All language subtitles for Inside.The.Factory.How.Our.Favourite.Foods.Are.Made.2of3.Chocolate.720p.HDTV.x264.AAC.MVGroup.org.eng
Afrikaans
Albanian
Amharic
Arabic
Armenian
Azerbaijani
Basque
Belarusian
Bengali
Bosnian
Bulgarian
Catalan
Cebuano
Chichewa
Chinese (Simplified)
Chinese (Traditional)
Corsican
Croatian
Czech
Danish
Dutch
English
Esperanto
Estonian
Filipino
Finnish
French
Frisian
Galician
Georgian
German
Greek
Gujarati
Haitian Creole
Hausa
Hawaiian
Hebrew
Hindi
Hmong
Hungarian
Icelandic
Igbo
Indonesian
Irish
Italian
Japanese
Javanese
Kannada
Kazakh
Khmer
Korean
Kurdish (Kurmanji)
Kyrgyz
Lao
Latin
Latvian
Lithuanian
Luxembourgish
Macedonian
Malagasy
Malay
Malayalam
Maltese
Maori
Marathi
Mongolian
Myanmar (Burmese)
Nepali
Norwegian
Pashto
Persian
Polish
Portuguese
Punjabi
Romanian
Russian
Samoan
Scots Gaelic
Serbian
Sesotho
Shona
Sindhi
Sinhala
Slovak
Slovenian
Somali
Spanish
Sundanese
Swahili
Swedish
Tajik
Tamil
Telugu
Thai
Turkish
Ukrainian
Urdu
Uzbek
Vietnamese
Welsh
Xhosa
Yiddish
Yoruba
Zulu
Odia (Oriya)
Kinyarwanda
Turkmen
Tatar
Uyghur
Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:02,000 --> 00:00:04,280
We are, without doubt,
a nation of chocolate lovers.
2
00:00:04,280 --> 00:00:09,080
We eat, each of us, on average,
this much chocolate every year.
3
00:00:09,080 --> 00:00:14,240
'That's a whopping 266 bars each.'
4
00:00:14,240 --> 00:00:19,160
And the British love affair
with chocolate begins here,
5
00:00:19,160 --> 00:00:20,440
Liverpool port.
6
00:00:21,480 --> 00:00:29,000
Around 70,000 tonnes of cocoa beans
arrive into the UK every year.
7
00:00:29,000 --> 00:00:31,880
They're trucked to factories
all over Britain
8
00:00:31,880 --> 00:00:35,200
and they're used to feed
our insatiable sweet tooth.
9
00:00:37,280 --> 00:00:40,880
But how do you produce
chocolate on this scale?
10
00:00:40,880 --> 00:00:42,440
Whoa!
11
00:00:43,720 --> 00:00:47,080
We've come to one of the world's
largest chocolate makers
12
00:00:47,080 --> 00:00:48,120
to find out.
13
00:00:50,200 --> 00:00:51,800
'I'm Gregg Wallace...'
14
00:00:51,800 --> 00:00:53,320
I love chocolate.
15
00:00:53,320 --> 00:00:54,480
Whey!
16
00:00:54,480 --> 00:00:57,040
'And I've been given exclusive
access to this giant factory
17
00:00:57,040 --> 00:00:58,200
in York...'
18
00:00:58,200 --> 00:01:00,240
Oh, my word.
19
00:01:00,240 --> 00:01:04,360
'..to reveal how they make over
seven million bars in one day.'
20
00:01:05,680 --> 00:01:07,960
How much of a chocolate
geek have you become?
21
00:01:07,960 --> 00:01:09,400
Well, if I went on Mastermind
22
00:01:09,400 --> 00:01:12,200
I reckon I could
get through that quite easy.
23
00:01:12,200 --> 00:01:15,440
'I'm Cherry Healey
and I'm going to get hands-on
24
00:01:15,440 --> 00:01:17,960
'on a production line in Derbyshire.'
25
00:01:17,960 --> 00:01:21,120
What is this Willie Wonka
contraption?
26
00:01:21,120 --> 00:01:25,160
And historian Ruth Goodman will
delve into the factory archives
27
00:01:25,160 --> 00:01:28,440
and meet the people who found
love on the production line.
28
00:01:28,440 --> 00:01:30,840
And I said, "I'd love to take him
to bed and cuddle him..."
29
00:01:30,840 --> 00:01:32,320
cos he was like a teddy bear.
30
00:01:33,360 --> 00:01:37,080
From bean to bar, we're going
to follow the amazing journey
31
00:01:37,080 --> 00:01:39,920
of one of our
bestselling chocolates.
32
00:01:39,920 --> 00:01:43,320
You'll never look at a chocolate
bar the same way again.
33
00:01:43,320 --> 00:01:47,200
This is the incredible story
of the factories that feed Britain.
34
00:02:02,120 --> 00:02:04,760
This is the Nestle factory in York.
35
00:02:04,760 --> 00:02:09,760
It's one of the largest chocolate
manufacturers in the world.
36
00:02:09,760 --> 00:02:13,360
800 production staff
work around the clock to produce
37
00:02:13,360 --> 00:02:18,080
millions of bars a day which go to
every corner of the UK and Ireland.
38
00:02:19,560 --> 00:02:24,520
On this site, we'll see how
raw cocoa beans arrive by truck and
39
00:02:24,520 --> 00:02:27,520
leave just 24 hours later
as chocolate bars
40
00:02:27,520 --> 00:02:29,120
ready for the supermarket.
41
00:02:30,280 --> 00:02:33,840
And tonight, I'll be following
the journey of the Kit Kat.
42
00:02:36,400 --> 00:02:40,760
This is one of the most popular
chocolate bars in the world.
43
00:02:40,760 --> 00:02:45,640
We eat one billion of these
every year in the UK alone.
44
00:02:45,640 --> 00:02:50,840
'That's a staggering
1,900 every single minute.'
45
00:02:55,000 --> 00:02:58,000
But whether you like
your chocolate dark, milk or white
46
00:02:58,000 --> 00:03:00,200
it all starts with the cocoa bean.
47
00:03:02,840 --> 00:03:08,080
Every day, 120 tonnes of them
arrive at the bean processing plant
48
00:03:08,080 --> 00:03:09,640
to start the production.
49
00:03:10,960 --> 00:03:12,840
I'm going to roll up my sleeves
50
00:03:12,840 --> 00:03:18,040
and help cocoa bean expert Steve
Calpin unload his latest delivery.
51
00:03:19,480 --> 00:03:22,880
He's been here for over 40 years
and has worked everywhere
52
00:03:22,880 --> 00:03:26,800
from the chocolate production line
to the maintenance department.
53
00:03:29,480 --> 00:03:31,960
So, Steve, you pretty much
are at the start
54
00:03:31,960 --> 00:03:34,480
of the whole chocolate bar process?
55
00:03:34,480 --> 00:03:36,080
This is where it all starts.
56
00:03:36,080 --> 00:03:38,480
The beans get driven in here,
we process them,
57
00:03:38,480 --> 00:03:40,120
start making chocolate.
58
00:03:40,120 --> 00:03:41,960
Do you know how many beans
are on this truck?
59
00:03:41,960 --> 00:03:45,920
I've never actually counted them but
I think there'll be about 28 tonne.
60
00:03:45,920 --> 00:03:48,400
Just short of 30 tonne?
Just short of 30 tonne.
61
00:03:48,400 --> 00:03:50,480
Let me help you unload them.
62
00:03:50,480 --> 00:03:52,920
We've hooked it up
to the electric, now what?
63
00:03:52,920 --> 00:03:54,360
We just need to push the button
64
00:03:54,360 --> 00:03:56,480
and start off-loading
the beans into the system.
65
00:03:56,480 --> 00:03:58,120
Can I press the button? Yes.
66
00:04:00,440 --> 00:04:03,360
Whey! That's an avalanche of beans!
67
00:04:04,600 --> 00:04:07,280
In just 24 hours,
these beans will undergo
68
00:04:07,280 --> 00:04:09,200
an incredible transformation
69
00:04:09,200 --> 00:04:12,040
and leave York
as finished chocolate bars.
70
00:04:13,720 --> 00:04:17,040
But their journey
began thousands of miles away.
71
00:04:21,920 --> 00:04:27,640
90% of British chocolate begins life
as cocoa beans in West Africa.
72
00:04:27,640 --> 00:04:31,640
The main harvest of pods
from cocoa trees happens in March.
73
00:04:31,640 --> 00:04:34,600
Once the beans have been collected
they're dried in the African sun
74
00:04:34,600 --> 00:04:38,640
for seven days and then packed
and shipped to the UK.
75
00:04:41,000 --> 00:04:43,320
GREGG LAUGHS
76
00:04:43,320 --> 00:04:46,040
It looks like a handful of
grubby pebbles. Yeah.
77
00:04:46,040 --> 00:04:48,160
So this has literally
been transported
78
00:04:48,160 --> 00:04:50,880
straight from the Ivory Coast.
Straight from the Ivory Coast.
79
00:04:50,880 --> 00:04:53,680
And these have dried by the road
so they've got bits of grit in it...
80
00:04:53,680 --> 00:04:58,480
They've got bits of grit... Dirt.
Yeah. We've had shoes, snakes...
81
00:04:58,480 --> 00:05:00,800
Really? Yeah.
82
00:05:00,800 --> 00:05:04,080
'Now the beans begin
a nonstop three-hour ride.'
83
00:05:05,120 --> 00:05:07,880
'The aim is to crack
their hard outer shell
84
00:05:07,880 --> 00:05:10,200
'and release the cocoa-rich centre.'
85
00:05:10,200 --> 00:05:11,800
Come on.
86
00:05:11,800 --> 00:05:14,240
'But first, they
need to be cleaned.'
87
00:05:15,720 --> 00:05:18,640
'Specially-sized holes
in metal plates allow the beans
88
00:05:18,640 --> 00:05:23,200
'to fall through but capture
larger pieces of rubbish on top.'
89
00:05:23,200 --> 00:05:27,160
It separates all the string
and bits of rubbish.
90
00:05:27,160 --> 00:05:28,320
I get it.
91
00:05:28,320 --> 00:05:32,240
The beans you want drop through
but anything bigger stays.
92
00:05:32,240 --> 00:05:34,040
And that's the way. Brilliant.
93
00:05:35,160 --> 00:05:38,000
But it's not just grit and
rubbish that have hitched a ride
94
00:05:38,000 --> 00:05:40,040
over from Africa with the beans,
95
00:05:40,040 --> 00:05:42,040
sometimes there's treasure.
96
00:05:43,360 --> 00:05:47,160
I tend to get coins.
Get yourself a drink.
97
00:05:47,160 --> 00:05:50,120
Thanks, mate. Do I have to go to
the Ivory Coast to buy one?
98
00:05:50,120 --> 00:05:51,680
To the Ivory Coast, yeah.
99
00:05:55,440 --> 00:05:57,640
Next up is the de-shelling.
100
00:05:58,880 --> 00:06:00,880
What happens here,
101
00:06:00,880 --> 00:06:04,480
we have a series of rollers
in this machine here
102
00:06:04,480 --> 00:06:07,040
and as the beans go through,
it crushes them
103
00:06:07,040 --> 00:06:09,720
and takes the shell off the nib.
104
00:06:09,720 --> 00:06:15,040
The nib in the centre of the bean is
the Holy Grail of chocolate making.
105
00:06:15,040 --> 00:06:18,280
It contains all
the cocoa solids and fats
106
00:06:18,280 --> 00:06:20,800
that are the basis of chocolate.
107
00:06:20,800 --> 00:06:23,400
There you are, Gregg.
That's the nib?
108
00:06:23,400 --> 00:06:24,600
That's the nib.
