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00:00:03,000 --> 00:00:06,400
What's the difference between
chips and oven chips?

2
00:00:06,400 --> 00:00:09,920
Have they been coated in something?
My wife normally burns these ones.

3
00:00:09,920 --> 00:00:13,320
You can't beat a bit of
pub grub every now and then.

4
00:00:13,320 --> 00:00:17,560
These days, supermarkets
are selling typical
pub food for you to cook at home.

5
00:00:17,560 --> 00:00:20,840
But how do they make it
on an industrial scale?

6
00:00:20,840 --> 00:00:24,720
Why do you reckon
you'd have to X-ray a peanut?

7
00:00:24,720 --> 00:00:27,920
How do you turn one of
these into one of these?

8
00:00:27,920 --> 00:00:30,560
Perhaps they inject into the
chicken breast. Mince it up.

9
00:00:30,560 --> 00:00:33,560
Mince it up? Did you hear that?

10
00:00:33,560 --> 00:00:38,040
I'm going to reveal the secrets of
the pub menu...Food Factory style.

11
00:00:53,920 --> 00:00:58,800
Have you ever wondered what goes
into making your favourite pub food?

12
00:00:58,800 --> 00:01:03,800
I'm going to find out
because I'm setting up my own
food factory inside this barn.

13
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It may look as though it's full
of junk, but this barn has got

14
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everything I need to discover
the secrets of supermarket food.

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Steak and chips, fish and chips,
and burger and chips.

16
00:01:19,920 --> 00:01:23,400
It seems almost all pub
meals come with chips!

17
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So that's where I'm going to start.

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Pubs tend to use deep-fat fryers,
but these days, when you're cooking
chips at home,

19
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the traditional chip pan often stays
on the shelf, in favour of a baking
tray and a bag of frozen oven chips.

20
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But if you stick raw
potatoes in the oven
you don't end up with crispy chips.

21
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So what does the factory
do to create the crunch?

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Here in the barn, I'm going to
try to make my own oven chip shop.

23
00:01:55,680 --> 00:01:58,320
And every chippie
needs a potato peeler.

24
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My mum'll go mad when she sees
what I've done with her graters.

25
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I'll spin these spuds in
the bottom of this bucket.

26
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It's a bit like the
commercial potato peelers
in real chip factories.

27
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One potato in every four dug
out of the British soil
ends up in one of these.

28
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Right, let's see if this works.

29
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It looks like I've been savaged
by my dog, but it's working.

30
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Think I'd better stop,
cos my potatoes are getting smaller
and smaller, but look at that.

31
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It's a bit battered,
but I think you can call it peeled.

32
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The next step is
to make these ugly spuds
all chip shape and Bristol fashion.

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In the factory they use a slicing
machine called a hydro-cutter,

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which involves firing
a potato down a pipe, through
what they call a knife block,

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that slices the potato
into chip shapes.

36
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Sounds dangerous.

37
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Instead of sharp knives,
I'll be using a gun to fire my
potatoes at a tennis racket.

38
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I was rubbish at tennis anyway.

39
00:03:07,080 --> 00:03:09,760
I'm restringing my racket
with cheese wire.

40
00:03:09,760 --> 00:03:12,640
Don't try this at Wimbledon!

41
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Not too fiddly, this, is it?

42
00:03:15,160 --> 00:03:21,160
Right, that's that done - now, what
could be better to fire my potatoes
through the slicer than a spud gun?

43
00:03:24,040 --> 00:03:27,880
In the factory, they propel
the potato using a water jet.

44
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But my spud gun is powered
by a gas explosion.

45
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It all goes off in this chamber
at the end of the barrel. I'm
sure there's nothing to worry about.

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Pull the electrical trigger,
sets off an explosion and
fires the potato out,

47
00:03:42,560 --> 00:03:49,080
through my slicer. And hopefully,
chip-shaped potatoes come through.

48
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But before I try slicing,
I need to see if my potato gun
can actually shoot a spud.

49
00:03:55,240 --> 00:03:57,600
Little bit nervous.

50
00:03:57,600 --> 00:04:02,360
Right, three, two, one.

51
00:04:02,360 --> 00:04:06,080
Ohhh! Oh, my god, look at this!

52
00:04:09,560 --> 00:04:12,480
The potato has
totally obliterated...

53
00:04:12,480 --> 00:04:15,240
Look, it's knocked a whole
in the side of the shed.

54
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That is the only piece
of potato I could find.

55
00:04:18,160 --> 00:04:21,520
I'm not sure that tennis
racket is going to be up to it.

56
00:04:21,520 --> 00:04:23,040
There's only one way to find out.

57
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I've got my spud gun. That's going
to fire the potato, which is
going to hit my slicing device.

58
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The potato will pass through,
looking a bit more chip-like.

59
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And be captured...

60
00:04:37,600 --> 00:04:39,760
in here.

61
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Right, all set to make oven chips.

62
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Oh!

63
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I think I blew my bag off!

64
00:04:51,600 --> 00:04:54,400
There's bits of chip
all round the back of the barn.

65
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That's a very excitable spud gun.

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Oo-hoo-hoo!

