All language subtitles for Inside.the.Factory.S04E06.Frozen.Pizza.1080p.PMTP.WEB-DL.DDP5.1.H.264-BurCyg_track3_[eng]

[harpsichord music]

Us Brits love this
Italian classic.

Which explains why we slice
up around 14 million pizzas

every week.

Spending 2 and 1/2 billion
pounds on them each year.

And where's the best place
to learn how they're made?

This Italian pizza
factory, of course.

GREGG WALLACE: 600 people work
here producing a whopping 370

pizzas every minute.

I'm Gregg Wallace.

That is like whitewater
rafting for pizzas.

And tonight, I'll learn
how they guarantee

a crispy crust every time.

450 degree proper wood fired
oven with a stone base.

CHERRY HEALEY: I'm
Cherry Healey--

It looks like a sample
that I don't want to drink.

And I'll be investigating the
complex chemistry behind some

of our favorite toppings.

So the proteins in mozzarella
are just in that sweet spot

where they can melt beautifully.

GREGG WALLACE: And
historian Ruth Goodman

sees what was on the menu when
pizzas first came to Britain.

RUTH GOODMAN: It's a very
familiar list though.

I mean, things like the
Margarita, Four Seasons,

[inaudible].

Over the next 24
hours, this factory

will produce 400,000 pizzas.

And we're serving you a slice
of the production process.

Welcome to "Inside
the Factory."

[music playing]

This factory in the foothills
of Italy's Dolomite Mountains

makes an astonishing 500
different varieties of pizza.

They ship all over
the world, tailoring

their recipes to the individual
taste of each country.

For Italy, that means ultra
traditional thin crust

margaritas.

And for Germany, a deep
base topped with fish.

But our pizza is made for the
British market and the shelves

of supermarket chained Iceland.

And it's their stone baked,
spicy, double pepperoni version

that we're here to
learn how to make.

And as with any pizza,
it's all about the base.

This one is thin and
crispy with a chewy crust.

Production begins
in the intake area

with a delivery of wheat flour.

10 of these tankers
arrive here every week,

each one laden with
30 tons of the stuff.

Gabrieli [inaudible]
oversees all raw ingredients

that arrive on site.

Gabrieli, good to meet you.

This is the beginning?

Yes.

We intake the floor right here.

So this is more or
less 240,000 pizzas.

A quarter of a million pizzas?

Yes.

From that flour?

Even I can't eat
that many pizzas.

Tell me, what is the
perfect flour for a pizza?

We use a flour type 0.

When I read cookery books, a
lot of it is 00, double zero.

Why do you use 0 and not--

We prefer the 0, because it's
a little less refined flour

and gives a crispier
product that we want.

GREGG WALLACE: Flour comes
in many different grades

and subtle variations
can make a big difference

to the finished product.

The kind they're
about to unload here

is a strong, all
purpose, milled,

wheat flour, like you might
use to make a loaf of bread

at home.

Let's get this
flour off the lorry.

OK.

GREGG WALLACE: The
pipes are connected

and our frozen pizza
production line begins.

I love that pipe is dancing.

It looks like an eel.

The flour is blown along
this pulsating pipe

and into one of four 30 ton
silos, where it's stored

before joining the other
seven ingredients that

will go into our pizza base.

Every 12 minutes, a
batch of 250 kilos

is sent to the mixing area,
where I'm meeting Operations

Manager Alberto Urli.

Alberto, I'm Gregg.

Hi, Gregg.

I love making pizza.

I'm very excited to be here.

Is this the start
of the process?

Yeah.

Yeah.

Here, mainly we
prepare the dough.

That is the core of the
process of the pizza.

GREGG WALLACE: The base of
our pizza is a simple dough,

but we're not starting
with my flour.

So first of all, we
need to load the yeast.

This is industrial yeast.

It's fresher.

It's ready to give its
power to our dough.

GREGG WALLACE: Yeast is
the magical ingredient,

which transforms our dough.

It eats up the
naturally occurring

sugar in the flour producing
CO2 gas making the dough rise.

Good?

The second one, salt.

Yeah.