109
00:06:28,160 --> 00:06:31,920
'The last remaining shell pieces
are vacuumed off the nibs
110
00:06:31,920 --> 00:06:37,880
'and the clean ones are fed into
three giant ovens...and roasted.'
111
00:06:38,920 --> 00:06:40,440
The temperature of the ovens
112
00:06:40,440 --> 00:06:44,840
is so critical to the recipe,
it's kept a closely guarded secret.
113
00:06:46,920 --> 00:06:49,160
After an hour, the roasted nibs
114
00:06:49,160 --> 00:06:51,680
are fed into a giant
food processor...
115
00:06:53,920 --> 00:06:57,840
..which transforms them into
a thick brown liquid called liquor.
116
00:07:01,320 --> 00:07:03,160
The thing that's made
it liquid like that
117
00:07:03,160 --> 00:07:05,840
is the fat
that's come out of the nib.
118
00:07:05,840 --> 00:07:08,440
The same way that
oil comes out of an olive,
119
00:07:08,440 --> 00:07:10,640
your fat's coming out
of the chocolate nib?
120
00:07:10,640 --> 00:07:12,480
That's correct.
121
00:07:12,480 --> 00:07:15,680
Have you added anything
at all to this nib?
122
00:07:15,680 --> 00:07:17,960
Just a bit of love and care
and attention.
123
00:07:17,960 --> 00:07:20,080
We all need a bit of that, mate.
I know.
124
00:07:23,280 --> 00:07:26,400
Eight tonnes of
cocoa liquor is now piped
125
00:07:26,400 --> 00:07:30,680
from the bean processing plant
to the factory next door.
126
00:07:30,680 --> 00:07:34,800
Here they will turn the bitter thick
liquid into hundreds of tonnes
127
00:07:34,800 --> 00:07:36,640
of sweet milk chocolate.
128
00:07:37,800 --> 00:07:42,080
First it needs to be
mixed with the other ingredients.
129
00:07:42,080 --> 00:07:45,600
Sean Conricode is the factory's
chocolate specialist
130
00:07:45,600 --> 00:07:49,120
and has been the keeper
of recipes for over 38 years.
131
00:07:50,240 --> 00:07:53,440
All those stainless steel vessels
contain our liquid ingredients.
132
00:07:53,440 --> 00:07:55,760
So there's cocoa liquor,
cocoa butter,
133
00:07:55,760 --> 00:07:59,560
vegetable fat and then we take
all our dry ingredients so sugar...
134
00:07:59,560 --> 00:08:02,920
our milk component...are
all fed across into this mixer.
135
00:08:08,920 --> 00:08:12,040
The result is a coarse,
chocolaty powder
136
00:08:12,040 --> 00:08:16,000
churned out at a rate
of nine tonnes an hour.
137
00:08:16,000 --> 00:08:18,680
Conveyor belts drop
the mixed ingredients
138
00:08:18,680 --> 00:08:21,920
into the top of a giant,
heated blender, called a conch.
139
00:08:25,760 --> 00:08:28,000
'After seven to eight
hours of mixing
140
00:08:28,000 --> 00:08:31,520
'those ingredients will be
pumped out as liquid chocolate.'
141
00:08:31,520 --> 00:08:34,520
The smell in here - it's so strong.
142
00:08:34,520 --> 00:08:36,040
It's very distinctive.
143
00:08:36,040 --> 00:08:38,960
So that's the cooked aroma of
chocolate I can smell.
144
00:08:38,960 --> 00:08:42,320
It's like consuming, it's like
it's almost... Well, it's heady.
145
00:08:42,320 --> 00:08:44,880
It is.
Smell is just as important as taste
146
00:08:44,880 --> 00:08:48,040
so the chocolate's got to smell
right as well as taste right.
147
00:08:48,040 --> 00:08:51,120
'But what makes up that smell?
148
00:08:51,120 --> 00:08:53,640
'While I help Sean
prepare the chocolate,
149
00:08:53,640 --> 00:08:56,000
'Cherry's in Reading
to find out the secret
150
00:08:56,000 --> 00:08:58,920
'behind that unique
chocolate aroma.'
151
00:09:05,240 --> 00:09:07,040
Yes, please, thank you.
152
00:09:08,640 --> 00:09:10,640
'Food scientist Ashleigh Stuart
153
00:09:10,640 --> 00:09:14,400
'spends hours every day
sniffing chocolate.'
154
00:09:14,400 --> 00:09:17,600
You are a PhD student
studying chocolate.
155
00:09:17,600 --> 00:09:20,920
Is that the best job in the world?
Yeah, I think it could be.
156
00:09:20,920 --> 00:09:25,920
'Ashleigh thinks the reason we love
chocolate so much is the smell.'
157
00:09:25,920 --> 00:09:29,280
If you try the chocolate dessert
while you're holding your nose
158
00:09:29,280 --> 00:09:32,600
you shouldn't get very
much flavour at all.
159
00:09:32,600 --> 00:09:37,120
It's got a great texture.
I can taste that it's sweet.
160
00:09:37,120 --> 00:09:40,040
And then if you
unblock your nose,
161
00:09:40,040 --> 00:09:43,200
the flavour should suddenly
hit you. Oh, yeah.
162
00:09:43,200 --> 00:09:46,120
That's really good. Wow.
163
00:09:46,120 --> 00:09:48,240
'Like coffee or fine wine,
164
00:09:48,240 --> 00:09:51,120
'chocolate has hundreds
of different smells
165
00:09:51,120 --> 00:09:53,560
'that make up the aroma
we recognise.'
166
00:09:58,840 --> 00:10:02,160
To help me discover some
of those individual smells,
167
00:10:02,160 --> 00:10:05,760
Ashleigh has an instrument
called an olfactometer
168
00:10:05,760 --> 00:10:08,200
that can separate them out.
169
00:10:08,200 --> 00:10:10,840
So you'll get all
of the compounds individually
170
00:10:10,840 --> 00:10:13,640
rather than all in one go.
171
00:10:13,640 --> 00:10:18,000
'She gently warms the chocolate to
release the smell molecules inside
172
00:10:18,000 --> 00:10:19,800
'and then captures them.
173
00:10:19,800 --> 00:10:23,120
'These smells are then fed through
a tube one after another.'
174
00:10:23,120 --> 00:10:25,600
You should be able to smell some
quite strange things.
175
00:10:27,360 --> 00:10:29,320
Oh, there's something.
176
00:10:29,320 --> 00:10:32,920
That is really yummy, it's
like...butter popcorn.
177
00:10:32,920 --> 00:10:34,440
That's really delicious.
178
00:10:36,840 --> 00:10:40,200
It's a little bit earthy...
179
00:10:40,200 --> 00:10:41,600
Moss?
180
00:10:41,600 --> 00:10:44,480
Well, it's a mushroomy compound...
Oh, mushrooms.
181
00:10:44,480 --> 00:10:47,240
Once you know, it's really obvious.
182
00:10:48,760 --> 00:10:50,240
Raw potato.
183
00:10:50,240 --> 00:10:51,960
Yeah. Yes. Yeah, yeah.
184
00:10:51,960 --> 00:10:54,880
'These molecules are not
added to the chocolate,
185
00:10:54,880 --> 00:10:57,760
'they're found naturally
in the ingredients
186
00:10:57,760 --> 00:11:00,320
'and some of them
aren't very pleasant.'
187
00:11:01,840 --> 00:11:03,320
I want to say burnt rubber.
188
00:11:05,680 --> 00:11:07,320
Eurgh! What is that?!
189
00:11:08,920 --> 00:11:10,320
That is smelly feet.
190
00:11:10,320 --> 00:11:14,200
Like worse than after I've been
to the gym smelly feet.
191
00:11:14,200 --> 00:11:15,280
Bleurgh!
192
00:11:15,280 --> 00:11:17,960
That one stinks.
It's a very stinky cheese.
193
00:11:20,440 --> 00:11:24,920
In fact, the smell of chocolate
is made up of a whole host
194
00:11:24,920 --> 00:11:27,960
of different molecules.
195
00:11:27,960 --> 00:11:30,280
Nutty, popcorny, woody...
196
00:11:30,280 --> 00:11:32,200
And then you've got some
of the horrible ones
197
00:11:32,200 --> 00:11:34,720
that you've just smelt,
the cheesy, the sweaty feet.
198
00:11:34,720 --> 00:11:36,000
But they're all in there.
199
00:11:36,000 --> 00:11:38,040
And when you're smelling
chocolate as a whole,
200
00:11:38,040 --> 00:11:40,760
all of those different smells
are hitting it all at once
201
00:11:40,760 --> 00:11:43,760
and it's the combination that gives
you the smell of chocolate.
202
00:11:43,760 --> 00:11:45,320
That's amazing.
203
00:11:46,840 --> 00:11:49,440
And that's the job
of a chocolate maker,
204
00:11:49,440 --> 00:11:53,840
to design each part of their process
so they release the different smells
205
00:11:53,840 --> 00:11:58,840
that combine to create the
chocolate aroma we all love.
206
00:12:09,280 --> 00:12:13,720
After cooking in the
conches for seven hours,
207
00:12:13,720 --> 00:12:18,240
the liquid chocolate is pumped
out into giant vats.
208
00:12:20,360 --> 00:12:22,560
And I cannot wait to taste it.
209
00:12:24,320 --> 00:12:27,560
So that batch of chocolate
will end up in this tank here.
210
00:12:27,560 --> 00:12:29,120
How many Kit Kats in here?
211
00:12:29,120 --> 00:12:32,880
This storage tank
holds 28 tonnes of chocolate
212
00:12:32,880 --> 00:12:34,800
so you can make two million.
213
00:12:34,800 --> 00:12:38,160
That tank will empty and
fill again today.
214
00:12:38,160 --> 00:12:39,400
Four million a day?
215
00:12:39,400 --> 00:12:43,800
Yeah. Put your sample jar under
there and just unwind that.
216
00:12:45,040 --> 00:12:46,680
Whoa, whoa-whoa-whoa, how do I...?
217
00:12:47,680 --> 00:12:50,240
GREGG LAUGHS
218
00:12:52,600 --> 00:12:54,920
And here we are. Here we are.
219
00:13:02,200 --> 00:13:04,720
We've got 28 tonnes
of liquid chocolate
220
00:13:04,720 --> 00:13:07,520
and a very happy,
bald television presenter.
221
00:13:07,520 --> 00:13:10,200
Fantastic.
Do you sell it by the pint?
222
00:13:10,200 --> 00:13:12,280
Unfortunately,
we don't sell it by the pint,
223
00:13:12,280 --> 00:13:13,320
we sell it by the bar.
224
00:13:18,760 --> 00:13:22,520
They make 16 different chocolate
recipes here at the factory,
225
00:13:22,520 --> 00:13:24,600
a different one for each product.
226
00:13:25,600 --> 00:13:28,720
But what I don't understand is,
why do they bother?
227
00:13:28,720 --> 00:13:33,920
Why not just get one great recipe
and use it for all of them?
228
00:13:33,920 --> 00:13:36,720
Vicky Geal
is the senior confectioner
229
00:13:36,720 --> 00:13:40,240
in charge of developing
new flavours and products.
230
00:13:40,240 --> 00:13:41,680
And she's going to show me
231
00:13:41,680 --> 00:13:44,080
why the chocolate recipe
is so important.
232
00:13:45,280 --> 00:13:48,600
Kit Kat chocolate is designed
specifically for Kit Kat.
233
00:13:48,600 --> 00:13:51,560
What I've done here is made some
with some different chocolates
234
00:13:51,560 --> 00:13:53,920
to prove that other
chocolates do not work.
235
00:13:53,920 --> 00:13:55,160
What different chocolates?
236
00:13:55,160 --> 00:13:57,600
The first one, I've used
a standard Kit Kat chocolate.
