1 00:00:02,320 --> 00:00:05,240 Us Brits love this Italian classic. 2 00:00:06,680 --> 00:00:10,600 Which explains why we slice up around 14 million 3 00:00:10,600 --> 00:00:12,400 pizzas every week. 4 00:00:12,400 --> 00:00:16,080 Spending £2.5 billion on them each year. 5 00:00:20,440 --> 00:00:23,560 Where's the best place to learn how they're made? 6 00:00:23,560 --> 00:00:26,600 This Italian pizza factory, of course! 7 00:00:29,920 --> 00:00:32,400 600 people work here, 8 00:00:32,400 --> 00:00:37,800 producing a whopping 370 pizzas every minute. 9 00:00:39,160 --> 00:00:40,520 I'm Gregg Wallace... 10 00:00:40,520 --> 00:00:44,160 That's like whitewater rafting for pizzas. 11 00:00:44,160 --> 00:00:47,200 ..and tonight I'll learn how they guarantee 12 00:00:47,200 --> 00:00:49,840 a crispy crust every time. 13 00:00:49,840 --> 00:00:54,720 450-degree, proper wood-fired oven with a stone base. 14 00:00:54,720 --> 00:00:56,160 I'm Cherry Healey... 15 00:00:56,160 --> 00:00:58,400 It looks like a sample that I don't want to drink! 16 00:00:58,400 --> 00:01:01,800 ..and I'll be investigating the complex chemistry behind some 17 00:01:01,800 --> 00:01:03,400 of our favourite toppings. 18 00:01:03,400 --> 00:01:07,320 So, the proteins in mozzarella are just in that sweet spot 19 00:01:07,320 --> 00:01:09,480 where they can melt beautifully. 20 00:01:09,480 --> 00:01:11,640 And historian Ruth Goodman sees 21 00:01:11,640 --> 00:01:14,880 what was on the menu when pizzas first came to Britain. 22 00:01:14,880 --> 00:01:18,920 It's a very familiar list, though. I mean, things like the Margherita, 23 00:01:18,920 --> 00:01:21,320 Four Seasons, La Reine.... 24 00:01:21,320 --> 00:01:22,960 Over the next 24 hours, 25 00:01:22,960 --> 00:01:27,320 this factory will produce 400,000 pizzas! 26 00:01:27,320 --> 00:01:30,400 And we're serving you a slice of the production process. 27 00:01:30,400 --> 00:01:32,600 Welcome to Inside The Factory. 28 00:01:51,600 --> 00:01:55,560 This factory in the foothills of Italy's Dolomite mountains 29 00:01:55,560 --> 00:01:59,640 makes an astonishing 500 different varieties of pizza. 30 00:02:01,240 --> 00:02:04,240 They ship all over the world, tailoring their recipes 31 00:02:04,240 --> 00:02:07,160 to the individual taste of each country. 32 00:02:07,160 --> 00:02:10,320 For Italy, that means ultra-traditional 33 00:02:10,320 --> 00:02:12,280 thin crust margheritas. 34 00:02:12,280 --> 00:02:16,440 And. for Germany, a deep base topped with fish. 35 00:02:16,440 --> 00:02:19,680 But our pizza is made for the British market 36 00:02:19,680 --> 00:02:23,360 and the shelves of supermarket chain Iceland. 37 00:02:23,360 --> 00:02:27,880 And it's their stone-baked, spicy, double pepperoni version 38 00:02:27,880 --> 00:02:30,240 that we're here to learn how to make. 39 00:02:32,520 --> 00:02:36,480 And, as with any pizza, it's all about the base. 40 00:02:36,480 --> 00:02:39,960 This one is thin and crispy with a chewy crust. 41 00:02:39,960 --> 00:02:43,200 # I know you can tell just by looking at my face 42 00:02:43,200 --> 00:02:45,240 # A word about my weakness 43 00:02:45,240 --> 00:02:47,960 # I'm totally addicted to bass... # 44 00:02:47,960 --> 00:02:53,200 Production begins in the intake area with the delivery of wheat flour. 45 00:02:53,200 --> 00:02:56,120 Ten of these tankers arrive here every week, 46 00:02:56,120 --> 00:03:00,000 each one laden with 30 tonnes of the stuff. 47 00:03:00,000 --> 00:03:04,760 Gabriele Bot oversees all raw ingredients that arrive onsite. 48 00:03:06,560 --> 00:03:09,720 Gabriele, good to meet you. 49 00:03:09,720 --> 00:03:13,080 HE SPEAKS IN ITALIAN 50 00:03:14,240 --> 00:03:16,680 This is the beginning? Yes. 51 00:03:16,680 --> 00:03:18,840 We take the flour right here. 52 00:03:18,840 --> 00:03:22,520 So, this is more or less 240,000 pizzas. 53 00:03:22,520 --> 00:03:25,560 A quarter of a million pizzas? Yes. From that flour? 54 00:03:25,560 --> 00:03:28,280 Even I can't eat that many pizzas. 55 00:03:28,280 --> 00:03:32,400 Tell me, what is the perfect flour for a pizza? 56 00:03:32,400 --> 00:03:34,960 We use flour type zero. 57 00:03:34,960 --> 00:03:39,080 When I read cookery books, a lot of it is zero zero - double zero. 58 00:03:39,080 --> 00:03:41,200 Why do you use zero and not... 59 00:03:41,200 --> 00:03:46,600 We prefer the zero because it's a little less refined flour 60 00:03:46,600 --> 00:03:50,440 and gives a crispier product that we want. 61 00:03:50,440 --> 00:03:52,760 Flour comes in many different grades 62 00:03:52,760 --> 00:03:57,120 and subtle variations can make a big difference to the finished product. 63 00:03:57,120 --> 00:04:00,720 The kind they're about to unload here is a strong, all-purpose milled 64 00:04:00,720 --> 00:04:04,800 wheat flour, like you might use to make a loaf of bread at home. 65 00:04:04,800 --> 00:04:07,680 Let's get this flour off the lorry. OK. 66 00:04:08,960 --> 00:04:10,960 The pipes are connected, 67 00:04:10,960 --> 00:04:15,200 and our frozen pizza production line begins. 68 00:04:15,200 --> 00:04:17,800 I love that pipe, it's dancing! 69 00:04:17,800 --> 00:04:19,360 It looks like an eel. 70 00:04:21,360 --> 00:04:24,880 The flour is blown along this pulsating pipe, 71 00:04:24,880 --> 00:04:28,240 and into one of four 30-tonne silos, 72 00:04:28,240 --> 00:04:31,640 where it's stored before joining the other seven ingredients 73 00:04:31,640 --> 00:04:34,160 that will go into our pizza base. 74 00:04:34,160 --> 00:04:39,000 Every 12 minutes, a batch of 250 kilos 75 00:04:39,000 --> 00:04:42,360 is sent to the mixing area, where I'm meeting 76 00:04:42,360 --> 00:04:46,080 operations manager Alberto Urli. 77 00:04:46,080 --> 00:04:49,080 Alberto, I'm Gregg. Hi, Gregg. 78 00:04:49,080 --> 00:04:52,840 I love making pizza. I'm very excited to be here! 79 00:04:52,840 --> 00:04:54,760 Is this the start of the process? 80 00:04:54,760 --> 00:04:58,000 Yeah, yeah. Here, mainly, we prepare the dough. 81 00:04:58,000 --> 00:05:00,640 That is the core of the process of the pizza. 82 00:05:00,640 --> 00:05:03,720 The base of our pizza is a simple dough, 83 00:05:03,720 --> 00:05:06,720 but we're not starting with my flour. 84 00:05:06,720 --> 00:05:10,920 So, first of all we need to load the yeast. 85 00:05:10,920 --> 00:05:13,920 This is industrial yeast. It's fresh, 86 00:05:13,920 --> 00:05:17,040 it's ready to give its power to our dough. 87 00:05:17,040 --> 00:05:19,120 That really's got a strong odour. Yes. 88 00:05:19,120 --> 00:05:22,680 Tell me - you're the expert - what does yeast do? 89 00:05:22,680 --> 00:05:25,640 I know I can't make bread without it, but what does it do? 90 00:05:25,640 --> 00:05:28,440 Yeah. The yeast is, er... 91 00:05:28,440 --> 00:05:31,000 ..creating gas into the dough. 92 00:05:31,000 --> 00:05:32,320 How does it do that? 93 00:05:32,320 --> 00:05:36,240 It's like a small animal that is eating something 94 00:05:36,240 --> 00:05:39,040 from the flour and it's creating gas. 95 00:05:39,040 --> 00:05:41,520 So, the yeast is eating... Yeah. ..and it's... 96 00:05:41,520 --> 00:05:42,840 MAKES FART SOUND 97 00:05:42,840 --> 00:05:44,440 Yeah, yeah. 98 00:05:44,440 --> 00:05:46,960 I don't think I'm ever going to look at pizza the same way! 99 00:05:46,960 --> 00:05:48,880 Does the yeast go in? Yeah. 100 00:05:50,240 --> 00:05:54,760 Yeast is the magical ingredient which transforms our dough. 101 00:05:54,760 --> 00:05:58,200 It eats up the naturally-occurring sugar in the flour, 102 00:05:58,200 --> 00:06:02,560 producing CO2 gas, making the dough rise. 103 00:06:02,560 --> 00:06:04,520 Good? The second one. 104 00:06:04,520 --> 00:06:06,560 Salt? Yeah. 105 00:06:06,560 --> 00:06:09,720 Next up is salt, which helps strengthen the dough 106 00:06:09,720 --> 00:06:11,840 and adds flavour. 107 00:06:11,840 --> 00:06:14,280 Followed by a sugar called dextrose, 108 00:06:14,280 --> 00:06:17,920 which will provide extra food for our yeast. 109 00:06:17,920 --> 00:06:20,240 How many pizzas will we get out of here? 110 00:06:20,240 --> 00:06:24,320 With this dough, around 1,800 pizzas. 111 00:06:24,320 --> 00:06:26,560 Nearly 2,000 pizzas? Yeah. 112 00:06:31,720 --> 00:06:36,680 250kg of the flour I saw arrive is dosed in 113 00:06:36,680 --> 00:06:40,440 followed by 125 litres of water 114 00:06:40,440 --> 00:06:44,240 and sunflower oil, which will make the dough easier to stretch. 115 00:06:46,920 --> 00:06:49,440 Can I press the button? Yeah, let's start. 116 00:06:51,920 --> 00:06:54,840 The mixing process begins. 117 00:06:54,840 --> 00:06:57,840 So, that's just mixing like I would mix at home with a big spoon? 118 00:06:57,840 --> 00:06:59,160 Yeah, more or less. 119 00:07:01,600 --> 00:07:06,160 Ten minutes, mixing at 280 RPM, is enough 120 00:07:06,160 --> 00:07:08,280 to combine these ingredients. 121 00:07:09,600 --> 00:07:12,560 Whoa! That is a big... 122 00:07:12,560 --> 00:07:15,800 That is more like bubble gum right now. Yeah. 123 00:07:15,800 --> 00:07:18,480 OK, this is going to rest, right? Yeah, for five hours. 124 00:07:18,480 --> 00:07:19,680 Five hours? Yeah. 125 00:07:19,680 --> 00:07:22,120 And how do you want it to be after it's rested? 126 00:07:22,120 --> 00:07:27,680 We want a more relaxed dough because we need to create 127 00:07:27,680 --> 00:07:30,320 the perfect round of the pizza. 128 00:07:30,320 --> 00:07:33,520 What would happen if we tried to make pizza now with this? 129 00:07:33,520 --> 00:07:37,560 It would be a disaster. Would be impossible to get the right shape 130 00:07:37,560 --> 00:07:39,280 because it's impossible to stretch. 