1 00:00:02,040 --> 00:00:05,200 Mayonnaise. Every year in Britain we work our way through nearly 2 00:00:05,200 --> 00:00:07,120 40 million kilos of the stuff. 3 00:00:09,320 --> 00:00:13,040 And it all starts with thousands of eggs, like these! 4 00:00:14,480 --> 00:00:19,720 Which go on an incredible journey before ending up in jars like this. 5 00:00:22,120 --> 00:00:24,120 This time we are in the Netherlands 6 00:00:24,120 --> 00:00:27,320 with the amazing story of one of our favourite condiments. 7 00:00:27,320 --> 00:00:28,720 By taking you inside 8 00:00:28,720 --> 00:00:31,960 one of the largest sauce factories in the world. 9 00:00:35,640 --> 00:00:37,080 I'm Gregg Wallace. 10 00:00:37,080 --> 00:00:38,680 HE CACKLES 11 00:00:38,680 --> 00:00:42,040 And I'll come face-to-face with some cracking technology. 12 00:00:43,080 --> 00:00:46,160 That may be the best machine I have ever seen! 13 00:00:47,400 --> 00:00:49,400 I'm Cherry Healy, 14 00:00:49,400 --> 00:00:53,360 and I'll be revealing the secrets of our favourite sauces, 15 00:00:53,360 --> 00:00:57,840 including the 2000-year-old recipe for soy sauce. 16 00:00:57,840 --> 00:01:00,120 So salty! Yeah. 17 00:01:00,120 --> 00:01:01,440 I can taste it. 18 00:01:02,720 --> 00:01:04,560 While historian Ruth Goodman 19 00:01:04,560 --> 00:01:08,160 investigates the fishy origins of Worcester sauce. 20 00:01:08,160 --> 00:01:12,600 So, this idea that they had to discover the fermentation. 21 00:01:12,600 --> 00:01:14,360 People had been doing it for years. 22 00:01:16,480 --> 00:01:17,880 Over the next 24 hours, 23 00:01:17,880 --> 00:01:21,600 this factory will produce three quarters of a million 24 00:01:21,600 --> 00:01:23,440 jars and bottles of mayonnaise. 25 00:01:23,440 --> 00:01:26,920 And we're going to show you just how they manage production 26 00:01:26,920 --> 00:01:28,800 on such a massive scale. 27 00:01:28,800 --> 00:01:30,400 Welcome to Inside The Factory. 28 00:01:54,480 --> 00:01:59,240 This is the Heinz factory in the town of Elst in the Netherlands. 29 00:01:59,240 --> 00:02:01,880 One of the biggest sauce factories in Europe, 30 00:02:01,880 --> 00:02:05,720 churning out almost a quarter of a million tonnes every year. 31 00:02:07,920 --> 00:02:12,480 They produce a saucy smorgasbord that includes tomato ketchup, 32 00:02:12,480 --> 00:02:16,920 brown sauce and salad cream, as well as mayonnaise. 33 00:02:18,400 --> 00:02:23,640 And, amazingly, over half of what they produce here is sent to the UK. 34 00:02:25,040 --> 00:02:32,960 This 19.5 acre site runs 24 hours a day and 350 people work here. 35 00:02:32,960 --> 00:02:37,320 Tonight, we take a look at how they make their traditional mayonnaise 36 00:02:37,320 --> 00:02:38,360 in jars. 37 00:02:43,960 --> 00:02:46,000 But before we can start making mayonnaise, 38 00:02:46,000 --> 00:02:49,520 we need one of the most important ingredients - eggs. 39 00:02:52,960 --> 00:02:56,920 I'm heading 15 miles east, close to the city of Arnhem, 40 00:02:56,920 --> 00:03:00,520 to one of 200 farms that supply our factory. 41 00:03:03,760 --> 00:03:06,520 This one is run by Theo Janson. 42 00:03:06,520 --> 00:03:10,960 His 23,000 free-range hens lay their eggs 43 00:03:10,960 --> 00:03:14,400 in this 2,600 square metre barn. 44 00:03:16,000 --> 00:03:17,040 Theo. 45 00:03:18,120 --> 00:03:20,160 Hello. Hello, Gregg. 46 00:03:20,160 --> 00:03:23,120 This is far more noisy than I expected. 47 00:03:23,120 --> 00:03:24,800 Yes, very much noise. 48 00:03:24,800 --> 00:03:28,960 Can you explain to me, please, how you collect the eggs? 49 00:03:28,960 --> 00:03:33,040 OK, in the morning, about seven, the lights go on 50 00:03:33,040 --> 00:03:35,240 and the chickens wake up. 51 00:03:35,240 --> 00:03:38,960 And, then, in a few hours, they get laying the eggs. 52 00:03:38,960 --> 00:03:40,400 And the eggs roll down, 53 00:03:40,400 --> 00:03:43,480 cos the nests are a bit... Ah, I see! ..like that. 54 00:03:44,920 --> 00:03:47,800 So, the nest is sloped? 55 00:03:47,800 --> 00:03:51,080 Yes. And, at the bottom of the slope is a conveyor belt. 56 00:03:51,080 --> 00:03:55,120 Yes, a belt. And the eggs gently roll down onto the belt. 57 00:03:57,680 --> 00:03:59,600 How many eggs every day? 58 00:03:59,600 --> 00:04:02,600 We have about 21,500 eggs. 59 00:04:03,800 --> 00:04:07,160 Over 20,000 eggs rolling down a hill? 60 00:04:07,160 --> 00:04:08,600 Yes. Every day. 61 00:04:10,360 --> 00:04:13,280 This is where our mayonnaise production line begins. 62 00:04:15,760 --> 00:04:17,480 Most hens lay an egg a day 63 00:04:17,480 --> 00:04:20,720 and the factory is depending on them because, 64 00:04:20,720 --> 00:04:23,120 without eggs, there's no mayo. 65 00:04:24,200 --> 00:04:27,120 The chickens sleep and lay in the barn. 66 00:04:27,120 --> 00:04:29,600 The rest of the day, they head outside to play. 67 00:04:32,040 --> 00:04:35,920 Meanwhile, their eggs are travelling 80 metres along a series 68 00:04:35,920 --> 00:04:38,360 of conveyor belts to the sorting area. 69 00:04:38,360 --> 00:04:41,120 So, the eggs are rolling in there. 70 00:04:41,120 --> 00:04:44,280 Yeah. So, what are you picking out here? 71 00:04:44,280 --> 00:04:45,880 The wrong ones I get out. 72 00:04:45,880 --> 00:04:47,560 What you mean wrong ones? Why wrong? 73 00:04:47,560 --> 00:04:50,080 Broken eggs, or a very big egg, 74 00:04:50,080 --> 00:04:53,840 because a very big egg can't go through the machine. 75 00:04:58,080 --> 00:05:01,600 Each egg is delicately placed into a tray ready for transportation, 76 00:05:01,600 --> 00:05:03,440 always pointed side down, 77 00:05:03,440 --> 00:05:05,840 which ensures the yolk sits perfectly 78 00:05:05,840 --> 00:05:07,560 in the centre of the shell. 79 00:05:08,880 --> 00:05:11,600 It's a machine but it has to be very gentle. 80 00:05:11,600 --> 00:05:14,200 It has. Very gentle. 81 00:05:14,200 --> 00:05:15,280 If this goes wrong, 82 00:05:15,280 --> 00:05:19,240 it must make the biggest mess you can possibly imagine. 83 00:05:19,240 --> 00:05:20,280 Yes. 84 00:05:21,280 --> 00:05:28,000 The 21,500 eggs rolling along here will be enough to make nearly 11,000 85 00:05:28,000 --> 00:05:29,080 jars of mayonnaise. 86 00:05:30,360 --> 00:05:34,080 But they're not going anywhere until a code has been stamped 87 00:05:34,080 --> 00:05:35,440 onto their shells. 88 00:05:35,440 --> 00:05:37,480 This is a sort of egg passport. 89 00:05:37,480 --> 00:05:43,160 We are not allowed to move any egg from our company without a print. 90 00:05:43,160 --> 00:05:44,360 And what does it say? 91 00:05:44,360 --> 00:05:47,600 There is a one, one means free-range. 92 00:05:47,600 --> 00:05:52,200 If there is, for example, a zero, it's organic. 93 00:05:52,200 --> 00:05:55,480 OK. Two is for a barn egg. 94 00:05:55,480 --> 00:05:58,520 Right. And three is in a cage. 95 00:05:58,520 --> 00:06:01,280 Is that for eggs in the UK the same? 96 00:06:01,280 --> 00:06:03,000 Yeah. And what are the other numbers? 97 00:06:03,000 --> 00:06:07,160 It's the number of our company, and the number of the barn. 98 00:06:08,280 --> 00:06:11,440 The code means each egg can be tracked 99 00:06:11,440 --> 00:06:13,920 right up until the very moment it's cracked open. 100 00:06:15,480 --> 00:06:17,720 You know, we all eat eggs. 101 00:06:17,720 --> 00:06:20,320 I don't know how many people read eggs. 102 00:06:20,320 --> 00:06:23,080 How long does it take to process all those eggs? 103 00:06:23,080 --> 00:06:24,880 About an hour. 104 00:06:24,880 --> 00:06:27,000 What do you do with the rest of your day? 105 00:06:27,000 --> 00:06:28,880 Keep my wife company. 106 00:06:29,920 --> 00:06:30,960 Good plan. Yeah. 107 00:06:33,640 --> 00:06:36,200 While Theo keeps his wife company, 108 00:06:36,200 --> 00:06:38,840 the free-range eggs are loaded onto pallets. 109 00:06:38,840 --> 00:06:41,280 Then they're off on another journey. 110 00:06:41,280 --> 00:06:43,200 They travel 40 miles north 111 00:06:43,200 --> 00:06:46,240 from the farm to a specialist processing factory... 112 00:06:49,600 --> 00:06:53,720 ..which receives and processes up to four million eggs 113 00:06:53,720 --> 00:06:55,120 every single day. 114 00:06:56,400 --> 00:06:57,960 Careful! Don't break any! 115 00:06:58,960 --> 00:07:03,600 In charge of this huge undertaking is Jan Zuiderveld. 116 00:07:05,040 --> 00:07:06,160 Jan? 117 00:07:06,160 --> 00:07:08,400 Yes, hello. I'm Gregg. 118 00:07:08,400 --> 00:07:10,440 Nice to meet you. Jan, 119 00:07:10,440 --> 00:07:13,880 I don't think anybody really has seen this many eggs. 120 00:07:13,880 --> 00:07:16,320 Well, there are many eggs here, 121 00:07:16,320 --> 00:07:20,400 approximately 10 million ladies are working to produce these eggs. 122 00:07:22,040 --> 00:07:26,680 The ladies in question produced this lot just 2.5 hours ago. 123 00:07:26,680 --> 00:07:30,080 Now the green trays are removed from the pallets 124 00:07:30,080 --> 00:07:32,920 and their fragile cargo is lifted out. 125 00:07:34,800 --> 00:07:38,160 That looks like a very delicate operation. 126 00:07:38,160 --> 00:07:42,680 Yes, it is. Each egg is taken individually by the suckers, 127 00:07:42,680 --> 00:07:44,120 and transferred onto the belt. 128 00:07:44,120 --> 00:07:45,560 And spun around and placed down? 129 00:07:45,560 --> 00:07:47,480 Yeah, exactly. 130 00:07:47,480 --> 00:07:51,080 I'm just nervous. I'm watching eggs flying through the air, 131 00:07:51,080 --> 00:07:54,560 held up by adapted vacuum cleaners, and it makes me nervous. 