237
00:13:57,600 --> 00:13:59,800
The second one is a Yorkie chocolate
238
00:13:59,800 --> 00:14:03,840
and the third one is a competitor
chocolate which I shall not name.
239
00:14:03,840 --> 00:14:05,880
See which you think's the best.
240
00:14:10,360 --> 00:14:13,480
Well, I can't really taste
the chocolate on this one.
241
00:14:13,480 --> 00:14:15,120
Let me try the middle one.
242
00:14:18,240 --> 00:14:21,480
The chocolate's...creamier...
243
00:14:21,480 --> 00:14:24,120
rounded...deeper.
244
00:14:24,120 --> 00:14:26,320
Let me try the last one.
245
00:14:29,480 --> 00:14:31,520
That's the Kit Kat,
that's the original Kit Kat.
246
00:14:31,520 --> 00:14:33,760
That is the original...
Whey-hey-hey!
247
00:14:33,760 --> 00:14:36,400
The insides are exactly the
same on every product,
248
00:14:36,400 --> 00:14:38,560
it's just the chocolate
that's changed.
249
00:14:38,560 --> 00:14:41,240
You've made your point, Vicky.
There you go.
250
00:14:41,240 --> 00:14:44,080
In a delightful way.
Let's have a hug.
251
00:14:46,720 --> 00:14:49,720
So, it turns out,
even without realising it,
252
00:14:49,720 --> 00:14:51,880
we consumers expect
a certain chocolate flavour
253
00:14:51,880 --> 00:14:53,280
to be on a particular bar.
254
00:14:54,720 --> 00:14:57,720
So to keep us happy,
this factory uses a number
255
00:14:57,720 --> 00:15:00,240
of different chocolate recipes,
each tailor-made
256
00:15:00,240 --> 00:15:02,760
for the product
it's going to end up in.
257
00:15:10,000 --> 00:15:12,520
This 28 tonnes of melted chocolate
258
00:15:12,520 --> 00:15:16,160
is all going to end up making
just one kind of chocolate bar.
259
00:15:18,080 --> 00:15:20,680
But Cherry's getting
her hands dirty in Derbyshire
260
00:15:20,680 --> 00:15:23,280
to learn how you make
a chocolate box
261
00:15:23,280 --> 00:15:25,280
full of many different varieties.
262
00:15:30,480 --> 00:15:31,880
I'm at Thornton's,
263
00:15:31,880 --> 00:15:36,160
the largest British-owned chocolate
manufacturer in the country.
264
00:15:37,400 --> 00:15:40,760
They've been making chocolates
for over 100 years
265
00:15:40,760 --> 00:15:45,200
and produce a colossal
25 million boxes every year.
266
00:15:47,640 --> 00:15:50,040
Most of the chocolate
made at Thornton's ends up
267
00:15:50,040 --> 00:15:51,680
in boxes like these.
268
00:15:51,680 --> 00:15:55,080
And while your first thought might
be to scramble for your favourite one
269
00:15:55,080 --> 00:15:57,120
you might be surprised to know
270
00:15:57,120 --> 00:16:00,600
how much work goes into
making each and every one.
271
00:16:02,360 --> 00:16:05,600
Over 1,000 people work
in this Derbyshire factory
272
00:16:05,600 --> 00:16:07,920
and today I'm getting stuck in too.
273
00:16:07,920 --> 00:16:10,080
You need to put four blocks in.
274
00:16:10,080 --> 00:16:12,440
Operations manager, Nathan Worth,
275
00:16:12,440 --> 00:16:14,760
is teaching me
to make a vanilla truffle.
276
00:16:14,760 --> 00:16:16,960
I don't think
even I could eat all this in a day.
277
00:16:16,960 --> 00:16:18,200
Oh, I could easily.
278
00:16:18,200 --> 00:16:20,360
'The truffle begins with the centre
279
00:16:20,360 --> 00:16:23,120
'made from chocolate,
sugar and butter.'
280
00:16:23,120 --> 00:16:25,280
And now we'll mix it
for a few minutes.
281
00:16:30,920 --> 00:16:32,520
Oh, wow.
282
00:16:32,520 --> 00:16:35,960
'100 kilos of filling
needs to be handfed
283
00:16:35,960 --> 00:16:38,880
'into the start
of the production line.'
284
00:16:38,880 --> 00:16:41,520
Oh, look at that massive blob.
285
00:16:41,520 --> 00:16:44,160
That's it, I think we're going to
lose you in there in a minute.
286
00:16:44,160 --> 00:16:45,840
Bye.
287
00:16:45,840 --> 00:16:47,880
It's like Willie Wonka's
chocolate factory.
288
00:16:47,880 --> 00:16:49,880
It's Willie Wonka
without the Oompa-Loompas
289
00:16:49,880 --> 00:16:51,800
and the chocolate fountain,
I'm afraid.
290
00:16:54,040 --> 00:16:56,720
'Then the mix is forced
through a cutter,
291
00:16:56,720 --> 00:16:59,960
'slicing into more centres
than I've ever seen.'
292
00:16:59,960 --> 00:17:02,600
How many of these are in one row?
293
00:17:02,600 --> 00:17:05,080
So there's 16 rows on here. 16 rows.
294
00:17:05,080 --> 00:17:08,320
And on this line, on this product
we run 62 rows a minute.
295
00:17:09,360 --> 00:17:14,320
So, an hour on here we're making
55,000 chocolates an hour.
296
00:17:14,320 --> 00:17:17,240
In a week, we could be making
up to 25 million.
297
00:17:18,280 --> 00:17:21,240
That is a staggering
number of chocolates.
298
00:17:21,240 --> 00:17:23,520
Yeah, and I think I eat
a large percentage of those
299
00:17:23,520 --> 00:17:24,720
while I'm working.
300
00:17:24,720 --> 00:17:26,720
I'm right there with you.
301
00:17:26,720 --> 00:17:32,560
The centre gets individually
drizzled with a drape of chocolate.
302
00:17:33,720 --> 00:17:34,920
This is an enrober.
303
00:17:36,120 --> 00:17:40,120
Enrobing is where we put a curtain
of chocolate over the centres.
304
00:17:40,120 --> 00:17:43,000
So what we're doing is,
we're drizzling the chocolate over.
305
00:17:43,000 --> 00:17:45,440
So instead of moulding it
as a lot of people do,
306
00:17:45,440 --> 00:17:48,360
we're actually coating
the chocolate. Wow.
307
00:17:50,040 --> 00:17:55,480
And the secret to perfect chocolate
is a process called tempering.
308
00:17:55,480 --> 00:17:59,280
So we take chocolate at 45 degrees,
309
00:17:59,280 --> 00:18:01,800
cool that down to 25 degrees,
310
00:18:01,800 --> 00:18:05,680
heat it back up to 30 degrees to get
the correct crystal structure.
311
00:18:05,680 --> 00:18:09,560
What would happen if you didn't heat
up and cool the chocolate down?
312
00:18:09,560 --> 00:18:13,400
What you'd find is it'd start going
white, go a little bit greasy,
313
00:18:13,400 --> 00:18:17,560
it wouldn't snap if it was a bar of
chocolate and it wouldn't eat nice.
314
00:18:17,560 --> 00:18:20,400
So sometimes you'll see chocolate
that's gone a little bit grey,
315
00:18:20,400 --> 00:18:22,440
that doesn't mean it's going mouldy,
316
00:18:22,440 --> 00:18:25,200
it just means the crystal
structure has broken down
317
00:18:25,200 --> 00:18:26,720
and it's not how we want it to be.
318
00:18:26,720 --> 00:18:30,320
Those grey bits are still
perfectly safe to eat
319
00:18:30,320 --> 00:18:32,560
but to keep their chocolate
looking its best
320
00:18:32,560 --> 00:18:36,960
all factories like this rely
on their giant tempering machines.
321
00:18:36,960 --> 00:18:39,400
In this kind of machine here
that's behind you,
322
00:18:39,400 --> 00:18:41,960
it's the workhorse of the factory
323
00:18:41,960 --> 00:18:44,520
but, actually,
nobody ever really sees it.
324
00:18:44,520 --> 00:18:48,240
Oh, no, it's the unsung
hero of your factory.
325
00:18:49,240 --> 00:18:53,360
I appreciate you turbo ther...temper.
NATHAN LAUGHS
326
00:18:53,360 --> 00:18:55,080
I appreciate you.
327
00:18:58,360 --> 00:19:01,200
Once the first milk chocolate
layer cools and sets,
328
00:19:01,200 --> 00:19:03,960
it's ready for a smothering
of white chocolate.
329
00:19:09,480 --> 00:19:13,400
The vibrating conveyor belt
shakes off the excess chocolate
330
00:19:13,400 --> 00:19:17,080
to make sure each one
weighs exactly the same.
331
00:19:17,080 --> 00:19:20,600
Wow. It's a river of chocolate.
332
00:19:22,480 --> 00:19:25,800
'But what comes next is
the real magic.
333
00:19:25,800 --> 00:19:29,760
'Every one of the truffles
is skilfully hand decorated,
334
00:19:29,760 --> 00:19:32,680
'with not a machine in sight.'
335
00:19:43,760 --> 00:19:46,400
CHERRY GASPS
336
00:19:46,400 --> 00:19:47,760
Oh, wow.
337
00:19:50,360 --> 00:19:52,720
It really is done by hand.
338
00:19:52,720 --> 00:19:54,600
No machinery at this point.
339
00:19:56,360 --> 00:19:57,560
And away you go.
340
00:20:03,520 --> 00:20:05,600
Oh, that's really fun.
341
00:20:06,640 --> 00:20:10,640
Oh, no, I messed it up.
No, no, they're fine. Very good.
342
00:20:10,640 --> 00:20:13,840
Ah-ah. Got it. It goes really quick.
343
00:20:13,840 --> 00:20:16,280
I missed one... No problem.
344
00:20:16,280 --> 00:20:18,040
You're going to have to
pick up my slack.
345
00:20:18,040 --> 00:20:19,920
That's no problem at all.
346
00:20:19,920 --> 00:20:22,480
Do you think that people don't
really appreciate
347
00:20:22,480 --> 00:20:24,760
how much work goes
into a piece of chocolate?
348
00:20:25,800 --> 00:20:27,680
I think when people buy chocolates,
349
00:20:27,680 --> 00:20:30,320
they don't realise
how much we do do here.
350
00:20:30,320 --> 00:20:32,640
I think they probably think
a machine does this,
351
00:20:32,640 --> 00:20:34,640
do you know what I mean? Yes.
352
00:20:34,640 --> 00:20:37,880
Look at you go.
I mean, you're a demon.
353
00:20:37,880 --> 00:20:39,720
Years of practice.
Years of practice.
354
00:20:39,720 --> 00:20:43,240
How long have you been doing this?
Well, I've worked here for 21 years.
355
00:20:43,240 --> 00:20:46,880
21 years. So you're a pro?
356
00:20:46,880 --> 00:20:48,560
I hope so by now.
357
00:20:48,560 --> 00:20:51,120
Is it hard to be doing this
and not take one?
358
00:20:52,160 --> 00:20:55,200
It's extremely hard
and I'm a total chocoholic.
359
00:20:55,200 --> 00:20:56,560
I love it.
360
00:20:58,400 --> 00:21:02,880
One down but they're still 11
varieties short of a chocolate box
361
00:21:02,880 --> 00:21:04,760
so the team keep on going.
362
00:21:07,120 --> 00:21:11,400
I'm blown away by the effort
to hand decorate the chocolate
363
00:21:11,400 --> 00:21:15,120
but I do worry for whoever
has to pack them into boxes.
364
00:21:28,960 --> 00:21:33,760
It turns out this is the one area
where even humans need a hand.
365
00:21:33,760 --> 00:21:38,720
A team of lightning-fast robots
pack the chocolates into trays.