GREGG WALLACE: Next up is
salt, which helps strengthen

the dough and adds
flavor, followed

by a sugar called dextrose,
which will provide

extra food for our yeast.

How many pizzas will
we get out of here?

With this dough,
around 1,800 pizzas.

GREGG WALLACE:
Nearly 2,000 pizzas?

Yeah.

GREGG WALLACE: 250 kilograms of
the flour I saw arrive is dosed

in, followed by
125 liters of water

and sunflower oil,
which will make

the dough easier to stretch.

Can I press the button?

Yeah, let's start.

GREGG WALLACE: The
mixing process begins.

So that's just
mixing like I would

mix at home with a big spoon.

Yeah, more or less.

GREGG WALLACE: 10
minutes mixing at 280 RPM

is enough to combine
these ingredients.

Whoa.

That is a big--

that is more like
bubble gum right now.

Yeah.

OK, this is going
to rest, right?

For five hours.

Five hours?

Yeah.

And how do you want it
to be after it has rested?

We want a more relaxed dough,
because we need to create

the perfect round of the pizza.

What would happen if we tried
to make pizza now with this?

Ah, it would be a disaster.

Would be impossible to get
the right shape because it's

impossible to stretch.

GREGG WALLACE: In the other 1
hour and 43 minutes since it

arrived at the factory,
my flour has been working

very hard becoming dough.

But now it gets a chance to
have a breather as it trundles

along 30 meters of mechanical
conveyors and lifts

before it's tucked into the
resting room for 40 winks.

Today in Britain, we spend
more on takeaway pizza

than we do on fish and chips.

Ruth is on the trail
of the man who first

brought us a pizza the action.

In the late 50s and early
60s, all things Italian became

super fashionable in the UK.

But there was one thing
missing from the cafes

and spaghetti houses, pizza.

Italian immigrants had tried
and failed to introduce pizza

to the Brits, but it took a
man from Peterborough to really

make us fall in love with it.

I interviewed Peter Boizot
about the first pizza he tasted

70 years earlier in Italy.

I went to Florence.

Delightedly, they made for
me a pizza, the first one

I'd ever had or seen.

And what was it like?

Well, it was good, tasty,
the dough had risen properly.

It had, of course, a lot
of mozzarella cheese on it.

RUTH GOODMAN: When he
came back to London,

Peter couldn't find what he felt
was a proper pizza anywhere.

So in 1965, he decided to
set up his very own pizzeria.

But you needed a
special oven, a hot oven,

so I went over to Italy and
contacted a wonderful man,

[inaudible],, and he sent me a
specially designed pizza oven.

In order to get it
into my restaurant,

we had to knock the
wall down because it

was too big for the door.

What was the name
of your restaurant?

Pizza Express.

Peter's first pizzeria was
here in Wardour Street in Soho,

today at the very
heart of Chinatown.

And that very first
restaurant is still

here and still serving pizza.

The restaurant chains
biographer, Matthew Reevell,

believes this place hit upon
a recipe for success right

from the start.

What were they serving in
that very first restaurant?

I've got the menu here
that shows you what they had,

and the first thing
that will strike you

is there's no pasta,
salad, desserts,

or dough balls on there.

It's all pizzas.

It's a very
familiar list though.

I mean, things like
obviously the Margherita,

the Four Seasons, your
mushroom pizza, [inaudible]..

When pizza first
set up the restaurant,

you could see the
buzz of pizzaiolos

throwing dough in the air and
making them in front of people.

However, it was the food that
was the real selling point.

It was eating from an
authentic wood oven,

eating real Italian pizzas
that was so successful.

How did it go
then from being one

small shop in Wardour Street
to being this great big chain?

His plan wasn't to
make a lot of money.

His plan was to create this
different type of dining

experience, which was
inexpensive, lots of energy,

lots of buzz around
the restaurant,

and it was so successful
that he basically

had to keep on expanding it.

RUTH GOODMAN: And where
Peter led, others followed.

Today, around 5,000 restaurants
and takeaways across the UK

sell a slice of
the big pizza pie.