132 00:07:54,560 --> 00:07:56,520 Yeah, no, but nothing will happen. 133 00:07:56,520 --> 00:08:00,760 We want eggs only to be cracked when it's necessary, and not before. 134 00:08:03,720 --> 00:08:05,720 Well, that's my eggs sorted. 135 00:08:05,720 --> 00:08:07,600 You can't make mayonnaise without them. 136 00:08:08,960 --> 00:08:12,440 This particular mayo was launched just 18 months ago. 137 00:08:12,440 --> 00:08:16,520 Cherry went to find out how its recipe was developed. 138 00:08:18,800 --> 00:08:20,040 Three years ago, 139 00:08:20,040 --> 00:08:23,120 the consumer scientists at this innovation centre were asked 140 00:08:23,120 --> 00:08:25,520 to come up with a new mayonnaise. 141 00:08:25,520 --> 00:08:27,040 Sounds simple enough? 142 00:08:27,040 --> 00:08:29,000 Well, it turns out, not quite. 143 00:08:31,440 --> 00:08:35,240 Manuel Elgabi is the head of the sensory team here. 144 00:08:35,240 --> 00:08:37,920 Hi, Manuel, nice to meet you, I'm Cherry. Hi, Cherry. 145 00:08:37,920 --> 00:08:42,000 Tasked with developing a mayonnaise everyone in Europe would like. 146 00:08:43,480 --> 00:08:45,360 What was your mission? 147 00:08:45,360 --> 00:08:47,120 It was a big challenge for us 148 00:08:47,120 --> 00:08:50,400 to develop the best mayonnaise recipe for Europe. 149 00:08:50,400 --> 00:08:52,200 That sounds simple enough, 150 00:08:52,200 --> 00:08:54,200 just make a really fantastic mayonnaise. 151 00:08:54,200 --> 00:08:56,800 It's not that simple and I'm going to show you now why. 152 00:08:58,000 --> 00:09:02,400 Manuel checked out the most popular mayonnaise on the market 153 00:09:02,400 --> 00:09:04,720 in each of 11 European countries 154 00:09:04,720 --> 00:09:07,880 and found they were remarkably different. 155 00:09:07,880 --> 00:09:10,200 This is, for example, like mayonnaise from the UK. 156 00:09:10,200 --> 00:09:12,560 So, this one, I imagine, will be very familiar. 157 00:09:13,560 --> 00:09:15,680 Very eggy, a bit salty. 158 00:09:15,680 --> 00:09:17,120 OK, that's quite typical. 159 00:09:19,440 --> 00:09:21,240 Let's taste one from Belgium. 160 00:09:21,240 --> 00:09:22,280 OK. 161 00:09:25,160 --> 00:09:26,400 Is that more vinegary? 162 00:09:26,400 --> 00:09:28,440 Mm-hmm. You got it. Yes! You got it. 163 00:09:29,560 --> 00:09:32,800 Slightly creamier. And what about the colour, for example? 164 00:09:32,800 --> 00:09:36,680 Definitely more yellow, and less lumpy than a UK one. Yeah. 165 00:09:38,800 --> 00:09:41,120 Then you have the French one. 166 00:09:41,120 --> 00:09:44,000 This is very yellow. It is yellow, it's thick, 167 00:09:44,000 --> 00:09:46,040 but also you can pick easily... 168 00:09:46,040 --> 00:09:49,960 Yes, mustard. You got it. Very mustard. You got it. 169 00:09:49,960 --> 00:09:53,800 In Poland, they like an extra thick mayo. 170 00:09:53,800 --> 00:09:55,320 Almost looks like porridge. 171 00:09:55,320 --> 00:09:56,960 Yeah, like porridge. Ach! 172 00:09:56,960 --> 00:09:59,640 While the Germans like it sugary. 173 00:09:59,640 --> 00:10:02,320 Gosh, that's like jam. 174 00:10:02,320 --> 00:10:04,640 It's really sweet. Really, really, really sweet. 175 00:10:05,800 --> 00:10:07,920 I mean, they're so different. 176 00:10:07,920 --> 00:10:09,600 Yeah, as you can see, 177 00:10:09,600 --> 00:10:13,840 differences in colour, texture, taste, from salt, 178 00:10:13,840 --> 00:10:16,320 sweet, sour, mustardy. 179 00:10:18,000 --> 00:10:20,320 Flavour preferences identified, 180 00:10:20,320 --> 00:10:22,400 Manuel's team next looked at 181 00:10:22,400 --> 00:10:25,640 how people in each country used mayonnaise. 182 00:10:25,640 --> 00:10:29,920 Most of us are familiar with the Dutch love of mayo on chips... 183 00:10:29,920 --> 00:10:31,560 Oh! Is there anything better? 184 00:10:31,560 --> 00:10:34,760 ..but the team's development chef, Paul Murphy, 185 00:10:34,760 --> 00:10:38,160 discovered some more unusual uses. 186 00:10:38,160 --> 00:10:41,560 When I think of mayo, I think of chips and sandwiches. 187 00:10:41,560 --> 00:10:44,600 Maybe salad. But how else do people use mayonnaise? 188 00:10:44,600 --> 00:10:47,440 We discovered that mayonnaise is used certainly in southern Europe, 189 00:10:47,440 --> 00:10:50,200 especially Spain, to marinade fish for baking. 190 00:10:50,200 --> 00:10:51,560 What?! Seriously. 191 00:10:51,560 --> 00:10:55,200 That is really odd, to marinade something in mayonnaise. 192 00:10:55,200 --> 00:10:57,720 It's as simple as brushing the fish with mayonnaise, 193 00:10:57,720 --> 00:11:00,960 it's baked in the oven, and that really locks in the flavour and the moisture. 194 00:11:00,960 --> 00:11:02,720 Interesting. Interesting. 195 00:11:04,280 --> 00:11:07,120 Other nationalities used mayo for everything 196 00:11:07,120 --> 00:11:10,440 from dips to couscous salad. 197 00:11:10,440 --> 00:11:14,120 In the UK, it's very popular to have pizza crusts to dip into mayonnaise 198 00:11:14,120 --> 00:11:17,000 and other sauces. I have to say, I absolutely love doing that. 199 00:11:17,000 --> 00:11:18,480 I didn't know that was a thing. Yeah. 200 00:11:18,480 --> 00:11:20,840 I just thought that was something that my household did. 201 00:11:20,840 --> 00:11:22,320 That's something that horrified 202 00:11:22,320 --> 00:11:24,720 some of our colleagues from across Europe. Really?! 203 00:11:28,920 --> 00:11:31,200 So, you've done your research, 204 00:11:31,200 --> 00:11:35,000 you know what kind of flavours the different areas like, 205 00:11:35,000 --> 00:11:37,280 and you know how people eat their mayonnaise. 206 00:11:37,280 --> 00:11:38,760 Right. So, what happens next? 207 00:11:38,760 --> 00:11:41,720 How do you then create the perfect mayonnaise? 208 00:11:41,720 --> 00:11:43,760 You have to listen to consumers. 209 00:11:43,760 --> 00:11:45,680 OK. And this is what we did. 210 00:11:48,360 --> 00:11:51,280 How many people tried and tested your recipes? 211 00:11:51,280 --> 00:11:55,240 In total, during the whole process, more than 5,000 consumers. 212 00:11:55,240 --> 00:11:57,960 So, this has been a huge mission? 213 00:11:57,960 --> 00:11:59,440 You're right. 214 00:11:59,440 --> 00:12:02,360 Manuel tested and rejected 215 00:12:02,360 --> 00:12:07,240 over 70 recipes until a winner was found. 216 00:12:07,240 --> 00:12:12,680 So, this is definitively the European mayonnaise? 217 00:12:12,680 --> 00:12:13,720 OK. 218 00:12:14,840 --> 00:12:16,160 Very balanced. 219 00:12:16,160 --> 00:12:19,800 I can absolutely see why you are so proud of that. 220 00:12:19,800 --> 00:12:24,080 When you develop recipes, it's about what the consumers like. 221 00:12:24,080 --> 00:12:25,480 But, in this case, 222 00:12:25,480 --> 00:12:29,600 consumers loved this recipe and I love it, too. 223 00:12:32,760 --> 00:12:37,800 So, next time you dip a chip, spare a thought for Manuel and his team. 224 00:12:46,400 --> 00:12:48,360 Back at the egg processing factory, 225 00:12:48,360 --> 00:12:52,200 my eggs have, so far, been handled with kid gloves, 226 00:12:52,200 --> 00:12:54,440 but that's about to change. 227 00:12:54,440 --> 00:12:56,840 They need to be cracked open. 228 00:12:56,840 --> 00:12:59,600 Mayonnaise requires only the egg yolk, 229 00:12:59,600 --> 00:13:03,120 so this must be separated from the white. 230 00:13:04,280 --> 00:13:06,680 Jan has a test for me. 231 00:13:06,680 --> 00:13:08,960 OK, Gregg, I have a challenge for you. 232 00:13:08,960 --> 00:13:11,760 How many eggs can you separate in ten seconds? 233 00:13:11,760 --> 00:13:14,000 I think you'd be lucky to do one in ten seconds. 234 00:13:14,000 --> 00:13:15,920 Try it. I will count for you. 235 00:13:15,920 --> 00:13:18,280 You're going to time me? Yeah. 236 00:13:18,280 --> 00:13:21,800 10... Whoa, whoa! Wait for it! Haven't got me hands on it! HE LAUGHS 237 00:13:21,800 --> 00:13:24,200 OK. Go! OK. 10, 238 00:13:24,200 --> 00:13:26,520 9, 8, 239 00:13:26,520 --> 00:13:29,200 7, 6, 240 00:13:29,200 --> 00:13:30,920 5, 4... 241 00:13:30,920 --> 00:13:33,360 Uh-oh, I broke it! 3, 242 00:13:33,360 --> 00:13:34,760 2, 243 00:13:34,760 --> 00:13:35,800 1. 244 00:13:37,080 --> 00:13:38,920 OK, that counts. 245 00:13:38,920 --> 00:13:40,200 That's two. 246 00:13:40,200 --> 00:13:43,480 Shall I show you a machine which can break, in ten seconds, 247 00:13:43,480 --> 00:13:45,360 280 eggs? 248 00:13:45,360 --> 00:13:46,400 No way. 249 00:13:50,320 --> 00:13:53,760 Two hours and 55 minutes after they were collected, 250 00:13:53,760 --> 00:13:57,560 the eggs reach the SANOVO OptiBreaker 12 251 00:13:57,560 --> 00:14:00,080 egg breaking machine. 252 00:14:00,080 --> 00:14:02,240 Its job is simple - crack open the eggs 253 00:14:02,240 --> 00:14:05,480 and separate the yolks from the whites. 254 00:14:05,480 --> 00:14:08,680 And at a rate of nearly 1,700 a minute, 255 00:14:08,680 --> 00:14:11,040 it does this very efficiently. 256 00:14:13,240 --> 00:14:15,520 What on earth is going on? 257 00:14:15,520 --> 00:14:17,040 How is it doing that? 258 00:14:17,040 --> 00:14:19,120 It's got egg yolks on the top, 259 00:14:19,120 --> 00:14:21,560 and it's got a cup of egg whites... 260 00:14:21,560 --> 00:14:24,640 How is it doing that? It's not doing it that much different 261 00:14:24,640 --> 00:14:27,520 than you just did with the bowl. 262 00:14:27,520 --> 00:14:31,360 The eggs come through the machine, a knife will cut the shell, 263 00:14:31,360 --> 00:14:35,200 then the egg breaks, the contents will fall down, and, as you can see, 264 00:14:35,200 --> 00:14:39,000 the yolk will stay in the upper cup and the egg white 265 00:14:39,000 --> 00:14:41,560 will flow nicely to the lower cup. 266 00:14:43,920 --> 00:14:46,760 So, the yolk is in one little plastic hand, 267 00:14:46,760 --> 00:14:51,840 and the egg white is in a little plastic tray underneath? 