366
00:21:40,080 --> 00:21:42,720
The robots have laser-guided eyes
367
00:21:42,720 --> 00:21:45,360
that can tell the shape
of each chocolate
368
00:21:45,360 --> 00:21:47,880
and where it is
on the conveyor belt.
369
00:21:49,280 --> 00:21:52,880
They then rotate the chocolates
to match them up exactly
370
00:21:52,880 --> 00:21:54,920
with the shape in the trays.
371
00:21:56,040 --> 00:21:59,400
This area last year did over
30 million finished boxes.
372
00:22:00,600 --> 00:22:03,640
And they can do it with
absolute precision -
373
00:22:03,640 --> 00:22:05,400
over and over again.
374
00:22:16,040 --> 00:22:19,960
Despite all the machinery
and hi-tech robots,
375
00:22:19,960 --> 00:22:24,560
it still takes over a 100 people
to make a box of chocolate
376
00:22:24,560 --> 00:22:26,120
like this one.
377
00:22:26,120 --> 00:22:29,000
So think about that
next time you're squabbling
378
00:22:29,000 --> 00:22:30,680
over who gets the last one.
379
00:22:32,160 --> 00:22:35,160
Later, I'll be back at Thornton's
to reveal the secret
380
00:22:35,160 --> 00:22:38,360
of how they make Easter eggs hollow.
381
00:22:45,120 --> 00:22:49,160
Back in York, I've moved from
the chocolate factory to wafers.
382
00:22:52,160 --> 00:22:56,680
Wafer line manager Mark Barratt
has worked here for over 20 years.
383
00:22:56,680 --> 00:22:58,960
He used to make the chocolate,
but for him now,
384
00:22:58,960 --> 00:23:01,920
the filling is more than just the
middle, it's everything.
385
00:23:03,040 --> 00:23:05,120
What's better, chocolate or wafer?
386
00:23:05,120 --> 00:23:07,400
Wafer. Why?
387
00:23:07,400 --> 00:23:09,440
That's the beginning of it,
that's the middle.
388
00:23:09,440 --> 00:23:12,080
If you don't get that great snap,
you haven't got the bar.
389
00:23:12,080 --> 00:23:14,000
Do you think you might be
turning into a bit of
390
00:23:14,000 --> 00:23:15,400
a chocolate bar anorak, Mark?
391
00:23:15,400 --> 00:23:17,840
I think I'm there.
I've been there a while.
392
00:23:17,840 --> 00:23:22,720
What is the first step
to making wafer?
393
00:23:22,720 --> 00:23:27,600
So we start off making a batter
mix with flour and water
394
00:23:27,600 --> 00:23:30,520
and a few...few pretty
special ingredients
395
00:23:30,520 --> 00:23:32,840
that we like to keep to ourselves.
396
00:23:34,600 --> 00:23:38,080
Flour from giant silos outside
is fed into the mixers.
397
00:23:39,520 --> 00:23:41,560
These mixers work around the clock,
398
00:23:41,560 --> 00:23:45,880
producing 40 kilos
of batter every minute.
399
00:23:45,880 --> 00:23:47,520
But mixing all that is one thing.
400
00:23:47,520 --> 00:23:49,800
How on earth are
you going to bake it all?
401
00:23:50,840 --> 00:23:54,840
You start by piping it into
100 hinged waffle irons
402
00:23:54,840 --> 00:23:56,160
called carriers.
403
00:23:57,360 --> 00:23:59,600
The top of the carrier shuts down.
404
00:23:59,600 --> 00:24:04,520
As it shuts down, the batter spreads
and it fills the rectangle.
405
00:24:04,520 --> 00:24:05,920
Got ya.
406
00:24:05,920 --> 00:24:08,520
Conveyor belts take the
squashed batter squares
407
00:24:08,520 --> 00:24:11,040
directly into 100-foot-long ovens.
408
00:24:13,560 --> 00:24:17,120
After just two minutes at
150 degrees, the carriers leave
409
00:24:17,120 --> 00:24:21,360
the ovens, open up and spit
out rich, golden wafers.
410
00:24:22,520 --> 00:24:24,600
Oh! There they are, popping out.
411
00:24:24,600 --> 00:24:28,000
Mate, they're like carpet tiles
or they're like lino tiles.
412
00:24:28,000 --> 00:24:29,480
Yeah.
413
00:24:29,480 --> 00:24:31,120
Shall we have a look at one?
414
00:24:31,120 --> 00:24:32,280
There you go.
415
00:24:32,280 --> 00:24:34,160
It's like an enormous poppadom.
416
00:24:35,320 --> 00:24:36,800
It doesn't seem that crispy.
417
00:24:36,800 --> 00:24:37,880
No.
418
00:24:39,920 --> 00:24:42,320
Sorry. I'll
clean...I'll clean it up.
419
00:24:44,960 --> 00:24:48,400
To crisp up the wafers,
they're fed into a cooling rack,
420
00:24:48,400 --> 00:24:51,960
snaking 30 feet into the
air to save space.
421
00:24:53,520 --> 00:24:55,640
Over an arch on the second floor.
422
00:24:57,840 --> 00:24:59,600
Then back downstairs.
423
00:24:59,600 --> 00:25:04,280
After cooling, they come down
that ski slope, come along here
424
00:25:04,280 --> 00:25:08,080
and then the filling is spread
on top of the sheet.
425
00:25:11,440 --> 00:25:14,800
The sweet filling is made of
cocoa liquor and sugar.
426
00:25:17,120 --> 00:25:21,160
It's like a perfectly precisely
buttered piece of toast.
427
00:25:21,160 --> 00:25:22,240
That's right.
428
00:25:22,240 --> 00:25:24,560
The same level all the time,
the same thickness.
429
00:25:25,640 --> 00:25:28,440
Then the machine stacks
one coated wafer
430
00:25:28,440 --> 00:25:30,520
on top of another coated wafer.
431
00:25:31,480 --> 00:25:36,920
OK. One, two, and then we've
got some coming over the top
432
00:25:36,920 --> 00:25:38,640
which haven't got filling on.
433
00:25:40,840 --> 00:25:45,560
And the results, every five seconds,
a perfectly lined-up square
434
00:25:45,560 --> 00:25:50,080
of two layers of filling sandwiched
between three layers of wafer.
435
00:25:50,080 --> 00:25:51,640
Perfect every time?
436
00:25:51,640 --> 00:25:53,200
Perfect every time, yeah.
437
00:25:53,200 --> 00:25:54,320
Almost every time?
438
00:25:55,320 --> 00:25:58,040
Almost.
HE LAUGHS
439
00:25:59,560 --> 00:26:02,280
A team of robots
then stacks the wafers...
440
00:26:05,320 --> 00:26:06,920
..cuts them into blocks...
441
00:26:08,280 --> 00:26:11,360
..and then sends them off
to be covered in chocolate.
442
00:26:13,200 --> 00:26:17,040
It's hard to imagine a time without
our favourite chocolate bars,
443
00:26:17,040 --> 00:26:19,360
but where did they come from
in the first place?
444
00:26:20,760 --> 00:26:24,720
Historian Ruth Goodman's been
looking at chocolate's magic decade.
445
00:26:26,080 --> 00:26:29,200
One of the earliest memories
we probably all share
446
00:26:29,200 --> 00:26:31,360
is visiting the sweet shop.
447
00:26:31,360 --> 00:26:33,720
It's usually the first
time as children
448
00:26:33,720 --> 00:26:36,480
we get to spend our own money.
449
00:26:38,800 --> 00:26:42,400
But the chocolate bars we buy today
are likely to be exactly
450
00:26:42,400 --> 00:26:45,600
the same as those that our parents
bought, or our grandparents,
451
00:26:45,600 --> 00:26:49,040
even our great grandparents,
when they were young.
452
00:26:49,040 --> 00:26:54,400
They all originate in the same
amazing ten-year period.
453
00:26:54,400 --> 00:26:58,680
Roald Dahl once likened it as
"the chocolate equivalent of the
454
00:26:58,680 --> 00:27:03,800
"Italian Renaissance for painting."
And that decade was the 1930s.
455
00:27:07,760 --> 00:27:12,960
The 1930s witnessed a huge social
shift in British society.
456
00:27:12,960 --> 00:27:16,160
Improved working conditions
meant people had more time off.
457
00:27:17,760 --> 00:27:23,280
And this new concept of leisure time
brought a shift in buying habits.
458
00:27:23,280 --> 00:27:27,480
Until now, chocolate had been
an expensive treat for the wealthy
459
00:27:27,480 --> 00:27:30,440
and mostly only bought on
special occasions.
460
00:27:31,560 --> 00:27:34,560
In the '30s,
cheaper manufacturing costs
461
00:27:34,560 --> 00:27:37,760
meant it could be made
for a lot less.
462
00:27:37,760 --> 00:27:41,240
Suddenly, 90% of the country
could now afford
463
00:27:41,240 --> 00:27:43,400
to buy chocolate regularly.
464
00:27:46,960 --> 00:27:50,920
A new mass market had been created
at the beginning of the decade
465
00:27:50,920 --> 00:27:54,600
and now it was up to the
chocolatiers to feed it.
466
00:27:54,600 --> 00:27:57,840
Amongst the first off the
block was an American.
467
00:27:57,840 --> 00:28:01,200
In 1932, the Mars Bar
caused quite a stir.
468
00:28:04,280 --> 00:28:06,600
A so-called combination bar,
469
00:28:06,600 --> 00:28:09,440
it added a core to the standard
chunk of chocolate that
470
00:28:09,440 --> 00:28:11,120
Britain was used to.
471
00:28:11,120 --> 00:28:13,440
An American invention,
they were considered
472
00:28:13,440 --> 00:28:18,160
low-rent and faddish by chocolate
makers on this side of the Atlantic.
473
00:28:20,120 --> 00:28:25,680
But British consumers had other
ideas and happily scoffed them up.
474
00:28:25,680 --> 00:28:29,680
The snobbery soon turned to envy
as British manufacturers
475
00:28:29,680 --> 00:28:32,080
realised that they would
have to respond.
476
00:28:33,320 --> 00:28:36,440
And so began what had been called
"the chocolate wars."
477
00:28:36,440 --> 00:28:40,320
Terry's gave us the
Chocolate Orange in 1932.
478
00:28:40,320 --> 00:28:45,640
Rowntree's responded with both
the Aero and the Kit Kat in 1935.
479
00:28:45,640 --> 00:28:51,400
Cadbury's contribution was the
Whole Nut and Roses in 1938.
480
00:28:51,400 --> 00:28:55,800
And Mars fought back with
the Milky Way and Maltesers.
481
00:28:56,800 --> 00:29:00,640
Suddenly the high street was
choc-a-block with chocolate.
482
00:29:00,640 --> 00:29:04,320
Chocolatiers knew that they couldn't
rely just on their packaging
483
00:29:04,320 --> 00:29:05,520
to sell their bars.
484
00:29:05,520 --> 00:29:07,840
They needed to come up
with some really
485
00:29:07,840 --> 00:29:10,640
imaginative advertising campaigns.
486
00:29:14,200 --> 00:29:17,520
"Where have you been to,
sir?" she said.
487
00:29:18,640 --> 00:29:22,200
I've been York milking,
my pretty maid.
488
00:29:22,200 --> 00:29:26,800
To entertain cinema audiences
Rowntree's created a world first,
489
00:29:26,800 --> 00:29:30,160
an animated advert
with synchronised sound.
490
00:29:30,160 --> 00:29:31,240
Ooh!
491
00:29:31,240 --> 00:29:33,040
Mr York's York.
492
00:29:33,040 --> 00:29:34,840
Isn't it lovely?
493
00:29:34,840 --> 00:29:37,400
Nothing like this had been tried
before to sell a product.