You know, if Peter Boizot
hadn't first given us that taste

of the real thing,
I'm not sure that we'd

be the nation of pizza
lovers that we are today.

GREGG WALLACE: Back in
Italy, our pampered pizza

dough has been having a little
nap in the resting room.

Yeast has trapped tiny
bubbles of CO2 gas

inside it, causing it to
rise and double in size.

It's now what bakers call a
relaxed dough, meaning it'll

be easy to stretch into shape.

6 hours and 43 minutes
into the process,

it heads to the beginning
of the pizza line.

OK.

Well, that's lighter.

It was very tight at the
start and now is more relaxed.

GREGG WALLACE: But our dough's
had enough time lazing about.

Now it needs to get in
shape and this machine

is going to give it a workout.

What is happening
in here, Alberto?

So this is our
knocking back process.

The portion, the right
quantity of dough that we

need for each single pizza.

GREGG WALLACE: The dough drops
down into the machine, blades

rotating at 150 RPM
slice 190 gram pieces off

before two super sized
rolling pins massage

them, creating six
perfectly formed

balls every four seconds.

This vigorous massage alters
our dough's structure.

Each ball is held together by
a net of protein called gluten,

and as it's kneaded, the
strands of this gluten

align giving the
dough more strength.

Important because it's
about to rise again

and be stretched to its limits.

So where are these
dough balls going?

They're going in
to this big cell.

This is a proofing cell.

GREGG WALLACE: Just like me
after a vigorous workout,

the dough balls
deserve a little R&R.

They drop into
individual cups and head

off for their version of a sauna
in this huge proofing cell.

Inside, the temperature is 35
degrees Celsius and humidity

hits 75%, perfect
conditions for the yeast,

which continues eating
those natural sugars

and pushing out more CO2.

After one hour, they emerge.

Oh, wow.

It's very light.

Yeah.

Very light.

It almost feels-- it feels
like a small cushion.

Yeah, if you want,
you can stretch it.

Wow.

That is much lighter
than my dough at home.

That feels like silk.

The yeast relaxes
the gluten net

and that's why it's
so easy to stretch.

GREGG WALLACE: After their
pampering at the pizza spa,

our dough balls are now ready
for their next treatment.

So how do I make this into
a perfect round shape?

Not easy, huh, Gregg?

Not easy, huh, Gregg?

It's really--

No good?

Let's try it with this machine.

We take the ball, we
put it in the middle

of these two hot plates.

That's very hot.

- I can feel that heat.
- Yeah.

Yeah.
Yeah.

Yeah.

And then we press.

Can you help me?

Yeah.

Let's go.

GREGG WALLACE: Two plates heated
to 157 degrees Celsius pushed

GREGG WALLACE: Two plates heated
to 157 degrees Celsius pushed

together, creating an
8 millimeter thick,

25 centimeter diameter base.

And here you are,
a perfect circle.

This is the result.

That is hard.

Yeah, you have a skin.

GREGG WALLACE: It's
like you sealed it.

Yeah, and this way it's
impossible for the water of the

tomato sauce to go inside it.

GREGG WALLACE: How many
pizzas do you do every day?

About 400,000 pizzas.

But you can't do
400,000 like this.

No.

Of course, we have a big machine
with many heads like that.

But unfortunately, I cannot show
you, because it's our secret

machine.

This is not the first time it
has happened inside a factory,

someone has a secret
machine I can't see.

Yeah.

Yeah.

GREGG WALLACE: Secret it may
be, but the results are clear.

Now our perfectly flat,
heat-sealed pizza bases

are pricked with 278 4
millimeter deep holes

to let excess moisture escape
and ensure they're perfectly

crispy when cooked in the oven.

Base is sorted.

Next we need some sauce, but why
do we always reach for tomato?

Cherry's visiting a farm
in Worcestershire that

grows 560 tons of them a year.

I want to discover what it is
about the tomato that makes it

the perfect partner for
pizza, pasta, and so

many other classic dishes.

Helping me isolate the taste
that makes it so special

is food scientist
Professor Lisa Methen.

Oh, look at this.

So what we're
going to do is think

about what is actually
in the middle of this

that's got the taste in it.