131 00:07:39,280 --> 00:07:41,560 Where does it rest? Upstairs. 132 00:07:41,560 --> 00:07:44,040 It goes upstairs to bed? Yeah! 133 00:07:44,040 --> 00:07:45,400 OK. 134 00:07:47,760 --> 00:07:52,680 In the one hour and 43 minutes since it arrived at the factory, my flour 135 00:07:52,680 --> 00:07:56,520 has been working very hard, becoming dough. 136 00:07:56,520 --> 00:07:59,880 But now it gets a chance to have a breather as it trundles 137 00:07:59,880 --> 00:08:04,000 along 30 metres of mechanical conveyors and lifts... 138 00:08:05,560 --> 00:08:09,440 ..before it's tucked into the resting room for 40 winks. 139 00:08:11,440 --> 00:08:14,840 Today in Britain, we spend more on takeaway pizza 140 00:08:14,840 --> 00:08:16,920 than we do on fish and chips. 141 00:08:16,920 --> 00:08:18,800 Ruth is on the trail of the man 142 00:08:18,800 --> 00:08:21,720 who first brought us a PIZZA the action. 143 00:08:28,080 --> 00:08:29,920 In the late '50s and early '60s, 144 00:08:29,920 --> 00:08:33,440 all things Italian became super-fashionable in the UK. 145 00:08:36,000 --> 00:08:38,840 But there was one thing missing from the cafes 146 00:08:38,840 --> 00:08:40,720 and spaghetti houses - 147 00:08:40,720 --> 00:08:42,040 pizza. 148 00:08:44,640 --> 00:08:48,440 Italian immigrants had tried and failed to introduce pizza 149 00:08:48,440 --> 00:08:51,560 to the Brits, but it took a man from Peterborough 150 00:08:51,560 --> 00:08:54,320 to really make us fall in love with it. 151 00:08:54,320 --> 00:08:59,120 I interviewed Peter Boizot in 2018 about the first pizza he tasted 152 00:08:59,120 --> 00:09:00,800 70 years earlier in Italy. 153 00:09:02,120 --> 00:09:04,680 I went to Florence. 154 00:09:04,680 --> 00:09:09,800 Delightedly, they made for me a pizza. 155 00:09:09,800 --> 00:09:12,760 The first one I'd ever had or seen. 156 00:09:12,760 --> 00:09:15,920 And what was it like? Well, it was good. Tasty... 157 00:09:15,920 --> 00:09:19,000 ..the dough had risen properly. 158 00:09:19,000 --> 00:09:23,480 It had, of course, a lot of mozzarella cheese on it. 159 00:09:24,800 --> 00:09:28,040 When he came back to London, Peter couldn't find what he felt 160 00:09:28,040 --> 00:09:30,480 was a proper pizza anywhere. 161 00:09:30,480 --> 00:09:36,000 So, in 1965, he decided to set up his very own pizzeria. 162 00:09:37,760 --> 00:09:41,240 What's unique is a special oven, a hot oven, 163 00:09:41,240 --> 00:09:44,680 so I went over to Italy and contacted 164 00:09:44,680 --> 00:09:47,960 a wonderful man - Signor Notaro - 165 00:09:47,960 --> 00:09:53,840 and he sent me a specially-designed pizza oven. 166 00:09:53,840 --> 00:09:56,280 In order to get it into my restaurant, 167 00:09:56,280 --> 00:09:58,440 we had to knock the wall down... 168 00:09:59,800 --> 00:10:02,400 ..because it was too big for the door! 169 00:10:02,400 --> 00:10:04,560 What was the name of your restaurant? 170 00:10:04,560 --> 00:10:06,320 Pizza Express. 171 00:10:10,120 --> 00:10:14,800 Peter's first pizzeria was here in Wardour Street in Soho, 172 00:10:14,800 --> 00:10:17,080 today at the very heart of Chinatown. 173 00:10:21,920 --> 00:10:25,480 And that very first restaurant is still here 174 00:10:25,480 --> 00:10:27,960 and still serving pizza. 175 00:10:32,360 --> 00:10:36,080 The restaurant chain's biographer, Matthew Reville, believes this place 176 00:10:36,080 --> 00:10:39,440 hit upon a recipe for success right from the start. 177 00:10:41,600 --> 00:10:44,280 What were they serving in that very first restaurant? 178 00:10:44,280 --> 00:10:45,480 I've got the menu here. 179 00:10:45,480 --> 00:10:48,720 It shows you what they had, and the first thing that will strike you 180 00:10:48,720 --> 00:10:51,600 is there's no pasta, salad, desserts or dough balls on there. 181 00:10:51,600 --> 00:10:54,280 It's all pizzas. It's a very familiar list, though. 182 00:10:54,280 --> 00:10:57,360 I mean, things like, you know, obviously the Margherita, 183 00:10:57,360 --> 00:11:00,680 the Four Seasons, your mushroom pizza, your La Reine. 184 00:11:00,680 --> 00:11:03,160 When Peter first set up the restaurant, 185 00:11:03,160 --> 00:11:06,640 he could see the buzz of pizzaiolos, throwing dough in the air 186 00:11:06,640 --> 00:11:08,640 and making them in front of people. 187 00:11:08,640 --> 00:11:12,080 However, it was the food that was the real selling point. 188 00:11:12,080 --> 00:11:17,000 It was eating from an authentic wood oven, eating real Italian pizzas 189 00:11:17,000 --> 00:11:18,520 that was so successful. 190 00:11:18,520 --> 00:11:22,520 How did it go, then, from being one, small shop in Wardour Street 191 00:11:22,520 --> 00:11:24,120 to being this great, big chain? 192 00:11:24,120 --> 00:11:26,520 His plan wasn't to make a lot of money. 193 00:11:26,520 --> 00:11:29,240 His plan was to create this different type of dining 194 00:11:29,240 --> 00:11:32,280 experience, which was inexpensive, 195 00:11:32,280 --> 00:11:35,760 lots of energy, lots of buzz around the restaurant, 196 00:11:35,760 --> 00:11:37,560 and it was so successful 197 00:11:37,560 --> 00:11:40,960 that he basically had to keep on expanding it. 198 00:11:43,480 --> 00:11:46,560 And where Peter led, others followed. 199 00:11:46,560 --> 00:11:51,040 Today, around 5,000 restaurants and takeaways across the UK sell 200 00:11:51,040 --> 00:11:53,600 a slice of the big pizza pie. 201 00:11:54,920 --> 00:11:58,440 You know, if Peter Boizot hadn't first given us 202 00:11:58,440 --> 00:12:00,640 that taste of the real thing, 203 00:12:00,640 --> 00:12:05,360 I'm not sure that we'd be the nation of pizza lovers that we are today. 204 00:12:17,200 --> 00:12:22,840 Back in Italy, our pampered pizza dough has been having a little nap 205 00:12:22,840 --> 00:12:24,960 in the resting room. 206 00:12:24,960 --> 00:12:30,040 Yeast has trapped tiny bubbles of CO2 gas inside it, 207 00:12:30,040 --> 00:12:32,840 causing it to rise and double in size. 208 00:12:32,840 --> 00:12:36,040 It's now what bakers call a relaxed dough, 209 00:12:36,040 --> 00:12:39,480 meaning it'll be easy to stretch into shape. 210 00:12:39,480 --> 00:12:43,080 Six hours and 43 minutes into the process, 211 00:12:43,080 --> 00:12:45,840 it heads to the beginning of the pizza line. 212 00:12:54,840 --> 00:12:55,880 OK! 213 00:12:55,880 --> 00:12:57,000 HE LAUGHS 214 00:12:58,640 --> 00:13:01,280 Well, that's lighter. 215 00:13:01,280 --> 00:13:04,400 Was very tired at the start, 216 00:13:04,400 --> 00:13:07,280 and now is more relaxed. 217 00:13:07,280 --> 00:13:10,560 But our dough's had enough time lazing about. 218 00:13:10,560 --> 00:13:12,560 Now it needs to get in shape 219 00:13:12,560 --> 00:13:15,720 and this machine is going to give it a workout. 220 00:13:15,720 --> 00:13:18,680 What is happening in here, Alberto? 221 00:13:18,680 --> 00:13:21,760 So, this is our knocking back process. 222 00:13:21,760 --> 00:13:24,680 We portion the right quantity of dough 223 00:13:24,680 --> 00:13:26,840 that we need for each single pizza. 224 00:13:26,840 --> 00:13:29,040 # Work, work, work, work, work, work 225 00:13:29,040 --> 00:13:32,400 # You see me I be work, work, work, work, work, work... # 226 00:13:32,400 --> 00:13:36,320 The dough drops down into the machine. Blades rotating 227 00:13:36,320 --> 00:13:41,040 at 150 RPM slice 190g pieces off 228 00:13:41,040 --> 00:13:44,280 before two super sized rolling pins massage them, 229 00:13:44,280 --> 00:13:49,200 creating six perfectly formed balls every four seconds. 230 00:13:49,200 --> 00:13:53,480 At home, I get the dough when it has rested and I move it. 231 00:13:53,480 --> 00:13:55,160 Yeah. Yeah. Like this. 232 00:13:55,160 --> 00:13:58,120 Is this what's happening? This process is simulating 233 00:13:58,120 --> 00:14:01,400 what you're doing in your home with your hands. 234 00:14:01,400 --> 00:14:03,320 We fold 235 00:14:03,320 --> 00:14:05,600 and we create this ball 236 00:14:05,600 --> 00:14:09,720 and, in this way, we give the right strength to the dough. 237 00:14:09,720 --> 00:14:12,240 It's working it. It's working the dough. 238 00:14:13,560 --> 00:14:16,160 That is a powerful little machine, right? 239 00:14:18,400 --> 00:14:23,080 This vigorous massage alters our dough's structure. 240 00:14:23,080 --> 00:14:27,560 Each ball is held together by a net of protein called gluten, 241 00:14:27,560 --> 00:14:31,720 and, as it's kneaded, the strands of this gluten align, 242 00:14:31,720 --> 00:14:33,800 giving the dough more strength. 243 00:14:33,800 --> 00:14:36,800 Important, because it's about to rise again 244 00:14:36,800 --> 00:14:38,920 and be stretched to its limits. 245 00:14:40,960 --> 00:14:43,440 So, where are these dough balls going? 246 00:14:43,440 --> 00:14:46,480 Are going into this big cell. 247 00:14:46,480 --> 00:14:48,680 This is a proofing cell. 248 00:14:48,680 --> 00:14:51,920 Just like me, after a vigorous workout, 249 00:14:51,920 --> 00:14:54,880 the dough balls deserve a little R&R. 250 00:14:54,880 --> 00:14:58,240 They drop into individual cups and head off for their version 251 00:14:58,240 --> 00:15:01,800 of a sauna, in this huge proofing cell. 252 00:15:03,160 --> 00:15:06,400 Inside, the temperature is 35 degrees Celsius 253 00:15:06,400 --> 00:15:09,760 and humidity hits 75%. 254 00:15:09,760 --> 00:15:13,880 Perfect conditions for the yeast, which continues eating those natural 255 00:15:13,880 --> 00:15:17,480 sugars and pushing out more CO2. 256 00:15:17,480 --> 00:15:20,480 After one hour, they emerge. 257 00:15:20,480 --> 00:15:22,640 Oh, wow! 258 00:15:22,640 --> 00:15:25,120 It's very light. Yeah. Very light. 