67
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Look at that!

68
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Right, I've got an idea
to slow the potato down.

69
00:05:02,320 --> 00:05:06,400
If I put a tea towel over here,
as the potato passes through here,

70
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it should be captured,
and slow its speed down.

71
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That's the idea - right,
let's see if it works.

72
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Ohh!

73
00:05:21,840 --> 00:05:24,680
Well, the tea towel's gone.
Let's see.

74
00:05:24,680 --> 00:05:26,120
Let's see, let's see.

75
00:05:29,320 --> 00:05:31,560
Ta-dah! Look at that!

76
00:05:33,240 --> 00:05:37,720
Chips - it works, just got
to make more of them now.

77
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Ohh!

78
00:05:45,160 --> 00:05:46,880
I'm getting quite good at this.

79
00:05:48,560 --> 00:05:53,320
See - when you put your mind
to it, nothing is impossible!

80
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Later, I'm going to try to turn
these into frozen oven chips.

81
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It'll be crunch time.

82
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A nice bit of sirloin steak.
Where do you reckon it comes from?

83
00:06:16,240 --> 00:06:19,760
There. Haven't got a clue! Here.

84
00:06:19,760 --> 00:06:22,480
Just down a bit there.
Its bum. The bum?

85
00:06:22,480 --> 00:06:25,240
Down a bit...back, back. There?

86
00:06:25,240 --> 00:06:27,840
Why would you say there?
The chunkiest bit.

87
00:06:27,840 --> 00:06:29,440
It's on the leg. The leg...yeah.

88
00:06:29,440 --> 00:06:31,720
I'm totally wrong, aren't I?

89
00:06:31,720 --> 00:06:36,000
So it's a mystery -
anywhere from the neck to the leg!

90
00:06:36,000 --> 00:06:40,480
In fact, the sirloin steak
comes from the loin area,
so it's along here.

91
00:06:40,480 --> 00:06:42,480
Sirloin...of course!
The great British steak!

92
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No-one likes a tough one.

93
00:06:45,760 --> 00:06:49,240
But how do you make sure
every one is mouthwatering?

94
00:06:51,840 --> 00:06:54,680
One farm boss who reckons he
knows the answer is Richard Phelps.

95
00:06:54,680 --> 00:06:59,360
He produces 480,000
sirloin steaks a year,

96
00:06:59,360 --> 00:07:03,360
and supplies a major
UK supermarket.

97
00:07:03,360 --> 00:07:06,680
So Richard,
what makes the perfect steak?

98
00:07:06,680 --> 00:07:11,920
The perfect steak has got to be
tender, juicy, tasty and consistent.

99
00:07:11,920 --> 00:07:14,560
So if you have it in a restaurant
and it's delicious,

100
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you go back next week you want
it to be the same, don't you?

101
00:07:16,880 --> 00:07:19,960
That's right - the problem we have
is because so many different farmers

102
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do different systems, different
ages, different breeds, that we
get inconsistency in the steaks.

103
00:07:25,000 --> 00:07:29,840
Richard has 16,000 cattle
spread across many farms.

104
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So, to make sure every steak
tastes the same, all his animals
are brought up the same way.

105
00:07:36,120 --> 00:07:42,400
So your secret is to get the
farmers to do exactly the same
thing, wherever their farm is?

106
00:07:42,400 --> 00:07:45,360
That's right - using the same feed,
the same health systems,

107
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so every animal is the same
that comes through our process.

108
00:07:49,240 --> 00:07:51,360
And it starts before they're born.

109
00:07:51,360 --> 00:07:54,400
Paul Westaway is one of
Richard's cattle breeders.

110
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If good genes produce good
offspring, then this is your man.

111
00:07:57,800 --> 00:08:00,560
No, not Paul - meet Goliath.

112
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He's smashing, but what
makes him such a great animal?

113
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From a steak point of view,
he's really fantastic between
his shoulders and his hook bone.

114
00:08:08,200 --> 00:08:11,560
So from a butcher's point of view
there'll be lots of steaks there.

115
00:08:11,560 --> 00:08:14,120
But the important thing about
Goliath here is we're not going to

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turn him into steaks, it's what he
can do for his offspring, isn't it?

117
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That's right.
His job is to sire sons and daughters
that will go into the beef chain.

118
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So he's like a stamp that he
can put all the good qualities
onto his next generation.

119
00:08:28,120 --> 00:08:33,600
Absolutely, he's been specially
selected and bred to make sure he
sires perfect steaks every time.

120
00:08:33,600 --> 00:08:40,120
Goliath could father some 200,000
beef calves and Paul reckons
he's worth around 50 grand.

121
00:08:40,120 --> 00:08:42,600
If only he could play football too!

122
00:08:42,600 --> 00:08:45,800
He loves us talking about him.
We've said nothing but praise!

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He's a bit of a superstar.
There's a bit of an ego going on!

124
00:08:50,040 --> 00:08:56,520
Good breeding is just the start -
at around a week old, the calves
are sent to a different farm.

125
00:08:56,520 --> 00:09:02,120
Nigel and David Maidment
specialise in a kind of nursery
school for young cattle.