268 00:14:51,840 --> 00:14:53,920 That's correct. That is amazing! 269 00:14:53,920 --> 00:14:56,800 That may be the best machine I have ever seen. 270 00:14:59,240 --> 00:15:01,480 The shells shoot out of the side, 271 00:15:01,480 --> 00:15:03,880 while the white is siphoned off, 272 00:15:03,880 --> 00:15:06,800 destined for use in things like cakes and meringues. 273 00:15:08,480 --> 00:15:12,240 The yolks I need for my mayonnaise head out along the shoot. 274 00:15:13,600 --> 00:15:17,200 Then they're pumped into a 10,000 litre tank. 275 00:15:19,320 --> 00:15:22,320 Next, Jan and his team add salt. 276 00:15:23,480 --> 00:15:25,760 It's about 20 feet high, full of egg yolks! 277 00:15:25,760 --> 00:15:27,800 Yeah, that's right. And now you add salt? 278 00:15:27,800 --> 00:15:30,160 Now we add the salt. Shall we put the salt in? 279 00:15:31,560 --> 00:15:33,200 Ba-roop ta-rot ta-trot? HE CHUCKLES 280 00:15:34,400 --> 00:15:36,800 All right, OK! All right. 281 00:15:36,800 --> 00:15:38,840 How long is that process now? 282 00:15:38,840 --> 00:15:42,040 The whole thing itself takes about 30 minutes. 283 00:15:42,040 --> 00:15:43,800 Why do you add salt? 284 00:15:43,800 --> 00:15:47,240 Without salt, the shelf life is only two weeks. 285 00:15:47,240 --> 00:15:49,920 With salt, it can be up to three months. 286 00:15:49,920 --> 00:15:53,040 Salt increases the shelf life of egg yolks 287 00:15:53,040 --> 00:15:56,600 from possibly two weeks to possibly three months? 288 00:15:56,600 --> 00:15:57,640 That's right. 289 00:15:59,520 --> 00:16:01,760 Salt is a natural preservative. 290 00:16:01,760 --> 00:16:03,880 It creates a hostile environment 291 00:16:03,880 --> 00:16:08,040 for the organisms that cause food to go off. 292 00:16:08,040 --> 00:16:11,640 It makes up 11% of my egg yolk mix, 293 00:16:11,640 --> 00:16:16,080 which is then pasteurised to kill any remaining bacteria. 294 00:16:16,080 --> 00:16:17,640 What is that? 295 00:16:17,640 --> 00:16:20,680 That's the container where the final product is packed in. 296 00:16:20,680 --> 00:16:25,080 Each container will contain 1,000 kilos of salted product. 297 00:16:25,080 --> 00:16:28,000 1,000 kilos of salted egg yolks? 298 00:16:28,000 --> 00:16:29,720 Yes, that's right. 299 00:16:29,720 --> 00:16:33,240 That's 49,000 yolks. 300 00:16:33,240 --> 00:16:37,720 You'd need a very big toasted soldier to dip into that egg yolk. 301 00:16:39,920 --> 00:16:42,760 Just over six hours after my eggs were collected, 302 00:16:42,760 --> 00:16:46,560 their yolks take a 50 mile journey to the sauce factory. 303 00:16:46,560 --> 00:16:49,400 They'll soon be playing a very important role 304 00:16:49,400 --> 00:16:51,920 in the production of my condiment. 305 00:16:54,040 --> 00:16:56,840 There's enough egg in that container 306 00:16:56,840 --> 00:16:59,600 to make 25,000 jars of mayonnaise. 307 00:17:00,720 --> 00:17:04,680 But that's just a tiny proportion of the amount we get through 308 00:17:04,680 --> 00:17:06,040 every year in the UK. 309 00:17:06,040 --> 00:17:09,280 Ruth's been finding out when we first fell in love with it. 310 00:17:14,440 --> 00:17:18,440 Today, mayonnaise is the sauce that lubricates our lunchtime sandwiches 311 00:17:18,440 --> 00:17:23,120 and salads, as well as our late night fast food. 312 00:17:23,120 --> 00:17:26,400 But how did this white sauce conquer our taste buds? 313 00:17:29,280 --> 00:17:32,840 To find out, I have to rewind to the 1960s, 314 00:17:32,840 --> 00:17:35,080 when American sauce company Hellmann's 315 00:17:35,080 --> 00:17:37,600 launched their jars of mayonnaise in the UK. 316 00:17:40,400 --> 00:17:44,080 To see how it transformed the decade's eating habits, 317 00:17:44,080 --> 00:17:48,240 I'm meeting food anthropologist Kaori O'Connor. 318 00:17:49,520 --> 00:17:53,160 What a spread! It's so colourful! Isn't it gorgeous? 319 00:17:53,160 --> 00:17:57,080 These are salads from the great days when mayonnaise first came 320 00:17:57,080 --> 00:18:00,600 to Britain. So, what was there before mayonnaise, then? 321 00:18:00,600 --> 00:18:02,280 Oh, there was salad cream. 322 00:18:02,280 --> 00:18:05,040 There was this boiled, sour dressing 323 00:18:05,040 --> 00:18:08,880 that you just dribbled over a naked British salad... 324 00:18:08,880 --> 00:18:12,440 I remember that. ..which was just lettuce, tomato and cucumber. 325 00:18:14,440 --> 00:18:18,160 This had been Britain's sauce of choice through wartime rationing, 326 00:18:18,160 --> 00:18:19,960 but this vinegary favourite 327 00:18:19,960 --> 00:18:22,880 was pushed aside by the more exotic newcomer, 328 00:18:22,880 --> 00:18:24,840 which introduced British housewives 329 00:18:24,840 --> 00:18:27,800 to a new world of culinary creativity. 330 00:18:27,800 --> 00:18:29,400 So, what exactly have we got here? 331 00:18:29,400 --> 00:18:31,960 Here is a mayonnaise mould. 332 00:18:31,960 --> 00:18:35,240 Carrot on the top, spinach on the bottom and, in the middle, 333 00:18:35,240 --> 00:18:36,680 you've got mayonnaise. 334 00:18:40,080 --> 00:18:42,200 Another, um, innovation 335 00:18:42,200 --> 00:18:44,600 was Polynesian pineapple with ham. 336 00:18:45,600 --> 00:18:48,320 You've got some tinned peaches in there as well, 337 00:18:48,320 --> 00:18:51,280 tossed together with this wonderful mayonnaise sauce, 338 00:18:51,280 --> 00:18:53,760 and sprinkled over with toasted almonds. 339 00:18:53,760 --> 00:18:55,520 It is, like, irresistible! 340 00:18:55,520 --> 00:18:57,000 Very exotic! 341 00:18:59,000 --> 00:19:02,040 All of these dishes come from popular magazine recipes 342 00:19:02,040 --> 00:19:04,960 of the time, and the piece de resistance 343 00:19:04,960 --> 00:19:08,000 was the spectacular frosted party loaf. 344 00:19:10,520 --> 00:19:11,760 Oh, my goodness! 345 00:19:11,760 --> 00:19:14,440 Isn't that gorgeous? 346 00:19:14,440 --> 00:19:16,240 It's a sandwich cake. 347 00:19:16,240 --> 00:19:19,400 It does look rather cake like, except it's got radishes on it. 348 00:19:19,400 --> 00:19:23,920 It's bread with layers of ham and salmon and tuna. 349 00:19:23,920 --> 00:19:26,400 All sort of smothered in mayonnaise? 350 00:19:26,400 --> 00:19:28,160 Yes! Good gracious! 351 00:19:30,760 --> 00:19:33,800 Mayonnaise, you know, really changed what we eat, like, 352 00:19:33,800 --> 00:19:36,520 you've never seen this before. Never seen this before. 353 00:19:36,520 --> 00:19:38,560 And it also changes the way we eat. 354 00:19:38,560 --> 00:19:41,080 Like, not necessarily in formal courses, 355 00:19:41,080 --> 00:19:44,760 but informally in the garden with this fun food. 356 00:19:44,760 --> 00:19:46,160 OK, let's give it a go. Mm! 357 00:19:47,600 --> 00:19:49,360 Very unusual. Mm. 358 00:19:49,360 --> 00:19:51,280 Very unusual. Unusual's the word! 359 00:19:53,600 --> 00:19:58,080 By the 1970s, mayonnaise had conquered British dinner tables. 360 00:19:58,080 --> 00:20:01,600 And it started to transform eating out, too, 361 00:20:01,600 --> 00:20:05,240 when American style burger joints burst onto the scene. 362 00:20:05,240 --> 00:20:07,440 After all, what's a hamburger and fries 363 00:20:07,440 --> 00:20:09,200 without a good helping of mayo? 364 00:20:11,000 --> 00:20:15,480 The real American burger brought in a whole new way of eating. 365 00:20:15,480 --> 00:20:17,640 You picked it up with your hands, 366 00:20:17,640 --> 00:20:22,400 the mayonnaise ran down your arms and you just enjoyed it! 367 00:20:27,720 --> 00:20:29,160 And, if you could, 368 00:20:29,160 --> 00:20:32,840 you got hold of fries and you dipped them in the mayonnaise as well. 369 00:20:35,360 --> 00:20:38,720 This is a new thing, isn't it, the idea of dipping foods, 370 00:20:38,720 --> 00:20:41,200 sharing it across the table. Oh, dipping, absolutely! 371 00:20:41,200 --> 00:20:44,360 And mayonnaise really lends itself to this sort of eating. 372 00:20:49,160 --> 00:20:53,000 Next, mayonnaise was to revolutionise the working lunch. 373 00:20:54,800 --> 00:20:58,920 In 1981, Marks & Spencer introduced its packet sandwiches, 374 00:20:58,920 --> 00:21:02,920 and the bestseller was prawn mayo. Just as it is today. 375 00:21:04,960 --> 00:21:06,280 Cheers, mate, thank you. 376 00:21:06,280 --> 00:21:09,320 In about 60 years, mayonnaise has done something unique. 377 00:21:09,320 --> 00:21:13,720 It has become the food for every occasion, from dinner parties, 378 00:21:13,720 --> 00:21:17,160 eating out, to a quick sandwich at your desk. 379 00:21:17,160 --> 00:21:21,000 Mind you, I do hope that the frosted party loaf 380 00:21:21,000 --> 00:21:24,280 never, ever comes back into fashion. 381 00:21:35,560 --> 00:21:36,920 Back in the Netherlands, 382 00:21:36,920 --> 00:21:39,000 the egg yolk needed for my mayonnaise 383 00:21:39,000 --> 00:21:41,000 has made the one-hour journey from 384 00:21:41,000 --> 00:21:43,480 the processing plant to the main factory. 385 00:21:45,440 --> 00:21:46,800 At ingredients intake, 386 00:21:46,800 --> 00:21:49,680 receiving delivery of the other main ingredient 387 00:21:49,680 --> 00:21:52,640 is logistics manager Dan Schreiber. 