If we cut that tomato
up, blend it in a mixer,

we can spin out all of
the taste part to it

and it actually looks like this.

Oh.

It looks like a sample
that I don't want to drink.

Well, I'm going to get you to.

CHERRY HEALEY: What we
consider as flavor is made

up of both taste and smell.

So in order to discover the
underlying true tomato flavor,

I need to block my nose.

I'm going to get you
to wear the nose clip.

What I want you
to concentrate on

is just what's on your tongue.

Bottoms up.

It's a little bit sharp.

It's a little bit tart.

It's a little bit sweet.

I can almost taste savory.

It doesn't really taste
like tomato at all.

That is absolute extraordinary.

So when I couldn't smell it, I
felt like I could taste savory.

Absolutely, you can
taste the savory taste.

That's called umami.

So I've heard
of umami, but I've

never really known what it is.

It's one of your
five basic tastes.

So you've got your sweet taste,
sour, salt, bitter, and the

fifth one's your umami taste.

One of the taste compounds
in there is glutamate.

That gives you umami
taste and actually that

is present in so many
foods, but particularly high

in the tomato.

CHERRY HEALEY: High levels are
also found in mushrooms, soy

sauce, and Parmesan
cheese, all ingredients

that, like tomatoes,
act as brilliant flavor

enhancers in cooking.

Umami taste compounds
work really well together.

So you can take a tomato and put
it with other foods that have

some savory component
to them because you

get all this great synergy
from the taste together.

So when it comes to
umami, more is more.

They love to work together.

Absolutely.

CHERRY HEALEY: When
it comes to tomatoes,

it's all about the umami.

Now I understand the
chemistry I can see why

they're the basis of so
many of our favorite dishes,

including pizza.

GREGG WALLACE: Back
at the factory,

after 7 hours and 55 minutes
of careful preparation,

our bases are made and
they're ready for their all

important tomato topping.

So I'm heading to the
sauce preparation area.

Every pizza sauce they use
here is mixed up fresh on site,

and they all start with
100% Italian tomatoes.

Gabrieli, good to see you again.

Hello.

I'm guessing this is
tomato puree, right?

How much of this do we use
for our mix, for our sauce?

1 and 1/2 of a drum.

GREGG WALLACE: The first
step to creating our source--

Whoa.

Whoa.

Is to pump the concentrated
puree into a 500 liter mixer.

And now what?

Push the green
button, keep it pressed.

This is going to
be messy, isn't it?

Oh.

Whoa, whoa, whoa, whoa.

Let go.

GREGG WALLACE: Using
puree means the factory

has a supply of perfectly
ripe, umami rich tomatoes

year round, not just
at harvest time.

It's working.

It's definitely working.

Five minutes later,
our mixer is full.

So we got our lovely tomatoes,
beautifully pumped by me.

Now we put the olive oil.

- Olive oil?
- Yes.

OK.

It gives a little
bit of flavor

and the creaminess of the sauce.

GREGG WALLACE: With a
simple push of the button,

5 liters of olive
oil is dosed in.

OK.

Now?

Now we can put the water.

GREGG WALLACE: Followed
by 125 liters of water.

And next, seasoning.

Oh, what is in here?

It's made of dry oregano,
sugar, salt, and yeast extract.

GREGG WALLACE: A paddle spinning
at 280 RPM blends our 500

kilo batch of sauce together.

How many pizzas will it cover?

7,000 pizzas.

Half a ton of sauce
for 7,000 pizzas.

Beautiful mix.

It's pumped through 55
meters of overhead pipes

towards the sauce applicator,
where our naked pizza bases

receive a splash of color.

Alberto, I am back.

Good to see you again.

That is my tomato sauce.

I made it with Gabrieli.

Yes.

Yes.

Here we distribute 60 grams
of tomato sauce on each one.

Does my sauce look better than
the normal sauce or the same?

It's better.

Ha ha ha ha ha.

What is that?

That's a camera
machine that is taking

a picture for each pizza.

GREGG WALLACE: Why?

Because in this way,
can give to this machine

the right position
of each pizza.

So we want to be sure
that we are spreading

exactly in the center.