494
00:29:40,960 --> 00:29:44,280
Not to be outdone,
Cadbury's hit back.
495
00:29:44,280 --> 00:29:46,320
At seaside resorts across
the country,
496
00:29:46,320 --> 00:29:49,200
Cadburys sent the
chocolate mystery man.
497
00:29:49,200 --> 00:29:51,360
If you spotted him
roaming the streets,
498
00:29:51,360 --> 00:29:53,400
you'd win a chocolaty prize.
499
00:29:54,800 --> 00:29:56,320
In an unprecedented move,
500
00:29:56,320 --> 00:30:01,960
Cadbury's even sent vans selling
hot cocoa to busy public events.
501
00:30:01,960 --> 00:30:03,520
Chocolate was everywhere.
502
00:30:04,760 --> 00:30:06,520
Their hard work paid off.
503
00:30:06,520 --> 00:30:10,400
By the end of the 1930s,
Britain was the largest
504
00:30:10,400 --> 00:30:13,600
consumer of
confectionary in the world.
505
00:30:15,280 --> 00:30:21,480
In the 1920s, the average
Briton consumed 4oz
506
00:30:21,480 --> 00:30:23,040
of confectionary a week.
507
00:30:25,720 --> 00:30:32,800
By 1938, it had nearly
doubled to a full 7oz...
508
00:30:33,840 --> 00:30:36,840
..and the difference was chocolate.
509
00:30:43,520 --> 00:30:48,720
Down through the generations
we are still remarkably faithful
510
00:30:48,720 --> 00:30:53,400
to these original brands first
invented in the chocolate decade.
511
00:31:10,760 --> 00:31:13,880
Here in York, we've gone
bean to liquor to chocolate.
512
00:31:13,880 --> 00:31:15,240
And now the filled wafers
513
00:31:15,240 --> 00:31:19,120
are arriving in the final
production hall by the thousands.
514
00:31:25,360 --> 00:31:26,760
In this final stage,
515
00:31:26,760 --> 00:31:29,440
all the elements of the chocolate
bar are put together.
516
00:31:34,080 --> 00:31:38,480
Phil Ashley, factory quality
manager, is going to show me how.
517
00:31:41,120 --> 00:31:43,360
Can you take me through the process?
518
00:31:43,360 --> 00:31:46,320
Yeah, certainly.
So, you've seen how we've made wafer
519
00:31:46,320 --> 00:31:48,240
and you've seen
how we make chocolate.
520
00:31:48,240 --> 00:31:51,640
Well, this is the plant where we put
both wafer and chocolate together.
521
00:31:51,640 --> 00:31:54,280
The chocolate gets
deposited into a mould.
522
00:31:54,280 --> 00:31:56,080
You can see on the mould here
523
00:31:56,080 --> 00:31:59,240
we have an impression on the
bottom of the mould.
524
00:31:59,240 --> 00:32:02,040
So when the chocolate
gets deposited on there
525
00:32:02,040 --> 00:32:05,320
and the bar finally gets de-moulded,
you can see "Kit Kat" on the top.
526
00:32:06,800 --> 00:32:09,000
Chocolate gets squirted in here?
Yes.
527
00:32:09,000 --> 00:32:11,560
It's travelling along.
Then what happens?
528
00:32:11,560 --> 00:32:13,920
Then we put the wafer into
the mould itself.
529
00:32:15,920 --> 00:32:20,160
And it's the job of Michelle
Jarvis to load those wafers.
530
00:32:20,160 --> 00:32:23,560
Michelle's been working
on this line for 12 years.
531
00:32:23,560 --> 00:32:25,680
Can I come in? Come on.
532
00:32:25,680 --> 00:32:27,320
Could I have a go at this? Yes.
533
00:32:29,000 --> 00:32:31,400
So, I've watched these
wafers get made,
534
00:32:31,400 --> 00:32:33,480
I watched the chocolate being made.
535
00:32:35,160 --> 00:32:38,320
And now I want to put them
in the machine,
536
00:32:38,320 --> 00:32:40,200
see the whole thing happening.
537
00:32:40,200 --> 00:32:42,520
Oh, oh, I can't...
538
00:32:42,520 --> 00:32:44,840
You pick them all up, the whole row.
539
00:32:47,040 --> 00:32:48,080
Pick them all up.
540
00:32:49,120 --> 00:32:50,720
Like that. Don't be ridiculous.
541
00:32:51,760 --> 00:32:54,080
Go on. Your turn.
542
00:32:58,000 --> 00:33:00,800
Yay! Oh, yeah, baby! Oh, yeah, baby!
543
00:33:00,800 --> 00:33:02,200
Call me Mr Wafer.
544
00:33:03,360 --> 00:33:05,880
I'm leaving this to you and
I'm going for tea.
545
00:33:05,880 --> 00:33:08,440
If these go down to nothing,
am I in trouble?
546
00:33:08,440 --> 00:33:09,920
Yes. Bye!
547
00:33:10,920 --> 00:33:12,920
Don't do that, please.
548
00:33:12,920 --> 00:33:14,680
I'm not very confident.
549
00:33:14,680 --> 00:33:15,720
Ah!
550
00:33:18,120 --> 00:33:19,560
I've run out of biscuits!
551
00:33:21,480 --> 00:33:23,320
The filled wafers are cut to size
552
00:33:23,320 --> 00:33:26,800
and dropped into the moulds
on top of the chocolate.
553
00:33:28,640 --> 00:33:31,040
You can now see the chocolate
underneath the wafer.
554
00:33:31,040 --> 00:33:33,360
I don't know how the chocolate
gets on top of the wafer.
555
00:33:33,360 --> 00:33:36,320
OK, so we're going to move further
down the plant to show you that.
556
00:33:38,440 --> 00:33:40,200
Is that a laser at the
end of that machine?
557
00:33:40,200 --> 00:33:43,000
It is, yeah. This is a very
clever piece of equipment.
558
00:33:44,200 --> 00:33:47,320
This is the camera that's showing
the wafers going through.
559
00:33:48,760 --> 00:33:52,120
When there's a wafer missing,
it shows up there in a red light.
560
00:33:54,440 --> 00:33:56,080
Yeah, it's just nabbed one.
561
00:33:56,080 --> 00:33:59,160
That's right. So now the machine
knows exactly which bar that is.
562
00:33:59,160 --> 00:34:02,240
Right at the end of the process then,
it will reject that particular bar.
563
00:34:02,240 --> 00:34:06,080
What's it done, made a recording,
like, row 12, seat 137?
564
00:34:06,080 --> 00:34:09,440
Exactly that. It's a computer, it'll
remember all that information.
565
00:34:09,440 --> 00:34:12,840
There's a misdemeanour here, the
chocolate mould thinks it's got away
566
00:34:12,840 --> 00:34:16,000
with it and it's going to get nabbed
further on down the line there.
567
00:34:16,000 --> 00:34:17,240
That's right.
568
00:34:21,560 --> 00:34:23,800
This snack is gradually
coming together.
569
00:34:23,800 --> 00:34:24,920
What's the next stage?
570
00:34:24,920 --> 00:34:27,840
OK, so now we put chocolate
on the back of the bar.
571
00:34:27,840 --> 00:34:30,880
Chocolate comes down the pipe,
gets deposited here...
572
00:34:31,840 --> 00:34:33,840
..and then just gets spread
across the mould.
573
00:34:38,240 --> 00:34:39,640
That's a beautiful thing.
574
00:34:40,800 --> 00:34:45,200
That's like a chocolate tide
crashing onto a beach. That's right.
575
00:34:50,800 --> 00:34:53,760
How come the chocolate
doesn't stick to the mould?
576
00:34:53,760 --> 00:34:56,320
OK, well, that's the next
important process.
577
00:34:56,320 --> 00:34:58,440
If you just want to
take hold of that mould.
578
00:34:58,440 --> 00:34:59,760
Try and twist that.
579
00:35:02,280 --> 00:35:04,440
No. No, it's solid,
it's hard plastic.
580
00:35:04,440 --> 00:35:05,840
If you look down here...
581
00:35:07,040 --> 00:35:10,080
..can you see how those moulds
are being twisted on either side?
582
00:35:10,080 --> 00:35:12,360
Oh, yeah! Yeah, yeah, yeah,
yeah, yeah, yeah, yeah.
583
00:35:12,360 --> 00:35:14,080
Like, twisting it one
way at one end,
584
00:35:14,080 --> 00:35:15,800
the other way at the other end.
Correct.
585
00:35:15,800 --> 00:35:18,840
That's very much how we would get
ice cubes out of an ice cube mould.
586
00:35:18,840 --> 00:35:20,200
Exactly, yeah. Twisting it.
587
00:35:20,200 --> 00:35:22,560
Absolutely. Except
this plastic's quite tough.
588
00:35:22,560 --> 00:35:24,840
Does it have to be that
horrible pink colour?
589
00:35:24,840 --> 00:35:27,480
It's pink so we can
differentiate it with the chocolate.
590
00:35:28,920 --> 00:35:31,440
So they're cool by now, aren't they?
They are, yes.
591
00:35:31,440 --> 00:35:34,320
They're cool and they're solid
at this stage.
592
00:35:34,320 --> 00:35:36,320
Give me a mould, I'll get them out.
593
00:35:37,640 --> 00:35:39,640
While I'm helping to de-mould,
594
00:35:39,640 --> 00:35:43,520
back at Thorntons in Derbyshire,
Cherry is having a sugar rush.
595
00:35:51,640 --> 00:35:55,120
Easter is second only to
Christmas for chocolate sales,
596
00:35:55,120 --> 00:36:00,400
and here at Thorntons they make over
nine million eggs each year.
597
00:36:00,400 --> 00:36:04,240
'They've been making Easter
eggs here since 1922,
598
00:36:04,240 --> 00:36:07,440
'but what I've wanted to know
ever since I was a kid
599
00:36:07,440 --> 00:36:10,520
'is how on earth
do they make them hollow?'
600
00:36:10,520 --> 00:36:13,120
What comes first,
the chicken or the egg?
601
00:36:13,120 --> 00:36:16,520
Well, when it comes to Easter eggs,
it's actually the mould. Oh.
602
00:36:16,520 --> 00:36:17,920
So what we do is...
603
00:36:17,920 --> 00:36:22,040
we have a mould that we're going
to actually form the egg in.
604
00:36:22,040 --> 00:36:26,080
'Melted chocolate is squirted inside
one half of the egg-shaped mould.
605
00:36:27,800 --> 00:36:30,200
'Then decorations are added.'
606
00:36:30,200 --> 00:36:33,200
We'll then put a second mould
on top of the first.
607
00:36:33,200 --> 00:36:36,000
We'll put that into a magnetic frame
and we'll put it onto
608
00:36:36,000 --> 00:36:38,280
one of these machines over here,
called a spinner.
609
00:36:47,120 --> 00:36:48,560
Wow.
610
00:36:51,160 --> 00:36:54,000
So it's a chocolate wall
installation.
611
00:36:54,000 --> 00:36:56,600
'The moulds are rotated
in every direction
612
00:36:56,600 --> 00:36:59,760
'to thoroughly coat the
inside with chocolate.'
613
00:36:59,760 --> 00:37:03,280
Because chocolate keeps setting,
it'll steadily build up a layer
614
00:37:03,280 --> 00:37:07,640
of chocolate on the inside of that
mould so it's really nice and even.
615
00:37:07,640 --> 00:37:10,160
That will give you that
perfect hollow shell.
616
00:37:10,160 --> 00:37:12,920
'As the chocolate dries
it sticks to the mould,
617
00:37:12,920 --> 00:37:14,600
'leaving a void in the middle.'
618
00:37:14,600 --> 00:37:18,160
So the machine mixes it around
619
00:37:18,160 --> 00:37:21,000
and around and around?
