00:38:57,600 --> 00:38:59,640
of every single label
that's applied.
858
00:38:59,680 --> 00:39:01,840
- That's to make sure
that every label
859
00:39:01,880 --> 00:39:04,880
has been stuck on straight.
860
00:39:04,920 --> 00:39:06,640
Are my beans
finally ready to go?
861
00:39:06,680 --> 00:39:08,360
- They're almost ready to go.
862
00:39:08,400 --> 00:39:09,840
We just need to do a couple
more quality checks.
863
00:39:09,880 --> 00:39:11,200
- You're kidding me.
- No.
864
00:39:11,240 --> 00:39:12,760
I'll just show you
one over here.
865
00:39:12,800 --> 00:39:13,560
- Listen, they're cooked!
They're in the can!
866
00:39:13,600 --> 00:39:15,160
They're gonna be okay!
867
00:39:15,200 --> 00:39:18,440
- Let me just show you
our final quality check.
868
00:39:18,480 --> 00:39:21,040
So we need to ensure that
the beans has got a vacuum.
869
00:39:21,080 --> 00:39:22,800
What we mean by a vacuum
is that the end
870
00:39:22,840 --> 00:39:23,920
is actually in a concave.
871
00:39:23,960 --> 00:39:25,400
So if you feel that,
872
00:39:25,440 --> 00:39:27,840
it's a nice tight vacuum
that's in the can.
873
00:39:27,880 --> 00:39:29,920
- If a can gets knocked
or dented,
874
00:39:29,960 --> 00:39:32,880
creating a hole,
the vacuum will be broken,
875
00:39:32,920 --> 00:39:36,160
and the bottom
of the can will bulge outwards.
876
00:39:36,200 --> 00:39:38,600
Luckily, the factory have
a way of preventing
877
00:39:38,640 --> 00:39:40,480
any of those from
getting through.
878
00:39:40,520 --> 00:39:42,320
Right.
879
00:39:42,360 --> 00:39:44,000
I've opened that just
a little bit, right?
880
00:39:44,040 --> 00:39:45,360
- Yep.
881
00:39:45,400 --> 00:39:46,680
- And now I'm gonna push
the lid down
882
00:39:46,720 --> 00:39:48,000
so the machine can't tell.
- Yep.
883
00:39:48,040 --> 00:39:49,680
- That looks like
a sealed can, right?
884
00:39:49,720 --> 00:39:51,440
- Correct.
885
00:39:51,480 --> 00:39:52,360
- But you reckon now
the bottom will have changed?
886
00:39:52,400 --> 00:39:54,160
- Yes.
887
00:39:54,200 --> 00:39:55,400
- I'm gonna make a little
scrape in it, all right?
888
00:39:55,440 --> 00:39:56,840
That ours.
889
00:39:56,880 --> 00:40:00,040
- Put it back in the machine.
- Okay.
890
00:40:00,080 --> 00:40:01,680
- The can passes
through a sensor,
891
00:40:01,720 --> 00:40:03,480
which checks its bottom.
892
00:40:03,520 --> 00:40:05,360
Even the smallest bulge
would indicate
893
00:40:05,400 --> 00:40:10,880
there's a leak in the can,
and it would be rejected.
894
00:40:10,920 --> 00:40:13,800
[laughs]
That's ridiculous!
895
00:40:13,840 --> 00:40:15,800
That's not the neatest,
896
00:40:15,840 --> 00:40:18,120
but that is in the top three
neatest things I've seen today.
897
00:40:18,160 --> 00:40:20,320
- [Hayley laughs]
- [upbeat music]
898
00:40:20,360 --> 00:40:23,520
My finished can
has been labeled.
899
00:40:23,560 --> 00:40:25,800
Next, it's wrapped
and stacked onto a pallet
900
00:40:25,840 --> 00:40:29,800
by two dancing robots.
901
00:40:29,840 --> 00:40:31,560
[dramatic music]
902
00:40:31,600 --> 00:40:34,280
But before the cans are sent
out to the supermarket,
903
00:40:34,320 --> 00:40:38,920
they pass through the factory's
national distribution center.
904
00:40:38,960 --> 00:40:42,520
Almost all Heinz products
made at their UK factories
905
00:40:42,560 --> 00:40:44,520
are stored here.
906
00:40:44,560 --> 00:40:45,960
As well as beans, soup,
907
00:40:46,000 --> 00:40:48,080
and spaghetti made
at this factory,
908
00:40:48,120 --> 00:40:50,600
the warehouse
will also store everything
909
00:40:50,640 --> 00:40:53,960
from tomato ketchup
to salad cream.
910
00:40:54,000 --> 00:40:56,120
Paul Andrews
is head of logistics
911
00:40:56,160 --> 00:40:59,080
for this mammoth operation.
912
00:40:59,120 --> 00:41:03,960
Oh my world.
What on earth?
913
00:41:04,000 --> 00:41:05,600
- It's amazing, isn't it?
914
00:41:05,640 --> 00:41:07,800
- That's just breathtaking.
915
00:41:07,840 --> 00:41:09,320
- In this warehouse here,
916
00:41:09,360 --> 00:41:13,000
we can store 70,000 pallets
of product.
917
00:41:13,040 --> 00:41:16,640
Imagine, on each pallet,
there's roughly 100 cases.
918
00:41:16,680 --> 00:41:21,360
- This is one of the largest
food storage sites in the UK.