259 00:15:25,120 --> 00:15:27,440 It almost feels... 260 00:15:27,440 --> 00:15:29,200 ..feels like a small cushion. Yeah. 261 00:15:29,200 --> 00:15:30,520 If you want, you can stretch it. 262 00:15:32,080 --> 00:15:34,720 Wow that is much lighter than my dough at home. 263 00:15:34,720 --> 00:15:36,320 That feels like silk. 264 00:15:36,320 --> 00:15:39,920 The yeast relaxes the gluten net, 265 00:15:39,920 --> 00:15:42,960 and that's why it's easy to stretch. 266 00:15:44,560 --> 00:15:48,800 After their pampering at the pizza spa, our dough balls are now ready 267 00:15:48,800 --> 00:15:50,600 for their next treatment. 268 00:15:52,680 --> 00:15:56,960 So, how do I make this into a perfect round shape? 269 00:15:59,880 --> 00:16:01,080 Not easy, ah, Gregg? 270 00:16:03,920 --> 00:16:06,720 Not good? No, let's try it with this machine. 271 00:16:06,720 --> 00:16:12,720 We take the ball, we put it in the middle of these two hot plates. 272 00:16:12,720 --> 00:16:14,880 That's very hot. I can feel that heat. 273 00:16:14,880 --> 00:16:16,240 Yeah, yeah, yeah. 274 00:16:16,240 --> 00:16:19,280 And then we press. Can you help me? Yeah. 275 00:16:19,280 --> 00:16:20,320 Let's go. 276 00:16:20,320 --> 00:16:24,560 Two plates heated to 157 degrees Celsius 277 00:16:24,560 --> 00:16:28,840 push together, creating an eight-millimetre thick 278 00:16:28,840 --> 00:16:31,640 25cm diameter base. 279 00:16:31,640 --> 00:16:34,960 And here you are, a perfect circle. 280 00:16:34,960 --> 00:16:37,080 This is the result. 281 00:16:37,080 --> 00:16:38,600 That's hard. Yeah. 282 00:16:38,600 --> 00:16:41,640 You have a skin. It's like you've sealed it. Yeah. 283 00:16:41,640 --> 00:16:45,920 In this way, it's impossible for the water of the tomato sauce 284 00:16:45,920 --> 00:16:47,760 to go inside the dough. 285 00:16:47,760 --> 00:16:50,000 How many pizzas do you do every day? 286 00:16:50,000 --> 00:16:55,080 About 400,000 pizzas. But you can't do 400,000 like this. 287 00:16:55,080 --> 00:16:59,760 Of course, we have a big machine with many heads like that, 288 00:16:59,760 --> 00:17:03,360 but, unfortunately, I cannot show you because it's our secret machine. 289 00:17:03,360 --> 00:17:06,840 This is not the first time it has happened inside a factory. 290 00:17:06,840 --> 00:17:10,080 Someone has a secret machine I can't see. Yeah. 291 00:17:10,080 --> 00:17:14,080 Secret it may be, but the results are clear. 292 00:17:14,080 --> 00:17:18,280 Now our perfectly flat heat-sealed pizza bases are pricked 293 00:17:18,280 --> 00:17:23,960 with 278 4mm-deep holes to let excess moisture escape and ensure 294 00:17:23,960 --> 00:17:27,000 they're perfectly crispy when cooked in the oven. 295 00:17:28,720 --> 00:17:31,440 Bases sorted. Next we need some sauce. 296 00:17:31,440 --> 00:17:34,200 But why do we always reach for tomato? 297 00:17:36,600 --> 00:17:39,880 Cherry's visiting a farm in Worcestershire that grows 298 00:17:39,880 --> 00:17:42,520 560 tonnes of them a year. 299 00:17:46,080 --> 00:17:50,560 I want to discover what it is about the tomato that makes it the perfect 300 00:17:50,560 --> 00:17:55,200 partner for pizza, pasta and so many other classic dishes. 301 00:17:55,200 --> 00:17:59,280 Helping me isolate the taste that makes it so special 302 00:17:59,280 --> 00:18:02,360 is food scientist Professor Lisa Methven. 303 00:18:02,360 --> 00:18:04,560 Oh, look at this! 304 00:18:04,560 --> 00:18:07,880 So, what we're going to do is think about what is actually 305 00:18:07,880 --> 00:18:09,960 in the middle of this that's got the taste in it. 306 00:18:09,960 --> 00:18:15,360 If we cut that tomato up, blend it in a mixer, we can spin out 307 00:18:15,360 --> 00:18:18,800 all of the taste parts of it, and it actually looks like this. 308 00:18:18,800 --> 00:18:21,320 Oh. Ugh! 309 00:18:21,320 --> 00:18:24,280 It looks like a sample that I don't want to drink. 310 00:18:24,280 --> 00:18:26,120 Well, I'm going to get you to! 311 00:18:27,480 --> 00:18:33,040 What we consider as flavour is made up of both taste and smell, 312 00:18:33,040 --> 00:18:37,520 so, in order to discover the underlying, true tomato flavour 313 00:18:37,520 --> 00:18:39,640 I need to block my nose. 314 00:18:39,640 --> 00:18:41,960 I'm going to get you to wear the nose clip. What I want 315 00:18:41,960 --> 00:18:44,440 you to concentrate on is just what's on your tongue. 316 00:18:44,440 --> 00:18:45,680 Bottoms up. 317 00:18:47,920 --> 00:18:49,360 It's a little bit sharp. 318 00:18:49,360 --> 00:18:51,000 A little bit tart. 319 00:18:51,000 --> 00:18:52,680 I guess a little bit sweet. 320 00:18:54,240 --> 00:18:56,160 I can almost taste savoury. 321 00:18:57,360 --> 00:19:00,200 It doesn't really taste like tomato at all. 322 00:19:01,440 --> 00:19:03,000 That is extraordinary. 323 00:19:03,000 --> 00:19:07,320 So, when I couldn't smell it, I felt like I could taste savoury. 324 00:19:07,320 --> 00:19:10,760 Absolutely you can taste the savoury taste, that's called umami. 325 00:19:10,760 --> 00:19:14,920 So, I've heard of umami but I've never really known what it is. 326 00:19:14,920 --> 00:19:16,600 It's one of your five basic tastes. 327 00:19:16,600 --> 00:19:19,920 So, you've got your sweet taste, sour, salt, bitter 328 00:19:19,920 --> 00:19:21,880 and the fifth one's your umami taste. 329 00:19:21,880 --> 00:19:24,720 One of the taste compounds in there is glutamate. 330 00:19:24,720 --> 00:19:26,600 That gives you umami taste, 331 00:19:26,600 --> 00:19:29,920 and, actually, that is present in so many foods 332 00:19:29,920 --> 00:19:32,600 but particularly high in the tomato. 333 00:19:32,600 --> 00:19:36,200 High levels are also found in mushrooms, soy sauce, 334 00:19:36,200 --> 00:19:38,400 and Parmesan cheese - 335 00:19:38,400 --> 00:19:41,800 all ingredients that, like tomatoes, act as brilliant 336 00:19:41,800 --> 00:19:43,960 flavour enhancers in cooking. 337 00:19:43,960 --> 00:19:46,600 Umami taste compounds work really well together 338 00:19:46,600 --> 00:19:49,640 so, you can take a tomato and put it with other foods that have some 339 00:19:49,640 --> 00:19:52,640 savoury component to them because you get all this great 340 00:19:52,640 --> 00:19:54,320 synergy from the taste together. 341 00:19:54,320 --> 00:19:58,480 So, when it comes to umami, more is more. 342 00:19:58,480 --> 00:20:01,040 They love to work together. Absolutely. 343 00:20:03,160 --> 00:20:07,760 The glutamate that gives tomatoes this magical, savoury taste 344 00:20:07,760 --> 00:20:12,040 can increase by as much as 600% as they ripen. 345 00:20:12,040 --> 00:20:14,600 So, the redder, the better. 346 00:20:14,600 --> 00:20:18,400 However, not all varieties are created equal. 347 00:20:18,400 --> 00:20:22,320 If I'm making a savoury dish, what's the best tomato to use? 348 00:20:22,320 --> 00:20:25,720 Tomatoes like these, really, these plum tomatoes. 349 00:20:25,720 --> 00:20:28,320 If you just rip that open, if you can, you'll see what I mean. 350 00:20:28,320 --> 00:20:29,720 Look at that. 351 00:20:29,720 --> 00:20:32,440 This part of the tomato here, the bit with all the seeds 352 00:20:32,440 --> 00:20:34,120 and that juicy bit in the middle, 353 00:20:34,120 --> 00:20:37,080 that's really where you get most of the taste components. 354 00:20:37,080 --> 00:20:39,400 So, if I buy ready-made tomato sauce, 355 00:20:39,400 --> 00:20:41,360 is it likely to be a plum tomato? 356 00:20:41,360 --> 00:20:44,320 Yeah, typically plum tomatoes are used for cooking, are used 357 00:20:44,320 --> 00:20:47,000 for making sauces. So, it's a hard-working tomato, 358 00:20:47,000 --> 00:20:49,320 this, particularly? Yeah, absolutely. 359 00:20:51,080 --> 00:20:54,760 When it comes to tomatoes, it's all about the umami. 360 00:20:56,160 --> 00:20:57,880 Now I understand the chemistry, 361 00:20:57,880 --> 00:21:01,400 I can see why they're the basis of so many of our favourite 362 00:21:01,400 --> 00:21:04,480 dishes, including pizza. 363 00:21:12,240 --> 00:21:13,680 Back at the factory, 364 00:21:13,680 --> 00:21:17,800 after seven hours and 55 minutes of careful preparation, 365 00:21:17,800 --> 00:21:19,600 our bases are made and they're ready 366 00:21:19,600 --> 00:21:22,800 for that all-important tomato topping. 367 00:21:23,760 --> 00:21:27,600 So, I'm heading to the sauce preparation area. 368 00:21:27,600 --> 00:21:32,560 Every pizza sauce they use here is mixed up fresh onsite. 369 00:21:32,560 --> 00:21:37,560 And they all start with 100% Italian tomatoes. 370 00:21:37,560 --> 00:21:39,720 Gabriele! 371 00:21:39,720 --> 00:21:41,040 Good to see you again. 372 00:21:41,040 --> 00:21:44,080 Hello. I'm guessing this is tomato puree, right? 373 00:21:44,080 --> 00:21:47,000 How much of this do we use for our mix, for our sauce? 374 00:21:47,000 --> 00:21:49,000 One and a half of a drum. 375 00:21:50,280 --> 00:21:53,000 The first step to creating our sauce... 376 00:21:53,000 --> 00:21:54,720 Whoa! Whoa! 377 00:21:54,720 --> 00:22:00,120 ..is to pump the concentrated puree into a 500-litre mixer. 378 00:22:00,120 --> 00:22:03,360 And now what? Push the green buttons. Keep it pressed. 379 00:22:03,360 --> 00:22:05,280 This is going to be messy, isn't it? 380 00:22:07,840 --> 00:22:10,720 Whoa! Whoa, whoa, whoa! 381 00:22:10,720 --> 00:22:12,800 Let's go. 382 00:22:12,800 --> 00:22:17,040 Using puree means the factory has a supply of perfectly ripe, 383 00:22:17,040 --> 00:22:22,400 umami-rich tomatoes year-round - not just at harvest time. 384 00:22:22,400 --> 00:22:23,720 It's working! 385 00:22:23,720 --> 00:22:25,360 It's definitely working. 