620
00:37:21,000 --> 00:37:25,840
Yeah. And then just let
the chocolate move to the edges.
621
00:37:25,840 --> 00:37:27,440
It's easier to put it on a machine
622
00:37:27,440 --> 00:37:29,600
than stand there for
15 minutes doing that.
623
00:37:34,560 --> 00:37:36,440
So we've had hollow eggs
for a long time.
624
00:37:36,440 --> 00:37:37,920
Has it always been done like this?
625
00:37:37,920 --> 00:37:40,640
It's always been done by
a spinning movement.
626
00:37:40,640 --> 00:37:44,680
Right back in the early days when
we first started doing hollow eggs.
627
00:37:47,840 --> 00:37:49,840
'Before the eggs
leave the factory...'
628
00:37:49,840 --> 00:37:51,640
Ah, magic.
629
00:37:51,640 --> 00:37:54,640
'..Nathan gives me one of
the nine million to try.'
630
00:37:57,120 --> 00:37:58,480
That's pretty good.
631
00:37:58,480 --> 00:38:00,400
That is hot off the press.
632
00:38:00,400 --> 00:38:03,400
You can't get a fresher
Easter egg than that.
633
00:38:03,400 --> 00:38:05,200
And it's definitely hollow. Yeah.
634
00:38:05,200 --> 00:38:09,320
We've only got another
8,999,999 to go, then.
635
00:38:22,360 --> 00:38:24,520
Back here on the
production line in York,
636
00:38:24,520 --> 00:38:25,960
the team are pumping out
637
00:38:25,960 --> 00:38:29,600
3,000 two-fingered chocolate
bars every minute.
638
00:38:31,520 --> 00:38:34,680
Before they're loaded on
trucks to come your way,
639
00:38:34,680 --> 00:38:36,760
they need to be wrapped and packed.
640
00:38:38,760 --> 00:38:40,640
But not before a final inspection
641
00:38:40,640 --> 00:38:44,240
by quality control
technician Julie Walker.
642
00:38:44,240 --> 00:38:46,880
What are you doing? You seem to be
throwing chocolates away.
643
00:38:46,880 --> 00:38:50,760
We're picking off ones which are
not of a good standard.
644
00:38:50,760 --> 00:38:53,000
Do you know, they all look
exactly the same to me.
645
00:38:53,000 --> 00:38:54,920
No, well they don't to us.
646
00:38:54,920 --> 00:38:56,360
What's wrong with that one?
647
00:38:56,360 --> 00:38:59,600
Well, we can see the wafer,
so that's wafer reveal.
648
00:38:59,600 --> 00:39:03,640
Apart from wafer reveal...
We have bubbles on the chocolate.
649
00:39:03,640 --> 00:39:07,320
Also, the chocolate is not as
shiny as it normally is.
650
00:39:07,320 --> 00:39:09,760
Mate, you're being a
little too fussy!
651
00:39:09,760 --> 00:39:12,120
Look, I'm a customer, all right?
652
00:39:12,120 --> 00:39:14,040
It doesn't bother me. Right.
653
00:39:14,040 --> 00:39:16,360
How much of a chocolate geek
have you become?
654
00:39:16,360 --> 00:39:17,920
Well, if I went on Mastermind,
655
00:39:17,920 --> 00:39:20,720
I reckon I could get through
that quite easily.
656
00:39:20,720 --> 00:39:23,200
Specialist subject - the Kit Kat.
Yes.
657
00:39:23,200 --> 00:39:25,840
What happens to all of the
ones you're throwing away?
658
00:39:25,840 --> 00:39:29,560
They all go into rework where they're
used for the fillings for the wafers.
659
00:39:29,560 --> 00:39:30,800
What's the wafer filling?
660
00:39:30,800 --> 00:39:33,360
Well, as you can see here,
we have a wafer...
661
00:39:33,360 --> 00:39:34,520
Oh, in between the wafers?
662
00:39:34,520 --> 00:39:36,600
Yes, that's right. I saw that put on.
663
00:39:36,600 --> 00:39:38,960
Right, OK. Yeah, yeah, yeah.
OK, brilliant.
664
00:39:38,960 --> 00:39:42,080
Now do you understand that?
Brilliant. Right, good. Brilliant.
665
00:39:42,080 --> 00:39:45,520
It's incredible that we've got
all this hi-tech machinery,
666
00:39:45,520 --> 00:39:48,960
yet you and I are picking out
defunct Kit Kats by hand.
667
00:39:48,960 --> 00:39:51,960
Because machinery is not
perfect either, is it?
668
00:39:51,960 --> 00:39:55,360
I suppose you're right. The only
time I've ever stared at anything
669
00:39:55,360 --> 00:39:57,920
and seen no defect at all
is the shaving mirror.
670
00:39:57,920 --> 00:40:01,480
SHE LAUGHS
I won't comment on that.
671
00:40:05,640 --> 00:40:09,960
It is incredible how many chocolate
bars are being produced here
672
00:40:09,960 --> 00:40:11,320
with so few people.
673
00:40:12,320 --> 00:40:15,440
As hi-tech as all this seems,
they've actually been making
674
00:40:15,440 --> 00:40:17,840
chocolate here for over 100 years,
675
00:40:17,840 --> 00:40:20,680
but back then the factory
floor would have looked
676
00:40:20,680 --> 00:40:22,160
very, very different.
677
00:40:28,160 --> 00:40:31,440
In the shadow of the modern
factory, there's a monument
678
00:40:31,440 --> 00:40:33,040
to chocolate-making past.
679
00:40:37,360 --> 00:40:40,160
This is the old Rowntree's
factory in York.
680
00:40:40,160 --> 00:40:42,840
It was acquired by Nestle in 1987,
681
00:40:42,840 --> 00:40:46,520
and there was so much rich history
that they appointed a dedicated
682
00:40:46,520 --> 00:40:49,640
Rowntree historian -
Alex Hutchinson - to preserve
683
00:40:49,640 --> 00:40:52,000
its significant past.
684
00:40:52,000 --> 00:40:54,080
I've been given access
to the old site
685
00:40:54,080 --> 00:40:58,080
and its archives to discover
just why it's so special.
686
00:40:58,080 --> 00:41:00,040
In comparison to other
factories at the time,
687
00:41:00,040 --> 00:41:01,600
was this a good one, a bad one?
688
00:41:01,600 --> 00:41:03,520
This was a good one.
This was a very good one.
689
00:41:03,520 --> 00:41:06,520
Everybody wanted to work for
Rowntree's. Very good pensions.
690
00:41:06,520 --> 00:41:09,280
If you were ill, there was a doctor.
If you needed a dentist,
691
00:41:09,280 --> 00:41:11,640
you could see a dentist.
And they would look after you.
692
00:41:11,640 --> 00:41:13,760
They would look after you
very, very well indeed.
693
00:41:14,800 --> 00:41:16,680
The Rowntrees were Quakers,
694
00:41:16,680 --> 00:41:20,440
a religious society formed
in England in the 17th century.
695
00:41:20,440 --> 00:41:24,560
The highly moral Quaker grocers
were trusted to produce
696
00:41:24,560 --> 00:41:26,320
unadulterated chocolate.
697
00:41:26,320 --> 00:41:28,360
TRAIN TOOTS
698
00:41:30,520 --> 00:41:33,440
And so a handful of these
Quaker families became the
699
00:41:33,440 --> 00:41:35,840
top chocolate makers in Britain.
700
00:41:35,840 --> 00:41:39,560
Birmingham had Cadbury's,
Bristol had Fry's
701
00:41:39,560 --> 00:41:42,040
and York had Rowntree's.
702
00:41:42,040 --> 00:41:43,720
The Rowntree family are Quaker.
703
00:41:43,720 --> 00:41:46,320
Do you think that made a difference
to how they did business?
704
00:41:46,320 --> 00:41:47,360
Very much so.
705
00:41:47,360 --> 00:41:49,920
They wanted to treat their workers
like they were family.
706
00:41:49,920 --> 00:41:52,280
They didn't want to view them
as cogs in a machine.
707
00:41:53,560 --> 00:41:56,520
To improve their workers' lives,
the Rowntree family designed
708
00:41:56,520 --> 00:42:00,840
a factory that was bright and airy
and chock-full of perks.
709
00:42:00,840 --> 00:42:04,640
You've got your theatre,
library, ballroom,
710
00:42:04,640 --> 00:42:10,160
sports grounds and, of course,
there's a sick pay, paid holiday.
711
00:42:10,160 --> 00:42:12,280
The wage packet
was quite healthy too.
712
00:42:14,120 --> 00:42:15,920
What was it like in production,
713
00:42:15,920 --> 00:42:18,560
inside that factory
when it was at full bustle?
714
00:42:18,560 --> 00:42:23,520
# Pack all your troubles
in your old kitbag and smile... #
715
00:42:23,520 --> 00:42:25,960
It would have been noisy,
you'd have rows and rows of girls
716
00:42:25,960 --> 00:42:28,160
with piping bags
full of liquid chocolate,
717
00:42:28,160 --> 00:42:30,000
hand-piping chocolates.
718
00:42:30,000 --> 00:42:32,840
'There's no girl like a Yorkshire
girl for dexterity and quickness
719
00:42:32,840 --> 00:42:35,160
'in squeezing out the swirls
of rich chocolate.'
720
00:42:35,160 --> 00:42:37,480
And then you'd have had
men coming in and out with
721
00:42:37,480 --> 00:42:40,640
sack barrows, collecting boxes
full of finished products
722
00:42:40,640 --> 00:42:43,280
and taking them off to the railways
to go all over the world.
723
00:42:45,880 --> 00:42:49,080
The welfare pioneered in the
chocolate factories was soon adopted
724
00:42:49,080 --> 00:42:50,840
across Britain.
725
00:42:50,840 --> 00:42:53,360
While the founding members
of the Rowntree family may have
726
00:42:53,360 --> 00:42:57,520
passed on, the community they
created lasted for generations.
727
00:42:59,440 --> 00:43:02,160
I want to meet the people who
lived and worked here
728
00:43:02,160 --> 00:43:04,720
to hear for myself
what life was really like.
729
00:43:06,000 --> 00:43:09,920
Bernice and Eddie Atkinson
worked here for over 40 years.
730
00:43:09,920 --> 00:43:12,320
They married in 1957.
731
00:43:12,320 --> 00:43:14,760
So you met on the same
production line?
732
00:43:14,760 --> 00:43:17,680
Well, I was what they used
to call a "material server,"
733
00:43:17,680 --> 00:43:19,440
being straight from school,
734
00:43:19,440 --> 00:43:21,840
and she worked on the
conveyor packing. Packing.
735
00:43:21,840 --> 00:43:24,400
We'd get talking and that's...
that's how you meet.
736
00:43:24,400 --> 00:43:27,080
And the first time I saw him,
he was little...
737
00:43:27,080 --> 00:43:30,040
I still am.
..with rosy cheeks, small.
738
00:43:30,040 --> 00:43:34,280
And I said to somebody, "I'd love to
take him to bed and cuddle him,"
739
00:43:34,280 --> 00:43:38,520
cos he was like a teddy bear...
Never dreaming I would years later.
740
00:43:38,520 --> 00:43:40,920
RUTH LAUGHS
I enjoyed it all.
741
00:43:40,920 --> 00:43:42,400
I loved working in the factory.
742
00:43:45,120 --> 00:43:48,840
Alex has uncovered some film archive
with a surprise for Bernice
743
00:43:48,840 --> 00:43:52,960
and Eddie, so I've arranged a
special viewing in the old factory.
744
00:43:52,960 --> 00:43:54,760
Oh. Oh, God.
745
00:43:54,760 --> 00:43:58,880
That goes in there and that fondant
comes on top, and that sets,
746
00:43:58,880 --> 00:44:02,440
and then it goes to them rollers
to get covered with chocolate.