GREGG WALLACE: Information is
sent straight from the cameras

to these nubbly
rollers, which adjust

their position depending on
the location of the pizza bases

below.

It looks like you are putting
the sauce on with a corn cob.

126 nodules on each roller help
pick up the bright red sauce

and distribute it evenly
around our nude bases.

Whoa.

That is a slow moving
river of pizza.

Reminds me of like a
military procession.

We had a batch of 1,800 pizzas?

Yeah.

Yeah.

How long would it take
before they all went past us?

So at the moment,
this line is running

at 100 pieces per minute.

Is it?

Yeah, so it means that that
batch will go in 18 minutes.

And these are all for the UK?

Yeah.

GREGG WALLACE: We're 8 hours,
32 minutes, and 40 seconds

into production, and even though
they're only partially dressed

without their toppings on,
our saucy saucers of dough

are on their way to a hot date.

They strap six at a time into
this huge 4 meter high, 12.5

meter long conveyor
oven, where they'll

face temperatures far higher
than any domestic oven could

manage.

How hot is that oven?

450 degrees.

450 degrees?

Yes.

And if you didn't start
the cooking process here,

we would never get that
crispy base, would we?

Yes.

It can't take very long
to cook these pizzas.

No, 80 seconds.

80 seconds?

Yes.

That is impressive,
but it's not authentic

like a wood fired oven, is it?

Yes, of course, it is.

How?

We use this.

Wood pellets?

Yeah.

That is a wood fired oven?

Yes.

I can see the
embers coming off.

Why is wood so good?

Because its aroma.

You understand aroma?

Yeah.

Not the capital of
Italy, the smell.

The fragrance.

Yes.

What is your conveyor
belt made from?

It's made of natural
volcanic stone.

It's from Etna
volcano from Sicily.

You have a conveyor
belt made of stone?

Yes.

GREGG WALLACE: It turns
out stone-baked means

just that, cooked on stone.

The sizzling rock used here
is porous, which helps the air

circulate around our pizzas
and draw steam away ensuring

a perfectly crisp base.

Exactly 80 seconds after their
rocky ride through the oven

began, our pizzas
emerge at the other end.

Now I can see that
volcanic rock very clearly.

How does the crust
puff up like that?

Like, just gets much bigger.

Inside the dough,
there is the gas

that was produced by the heat.

And now with the temperature,
the gas increases the pressure

and the gluten net is like
the balloon that is inflating.

That pizza is cooked, right?

In fact, now the pizza is
partially cooked, because we

put the topping after the oven.

You don't want to cook the
toppings before we get it.

No.

When we put it in the oven,
the rest of the base and

the topping will cook the same.

Are you spraying water on there?

Yeah.

Yeah.

We are spraying
water to cool down

the base because
in a few minutes,

we will top the
mozzarella cheese.

We've got thin crispy
bases and tasty tomato sauce,

but it's no use getting
all that right if you

top them with the wrong cheese.

Cherry's on a melty mission.

CHERRY HEALEY: I'm heading
to the University of Redding

for a pizza cheese
showdown with food

scientist Dr. Stuart Ferrymand.

Hi, Dr. Stuart.

Hi, Cherry, great to see you.

Welcome have we got here?

A variety of
cheeses because there

is some serious science behind
getting that perfect cheese.

CHERRY HEALEY: First, we're
assessing meltability.

Not every cheese melts so one
of the most important factors

is how acidic the cheese is,
and we measure that with the pH.

And so we're going
to test that now

with these different cheeses.

CHERRY HEALEY: We're
measuring the pH levels

of some popular varieties.

We'll start at this end with
blue cheese, with Stilton.

One of my favorite.

Stinky cheese, the
stinkier the better.

In we go.

A low number is very acid.

A higher number
is more alkaline.

What we're looking for is
a pH of between 5 and 5.9.

Ideally in the middle
5.3 is the sweet spot.

So what you can see already is
that it's a much higher number.

6.27 already.

And that means that
it's less acidic.

CHERRY HEALEY: Low acidity
tells us about the protein

network of the Stilton.

It's like this ball
of elastic bands.