388 00:21:54,000 --> 00:21:55,680 This tanker is full of what? 389 00:21:55,680 --> 00:21:57,560 Rapeseed oil. Rapeseed oil. 390 00:21:57,560 --> 00:22:01,280 How much rapeseed oil? 24.5 tonnes, actually. 391 00:22:01,280 --> 00:22:03,520 Right, OK. So, what do you do? 392 00:22:03,520 --> 00:22:06,280 We need to take a sample, of course, and do some basic measurements, 393 00:22:06,280 --> 00:22:07,920 and then once that's all clear, 394 00:22:07,920 --> 00:22:10,200 we can unload it and hook it up to our tanks. 395 00:22:10,200 --> 00:22:12,000 Can I take the sample? Yes, you can do that. 396 00:22:12,000 --> 00:22:14,320 I can show you. Is it going to come out...? 397 00:22:14,320 --> 00:22:16,760 No, no. Normally, not. Normally, not. 398 00:22:18,520 --> 00:22:20,960 So, basically, you're putting it below that... 399 00:22:20,960 --> 00:22:24,360 Oh, here. Yeah, and then you can lift the lever, the blue one. 400 00:22:25,640 --> 00:22:28,760 68% of my finished mayonnaise will be oil, 401 00:22:28,760 --> 00:22:33,480 so it's important to check the quality is up to scratch... 402 00:22:33,480 --> 00:22:34,920 Perfect. 403 00:22:34,920 --> 00:22:37,600 ..before it's piped into the factory. 404 00:22:37,600 --> 00:22:40,040 Who takes it? You give it to the driver, and he can take it into 405 00:22:40,040 --> 00:22:42,920 our lab. Morning! Morning. Thank you, sir. 406 00:22:44,480 --> 00:22:47,080 Rapeseed oil is ideal for our recipe, 407 00:22:47,080 --> 00:22:51,040 because of its light taste and colour. 408 00:22:51,040 --> 00:22:54,520 Test passed, we're ready to unload. 409 00:22:54,520 --> 00:22:56,480 Right-oh. Ready, Dan? Ready. 410 00:22:56,480 --> 00:23:00,560 We just release the valve and then we put it on. 411 00:23:00,560 --> 00:23:01,840 Whoa! 412 00:23:01,840 --> 00:23:03,560 And then putting it on. 413 00:23:03,560 --> 00:23:04,920 That? To the right. 414 00:23:05,920 --> 00:23:07,160 Perfect, we're on. 415 00:23:08,840 --> 00:23:10,640 It takes an hour and a half 416 00:23:10,640 --> 00:23:13,520 to unload the oil into these huge tanks. 417 00:23:13,520 --> 00:23:16,200 Plenty of time to check the other ingredients are ready. 418 00:23:18,200 --> 00:23:21,640 Well, I recognise this. Yeah? Yeah, these are the egg yolks. 419 00:23:21,640 --> 00:23:23,320 Definitely. Right, OK. 420 00:23:23,320 --> 00:23:25,920 What is that? Mustard. 421 00:23:25,920 --> 00:23:28,120 We use it in mayo kitchen to make our mayonnaise. 422 00:23:28,120 --> 00:23:29,680 Do you know what type of mustard it is? 423 00:23:29,680 --> 00:23:32,080 It's not the same as you would put on your potatoes at home. 424 00:23:32,080 --> 00:23:34,080 It's a little lower oil content, 425 00:23:34,080 --> 00:23:36,440 so the sharpness is a little bit gone, 426 00:23:36,440 --> 00:23:39,520 but it's perfect for using in our mayonnaise. 427 00:23:39,520 --> 00:23:41,880 Oh, right. We've got egg yolks... 428 00:23:41,880 --> 00:23:44,120 Yes. Mustard. Mustard. 429 00:23:44,120 --> 00:23:45,520 Oil from the tanker. 430 00:23:45,520 --> 00:23:48,000 Yes. We're done. Let's get it to the kitchen and we... 431 00:23:48,000 --> 00:23:51,120 Kitchen? You call it a kitchen? Yeah. 432 00:23:51,120 --> 00:23:52,840 My ingredients are collected... 433 00:23:55,800 --> 00:23:59,360 ..and taken to the kitchen by a team of forklift drivers. 434 00:24:03,080 --> 00:24:05,240 If you asked me to make mayonnaise at home, 435 00:24:05,240 --> 00:24:08,600 I'd pretty much use the same ingredients as they do here, 436 00:24:08,600 --> 00:24:11,560 but I don't mind admitting, what goes into another 437 00:24:11,560 --> 00:24:14,360 of our favourite sauces is a bit more mysterious. 438 00:24:21,880 --> 00:24:25,880 If, like me, you can't let a week go by without some sushi, 439 00:24:25,880 --> 00:24:31,040 you might be wondering how this little sachet of soy sauce is made, 440 00:24:31,040 --> 00:24:35,480 and where. Well, I've travelled miles and miles 441 00:24:35,480 --> 00:24:37,320 to find the answer. 442 00:24:37,320 --> 00:24:40,480 Today, I'm in Wales. 443 00:24:42,600 --> 00:24:44,720 Abertillery, in the Welsh Valleys, 444 00:24:44,720 --> 00:24:47,520 is home to Shoda Sauces' European factory. 445 00:24:50,040 --> 00:24:52,880 Leanne Ford is the technical manager. 446 00:24:52,880 --> 00:24:56,200 She's introducing me to the secrets of soy's 447 00:24:56,200 --> 00:24:58,920 2,000-year-old Japanese recipe. 448 00:24:58,920 --> 00:25:01,160 Hi, Leanne! Hi, nice to meet you. 449 00:25:01,160 --> 00:25:02,400 Lovely to meet you. 450 00:25:02,400 --> 00:25:07,040 So, first things first, what is soy sauce made of? 451 00:25:07,040 --> 00:25:10,480 OK, so, soy sauce is made of soy beans, 452 00:25:10,480 --> 00:25:12,600 wheat, water and salt. 453 00:25:12,600 --> 00:25:14,760 We'll soak the beans in water, 454 00:25:14,760 --> 00:25:17,720 then we will take the beans and cool them. 455 00:25:20,720 --> 00:25:23,680 Wahey! Whoa! That is one big tin of beans. 456 00:25:25,680 --> 00:25:27,880 So, these are soy beans... Yes. 457 00:25:27,880 --> 00:25:33,120 ..and they have been soaked and cooked and cooled? Yes. 458 00:25:33,120 --> 00:25:37,560 Soy sauce is made from soy beans - the clue's in the name. 459 00:25:37,560 --> 00:25:41,720 But the next ingredient is much more surprising. 460 00:25:41,720 --> 00:25:43,880 Mould. 461 00:25:43,880 --> 00:25:45,640 This koji, mould, 462 00:25:45,640 --> 00:25:49,800 it's called koji, is absolutely essential for soy sauce brewing. 463 00:25:49,800 --> 00:25:52,120 Why do you use this one? 464 00:25:52,120 --> 00:25:54,200 It gives the distinct flavour, 465 00:25:54,200 --> 00:25:58,200 it gives the characteristics of soy sauce and it is Japanese. 466 00:25:58,200 --> 00:26:00,560 Is this where the magic happens? Yes. 467 00:26:02,000 --> 00:26:07,040 The mould powder is poured into one tonne of organic wheat. 468 00:26:07,040 --> 00:26:10,000 This is hoisted up and added into the tank 469 00:26:10,000 --> 00:26:13,800 of cooked soy beans, where it's all mixed up together. 470 00:26:18,520 --> 00:26:22,040 From the mixer, it's piped into what looks like 471 00:26:22,040 --> 00:26:24,600 a silver space capsule. 472 00:26:24,600 --> 00:26:28,320 Wow. OK, so this is the koji machine, as we call it. 473 00:26:30,040 --> 00:26:33,640 Wow! What goes on inside here? 474 00:26:33,640 --> 00:26:36,200 OK, so the floor rotates as we fill it. 475 00:26:36,200 --> 00:26:39,680 And then in here gets turned, and we control the temperature and humidity 476 00:26:39,680 --> 00:26:41,440 so that the mould can start working. 477 00:26:44,840 --> 00:26:48,520 This hot tank provides the perfect conditions 478 00:26:48,520 --> 00:26:50,520 for the koji to grow. 479 00:26:50,520 --> 00:26:53,200 Moulds can make foods inedible, 480 00:26:53,200 --> 00:26:57,720 but here it's performing an astonishing chemical transformation. 481 00:26:59,160 --> 00:27:03,360 Over 48 hours, it breaks down the wheat and beans, 482 00:27:03,360 --> 00:27:05,480 releasing starch and sugars. 483 00:27:07,440 --> 00:27:11,880 Salt and soft Welsh water are added to the mix. 484 00:27:11,880 --> 00:27:14,560 And it's pumped into 12 tanks 485 00:27:14,560 --> 00:27:17,400 that each hold 14,000 litres. 486 00:27:18,360 --> 00:27:20,280 But it's far from ready. 487 00:27:20,280 --> 00:27:22,440 Yeast is added to kick-start 488 00:27:22,440 --> 00:27:25,800 what will be a six-month fermentation process. 489 00:27:25,800 --> 00:27:27,800 So, this is one of the newest. 490 00:27:27,800 --> 00:27:31,000 So, this in here, the fermentation process has started. 491 00:27:31,000 --> 00:27:33,720 It's at the very beginning here, so it's only been in there 492 00:27:33,720 --> 00:27:35,800 about a month, so it's got five months to go. 493 00:27:35,800 --> 00:27:38,200 It's here that the distinctive colour, 494 00:27:38,200 --> 00:27:41,240 flavour and aroma of soy sauce develop. 495 00:27:42,400 --> 00:27:44,320 Wow! SHE GASPS 496 00:27:45,800 --> 00:27:47,600 I mean, I... 497 00:27:47,600 --> 00:27:49,160 I can taste it. 498 00:27:49,160 --> 00:27:51,640 I mean, it's incredibly strong! Yeah. 499 00:27:53,040 --> 00:27:57,000 It's like having a mouthful of something. Yes. 500 00:27:57,000 --> 00:27:59,720 So salty! Yeah. 501 00:28:01,280 --> 00:28:03,520 After half a year of fermentation, 502 00:28:03,520 --> 00:28:05,920 the mixture is sent to the press. 503 00:28:05,920 --> 00:28:08,120 Whoa-ho-ho! 504 00:28:08,120 --> 00:28:10,720 Wow, that is a vision. 505 00:28:10,720 --> 00:28:12,240 So... 506 00:28:12,240 --> 00:28:14,000 Oh, my goodness me! 507 00:28:14,000 --> 00:28:15,800 So, there it is. 508 00:28:15,800 --> 00:28:18,360 It doesn't look...wonderful. SHE CHUCKLES 509 00:28:18,360 --> 00:28:19,880 No, it doesn't, no. 510 00:28:19,880 --> 00:28:21,880 But it smells incredible. 511 00:28:23,400 --> 00:28:25,760 There's still one final process. 512 00:28:26,800 --> 00:28:28,080 So, here we go. 513 00:28:31,320 --> 00:28:32,840 Oh! It makes a great noise. 514 00:28:34,720 --> 00:28:39,080 140 layers are stacked up on top of each other. 515 00:28:39,080 --> 00:28:41,360 This labour-intensive technique 516 00:28:41,360 --> 00:28:44,200 ensures that the maximum quantity of sauce 517 00:28:44,200 --> 00:28:46,200 can be extracted from the mix. 518 00:28:46,200 --> 00:28:47,720 Oh! A bit more on the top. 519 00:28:47,720 --> 00:28:51,200 This is one of the most satisfying things I've ever done. 520 00:28:51,200 --> 00:28:52,360 There we go. 521 00:28:55,640 --> 00:28:57,280 80 tonnes of pressure 522 00:28:57,280 --> 00:29:01,320 forces the liquid out of the mixture. 