All language subtitles for Inside.the.Factory.S06E03.Yogurt.1080p.PMTP.WEB-DL.DDP5.1.H.264-BurCyg_track3_[eng]

[audio logo]

Every self-respecting
packed lunch has one of these,

a yogurt.

And we Brits love them,
eating a whopping 500,000

tons of the stuff every year.

That's a massive
yogurt shopping

bill of 1.4 billion pounds.

GREGG WALLACE (VOICEOVER):
Whether you like natural

or Greek, fruity or fat-free--

You can find them all here.

In a factory that produces
nearly 2 and 1/2 1,000 tons

of yogurt every single week.

Come on, you beauty.

GREGG WALLACE (VOICEOVER):
I'm Gregg Wallace.

Oh!

[laughs] I'm not
very good, am I?

GREGG WALLACE (VOICEOVER):
And tonight, I'm

getting sucked into
yogurt-making, meeting

the cows that get it mooving.

They are really
scary and huge.

GREGG WALLACE
(VOICEOVER): And helping

the humans who keep it sweet.

How much fruit do
you go through a day?

11 tons of fruit a day.

Mate, there's not that
much fruit in the world.

CHERRY HEALEY (VOICEOVER):
I'm Cherry Healey.

Whoa-ho!

CHERRY HEALEY
(VOICEOVER): And I'm

down on the farm
where we're harvesting

enough blackcurrants--

To make a year's
supply of yogurt.

GREGG WALLACE (VOICEOVER):
And dreams come

true for historian Ruth Goodman

I'd love to have a go.

I'll be honest.

- GREGG WALLACE (VOICEOVER):
- -as she takes the wheel

of a British classic--

Woo.

- GREGG WALLACE (VOICEOVER):
- -to reveal the history

of the electric milk float.

She's a robust little
thing, isn't she?

Woo!

[laughs]

GREGG WALLACE: 1 million
yogurt pots will leave

this factory every 24 hours.

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

Welcome to "Inside
the Factory."

[theme music]

This is the Yeo Valley yogurt
factory in rural Somerset.

Every year, they churn out
125,000 tons of yogurt.

That's enough to fill 60
Olympic-sized swimming pools.

GREGG WALLACE (VOICEOVER):
The site produces

94 different types of yogurt.

Tonight, I'll be
learning how they make one

of their best-sellers,
the organic Fruity Flavors

Multipack made up
of raspberry, peach,

strawberry, and
blackcurrant-flavored yogurts.

GREGG WALLACE (VOICEOVER):
But first, I'm

taking a short stroll
to meet the crack

team of heavyweights who get
yogurt production started.

[mooing]

A herd of organic Friesian
cows.

Gabby, hello.

GREGG WALLACE
(VOICEOVER): Looking

after them on the factory's
very own farm is Gabby Coles.

Rather her than me.

This isn't my usual factory
setting, I have to say.

But I get it, right?

Yogurt, we need milk,
so we need cows.

And that's it, right?
It's about the milk.

Not quite.

It all starts from the grass.

And that starts from the soil.

If you see what we got here,
so we got some clover leys,

some ryegrass.

And we also have some
herbal leys mixed in.

So these are all organic
cows, what we have here.

So they've got to have at
least 60% grass to be organic.

And also we don't use any
fertilizers or pesticides

or anything like that.

So basically, the better
quality the grass, better quality milk.

Before we think about the
milk, we think about the grass.

And before that, we
think about the soil.

Exactly.

[mooing]

GREGG WALLACE
(VOICEOVER): Yogurt

production started on the farm
back in the mid-'70s with just

35 cows.

Things have changed
a bit since then,

and the herd is now 240 strong.

The herd produces 6,000
liters of milk a day.

That sounds like a lot, but
incredibly, it's less than 2%

of the yogurt
factory's daily intake,

with the rest coming from a
local co-op of organic farms.

Come on.

GREGG WALLACE
(VOICEOVER): Milking

these bulky beasts is no
tiny undertaking, especially

for a city boy like me.

They are really
scary and huge.

Are they supposed
to be this big?

Is that a sign of there's
loads of milk in there?

Full of milk, yeah.

I'm getting the
hang of this cow lot.

Go on.

GREGG WALLACE
(VOICEOVER): As they come

into the milking parlor,
electronic tags on their necks

identify each cow.

The computer then
calculates how much

high-energy feed to give each
one based on their milk yield.

And while they
munch away happily,

Gabby and I get busy
down the business end.

So I've got to
wipe the cows teat.

Yeah.

Am I likely to get
a kick in the face?

Um.

Have you had a kick in the
face?

I've been close to it.

Because you're getting
better and better at this.

GREGG WALLACE
(VOICEOVER): Cleaning

the teats with antiseptic
wipes gets rid of poo and dirt.

It also replicates the
sucking action of a calf

and stimulates the milk.

The units, or clusters,
attach to the cows' udders

and extract milk
using a gentle vacuum.

Well, that's what you're
supposed to do with them.

Automated milking usually
takes just 6 minutes per cow.

- You ready?
- Yeah.

If I don't come out of here,
I want to be buried in Kent.

OK, got you.