126
00:09:02,120 --> 00:09:08,400
They need to make sure all their
pupils grow at the same rate
and get the same amount to eat.

127
00:09:08,400 --> 00:09:11,760
When I was at school, there was
always someone who distracted you,

128
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you had the greedy one.
How do you stop the greedy one
getting too fat in here?

129
00:09:16,680 --> 00:09:22,000
Basically, this mixes the milk
powder, it's a replacement for
the cow's udder, effectively.

130
00:09:22,000 --> 00:09:26,000
So that's almost like a mechanical
mum, it's a computerised cow.

131
00:09:26,000 --> 00:09:28,240
It's exactly that, exactly that.

132
00:09:28,240 --> 00:09:31,960
How does she know that
number two's coming in for its
second feed and it shouldn't be?

133
00:09:31,960 --> 00:09:35,360
They all have a little tag
that we put in their ear.
Every tag is different,

134
00:09:35,360 --> 00:09:37,000
so every calf is different
to the machine.

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I've got you, so if number two comes
in and happens to be a greedy calf,

136
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the tag will get beeped,
and then mechanical mum won't
give you any milk. Yes.

137
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That's some mum, isn't it?
She looks after them well.

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00:09:47,960 --> 00:09:52,000
When the calves are
weaned off mechanical mum,
they move farms again.

139
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For this bunch, it's back to
human dad Paul Westaway.
What are you doing here now, then?

140
00:09:58,200 --> 00:10:04,080
We're trying to make sure that
the cattle grow at a very level
rate every day that they're here.

141
00:10:04,080 --> 00:10:06,640
We're looking for them to
average about 1.1 kilos a day,

142
00:10:06,640 --> 00:10:09,640
so the steaks develop properly and
they stay really nice and healthy.

143
00:10:09,640 --> 00:10:11,920
And it seems to work.

144
00:10:11,920 --> 00:10:14,960
Look at these calves -
they're the same height and size.

145
00:10:14,960 --> 00:10:16,960
I wish I'd brought my spirit level!

146
00:10:16,960 --> 00:10:19,680
Tall and well-built,
just like yourself.

147
00:10:19,680 --> 00:10:21,840
Thank you, Jimmy. Pleasure.

148
00:10:26,720 --> 00:10:28,920
Paul checks how fast they grow
by weighing them.

149
00:10:28,920 --> 00:10:30,560
What is she?

150
00:10:30,560 --> 00:10:32,360
About 410, 415.

151
00:10:32,360 --> 00:10:33,520
Not bad. Spot on.

152
00:10:33,520 --> 00:10:38,960
That's dead on.
That's just what you want, isn't it?
All exactly the same.

153
00:10:38,960 --> 00:10:42,880
Come on, lovelies! Here they come.

154
00:10:42,880 --> 00:10:46,400
So according to Richard, good
breeding and a strict upbringing

155
00:10:46,400 --> 00:10:49,920
are the key to a consistently great
steak. But does it really work?

156
00:10:49,920 --> 00:10:53,440
To find out,
Richard's invited me to lunch.

157
00:10:53,440 --> 00:10:56,400
So tell me, what's the
test for tenderness?

158
00:10:56,400 --> 00:10:59,040
A good tender steak,
when you cut it, you should

159
00:10:59,040 --> 00:11:01,880
be able to cut with a standard
cutlery knife, not a steak knife.

160
00:11:01,880 --> 00:11:08,400
So will I be able to tell the
difference between a mid-range steak
and one of Richard's?

161
00:11:08,400 --> 00:11:10,760
I'm going to have to
saw through that one.

162
00:11:14,480 --> 00:11:16,120
Wow, that just went
straight through.

163
00:11:16,120 --> 00:11:20,200
So after what you've said, I'd say
that is probably your steak

164
00:11:20,200 --> 00:11:23,200
because it was easier to cut.
Let's have a look.

165
00:11:23,200 --> 00:11:27,680
There we are. Now, you sure
you didn't swap them over?

166
00:11:27,680 --> 00:11:32,520
Right, I'm going to polish these two
steaks off. Are you that hungry?
I feel like Desperate Dan.

167
00:11:42,320 --> 00:11:47,960
Back at the barn,
to go with that steak, I'm making my
own frozen oven chips from scratch.

168
00:11:47,960 --> 00:11:52,880
I've built a high-speed spud gun,
which did a great
job slicing my potatoes.

169
00:11:52,880 --> 00:11:55,680
That's the most fun I've
ever had making chips.

170
00:11:55,680 --> 00:12:02,040
Now I need to work out how the
factory get their oven chips
all crispy and golden brown.

171
00:12:02,040 --> 00:12:04,160
Look at those...
fresh out the fryer.

172
00:12:04,160 --> 00:12:07,120
Now, apart from the golden colour
and the delicious flavour,

173
00:12:07,120 --> 00:12:09,720
what really makes
a chip a chip is the crunch.

174
00:12:09,720 --> 00:12:10,680
CRUNCH

175
00:12:13,120 --> 00:12:15,880
I can't find my mouth.