386 00:22:26,480 --> 00:22:28,440 Five minutes later... 387 00:22:28,440 --> 00:22:30,520 ..our mixer is full. 388 00:22:30,520 --> 00:22:34,480 So we've got our lovely tomatoes, beautifully pumped by me. 389 00:22:35,520 --> 00:22:38,760 Now we put the olive oil in. Olive oil! Yeah. OK. 390 00:22:38,760 --> 00:22:42,600 It gives a little bit of flavour and a creaminess of the sauce. 391 00:22:43,720 --> 00:22:45,920 With a simple push of the button, 392 00:22:45,920 --> 00:22:48,880 five litres of olive oil is dosed in. 393 00:22:48,880 --> 00:22:52,440 OK. Now? Now we can put the water. 394 00:22:52,440 --> 00:22:57,960 Followed by 125 litres of water and, next, seasoning. 395 00:22:57,960 --> 00:22:59,920 What is in here? 396 00:22:59,920 --> 00:23:02,360 It's made of dry oregano, 397 00:23:02,360 --> 00:23:05,160 sugar, salt and yeast extract. 398 00:23:08,760 --> 00:23:11,720 A paddle, spinning at 280 RPM, 399 00:23:11,720 --> 00:23:16,280 blends our 500-kilo batch of sauce together. 400 00:23:16,280 --> 00:23:18,400 How many pizzas will it cover? 401 00:23:18,400 --> 00:23:20,960 7,000 pizzas. 402 00:23:20,960 --> 00:23:24,320 Half a tonne of sauce for 7,000 pizzas. 403 00:23:25,800 --> 00:23:27,200 Beautiful mix. 404 00:23:31,400 --> 00:23:33,320 It's pumped through 55 metres 405 00:23:33,320 --> 00:23:37,240 of overhead pipes towards the sauce applicator... 406 00:23:39,040 --> 00:23:42,920 ..where our naked pizza bases receive a splash of colour. 407 00:23:45,920 --> 00:23:49,160 Alberto! I'm back. Nice to see you again. 408 00:23:49,160 --> 00:23:51,440 That is my tomato sauce. 409 00:23:51,440 --> 00:23:54,120 I made it with Gabriele. Yes, yes. 410 00:23:54,120 --> 00:23:59,800 Here we distribute 60g of tomato sauce on each one. 411 00:23:59,800 --> 00:24:02,880 Does my sauce look better than the normal sauce? 412 00:24:02,880 --> 00:24:05,200 Or the same? It's better. 413 00:24:07,400 --> 00:24:09,000 What is that? 414 00:24:09,000 --> 00:24:12,120 That's a camera machine. 415 00:24:12,120 --> 00:24:15,800 That is taking a picture for each pizza. 416 00:24:15,800 --> 00:24:19,040 Why? Because, in this way, 417 00:24:19,040 --> 00:24:24,280 you can give to this machine the right position of each pizza, 418 00:24:24,280 --> 00:24:28,920 so we want to be sure that we are spreading exactly in the centre. 419 00:24:32,280 --> 00:24:35,000 Information is sent straight from the cameras 420 00:24:35,000 --> 00:24:38,920 to these knobbly rollers, which adjust their position depending 421 00:24:38,920 --> 00:24:41,960 on the location of the pizza bases below. 422 00:24:41,960 --> 00:24:44,960 It looks like you are putting the sauce on with a corn cob! 423 00:24:46,440 --> 00:24:51,840 126 nodules on each roller help pick up the bright red sauce 424 00:24:51,840 --> 00:24:55,920 and distribute it evenly around our nude bases. 425 00:24:55,920 --> 00:24:58,240 They work tirelessly to cover 426 00:24:58,240 --> 00:25:01,480 the modesty of 20 pizzas every ten seconds. 427 00:25:04,160 --> 00:25:05,200 Wow! 428 00:25:06,800 --> 00:25:09,480 That is a slow-moving river of pizza. 429 00:25:11,800 --> 00:25:14,480 Reminds me of, like, a military procession. 430 00:25:16,800 --> 00:25:20,480 We had a batch of 1,800 pizzas? Yeah, yeah. 431 00:25:20,480 --> 00:25:23,520 How long would it take before they all went past us? 432 00:25:23,520 --> 00:25:28,200 So, at the moment, this line is running at 100 pizzas per minute. 433 00:25:30,000 --> 00:25:35,640 Is it? Yeah, so it means that that batch will go in 18 minutes. 434 00:25:37,440 --> 00:25:40,240 And these are all for the UK? Yeah. 435 00:25:43,120 --> 00:25:48,360 We're eight hours, 32 minutes and 40 seconds into production 436 00:25:48,360 --> 00:25:50,800 and, even though they're only partially dressed 437 00:25:50,800 --> 00:25:52,640 without their toppings on, 438 00:25:52,640 --> 00:25:57,280 our saucy saucers of dough are on their way to a hot date. 439 00:25:57,280 --> 00:26:01,680 They strut, six at a time, into this huge, four-metre-high, 440 00:26:01,680 --> 00:26:05,280 12.5-metre-long conveyor oven, 441 00:26:05,280 --> 00:26:07,080 where they'll face temperatures 442 00:26:07,080 --> 00:26:10,560 far higher than any domestic oven could manage. 443 00:26:12,240 --> 00:26:15,520 How hot is that oven? 450 degrees. 444 00:26:15,520 --> 00:26:17,760 450 degrees? Yes. 445 00:26:17,760 --> 00:26:21,840 And if you didn't start the cooking process here, we would never get 446 00:26:21,840 --> 00:26:23,920 that crispy base, would we? Yes. 447 00:26:23,920 --> 00:26:26,120 It can't take very long to cook these pizzas. 448 00:26:26,120 --> 00:26:28,120 No, 80 seconds. 449 00:26:28,120 --> 00:26:30,680 80 seconds? Yes. 450 00:26:30,680 --> 00:26:32,560 That is impressive... Yeah. 451 00:26:32,560 --> 00:26:36,880 ..but it's not authentic, like a wood-fired oven, is it? 452 00:26:36,880 --> 00:26:39,240 Yes! Of course it is. 453 00:26:39,240 --> 00:26:40,960 How? 454 00:26:40,960 --> 00:26:42,360 We use this. 455 00:26:45,080 --> 00:26:46,760 Wood pellets? Yes. 456 00:26:47,960 --> 00:26:50,000 That is a wood-fired oven? Yes. 457 00:26:51,600 --> 00:26:54,240 I can see the embers coming off! 458 00:26:54,240 --> 00:26:56,280 Why is wood so good? 459 00:26:56,280 --> 00:27:00,080 Because it's aroma. You understand, aroma? Yeah. 460 00:27:00,080 --> 00:27:02,040 Not the capital of Italy. Yeah! 461 00:27:02,040 --> 00:27:05,240 The smell, the fragrance. Yes. 462 00:27:05,240 --> 00:27:07,840 What is your conveyor belt made from? 463 00:27:07,840 --> 00:27:10,760 It's made of natural volcanic stone. 464 00:27:10,760 --> 00:27:13,800 It's from Etna volcano, from Sicily. 465 00:27:13,800 --> 00:27:16,880 You have a conveyor belt made of stone? Yes. 466 00:27:18,400 --> 00:27:23,520 It turns out stone-baked means just that - cooked on stone. 467 00:27:25,320 --> 00:27:29,320 The sizzling rock used here is porous, which helps the air 468 00:27:29,320 --> 00:27:33,280 circulate around our pizzas and draw steam away, 469 00:27:33,280 --> 00:27:35,960 ensuring a perfectly crisp base. 470 00:27:35,960 --> 00:27:42,040 450-degree wood...proper wood-fired oven... Yeah. ..with a stone base... 471 00:27:42,040 --> 00:27:44,880 Yes. ..to crisp up the bottom. 472 00:27:44,880 --> 00:27:47,760 I'm learning so much. I'm very impressed. 473 00:27:47,760 --> 00:27:51,480 # I want some hot stuff 474 00:27:51,480 --> 00:27:54,840 # I need hot stuff... # 475 00:27:56,120 --> 00:28:00,840 Exactly 80 seconds after their rocky ride through the oven began, 476 00:28:00,840 --> 00:28:03,440 our pizzas emerge at the other end. 477 00:28:03,440 --> 00:28:06,920 Now I can see that volcanic rock very clearly. 478 00:28:06,920 --> 00:28:10,600 How does the crust puff up like that? It just gets much bigger. 479 00:28:10,600 --> 00:28:13,320 Inside that dough, there is the gas 480 00:28:13,320 --> 00:28:15,600 that was produced by the yeast 481 00:28:15,600 --> 00:28:20,480 and, now, with the temperature, the gas increases the pressure 482 00:28:20,480 --> 00:28:24,640 and the gluten net is like the balloon that is inflating. 483 00:28:24,640 --> 00:28:26,320 That pizza is cooked, right? 484 00:28:26,320 --> 00:28:29,480 In fact, now the pizza is partially cooked 485 00:28:29,480 --> 00:28:32,320 because we put the topping after the oven. 486 00:28:32,320 --> 00:28:35,200 You don't want to cook the toppings before we get it? No. 487 00:28:35,200 --> 00:28:38,240 When we put it in the oven, the rest of the base and the topping 488 00:28:38,240 --> 00:28:40,080 will cook the same. 489 00:28:40,080 --> 00:28:41,760 Are you spraying water on there? 490 00:28:41,760 --> 00:28:45,640 Yeah, yeah. We are spraying water to cool down the base 491 00:28:45,640 --> 00:28:49,600 because, in a few minutes, we will top with mozzarella cheese. 492 00:28:54,480 --> 00:28:57,960 We've got thin, crispy bases and tasty tomato sauce 493 00:28:57,960 --> 00:29:00,280 but it's no use getting all that right 494 00:29:00,280 --> 00:29:02,560 if you top them with the wrong cheese. 495 00:29:02,560 --> 00:29:04,840 Cherry's on a melty mission. 496 00:29:04,840 --> 00:29:07,280 # Freak me, baby 497 00:29:07,280 --> 00:29:11,760 # Let me lick you up and down... # 498 00:29:11,760 --> 00:29:14,480 Have to admit, whether it's deep pan or thin and crispy, 499 00:29:14,480 --> 00:29:18,280 is there anything better than that beautiful, 500 00:29:18,280 --> 00:29:21,240 melted, golden cheese on a pizza? 501 00:29:23,120 --> 00:29:28,120 But is mozzarella the best choice scientifically? 502 00:29:28,120 --> 00:29:31,080 # Let me lick you up and down... # 503 00:29:31,080 --> 00:29:34,440 I'm heading to the University of Reading for a pizza cheese 504 00:29:34,440 --> 00:29:38,000 showdown with food scientist Dr Stuart Farrimond. 505 00:29:39,600 --> 00:29:41,640 Hi, Dr Stu. Hi, Cherry, great to see you. 506 00:29:41,640 --> 00:29:43,200 What have we got here? 507 00:29:43,200 --> 00:29:46,400 A variety of cheeses because there is some serious science 508 00:29:46,400 --> 00:29:49,040 behind getting that perfect cheese. 509 00:29:49,040 --> 00:29:52,200 First, we're assessing meltability. 510 00:29:52,200 --> 00:29:55,600 Not every cheese melts, so, one of the most important factors 511 00:29:55,600 --> 00:29:58,200 is how acidic the cheese is 512 00:29:58,200 --> 00:30:00,400 and we measure that with the PH. 513 00:30:00,400 --> 00:30:04,200 So, we're going to test that now with these different cheeses. 514 00:30:04,200 --> 00:30:08,320 We're measuring the PH levels of some popular varieties. 515 00:30:09,320 --> 00:30:12,480 We'll start at this end with blue cheese - we've got Stilton. 