GREGG WALLACE
(VOICEOVER): But that

doesn't include the time it
takes to get the clusters on.

Whoa!

Can you feel the
vacuum taking it on too?

Yeah.

Oh, she's moving.

She's moving.

Listen, it's hard
enough as it is.

Come on!

So I'm proud of myself.
Look at that.

Look.

I'm really pleased I did that.

I come from an inner city area.

Right.

I normally get nervous
when I run out of concrete.

I found that very scary.

But I did it, right?

You did it.

GREGG WALLACE (VOICEOVER):
The clusters are finally on.

The milk is flowing, and
production of our yogurt

has begun.

That's the happiest
cow along this line.

- Is it?
- Oh, yeah.

Gentle I am, see?

There.

Look at that.

GREGG WALLACE (VOICEOVER):
Our milk is piped, filtered,

and cooled from the
cow's body temperature,

a 38.5c, to a chilly 3 degrees.

Right.

So these are ready to go now.

Big old lumps, isn't it?

- Yeah.
- Look at them.

GREGG WALLACE (VOICEOVER): It's
stored in a 16,000 liter bulk

tank before being piped
into a refrigerated truck

and driven to the yogurt
factory, a handy 10 minutes

up the road.

Four hours into
production, and our tanker

has made the short trip
from farm to factory.

So with hairnet on, I'm
heading to the milk intake area

to meet supply manager Adam
Fry.

Adam, this is my milk.

'Tis.

I want you to take
special care of this, OK?

Of course.

How much milk is on here?

There's 28,000
liters on this tanker.

Wow.

That's a serious
amount of milk, right?

GREGG WALLACE (VOICEOVER): To
keep yogurt production moving

24/7, 12 of these
monster tankers

deliver organic milk every day
from the factory's own farm

nearby and others
within 20 miles.

Then it's stored in
these giant silos.

All these silos are
full of milk, right?

Yes.

So how many liters of
milk do you have here?

On site, we hold around
about 350,000 liters of milk.

How long would that last you?

If you didn't get a
lot of delivery in,

how long would that last you?

That's a day's
worth of production.

GREGG WALLACE (VOICEOVER): Each
of the silos stores enough milk

to make 154,000 pots of yogurt.

Put all six silos together,
and we've got milk

to make more than 900,000 pots.

But before a drop of my
milk can leave the tanker,

Adam has to take a
sample for testing.

I find that
incredibly comforting

that you still use a bucket.

So you take the sample.

That's going to be a very
small bowl of breakfast cereal.

I don't think that one will
keep you happy in the mornings.

Time for a test, right?

Time for a test.
These are ready, mate.

GREGG WALLACE (VOICEOVER):
As we stand by,

my milk whizzes up
to the factory's

lab, which deals with up
to 250 samples every day.

What exactly are
we testing for?

So we're testing now for
the fat content of the milk,

to ensure that it's
between 3.6% and 4.6%.

That gives us the
average amount of fat

that you'd see in cow's milk.

If it was outside of that,
there would be something wrong.

I see.

That's the average fat
in milk anyway, right?

That's the average fat
you would see in milk.

Ah, ok.

When will I know
whether my milk is OK?

That process takes
5 minutes to complete.

What if he's gone off to have
a cup of tea and a biscuit?

With 4.6% milk?

I think I'd have coffee.

[laughs]

GREGG WALLACE (VOICEOVER): But
if the milk fails the test,

the entire 28,000 liter tanker
will be sent back to the farm.

Results are zapped from
the lab to the loading bay.

And there you can
see it on the screen.

It's just come through
now that it's ready to go.

So it's passed all of our
tests.

We can unload, right?

Yeah, we're ready to unload.

The milk's good!

- I knew it anyway.
- Milk's good.

We can unload.

GREGG WALLACE
(VOICEOVER): Pumping

at a rate of 250
kilograms per minute,

my milk is then
moved to the raw milk

blend area, where it is mixed with cream
blend area, where it is mixed with cream

and skimmed milk powder.

Are we finally making yogurt?

So this is us making yogurt.

How much are we making?

How much is a batch?

So we're making a
25,000 liter batch.

25,000 liters?

25,000 liters.

How many pots is that, please?

That would make around
about 150,000 pots.

Right.

So what are we doing here?

So here we would be
adding dry ingredients,

such as protein powders, or
in this case, organic sugar.

GREGG WALLACE
(VOICEOVER): The sugar

comes in hefty 25 kilo bags.

And you've got to
tip them in there?

Yep, they all go into here.

GREGG WALLACE (VOICEOVER):
Sounds easy enough.

The sugar's sucked through a
funnel and a spaghetti junction

of pipes to the mixing
tank, where it's blended

with the liquid ingredients.

Sugar makes up just 3% of
the yogurt's ingredients,

but it's still a
backbreaking 900 kilos.

This isn't an easy
job after all.

Oh, it's gone down now.

GREGG WALLACE (VOICEOVER):
The sugar's got

to go through at a steady pace.

If the flow slows,
air will get in,

and the yogurt recipe
will be ruined.

It won't rip.

It won't rip, and it's empty.

Quick.

You get in there.