919
00:41:21,400 --> 00:41:23,960
It's warm in here.
Do you heat this warehouse?
920
00:41:24,000 --> 00:41:25,560
No, we don't need to at all.
921
00:41:25,600 --> 00:41:27,000
Yeah, these beans that
will come in here today,
922
00:41:27,040 --> 00:41:28,880
they're still warm
from the factory,
923
00:41:28,920 --> 00:41:30,880
so actually, all the heat
from the product
924
00:41:30,920 --> 00:41:32,800
is heating the warehouse here.
925
00:41:32,840 --> 00:41:33,960
- No way.
926
00:41:34,000 --> 00:41:35,680
The heat I can feel,
927
00:41:35,720 --> 00:41:37,680
because this is markedly warmer
than out there,
928
00:41:37,720 --> 00:41:39,520
is just the heat from
the cooked beans?
929
00:41:39,560 --> 00:41:42,040
- It's just the heat
from the cooked beans.
930
00:41:42,080 --> 00:41:44,080
- Is anybody driving
those cranes?
931
00:41:44,120 --> 00:41:45,960
- These cranes
are all automatic.
932
00:41:46,000 --> 00:41:49,000
[machinery whirs and beeps]
933
00:41:49,040 --> 00:41:52,480
This is just food
on a giant scale.
934
00:41:52,520 --> 00:41:56,800
That's what it takes
to feed the nation.
935
00:41:56,840 --> 00:41:58,560
[lift whines]
936
00:41:58,600 --> 00:42:00,600
Just two hours ago,
I was hoisting my bag of beans
937
00:42:00,640 --> 00:42:03,960
into place and releasing them
into the factory.
938
00:42:04,000 --> 00:42:07,200
Now they are under the control
939
00:42:07,240 --> 00:42:10,160
of these giant cranes.
940
00:42:10,200 --> 00:42:14,200
The pallets of cans are stored
in the warehouse for 17 hours
941
00:42:14,240 --> 00:42:17,960
while final quality tests
are completed
942
00:42:18,000 --> 00:42:21,720
before being rolled out,
ready for departure.
943
00:42:21,760 --> 00:42:23,280
Take it out and stick it
on a lorry.
944
00:42:23,320 --> 00:42:25,120
- Off it goes.
945
00:42:25,160 --> 00:42:29,160
- All of these coming past me
are all going to shops,
946
00:42:29,200 --> 00:42:32,120
a constant conveyor belt
into our kitchens.
947
00:42:32,160 --> 00:42:36,040
- Into your kitchens.
- Never ending.
948
00:42:36,080 --> 00:42:39,400
[pleasant upbeat music]
949
00:42:39,440 --> 00:42:41,680
They make three million cans
950
00:42:41,720 --> 00:42:44,160
of baked beans here
every single day.
951
00:42:44,200 --> 00:42:45,680
But then when you think
about it,
952
00:42:45,720 --> 00:42:47,440
there's hardly a kitchen
in the whole country
953
00:42:47,480 --> 00:42:49,200
that hasn't got
a tin of beans in it.
954
00:42:49,240 --> 00:42:51,760
It's the only product I know
that we would happily eat
955
00:42:51,800 --> 00:42:55,400
for breakfast,
lunch, and dinner.
956
00:42:55,440 --> 00:42:58,640
What I didn't realize
is the incredible technology
957
00:42:58,680 --> 00:43:00,120
that goes into making
958
00:43:00,160 --> 00:43:03,160
such an inexpensive
but everyday item.
959
00:43:03,200 --> 00:43:05,720
I suppose, in a way,
it's quite fitting
960
00:43:05,760 --> 00:43:08,360
that the country that eats
the most baked beans
961
00:43:08,400 --> 00:43:14,000
also has the biggest
baked bean factory on earth.
962
00:43:14,040 --> 00:43:16,000
Beans made at this factory
in Wigan
963
00:43:16,040 --> 00:43:18,760
will go to homes all over the
UK
964
00:43:18,800 --> 00:43:20,720
with the Northwest
taking the crown
965
00:43:20,760 --> 00:43:23,040
for the biggest bean eaters.
966
00:43:23,080 --> 00:43:25,960
They also head
to Ireland and Europe,
967
00:43:26,000 --> 00:43:29,920
in fact, all over the world,
as far away as Nigeria,
968
00:43:29,960 --> 00:43:32,360
India, and Australia,
969
00:43:32,400 --> 00:43:33,840
who eat more baked beans
970
00:43:33,880 --> 00:43:38,480
than any other country
outside the UK.
971
00:43:38,520 --> 00:43:40,200
Last one?
972
00:43:40,240 --> 00:43:42,200
- Yeah.
- All done?
973
00:43:42,240 --> 00:43:46,360
Thanks, mate.
Thank you very much.
974
00:43:46,400 --> 00:43:50,440
♪
975
00:43:50,480 --> 00:43:54,440
There, 3,000 tins of beans
on that lorry,
976
00:43:54,480 --> 00:43:57,640
and I saw those beans come in
dried from North America.
977
00:43:57,680 --> 00:43:59,720
But who knows?
978
00:43:59,760 --> 00:44:02,320
In a few days, someone might be
dipping their chips into 'em.
979
00:44:02,360 --> 00:44:06,480
Okay, let's go!
980
00:44:06,520 --> 00:44:09,080
Bean and gone.
74618
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