1
00:00:02,800 --> 00:00:05,640
Right, guys,
taste this yeast extract.

2
00:00:05,640 --> 00:00:06,920
Try some of these.

3
00:00:06,920 --> 00:00:08,600
Oh, you don't want it!
HE LAUGHS

4
00:00:08,600 --> 00:00:10,200
Mmm! I like it too!

5
00:00:10,200 --> 00:00:12,040
Eugh! Horrible.

6
00:00:12,040 --> 00:00:15,960
There are some foods
that completely divide us.

7
00:00:15,960 --> 00:00:19,600
Unbelievably yummy for some,
and downright yucky for others.

8
00:00:19,600 --> 00:00:23,920
How do the food factories
come up with tastes that give us
such extreme reactions?

9
00:00:23,920 --> 00:00:26,200
So what does chocolate mean to you?

10
00:00:26,200 --> 00:00:28,880
Everything. It's a necessity.

11
00:00:28,880 --> 00:00:31,840
Couldn't live without it!
We are chocaholics.

12
00:00:31,840 --> 00:00:32,960
Would you chew this?

13
00:00:32,960 --> 00:00:34,760
No. Have a go!

14
00:00:34,760 --> 00:00:39,480
What do you reckon this
has to do with a piece of
chewing gum like that?

15
00:00:39,480 --> 00:00:45,320
I'll be revealing the secrets behind
some of the foods that delight
and disgust us by making them,

16
00:00:45,320 --> 00:00:46,960
food-factory style.

17
00:01:04,040 --> 00:01:08,960
There are some foods we buy
week after week, while others never
make it on the shopping list.

18
00:01:08,960 --> 00:01:11,800
So what makes us love some foods
and loathe others?

19
00:01:11,800 --> 00:01:16,960
And what goes on behind the scenes
to create these monsters or marvels
of the supermarket shelves?

20
00:01:16,960 --> 00:01:21,760
I'm going to set up
my own food factory in this barn
to find out how it's done.

21
00:01:21,760 --> 00:01:26,160
It may look as though it's full of
junk, but it's got everything I need

22
00:01:26,160 --> 00:01:29,440
to discover the secrets
of supermarket food.

23
00:01:32,520 --> 00:01:36,120
Now there is one supermarket product
that really divides people

24
00:01:36,120 --> 00:01:39,560
on the yuck-yum spectrum
and it's this stuff, yeast extract.

25
00:01:39,560 --> 00:01:42,640
For some people,
it has a taste to die for,

26
00:01:42,640 --> 00:01:45,960
for others, it tastes like
something's died.

27
00:01:48,320 --> 00:01:50,200
Got a little something for you.

28
00:01:50,200 --> 00:01:55,760
Tell me what you think of it and
then tell me what the flavours are?

29
00:01:55,760 --> 00:01:58,680
You don't like that at all? No.
You're not a big fan.

30
00:01:58,680 --> 00:01:59,840
That's mustard.

31
00:01:59,840 --> 00:02:01,840
Yeasty. Yeasty.

32
00:02:01,840 --> 00:02:04,320
Sort of musky in a good way.
Beefy salt.

33
00:02:04,320 --> 00:02:07,560
I could easily have that on toast.
You'd enjoy that? Oh, yeah.

34
00:02:08,880 --> 00:02:11,640
So what gives it
its massive flavour?

35
00:02:14,080 --> 00:02:19,840
Here in the barn, I'm fully equipped
to go back to basics
and make my own yeast extract.

36
00:02:19,840 --> 00:02:21,440
Clearly, the main ingredient

37
00:02:21,440 --> 00:02:24,080
in yeast extract is yeast.

38
00:02:24,080 --> 00:02:27,080
This stuff. You'll be familiar
with yeast if you bake bread,

39
00:02:27,080 --> 00:02:28,520
it's what makes it rise.

40
00:02:28,520 --> 00:02:30,800
But did you know it's a fungus?

41
00:02:30,800 --> 00:02:34,880
We can also thank it for
the alcohol in our beer and wine.

42
00:02:34,880 --> 00:02:37,920
But being one of the yeasty boys
isn't easy.

43
00:02:37,920 --> 00:02:40,960
MUSIC: "Funeral March"
by Frederic Chopin

44
00:02:40,960 --> 00:02:46,040
When you turn yeast into yeast
extract, something terrible happens.

45
00:02:46,040 --> 00:02:49,880
Now it sounds dramatic,
but all the yeast must die.

46
00:02:49,880 --> 00:02:52,760
In fact, the individual cells
that make up the yeast

47
00:02:52,760 --> 00:02:55,760
have to self-destruct
then splurge out their innards.

48
00:02:59,640 --> 00:03:02,080
It's like the yeastern front
out there.

49
00:03:02,080 --> 00:03:07,520
To extract the extract,
scientists use an instrument
of torture called a bioreactor.

50
00:03:07,520 --> 00:03:10,000
I could do with a cup of tea.

51
00:03:10,000 --> 00:03:14,080
I couldn't find a bioreactor in the
barn so I'm using a tea urn instead.

52
00:03:14,080 --> 00:03:18,360
In here will go the yeast cells
and some water.

53
00:03:18,360 --> 00:03:22,160
To keep everything moving, I'm using
the motor from an ice-cream maker.

54
00:03:22,160 --> 00:03:24,400
CHILD'S MOBILE JINGLE PLAYS

55
00:03:24,400 --> 00:03:26,400
That's going to be my stirrer.

56
00:03:28,320 --> 00:03:34,120
Like a bioreactor, this should mix
together the cells and convince them
to give up the ghost.

57
00:03:34,120 --> 00:03:36,760
# No more Mr Nice Guy... #

58
00:03:36,760 --> 00:03:38,920
Right, this is how
it's going to work.