GREGG WALLACE (VOICEOVER):
Adam to the rescue.

You rip.

I'll put the bags on.

Oh, crikey!

That's 25 kilos.

25 kilos.

That's the same weight
as a bag of spuds.

Making yogurt shouldn't be
this physical, should it?

GREGG WALLACE
(VOICEOVER): I'm sugared.

But there's no time to rest.

It's bucket time.

Before my newly blended mix
of milk, cream, skim milk

powder, and sugar
can move on, there's

another trip to the lab.

So that's ready now to
be off and tested to make

sure it hits specifications.

You lead on.

What about your bucket?

I'll get it.

OK.

How many tests will these guys be doing?
How many tests will these guys be doing?

So these guys will be
doing three tests in total.

They will test this for its
fat content, its total solids,

and for its pH.

GREGG WALLACE (VOICEOVER):
That means my milk mix has got

to have the right
creaminess, thickness,

and acidity to make yogurts.

If any of the tests
fail, it's game

over for my 25,000 liter batch.

Are you finished?

How'd we get on?

Passed.

Yeah!

GREGG WALLACE (VOICEOVER): My
milk mix has come up trumps,

so it's piped across to
milk-based processing

for more high-tech treatment.

First, it's homogenized
by distributing

the milk's fat content evenly
to make it silky smooth.

The homogenizer forces
the liquid through tiny 3

millimeter holes
at high pressure,

smashing the fat globules
into minuscule particles,

mixing them through the
milk for a glossy finish.

Then it's on to
pasteurization, the process

of killing off harmful
bacteria through heating.

Flowing through the pasteurizer
at a rate of 15,000 liters

per hour, the milk blend is
warmed to 98c for around 3

minutes, leaving me with
a food safe mix that's

ready to be made into yogurt.

RUTH GOODMAN (VOICEOVER): The
whirr of an electric motor,

the glow of headlights
on a crisp morning,

and the clink of glass
bottles--

50 years ago, such
sights and sounds

were synonymous with a
daily delivery of milk

to your front door.

[clink]

CHERRY HEALEY (VOICEOVER):
And their fleet of milk

floats delivering pre-dawn
pints became a British icon.

To find out their origins,
I'm meeting Dennis Chick at

the Wythall Transport Museum.

So when did the
electric milk float start?

1920s.

Up until then, horses were
pulling the milk floats.

The problem was that horses
were becoming not very practical.

Milk sales went
up, loads went up.

Horses started to
complain about the loads.

[laughs]

And an alternative was
needed, so the electric float

was developed.

And when was this?

1923.

RUTH GOODMAN (VOICEOVER):
But this wasn't

the first electric vehicle.

As early as the 1880s,
electric cars were powered

by rechargeable batteries.

But by the turn of
the century, they

were being overtaken by
petrol cars, which were

faster and traveled further.

But the sturdy little
electric milk float endured.

Why on earth did the milk
industry not go with petrol?

Petrol was expensive to run.

Petrol or diesel engine
needed maintaining,

and it's cheap to run with
electricity, cheap to maintain,

and did exactly the
job it was needed

to do in a day on a full
charge of electricity,

and then you charge
it again overnight.

And off you go the next
day for another day's work.

RUTH GOODMAN (VOICEOVER):
And of course,

the electric floats were quiet
for those pre-dawn deliveries.

As the British thirst for
pints on the doorstep grew,

the '50s and '60s saw
a milk float boom.

And by the 1970s, there
were 50,000 on our roads,

the most extensive use of
electric vehicles in the world.

And I have a very
personal link to them.

Do you know, way back in 1925,
this is what my grandfather was

doing age 14?

He was in charge
of milk deliveries.

Really?

14?

14 years old on the public
road, blind in one eye.

- As well?
- Yeah.

[laughs]

I'm glad I wasn't around.

I'd love to have a go.
I'll be honest.

You can't drive this one.

This is a museum
exhibit, I'm afraid.

But there are still
a few on the road.

Oh, really?

You should seek one out.

Yes, it's great fun.

Ooh.

RUTH GOODMAN
(VOICEOVER): I think

that this could be in my blood.

[uplifting music]

So I set my alarm for 5:00 AM
to meet Paul Cartwell, who's

been a milkman for 40 years.

But his electric milk float
has been in the business

even longer.

Built in 1975, it's still
delivering every day.

Hi, Paul.

- Hiya.
- Good morning.

Morning.

How on earth-- how
long have you been up?

Since 2 o'clock.

I don't want to get in your
way, but if there's anything

I can do to help.

- You can drive if you want.
- Really?

- Yeah.
- Really?

Yeah.

I'm sure you'll get it going.

RUTH GOODMAN (VOICEOVER):
What a thrill.

Finally behind the wheel of a
working electric milk float,

let's hope me and the bottles
make it through in one piece.

The only thing you need to
know is you've got two pedals.

Yeah.

The small one is to go.

And that one's to stop.

It is.

Take that brake off,
press that pedal.

Oh, god. Yeah.
Woo!

Where am I going?

RUTH GOODMAN (VOICEOVER):
Electric floats

like this delivered 90% of our
milk right up until the 1980s,

when cheaper supermarket
prices almost killed

off the morning milk round.