176
00:12:15,880 --> 00:12:18,280
That crunch is what
my oven chips need.

177
00:12:18,280 --> 00:12:23,560
It comes from the crispy outer skin
that forms on the chip
when it's fried.

178
00:12:23,560 --> 00:12:28,000
The trouble is,
you can't create that crispy skin
in the oven from just raw potato.

179
00:12:28,000 --> 00:12:32,680
So the oven chip makers
have to create that crispy
skin for you in the factory.

180
00:12:32,680 --> 00:12:35,920
The key is starch -
it's the milky stuff

181
00:12:35,920 --> 00:12:39,000
that leaks out of a potato
when you slice it.

182
00:12:39,000 --> 00:12:42,840
Starch is what the potato
plant uses to store the
energy it needs to grow.

183
00:12:42,840 --> 00:12:48,320
And these little gritty bits in
the potato juice are actually
tiny little grains of starch.

184
00:12:48,320 --> 00:12:53,960
On their own, these gritty bits
won't provide the crispy skin
that you look for in a chip.

185
00:12:53,960 --> 00:12:56,240
They need a bit of encouragement.

186
00:12:56,240 --> 00:13:02,000
The factory take the sliced up
potato and they soak them in really
hot water - they blanch them.

187
00:13:02,000 --> 00:13:06,200
Blanching for around 40 minutes
makes the starch grains
swell up and go softer.

188
00:13:06,200 --> 00:13:10,000
This makes the chip
fluffier on the inside.

189
00:13:10,000 --> 00:13:16,560
Now the top layers of starch have
gone slimy, almost pasty-like,
and it's the layers of starch

190
00:13:16,560 --> 00:13:21,240
on the top of this slice that
eventually will give us that
nice crisp texture to the chip.

191
00:13:21,240 --> 00:13:28,520
I just need to dry the slices,
leaving behind that
starchy skin coating.

192
00:13:28,520 --> 00:13:31,000
Here we go.
All ready for Saturday night now.

193
00:13:32,760 --> 00:13:34,520
FAT SIZZLES

194
00:13:34,520 --> 00:13:35,960
That's a great sound, isn't it?

195
00:13:35,960 --> 00:13:39,720
You might not have realised
oven chips are pre-fried.

196
00:13:39,720 --> 00:13:43,520
The hot oil makes the starchy
skin go brittle and crispy.

197
00:13:43,520 --> 00:13:48,040
Timing is everything - you don't
want to completely cook them.
That's what your oven will do.

198
00:13:48,040 --> 00:13:52,440
All I want to do is add that
layer of crispy "chippiness".

199
00:13:52,440 --> 00:13:55,160
Oh, getting hungry!

200
00:13:55,160 --> 00:13:58,120
Now you can see the effect
the blanching has had

201
00:13:58,120 --> 00:14:01,280
on those slices of potatoes,
because they've gone sort of

202
00:14:01,280 --> 00:14:05,680
fluffy round the outside, and that's
allowed them to get really crispy
in that hot oil - look at that.

203
00:14:05,680 --> 00:14:08,480
You can see them bubbling away.

204
00:14:13,640 --> 00:14:16,880
The starchy skin
gives the chip its crunch.

205
00:14:16,880 --> 00:14:20,320
It also stops the chip
from soaking up too much oil.

206
00:14:20,320 --> 00:14:24,160
And because they spend
less time in the fryer than
the ones from your local chippy,

207
00:14:24,160 --> 00:14:26,840
they have a third less fat.

208
00:14:26,840 --> 00:14:30,920
Looks like they're done.
One last thing to do,
and that's to freeze them.

209
00:14:30,920 --> 00:14:34,640
In the factory,
they use an icy gust of air,

210
00:14:34,640 --> 00:14:38,720
at minus 29 degrees centigrade,
to freeze the oven chips.

211
00:14:38,720 --> 00:14:44,680
I'm using a leaf blower to push
air through this tube and across
dry ice - frozen carbon dioxide.

212
00:14:44,680 --> 00:14:46,280
And hey presto...

213
00:14:46,280 --> 00:14:48,120
a cold-air blaster!

214
00:14:48,120 --> 00:14:49,560
Chilly chips!

215
00:14:51,200 --> 00:14:52,800
Right.

216
00:14:54,360 --> 00:14:57,000
Let's test those chips!

217
00:14:58,040 --> 00:14:59,320
SOLID TAPPING

218
00:14:59,320 --> 00:15:01,160
That sounds frozen to me.

219
00:15:01,160 --> 00:15:06,400
The weird thing is, it can take
the factory about an hour and
a half from start to finish.

220
00:15:06,400 --> 00:15:10,160
Way longer than it'd take
you to make normal chips.

221
00:15:10,160 --> 00:15:12,920
Let's have a look at these beauties.

222
00:15:16,200 --> 00:15:20,680
Well, they look like the real deal.
Look how amazing and how
clean the edges are.

223
00:15:20,680 --> 00:15:24,720
And that's really good, if you think
I fired it through a tennis racket.

224
00:15:24,720 --> 00:15:27,320
But the real test,
has it got that crunch?