59
00:03:38,920 --> 00:03:42,920
I've filled my urn up with water
and it's got a nice heating element
inside it

60
00:03:42,920 --> 00:03:46,840
which is going to keep the water
nice and warm,
around 50 degrees Celsius.

61
00:03:46,840 --> 00:03:49,240
Inside, I'm going to put my yeast.

62
00:03:49,240 --> 00:03:53,160
Now this is dried baker's yeast
but the yeast-extract factories

63
00:03:53,160 --> 00:03:55,720
use the waste yeast
from the brewing industry.

64
00:03:55,720 --> 00:03:59,760
Now, in that goes.
Right, let's give that a stir.

65
00:03:59,760 --> 00:04:03,080
Now it's time for my last
ingredient, which is pretty deadly,

66
00:04:03,080 --> 00:04:08,040
it's going to cause these
yeast cells to self-destruct
and then splurge their insides out.

67
00:04:08,040 --> 00:04:10,400
And the killer ingredient...

68
00:04:11,520 --> 00:04:13,200
..salt.

69
00:04:13,200 --> 00:04:18,240
It starts a natural self-destruction
process in the yeast.

70
00:04:19,840 --> 00:04:23,120
But I want to look at this
more closely.

71
00:04:23,120 --> 00:04:25,680
Now under the microscope,
yeast looks like this.

72
00:04:25,680 --> 00:04:29,320
Now each one of those blobs
is a living cell

73
00:04:29,320 --> 00:04:33,000
that contains, amongst other things,
a surprising amount of water.

74
00:04:33,000 --> 00:04:37,120
The salt draws water out of the
yeast cells and they start to die.

75
00:04:37,120 --> 00:04:41,000
This triggers
the production of chemicals

76
00:04:41,000 --> 00:04:45,520
that weaken the cell walls
and wreak havoc inside their insides

77
00:04:45,520 --> 00:04:49,920
Now once the walls of
the cells are damaged,
everything starts to ooze out.

78
00:04:49,920 --> 00:04:56,280
It sounds yucky,
but this yeasty ooze
gives the extract its yummy taste.

79
00:04:56,280 --> 00:04:59,240
Right, time to turn it on.

80
00:05:00,920 --> 00:05:06,680
It'll take a few hours to work,
but with luck, by tomorrow,
all my yeast will have died off.

81
00:05:06,680 --> 00:05:11,480
Well, I'll leave these guys
to their fate, they're doomed.

82
00:05:11,480 --> 00:05:14,480
MUSIC: "Funeral March"
by Frederic Chopin

83
00:05:24,880 --> 00:05:26,880
I love the smell of onions frying.

84
00:05:26,880 --> 00:05:28,960
It's already got my mouth watering.

85
00:05:28,960 --> 00:05:32,360
But I hate chopping them.
It's a bit embarrassing really -

86
00:05:32,360 --> 00:05:34,680
a vegetable making you cry?

87
00:05:34,680 --> 00:05:38,000
How do you stop yourself crying
when you're chopping onions?
Keep the end on.

88
00:05:38,000 --> 00:05:41,360
I've heard that if you suck
a small spoon...

89
00:05:41,360 --> 00:05:45,000
Contact lenses. With your lenses
in, you don't get any watering? Yes.

90
00:05:45,000 --> 00:05:48,840
'Another way to chop without weeping
is to wear onion specs.'

91
00:05:48,840 --> 00:05:50,880
Try those on. All right.

92
00:05:50,880 --> 00:05:56,360
'They fit tightly around the eyes
and stop any onion vapour
from getting in. Very fetching.'

93
00:05:56,360 --> 00:05:59,480
Are they making your eyes water?
No. No.

94
00:05:59,480 --> 00:06:03,160
No. There you are, they work.
Brilliant job. Yeah!

95
00:06:03,160 --> 00:06:06,080
'Whatever we do to try
and stop the tears...'

96
00:06:06,080 --> 00:06:07,720
Woo!

97
00:06:07,720 --> 00:06:10,120
'..we'd all prefer onions
didn't make us cry.'

98
00:06:14,400 --> 00:06:18,920
One person who literally knows
her onions is Dr Gemma Chope
from Cranfield University.

99
00:06:18,920 --> 00:06:23,120
And where better to meet her than
in the middle of an onion field?

100
00:06:27,000 --> 00:06:29,480
Why do onions make us cry?

101
00:06:29,480 --> 00:06:33,240
Well, this onion here is
a really rich source of sugars,

102
00:06:33,240 --> 00:06:36,080
so it's really attractive to
predators and pests,

103
00:06:36,080 --> 00:06:37,200
and over the years,

104
00:06:37,200 --> 00:06:40,720
it's developed quite a few
chemical weapons to defend itself.

105
00:06:40,720 --> 00:06:42,680
So it's got its
own chemical weapons,

106
00:06:42,680 --> 00:06:45,120
it hasn't just got a grudge
against us, then?

107
00:06:45,120 --> 00:06:47,520
No, it's nothing personal
against humans, no!

108
00:06:47,520 --> 00:06:49,080
Right, OK. Let's go!

109
00:06:49,080 --> 00:06:54,000
'The crying chemical is really a
defence mechanism against predators.

110
00:06:54,000 --> 00:06:58,120
'Onions aren't alone
in using natural defences
to protect themselves.

111
00:06:58,120 --> 00:07:01,360
'Nettles do the same thing
when they sting you.

112
00:07:01,360 --> 00:07:05,240
'And Gemma's brought along the daddy
of all natural defences.'

113
00:07:05,240 --> 00:07:08,600
Yep, Just going to waft
that around... That st...
HE COUGHS

114
00:07:08,600 --> 00:07:11,880
That stinks! I bet nobody invites
you to parties! That is wrong!