These days, just 3% of the UK's
milk arrives on our doorsteps.

But in recent years, the
service has been thrown a lifeline

from an unlikely rescuer.

It's been a steady
decline for a long time,

and then we saw a
nice increase when

they did the David
Attenborough program

about plastics in the sea.

RUTH GOODMAN (VOICEOVER):
After "Blue Planet" highlighted

plastic pollution in
our oceans in 2017,

Paul's milk supplier saw
orders increase by 30%.

A lot of people who
were using plastics then

chose to go on
glass, which is good.

I know it costs us
a little bit more,

but every single bottle
gets used over and over

and over again.

RUTH GOODMAN (VOICEOVER):
In fact, the empty bottles

that Paul returns to the dairy
are reused an incredible 30

times before they're recycled.

Here we are well
into the 21st century,

using a 45-year-old milk
float and delivering

milk in glass bottles.

And yet, suddenly
this outdated method

is looking rather
like a sustainable

solution for the future.

GREGG WALLACE (VOICEOVER):
Back in Somerset,

it's been eight hours since
cow milking commenced.

My 25,000 liters of milk
blend has been mixed, tested,

homogenized, and pasteurized.

So it's pumped to
the incubation hall,

where I'm meeting the factory's
technical scientist, Chris

Coggins.

- Chris.
- Hi.

Good to meet you.

What are you doing
in that freezer,

and what has it got
to do with my yogurt?

I'm getting the cultures out.

What are cultures?

Cultures are a
collection of bacteria

that have been specially
selected to make yogurt.

I can't help but think that
bacteria might be a bad thing.

No, you have good bacteria,
and you have bad bacteria.

It's good bacteria,
not bad bacteria.

So what part does bacteria
play in our yogurt-making?

The bacteria will live
off of the natural milk

sugars, lactose.

It will break that lactose
down into lactic acid, which

is what makes yogurt acidic.

And it will also give the
yogurt thickness as well.

Can I see them?

Yes, of course you can.

Oh.

Not what I expected.

They actually look like
little frozen sweets.

Yeah.

That much there is
probably getting on

for a billion bacteria.

Oh.

That's ridiculous, isn't it?

And how many of these do we
need for our batch of yogurt?

We need seven bags of these.

So billions and billions
of billions of bacteria?

- Yeah.
- How amazing.

GREGG WALLACE
(VOICEOVER): My bacteria

may be the microscopic
magicians that

turn my milk mixture to yogurt.

Hello.

I just put them
in a shopping bag.

It's like Bacteria R Us.

GREGG WALLACE (VOICEOVER):
But if you want

to make yogurt on
a massive scale,

you need some serious hardware.

This is the incubation hall.

It contains 12 giant
stainless steel tanks.

They've got a combined capacity
of a quarter of a million

liters and are the
colossal cooking

pots where 90 million
liters of milk

turns to yogurt every year.

So this is our tank.

Whoa.

It's a little bit
warm at the moment.

Yeah, it's hot.

This is yogurt milk
base going in here now.

Right.

And now I have to
empty these into there?

So now we've got
to add the bacteria

so that we can produce yogurt.

This is getting
very interesting.

Would you let me do it?

I don't see why not.

Have they actually got names,
these different bacteria?

Yes.

There are three different
bacteria in there--

streptococcus thermophilus,
lactobacillus acidophilus.

No!

And bifidobacterium.

GREGG WALLACE (VOICEOVER):
My tongue-twisting bacteria

occur naturally on plants.

But for yogurt
production, they're

grown under controlled
conditions in a lab.

And it takes just 3
and 1/2 kilos of them

to turn my 25,000 liter
milk mix to yogurt.

Do you know roughly how many
bacteria I'm putting in here?

Yes.

Every gram will be
about 100 million.

This is beyond
my comprehension.

GREGG WALLACE (VOICEOVER):
This tank is kept at 42 degrees

C to encourage the
bacteria to multiply.

The bacteria doubles
every 30 minutes

until there are 100
billion friendly bacteria

for every gram of yogurt.

To check it's working,
after 6 and 1/2 hours,

a sample is taken for
lab test number 3.

Now, that looks like yogurt.

That looks good.

Right.

How do I test this now?

Right.

Take the probes, and I'll
place them in the yogurt.

And that will tell
you what the pH is.

Our pH currently below 4.6.

So it's now safe to eat.

Right.

OK.

So now what do we do?

All we've got to do
is initiate the cooling.

There you are.

Away it goes.

GREGG WALLACE
(VOICEOVER): The tank

is called for another 4
hours to slow the action

of that busy bacteria.

And while my mix
cools, it's onto the

next vital ingredient-- fruit.

My multipack yogurts
need strawberries,

raspberries, peaches,
and apricots,

which all come from Europe.

But the blackcurrants are
harvested right here in the UK.

Cherry, why don't
you give them a hand?

CHERRY HEALEY
(VOICEOVER): I've been

up since the crack of dawn.

And I'm here in
South Herefordshire

to help out with the biggest
blackcurrant harvest in the UK.

In a very short window
of about six weeks,

an entire year's supply of
these little juicy currants

need to be picked and stored.