225
00:15:27,320 --> 00:15:29,360
CRUNCH

226
00:15:30,440 --> 00:15:34,880
Oh! Really "chippy"
crunchiness about them.

227
00:15:34,880 --> 00:15:36,720
Do you know what?

228
00:15:36,720 --> 00:15:38,960
I think...

229
00:15:38,960 --> 00:15:43,200
you can't really tell the difference
between my oven chips and the
ones from the supermarket.

230
00:15:43,200 --> 00:15:46,000
They're really good.

231
00:15:46,000 --> 00:15:48,480
Oh! Fantastic!

232
00:15:51,160 --> 00:15:55,480
There we go.
My very own oven chips.

233
00:15:55,480 --> 00:15:58,240
Brilliant!

234
00:15:58,240 --> 00:16:02,520
But don't to take my word for it.
Later on, we made another
batch to the same recipe.

235
00:16:02,520 --> 00:16:07,600
When it came to the crunch,
would my oven chips be a
hit down on the farm?

236
00:16:07,600 --> 00:16:11,280
Here's my version of oven chips -
want you to taste them.

237
00:16:11,280 --> 00:16:13,640
They are... Very crispy.

238
00:16:13,640 --> 00:16:16,480
Yeah, they are very crispy.
A lot better than normal oven chips.

239
00:16:16,480 --> 00:16:18,520
And they're not greasy at all.

240
00:16:18,520 --> 00:16:20,960
Nice taste. Slightly dry.

241
00:16:20,960 --> 00:16:22,880
I might have overcooked them!

242
00:16:29,160 --> 00:16:32,000
Peanuts are a favourite pub nibble.

243
00:16:32,000 --> 00:16:33,560
But do you know how they grow?

244
00:16:33,560 --> 00:16:36,200
Any ideas how peanuts grow?

245
00:16:36,200 --> 00:16:38,240
No idea. Like that.

246
00:16:38,240 --> 00:16:40,280
Like this, on a bush?
More like a tree.

247
00:16:40,280 --> 00:16:42,480
Bigger, you think? Yeah.
What about that?

248
00:16:42,480 --> 00:16:44,320
No. On the ground.

249
00:16:44,320 --> 00:16:45,960
Oh, around a bush?

250
00:16:45,960 --> 00:16:48,040
Looks pretty convincing to me.

251
00:16:48,040 --> 00:16:50,840
They look stuck on, but I've
got no idea how they grow.

252
00:16:50,840 --> 00:16:56,040
Stuck on! Now, you might think
peanuts grow on bushes like this,
but I can reveal this is a fake...

253
00:16:56,040 --> 00:16:58,840
I made this.
This is how peanuts grow...

254
00:16:58,840 --> 00:17:01,560
Look at that!

255
00:17:01,560 --> 00:17:02,800
Oh my word! They're great!

256
00:17:02,800 --> 00:17:05,160
Underground!

257
00:17:05,160 --> 00:17:07,880
Just like spuds.
I'm shocked, I didn't realise.

258
00:17:07,880 --> 00:17:10,120
They look...like potatoes! Weird!

259
00:17:15,680 --> 00:17:20,680
Now, as peanuts grow underground,
when they're harvested so are many
things that we're not that keen on.

260
00:17:23,520 --> 00:17:28,440
So how do you detect imposters
trying to smuggle themselves
inside your pack of peanuts?

261
00:17:28,440 --> 00:17:34,640
To find out,
I've decided to turn detective
and join the peanut police.

262
00:17:34,640 --> 00:17:39,200
Michelle Wake and Jon Sweeting
have to stop any shady characters

263
00:17:39,200 --> 00:17:43,000
that might sneak from the soil
into your packet of peanuts.

264
00:17:43,000 --> 00:17:44,880
This is what they want to avoid ...

265
00:17:44,880 --> 00:17:48,120
If you dig them out of the ground,
you'll get all sorts of debris.

266
00:17:48,120 --> 00:17:53,240
I've got some funny little nut
there, I've got some twigs, I've got
a sweet wrapper, bit of sweet corn.

267
00:17:53,240 --> 00:17:57,480
You're going to take up anything
that happens to be lying
around in the ground.

268
00:17:57,480 --> 00:18:00,840
The nuts are cleaned
and shelled before they
arrive here at the factory.

269
00:18:00,840 --> 00:18:07,000
But there could still be
all sorts of dodgy things
lurking in the shadows.

270
00:18:08,480 --> 00:18:11,280
So the detective work starts
with an x-ray machine.

271
00:18:11,280 --> 00:18:15,360
So you x-ray every single peanut,
I can see them going through here.

272
00:18:15,360 --> 00:18:19,240
Every nut and peanut that comes
through this factory gets x-rayed.

273
00:18:19,240 --> 00:18:22,480
So this will detect any metal
or foreign objects?

274
00:18:22,480 --> 00:18:24,880
Metal, stone, glass, stalk.

275
00:18:24,880 --> 00:18:27,960
If the machine spots anything
like that, it's rejected.

276
00:18:27,960 --> 00:18:34,640
That should have dealt with any
unwanted intruders, but the peanuts
are still under strict surveillance.