115
00:07:11,880 --> 00:07:13,520
Man alive!

116
00:07:13,520 --> 00:07:16,560
What's wrong with you?

117
00:07:16,560 --> 00:07:18,800
Who's made that smell?

118
00:07:18,800 --> 00:07:21,160
Well, actually, I can show you.

119
00:07:21,160 --> 00:07:23,920
That's an animal
I recognise immediately.

120
00:07:23,920 --> 00:07:27,200
Absolutely, this is a skunk.
Lovely, isn't he?

121
00:07:27,200 --> 00:07:30,400
What on Earth has an onion got to
do with this lovely creature?

122
00:07:30,400 --> 00:07:33,080
The link is based in sulphur.

123
00:07:33,080 --> 00:07:37,480
Sulphur is at the basis
of the skunk's defence system
and it's the same with onions.

124
00:07:40,560 --> 00:07:44,720
You'll find sulphur in gunpowder
and insecticides.

125
00:07:44,720 --> 00:07:48,120
Mr Skunk uses its whiffy smell
to chase away predators,

126
00:07:48,120 --> 00:07:51,640
while onions employ sulphur
to blind us with tears.

127
00:07:51,640 --> 00:07:56,240
I have to say, it's not having much
effect on Gemma's little friend.

128
00:07:56,240 --> 00:08:01,080
But exactly how does sulphur
in onions reduce us to floods?

129
00:08:01,080 --> 00:08:05,760
Even when you start peeling
the skin, you get that hit of onion,
don't you?

130
00:08:05,760 --> 00:08:10,000
Every time you chop with a knife,
you're breaking up
the cells in the onion.

131
00:08:10,000 --> 00:08:14,040
You're allowing two different types
of sulphur-based chemicals to mix.

132
00:08:14,040 --> 00:08:20,240
And it finishes up in a molecule
that's so light it, flies up from the
onion and gets you right in the eye.

133
00:08:20,240 --> 00:08:23,200
Yeah, you do get it.
SHE LAUGHS

134
00:08:23,200 --> 00:08:26,840
Straightaway.
But I always think that...

135
00:08:26,840 --> 00:08:28,680
SHE LAUGHS

136
00:08:28,680 --> 00:08:30,960
# You upsets me, baby

137
00:08:30,960 --> 00:08:34,600
# Yes, you upsets me, baby... #

138
00:08:34,600 --> 00:08:38,480
This sulphur-based molecule
irritates the nerve endings
in our eyes,

139
00:08:38,480 --> 00:08:43,240
which switch on the waterworks
as we try to wash it away.

140
00:08:44,480 --> 00:08:48,800
And the stronger an onion tastes,
the more sulphur it contains.

141
00:08:48,800 --> 00:08:51,880
But now there's a new onion
in the supermarket.

142
00:08:51,880 --> 00:08:57,600
Farmer Paul Cripsey has spent ten
years developing a milder-tasting
onion that won't make us cry.

143
00:08:57,600 --> 00:09:01,400
Could he have turned
a yuck into a yum?

144
00:09:01,400 --> 00:09:05,040
Right, so the big test is,
will it make me cry if I chop it?

145
00:09:05,040 --> 00:09:07,320
No, it won't Jimmy, it won't.

146
00:09:07,320 --> 00:09:10,880
Oh, the smell comes
across straightaway.

147
00:09:10,880 --> 00:09:14,400
Look at my eyes, into my eyes,
not round my eyes. But no tears.

148
00:09:14,400 --> 00:09:19,040
No tears. So how do you achieve that?
The sulphur creates the strength,

149
00:09:19,040 --> 00:09:23,560
so we must limit how much sulphur.
Half of it's really
in the breeding of the onion.

150
00:09:23,560 --> 00:09:27,040
But also we have to have soils
which are low in sulphur,

151
00:09:27,040 --> 00:09:30,160
and when we feed it, we must put
no sulphur into the soil.

152
00:09:30,160 --> 00:09:36,160
Because if you put too much
sulphur in, the onion will be strong.
Bit of a balancing game.

153
00:09:36,160 --> 00:09:43,080
But if sulphur gives an onion its
strong flavour, will a sulphur-less
onion be bland and tasteless?

154
00:09:43,080 --> 00:09:47,600
Have a bite of it now, see what
it tastes like. Are you sure?
Eat it like an apple, try it!

155
00:09:51,400 --> 00:09:55,080
That's really sweet.
Has this got more sugar in it
than a normal onion?

156
00:09:55,080 --> 00:09:58,680
All onions have the same amount
of sugar, but this one's

157
00:09:58,680 --> 00:10:03,400
got less sulphur, so it's not masking
the sweetness. Let's have another go.

158
00:10:03,400 --> 00:10:04,760
Mmm! Enjoy it? Yeah.

159
00:10:04,760 --> 00:10:08,000
My wife's going to go mad
with all this onion breath!

160
00:10:09,640 --> 00:10:12,480
If you like your onions
mild and sweet,

161
00:10:12,480 --> 00:10:15,520
there's no need for tears
in the kitchen any more -

162
00:10:15,520 --> 00:10:16,960
the no-cry onion is here.

163
00:10:16,960 --> 00:10:19,720
But if you like your onions with a
bit more flavour,

164
00:10:19,720 --> 00:10:23,440
then you'll have to hang on to
your goggles a little bit longer.

165
00:10:31,720 --> 00:10:38,920
Back at the barn,
I'm making something you either love
or loathe. Yeast extract.

166
00:10:38,920 --> 00:10:41,760
I've been heating yeast
in this tea urn all night

167
00:10:41,760 --> 00:10:45,760
to make the yeast cells burst open
so I can get at
their yeasty delights.

168
00:10:45,760 --> 00:10:48,640
But it's not gone according to plan.