So I should probably get
moving.

CHERRY HEALEY (VOICEOVER):
Overseeing the harvest

is farm owner Anthony Snell.

- Hello, Anthony.
- Yep.

Hi, Cherry.

Nice to meet you.

Nice to meet you.

What a beautiful field.

The bushes are absolutely
dense with blackcurrant.

And they do look very big
and juicy and beautiful.

So these are ready
to be harvested.

Yes, and as soon
as they're ready,

we check the natural
sugar levels.

And we inspect them daily
to make sure that there's

no green or red fruits.

When do you start your day?

Is it pretty early?

We wait until the bushes are
nice and dry in the morning.

Otherwise, if you start
harvesting very early

in the morning when
they're wet, you get

slugs and snails up the bushes.

So it's thanks to the
snails that you don't have

to get up at the crack of dawn.

That's right.

Thanks, snails.

That's convenient.

CHERRY HEALEY (VOICEOVER): I
wish someone had told me that.

With only one week left to
finish this entire harvest,

Anthony's son James needs
an experienced driver

for one of the harvesters.

But he's got me instead.

- Hello, James.
- Oh.

Hi, Cherry.

- Can I come aboard?
- Yes, of course.

Wow.

This is a big machine.

CHERRY HEALEY (VOICEOVER):
The farm has almost

300 acres of blackcurrants.

Around half of that is devoted
to organic cultivation.

- Whoa-ho!
- There we are.

It's like this.

That was really fun.

CHERRY HEALEY (VOICEOVER):
Each of the two

harvesters gathers in 15
to 25 tons of fruit a day.

Is that right?

Yeah, that's good. That's good.

CHERRY HEALEY (VOICEOVER):
Inside the harvester,

the berries are shaken
off the branches.

Conveyor belts catch
the falling fruit

and take them to
a team of sorters,

boxing up the
berries at the back.

There's so much to do.

I mean, I'm so conscious
that if I lose concentration,

I could wipe out the
whole row of bushes.

CHERRY HEALEY
(VOICEOVER): In this sort

six week harvest,
James and the team

will collect a massive
650 tons of blackcurrants,

the same weight as half
a dozen blue whales.

And this year,
almost 10% of that

is going to yogurt
production at our factory.

So reluctantly I need to let
the professionals get back to work.

But I'm not finished yet.

To maintain freshness,
the blackcurrants

must get from field to
freezer in less than an hour.

And this massive unit
stores a year's supply.

I mean, it is absolutely
freezing in here.

I'm wearing my ski things,
and I'm still really cold.

What's the temperature in here?

So it's a minimum of minus 18.

CHERRY HEALEY: Are
these all blackcurrant?

They are.

That's incredible.

How long do they
stay in this freezer

before they go to make yogurt?

We just supply when the
customer demands them.

So you actually hold on to
them until they need them.

Yeah, that's the beauty of
a freezing process like this,

is that you can store
products for up to two years

just exactly the same quality
as when they're fresh.

You can have British
fruit all year round.

CHERRY HEALEY (VOICEOVER): This
freezer holds 300 tons of fruit

on 1,000 pallets in
subarctic conditions.

This is what it feels like to
be a fish finger in my freezer.

Yeah.

CHERRY HEALEY
(VOICEOVER): Just hours

since they were shaken
from their bushes,

my blackcurrants are now
sorted, boxed, and frozen solid.

And now they'll wait
patiently in the freezer

until they're ready to
be sent off to Gregg.

GREGG WALLACE (VOICEOVER):
Back at the factory,

I'm nine hours into production.

My milk blend has been mixed
with bacteria to make a $25,000

liter batch of plain yogurt.

And while it cools in a
giant incubation tank,

I'm heading 42 miles down the
road to the processing plant

at Crewkerne, where
they make the four

fruity conserves for my yogurt.

A whopping 20 tons of
Cherry's frozen blackcurrants

have just arrived.

Team manager Matt Pullen takes
charge of them from here.

- Matt, right?
- Yep.

All right, Gregg.

These are our
Cherry's currants?

Blackcurrants, yep.

And we're going
to be sorting them

in the sorting table today.

Can I have a go?

Yeah, of course you can.

Come on 'round.

What do I do?

So you need to bang
the box on the table.

That will break up any lumps
of frozen blackcurrants

inside the box.

Oh, this is great fun.

- Can I have another go?
- Yep.

- There you go.
- Great.

OK, so now remove the tape.

Whoa.

They're lovely.

Oh, look at them.

It feels like cold marbles.

GREGG WALLACE (VOICEOVER): Most
of the stalks are removed back

at the farm, but an
8-meter long conveyor

carries the blackcurrants
through one final check.

My river of blackcurrants flows
at a rate of 600 kilos an hour,

so you need eyes out
on stalks for this job.

Right.

What are we looking for?

So we're looking for anything
that shouldn't be there.

Bits of stalk, bits of leaf,
misformed blackcurrants.

So that?

Yeah, you wouldn't want that
in your yogurt, would you?

A shriveled one.

Because they're
frozen, does that

help them keep their shape?

It will help them
throughout our process.

We try to retain as much of the
fruit ID as we possibly can.