277
00:18:40,040 --> 00:18:41,960
So Jon, what does this machine do?

278
00:18:41,960 --> 00:18:44,000
It's actually an
optical colour sorter.

279
00:18:44,000 --> 00:18:47,080
It takes a picture of the peanut
on both sides

280
00:18:47,080 --> 00:18:49,240
so we get 360 degrees
coverage of the peanut.

281
00:18:49,240 --> 00:18:52,360
And if it's different
from the known colour, we reject it.

282
00:18:52,360 --> 00:18:54,840
It's like a peanut identity parade.

283
00:18:54,840 --> 00:18:58,840
It is, yeah. And they're firing
through like bullets, aren't they?

284
00:18:58,840 --> 00:19:02,880
They are, there's a picture
taken every three milliseconds.
That is incredible.

285
00:19:02,880 --> 00:19:07,760
By travelling so fast,
any "iffy" peanut might think
they've got away with it.

286
00:19:07,760 --> 00:19:12,640
But Peanut CCTV can sort out the
good guys from the bad guys and can

287
00:19:12,640 --> 00:19:16,680
take out that reject peanut with
just one blast of compressed air.

288
00:19:16,680 --> 00:19:18,280
You're nicked!

289
00:19:21,160 --> 00:19:25,120
This factory produces nearly
two million bags of peanuts a week.

290
00:19:25,120 --> 00:19:30,080
That's a lot of nuts to keep an eye
on. And the job isn't finished yet.

291
00:19:30,080 --> 00:19:32,800
So Michelle,
what's going on here, then?

292
00:19:32,800 --> 00:19:34,760
This is where our peanuts are fried.

293
00:19:34,760 --> 00:19:37,400
You can smell them,
that real sort of nutty aroma.

294
00:19:40,880 --> 00:19:43,320
But they're still not
ready for the packet.

295
00:19:43,320 --> 00:19:47,560
A peanut isn't a peanut
without a coating of salt.

296
00:19:49,240 --> 00:19:54,720
To make sure every nut
gets just the right amount,
they have an ingenious test.

297
00:19:54,720 --> 00:20:00,440
Peanut technician John Christie,
first mixes them with water.

298
00:20:00,440 --> 00:20:03,600
So in that water should be
all the salt from the nuts?

299
00:20:03,600 --> 00:20:10,360
That's right yes, all dissolved. John
passes an electrical current through
the solution to see how salty it is.

300
00:20:10,360 --> 00:20:14,000
So from this test here then you
can say, right, our peanuts need

301
00:20:14,000 --> 00:20:17,120
a little bit more salt, or cut back
on the salt... Yes, that's right.

302
00:20:17,120 --> 00:20:19,960
And this has to go on all the time?
It does yes, every 30 minutes.

303
00:20:19,960 --> 00:20:22,120
How long have you been
doing this, then, John?

304
00:20:22,120 --> 00:20:25,360
This particular job, I'm
still training and I'm
passing out this week.

305
00:20:25,360 --> 00:20:28,440
How long have you been here?
I've been here 17 years.

306
00:20:28,440 --> 00:20:32,520
17 years and still training? Yes.
You're doing a very good job.

307
00:20:32,520 --> 00:20:37,720
The peanuts are ready to
be packaged and sent off to
the pubs and supermarkets.

308
00:20:37,720 --> 00:20:40,240
Thanks to all these
detection devices,

309
00:20:40,240 --> 00:20:44,840
we can be sure there's
nothing untoward lurking
in our packets of peanuts.

310
00:20:44,840 --> 00:20:48,080
The peanut police have
the place locked down.

311
00:20:48,080 --> 00:20:51,000
My work here is done.

312
00:21:03,160 --> 00:21:07,960
Back at the barn, I'm going to get
my hands dirty with a retro classic.

313
00:21:07,960 --> 00:21:10,080
No, not the car!

314
00:21:10,080 --> 00:21:12,240
This isn't Top Gear,
it's Food Factory.

315
00:21:12,240 --> 00:21:14,080
Remember the 1970s?

316
00:21:14,080 --> 00:21:16,040
Then you'll remember prawn cocktail,

317
00:21:16,040 --> 00:21:18,120
black forest gateau
and chicken kiev.

318
00:21:18,120 --> 00:21:23,200
Popular then and we're
still eating them now!

319
00:21:23,200 --> 00:21:26,640
When I was a kid,
chicken kievs were a real treat!

320
00:21:26,640 --> 00:21:29,640
Nowadays they're a familiar
sight on pub menus

321
00:21:29,640 --> 00:21:33,600
and you're just as
likely to see them in the
chill cabinet at the supermarket.

322
00:21:33,600 --> 00:21:36,640
But there's a huge price variation,
from around

323
00:21:36,640 --> 00:21:38,920
a fiver for two
premium chicken kievs

324
00:21:38,920 --> 00:21:41,800
down to around a pound
for two economy ones.

325
00:21:41,800 --> 00:21:43,960
But how's it possible
to make them so cheaply?

326
00:21:43,960 --> 00:21:46,400
Well, to find out,
I'm going to make my own.