523 00:29:01,320 --> 00:29:05,440 Then it's pasteurised and bottled. 524 00:29:05,440 --> 00:29:07,440 Or put into sachets. 525 00:29:09,840 --> 00:29:12,880 So, next time you tear open your sachet of soy sauce 526 00:29:12,880 --> 00:29:17,400 and you enjoy that 2000-year-old traditional recipe, 527 00:29:17,400 --> 00:29:21,240 spare a thought for the distance that it's travelled - 528 00:29:21,240 --> 00:29:23,680 all the way from the Welsh Valleys. 529 00:29:31,400 --> 00:29:33,920 Ten hours after my eggs were collected, 530 00:29:33,920 --> 00:29:36,600 everything I need to make my mayonnaise is in place. 531 00:29:38,880 --> 00:29:42,760 My ingredients have travelled from the intake area to the mixing room, 532 00:29:42,760 --> 00:29:44,440 known as the kitchen. 533 00:29:46,440 --> 00:29:48,840 I'm meeting Danielle. 534 00:29:48,840 --> 00:29:52,920 Danielle? Hey! Gregg. Hi, Danielle. Nice to meet you. 535 00:29:52,920 --> 00:29:56,400 You, apparently, are the mayonnaise expert. 536 00:29:56,400 --> 00:29:58,040 I hope I can prove you right. 537 00:29:58,040 --> 00:30:02,760 Now, look, I've seen the egg yolks, the oil and the mustard. 538 00:30:02,760 --> 00:30:04,680 How do you make mayonnaise here? 539 00:30:04,680 --> 00:30:08,840 Well, we add water, we add salt, we add a bit of sugar, 540 00:30:08,840 --> 00:30:11,840 we add a bit of mustard and some secret spices. 541 00:30:11,840 --> 00:30:13,920 Secret spices? Yeah. 542 00:30:13,920 --> 00:30:16,200 Every company has its secret, doesn't it? 543 00:30:16,200 --> 00:30:19,560 Every company has its own secret spices. Yeah, exactly. 544 00:30:19,560 --> 00:30:22,560 But at home, it's only egg, 545 00:30:22,560 --> 00:30:25,080 mustard and oil - no water. 546 00:30:25,080 --> 00:30:27,520 A bit of water. Never. 547 00:30:27,520 --> 00:30:30,080 You use water at home? Yeah, a little bit. Oh, OK. 548 00:30:30,080 --> 00:30:33,360 Yeah. All right. When we make mayonnaise, we always start with, 549 00:30:33,360 --> 00:30:35,640 what we call, a water phase. 550 00:30:35,640 --> 00:30:40,360 With the press of a button, 1,500 litres of water 551 00:30:40,360 --> 00:30:44,200 mixed with salt is pumped into a mixing tank, 552 00:30:44,200 --> 00:30:47,160 along with sugar and vinegar. 553 00:30:47,160 --> 00:30:49,920 What I will now do is add the spices. 554 00:30:49,920 --> 00:30:52,760 Oh, it's here. Yeah. Let me smell, let me smell. 555 00:30:55,440 --> 00:30:58,200 What do you think? I think you've got more salt. 556 00:31:00,840 --> 00:31:02,640 I'm not going to spoil the secret. 557 00:31:02,640 --> 00:31:05,240 And something that smells a little bit citrus-y. 558 00:31:05,240 --> 00:31:09,000 Yeah, could be. So, do you want to do the honours and add it? 559 00:31:09,000 --> 00:31:12,320 I'll do it. Yeah? There you go. Gradually? Doesn't matter, right? 560 00:31:12,320 --> 00:31:13,720 No! 561 00:31:13,720 --> 00:31:17,360 The secret spices give the mayonnaise the specific flavour 562 00:31:17,360 --> 00:31:20,720 profile that was so carefully developed by Manuel 563 00:31:20,720 --> 00:31:22,120 in the research lab. 564 00:31:22,120 --> 00:31:25,240 We have to add some mustard as well. For the spices. 565 00:31:25,240 --> 00:31:27,040 That's a big pot of mustard! 566 00:31:27,040 --> 00:31:28,920 It is. Are you ready? 567 00:31:34,320 --> 00:31:36,960 We'll confirm on the display that 568 00:31:36,960 --> 00:31:39,600 it's ready, that we added the mustard. 569 00:31:39,600 --> 00:31:40,640 Just push the button. 570 00:31:43,160 --> 00:31:45,840 And now look at the tank, it's cooling. 571 00:31:45,840 --> 00:31:48,080 Is that going to come over the top? 572 00:31:48,080 --> 00:31:50,440 This watery mixture is heated up. 573 00:31:52,200 --> 00:31:56,080 The next stage involves an ingredient - starch - 574 00:31:56,080 --> 00:31:58,960 that I never use at home when I'm making mayonnaise. 575 00:31:59,960 --> 00:32:03,080 Normally, when you make mayonnaise at home, you keep it for a day 576 00:32:03,080 --> 00:32:05,480 or two days, but because we make it industrial, 577 00:32:05,480 --> 00:32:08,280 we have to keep it at a nice viscosity for a longer time, 578 00:32:08,280 --> 00:32:10,560 and that is why we need some help from starches. 579 00:32:10,560 --> 00:32:13,840 Without starch, with age, the mayonnaise would get thinner. Yeah. 580 00:32:13,840 --> 00:32:17,120 It will get thinner, and it's strange when you open a mayonnaise 581 00:32:17,120 --> 00:32:20,080 and it looks like yoghurt. Yeah, I got you. 582 00:32:20,080 --> 00:32:23,520 Starch is added to a small amount of the rapeseed oil 583 00:32:23,520 --> 00:32:25,600 I helped unload earlier. 584 00:32:25,600 --> 00:32:28,040 Can you handle it? I was a greengrocer. 585 00:32:36,360 --> 00:32:37,920 All done? Yeah, all done. 586 00:32:37,920 --> 00:32:40,240 How long will it take? It will take about five minutes. 587 00:32:40,240 --> 00:32:41,720 Then we're going to mix. 588 00:32:41,720 --> 00:32:44,520 Finally! That's how we do it. 589 00:32:46,840 --> 00:32:49,360 Well, I'm well on the way to making my mayonnaise. 590 00:32:49,360 --> 00:32:51,480 But choosing a successful sauce 591 00:32:51,480 --> 00:32:53,960 isn't just about what you put into it, 592 00:32:53,960 --> 00:32:56,840 but how you market it, as Ruth discovers. 593 00:33:01,720 --> 00:33:04,480 Worcester sauce is a favourite addition to food, 594 00:33:04,480 --> 00:33:07,760 snacks and drinks the world over. 595 00:33:07,760 --> 00:33:11,520 It's a potent mix of fermented anchovies, onions, 596 00:33:11,520 --> 00:33:14,200 garlic and a blend of spices. 597 00:33:14,200 --> 00:33:17,000 The story goes that it was invented 598 00:33:17,000 --> 00:33:19,960 by two chemists developing a recipe 599 00:33:19,960 --> 00:33:25,520 that has come all the way from Bengal in 1837. 600 00:33:25,520 --> 00:33:28,640 Oh, thank you. Thanks. 601 00:33:28,640 --> 00:33:30,720 The first concoction was not to their liking, 602 00:33:30,720 --> 00:33:34,120 so they shoved it in the cellar and forgot about it. 603 00:33:34,120 --> 00:33:36,280 And then 18 months later, 604 00:33:37,520 --> 00:33:38,920 they got it out and tried it again. 605 00:33:40,080 --> 00:33:42,080 And somehow it had become delicious. 606 00:33:44,760 --> 00:33:46,560 And the chemists' names? 607 00:33:46,560 --> 00:33:48,840 John Lea and William Perrins. 608 00:33:50,160 --> 00:33:52,000 Today, the names Lea and Perrins 609 00:33:52,000 --> 00:33:54,560 are synonymous with Worcestershire sauce. 610 00:33:56,080 --> 00:33:59,000 The company factory is still based in Worcester, 611 00:33:59,000 --> 00:34:02,440 and, for over a century, the bottles have been marketed 612 00:34:02,440 --> 00:34:05,400 as the original Worcestershire sauce. 613 00:34:06,480 --> 00:34:08,600 But food historian Glyn Hughes... 614 00:34:08,600 --> 00:34:09,680 Well, hello, Ruth. 615 00:34:09,680 --> 00:34:13,200 ..thinks the traditional long-standing story of its invention 616 00:34:13,200 --> 00:34:15,880 sounds a bit fishy. 617 00:34:15,880 --> 00:34:18,320 At Worcester Archives, he's unearthed a recipe 618 00:34:18,320 --> 00:34:21,560 for something that sounds very like Worcestershire sauce, 619 00:34:21,560 --> 00:34:26,040 in a cookery book published as early as 1723. 620 00:34:27,160 --> 00:34:29,560 Have a look at this. The recipe for lampreys, 621 00:34:29,560 --> 00:34:32,160 which were the famous fish caught at Worcester. 622 00:34:32,160 --> 00:34:34,920 OK. And the special sauce to go with lampreys, 623 00:34:34,920 --> 00:34:36,920 which is made mainly from vinegar 624 00:34:36,920 --> 00:34:40,000 and spices and anchovies. 625 00:34:40,000 --> 00:34:44,160 The same basic ingredients that go into Worcester sauce. 626 00:34:44,160 --> 00:34:47,040 Way back in 1720s. 627 00:34:48,920 --> 00:34:52,600 And Glyn has more evidence that questions our chemists' story 628 00:34:52,600 --> 00:34:55,480 of its invention in 1837. 629 00:34:55,480 --> 00:34:58,680 The first record we can find of ready-made Worcester sauce 630 00:34:58,680 --> 00:35:00,960 is from 1830. 631 00:35:00,960 --> 00:35:03,360 This is an advertisement in the Salopian Journal. 632 00:35:03,360 --> 00:35:05,480 And that's an interesting date, 1830. 633 00:35:05,480 --> 00:35:08,760 That's seven years before the supposed invention. 634 00:35:08,760 --> 00:35:10,160 Well, yeah. 635 00:35:10,160 --> 00:35:14,120 So, this idea that they had to discover the fermentation - 636 00:35:14,120 --> 00:35:15,720 people had been doing it for years. 637 00:35:15,720 --> 00:35:17,600 And there's already a product on the market. 638 00:35:17,600 --> 00:35:19,040 Who's the company involved here? 639 00:35:19,040 --> 00:35:22,200 So, we've got... Oh, yes, Twinberrow and Evans, 640 00:35:22,200 --> 00:35:25,480 chemists, Broad Street in Worcester. 641 00:35:27,720 --> 00:35:29,960 So, it can't be far off here. 642 00:35:31,440 --> 00:35:35,480 The exact address is listed in a trade directory from 1835 643 00:35:35,480 --> 00:35:38,600 as No 53 Broad St. 644 00:35:38,600 --> 00:35:40,840 So, this is it, then, 53. 645 00:35:42,560 --> 00:35:45,560 So, could this place claim to be the birthplace 646 00:35:45,560 --> 00:35:47,920 of bottled Worcester sauce? As far as we can tell, yes, 647 00:35:47,920 --> 00:35:50,960 Twinberrow and Evans are certainly the first company who ever 648 00:35:50,960 --> 00:35:53,640 advertised bottled Worcester sauce. 