747
00:44:02,440 --> 00:44:04,440
Aye, it was marvellous
how they did it.
748
00:44:05,720 --> 00:44:08,000
They did that day in, day
out, hours on end.
749
00:44:08,000 --> 00:44:10,920
Right up until... Yeah.
..the 1980s.
750
00:44:10,920 --> 00:44:12,320
I wouldn't have liked that.
751
00:44:12,320 --> 00:44:14,080
No. Definitely not.
752
00:44:14,080 --> 00:44:16,960
That's all you were doing all the
time, making the cardboard
753
00:44:16,960 --> 00:44:18,840
cartons for Black Magic.
754
00:44:18,840 --> 00:44:20,480
Now, that would have been monotonous.
755
00:44:20,480 --> 00:44:22,720
That's it. Them were the jobs
you did. I know you did.
756
00:44:25,080 --> 00:44:27,280
At its height, the Rowntree's
factory even had
757
00:44:27,280 --> 00:44:31,120
its own railway station to shift
the huge numbers of products
758
00:44:31,120 --> 00:44:32,200
and workers.
759
00:44:34,760 --> 00:44:36,560
After moving off the
production line,
760
00:44:36,560 --> 00:44:40,200
Eddie became a supervisor
of the Rowntree's delivery trains.
761
00:44:42,600 --> 00:44:45,080
Who's that there? Who's that?
I think that's me.
762
00:44:45,080 --> 00:44:47,240
That's you? I think so, yeah. It is!
763
00:44:47,240 --> 00:44:49,760
What, with the shunting pole?
Yeah. Yeah, that's me, yeah.
764
00:44:49,760 --> 00:44:51,680
That is you. Yeah. Film star.
765
00:44:57,640 --> 00:45:01,080
But, by the late 1980s, consumer
demand for cheaper chocolate
766
00:45:01,080 --> 00:45:04,200
saw the beginning of the
end for the old ways.
767
00:45:04,200 --> 00:45:07,000
The more labour-intensive parts
of the production lines
768
00:45:07,000 --> 00:45:09,920
were replaced with mechanised
systems and machines
769
00:45:09,920 --> 00:45:13,080
capable of churning out
chocolates by the millions.
770
00:45:14,080 --> 00:45:16,040
Before retiring, Eddie and Bernice
771
00:45:16,040 --> 00:45:19,400
were amongst the last to
make chocolate the old way.
772
00:45:19,400 --> 00:45:21,920
But the sense of welfare
began by the Quakers
773
00:45:21,920 --> 00:45:25,800
has left a lasting mark on
the British workplace.
774
00:45:28,120 --> 00:45:31,200
The way we make chocolate
may well have changed,
775
00:45:31,200 --> 00:45:34,880
but the legacy of those early
chocolate makers lives on.
776
00:45:34,880 --> 00:45:40,640
# And smile, smile, smile. #
777
00:45:46,200 --> 00:45:50,200
Here at Nestle, we're 21 hours
into the chocolate-making process.
778
00:45:52,160 --> 00:45:56,000
And we've already got millions of
chocolate bars ready to be eaten.
779
00:45:57,520 --> 00:46:00,480
But before that can happen,
they need packing up.
780
00:46:02,080 --> 00:46:05,600
In this factory, 3.5 million
of these chocolate bars
781
00:46:05,600 --> 00:46:08,720
need to be individually
wrapped every day.
782
00:46:14,080 --> 00:46:16,080
First, it's the foil wrap.
783
00:46:21,120 --> 00:46:22,400
And then the paper.
784
00:46:24,440 --> 00:46:26,880
27 feet are used every second.
785
00:46:32,040 --> 00:46:34,320
Then they're bundled
into multipacks.
786
00:46:39,880 --> 00:46:42,880
Ex-army man Scott Robinson
gives the bars
787
00:46:42,880 --> 00:46:46,520
one last inspection
before they're packed into boxes
788
00:46:46,520 --> 00:46:48,040
with military precision.
789
00:46:51,400 --> 00:46:54,960
Why, with all this machinery, are
we packing them by hand?
790
00:46:54,960 --> 00:46:57,040
Because, er, we can actually...
791
00:46:57,040 --> 00:46:58,800
We get a better quality finish.
792
00:46:58,800 --> 00:47:01,160
People can see anything
that's gone wrong.
793
00:47:01,160 --> 00:47:02,960
Machines can go,
you can have sensors,
794
00:47:02,960 --> 00:47:05,800
but they won't feel or see
things that are not right.
795
00:47:05,800 --> 00:47:08,360
Can I have a go? Yeah. Feel free.
796
00:47:08,360 --> 00:47:09,920
Come on, down you come!
797
00:47:09,920 --> 00:47:11,400
Here we go now, lovely.
798
00:47:12,840 --> 00:47:15,120
Like that? Fold it that way now.
799
00:47:15,120 --> 00:47:16,920
Ah, quick! Push it through there.
800
00:47:16,920 --> 00:47:19,080
That's it, nice and gently.
Make sure it's square.
801
00:47:19,080 --> 00:47:21,160
I ain't got time to do
it gently. Right.
802
00:47:21,160 --> 00:47:22,680
'It's not as easy as it looks.'
803
00:47:22,680 --> 00:47:24,680
Oh, my gawd.
804
00:47:24,680 --> 00:47:27,400
For crying out loud, we've got
an avalanche happening here.
805
00:47:27,400 --> 00:47:29,440
How many do you lift at a time?
Five.
806
00:47:29,440 --> 00:47:31,480
What, have you go got
hands like a bear?
807
00:47:31,480 --> 00:47:32,760
I'm just lucky. I have, yeah.
808
00:47:32,760 --> 00:47:35,680
Oh, that's it(!) Just dump another
load at the front, make it harder.
809
00:47:35,680 --> 00:47:37,520
SCOTT LAUGHS
810
00:47:37,520 --> 00:47:40,920
This is actually
physically quite challenging.
811
00:47:40,920 --> 00:47:42,680
It is. Do you dream about it?
812
00:47:42,680 --> 00:47:44,160
Uh, not any more.
813
00:47:44,160 --> 00:47:46,760
Stop 'em, they're going
to roll off the end.
814
00:47:46,760 --> 00:47:48,440
The box really slows you down.
815
00:47:50,200 --> 00:47:53,440
So they've sold the whole principle
on this on having a break,
816
00:47:53,440 --> 00:47:54,920
yet me and you don't get one.
817
00:47:54,920 --> 00:47:57,560
There's a bit of an irony there,
don't you think so, Scott?
818
00:47:57,560 --> 00:47:58,800
Yeah, you need it.
819
00:47:58,800 --> 00:48:00,360
Panic's setting in here.
820
00:48:01,560 --> 00:48:04,240
GREGG LAUGHS
You have to come and help me, mate.
821
00:48:04,240 --> 00:48:07,120
I can't get them done quick enough,
look. Give it a go, then.
822
00:48:07,120 --> 00:48:09,520
I've tried my best, Scott.
Yeah, you've done well.
823
00:48:12,800 --> 00:48:16,920
While Scott shows me how it's done,
Cherry's off to meet an expert
824
00:48:16,920 --> 00:48:21,160
chocolatier to find out why we're
so patriotic about our chocolate.
825
00:48:24,120 --> 00:48:28,960
Chocolate has been our favourite
sweet treat for over 200 years.
826
00:48:30,080 --> 00:48:33,360
But it's not imported
chocolate we buy the most of.
827
00:48:33,360 --> 00:48:35,800
The top three selling
brands in the UK -
828
00:48:35,800 --> 00:48:40,400
Dairy Milk, Kit Kat and Snickers -
are all made right here.
829
00:48:41,440 --> 00:48:43,760
So what is it about
British chocolate
830
00:48:43,760 --> 00:48:47,000
that we all find so irresistible?
831
00:48:47,000 --> 00:48:51,800
To find out, I've come to meet
master chocolatier Paul A Young.
832
00:48:51,800 --> 00:48:54,520
He's won many awards for
making chocolates
833
00:48:54,520 --> 00:48:56,600
with a uniquely British flavour.
834
00:48:58,680 --> 00:49:01,760
I feel like I'm meeting
chocolate royalty.
835
00:49:01,760 --> 00:49:07,360
You are definitely the most
qualified person to answer this.
836
00:49:07,360 --> 00:49:11,280
Why do we love British
chocolate so much?
837
00:49:11,280 --> 00:49:13,920
It makes us really happy.
It does! It does.
838
00:49:13,920 --> 00:49:15,160
It makes me so happy.
839
00:49:15,160 --> 00:49:18,480
It's not just the sugar -
it's the feeling, the texture,
840
00:49:18,480 --> 00:49:23,360
the nostalgic reminiscence of
childhood of when you first had it.
841
00:49:23,360 --> 00:49:26,000
Hand anyone chocolate
and they'll smile.
842
00:49:26,000 --> 00:49:29,560
'These days, we have the choice
of chocolate from any country
843
00:49:29,560 --> 00:49:33,120
'we like, but yet we
still choose British.'
844
00:49:33,120 --> 00:49:37,080
What is it about foreign chocolate
that just doesn't sit right with us?
845
00:49:37,080 --> 00:49:40,440
We are tuned to love British
chocolate from being very young,
846
00:49:40,440 --> 00:49:42,920
but there are chocolates
from all around the world.
847
00:49:42,920 --> 00:49:46,280
America, Belgium, Switzerland,
Holland, France, you name it,
848
00:49:46,280 --> 00:49:48,240
and it's all specifically different
849
00:49:48,240 --> 00:49:50,960
and tailored to the palate
of the country.
850
00:49:50,960 --> 00:49:56,080
So it seems we all hanker after
the chocolate we ate as children.
851
00:49:56,080 --> 00:49:58,400
But can we really
taste the difference
852
00:49:58,400 --> 00:50:00,640
between British and foreign brands?
853
00:50:02,000 --> 00:50:06,360
Paul and I are going to put the
Great British public to the test.
854
00:50:06,360 --> 00:50:08,720
We're going to take
four different chocolates
855
00:50:08,720 --> 00:50:12,600
from four different countries
and see which one people prefer.
856
00:50:14,640 --> 00:50:17,920
But first, we need to melt down
the chocolates and reset them
857
00:50:17,920 --> 00:50:21,480
in the same shape to make sure
they all look the same.
858
00:50:22,720 --> 00:50:24,040
So they all look the same
859
00:50:24,040 --> 00:50:26,440
and no-one will be able
to tell which one is which.
860
00:50:26,440 --> 00:50:28,520
They won't... Mwa-ha-ha.
..it's a secret.
861
00:50:31,360 --> 00:50:35,480
Milk chocolate is made up of
cocoa, sugar and milk,
862
00:50:35,480 --> 00:50:39,440
but the proportions can vary
according to its country of origin.
863
00:50:42,520 --> 00:50:45,080
We've got four varieties
of milk chocolate.
864
00:50:45,080 --> 00:50:49,440
So we've got Belgian,
American, British and Swiss.
865
00:50:49,440 --> 00:50:55,560
The Swiss is very, very milky,
incredibly smooth, light colour.
866
00:50:55,560 --> 00:50:58,680
I think most people would say,
"That's a nice milky chocolate."
867
00:50:58,680 --> 00:50:59,920
Hmm.
868
00:50:59,920 --> 00:51:02,480
At the opposite end of
the spectrum is the American.
869
00:51:03,480 --> 00:51:05,480
Eurgh! I mean, it is...
870
00:51:06,640 --> 00:51:09,960
This is probably the
biggest-selling American chocolate.
871
00:51:09,960 --> 00:51:12,560
So, what is it that gives it that -
to be polite -
872
00:51:12,560 --> 00:51:15,000
distinctive flavour and taste?