Fruit ID?

Yeah.

Fruit ID?

And does the fruit have
to carry its ID with it

wherever it goes in case it's
stopped by a yogurt policeman?

GREGG WALLACE
(VOICEOVER): Identities

intact, the blackcurrants
line up for a final check

at the metal detector.

Then we head upstairs to
turn some of Cherry's berries

into fruity conserve
for my yogurt.

Coming through!

Got your currants.

GREGG WALLACE (VOICEOVER):
This cooking area

has six giant vessels
that churn out 20 tons

of fruit conserve every day.

We're making a 1-ton blackcurrant batch.
We're making a 1-ton blackcurrant batch.

First, 238 kilos of
water is added to the pot

before Cherry's frozen
blackcurrants are tipped

in by the 100-kilo bucket load.

How many of those we've
got to get in there?

Another four-- five in total.

500 kilos of fruit?

How much fruit do
you go through a day?

11 tons of fruit a day.

11 tons every day?

Mate, there's not that
much fruit in the world.

GREGG WALLACE
(VOICEOVER): That's

the blackcurrant equivalent
of seven family cars.

But even on this massive
scale, nothing's wasted.

What do you do with that, get
the ice off your windscreen?

GREGG WALLACE
(VOICEOVER): Scraping

stray currants into a vat?

That can't be berry hard.

I think I got some
blackcurrants up my sleeve.

GREGG WALLACE (VOICEOVER):
Outsmarted by frozen fruit?

That's got to be a first.

[laughs]

GREGG WALLACE (VOICEOVER):
Even I can't go too far wrong

with the next ingredient--

sugar.

Sweet.

GREGG WALLACE (VOICEOVER):
Into the frozen fruit and water

goes 142 kilos of cane sugar
to sweeten the blackcurrants.

The vessel is heated,
and the sugary fruit

is cooked with
starch, lemon juice,

and blackcurrant flavoring.

It is just like making jam
at home but on a massive scale.

An hour later, my
conserve is complete.

All right, let's have a go.

All the flavor of the fruit
is there, but that is sharp.

You're going to need some
yogurt to take the sharpness away.

GREGG WALLACE
(VOICEOVER): The conserve

is pumped directly
from cooking vessel

to a vertical form film sealer.

Yup.

That's a bagging
machine to you and me.

The 9-kilogram
blackcurrant bags are

air cooled and
loaded onto trucks

bound for the yogurt factory.

I am back at my West
Country yogurt factory,

and the blackcurrant
conserve has arrived too.

hours into production, and my
bacteria-rich plain yogurt mix

is cooling and thickening.

So back in the incubation
hall, I'm catching

up with supply manager Adam.

Good to see you again.

Hello again, Gregg.

Are we ready?

We are now ready.

So the base has now cooled
down to below 23 degrees.

And it is ready to
be drawn off into one

of the smaller mobile vessels.

GREGG WALLACE (VOICEOVER):
As it's decanted

from the towering incubation
tanks to smaller vessels,

my 25,000 liters of yogurt
passes through a super fine

filter with holes smaller
than a fifth of a millimeter,

making it much smoother.

And what you'll see
here is the final product,

when it comes out, has
a nice, polished sheen

on the top of it.

[laughs] Why polished?

Because it's shiny?

Because it's shiny, yeah.

That's incredible.

So the filter not only
gets rid of the lumps,

but it makes it
shiny or polished.

And makes it more appealing.

Next time I open
a pot of yogurt,

I'm going to tell my wife
that this one is polished.

[laughed]

GREGG WALLACE (VOICEOVER): The
buffed up yogurt is finally

ready for my fruity conserve.

So what we have here,
we have a fruit bath.

And in here, each of these
fruit bags go in as they are.

They don't need to be opened.

What we don't want is any
unfortunate bad bacteria to be

added back into the product.

So it's actually sterilizing
the outside edge of the bag.

So the bacteria that
may get into your yogurt

is not inside my currants.

It may be on the bag.

It is purely the
outside of the bag.

You know what?

I never really trusted that
bag.

GREGG WALLACE (VOICEOVER):
The blackcurrant

bags spend 2 minutes relaxing
in the bath before being cut open

and the fruit squeezed
into the yogurt.

Come on, you beauty.

Come on.

Ah.

Ah, ah.

What's the total weight of
fruit going into our yogurt?

So in an ideal
world, 71 kilos.

The way you were fruiting
that, around about 68.

[laughs] I'm not
very good, am I?

GREGG WALLACE (VOICEOVER):
With just enough conserve

in my yogurt, it heads off
on a nifty little forklift

to blending.

Let's see if I can give
this job It's just desserts.

So this is where you mix it.

So this is where we mix it.

GREGG WALLACE: With that?

ADAM: With that?

That looks like-- you
know like a stick blender

you get at home in the kitchen?

Just an enormous
one of them, right?

Just a giant hand blender.

Oh!

So imagine you're now on a
grabber machine at the fair.

GREGG WALLACE (VOICEOVER):
No prize for me yet.

- It's got a mind of its own!
- Yeah.

Hang on, hang on, hang on.

Come on!

Come on!

You better do this.