169
00:10:48,640 --> 00:10:53,000
Look at this, this is a bit of
a disaster site, now last night,

170
00:10:53,000 --> 00:10:58,400
the thermostat on the tea urn went
and the whole thing has boiled over,
I've even sprung a leak.

171
00:10:58,400 --> 00:11:01,720
It's like my yeasts are trying
to resist self-destructing.

172
00:11:02,800 --> 00:11:05,800
But they're not going
to escape that easily.

173
00:11:05,800 --> 00:11:10,000
I've managed to save some
and I'm heating it in the oven.

174
00:11:11,360 --> 00:11:13,440
Now it smells totally different.

175
00:11:13,440 --> 00:11:17,720
Before, it was fairly fragrant, it
had a bready-type smell about it.

176
00:11:17,720 --> 00:11:21,400
Now the smell's much heavier.
Let's have a look at the colour.

177
00:11:21,400 --> 00:11:24,560
Well, all the lumps have dissolved
and it's turned beige

178
00:11:24,560 --> 00:11:28,680
and it's quite gloopy as well.

179
00:11:28,680 --> 00:11:33,960
In here, should be the insides
of billions of yeast cells.

180
00:11:33,960 --> 00:11:38,840
Now these small fragments
have a very strong flavour and
that's what I'm beginning to smell.

181
00:11:38,840 --> 00:11:42,280
The same thing happens when you
cook meat. The protein breaks down

182
00:11:42,280 --> 00:11:45,240
into small fragments
that have a strong flavour.

183
00:11:45,240 --> 00:11:49,360
That's why yeast extracts
can taste meaty,
even though they're vegetarian.

184
00:11:50,960 --> 00:11:54,520
But this stuff is way too watery
to spread on my toast.

185
00:11:54,520 --> 00:11:58,120
I need to get rid of
some of the liquid.

186
00:11:58,120 --> 00:12:02,200
To do that, I need to build
something called an evaporator.

187
00:12:02,200 --> 00:12:04,840
Luckily,
everything I need is in this barn.

188
00:12:04,840 --> 00:12:08,040
I knew that sheet of
corrugated metal would come in handy

189
00:12:08,040 --> 00:12:13,160
It's amazing what you can knock
together with a bucket
and some pipes.

190
00:12:13,160 --> 00:12:16,960
Right, that's all in.
Now, this is my evaporator,

191
00:12:16,960 --> 00:12:21,240
and how it works is,
my yeast extraction is going to pass

192
00:12:21,240 --> 00:12:23,880
all the way through this pipe here

193
00:12:23,880 --> 00:12:28,520
and come out here on these four
little copper pipes, run along this

194
00:12:28,520 --> 00:12:31,840
corrugated metal sheet and
I'm going to be blowing lots of heat

195
00:12:31,840 --> 00:12:37,520
through it with this space heater
to heat it up so, hopefully, it will
begin to evaporate and at the end,

196
00:12:37,520 --> 00:12:44,400
I shall collect some nice, thick,
concentrated yeast extract that,
hopefully, I can spread on my toast.

197
00:12:50,320 --> 00:12:52,920
Look at this, here it comes!

198
00:12:52,920 --> 00:12:57,560
Got to get the flow just right,
if it's too fast it will just run

199
00:12:57,560 --> 00:13:02,960
all the way to the end. If it's
too slow, it could begin to dry.

200
00:13:02,960 --> 00:13:04,440
It's like a yeast race.

201
00:13:04,440 --> 00:13:08,400
These rivers of yeast extract
allow me to drive off lots of water,

202
00:13:08,400 --> 00:13:12,080
leaving behind a concentrated goo.

203
00:13:12,080 --> 00:13:15,520
Now I've got the flow just right,
it's just dripping out

204
00:13:15,520 --> 00:13:18,160
and slowly travelling down
the little channels

205
00:13:18,160 --> 00:13:21,600
and it's getting hotter and hotter
so the water's evaporating,

206
00:13:21,600 --> 00:13:24,440
so as we get right to the end -
look at that bubbling away -

207
00:13:24,440 --> 00:13:25,680
so that yeast extract

208
00:13:25,680 --> 00:13:30,120
is getting nice and thick now,
so I might start collecting that.

209
00:13:30,120 --> 00:13:31,520
# Drip, drip

210
00:13:32,440 --> 00:13:33,880
# Drippity-drop... #

211
00:13:33,880 --> 00:13:37,440
Look at that,
it's becoming really pasty.

212
00:13:37,440 --> 00:13:40,080
Not quite enough for breakfast yet,

213
00:13:40,080 --> 00:13:41,720
but that's not bad.

214
00:13:41,720 --> 00:13:46,760
My effort is a lot lighter
than the dark-brown stuff
you get in the supermarket.

215
00:13:46,760 --> 00:13:51,880
I think it could do with being
more concentrated,
but we're on our yeasty way.

216
00:13:51,880 --> 00:13:57,560
# You know this empty room
is driving me insane... #

217
00:13:57,560 --> 00:14:00,600
That is the same consistency
as the yeast extract

218
00:14:00,600 --> 00:14:03,840
you would get in the shops.
That would spread beautifully.

219
00:14:03,840 --> 00:14:07,280
Mmmm. I can't resist the smell
any longer.

220
00:14:07,280 --> 00:14:10,320
Time for the toast test.

221
00:14:10,320 --> 00:14:12,360
That's not too runny,

222
00:14:12,360 --> 00:14:15,440
not too thick,

223
00:14:15,440 --> 00:14:17,120
that's just right.

224
00:14:17,120 --> 00:14:18,640
Let's have a little taste.

225
00:14:25,120 --> 00:14:26,560
It's very yeasty.