873
00:51:15,000 --> 00:51:17,400
It's the milk crumb,
and they've manipulated it
874
00:51:17,400 --> 00:51:18,800
to create butyric acid.
875
00:51:18,800 --> 00:51:23,920
That gives it the cheesy, sour,
really off smell and taste to us.
876
00:51:23,920 --> 00:51:27,640
And did you know that butyric acid
is a component of vomit?
877
00:51:27,640 --> 00:51:29,200
Oh, that's not OK!
878
00:51:29,200 --> 00:51:30,480
It's not OK for me.
879
00:51:30,480 --> 00:51:32,600
Do you think most people
would be able to tell
880
00:51:32,600 --> 00:51:35,280
the difference between these
four types of chocolate?
881
00:51:35,280 --> 00:51:37,640
I think they will, and I think
the British chocolate
882
00:51:37,640 --> 00:51:38,920
will be the most popular.
883
00:51:41,080 --> 00:51:42,840
But will Paul be right?
884
00:51:42,840 --> 00:51:46,320
With all the chocolates cleverly
disguised, we're taking to the
885
00:51:46,320 --> 00:51:50,000
streets to see if people really
do prefer British chocolate.
886
00:51:51,760 --> 00:51:56,040
Hi, is there any way that we could
tempt you to try some chocolate?
887
00:51:56,040 --> 00:51:57,360
Yeah?
888
00:51:57,360 --> 00:51:59,560
We're doing a taste test.
889
00:51:59,560 --> 00:52:02,400
Yeah, shall we? Yes! Do you want to
try some before your main course?
890
00:52:02,400 --> 00:52:05,000
First, they try the American version.
891
00:52:05,000 --> 00:52:07,560
Erm... No? You don't like that?
892
00:52:07,560 --> 00:52:10,320
There's an aftertaste. There is.
What is the aftertaste?
893
00:52:10,320 --> 00:52:12,120
Oh, wow, like off milk.
894
00:52:12,120 --> 00:52:15,320
And it seems that American chocolate
isn't a hit with British
895
00:52:15,320 --> 00:52:17,200
taste buds anywhere we go.
896
00:52:17,200 --> 00:52:19,440
I'm not particularly
impressed with that.
897
00:52:19,440 --> 00:52:21,320
It's got this really
bitter taste to it.
898
00:52:21,320 --> 00:52:23,440
It's actually a bit sicky.
899
00:52:23,440 --> 00:52:26,440
It's too... It's not nice.
900
00:52:27,440 --> 00:52:31,680
'In fact, out of the four - American,
British, Belgian and Swiss -
901
00:52:31,680 --> 00:52:34,600
'it was the British chocolate
that came out the winner.'
902
00:52:36,120 --> 00:52:38,600
It's just a different texture.
It's creamier.
903
00:52:38,600 --> 00:52:40,480
That's a bit more, like...
More, like...
904
00:52:40,480 --> 00:52:42,800
A bit more Dairy Milk
chocolate kind of taste.
905
00:52:42,800 --> 00:52:43,960
Mmm, it's nice.
906
00:52:43,960 --> 00:52:45,200
'From garages...
907
00:52:47,080 --> 00:52:48,760
'..to hairdressers.'
908
00:52:48,760 --> 00:52:51,120
Creamier than the first
and second one.
909
00:52:51,120 --> 00:52:52,560
Really smooth, really rich.
910
00:52:52,560 --> 00:52:55,480
That's very creamy, I think. Hmm.
911
00:52:55,480 --> 00:52:58,080
We have a winner on our hands.
Yes! Really?
912
00:52:58,080 --> 00:53:00,480
That is the British chocolate.
Well done.
913
00:53:04,200 --> 00:53:07,000
So, obviously, people still
love British chocolate,
914
00:53:07,000 --> 00:53:08,360
but no-one's picked American.
915
00:53:08,360 --> 00:53:09,720
No-one's picked American.
916
00:53:11,640 --> 00:53:14,640
We did find some people
who like American chocolate...
917
00:53:14,640 --> 00:53:16,000
Americans.
918
00:53:16,000 --> 00:53:20,640
MUSIC: US National Anthem
919
00:53:21,880 --> 00:53:23,120
Oh.
920
00:53:24,880 --> 00:53:27,600
I'm going to have to change
all of my answers.
921
00:53:27,600 --> 00:53:29,080
That's definitely American.
922
00:53:30,080 --> 00:53:31,520
That's my favourite.
923
00:53:31,520 --> 00:53:34,400
It's just sort of, like,
bringing home to you
924
00:53:34,400 --> 00:53:36,960
versus you having to go home.
925
00:53:36,960 --> 00:53:38,280
It doesn't taste fake to me,
926
00:53:38,280 --> 00:53:40,280
and that's why I think
it's pretty great.
927
00:53:41,520 --> 00:53:44,760
Whether we want a bar to treat
ourselves, or as a comfort,
928
00:53:44,760 --> 00:53:47,720
we know what we like
and we like the familiar,
929
00:53:47,720 --> 00:53:51,360
but it's those childhood memories
that keep us Brits so loyal
930
00:53:51,360 --> 00:53:53,400
to the chocolate that we love.
931
00:54:01,560 --> 00:54:05,040
22 hours after the beans
first came on site,
932
00:54:05,040 --> 00:54:08,120
the wrapped chocolate bars are
now ready for customers.
933
00:54:12,600 --> 00:54:16,600
A team of 30-foot-high robots now
stack them onto pallets.
934
00:54:23,040 --> 00:54:26,760
And conveyor belts take them to
a warehouse to await distribution.
935
00:54:28,160 --> 00:54:32,680
But, with four million chocolate
bars to deal with every day,
936
00:54:32,680 --> 00:54:35,280
this is no ordinary warehouse.
937
00:54:35,280 --> 00:54:38,520
Distribution manager Sally Wright
has let me inside.
938
00:54:40,120 --> 00:54:42,040
Oh, my word!
939
00:54:52,560 --> 00:54:54,560
Crying out loud.
940
00:54:59,200 --> 00:55:02,200
I didn't realise this much chocolate
actually existed in the world.
941
00:55:03,520 --> 00:55:05,240
Good grief.
942
00:55:05,240 --> 00:55:07,280
GREGG LAUGHS
943
00:55:07,280 --> 00:55:10,120
What do you call this place?
This is the building.
944
00:55:10,120 --> 00:55:11,640
"The building?" The building.
945
00:55:14,800 --> 00:55:18,440
Occupying the land space of
two football pitches
946
00:55:18,440 --> 00:55:21,240
and towering eight storeys high,
947
00:55:21,240 --> 00:55:25,680
every single pallet of chocolate
is stored, monitored
948
00:55:25,680 --> 00:55:28,200
and moved by robots.
949
00:55:31,720 --> 00:55:34,520
Once the stock's been fed
into "the building"
950
00:55:34,520 --> 00:55:36,040
by the conveyor belts,
951
00:55:36,040 --> 00:55:39,520
the humans no longer have any
control over what happens to it.
952
00:55:41,160 --> 00:55:43,080
We don't have human's controlling it.
953
00:55:43,080 --> 00:55:45,520
We don't have fork truck
drivers in here.
954
00:55:45,520 --> 00:55:48,320
The building knows where all
the empty spaces are,
955
00:55:48,320 --> 00:55:49,560
where all the stock is.
956
00:55:49,560 --> 00:55:52,440
When we have orders, it knows
where to go and get the stock.
957
00:55:52,440 --> 00:55:55,720
When we have fresh stock coming in,
it knows where to put it away.
958
00:55:55,720 --> 00:55:57,200
It self controls.
959
00:55:57,200 --> 00:56:01,360
The building runs itself?
Pretty much so, yeah.
960
00:56:01,360 --> 00:56:04,040
We watch over it
with a computer system,
961
00:56:04,040 --> 00:56:06,520
but ultimately, it self manages.
962
00:56:07,560 --> 00:56:10,520
From the moment the chocolate
comes into the building,
963
00:56:10,520 --> 00:56:15,760
the five giant unmanned cranes
stack the pallets, store them,
964
00:56:15,760 --> 00:56:19,560
and then send them to the loading
area when the orders come in.
965
00:56:19,560 --> 00:56:20,960
Do humans get in those?
966
00:56:20,960 --> 00:56:22,640
The engineers do, yeah.
967
00:56:22,640 --> 00:56:25,600
Could I have a ride on one of them?
Yes, we can arrange that.
968
00:56:30,080 --> 00:56:32,160
Whoa!
969
00:56:32,160 --> 00:56:33,960
Wahey-hey-hey!
970
00:56:34,920 --> 00:56:37,760
HE LAUGHS
Wahey!
971
00:56:39,120 --> 00:56:41,320
Whoooa!
972
00:56:43,440 --> 00:56:46,040
Whoa! Ha-ha!
973
00:56:46,040 --> 00:56:48,120
Will it stop before the
wall at the end?
974
00:56:48,120 --> 00:56:51,200
It may do.
GREGG LAUGHS
975
00:56:51,200 --> 00:56:55,640
MUSIC: Song 2
by Blur
976
00:56:55,640 --> 00:56:56,680
This is nuts!
977
00:56:59,320 --> 00:57:01,080
All that to give us a chocolate bar?
978
00:57:01,080 --> 00:57:02,280
Yeah.
979
00:57:02,280 --> 00:57:04,040
It's a strange world.
980
00:57:04,040 --> 00:57:06,320
Wahey-hey-hey!
981
00:57:06,320 --> 00:57:08,600
GREGG LAUGHS
982
00:57:11,520 --> 00:57:14,640
It takes the building just one
week to get through
983
00:57:14,640 --> 00:57:16,920
its entire stock of chocolate.
984
00:57:18,760 --> 00:57:21,520
Every day, up to
60 trucks are loaded
985
00:57:21,520 --> 00:57:23,720
from the dispatch hall
at this site...
986
00:57:25,280 --> 00:57:29,360
..and leave York with chocolate
destined for shops and supermarkets
987
00:57:29,360 --> 00:57:31,680
all over the UK and Ireland.
988
00:57:34,720 --> 00:57:37,800
So next time you open a bar
of chocolate, just think,
989
00:57:37,800 --> 00:57:44,240
it is one very small part of an
enormous, global chocolate empire.
990
00:57:44,240 --> 00:57:45,280
Wow.
991
00:57:49,240 --> 00:57:52,440
'Next time, I'll be taking you
inside one of the largest
992
00:57:52,440 --> 00:57:54,960
'fresh milk processing
plants on earth.'
993
00:57:54,960 --> 00:57:57,720
I've never seen anything
like this, ever.
994
00:57:57,720 --> 00:58:00,640
'I'll meet the people
and the robots...'
995
00:58:00,640 --> 00:58:02,280
Come on, come on.
996
00:58:02,280 --> 00:58:04,560
HE LAUGHS
997
00:58:04,560 --> 00:58:08,280
'..who get the milk from cow to
carton in as little as 24 hours.'
998
00:58:08,280 --> 00:58:09,720
Mate, I love this.
999
00:58:09,720 --> 00:58:11,800
I absolutely love it.
1000
00:58:11,800 --> 00:58:12,880
Wow.
1001
00:58:12,880 --> 00:58:15,000
'And Cherry will lift the lid...'
1002
00:58:15,000 --> 00:58:17,000
Oh, whoa! Eurgh!
1003
00:58:17,000 --> 00:58:19,000
Looks like scrambled eggs.
1004
00:58:19,000 --> 00:58:22,520
'..on how you produce
cheese on an epic scale.'
1005
00:58:22,520 --> 00:58:26,360
Tasting cheese all day,
I am happy as Larry.
1006
00:58:26,360 --> 00:58:29,400
'You'll never look at milk
in the same way again.'
83094
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.