327
00:21:46,400 --> 00:21:51,600
Your top-end chicken kiev
is made from chicken breast
with garlic butter.

328
00:21:51,600 --> 00:21:54,520
But inside your cheap
and cheerful one,

329
00:21:54,520 --> 00:21:56,520
you'll find a knob of
garlic-flavoured margarine

330
00:21:56,520 --> 00:21:58,080
and this stuff.

331
00:21:59,240 --> 00:22:02,880
It really doesn't look like it's
come off a prime chicken breast.

332
00:22:02,880 --> 00:22:07,720
It almost looks like some
sort of...chicken toothpaste.

333
00:22:07,720 --> 00:22:13,800
So my first step to try
to create my own kiev will
be making this weird meaty stuff.

334
00:22:13,800 --> 00:22:17,760
And you might well ask, which
part of the chicken it comes from.

335
00:22:18,920 --> 00:22:22,160
Well, the breasts, wings and thighs
are generally used

336
00:22:22,160 --> 00:22:25,000
for more expensive products,
or premium kievs.

337
00:22:25,000 --> 00:22:28,720
Now I've taken all the prime
cuts off, I'm left with a carcass.

338
00:22:28,720 --> 00:22:31,360
There's still quite a lot
of meat left on here.

339
00:22:31,360 --> 00:22:34,280
But if you multiply this
by millions of chickens,

340
00:22:34,280 --> 00:22:35,680
that's a huge amount of meat.

341
00:22:35,680 --> 00:22:38,760
So what are we going to do with it?
Throw it away? Well, of course not.

342
00:22:41,120 --> 00:22:45,480
What I'm after is a machine
that'll strip off any meat
that's left on the carcass.

343
00:22:45,480 --> 00:22:49,560
If a supermarket wants to sell
kievs for just 50p each,

344
00:22:49,560 --> 00:22:52,200
they can't afford to chuck
a single scrap.

345
00:22:52,200 --> 00:22:56,240
There we go, that's
really solid, spot on.

346
00:22:58,920 --> 00:23:02,160
How it's going to work is that I'm
going to place my chicken carcass

347
00:23:02,160 --> 00:23:04,920
here between these two rotating
wheels.

348
00:23:04,920 --> 00:23:10,680
And the pressure of the tyre pushing
against this perforated cylinder
should strip the meat off.

349
00:23:10,680 --> 00:23:13,520
Now they obviously don't
use old car tyres

350
00:23:13,520 --> 00:23:17,000
and pieces of junk in the factory,
but the principle is the same.

351
00:23:20,240 --> 00:23:24,040
Inside the factory,
all this is subject to very
strict temperature controls.

352
00:23:24,040 --> 00:23:29,520
So my chicken carcass is
just out of the fridge
and will go back in straight away.

353
00:23:29,520 --> 00:23:31,320
Right, let's get this cranking.

354
00:23:35,520 --> 00:23:39,840
It's like some medieval
torture equipment.

355
00:23:41,600 --> 00:23:45,880
SQUELCH
Aww, listen to that!

356
00:23:45,880 --> 00:23:50,640
Ha...it looks disgusting!

357
00:23:50,640 --> 00:23:53,480
Through you go again.

358
00:23:53,480 --> 00:23:57,400
Now you might have heard
of "mechanically recovered meat".

359
00:23:57,400 --> 00:24:01,080
It's the kind of thing you see
on the packs of ingredients

360
00:24:01,080 --> 00:24:04,200
of cheap, processed food,
like tinned hot dogs.

361
00:24:04,200 --> 00:24:09,000
Mechanically recovered meat
is stripped from the carcass using
very high-pressure machinery.

362
00:24:09,000 --> 00:24:12,440
That process destroys
the structure of the meat.

363
00:24:12,440 --> 00:24:15,840
Look at that, it's pretty gross,
looks a bit like a horror film.

364
00:24:15,840 --> 00:24:19,320
I'm not using such high
pressure to squash out the meat,

365
00:24:19,320 --> 00:24:21,600
and there's a good reason for that.

366
00:24:21,600 --> 00:24:23,600
I've got two
microscope pictures here.

367
00:24:23,600 --> 00:24:26,440
The first is of normal minced
chicken and if you look,

368
00:24:26,440 --> 00:24:30,720
you can really see the meat cell
structure quite clearly.

369
00:24:30,720 --> 00:24:35,160
The second picture is of old-school
mechanically recovered meat.

370
00:24:35,160 --> 00:24:40,440
To be honest, it's a bit of a mess
because you can't see any of that
structure of the meat cells at all.

371
00:24:40,440 --> 00:24:42,280
Let's look at the meat
from my machine.

372
00:24:42,280 --> 00:24:46,160
I'm hoping that the meat I'm making
won't need to be labelled

373
00:24:46,160 --> 00:24:49,320
as mechanically recovered,
even though I'm using a machine.

374
00:24:49,320 --> 00:24:54,680
There we go, look at that.
You can really see the structures
of the meat fibres here.

375
00:24:54,680 --> 00:24:58,160
Even though it's gone
through my machine,
they've come out pretty well.