It can't get apart
because the proteins

are too tightly bound together.

So that when you melt
it, they don't really

have that lovely, soft,
melty, stringy effect.

They just stay like this.

Next up, crumbly feta.

In we go.

So it's landed at 4.26.

What does that mean?

Well, the feta is too acidic.

CHERRY HEALEY:
High acidity makes

the protein network too loose.

So when you melt it--

It will actually
burn rather than melt.

CHERRY HEALEY: Third
up is mozzarella.

Try that cheese.

Bang in the middle between 5
and 5.9, so the melting zone.

So the proteins
in the mozzarella,

they're just in that
sweet spot where

they can melt
beautifully because it

has got the perfect acidity.

Yes, but there's
another reason that

makes mozzarella
so good for pizza,

and that is the stringiness.

Yes.

And it's the way
in which it's made.

CHERRY HEALEY:
Mozzarella is kneaded

just like pizza dough, which
gives it extra stretchability.

And that's why it has the long,
lovely, cheesy, stringiness.

Mm-hmm.

So to make our ultimate pizza,
feta and blue cheese are out.

Out.

So mozzarella is in.

Are there any other
cheeses we should try?

Yes.

There are other cheeses that
are in the melting zone.

We've got here some cheddar
and we've got some Gruyere.

They're all between 5 and 5.9,
but the only way to find out

which is best is to
do some experiments,

and you're going to hate this.

We're going to have
to make some pizza.

Yes.

CHERRY HEALEY: We're topping
identical plain tomato

bases with our three cheeses.

In we go.

CHERRY HEALEY: After
10 minutes cooking,

there are clear
visual differences.

All right, they look
absolutely gorgeous.

- There we go.
- Thank you.

Thank you.

So here we've got our
lovely pizzas, Gruyere,

cheddar, and mozzarella.

So I want to point out to
you something with the cheddar.

You can see here that
you've got oily patches,

and what's happened
there is that the fat

has separated out as this oil.

So that's not ideal.

Cheddar's high fat content
makes it look unappealing.

Gruyere looks more promising.

If we look here
at the Gruyere,

you can see this blistering
if you look around the edges,

and that's because there's quite
a lot of moisture in Gruyere.

Yeah.

And so as it heats up,
the water turns to steam

and it comes up as these
bubbles, this blistering

that we see.

When the bubbles burst,
then you get a rough surface

and that helps the browning.

So why do we want
the browning effect?

That's where
all the flavor is.

That's where the magical
reaction is happening.

CHERRY HEALEY: But mozzarella
is the clear winner.

If we go to the
mozzarella, this

has even more moisture
in it and so you've got

more of this bubbling effect.

CHERRY HEALEY: So
the mozzarella is

good because it browns
faster without separating

into oily pools.

You've got it.

Mozzarella is the winner.

It's got my vote.

CHERRY HEALEY: Science confirms
tradition, great meltability

and beautiful browning
make mozzarella

the perfect pizza cheese.

GREGG WALLACE: We are 8 hours
and 34 minutes into the pizza

making process.

As they emerge from
the oven, our pizzas

take a spin along 100
meters of computer

controlled conveyor belts.

Gently cooling from 90 degrees
Celsius to 35 as they go.

Any that aren't up to
scratch are unceremoniously

dropped off the line.

Those that pass muster
are now cool enough

to be topped with
cheese, which is,

of course, 100% mozzarella, and
grated fresh to order on site.

Coming through.

GREGG WALLACE: They get
through an astonishing 10

tons of the stuff every day.

Alberto.

Oh, yeah.

Does it go in there?

Yeah, because we
want it on the pizza.

So please, let's
load the machine.

Just throw it in?

Yeah.

Yeah.

GREGG WALLACE: This
cheese has 1% chives.

Fantastic, Gregg.

GREGG WALLACE: Which add color
and a subtle hint of onion.

Perfect.

My freshly grated
mozzarella falls

onto a conveyor belt,
which carries it

to the waterfall distributor.

Look, it's coming there and
is flowing through the machine

and is topping the pizza.