649 00:35:53,640 --> 00:35:57,760 Interestingly, the trade directory lists rival chemists John Lea 650 00:35:57,760 --> 00:36:01,000 and William Perrins as being just down the road 651 00:36:01,000 --> 00:36:02,880 at No 68 Broad St. 652 00:36:03,880 --> 00:36:06,600 They are very close to each other, aren't they? I mean... 653 00:36:06,600 --> 00:36:09,160 Only just down there... It's hard to think that they 654 00:36:09,160 --> 00:36:13,400 wouldn't have known about each other's projects. Impossible, wasn't it? 655 00:36:13,400 --> 00:36:18,560 Mid-19th century chemists didn't just dispense medicines - 656 00:36:18,560 --> 00:36:21,920 they also made and sold all kinds of other products, 657 00:36:21,920 --> 00:36:24,720 from soap to condiments. 658 00:36:24,720 --> 00:36:28,320 And I suppose we have no idea what exact recipe 659 00:36:28,320 --> 00:36:31,480 Twinberrow and Evans were actually making. 660 00:36:31,480 --> 00:36:35,160 I suppose we can be confident that every chemist had their own recipe 661 00:36:35,160 --> 00:36:36,720 for everything they made. 662 00:36:36,720 --> 00:36:39,880 So, whether there was much similarity, or whether they 663 00:36:39,880 --> 00:36:42,080 were completely different 664 00:36:42,080 --> 00:36:44,960 between No 53 and No 68, 665 00:36:44,960 --> 00:36:46,360 we just don't know. 666 00:36:47,760 --> 00:36:50,800 Ultimately, the battle of the Worcester sauces would be won by 667 00:36:50,800 --> 00:36:53,680 the chemists at No 68. 668 00:36:53,680 --> 00:36:56,240 They turned it into an international brand. 669 00:36:56,240 --> 00:36:58,000 They were geniuses at marketing. 670 00:36:58,000 --> 00:37:01,000 They had bottles of Lea and Perrins put on the tables on cruise ships. 671 00:37:01,000 --> 00:37:02,320 That's clever! 672 00:37:02,320 --> 00:37:06,000 In, I think, 1842, they went from something like, in one year, 673 00:37:06,000 --> 00:37:08,880 600-odd bottles to 14,000, 674 00:37:08,880 --> 00:37:11,280 in a period of 12 months. Wow. 675 00:37:11,280 --> 00:37:14,400 The old story of its origins may be something of a fiction, 676 00:37:14,400 --> 00:37:18,440 but the power of marketing has made this the world's bestselling 677 00:37:18,440 --> 00:37:19,840 Worcestershire sauce brand. 678 00:37:22,040 --> 00:37:25,480 Twinberrow and Evans had neither the ambition, 679 00:37:25,480 --> 00:37:28,680 nor were they as canny as Mr Lea and Mr Perrins, 680 00:37:28,680 --> 00:37:30,680 so the lesson here is clear, 681 00:37:30,680 --> 00:37:35,000 if you want your sauce to become the stuff of legends, 682 00:37:36,080 --> 00:37:37,720 then you need to think big. 683 00:37:45,120 --> 00:37:50,240 Over 340 miles from Worcester, I'm in the mayonnaise kitchen. 684 00:37:50,240 --> 00:37:54,040 I've prepared my water mix and my starch mix, 685 00:37:54,040 --> 00:37:58,000 and ten hours and 15 minutes since my eggs were collected, 686 00:37:58,000 --> 00:38:00,240 their big moment has finally arrived. 687 00:38:01,560 --> 00:38:03,560 This is the egg. This is my eggs. 688 00:38:03,560 --> 00:38:05,880 Do you recognise it? Absolutely. 689 00:38:05,880 --> 00:38:08,720 Are we ready now to add some ingredients to the eggs? 690 00:38:08,720 --> 00:38:11,840 Yeah, we are. We are really ready to make the mayonnaise now. 691 00:38:11,840 --> 00:38:14,040 And this is where we're going to mix it. 692 00:38:15,640 --> 00:38:18,800 So, Gregg, in this tank, we started our process. 693 00:38:18,800 --> 00:38:21,160 We add some water mix, some starches 694 00:38:21,160 --> 00:38:23,160 and then start adding the oil. 695 00:38:23,160 --> 00:38:24,600 It all happens in here. 696 00:38:24,600 --> 00:38:27,040 We have a little window if you want to have a look. 697 00:38:28,280 --> 00:38:29,720 That is really cool. 698 00:38:29,720 --> 00:38:33,440 It is, isn't it? You've got a little porthole with a light. 699 00:38:33,440 --> 00:38:35,840 Exactly, you can actually follow the process. 700 00:38:37,000 --> 00:38:40,240 This jumbo mixer will make enough mayonnaise 701 00:38:40,240 --> 00:38:43,440 for 735 jars. 702 00:38:43,440 --> 00:38:45,320 And with two yolks in each jar, 703 00:38:45,320 --> 00:38:49,080 I'm looking at nearly 1,500 of them whizzing around in here. 704 00:38:51,040 --> 00:38:52,080 It's quite wet. 705 00:38:54,360 --> 00:38:56,480 It doesn't look much like mayonnaise yet. 706 00:38:57,560 --> 00:38:59,560 I have a small experiment for you. 707 00:38:59,560 --> 00:39:01,200 Is it safe? 708 00:39:01,200 --> 00:39:04,640 Danielle's got a simple way it to replicate the process 709 00:39:04,640 --> 00:39:06,720 going on inside the mixer. 710 00:39:08,240 --> 00:39:10,120 So, here I have the ingredients for you. 711 00:39:10,120 --> 00:39:12,400 Let's see if we can make a mayonnaise out of it. 712 00:39:12,400 --> 00:39:13,760 By hand. 713 00:39:13,760 --> 00:39:16,840 Well, at home, I would start with the eggs. 714 00:39:19,160 --> 00:39:20,760 Are you going to pour? 715 00:39:20,760 --> 00:39:24,560 To my egg yolk, I had the water mix containing the salt, 716 00:39:24,560 --> 00:39:26,960 mustard and spices. 717 00:39:26,960 --> 00:39:29,480 I'm guessing now I add some starch? 718 00:39:29,480 --> 00:39:30,640 Good guess. 719 00:39:30,640 --> 00:39:32,760 In goes my starch mix. 720 00:39:32,760 --> 00:39:34,600 Just pour it in and keep on mixing. 721 00:39:36,320 --> 00:39:38,320 Now we have to add the oil bit by bit. 722 00:39:38,320 --> 00:39:39,920 Yeah. We have to do it slowly. 723 00:39:41,120 --> 00:39:43,920 Oil and water can only be combined 724 00:39:43,920 --> 00:39:47,040 using a process called emulsification. 725 00:39:47,040 --> 00:39:52,120 As the oil is added, whisking breaks it into tiny droplets. 726 00:39:52,120 --> 00:39:55,240 This distributes it evenly through the mix. 727 00:39:55,240 --> 00:39:57,600 The egg yolk stops it from separating 728 00:39:57,600 --> 00:39:59,560 and thickens the mayonnaise. 729 00:40:00,520 --> 00:40:02,400 Do you want to try a different method? 730 00:40:03,760 --> 00:40:06,400 Look over there. You're kidding me. Yeah. 731 00:40:13,240 --> 00:40:15,480 The final ingredient is vinegar, 732 00:40:15,480 --> 00:40:18,520 added to bring out the acidity in the flavour. 733 00:40:18,520 --> 00:40:20,320 It's getting there. Yeah. 734 00:40:20,320 --> 00:40:21,760 It's quite tricky. 735 00:40:21,760 --> 00:40:25,000 If I stop whisking, or add to much oil at once, 736 00:40:25,000 --> 00:40:29,160 the emulsification won't work and the sauce will split, 737 00:40:29,160 --> 00:40:32,080 creating an unpleasant, lumpy texture. 738 00:40:35,440 --> 00:40:37,760 Can I see how the proper big batch is getting on? 739 00:40:37,760 --> 00:40:39,760 Yeah, let's see how we do it here. 740 00:40:41,480 --> 00:40:45,720 This clever mixer performs the emulsification process 741 00:40:45,720 --> 00:40:47,960 perfectly, every time. 742 00:40:47,960 --> 00:40:53,080 It's mixing this 480-kilo batch very effectively. 743 00:40:53,080 --> 00:40:56,480 It's thickening up in here quicker than we did it over there. 744 00:40:56,480 --> 00:40:57,680 With less work. 745 00:40:58,680 --> 00:41:02,200 Any emulsification in a kitchen is a delicate business, 746 00:41:02,200 --> 00:41:04,800 but this is doing it on a massive scale. 747 00:41:06,680 --> 00:41:07,960 You've got mayonnaise! 748 00:41:09,320 --> 00:41:11,960 All we need now is a big row of fish fingers 749 00:41:11,960 --> 00:41:13,560 and two loaves of bread. 750 00:41:17,520 --> 00:41:19,320 Less than ten and a half hours 751 00:41:19,320 --> 00:41:21,240 after my eggs were collected, 752 00:41:21,240 --> 00:41:22,880 I've got mayonnaise. 753 00:41:24,240 --> 00:41:26,760 Next, I need something to put it in. 754 00:41:28,000 --> 00:41:30,080 Cherry is sorting that out for me. 755 00:41:31,880 --> 00:41:36,200 The glass jar, so familiar, so widely used, 756 00:41:36,200 --> 00:41:38,800 we barely give it a second glance. 757 00:41:38,800 --> 00:41:40,280 But how was it made? 758 00:41:42,760 --> 00:41:46,480 The jars for Gregg's mayonnaise begin at this factory in Maastricht 759 00:41:46,480 --> 00:41:48,760 in the Netherlands. 760 00:41:48,760 --> 00:41:52,240 I'm meeting factory manager Ralph Klaassens... 761 00:41:52,240 --> 00:41:53,600 Hi, Cherry. Nice to meet you. 762 00:41:53,600 --> 00:41:56,080 ..who's showing me the glass-making process. 763 00:41:58,240 --> 00:42:02,440 The only thing I know about glass is it starts with sand. 764 00:42:02,440 --> 00:42:06,280 Yes, and we use about 2,100 tonnes of sand per week. 765 00:42:07,920 --> 00:42:10,680 The sand comes from a nearby quarry, 766 00:42:10,680 --> 00:42:12,760 and has a low iron content... 767 00:42:12,760 --> 00:42:14,560 Wow, there it goes. 768 00:42:14,560 --> 00:42:19,160 ..to ensure the finished glass will be totally colourless. 769 00:42:19,160 --> 00:42:23,000 The jar's other main ingredient is glass itself. 770 00:42:25,880 --> 00:42:28,720 That is quite a huge pile of recycled glass. 771 00:42:28,720 --> 00:42:32,200 What is the percentage of recycled glass to sand? 772 00:42:32,200 --> 00:42:36,760 56% recycled glass and 35% of sand. 773 00:42:36,760 --> 00:42:40,400 So, it is a huge amount of recycled glass. Yes. 774 00:42:40,400 --> 00:42:44,320 The final 9% is soda ash, made from salt. 775 00:42:45,280 --> 00:42:48,840 This lowers the melting point of the glass and sand, 776 00:42:48,840 --> 00:42:53,760 reducing the amount of energy needed for the production process. 