226
00:14:26,560 --> 00:14:29,000
HE LAUGHS

227
00:14:29,000 --> 00:14:32,520
That is borderline on the yuck,

228
00:14:32,520 --> 00:14:35,160
it's a bit like beer
that's gone off

229
00:14:35,160 --> 00:14:39,600
and it's not as salty as the stuff
you buy in the supermarket

230
00:14:39,600 --> 00:14:40,720
but it's not right.

231
00:14:40,720 --> 00:14:44,400
You wouldn't have that for breakfast
and go out and have a good day.

232
00:14:44,400 --> 00:14:48,600
There we go,
my very own yeast extract.

233
00:14:48,600 --> 00:14:52,000
# Yummy, yummy, yummy
I got love in my tummy... #

234
00:14:52,000 --> 00:14:58,240
Later, we made some more to the same
recipe, only this time we cooked
it longer, so it looks browner.

235
00:14:58,240 --> 00:15:01,720
So, yuck or yum?

236
00:15:01,720 --> 00:15:04,760
I am an expert. I have it every day.

237
00:15:04,760 --> 00:15:07,000
I love it. It's edible.

238
00:15:07,000 --> 00:15:08,920
So is cardboard! Yeah!

239
00:15:08,920 --> 00:15:11,040
Tastes similar but not the same.

240
00:15:11,040 --> 00:15:13,120
You really hate it. Mmm.

241
00:15:13,120 --> 00:15:16,160
It tastes like horrible cheese.
I'll take it way from you,

242
00:15:16,160 --> 00:15:19,600
cos it's making you pull
some interesting faces!

243
00:15:25,880 --> 00:15:29,800
Yeast extract is one of those
foods that gets extreme reactions.

244
00:15:29,800 --> 00:15:33,280
By there is one food that seems to
please just about everyone

245
00:15:33,280 --> 00:15:34,720
and that is chocolate.

246
00:15:34,720 --> 00:15:38,480
But giving chocolate its
glossy irresistible appearance

247
00:15:38,480 --> 00:15:40,520
is not as easy as you may think.

248
00:15:40,520 --> 00:15:43,360
# Candy man

249
00:15:43,360 --> 00:15:44,560
# Hey, candy man... #

250
00:15:44,560 --> 00:15:50,480
For almost 75 years, this factory in
Halifax has been churning out chocs.

251
00:15:50,480 --> 00:15:54,520
For not nearly as long,
Marie Guest has been making sure
around seven million

252
00:15:54,520 --> 00:15:58,160
of these little beauties roll off
the production line every day.

253
00:15:58,160 --> 00:16:00,080
# The candy man... #

254
00:16:00,080 --> 00:16:04,120
Marie, tell me, what
do the British public want
from their chocolate bar?

255
00:16:04,120 --> 00:16:08,320
They want really good, shiny
chocolate with a really good snap.

256
00:16:08,320 --> 00:16:10,400
So isn't chocolate naturally shiny?

257
00:16:10,400 --> 00:16:15,080
No, it would be dull
if we didn't process it correctly.

258
00:16:15,080 --> 00:16:17,920
Can I lick my fingers?
No, Jimmy, not in a food factory.

259
00:16:17,920 --> 00:16:22,320
It's hard working here,
you can't lick your fingers
when you've got chocolate on it!

260
00:16:22,320 --> 00:16:24,120
I wouldn't last a day!

261
00:16:24,120 --> 00:16:25,400
# Golden brown

262
00:16:25,400 --> 00:16:27,240
# Texture like sun... #

263
00:16:27,240 --> 00:16:31,600
To give chocolate a sleek and shiny
coat it has to be kept
at the right temperature.

264
00:16:31,600 --> 00:16:36,000
That's the job of chocolate wizard
Marie Wainwright.

265
00:16:36,000 --> 00:16:39,880
My job is to get it from this
liquid form into this solid form

266
00:16:39,880 --> 00:16:44,520
and still shiny,
but not like this, which is dull.

267
00:16:44,520 --> 00:16:47,480
Right, you can see
the difference there.

268
00:16:47,480 --> 00:16:50,760
If I snap that, look at that. It
hasn't got a snap to it has it?

269
00:16:50,760 --> 00:16:53,040
It hasn't got a snap, no.
It's very crumbly.

270
00:16:53,040 --> 00:16:54,800
Very crumbly, that whirl to it.

271
00:16:54,800 --> 00:16:56,120
Give this one...
SNAP!

272
00:16:56,120 --> 00:16:59,000
Oh, now you're talking.
Look at the difference!

273
00:16:59,000 --> 00:17:02,120
So how do you get your chocolate
nice and shiny?

274
00:17:02,120 --> 00:17:05,920
When I start to cool the chocolate,
I get all fat crystals forming

275
00:17:05,920 --> 00:17:09,720
and what I want is these crystals
all in a uniform shape.

276
00:17:09,720 --> 00:17:12,960
So what happens if the chocolate
cools a bit willy-nilly?

277
00:17:12,960 --> 00:17:16,640
What happens then is you get all
sorts of different crystals forming

278
00:17:16,640 --> 00:17:20,440
which are all different shapes and
they won't pack tightly together.

279
00:17:20,440 --> 00:17:23,760
Right, so you get all these
odd crystals forming.

280
00:17:23,760 --> 00:17:27,560
The light coming
in would just scatter off
and you won't get the shine.

281
00:17:27,560 --> 00:17:29,400
That's right. So the even crystals,

282
00:17:29,400 --> 00:17:33,440
all neat and tidy,
the light comes in, bounces off
and it's shiny like a mirror.

283
00:17:33,440 --> 00:17:34,480
That's right.

284
00:17:35,920 --> 00:17:41,400
To make sure the chocolate crystals
are the proper shape, it goes
through a process called tempering.

285
00:17:41,400 --> 00:17:44,440
And the secret of tempering
is temperature control.