GREGG WALLACE: As the cheese
drops into the distributor,

148 individual metal fingers
help disperse it evenly

onto the pizza bases below.

It's helping to have always
the same quantity of mozzarella

cheese for each pizza.

That's where it's
holding and these wheels,

they are sifting
and making sure

this cheese does not
come out too fast.

Exactly.

So it's dropping
like a light rain.

Yes.

Do you know how much cheese
actually ends up on each pizza?

Yeah.

50 grams.

GREGG WALLACE: More cheese is
on the belt than the pizza.

Look, it's flowing
into the conveyor, then

up again and again into
the machine, so no waste.

Some cheese must
go round 50 times.

No, no, no, no.

In the average, we
calculated that is

flowing only three times.

I like it.

I think it's pretty.

GREGG WALLACE: 8 hours,
37 minutes, and 40 seconds

into production, our cheese
and tomato pizzas are

waiting for our spicy sausage.

Which is applied by the
pepperoni applicator.

Oh, I love this.

This has got to be the best
part of the whole factory.

She's got to hold on
to that while it's

so long because it will break.

Yeah.

That is like a crazy game.

Is that even real?

Yes.

Do they go in every hole?

Yeah.

Not that one.

Not that one.

Why not that one?

No, because we need only
12 slices for each pizza.

Oh.

This pepperoni, is
this an authentic pizza

topping for Italians?

No.

No.

In Italy, we have a
different kind of salami.

Is this more spicy
than you are used to?

It's more hot.

There's got to
be an easier way.

Right.

Whoa.

Whoa.

[non-english speech]

GREGG WALLACE: As the
pepperoni rocks back and forth,

blades lubricated
with water slice off

2 millimeter thick
pieces of meat.

A laser tells the machine when
there's a pizza underneath

and 12 bits of our spicy sausage
are dropped onto each one.

Brilliant.

I can actually see the
pepperoni dropping.

Yeah.

12 on each pizza.

Exactly.

How many pizzas going
through here, Alberto?

Around 100 per minute.

Yeah?

What are these ladies doing?

Because the pepperoni
is on the pizza.

Yeah, but sometimes
a slice is missing,

and we want exactly 12
slices for each pizza.

We don't want it perfect.

That is the beauty of the pizza.

You cut the slice sometimes,
you are lucky, sometimes--

Yes, I understand but
here we are in Italy.

I'm sorry.

And we want a good taste pizza
and a good looking pizza.

OK.

OK.

GREGG WALLACE: Italian
precision has applied

our spicy Austrian
sausage, but because us

Brits love loads of toppings,
we're only halfway there.

Next up, it's precisely
20 grams of red onion

applied just like our cheese,
by a waterfall applicator.

Now, time for even
more pepperoni,

which relies on something
a little more low tech.

They are putting
on more pepperoni?

Yeah, they are hand topping.

There's more pepperoni.

So it's a different
taste because we

want to have a good balance
of taste of meat in the pizza.

So first we need to wear this.

For each one, we need 10 grams.

OK, try.

Not bad.

Not bad.

OK.

OK.

Why can't this be
done with a machine?

Because this material is not
easy to top with a waterfall

machine and we want
a good distribution,

so we prefer to top by hand.

I am rubbish at this.

I am OK eating them, but
there is no way I can do

this as fast as these ladies.

That looks simple, but you
are doing like two pizzas

every second.

I cannot do this.

Yeah.

GREGG WALLACE: The final
topping is 25 grams

of fiery jalapeno peppers.

8 hours, 38 minutes,
and 40 seconds after we

began, our pizzas are complete
and ready for the freezer.

That's it.

That's the finished
pizza, right?

Yeah.

GREGG WALLACE: Are you
spraying them with water again?

Yes.

Because in this way,
in the first part

of the freezing
tunnel, the water

will freeze immediately so
we freeze the topping exactly

where it is at this stage.

And when I get it
home and cook it,

it will be the same as that?

Exactly the same.

GREGG WALLACE: 100 pizzas a
minute head into the freezer,

where they'll stay for
30 minutes at an icy

minus 40 degrees Celsius.