516 00:30:12,480 --> 00:30:14,600 One of my favourites. 517 00:30:14,600 --> 00:30:16,040 Stinky cheese! 518 00:30:16,040 --> 00:30:18,400 The stinkier, the better. 519 00:30:18,400 --> 00:30:19,960 In we go. 520 00:30:19,960 --> 00:30:21,560 A lower number is very acid. 521 00:30:21,560 --> 00:30:23,760 A higher number is more alkaline. 522 00:30:23,760 --> 00:30:28,200 What we're looking for is a PH of between 5 and 5.9. 523 00:30:28,200 --> 00:30:30,000 Ideally in the middle. 524 00:30:30,000 --> 00:30:31,760 5.3 is the sweet spot. 525 00:30:31,760 --> 00:30:35,600 So, what you can see already is that it's a much higher number. 526 00:30:35,600 --> 00:30:37,440 6.27 already. 527 00:30:37,440 --> 00:30:40,120 And that means that it's less acidic. 528 00:30:40,120 --> 00:30:44,800 Low acidity tells us about the protein network of the Stilton. 529 00:30:44,800 --> 00:30:47,720 It's like this ball of elastic band. It can't get apart 530 00:30:47,720 --> 00:30:50,120 cos the proteins are too tightly bound together. 531 00:30:50,120 --> 00:30:52,000 So that, when you melt it, 532 00:30:52,000 --> 00:30:55,440 they don't really have that lovely, soft, melty, 533 00:30:55,440 --> 00:30:58,400 stringy effect. They just stay like this. 534 00:30:58,400 --> 00:31:00,960 Next up, crumbly feta. 535 00:31:00,960 --> 00:31:02,720 In we go. 536 00:31:04,200 --> 00:31:07,680 It's landed at 4.26. What does that mean? 537 00:31:07,680 --> 00:31:09,640 Well, the feta is too acidic. 538 00:31:09,640 --> 00:31:14,040 High acidity makes the protein network too loose. 539 00:31:14,040 --> 00:31:17,720 So when you melt it... It will actually burn rather than melt. 540 00:31:17,720 --> 00:31:20,280 Third up is mozzarella. 541 00:31:20,280 --> 00:31:22,080 Probe that cheese! 542 00:31:22,080 --> 00:31:26,240 Bang in the middle between 5 and 5.9. It's in the melting zone. 543 00:31:26,240 --> 00:31:30,440 So, the proteins in the mozzarella, they're just in that sweet spot 544 00:31:30,440 --> 00:31:32,320 where they can melt beautifully 545 00:31:32,320 --> 00:31:35,080 because it has got the perfect acidity. Yes, 546 00:31:35,080 --> 00:31:37,480 but there's another reason that makes mozzarella 547 00:31:37,480 --> 00:31:40,800 so good for pizza and that is the stringiness. Yes. 548 00:31:40,800 --> 00:31:42,920 And it's the way in which it's made. 549 00:31:42,920 --> 00:31:46,800 Mozzarella is kneaded, just like pizza dough, 550 00:31:46,800 --> 00:31:49,560 which gives it extra stretchability. 551 00:31:49,560 --> 00:31:53,760 And that's why it has the long, lovely, cheesy stringiness? Mm-hm. 552 00:31:53,760 --> 00:31:58,400 So, to make our ultimate pizza, feta and blue cheese are out? Out. 553 00:31:58,400 --> 00:32:02,600 So, mozzarella is in. Are there any other cheeses we should try? 554 00:32:02,600 --> 00:32:06,160 Yes. There are other cheeses that are in the melting zone. 555 00:32:06,160 --> 00:32:08,880 We've got here some cheddar and we've got some Gruyere. 556 00:32:08,880 --> 00:32:11,160 They're all between five and 5.9. 557 00:32:11,160 --> 00:32:13,400 But the only way to find out which is best 558 00:32:13,400 --> 00:32:15,760 is to do some experiments. And you're going to hate this - 559 00:32:15,760 --> 00:32:18,560 we're going to have to make some pizza. Yes! 560 00:32:19,920 --> 00:32:25,480 We're topping identical plain tomato basses with our three cheeses. 561 00:32:25,480 --> 00:32:26,720 In you go. 562 00:32:29,240 --> 00:32:31,240 After ten minutes cooking, 563 00:32:31,240 --> 00:32:33,720 there are clear visual differences. 564 00:32:33,720 --> 00:32:35,360 All right. 565 00:32:37,000 --> 00:32:40,320 They look absolutely gorgeous. 566 00:32:41,520 --> 00:32:43,040 There we go. Thank you. Thank you. 567 00:32:43,040 --> 00:32:45,600 So here we've got our lovely pieces - 568 00:32:45,600 --> 00:32:48,080 Gruyere, cheddar and mozzarella. 569 00:32:48,080 --> 00:32:50,680 So, I want to point out to you something with the cheddar. 570 00:32:50,680 --> 00:32:53,520 You can see here that you've got oily patches, 571 00:32:53,520 --> 00:32:57,640 and what's happened there is the fat has separated out 572 00:32:57,640 --> 00:33:00,440 as this oil. So, that's not ideal. 573 00:33:01,720 --> 00:33:05,520 Cheddar's high fat content makes it look unappealing. 574 00:33:06,840 --> 00:33:09,240 Gruyere looks more promising. 575 00:33:09,240 --> 00:33:10,680 But look here at the Gruyere. 576 00:33:10,680 --> 00:33:13,480 You can see there's blistering if you look round the edges. Mm. 577 00:33:13,480 --> 00:33:16,640 And that's because there's quite a lot of moisture in Gruyere. Yeah. 578 00:33:16,640 --> 00:33:20,640 And, so, as it heats up, the water turns to steam and it comes 579 00:33:20,640 --> 00:33:25,160 up as these bubbles, this blistering that we see. When the bubbles burst, 580 00:33:25,160 --> 00:33:27,880 then you get a rough surface, and that helps the browning. 581 00:33:27,880 --> 00:33:30,360 So, why do we want the browning effect? That's where 582 00:33:30,360 --> 00:33:33,680 all the flavour is. That's where the magical reaction is happening. 583 00:33:34,720 --> 00:33:37,920 But mozzarella is the clear winner. 584 00:33:37,920 --> 00:33:40,880 If we go to the mozzarella, this has even more moisture in it, 585 00:33:40,880 --> 00:33:43,320 and, so, you've got more of this bubbling effect. 586 00:33:43,320 --> 00:33:46,320 So, the mozzarella is good because it browns faster 587 00:33:46,320 --> 00:33:48,560 without separating into oily pools. 588 00:33:48,560 --> 00:33:51,920 You've got it. Mozzarella is the winner. It's got my vote. 589 00:33:51,920 --> 00:33:54,600 Science confirms tradition. 590 00:33:54,600 --> 00:33:59,000 Great meltability and beautiful browning make mozzarella 591 00:33:59,000 --> 00:34:00,800 the perfect pizza cheese. 592 00:34:09,120 --> 00:34:14,200 We're eight hours and 34 minutes into the pizza-making process. 593 00:34:14,200 --> 00:34:16,320 As they emerge from the oven, 594 00:34:16,320 --> 00:34:21,240 our pizzas take a spin along 100m of computer-controlled 595 00:34:21,240 --> 00:34:25,000 conveyor belts, gently cooling from 90 degrees Celsius 596 00:34:25,000 --> 00:34:26,960 to 35 as they go. 597 00:34:28,920 --> 00:34:30,800 Any that aren't up to scratch 598 00:34:30,800 --> 00:34:33,600 are unceremoniously dropped off the line. 599 00:34:35,360 --> 00:34:39,680 Those that pass muster are now cool enough to be topped with cheese, 600 00:34:39,680 --> 00:34:43,160 which is, of course, 100% mozzarella. 601 00:34:43,160 --> 00:34:46,400 And grated fresh to order onsite. 602 00:34:47,520 --> 00:34:48,800 Coming through! 603 00:34:48,800 --> 00:34:51,320 HE SPEAKS IN ITALIAN 604 00:34:51,320 --> 00:34:53,120 HE LAUGHS 605 00:34:53,120 --> 00:34:58,960 They get through an astonishing ten tonnes of the stuff every day. 606 00:34:58,960 --> 00:35:00,920 Alberto. Oh, yeah. 607 00:35:00,920 --> 00:35:04,400 Does it go in there? Yeah, because we want it on the pizza, so, please, 608 00:35:04,400 --> 00:35:06,880 let's load the machine. Just throw it in? 609 00:35:06,880 --> 00:35:09,120 Yeah. Yeah. 610 00:35:09,120 --> 00:35:11,640 This cheese has 1% chives. 611 00:35:11,640 --> 00:35:13,440 Fantastic, Gregg. 612 00:35:14,560 --> 00:35:17,760 Which add colour and a subtle hint of onion. 613 00:35:17,760 --> 00:35:20,000 Perfect. 614 00:35:20,000 --> 00:35:23,560 My freshly grated mozzarella falls onto a conveyor belt, 615 00:35:23,560 --> 00:35:27,520 which carries it to the waterfall distributor. 616 00:35:27,520 --> 00:35:32,000 Look, it's coming there, and is flowing through the machine 617 00:35:32,000 --> 00:35:33,640 and is topping the pizza. 618 00:35:33,640 --> 00:35:36,320 As the cheese drops into the distributor, 619 00:35:36,320 --> 00:35:41,920 148 individual metal fingers help disperse it evenly onto the pizza 620 00:35:41,920 --> 00:35:45,680 bases below. It's helping to have always the same quantity 621 00:35:45,680 --> 00:35:47,880 of mozzarella cheese for each pizza. 622 00:35:47,880 --> 00:35:49,480 That's where it's holding, 623 00:35:49,480 --> 00:35:52,280 and these wheels, they are sifting... 624 00:35:53,680 --> 00:35:57,320 ..and making sure this cheese does not come out too fast. Exactly. 625 00:35:57,320 --> 00:36:00,880 So, it's dropping like light rain. Yes. 626 00:36:00,880 --> 00:36:04,000 Do you know how much cheese actually ends up on each pizza? 627 00:36:04,000 --> 00:36:06,080 Yeah. 50g. 628 00:36:07,240 --> 00:36:10,920 More cheese is on the belt than the pizza. 629 00:36:10,920 --> 00:36:15,640 Look, it's blowing into the conveyor, then up again, 630 00:36:15,640 --> 00:36:17,200 and again into the machine. 631 00:36:17,200 --> 00:36:18,880 So, no waste. 632 00:36:18,880 --> 00:36:21,400 Some cheese must go round 50 times! 633 00:36:21,400 --> 00:36:23,000 No, no, no, no. 634 00:36:23,000 --> 00:36:27,160 In the average, we calculated that it's flowing only three times. 635 00:36:30,800 --> 00:36:32,760 I like it. I think it's pretty. 636 00:36:34,680 --> 00:36:38,240 So far, we've made a basic Margherita but... 637 00:36:38,240 --> 00:36:41,760 ..pepperoni is the topping we reach for most often 638 00:36:41,760 --> 00:36:43,200 in the supermarket, 639 00:36:43,200 --> 00:36:46,720 accounting for a fifth of all the pizzas we buy. 640 00:36:46,720 --> 00:36:48,200 It's my favourite, too. 641 00:36:48,200 --> 00:36:51,520 So, how do they make this famous, spicy sausage? 642 00:36:51,520 --> 00:36:53,800 Over to Cherry. In Austria? 643 00:36:55,960 --> 00:36:57,800 Yes, Austria. 