286
00:17:44,440 --> 00:17:48,000
If they're too hot or too cold,
the chocolate crystals

287
00:17:48,000 --> 00:17:52,400
will be the wrong shape
and we won't get shiny chocolate.

288
00:17:52,400 --> 00:17:58,240
Wow. This is one of the temperers
that we use to temper our chocolate
within the factory.

289
00:17:58,240 --> 00:18:02,520
So this is the heart of
the chocolate factory?
It is, absolutely, yes.

290
00:18:02,520 --> 00:18:08,480
The temperature of the chocolate
in here has to be kept
within strict limits all the time.

291
00:18:08,480 --> 00:18:11,880
# Lick your lips, blow me a kiss

292
00:18:12,880 --> 00:18:14,920
# Take a nibble
of chocolate bliss... #

293
00:18:14,920 --> 00:18:20,400
So worst-case scenario,
say if something goes wrong,
what happens then?

294
00:18:20,400 --> 00:18:22,640
If it's got a centre in there,
for instance,

295
00:18:22,640 --> 00:18:26,080
caramel and hazelnut, we can't
recover that, so that is waste.

296
00:18:26,080 --> 00:18:28,480
Right, I've just found
a little opening for me.

297
00:18:28,480 --> 00:18:30,200
I could eat all the wasted ones.

298
00:18:30,200 --> 00:18:32,320
I'll bring my own chair
and everything.

299
00:18:36,040 --> 00:18:40,080
Are these peppermints?
These are actually orange creams,
soft centres.

300
00:18:40,080 --> 00:18:45,320
This is before they're actually
enrobed in chocolate. There was
a bit of controversy in my house.

301
00:18:45,320 --> 00:18:48,320
When I was growing up, you either
loved them or hated them

302
00:18:48,320 --> 00:18:51,280
and I liked the green triangles
and my mum loved these,

303
00:18:51,280 --> 00:18:55,040
but if she was to bite into one of
these her teeth would come out!

304
00:18:55,040 --> 00:18:58,760
We need a hard structure so that we
can actually coat it in chocolate.

305
00:18:58,760 --> 00:19:00,400
How do they go soft then?

306
00:19:00,400 --> 00:19:06,280
The sugars start to break down,
there's a chemical reaction,
so they become softer over,

307
00:19:06,280 --> 00:19:10,520
I would say about three days,
but they don't go completely soft.

308
00:19:10,520 --> 00:19:14,840
But how do you know that chocolate
is going to be shiny?

309
00:19:14,840 --> 00:19:19,320
Well, we don't,
we only know that when we actually
take the product out of the moulds.

310
00:19:19,320 --> 00:19:24,200
So you've got to wait until they
go through the whole process to see
if they've got a shine? Yes.

311
00:19:24,200 --> 00:19:27,640
Doesn't that worry you?
I'd be petrified.

312
00:19:27,640 --> 00:19:32,240
With the chocolates
out of their moulds,
there's only one thing left to do.

313
00:19:32,240 --> 00:19:35,880
This is my number-one yum.

314
00:19:35,880 --> 00:19:40,280
Here they are off
the production line, all
looking lovely, but are they shiny?

315
00:19:40,280 --> 00:19:43,680
Check them, Jimmy,
have a look at them.

316
00:19:43,680 --> 00:19:46,240
Right, it's your reputation
at stake...

317
00:19:46,240 --> 00:19:47,560
Yep, nice and shiny.

318
00:19:47,560 --> 00:19:51,760
What about texture? Has it
got the snap? Try it! You tell me.

319
00:19:51,760 --> 00:19:54,080
Mmm! Lovely snap.

320
00:19:54,080 --> 00:19:57,400
Need to test it again, obviously.

321
00:19:57,400 --> 00:20:01,120
Is there a job going here
where you need quality control?

322
00:20:01,120 --> 00:20:03,880
Would you like to be
our quality control check, yeah?

323
00:20:03,880 --> 00:20:06,280
I've got a good CV.
At the top it says "greedy"!

324
00:20:06,280 --> 00:20:08,960
Mmm! I feel a bit sick now!

325
00:20:15,480 --> 00:20:19,800
Next up on my yuck-yum top four
is something to get your teeth into.

326
00:20:19,800 --> 00:20:21,320
Chewing gum.

327
00:20:23,760 --> 00:20:26,320
Chewing gum is a unique product.

328
00:20:26,320 --> 00:20:28,160
But is it even food?

329
00:20:28,160 --> 00:20:31,080
And if it is, why doesn't it
disappear when you chew it?

330
00:20:31,080 --> 00:20:33,600
Well, to find out,
I'm going to make my own.

331
00:20:35,080 --> 00:20:41,600
Here in the barn,
I've got everything I need to
unstick the secrets of chewing gum.

332
00:20:41,600 --> 00:20:46,760
And it all starts
with something called gum base.
But what on Earth is it?

333
00:20:47,880 --> 00:20:50,560
Gum base is actually
a mixture of ingredients.

334
00:20:50,560 --> 00:20:52,880
It's strange that
chewing gum companies

335
00:20:52,880 --> 00:20:56,640
don't have to put them on the label,
because there's quite a few of them.

336
00:20:56,640 --> 00:20:58,800
But usually they're a trade secret.

337
00:20:58,800 --> 00:21:05,440
So what are the secret ingredients
of gum base in chewing gum?
Well, I can tell you...

338
00:21:05,440 --> 00:21:09,640
you won't find many of them in your
local supermarket. Look at this.

339
00:21:09,640 --> 00:21:13,640
It's sort of like a liquid
but it's not, it's a solid as well.

340
00:21:13,640 --> 00:21:15,480
'Its called polyisobutylene,

341
00:21:15,480 --> 00:21:17,720
'a type of rubber...'