GREGG WALLACE: In the
factory, our pizzas

have spent the last 30
minutes in the freezer,

and now, 9 hours and 10 minutes
since I saw the flour delivery,

they're heading out into the
light of the packing hall.

A jet of air blows
any ice crystals

from the top of each
one to ensure they look

their best before wrapping.

So are they frozen hard now?

Yeah.
Yeah.

Really?

Yeah.

OK.

But this room is warm.

Yeah.

How quickly do you want to get
these wrapped and into a box?

In 2 minutes, the pizza are
wrapped, then into the box,

and arrive to the pallet.

So we have got 2 minutes.

[non-english speech]

GREGG WALLACE: With
no time to spare,

the conveyor belt whisks
our pizzas to the first step

of the packing process.

At the moment, they're
wrapped in cellophane,

but this is soon to be
replaced with a starch based

alternative.

How is that pizza
getting wrapped

completely with only one sheet?

Basically, this plastic
film is created like a tube

and the film is pulled on.

GREGG WALLACE: It's happening
so fast it's hard to see.

Yeah.

You can see the speed.

This machine is adjusting
the speed to the line.

So at the moment, we
are 5,000 pizzas an hour.

Yeah.

Wow.

GREGG WALLACE: Blades cut
each one of our plastic socks

and the pizzas head
through the shrink wrapper,

where they're heated
to 220 degrees

Celsius for just 2 seconds.

That must start to
defrost the pizza.

There's not enough
energy to defrost the pizza

but is enough energy to shrink
the bag around the pizza.

But if you touch it, you
can feel the film is hot

and the pizza is frozen.

Frozen on the button.

Hot on the top, and that
goes cold again very quickly.

Yeah.

Very quickly.

Here.

Come on.

GREGG WALLACE: My 450
kilogram batch of dough

has been transformed
into 1,800 pizzas, enough

for every one in Aberystwyth
to have a slice for dinner

tonight.

Our procession continues
along a maze of conveyors.

Wow.

I love that.

That is like whitewater
rafting for pizzas.

They're engineered
to ensure they

reach the correct packing line.

And for the British market,
they go into cardboard.

The box machine.

Yeah.

That's actually one of my
favorite bits of any factory.

They amaze me because
they look so simple.

So this machine
is opening the box,

is pushing the
pizza into the box,

then it's folding
this part of the box.

It's spraying the glue and
this part is sealing the box.

In what, 1 second?

Yeah.

Let's say a few seconds.

Listen, Alberto, we said
we had about 2 minutes

to get the pizza around here.

I don't think it's
even taken 2 minutes.

Yeah, in less than
1 minute, the pizza

is here, and then in another
minute, will reach the pallet.

It's fast.

It's very fast.

GREGG WALLACE: Our freshly
boxed frozen pizzas are wrapped

in bundles of seven before
traveling to the palletizer,

where they're stacked
six layers high

and bound tightly in plastic.

After 9 hours and 13 minutes
of mixing, resting, cooking,

and topping, they're
ready for the final leg

of their journey and head
to the distribution area.

Factory owner, Dario Roncandin,
is overseeing the operation.

How many pallets are
going on that truck?

26 pallets.

Do you know how many
pizzas on each pallet?

It's 800 pizza per pallet.

So how many
pizzas on the truck?

20,000.

That seems like a
lot of pizza to me.

Is there a season where
you sell more pizza?

We sell more after Christmas
because the people are

enough with the
Christmas dinner,

and they want to
have a nice pizza.

Big Christmas dinner
and then pizza afterwards.

Should we leave him,
let him load the lorry?

- For sure.
- Thank you.

GREGG WALLACE: Every
week, six freezer

lorries leave this factory and
make the 1,000 mile journey

from the Italian Alps to the
Iceland distribution centers

in the UK.

From here, the pizzas head
out all over the country

and onto the shelves of
the supermarket stores.

Their biggest fans are
in Northern Ireland.

I am surprised
that they can make

so many frozen pizzas in
such an authentic way,

in a wood fired oven.

However, these flavors are
anything but authentic Italian.

They are adapted for the UK
market, and how do we like it?

We like it hot and spicy.

[music playing]