644 00:36:57,800 --> 00:37:00,320 Home of rolling hills, 645 00:37:00,320 --> 00:37:03,720 alpine chalets and smoked sausage. 646 00:37:04,960 --> 00:37:07,280 Because pepperoni isn't Italian. 647 00:37:07,280 --> 00:37:09,880 It's an American take on salami. 648 00:37:09,880 --> 00:37:14,600 So, here I am, in Austria, at the largest pepperoni factory 649 00:37:14,600 --> 00:37:19,320 in the country, where every day they turn 50 tonnes of meat 650 00:37:19,320 --> 00:37:22,680 into 10,000 spicy sausages. 651 00:37:22,680 --> 00:37:25,640 It's all overseen by Gerhard Lanz. 652 00:37:25,640 --> 00:37:27,560 Meat delivery. 653 00:37:27,560 --> 00:37:31,880 Each batch begins with a 400kg delivery. 654 00:37:31,880 --> 00:37:33,960 What kind of meat is this? 655 00:37:33,960 --> 00:37:39,400 This is pork shoulder, and this special trimming for pepperoni. 656 00:37:39,400 --> 00:37:43,120 You can see here, the fat is very, very low. 657 00:37:43,120 --> 00:37:44,920 Maximum 10% fat. 658 00:37:44,920 --> 00:37:46,960 It's a very, very lean meat. 659 00:37:46,960 --> 00:37:49,040 This fresh pork... 660 00:37:50,160 --> 00:37:51,440 Chops away! 661 00:37:53,360 --> 00:37:54,440 Aufwarts. 662 00:37:54,440 --> 00:37:57,920 ..is combined with an equal quantity of frozen, 663 00:37:57,920 --> 00:38:01,640 but a quarter of our finished pepperoni will be made up 664 00:38:01,640 --> 00:38:02,840 of pork back fat. 665 00:38:02,840 --> 00:38:07,360 Back fat is very, very urgent for texture in the pepperoni. 666 00:38:07,360 --> 00:38:09,680 When you have pepperoni, it has little bits of fat in it, 667 00:38:09,680 --> 00:38:12,800 and that comes from adding the back fat in. Correct. OK. 668 00:38:12,800 --> 00:38:15,880 Pepperoni is a cured sausage, 669 00:38:15,880 --> 00:38:19,280 meaning that it's preserved rather than cooked, 670 00:38:19,280 --> 00:38:23,000 which calls for an unexpected ingredient. 671 00:38:23,000 --> 00:38:27,640 You start with the starter culture. The starter culture, like cheese. 672 00:38:27,640 --> 00:38:29,600 Yes. So, this is bacteria? 673 00:38:29,600 --> 00:38:33,520 It's a bacteria. It's very, very important for the fermentation 674 00:38:33,520 --> 00:38:35,960 of the pepperoni. In pepperoni?! Yeah. 675 00:38:35,960 --> 00:38:38,520 Why do you ferment pepperoni? 676 00:38:38,520 --> 00:38:41,520 This is for stabilise the pepperoni. 677 00:38:41,520 --> 00:38:44,320 So, it's a kind of preservative method? Yes. 678 00:38:44,320 --> 00:38:48,600 The fermentation process creates an acidic environment in the meat, 679 00:38:48,600 --> 00:38:51,800 helping to prevent the growth of any harmful bacteria. 680 00:38:51,800 --> 00:38:54,320 P is to start. Is that P for pepperoni? 681 00:38:54,320 --> 00:38:55,840 P for pepperoni, yes. 682 00:38:55,840 --> 00:38:57,680 With the push of a button, 683 00:38:57,680 --> 00:38:59,480 our pork pours into the chopper... 684 00:38:59,480 --> 00:39:01,880 Here comes the meat. In it goes. 685 00:39:01,880 --> 00:39:04,520 ..which minces it into a smooth texture. 686 00:39:04,520 --> 00:39:09,640 And in goes our starter culture, along with another preservative. 687 00:39:09,640 --> 00:39:11,400 Salt! Yes. 688 00:39:11,400 --> 00:39:15,360 The salt's job is to draw moisture out of the meat. 689 00:39:15,360 --> 00:39:17,360 The whole thing. The whole thing?! Yes. 690 00:39:17,360 --> 00:39:21,680 And now to create that famous spicy pepperoni flavour. 691 00:39:21,680 --> 00:39:23,720 That's a lot of chilli! 692 00:39:23,720 --> 00:39:28,240 A seasoning mix containing ground chilli, pepper, nutmeg, garlic, 693 00:39:28,240 --> 00:39:29,960 ginger and paprika, 694 00:39:29,960 --> 00:39:32,560 which gives it that traditional deep, red colour. 695 00:39:34,280 --> 00:39:37,520 Great, your first pepperoni! 696 00:39:37,520 --> 00:39:38,920 Yeah! 697 00:39:38,920 --> 00:39:40,960 Two minutes later... 698 00:39:40,960 --> 00:39:42,800 It's like a meat wave. 699 00:39:42,800 --> 00:39:45,560 ..we have perfectly seasoned spicy pork. 700 00:39:46,720 --> 00:39:48,880 Might as well pull my weight around here. Yeah. 701 00:39:48,880 --> 00:39:51,760 Off to the filler! Up to the filler. 702 00:39:51,760 --> 00:39:54,160 It's the moment I've been waiting for. 703 00:39:54,160 --> 00:39:56,240 Wahey! 704 00:39:58,520 --> 00:40:00,160 Can I make a sausage? Yes. 705 00:40:00,160 --> 00:40:03,480 Yes! Press the green. Press the green button. Yes. 706 00:40:03,480 --> 00:40:05,200 And hold that. And hold here. 707 00:40:05,200 --> 00:40:08,920 I'm not going to mess it up? Ready? Start. Yeah. 708 00:40:08,920 --> 00:40:10,880 Under high pressure, 709 00:40:10,880 --> 00:40:15,560 our spicy pork meat is forced into a very thin casing. And stop. 710 00:40:15,560 --> 00:40:18,880 Oh, God. It's so fast! 711 00:40:18,880 --> 00:40:21,800 Wow, and they're so long. 712 00:40:23,760 --> 00:40:26,480 Look how many I made! 713 00:40:26,480 --> 00:40:29,520 They're chopped to exactly 1m in length. 714 00:40:32,560 --> 00:40:36,960 Holy moley! That is a long old stick of pepperoni. 715 00:40:36,960 --> 00:40:38,280 That is amazing. 716 00:40:38,280 --> 00:40:39,600 Look at it. 717 00:40:39,600 --> 00:40:43,920 Then, they're taken to one of 30 60-square-metre smokers. 718 00:40:43,920 --> 00:40:45,920 In we go. 719 00:40:45,920 --> 00:40:49,160 Each one holds 6,000 pepperoni. 720 00:40:49,160 --> 00:40:51,080 Let's start the process! Yes. 721 00:40:54,120 --> 00:40:59,040 Cold beach wood smoke envelops the sausages, giving them a smoky 722 00:40:59,040 --> 00:41:02,280 flavour, but, importantly, it doesn't cook them. 723 00:41:02,280 --> 00:41:06,440 After four days, they're transferred to a maturation chamber, 724 00:41:06,440 --> 00:41:08,120 where the meat is cured. 725 00:41:08,120 --> 00:41:09,800 Over the next two weeks, 726 00:41:09,800 --> 00:41:12,840 the water inside the sausages evaporates out, 727 00:41:12,840 --> 00:41:16,640 causing them to shrink by up to 25%. 728 00:41:16,640 --> 00:41:20,560 Wow, what an amazing sight. 729 00:41:20,560 --> 00:41:24,960 The colour is so much darker and richer, 730 00:41:24,960 --> 00:41:27,680 and it's so much harder. 731 00:41:28,920 --> 00:41:30,200 I mean, is it ready now? 732 00:41:30,200 --> 00:41:33,160 Next step is the pealing. All right. Lead the way. 733 00:41:37,320 --> 00:41:39,560 The cases are removed. 734 00:41:39,560 --> 00:41:43,200 Oh, that's so fun. Whee! 735 00:41:44,240 --> 00:41:46,200 And they're chopped in half. 736 00:41:47,640 --> 00:41:49,840 Cut that off. 737 00:41:49,840 --> 00:41:52,640 It's so good. You can see all the different parts. 738 00:41:52,640 --> 00:41:54,960 This is the different parts from the back fat 739 00:41:54,960 --> 00:41:57,080 and from the lean meat, from the shoulder. 740 00:41:57,080 --> 00:42:00,440 So, the lean meat, the back fat, the spices... Yes. 741 00:42:00,440 --> 00:42:02,320 ..everything that's gone into it. 742 00:42:03,400 --> 00:42:05,400 After 20 days of production, 743 00:42:05,400 --> 00:42:08,800 our Austrian pepperoni are packed 25 to a box, 744 00:42:08,800 --> 00:42:11,640 ready for the pizza factory. 745 00:42:14,320 --> 00:42:16,000 Over the border in Italy, 746 00:42:16,000 --> 00:42:19,920 eight hours 37 minutes and 40 seconds into production, 747 00:42:19,920 --> 00:42:21,840 our cheese and tomato pizzas 748 00:42:21,840 --> 00:42:24,760 are waiting for Cherry's spicy sausage... 749 00:42:37,600 --> 00:42:40,840 ..which is applied by the pepperoni applicator. 750 00:42:48,440 --> 00:42:50,360 Oh, I love this. 751 00:42:50,360 --> 00:42:53,240 This has got to be the best part of the whole factory! 752 00:42:53,240 --> 00:42:55,840 She's got to hold on to that while it's so long... 753 00:42:55,840 --> 00:42:57,880 Yeah. ..because it will break. Yeah. 754 00:42:57,880 --> 00:42:59,600 That is like a crazy game! 755 00:42:59,600 --> 00:43:01,920 Is that even real? Yes. 756 00:43:01,920 --> 00:43:04,080 Did they go in every hole? Yeah. 757 00:43:04,080 --> 00:43:06,560 Not that one? 758 00:43:06,560 --> 00:43:07,840 Why not that one? 759 00:43:09,440 --> 00:43:13,320 No, because we need only 12 slices for each pizza. Ah! 760 00:43:15,000 --> 00:43:16,600 This pepperoni, 761 00:43:16,600 --> 00:43:19,760 is this an authentic pizza topping for Italian? 762 00:43:19,760 --> 00:43:23,120 No. No. In Italy, we have a different kind of salami. 763 00:43:23,120 --> 00:43:26,440 Is this more spicy... Yeah. ..than you are used to? 764 00:43:26,440 --> 00:43:28,480 It's more hot. 765 00:43:28,480 --> 00:43:30,360 There's got to be an easier way! 766 00:43:30,360 --> 00:43:33,400 Right... Whoa, whoa! 767 00:43:33,400 --> 00:43:35,720 Piano, piano. 768 00:43:37,200 --> 00:43:40,160 As the pepperoni rocks back and forth, 769 00:43:40,160 --> 00:43:42,480 blades lubricated with water 770 00:43:42,480 --> 00:43:46,160 slice off 2mm-thick pieces of meat. 771 00:43:46,160 --> 00:43:49,440 A laser tells the machine when there's a pizza underneath, 772 00:43:49,440 --> 00:43:53,400 and 12 bits of our spicy sausage are dropped onto each one. 773 00:43:53,400 --> 00:43:55,720 Brilliant. 774 00:43:55,720 --> 00:43:58,600 I can actually see the pepperoni dropping. 775 00:43:58,600 --> 00:44:00,320 Yeah. 776 00:44:00,320 --> 00:44:02,120 12 on each pizza. 777 00:44:02,120 --> 00:44:05,280 Exactly. How many pizzas going through here, Alberto? 778 00:44:05,280 --> 00:44:07,640 Around 100 per minute. 779 00:44:07,640 --> 00:44:10,320 Yeah? What are these ladies doing? 780 00:44:10,320 --> 00:44:12,200 Because the pepperoni is on the pizza. 781 00:44:12,200 --> 00:44:16,160 Yeah, but sometimes a slice is missing. 782 00:44:16,160 --> 00:44:19,480 And we want exactly 12 slices per each pizza. 