Is this a two-man job normally?

- No.
- It is, isn't it?

It's not.

It is, isn't it?

It's not.

It so is.

GREGG WALLACE
(VOICEOVER): Well, someone

has mastered these
tricky mixers,

because the factory blends
a mouth-watering 120

tons of fruit yogurt every day.

- Is that done now, then?
- Yeah, that's done.

Oh, come on.
Let's have a look at it.

Well, OK.

That has got a lovely pink
purple tinge to it, hasn't it?

Am I allowed to taste it?

You can, yeah.

Well, I mean, I've been
there through every stage

of its life.

It's got a fine nose.

Hmm.

Very creamy, a little sour.

But a big fruity hit finish.

Certainly a little bit
of sharpness as well.

Have got a bit on me nose?

You have.

It's all right.

It matches me apron.

Very treasure.

[laughs]

GREGG WALLACE (VOICEOVER):
Despite my messy dabbling,

my blackcurrant yogurt is
miraculously ready to move on

to the filling area--

Mags!

Hi, Gregg.

Nice to meet you.

I'm coming up to see you.

OK.

GREGG WALLACE
(VOICEOVER): --where

Shift Manager Mags Gauley is
ready to, well, manage me.

Hi, Gregg.

Hey.

These must be our
yogurt pots, right?

They are our yogurt pots.

How many of these
do you go through?

We pack 28,800 pots an hour.

That is seriously,
seriously fast.

GREGG WALLACE
(VOICEOVER): This looks

like something I could master.

[laughs]

Just lead it in.

Oh!

GREGG WALLACE
(VOICEOVER): Or maybe not.

Um.

Are you going to jam
up my machine, Gregg?

Um.

Well-- whoa.

This side doesn't work
properly.

OK, try that side then.

Um.

They are joined together.

They're twin pots.

You got to be fast.

Oh, whoa, whoa!

Drop them down.

GREGG WALLACE (VOICEOVER): Once
my stack falls into the feeder,

individual pots are released
into a slatted conveyor

with precise pot-shaped holes.

A laser sensor then checks
there are containers in every slot

before the yogurt is dispensed.

So you'll see the
pots being filled here.

What's happening right
now is all the yogurt's

passing through some
pipework into a device

that we call the cup valve.

And that individually deposits
120 grams into each pot.

How many of
those every minute?

Every minute? 480.

How absolutely beautiful.

GREGG WALLACE
(VOICEOVER): One pair

of pots is filled with
raspberry and strawberry,

the other with peach and
apricot and my blackcurrant.

Then the lids are
heated sealed at 200c.

They're day-coded and lifted to
a conveyor belt which separates

the pairs of flavors and sends
them through a metal detector,

and then onto the packing hall.

So what does it take to make groundbreaking plastic pots
So what does it take to make groundbreaking plastic pots

that are better for the planet?

Cherry has been finding out.

Widely recycled.

Not yet recyclable.

I really do try to do my bit when it comes to recycling.
I really do try to do my bit when it comes to recycling.

Absolutely no idea.

But there are so many
different plastics used,

knowing what to recycle
and how to recycle

can be quite confusing.

CHERRY HEALEY
(VOICEOVER): It doesn't

help that the rules differ
depending on where you live.

Currently, we recycle
less than half

of the 1.5 million tons
of plastic packaging

we consume every year.

So not only do we need
to do our bit at home,

but the companies who
make the packaging

are also going to
have to do their bit

to look after the planet.

CHERRY HEALEY (VOICEOVER):
There is some 100% recycled plastic

food packaging on the
market, but much of the rest

still uses a layer
of new plastic

to stop the food touching
recycled material.

But packaging
manufacturer Faerch

is making food safe yogurt pots
with 100% recycled plastic.

Hi, Chris.

Hello, Cherry.

Nice to meet you!

CHERRY HEALEY (VOICEOVER):
Site manager Chris

Plant is showing me around.

Chris, what have you
just had delivered?

So we've just taken
receipt of 27 tons

of recyclable PET material.

And essentially what
that is is chopped up

water bottles, food trays that
can be regenerated and reused.

What does it look like?

- Let's go and have a look.
- OK.

CHERRY HEALEY (VOICEOVER):
PET stands for [inhales]

polyethylene terephthalate.

In layman's terms, it's a
type of recyclable plastic.

Gregg's containers are
made from 30% recycled PET,

but here they're
making yogurt pots

from 100% recycled material.

The first step is to heat the
shredded confetti-like plastic

to 300 degrees until it melts.

- Can I have a look?
- Yes, you can.

Just 'round here.

I got it.

Is that liquid?

It is liquid.

And now as it drops down,
it goes through a series

of chilled rollers, which
takes it from 300 degrees down

to ambient.

And therefore you
can see the sheet

that's produced afterwards.

CHERRY HEALEY
(VOICEOVER): These sheets

made from PET have undergone a
process called super cleaning,

where heat and pressure remove
any contaminating chemicals,

making it safe to
put next to food.

The result is the UK's
first yogurt pot made

from 100% recycled plastic.

So if that is possible,
to make something that

is made of 100%
recycled plastic,

why not make
everything out of that?