777 00:42:53,760 --> 00:42:58,680 These ingredients are sent inside to the giant furnace. 778 00:43:00,080 --> 00:43:01,120 Oh, my God. 779 00:43:14,680 --> 00:43:18,240 In here, the raw materials are combined. 780 00:43:18,240 --> 00:43:23,000 After 24 hours at 1,400 Celsius, 781 00:43:23,000 --> 00:43:25,280 they melt together 782 00:43:25,280 --> 00:43:28,560 and turn into molten glass, 783 00:43:28,560 --> 00:43:30,600 250 tonnes of it. 784 00:43:52,920 --> 00:43:57,680 Next, the molten glass is squeezed out of the furnace, 785 00:43:57,680 --> 00:44:02,280 in gobs at a scorching 1,100 degrees. 786 00:44:02,280 --> 00:44:04,640 Each one weighs 300g. 787 00:44:15,880 --> 00:44:19,400 They drop down at nearly 20 miles an hour. 788 00:44:30,640 --> 00:44:35,560 It's one of the most mesmerising processes I've ever seen. 789 00:44:37,120 --> 00:44:40,080 The glass fills the mould. 790 00:44:40,080 --> 00:44:42,400 They flip over, 791 00:44:42,400 --> 00:44:45,440 through 180 degrees, 792 00:44:45,440 --> 00:44:49,240 then air is forced in at high pressure, 793 00:44:49,240 --> 00:44:53,200 producing a jar in under six seconds. 794 00:44:55,160 --> 00:44:58,040 The bottom is still burning bright orange. 795 00:44:58,040 --> 00:44:59,920 Exactly. Does it then get cooled? 796 00:44:59,920 --> 00:45:02,240 Yes, we have cooling under the conveyor belt 797 00:45:02,240 --> 00:45:03,560 so the bottom is cooled. 798 00:45:03,560 --> 00:45:06,120 It's like something out of a science fiction film. 799 00:45:11,960 --> 00:45:14,320 How many jars do you make? 800 00:45:14,320 --> 00:45:17,640 We are producing about 260,000 jars a day. 801 00:45:17,640 --> 00:45:19,520 Does this jar get used only for mayonnaise 802 00:45:19,520 --> 00:45:23,680 or is it lots of different things? No, it's only for mayonnaise. 803 00:45:23,680 --> 00:45:26,400 To me, they look shiny and unblemished, 804 00:45:26,400 --> 00:45:28,680 but they're not finished yet. 805 00:45:35,880 --> 00:45:38,240 A protective coating is applied. 806 00:45:52,160 --> 00:45:56,600 It's extraordinary to think that something so pure, 807 00:45:56,600 --> 00:45:58,440 clear and fragile 808 00:45:58,440 --> 00:46:01,760 is a result of such a huge industrial process. 809 00:46:03,040 --> 00:46:05,160 Gregg, I hope you appreciate this jar. 810 00:46:14,720 --> 00:46:17,320 In the factory's filling area, 811 00:46:17,320 --> 00:46:20,760 the jars have arrived and are ready for action. 812 00:46:20,760 --> 00:46:24,440 Hans Hendriksen is the man in charge of this whole site. 813 00:46:25,440 --> 00:46:29,600 OK! Well, my friend Cherry had a hand in doing these. 814 00:46:29,600 --> 00:46:30,840 I heard so, yes. 815 00:46:30,840 --> 00:46:33,040 In a world of plastic squeezy, 816 00:46:33,040 --> 00:46:35,440 why are you sticking with glass? 817 00:46:35,440 --> 00:46:39,600 Actually, the glass is really our premium package. 818 00:46:41,440 --> 00:46:44,800 Consumers like the traditional look and feel of glass, 819 00:46:44,800 --> 00:46:47,360 which is why 45% of the mayonnaise 820 00:46:47,360 --> 00:46:49,520 produced in the factory 821 00:46:49,520 --> 00:46:51,000 ends up in jars. 822 00:46:53,280 --> 00:46:57,440 But, like the eggs I started with, they need careful handling. 823 00:47:00,120 --> 00:47:02,960 And this machine is pushing all of them off? 824 00:47:02,960 --> 00:47:05,120 Pushing on the whole layer in one. 825 00:47:07,520 --> 00:47:09,720 If you look at it now, you can see right now 826 00:47:09,720 --> 00:47:12,120 the whole layer is being pushed on. 827 00:47:13,400 --> 00:47:17,880 I'm amazed you haven't got jars smashing. 828 00:47:17,880 --> 00:47:19,920 I can tell you that it is very intricate. 829 00:47:19,920 --> 00:47:23,880 The pressure that you need to push it off gently, 830 00:47:23,880 --> 00:47:25,440 it's a trick. 831 00:47:25,440 --> 00:47:28,040 There are soapsuds on this conveyor belt. 832 00:47:28,040 --> 00:47:31,480 What is the soapsuds? So, it's like lubricant. 833 00:47:31,480 --> 00:47:32,880 It's as simple as that. 834 00:47:32,880 --> 00:47:36,640 We're turning all of this metal into an ice rink for glass. There you go. 835 00:47:39,880 --> 00:47:42,880 Right, come on, let's put some mayonnaise in them! Let's do it! 836 00:47:44,360 --> 00:47:47,680 Before they're filled, the jars are cleaned with a jet of air... 837 00:47:50,200 --> 00:47:52,720 ..before gliding onto the filling machine. 838 00:47:54,240 --> 00:47:58,560 Which loads 250 of them with mayo every minute. 839 00:48:03,240 --> 00:48:05,600 At last, mayonnaise in a jar! 840 00:48:05,600 --> 00:48:06,760 That's what it is. 841 00:48:09,960 --> 00:48:14,360 Each jar is filled with precisely 680g 842 00:48:14,360 --> 00:48:17,600 of freshly prepared mayonnaise. 843 00:48:17,600 --> 00:48:20,600 So, it's filling the jar very gently. 844 00:48:20,600 --> 00:48:24,840 It's critical because we want to keep the product nice and smooth. 845 00:48:24,840 --> 00:48:27,000 There's something quite beautiful about that. 846 00:48:29,920 --> 00:48:32,640 So, now we're ready to put the caps on? Correct. All right. 847 00:48:32,640 --> 00:48:36,320 And that's actually what's happening inside this machine. 848 00:48:38,760 --> 00:48:41,760 You cannot look in here, but the principle is as follows. 849 00:48:41,760 --> 00:48:43,600 A jar comes in like this, 850 00:48:43,600 --> 00:48:44,920 the cap is waiting, 851 00:48:44,920 --> 00:48:46,960 and it sort of grabs the cap 852 00:48:46,960 --> 00:48:48,480 and it's pulling it close. 853 00:48:48,480 --> 00:48:51,000 Just before the cap is actually totally put on, 854 00:48:51,000 --> 00:48:54,240 we put a little puff of hot steam in there. 855 00:48:54,240 --> 00:48:58,520 When the hot steam cools, it sucks in the button of the lid, 856 00:48:58,520 --> 00:49:01,760 creating a firm airtight seal. 857 00:49:01,760 --> 00:49:05,680 And that is why, when I open the jar, I get that... HE MAKES POPPING SOUND 858 00:49:05,680 --> 00:49:07,320 There you go. 859 00:49:07,320 --> 00:49:08,720 The labels go on... 860 00:49:10,400 --> 00:49:12,960 ..before one final check. 861 00:49:12,960 --> 00:49:15,640 A sensor scans the button on each cap. 862 00:49:15,640 --> 00:49:20,320 Most jars pass the test, but those with faulty caps 863 00:49:20,320 --> 00:49:21,520 get rejected. 864 00:49:25,520 --> 00:49:29,120 So, if it's firm and doesn't move, the seal is perfect? 865 00:49:29,120 --> 00:49:32,400 Correct. If it's got a bit of a bounce, it rejects it. 866 00:49:32,400 --> 00:49:35,160 That's it. We've got another one. Is that another bad one? 867 00:49:35,160 --> 00:49:37,240 There you go. Good job. 868 00:49:39,960 --> 00:49:42,440 So, that's the mayo - all bottled 869 00:49:42,440 --> 00:49:45,040 and ready to pop onto your burger, 870 00:49:45,040 --> 00:49:47,000 or anything else you fancy. 871 00:49:47,000 --> 00:49:50,840 But there are some sauces we only eat with certain foods. 872 00:49:50,840 --> 00:49:54,640 Cherry went to check out the science behind those perfect pairings. 873 00:49:57,560 --> 00:49:59,640 Hey, welcome to the Carvery. 874 00:49:59,640 --> 00:50:01,160 Amazing. 875 00:50:03,840 --> 00:50:05,240 What are you going to go for today? 876 00:50:05,240 --> 00:50:08,200 I'm going to go for a bit of all three, please. 877 00:50:08,200 --> 00:50:09,960 What's your favourite meat? 878 00:50:09,960 --> 00:50:13,120 Probably ham. Ham. And what's the sauce that you'd put with it? 879 00:50:13,120 --> 00:50:14,160 Mustard. 880 00:50:15,440 --> 00:50:18,000 Lamb with mint sauce is, like, my favourite. 881 00:50:18,000 --> 00:50:20,440 Is that the one? That is the one. 882 00:50:21,920 --> 00:50:24,400 It seems that we're pretty set in our ways 883 00:50:24,400 --> 00:50:27,560 when it comes to pairing meat with sauces. 884 00:50:27,560 --> 00:50:31,000 Lamb and mint, ham and mustard. 885 00:50:31,000 --> 00:50:33,680 Pork and apple. 886 00:50:33,680 --> 00:50:34,720 But why? 887 00:50:36,040 --> 00:50:39,800 To find out, I've enlisted the help of Professor Barry Smith 888 00:50:39,800 --> 00:50:42,360 from the University of London. 889 00:50:42,360 --> 00:50:46,480 He's an expert in sensory perceptions and food. 890 00:50:46,480 --> 00:50:50,840 So, Barry, why do we pair certain meats with certain sauces? 891 00:50:50,840 --> 00:50:52,920 Well, there are three reasons, Cherry. 892 00:50:52,920 --> 00:50:55,960 Historical, cultural and scientific. 893 00:50:55,960 --> 00:50:57,920 I'm going to test you on this. 894 00:50:57,920 --> 00:51:01,480 Barry, underneath cloche number one, we have... 895 00:51:02,960 --> 00:51:05,000 ..lamb and mint sauce. 896 00:51:05,000 --> 00:51:06,320 Classic combination. 897 00:51:06,320 --> 00:51:09,360 There are historical reasons for this - it used to be the case that 898 00:51:09,360 --> 00:51:11,560 people would keep their lambs a little bit long. 899 00:51:11,560 --> 00:51:15,000 The fatty acids breakdown and give off rather bad odours, 900 00:51:15,000 --> 00:51:16,360 kind of high note, 901 00:51:16,360 --> 00:51:20,000 and that stinging high note could be covered up by mint. 902 00:51:20,000 --> 00:51:22,320 That's really disgusting and very informative. 903 00:51:22,320 --> 00:51:23,680 Thank you, Barry. Pleasure. 904 00:51:25,480 --> 00:51:26,760 Cloche number two. 905 00:51:28,000 --> 00:51:30,240 Beef and horseradish. 906 00:51:30,240 --> 00:51:32,000 Ooh, good combination. 