783 00:44:19,480 --> 00:44:21,560 We don't want it perfect. 784 00:44:21,560 --> 00:44:23,400 That is the beauty of the pizza. 785 00:44:23,400 --> 00:44:24,760 Yeah, but... You cut the slice, 786 00:44:24,760 --> 00:44:26,560 sometimes you are lucky, sometimes... 787 00:44:26,560 --> 00:44:28,960 Yes, yes, I understand, but here we are in Italy. 788 00:44:28,960 --> 00:44:31,920 I'm sorry. And we want a good-tasting pizza 789 00:44:31,920 --> 00:44:33,240 and a good looking pizza. 790 00:44:34,480 --> 00:44:36,200 OK, OK. 791 00:44:38,680 --> 00:44:43,120 Italian precision has applied our spicy Austrian sausage. 792 00:44:43,120 --> 00:44:45,600 But because us Brits love loads of toppings, 793 00:44:45,600 --> 00:44:48,200 we're only halfway there. 794 00:44:48,200 --> 00:44:51,640 Next up, it's precisely 20g of red onion, 795 00:44:51,640 --> 00:44:55,760 applied just like our cheese, by a waterfall applicator. 796 00:44:58,200 --> 00:45:02,040 Now time for even more pepperoni. 797 00:45:02,040 --> 00:45:05,800 Which relies on something a little more low tech. 798 00:45:05,800 --> 00:45:08,000 They are putting on more pepperoni? 799 00:45:08,000 --> 00:45:12,280 Yeah, they are hand topping the small pepperoni. 800 00:45:12,280 --> 00:45:13,880 So, it's a different taste. 801 00:45:13,880 --> 00:45:16,120 Because we want to have a good balance 802 00:45:16,120 --> 00:45:17,720 of taste of meat in the pizza. 803 00:45:17,720 --> 00:45:20,680 So, first, we need to wear this. 804 00:45:20,680 --> 00:45:22,880 For each one, we need 10g. 805 00:45:22,880 --> 00:45:24,600 OK, try. 806 00:45:27,440 --> 00:45:29,680 Not bad. Not bad. 807 00:45:29,680 --> 00:45:31,560 OK. OK. 808 00:45:31,560 --> 00:45:33,680 Why can't this be done with a machine? 809 00:45:33,680 --> 00:45:38,600 Because this material is not easy to top with a waterfall machine, 810 00:45:38,600 --> 00:45:40,440 and we want a good distribution. 811 00:45:40,440 --> 00:45:43,080 So, we prefer to top by hand. 812 00:45:43,080 --> 00:45:45,120 I'm rubbish at this! 813 00:45:45,120 --> 00:45:47,560 I'm OK at eating them, 814 00:45:47,560 --> 00:45:51,360 but there is no way I can do this as fast as these ladies. 815 00:45:51,360 --> 00:45:52,680 That looks simple. 816 00:45:53,720 --> 00:45:56,600 But you are doing like two pizzas every second. 817 00:45:56,600 --> 00:45:58,120 Yeah. I cannot do this. Yeah. 818 00:46:00,400 --> 00:46:04,920 The final topping is 25g of fiery jalapeno peppers. 819 00:46:06,520 --> 00:46:09,520 Eight hours, 38 minutes and 40 seconds 820 00:46:09,520 --> 00:46:13,160 after we began, our pizzas are complete. 821 00:46:13,160 --> 00:46:14,680 And ready for the freezer. 822 00:46:16,320 --> 00:46:18,320 That's it. That's the finished pizza, right? 823 00:46:18,320 --> 00:46:19,720 Yeah. 824 00:46:19,720 --> 00:46:23,160 Are you spraying them with water again? Yeah. 825 00:46:23,160 --> 00:46:26,640 Because, in this way, then the first part of the freezing tunnel, 826 00:46:26,640 --> 00:46:32,040 the water will freeze immediately. So we freeze the topping exactly 827 00:46:32,040 --> 00:46:33,880 where it is at this stage. 828 00:46:33,880 --> 00:46:35,360 And when I get it home and cook it, 829 00:46:35,360 --> 00:46:37,760 it will be the same as that? Exactly the same. 830 00:46:39,320 --> 00:46:43,080 100 pizzas a minute head into the freezer. 831 00:46:44,640 --> 00:46:50,120 Where they'll stay for 30 minutes in an icy -40 degrees Celsius. 832 00:46:51,160 --> 00:46:55,480 We take it for granted that we can make and freeze a pizza here, 833 00:46:55,480 --> 00:46:59,480 in Italy, and then take it from a freezer in a supermarket 834 00:46:59,480 --> 00:47:02,040 in the UK in just over a week. 835 00:47:03,400 --> 00:47:05,680 Ruth is on the trail of the technology 836 00:47:05,680 --> 00:47:07,960 which makes this possible. 837 00:47:07,960 --> 00:47:13,080 These days, you can get any food you like, any time of year, 838 00:47:13,080 --> 00:47:15,040 from anywhere in the world. 839 00:47:21,200 --> 00:47:24,320 But, 150 years ago, it wasn't quite so easy. 840 00:47:25,720 --> 00:47:30,040 I'm discovering who and what revolutionised our eating habits 841 00:47:30,040 --> 00:47:32,080 with food historian Polly Russell. 842 00:47:32,080 --> 00:47:34,920 Polly! Hello! Hello! 843 00:47:34,920 --> 00:47:38,760 I brought us a pizza. Thank you very much. 844 00:47:38,760 --> 00:47:40,800 Why on Earth are we meeting in Greenwich? 845 00:47:40,800 --> 00:47:43,360 Well, we're here by the Cutty Sark, 846 00:47:43,360 --> 00:47:47,160 what was one of the fastest ships of its day in the 19th century, 847 00:47:47,160 --> 00:47:51,840 a merchant ship that would bring goods from all around the world. 848 00:47:53,080 --> 00:47:57,440 But one thing they weren't carrying as cargo on ocean-crossing voyages 849 00:47:57,440 --> 00:47:58,760 was fresh food. 850 00:47:58,760 --> 00:48:02,320 Only preserved or tinned goods could be transported. 851 00:48:02,320 --> 00:48:06,760 And I suppose this is sort of the moment when places like New Zealand 852 00:48:06,760 --> 00:48:12,000 and Australia are really starting to produce food on a massive scale. 853 00:48:12,000 --> 00:48:13,840 Particularly in Australia and New Zealand, 854 00:48:13,840 --> 00:48:17,680 there are millions of sheep being used to produce wool. 855 00:48:17,680 --> 00:48:20,480 Now, there are not big enough populations in those countries 856 00:48:20,480 --> 00:48:21,840 to consume all the meat. 857 00:48:21,840 --> 00:48:24,920 So, you've got this surplus of meat that is being wasted 858 00:48:24,920 --> 00:48:29,040 and you've got growing populations in Europe that want meat. 859 00:48:29,040 --> 00:48:32,600 So, the question is how do you resolve that problem? 860 00:48:32,600 --> 00:48:34,080 So, how did they do it? 861 00:48:34,080 --> 00:48:35,920 Well, you can't transport livestock 862 00:48:35,920 --> 00:48:37,840 that sort of length of journey. 863 00:48:37,840 --> 00:48:41,280 So, you need a way to chill or freeze that meat. 864 00:48:41,280 --> 00:48:44,600 So, couldn't you just, sort of, like, pack a whole ship 865 00:48:44,600 --> 00:48:46,440 full of ice? When you see... 866 00:48:48,600 --> 00:48:50,720 ..the length of this journey. 867 00:48:50,720 --> 00:48:54,960 I mean, this is 14,000 miles, coming through the tropics. 868 00:48:54,960 --> 00:48:57,920 There's absolutely no way the ice is going to last. 869 00:48:57,920 --> 00:49:00,720 And there is also nowhere to pick it up. Right. 870 00:49:01,880 --> 00:49:05,760 This problem was solved in the 1970s when a company called Bell-Coleman 871 00:49:05,760 --> 00:49:10,320 produced a freezer suitable for installation on board ships. 872 00:49:10,320 --> 00:49:12,040 A simple heat exchanger, 873 00:49:12,040 --> 00:49:17,640 it sucked warm air from below deck, compressed it, cooled it with water, 874 00:49:17,640 --> 00:49:20,520 and then released it back into the hold. 875 00:49:21,760 --> 00:49:24,200 This is a convincing onboard machine. 876 00:49:24,200 --> 00:49:26,560 It looks sturdy, doesn't it? It does look sturdy. 877 00:49:26,560 --> 00:49:30,600 And, in 1882, the Dunedin became one of the first vessels 878 00:49:30,600 --> 00:49:32,960 to utilise this new technology. 879 00:49:34,040 --> 00:49:36,200 The ship sailed from New Zealand to London 880 00:49:36,200 --> 00:49:40,280 and docked more than three months later with most of its cargo 881 00:49:40,280 --> 00:49:45,080 of 5,000 carcasses in perfect frozen condition. 882 00:49:45,080 --> 00:49:47,600 This took off in a really big way very fast. 883 00:49:47,600 --> 00:49:50,600 This technology becomes really important for feeding 884 00:49:50,600 --> 00:49:52,920 the population on imported meat. 885 00:49:54,040 --> 00:49:57,760 But transporting frozen meat across oceans only solved part 886 00:49:57,760 --> 00:50:01,880 of the problem of getting food to the masses. 887 00:50:01,880 --> 00:50:04,240 And Polly is going to show me why. 888 00:50:06,160 --> 00:50:08,800 I have to ask, Polly, glamorous though it is - 889 00:50:08,800 --> 00:50:10,800 and I'm not complaining... I think you are. 890 00:50:10,800 --> 00:50:13,440 ..why are we in a lorry park rather than at the Cutty Sark? 891 00:50:13,440 --> 00:50:16,760 Because food can arrive at the ports frozen, 892 00:50:16,760 --> 00:50:20,520 and then how do you get to distribute it across the country? 893 00:50:20,520 --> 00:50:23,880 Particularly in America, where cities, towns can be 894 00:50:23,880 --> 00:50:27,000 hundreds and hundreds of miles away from ports. 895 00:50:27,000 --> 00:50:29,400 What was needed was a freezer truck. 896 00:50:29,400 --> 00:50:32,360 Oh, God, I can feel it from here! A blast of air! 897 00:50:32,360 --> 00:50:35,680 Flippin' heck! Up you go. 898 00:50:37,600 --> 00:50:41,600 Wow, is this cold! This is -16 in here. 899 00:50:41,600 --> 00:50:46,800 And the reason that this is possible is because of this man here. 900 00:50:46,800 --> 00:50:49,800 He is Frederick McKinley Jones. 901 00:50:49,800 --> 00:50:55,400 Frederick Jones was born in 1893 in America's Deep South. 902 00:50:55,400 --> 00:50:57,800 He knew how to fix things. 903 00:50:57,800 --> 00:50:59,760 He was a kind of natural engineer. 904 00:50:59,760 --> 00:51:01,920 And, in 1938, 905 00:51:01,920 --> 00:51:05,800 he'd heard about the problems of transporting food in trucks, 906 00:51:05,800 --> 00:51:07,320 that they couldn't keep it cold. 907 00:51:07,320 --> 00:51:09,640 For a man like him, that was irresistible. 908 00:51:09,640 --> 00:51:15,320 At that time, around 40% of American households had a fridge. 