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