907 00:51:32,000 --> 00:51:34,960 We like that tanginess of horseradish, 908 00:51:34,960 --> 00:51:38,800 spicy hotness with the strong flavour and the tang of the beef. 909 00:51:38,800 --> 00:51:42,280 So, culturally, they have become the regular partners, 910 00:51:42,280 --> 00:51:44,400 and we like putting them together, 911 00:51:44,400 --> 00:51:47,520 and we think it's as natural as ice cream and apple pie. 912 00:51:47,520 --> 00:51:49,880 Barry, so far, so good. 913 00:51:51,760 --> 00:51:53,960 Under cloche number three, we have... 914 00:51:54,920 --> 00:51:56,440 Not my favourite meat. 915 00:51:56,440 --> 00:51:58,440 Turkey and cranberry. 916 00:51:58,440 --> 00:52:01,000 Bland and dry. So, what do we do to deal with that? 917 00:52:01,000 --> 00:52:05,200 Well, by having a cranberry sauce, we've got these very sour berries, 918 00:52:05,200 --> 00:52:06,640 and what they'll do is, 919 00:52:06,640 --> 00:52:09,560 they'll stimulate saliva flow, so you'll get 920 00:52:09,560 --> 00:52:12,480 this rush of moisture and saliva into the mouth that will help you 921 00:52:12,480 --> 00:52:15,080 masticate this otherwise quite dry turkey. 922 00:52:17,120 --> 00:52:18,880 So, a little sauce summary. 923 00:52:18,880 --> 00:52:21,640 With lamb and mint, it's a historical hangover. 924 00:52:21,640 --> 00:52:23,440 With beef and horseradish, 925 00:52:23,440 --> 00:52:26,520 it's cultural, and with turkey and cranberry, 926 00:52:26,520 --> 00:52:30,560 it's scientific, it's to get that saliva production flowing. 927 00:52:30,560 --> 00:52:33,240 So, there's always a reason for the pairing? 928 00:52:33,240 --> 00:52:34,440 Always a reason. 929 00:52:34,440 --> 00:52:37,040 You're either contrasting or masking 930 00:52:37,040 --> 00:52:39,600 or augmenting the flavours. 931 00:52:39,600 --> 00:52:44,040 But there's one meat that doesn't have a regular partner. 932 00:52:44,040 --> 00:52:45,440 Chicken. 933 00:52:45,440 --> 00:52:47,280 So, with all your expertise, Barry, 934 00:52:47,280 --> 00:52:49,760 I'd like you to see whether you can find 935 00:52:49,760 --> 00:52:51,840 the perfect sauce for chicken. 936 00:52:51,840 --> 00:52:53,400 Are you able to do that? 937 00:52:53,400 --> 00:52:54,640 I'm game. 938 00:52:57,120 --> 00:53:00,280 Barry has chosen a creamy lemon sauce 939 00:53:00,280 --> 00:53:04,680 that science suggests will be the perfect accompaniment for chicken. 940 00:53:04,680 --> 00:53:05,880 Yeah, that's beautiful. 941 00:53:05,880 --> 00:53:08,560 The light, citrus taste should complement 942 00:53:08,560 --> 00:53:10,440 the meat's delicate flavour, 943 00:53:10,440 --> 00:53:14,280 but will its subtle charms win out against two stronger, 944 00:53:14,280 --> 00:53:16,280 more robust sauces? 945 00:53:16,280 --> 00:53:20,480 We're putting it up against rich port gravy and mint sauce. 946 00:53:23,120 --> 00:53:25,960 Barry expects lemon to come out on top. 947 00:53:26,960 --> 00:53:29,040 But will our tasters agree? 948 00:53:31,160 --> 00:53:34,480 Which of those sauces do you think goes best with the chicken? 949 00:53:34,480 --> 00:53:37,120 The mint. The mint. 950 00:53:37,120 --> 00:53:39,680 Mint sauce goes with everything, so it's fine. 951 00:53:39,680 --> 00:53:42,960 Barry's matchmaking skills may be in question. 952 00:53:42,960 --> 00:53:45,880 I do think the mint one tastes better. Quite like the mint. 953 00:53:45,880 --> 00:53:49,320 Yeah, it's also very nice. I think I like the middle one best, though. 954 00:53:50,640 --> 00:53:52,880 Probably the lemon-y one with much more lemon in it. 955 00:53:52,880 --> 00:53:54,920 Much more lemon? OK. 956 00:53:54,920 --> 00:53:56,320 It'd have to be the mint. 957 00:53:57,400 --> 00:53:59,360 Flying in the face of science, 958 00:53:59,360 --> 00:54:02,480 mint sauce is our clear winner. 959 00:54:02,480 --> 00:54:05,320 So, Barry, I set you the task of finding the perfect sauce 960 00:54:05,320 --> 00:54:07,920 to go with chicken. Could you do it? 961 00:54:07,920 --> 00:54:10,720 We couldn't, actually, and that may be for a number of reasons. 962 00:54:10,720 --> 00:54:12,480 Chicken's very versatile, 963 00:54:12,480 --> 00:54:15,360 it will tolerate a lot of different sauces. 964 00:54:15,360 --> 00:54:17,720 Despite Barry's best efforts, 965 00:54:17,720 --> 00:54:22,240 chicken is still searching for its perfect saucy sidekick. 966 00:54:30,800 --> 00:54:34,280 It's been less than 11 hours since my eggs were collected. 967 00:54:35,960 --> 00:54:38,960 And now my mayonnaise is heading for distribution. 968 00:54:40,040 --> 00:54:44,480 My jars have been placed into cases and loaded onto pallets. 969 00:54:44,480 --> 00:54:49,680 They are transported around this huge site by 300 metres of 970 00:54:49,680 --> 00:54:54,280 computer-controlled conveyors, which move more than 1 million bottles 971 00:54:54,280 --> 00:54:57,520 and jars every day. 972 00:54:57,520 --> 00:54:59,320 Dan! Hey, how are you? 973 00:54:59,320 --> 00:55:01,360 I saw you at the start of the mayonnaise... Yes. 974 00:55:01,360 --> 00:55:04,520 ..and here you are at the end. Still here, yeah. What is this?! 975 00:55:04,520 --> 00:55:07,280 This is actually the start of our outbound process. 976 00:55:07,280 --> 00:55:11,160 Here, we make sure that pallets are prepared fit for transport. 977 00:55:11,160 --> 00:55:14,720 And that machine seems to be picking out that... 978 00:55:14,720 --> 00:55:17,760 What do you call it? Plastic... Plastic film, yeah. 979 00:55:17,760 --> 00:55:20,680 It picks out the plastic film in one sheet, 980 00:55:20,680 --> 00:55:25,000 opens it up and puts it over like a pillow case. Yeah. 981 00:55:25,000 --> 00:55:29,120 The machine shrink wraps the plastic sheet tightly around the pallet. 982 00:55:29,120 --> 00:55:33,400 This holds the delicate jars firmly in place. 983 00:55:33,400 --> 00:55:36,480 Why has that sheet there got little holes in it? 984 00:55:36,480 --> 00:55:39,800 That's to make sure that the warmth and the air can still evaporate 985 00:55:39,800 --> 00:55:41,400 out after the pallet has been wrapped. 986 00:55:41,400 --> 00:55:43,880 When they come here for distribution, they're still warm? 987 00:55:43,880 --> 00:55:47,680 Yeah. That's got to be the fastest production and distribution I've ever seen. 988 00:55:47,680 --> 00:55:50,360 It's literally one hour after production and, half an hour 989 00:55:50,360 --> 00:55:52,080 from here, we ship it out already. 990 00:55:53,920 --> 00:55:57,120 My mayonnaise has been mixed and packed. 991 00:55:57,120 --> 00:55:59,840 Now it heads to the fully automated 992 00:55:59,840 --> 00:56:02,320 2,000 square metre warehouse. 993 00:56:05,320 --> 00:56:08,320 Wow. How many pallets in here? Do you know? 994 00:56:08,320 --> 00:56:11,600 Yeah, it can range up to 2,500 pallets. 995 00:56:11,600 --> 00:56:13,760 That's only at 1.5 days. 996 00:56:13,760 --> 00:56:17,640 2,500 pallets is only enough for 1.5 days? Max. 997 00:56:17,640 --> 00:56:21,800 So, this machine is constantly moving pallets of sauces in and out? Yeah. 998 00:56:21,800 --> 00:56:23,160 There it goes again. Yeah. 999 00:56:24,520 --> 00:56:26,240 Is that my mayonnaise ready to go? 1000 00:56:27,440 --> 00:56:30,440 That's your mayonnaise. We've produced that specific pallet today, 1001 00:56:30,440 --> 00:56:32,280 and we're also shipping it out today. 1002 00:56:32,280 --> 00:56:34,680 Well, we better get on with it, hadn't we? 1003 00:56:34,680 --> 00:56:38,240 Just over 11 hours since my eggs were collected, 1004 00:56:38,240 --> 00:56:42,480 they're now making their way out of the factory as jars of sauce. 1005 00:56:44,120 --> 00:56:45,160 That's my batch. 1006 00:56:46,520 --> 00:56:47,880 Careful. Careful. 1007 00:56:50,000 --> 00:56:52,200 You know what? A chap knows his mayonnaise. 1008 00:56:53,800 --> 00:56:58,520 Every day, 150 trucks ship mayonnaise out of here. 1009 00:56:58,520 --> 00:57:03,000 With us Brits taking the crown for the keenest consumers. 1010 00:57:03,000 --> 00:57:05,840 People in the south-east get through the most, 1011 00:57:05,840 --> 00:57:09,280 but it also heads off to 39 different countries 1012 00:57:09,280 --> 00:57:12,760 around the world, from Malaysia to Panama. 1013 00:57:21,680 --> 00:57:23,680 I've enjoyed my trip here to the Netherlands. 1014 00:57:23,680 --> 00:57:25,960 I was blown away by the egg cracking machine. 1015 00:57:25,960 --> 00:57:27,960 I mean, that was incredible. 1016 00:57:27,960 --> 00:57:31,320 I was surprised they don't make mayonnaise the way that I make it 1017 00:57:31,320 --> 00:57:35,120 at home, and I was amazed by the fact that over half of everything 1018 00:57:35,120 --> 00:57:38,480 they produce in this factory is for us in the UK. 1019 00:57:38,480 --> 00:57:39,640 Take her away! 1020 00:57:49,400 --> 00:57:51,520 Next time, we're in Gloucestershire, 1021 00:57:51,520 --> 00:57:54,840 inside one of the largest soft drinks factories in Europe... 1022 00:57:54,840 --> 00:57:56,240 It's wonderful. 1023 00:57:56,240 --> 00:57:58,200 Technology that I've never seen before, 1024 00:57:58,200 --> 00:58:00,240 around a drink that I've known for years! 1025 00:58:00,240 --> 00:58:02,720 ..where 3 million bottles of blackcurrant drinks 1026 00:58:02,720 --> 00:58:05,360 pour off the production line every week. 1027 00:58:05,360 --> 00:58:06,680 Oh, mate! 1028 00:58:06,680 --> 00:58:09,360 Do you go home smelling like a blackcurrant? 1029 00:58:09,360 --> 00:58:14,040 And Cherry discovers how drinks bottles start life as other bottles. 1030 00:58:14,040 --> 00:58:15,760 Oh! 1031 00:58:15,760 --> 00:58:17,400 I thought it was water.