909 00:51:15,320 --> 00:51:18,560 Jones started tinkering around with the mechanics 910 00:51:18,560 --> 00:51:21,000 and made an incredible breakthrough. 911 00:51:21,000 --> 00:51:26,080 He came up with a version that would be strong enough 912 00:51:26,080 --> 00:51:29,520 and would work on a lorry and keep food frozen. 913 00:51:29,520 --> 00:51:32,000 And this is the patent for it. 914 00:51:32,000 --> 00:51:34,560 The technology he installed was very similar 915 00:51:34,560 --> 00:51:39,080 to that in a domestic freezer, but powered by the lorry's engine. 916 00:51:39,080 --> 00:51:43,160 In fact, the truck where we're standing in now is cooled 917 00:51:43,160 --> 00:51:47,160 by a system which was really basically designed by Jones. 918 00:51:47,160 --> 00:51:50,000 That's quite something. Yes. 919 00:51:50,000 --> 00:51:53,760 61 years after the invention that brought fresh New Zealand lamb 920 00:51:53,760 --> 00:51:55,200 to our ports, 921 00:51:55,200 --> 00:51:58,800 Jones brought it all the way to our dinner tables. 922 00:52:01,400 --> 00:52:04,440 The pioneers of frozen transport may not have known it, 923 00:52:04,440 --> 00:52:10,400 but their inventions spawned a multi-billion pound industry. 924 00:52:10,400 --> 00:52:13,520 It turns out that there's gold in cold. 925 00:52:20,000 --> 00:52:23,200 In the factory, our pizzas have spent the last 30 minutes 926 00:52:23,200 --> 00:52:24,520 in the freezer. 927 00:52:24,520 --> 00:52:29,560 And, now, nine hours and ten minutes since I saw the flour delivery, 928 00:52:29,560 --> 00:52:33,400 they're heading out, into the light of the packing hall. 929 00:52:33,400 --> 00:52:38,880 A jet of air blows any ice crystals from the top of each one to ensure 930 00:52:38,880 --> 00:52:41,280 they look their best before wrapping. 931 00:52:41,280 --> 00:52:45,280 So, are they frozen hard now? Yeah, yeah, yeah. Really? Yeah. 932 00:52:47,160 --> 00:52:49,560 GREGG LAUGHS 933 00:52:49,560 --> 00:52:51,600 OK. 934 00:52:51,600 --> 00:52:54,200 But this room is warm. Yeah. 935 00:52:54,200 --> 00:52:58,840 How quickly do you want to get these wrapped and into a box? 936 00:52:58,840 --> 00:53:02,440 In two minutes, the pizzas are wrapped, into the box 937 00:53:02,440 --> 00:53:04,240 and arrive to the pallet. 938 00:53:04,240 --> 00:53:06,720 So, we have got two minutes. Andiamo! 939 00:53:08,440 --> 00:53:10,000 With no time to spare, 940 00:53:10,000 --> 00:53:13,240 the conveyor belt whisks our pizzas to the first step 941 00:53:13,240 --> 00:53:15,440 of the packing process. 942 00:53:15,440 --> 00:53:18,760 At the moment, they're wrapped in cellophane, but this is soon 943 00:53:18,760 --> 00:53:22,160 to be replaced with a starch-based alternative. 944 00:53:23,240 --> 00:53:28,000 How is that pizza getting wrapped completely with only one sheet? 945 00:53:28,960 --> 00:53:34,040 Basically, with this plastic film, is created like a tube, 946 00:53:34,040 --> 00:53:35,960 and the film is pulled on. 947 00:53:35,960 --> 00:53:38,040 So, that one roll of film, 948 00:53:38,040 --> 00:53:41,440 that is covering both sides of the pizza? 949 00:53:41,440 --> 00:53:44,440 Yeah. There's not two sheets? No. Just one sheet. One, one. 950 00:53:44,440 --> 00:53:48,520 It's just folded around the pizza to create like a bag. 951 00:53:48,520 --> 00:53:51,480 It's happening so fast, it's hard to see. 952 00:53:51,480 --> 00:53:54,120 Yeah. You can... You can see the speed. 953 00:53:54,120 --> 00:53:58,720 This machine is adjusting the speed to the line. 954 00:53:58,720 --> 00:54:03,280 So, at the moment, we are 5,000 pizzas an hour. Yeah. Wow. 955 00:54:03,280 --> 00:54:06,600 Blades cut each one of our plastic socks, 956 00:54:06,600 --> 00:54:09,360 and the pizzas head through the shrink wrapper, 957 00:54:09,360 --> 00:54:12,080 where they're heated to 220 degrees Celsius 958 00:54:12,080 --> 00:54:14,040 for just two seconds. 959 00:54:14,040 --> 00:54:16,040 That must start to defrost the pizza. 960 00:54:16,040 --> 00:54:19,480 There's not enough energy to defrost the pizza, 961 00:54:19,480 --> 00:54:21,000 but is enough energy 962 00:54:21,000 --> 00:54:23,840 to shrink the bag around the pizza. 963 00:54:23,840 --> 00:54:26,760 But, if you touch it, you can feel - the film is hot 964 00:54:26,760 --> 00:54:28,320 and the pizza is frozen. 965 00:54:29,960 --> 00:54:32,480 Frozen on the bottom, hot on the top. 966 00:54:33,520 --> 00:54:35,600 And that goes cold again very quickly. 967 00:54:35,600 --> 00:54:37,800 Yeah. Very quickly. Here. 968 00:54:41,600 --> 00:54:46,320 My 450kg batch of dough has been transformed 969 00:54:46,320 --> 00:54:48,000 into 1,800 pizzas. 970 00:54:49,080 --> 00:54:53,640 Enough for everyone in Aberystwyth to have a slice for dinner tonight. 971 00:54:53,640 --> 00:54:57,480 Our procession continues along a maze of conveyors. 972 00:55:00,000 --> 00:55:04,880 Wow! I love that! That is like whitewater rafting for pizzas. 973 00:55:07,640 --> 00:55:12,040 They're engineered to ensure they reach the correct packing line. 974 00:55:12,040 --> 00:55:15,200 And, for the British market, they go into cardboard. 975 00:55:15,200 --> 00:55:16,440 The box machine. 976 00:55:16,440 --> 00:55:19,640 Yeah. That's actually one of my favourite bits of any factory. 977 00:55:19,640 --> 00:55:22,040 They amaze me because they look so simple. 978 00:55:22,040 --> 00:55:25,920 So, this machine is opening the box, 979 00:55:25,920 --> 00:55:29,600 is pushing the pizza into the box, 980 00:55:29,600 --> 00:55:33,480 then it's folding this part of the box, 981 00:55:33,480 --> 00:55:36,080 is spraying the glue in this part, 982 00:55:36,080 --> 00:55:37,520 is sealing the box. 983 00:55:38,920 --> 00:55:41,760 In what, one second? Yeah. 984 00:55:41,760 --> 00:55:43,960 Let's say a few seconds. 985 00:55:43,960 --> 00:55:45,640 Listen, Alberto, 986 00:55:45,640 --> 00:55:48,880 we said we had about two minutes to get the pizza round here. 987 00:55:48,880 --> 00:55:51,200 I don't think it's even taken two minutes. 988 00:55:51,200 --> 00:55:54,000 In less than one minute, the pizza is here. 989 00:55:54,000 --> 00:55:58,360 And, then, in another minute, will reach the pallet. 990 00:55:58,360 --> 00:56:01,200 It's fast. It's very fast. Very fast. 991 00:56:03,680 --> 00:56:08,200 Our freshly boxed frozen pizzas are wrapped in bundles of seven 992 00:56:08,200 --> 00:56:10,360 before travelling to the pallet sizer, 993 00:56:10,360 --> 00:56:14,680 where they're stacked six layers high and bound tightly in plastic. 994 00:56:16,560 --> 00:56:18,960 After nine hours and 13 minutes 995 00:56:18,960 --> 00:56:20,560 of mixing, resting, 996 00:56:20,560 --> 00:56:22,160 cooking and topping, 997 00:56:22,160 --> 00:56:24,840 they're ready for the final leg of their journey, 998 00:56:24,840 --> 00:56:27,920 and head to the distribution area. 999 00:56:27,920 --> 00:56:33,120 Factory owner Dario Roncadin is overseeing the operation. 1000 00:56:33,120 --> 00:56:37,120 How many pallets are going on that truck? 1001 00:56:37,120 --> 00:56:38,880 26 pallets. 1002 00:56:38,880 --> 00:56:42,840 Do you know how many pizzas on each pallet? It's 800 pizza per pallet. 1003 00:56:42,840 --> 00:56:44,480 So how many pizzas on the truck? 1004 00:56:44,480 --> 00:56:45,760 20,000. 1005 00:56:45,760 --> 00:56:48,360 That seems like a lot of pizza to me. 1006 00:56:48,360 --> 00:56:51,840 Is there a season where you sell more pizza? 1007 00:56:51,840 --> 00:56:56,400 Mm... We sell more after Christmas because the people are enough 1008 00:56:56,400 --> 00:56:59,440 with, you know, their Christmas dinner 1009 00:56:59,440 --> 00:57:01,440 and they want to have a nice pizza. 1010 00:57:01,440 --> 00:57:03,680 Big Christmas dinner and then pizza afterwards. Yeah. 1011 00:57:03,680 --> 00:57:07,000 Should we leave him, let him load the lorry? For sure. 1012 00:57:07,000 --> 00:57:08,040 Thank you. 1013 00:57:11,040 --> 00:57:14,760 Every week, six freezer lorries leave this factory 1014 00:57:14,760 --> 00:57:16,640 and make the 1,000-mile journey 1015 00:57:16,640 --> 00:57:20,400 from the Italian Alps to the Iceland distribution centres 1016 00:57:20,400 --> 00:57:22,560 in the UK. 1017 00:57:22,560 --> 00:57:26,000 From here, the pizzas head out all over the country 1018 00:57:26,000 --> 00:57:28,880 and onto the shelves of the supermarket stores. 1019 00:57:28,880 --> 00:57:31,920 Their biggest fans are in Northern Ireland. 1020 00:57:31,920 --> 00:57:37,240 I'm surprised that they could make so many frozen pizzas in such 1021 00:57:37,240 --> 00:57:40,240 an authentic way, in a wood-fired oven. 1022 00:57:40,240 --> 00:57:44,360 However, these flavours are anything but authentic Italian. 1023 00:57:44,360 --> 00:57:46,680 They are adapted for the UK market. 1024 00:57:46,680 --> 00:57:48,240 And how do we like it? 1025 00:57:48,240 --> 00:57:50,840 We like it hot and spicy. 1026 00:58:00,960 --> 00:58:02,360 Next time... 1027 00:58:02,360 --> 00:58:04,320 This is almost space age! 1028 00:58:04,320 --> 00:58:07,200 ..I'm in the biggest brewery in Britain... 1029 00:58:07,200 --> 00:58:09,680 This production is ginormous. 1030 00:58:09,680 --> 00:58:13,920 ..where, every year, 600 million cans of lager 1031 00:58:13,920 --> 00:58:15,920 roll off the production lines. 1032 00:58:15,920 --> 00:58:19,640 That volume of beer is really hard to comprehend. 1033 00:58:19,640 --> 00:58:22,680 And Cherry goes in search of the perfect pint. 1034 00:58:22,680 --> 00:58:26,280 Can definitely taste the coffee, the chocolate. 1035 00:58:27,480 --> 00:58:29,480 It's more like a meal!