First point is cost.

So the additional processing
that needs to happen

takes the cost up
of the material.

And the other key point is that
there isn't enough recycled PET

material out there to allow
us to move all of the products

over to 100% recycled.

Chris, when I'm at
home, and I'm tired,

and I'm thinking, how can I
be bothered to wash this out,

I will think Chris
needs this PET.

Thank you very much.

CHERRY HEALEY (VOICEOVER):
Every little helps.

Back on the production line,
our recycled plastic is ready to be

turned into yogurt pots.

So the material has
been threaded through.

It's transported through a
heating zone, top and bottom

to the point where we're
forming the product.

How many yogurt pots
does it create in one hour?

Roughly about 21,000 pots.

Which will give you about
400,000 in 24 hours.

Do we really eat
that much yogurt?

We must do.

CHERRY HEALEY
(VOICEOVER): And that's

for just one variety of yogurt
made in Gregg's factory.

Once these pots are
formed, they're slipped

into a cardboard sleeve.

Very smart.

Look at that.

Is that the first
ever yogurt pot to be

100% from recycled materials?

Yes, it is.

This combination is the first to market.
This combination is the first to market.

So that yogurt pot is
a bit of a trailblazer.

CHERRY HEALEY (VOICEOVER):
Soon, Gregg's multi-pack

will be switching to this
kind of recycled material too.

There's still a long way to go
with plastic food packaging,

but this 100% recycled
and recyclable pot

is a step in the
right direction.

And I hope that one day,
somehow, this little fellow

will end up back here,
ready to be reborn.

GREGG WALLACE (VOICEOVER):
21 hours into production,

at the factory, my four
fruity flavors are potted,

sealed, dated, and screened.

And they're on their way to
the cavernous packing hall.

Mags is showing me around.

OK, Gregg.

So we've just been
through there.

We've seen our pots filled.

And they're now coming down
here where they're going

to be separated into two lanes.

GREGG WALLACE
(VOICEOVER): One lane

carries raspberry
and strawberry,

the other blackcurrant
and peach and apricot.

The pots are jostled
into position

by white screw-like
fixtures called worms.

I can honestly watch
this stuff for hours.

I love it.

GREGG WALLACE (VOICEOVER):
The worms space the pots,

and sensors signal
to robotic arms

that the yogurts are
ready for packing.

Then they swoop down,
picking up 16 pots at a time,

placing them in their
cardboard sleeves

at a rate of 480 a minute.

Absolutely mesmerizing.

Are you sure there are four
different flavors coming down

here?

Absolutely sure.

Because there seems
to be a lot of pink.

There is a lot of pink.

However, we have a scanner
that side that tells us

that we've got the right
flavor in the right pot.

So raspberry, strawberry,
peach, and blackcurrant

is flying down here in
absolutely the correct order

and the correct time?

- Yes.
- That's outstanding.

I can't do that
with a fruit salad.

[laughs]

GREGG WALLACE (VOICEOVER): The
factory packs 1 million pots

of yogurt every day.

And it takes this machine just
five hours to box up my batch.

It's a pretty sight, isn't it?

It is.

A bit like me.

[laughs]

GREGG WALLACE (VOICEOVER): Once
pallets are stacked with 3,840

pots of my yogurts,
they're ready for the 1,400

square meter chiller.

Come on, Gregg.

Do you want me to push you on?

Yes, please.

GREGG WALLACE (VOICEOVER):
Where they're stored for six hours

at 5 degrees C to thicken
to the final perfect yogurty

consistency.

Very good.

Oh, yeah!

Do you know how long I've
been working in yogurts?

How long?

A couple of hours.

GREGG WALLACE (VOICEOVER): 23
hours since production started

back in the milking parlor,
our pasteurized, potted,

and packed yogurts finally
make it to factory dispatch.

Is that our truck?

Yep.

He's putting the
yogurt on the lorry.

So how many of these
trucks are leaving every day?

So over a 24-hour period,
we have 16 lorries leave us,

carrying over a
million pots of yogurt.

Right.

Shall we get the last pallet
on?

Let's do it.

Come on, my friend.

GREGG WALLACE
(VOICEOVER): The east

of England is home to the
nation's biggest yogurt fans,

followed by the Midlands
and Southern England.

I like that, you know.

I knew them yogurts when they
were still inside the cow.

[laughs]

GREGG WALLACE (VOICEOVER): 24
hours after my clumsy milking,

the fruity favorites
are on their way to feed

Britain's yogurt-hungry hordes.

I am really impressed.

Honestly, I can't
believe how much

work goes in to
making a pot of yogurt

and getting it on the shelf.

GREGG WALLACE (VOICEOVER):
I've loved the lot--

Come on, you beauty.

- GREGG WALLACE (VOICEOVER):
- -the messy mixing--

Oh, watch out.

[laughs]

- GREGG WALLACE (VOICEOVER):
- -and the clever chemistry.

Do you know how many
bacteria I'm putting in here?

Every gram will
be 100 million.

That's ridiculous, isn't it?

But you know what
really impressed me?

Do you know what I
really, honestly, loved?

It's where it all started--

those cows.

[mooing]

[theme music]