376
00:24:58,160 --> 00:25:03,400
So, in theory, I could label
this on the ingredients as meat.

377
00:25:03,400 --> 00:25:06,400
Factories that use a method of
squashing the carcass like this

378
00:25:06,400 --> 00:25:10,480
don't have to call their
meat "mechanically recovered".

379
00:25:10,480 --> 00:25:15,000
That's because you can
still see the meat fibres.

380
00:25:15,000 --> 00:25:22,320
It's not what I would call meat, but
I suppose it's using an ingredient
that would otherwise be wasted.

381
00:25:24,000 --> 00:25:29,120
This puree is too gloopy to make
a kiev, so I'm adding minced
chicken like the factory would.

382
00:25:31,200 --> 00:25:37,120
To keep costs down,
I can't put more than 50% chicken
in my economy kievs.

383
00:25:37,120 --> 00:25:41,640
So to make up the other half,
I'm adding cheap veggie mince -
soya protein.

384
00:25:41,640 --> 00:25:46,680
I'll mix that all in together
and it's starting to take on the
consistency of burger mince,

385
00:25:46,680 --> 00:25:49,320
which is a good thing because
an economy chicken kiev

386
00:25:49,320 --> 00:25:53,360
is basically two burgers
with a filling.

387
00:25:53,360 --> 00:25:54,600
I don't want it too thick.

388
00:25:54,600 --> 00:25:57,200
This hamburger press should
give me the shape I need.

389
00:25:57,200 --> 00:26:00,680
There we go, perfect. Number one.

390
00:26:00,680 --> 00:26:04,960
Now a chicken kiev
isn't a kiev without the
filling, so that goes in next.

391
00:26:04,960 --> 00:26:08,480
I'm adding garlic-flavoured
margarine.

392
00:26:10,640 --> 00:26:14,200
Ooh!
Nearly lost all my hard work then!

393
00:26:14,200 --> 00:26:18,760
Look at that, it looks like a
big fat burger, doesn't it?
More than a chicken kiev.

394
00:26:18,760 --> 00:26:23,480
Next, I need to coat
my kiev in batter and
roll it in breadcrumbs

395
00:26:23,480 --> 00:26:24,880
before popping it in hot oil.

396
00:26:24,880 --> 00:26:27,200
Now I've got to do this
really quickly because

397
00:26:27,200 --> 00:26:30,600
I don't want to cook the chicken
and I don't want to melt
the inside of it.

398
00:26:30,600 --> 00:26:36,880
Otherwise, when I bake it in
the oven for my dinner, all
the marge will soak into the kiev.

399
00:26:36,880 --> 00:26:39,680
There we go,
that is now ready for the shops.

400
00:26:39,680 --> 00:26:41,280
But it's not ready for tasting yet.

401
00:26:41,280 --> 00:26:43,160
I have to bake it.

402
00:26:43,160 --> 00:26:50,120
I can't believe I'm going
to eat pulverised chicken
that's been scraped off a car tyre.

403
00:26:50,120 --> 00:26:53,400
Right, moment of truth...

404
00:26:53,400 --> 00:26:58,560
Looks a little bit flat, but lovely
colour, nice and golden and
looks really crispy.

405
00:26:58,560 --> 00:27:01,040
Let's pop it on a plate. Here we go.

406
00:27:01,040 --> 00:27:06,160
Now for me, a really good chicken
kiev, when you cut it open,
the inside should be nice and soft

407
00:27:06,160 --> 00:27:09,320
and really ooze out, so let's
see if that's going to happen.

408
00:27:11,120 --> 00:27:12,720
Great crunch.

409
00:27:17,320 --> 00:27:18,920
It's empty, ha!

410
00:27:21,160 --> 00:27:27,320
I think what's happened, through
the cooking all that garlic-y
margarine has been absorbed

411
00:27:27,320 --> 00:27:33,480
by the meat, because look, it's just
like an empty pocket. Let's have a
go, let's see what it tastes like.

412
00:27:33,480 --> 00:27:36,760
Can't always go on looks.

413
00:27:36,760 --> 00:27:38,720
Smells nice.

414
00:27:46,320 --> 00:27:48,520
Mmm, it tastes like...

415
00:27:48,520 --> 00:27:50,960
it's been going round a tyre.

416
00:27:55,200 --> 00:27:57,360
Reminds me a bit of school dinners.

417
00:27:59,560 --> 00:28:02,320
Well, you know, I tried.

418
00:28:02,320 --> 00:28:05,920
It looks good,
it could taste a bit better.

419
00:28:07,840 --> 00:28:10,880
My very own, very cheap
chicken kiev.

420
00:28:13,560 --> 00:28:17,040
Like the car,
it's a '70s retro classic.

421
00:28:17,040 --> 00:28:19,400
Fire up the kiev!

422
00:28:21,080 --> 00:28:24,400
I've seen a school for steaks,
seen the processing behind

423
00:28:24,400 --> 00:28:27,800
a cheap chicken kiev
and made explosive oven chips.

424
00:28:27,800 --> 00:28:30,960
I had no idea pub grub
held so many secrets.

425
00:28:33,920 --> 00:28:36,920
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