342
00:21:17,720 --> 00:21:19,760
Look at it!
HE GROANS

343
00:21:19,760 --> 00:21:24,640
'..used to make basketballs
and the inner lining of car tyres.
Delicious!'

344
00:21:24,640 --> 00:21:27,280
Now you can eat
all of these ingredients,

345
00:21:27,280 --> 00:21:29,320
they are food grade. Look! Ooop!

346
00:21:29,320 --> 00:21:32,400
# I'm gonna chew
Won't give it to you... #

347
00:21:32,400 --> 00:21:34,320
It's like chewing an elastic band.

348
00:21:34,320 --> 00:21:38,040
Next up, these little guys.
Polyvinyl acetate.

349
00:21:39,680 --> 00:21:43,280
This is a plastic that goes rubbery
when it gets warm.

350
00:21:43,280 --> 00:21:47,000
Let's have a little taste
of one or two of these.

351
00:21:47,000 --> 00:21:51,400
You can use these to make glue.
I hope they don't
stick my teeth together.

352
00:21:51,400 --> 00:21:53,360
Hmmm. Really unpleasant.

353
00:21:53,360 --> 00:21:57,960
Then we've got big slabs of wax,
this is very similar to the
stuff you make candles out of.

354
00:21:57,960 --> 00:22:02,000
Then there's rosin, which is
made from the sap of pine trees.

355
00:22:02,000 --> 00:22:05,000
And then something we're
all very familiar with...

356
00:22:05,000 --> 00:22:06,760
talcum powder.

357
00:22:08,040 --> 00:22:12,560
So how do you turn all these
weird ingredients into lovely gum?

358
00:22:12,560 --> 00:22:15,120
My first job is to
make the gum base.

359
00:22:15,120 --> 00:22:18,120
So I've got to heat all these
ingredients and mix them up.

360
00:22:18,120 --> 00:22:20,480
But before I do that,
I've got to kit up.

361
00:22:23,040 --> 00:22:26,760
Hot, molten rubbery stuff
is not something you want

362
00:22:26,760 --> 00:22:31,840
to get on your skin because it
burns like crazy and it sticks as
well, so it wouldn't be much fun.

363
00:22:32,640 --> 00:22:36,320
First up, it's polyisobutylene.

364
00:22:36,320 --> 00:22:38,760
HE LAUGHS

365
00:22:42,040 --> 00:22:44,280
There's the first bit.
HE LAUGHS

366
00:22:44,280 --> 00:22:49,240
Little bit of talc, which is
something I thought I'd never say.

367
00:22:49,240 --> 00:22:52,000
Oh, yeah,
it makes it look much better.

368
00:22:52,000 --> 00:22:58,280
Time for a bit of polyvinyl acetate,
which I find is always
essential at this point.

369
00:22:58,280 --> 00:23:00,320
Does that look like
chewing gum to you?

370
00:23:00,320 --> 00:23:01,520
HE LAUGHS

371
00:23:03,160 --> 00:23:08,000
Polyisobutylene and polyvinyl
acetate stretch when they're heated.

372
00:23:09,800 --> 00:23:12,280
And without them, chum...no gum.

373
00:23:12,280 --> 00:23:15,120
It's like the
Creature From The Black Lagoon.

374
00:23:15,120 --> 00:23:17,960
# Beware of The Blob
It creeps and leaps... #

375
00:23:17,960 --> 00:23:21,760
You can never over-season
your chewing gum
with too much talcum powder.

376
00:23:21,760 --> 00:23:24,680
There's an incredible change
going on.

377
00:23:24,680 --> 00:23:30,080
It's really starting to come
together and look like
runny chewing gum.

378
00:23:30,080 --> 00:23:33,800
Next goes the pine-tree extract.

379
00:23:35,080 --> 00:23:39,280
That's the kind of thing
I used to have stuck
under my desk at school.

380
00:23:40,480 --> 00:23:43,560
Big lump of chewing gum.
It's probably still there.

381
00:23:43,560 --> 00:23:47,040
Right, time for everyone's
favourite, little bit of wax.

382
00:23:47,040 --> 00:23:52,720
The wax, rosin and talc change the
chewiness of the stretchy rubbers.

383
00:23:52,720 --> 00:23:57,560
The gum needs to be solid
at room temperature
but soft when heated in the mouth.

384
00:23:57,560 --> 00:23:59,400
# Be careful of The Blob... #

385
00:23:59,400 --> 00:24:03,080
Right, I think that's as good
as it's going to get.

386
00:24:04,640 --> 00:24:08,320
Look at that, lovely stuff.

387
00:24:08,320 --> 00:24:11,360
But not very tasty.

388
00:24:13,240 --> 00:24:19,040
To fill my rubbery blob
with flavour, I need to build
a very powerful mixer.

389
00:24:19,040 --> 00:24:21,560
I'll mix my gum
in this steel container.

390
00:24:21,560 --> 00:24:26,040
The mixing blade is turned by
a length of motorcycle chain.

391
00:24:26,040 --> 00:24:28,680
And the power comes from
this monster motor.

392
00:24:28,680 --> 00:24:32,520
Builders use it to mix thick cement.

393
00:24:32,520 --> 00:24:36,800
Finally, I need heat.
These wallpaper steamers
should do the job.

394
00:24:36,800 --> 00:24:40,280
They attach to holes
at the front of the mixer.

395
00:24:40,280 --> 00:24:43,880
Right, let's put it all together,
and see if it works.

396
00:24:48,400 --> 00:24:52,240
I've got my wallpaper steamers
connected up to this mixer

397
00:24:52,240 --> 00:24:56,720
because I want to keep it
nice and hot because if I don't,
the gum base will go solid.

398
00:24:58,680 --> 00:25:01,960
It seems to be working.

399
00:25:01,960 --> 00:25:05,200
Time to mix some sweetness
into my rubbery gloop...

400
00:25:05,200 --> 00:25:06,600
with glucose syrup.

401
00:25:06,600 --> 00:25:10,680
Right, that's enough of that.
Next ingredient, bit more sugar.

402
00:25:10,680 --> 00:25:13,120
In fact, quite a lot of sugar.

403
00:25:15,960 --> 00:25:18,000
Mint flavouring.

404
00:25:18,000 --> 00:25:19,800
That smells incredible.

405
00:25:21,920 --> 00:25:25,720
But as we all know,
the flavour doesn't last.

406
00:25:25,720 --> 00:25:32,880
That's because when you chew, the
sugar and flavour dissolve, leaving
behind a hard ball of gum base.

407
00:25:32,880 --> 00:25:35,080
because gum base
is a type of rubber,

408
00:25:35,080 --> 00:25:39,560
it won't dissolve in your mouth
no matter how much you chew it.

409
00:25:39,560 --> 00:25:43,400
Time to get out my mixture.
It's just about ready.

410
00:25:45,240 --> 00:25:50,480
To make this gum look like the real
deal, I need to get mangling.

411
00:25:50,480 --> 00:25:55,400
Look at that, probably a year's
worth of chewing gum here.

412
00:25:55,400 --> 00:25:59,200
Well, there will be, if I can get
125 pieces out of this one sheet.

413
00:25:59,200 --> 00:26:02,920
In the UK, that's how much your
average gum fan consumes in a year.

414
00:26:02,920 --> 00:26:06,360
You see, I forget, I keep thinking
I'm cutting something

415
00:26:06,360 --> 00:26:09,720
like pasta dough, but in fact,
it's a rubber concoction

416
00:26:09,720 --> 00:26:12,200
that gets really
hard when it gets cold.

417
00:26:12,200 --> 00:26:15,480
So it's like cutting through
a bicycle tyre.

418
00:26:15,480 --> 00:26:18,760
Hope it doesn't taste like one!

419
00:26:18,760 --> 00:26:21,240
Look at that,
it sort of looks like chewing gum,

420
00:26:21,240 --> 00:26:25,080
it smells like chewing gum, funny
little colour, but do you know what?

421
00:26:25,080 --> 00:26:29,960
After putting all those ingredients
in, I'm not sure about putting this
in my mouth,

422
00:26:29,960 --> 00:26:34,080
because it seems like a load
of plastic and wax went into it.
But let's have a go.

423
00:26:34,080 --> 00:26:37,000
Oh, I don't know.

424
00:26:38,360 --> 00:26:41,440
Ugh.

425
00:26:44,640 --> 00:26:49,400
It does taste like chewing gum,

426
00:26:49,400 --> 00:26:51,400
but it's like eating dried cement.

427
00:26:53,240 --> 00:26:54,400
Oh!

428
00:26:57,680 --> 00:27:01,360
You carry on chewing,
and it begins to form...

429
00:27:01,360 --> 00:27:02,680
chewing gum.

430
00:27:05,160 --> 00:27:07,320
But the initial stages
are repulsive.

431
00:27:07,320 --> 00:27:08,880
HE CLEARS HIS THROAT

432
00:27:10,320 --> 00:27:13,200
Look at that. It's like a little...

433
00:27:13,200 --> 00:27:14,840
Well, it's like chewing gum.

434
00:27:14,840 --> 00:27:19,280
It's a lot harder, almost like
a bit of clay, but for a product tha

435
00:27:19,280 --> 00:27:23,920
seems impossible to make in your
home, we've just about done it.

436
00:27:23,920 --> 00:27:26,240
# I put the penny
in the gum slot... #

437
00:27:26,240 --> 00:27:29,840
They're so thick
I can only get three in the box...

438
00:27:29,840 --> 00:27:34,200
There we go,
my very own mint chewing gum.

439
00:27:34,200 --> 00:27:38,400
# I put the penny in the gum slot
Eenie, meenie... #

440
00:27:38,400 --> 00:27:41,760
But will I come unstuck when
they get chewing down on my farm?

441
00:27:43,440 --> 00:27:46,920
This is my version of chewing gum.
Thank you.

442
00:27:46,920 --> 00:27:50,360
It's not easy to chew is it?
It's like eating Plasticine.

443
00:27:50,360 --> 00:27:54,800
I can't actually chew mine at
the moment, it's still almost solid.

444
00:27:54,800 --> 00:27:57,680
That's awful. I don't mind it.

445
00:27:57,680 --> 00:27:59,800
Out of ten,
what would you give my chewing gum?

446
00:27:59,800 --> 00:28:01,760
Seven. Seven? That's quite good.

447
00:28:01,760 --> 00:28:03,120
Seven. Seven!

448
00:28:03,120 --> 00:28:05,560
What would you give it? Erm, two.

449
00:28:05,880 --> 00:28:08,000
I can feel my fillings
coming out now.

450
00:28:08,000 --> 00:28:10,280
I probably go six. Sorry!

451
00:28:10,280 --> 00:28:13,600
You're saying six,
you're thinking two.

452
00:28:13,600 --> 00:28:15,240
They're too kind.

453
00:28:16,760 --> 00:28:21,080
Whether you're crazy about
these foods or they drive you crazy,

454
00:28:21,080 --> 00:28:25,280
food manufacturers try hard
to make us love their products.

455
00:28:25,280 --> 00:28:27,000
But when it comes to the crunch,

456
00:28:27,000 --> 00:28:29,080
it'll be your taste buds
that decide.

457
00:28:33,080 --> 00:28:36,120
Subtitles by Red Bee Media Ltd

458
00:28:36,120 --> 00:28:39,120
E-mail subtitling@bbc.co.uk