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Whether you like puff
or shortcrust pastry,

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fruit or nut-filled,

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us Brits LOVE our
sweet pies and tarts.

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We tuck into over ten million
of them every week.

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Spending more than
£125 million each year.

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Everyone's got their favourite.

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Do you know what, Gregg?

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I LOVE a Cherry Bakewell.

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Well, you're in luck...

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..cos that's exactly what they make
in this huge factory!

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I'm Gregg Wallace.

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I've got cherries!

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This time, I'm unpacking
the production secrets
of these tiny tarts.

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I can't believe that you actually
bake the whole thing in its tin,

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and now you put the icing on once
it's in the plastic.

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Don't tell me...you put
the cherry on once you've got

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it inside the box!

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I'm Cherry Healey...

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Oh, look at that!

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..and I'm learning how to swerve
a soggy bottom in my home baking.

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Ideally, you want between three
and five millimetres.

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I don't want to sound like
I'm not committed...

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..but I don't often have a ruler
in the kitchen to measure pastry.

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And historian Ruth Goodman is
sniffing out the origins of

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the fragrant filling that gives
Bakewell tarts their heart.

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Ooh, a lovely new pair of
red gloves!

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But what on earth has that
got to do with frangipane?

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In the next 24 hours,

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this factory will produce
over a quarter of a million
Cherry Bakewells.

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Getting through over
five tonnes of pastry.

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Welcome to Inside The Factory.

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This is the Premier Foods factory in
Stoke-on-Trent, Staffordshire.

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This ten-acre site produces over
50 tonnes of baked goods every day.

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That includes iced slices,
fruit cakes and pies.

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But we're following production
of one of their best sellers...

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..the Mr Kipling Cherry Bakewell.

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Production begins with
a delivery of flour.

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Three times a week,

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a lorry does an articulated dance to
manoeuvre into position.

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Greeting it is production
manager Mark Burnett.

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Hi, Gregg. Mark. Pleased to
meet you. Gregg.

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How much flour on a truck?
27 metric tonnes.

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What pastry is in a Bakewell tart?

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It's a shortcrust pastry.

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Anything particular about this flour
for the shortcrust?

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Yeah, it's a low protein flour.
Right.

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High protein flour is
more suitable for bread.

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How many tarts are
you likely to make today?

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Over a quarter of a million.

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I want to see this.
Be my guest.

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Can I just say...?

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I really like that bald head
and glasses look, Mark.

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Thank you.

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Enough larking about...

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..these Bakewells won't
make themselves.

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We need to get the flour
off the lorry.

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Right, which one?
It's the green button. The one...

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The green one that says "start
filling", right? That's the one.

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I was never that bright. Can I?

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Yeah.

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The clock is ticking,

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as compressed air pushes our flour
up into the 17-metre-high silos.

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From there, it's pumped directly
into the mixing bay...

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..where the appropriately named
Paul Baker is the mixing manager.

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He's going to turn it into light,
crumbly shortcrust pastry.

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Paul. Hiya. Nice to meet you.

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Tell me, what is the "short"
in shortcrust?

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Why does it make it short?

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The "short" is about keeping the
protein chains within the pastry

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literally short to stop
it being tough.

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How does that work? Would you mind
telling me?

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I've got no idea how that works.

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OK, so when...

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If you use a higher
proportion of fat to flour,

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it wraps all the flour particles
up in fat, so they can't

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all get together and make
a stringy, gooey mess. Simple.

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Right. No-one's ever explained
that to me.

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Oh, OK. That's what it is?

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Yeah.

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Swerving this stringy disaster zone
requires computerised precision.

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The recipe for Cherry Bakewells'
pastry is number eight,

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so you press eight...

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..and now that should start putting
ingredients in the mixing bowl.

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Right, what's going in there first?

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That's the margarine going
into the bottom of the bowl.

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40 kilograms of margarine are
automatically dropped in.

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Made from vegetable oil,
it's very similar to the stuff

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you'd buy at the supermarket,

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just without its familiar
yellow colouring.

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What is that sitting on?

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That is a weigh scale.

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So the recipe - let's say it wants
96 kilos of flour - it waits till

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the scales has read off 96 kilos,
and then it stops.

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Like at home, we would tip in
the bag and look at the reading...
Yeah, yeah. Absolutely.

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..the computer's doing the same
thing? The same thing.

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I love this!

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On top of our margarine goes
13.5 kilograms of sugar,

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followed by 13 litres of water.

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The computer is also
controlling the temperature,

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making sure the margarine
is soft enough to mix properly
with the flour.

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We try and sort of hit a pastry
temperature of around 25,

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which is the optimum temperature
for the fat to work.

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So, the computer also takes
the temperature of all these

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bulk ingredients, does a clever
little calculation, and then blends

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hot and cold water to try and keep
it around the 24, 25 degree mark.

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Genius. Yeah. Absolute genius.

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The flour's gone in now.
96 kilos of flour, yeah.

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So the weight we've got there now
is...?

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It'll be around 165 kilos.

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This super-sized mix will
make enough pastry for
7,500 Cherry Bakewells...

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..but it's not quite ready yet.

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We add 600g of salt,

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followed by 160g of baking powder.

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You would normally put this
baking powder in something

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that you wanted to rise.

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Yes. But what we're doing is using
the baking powder to open up

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the pastry texture to allow the
moisture to drive out,

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to allow it to bake quicker.

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Not enough to let the pastry rise?

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No, no, no, no.
But enough to open it up?

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Absolutely.

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Ingredients complete,
we can mix them together.

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Two hydraulic arms lift our
mixing bowl off the floor
and into position.

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All the way up? Yeah, yeah.

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It'll take just 90 seconds
to combine all seven ingredients

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into soft, crumbly shortcrust.

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While my pastry's getting
a good workout,

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Ruth is checking out the history of
these cherry-topped tarts.

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And she reckoned it was a good bet
to start in the Derbyshire town

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that gave them their name -
Bakewell.

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This place is packed
with bakeries...

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..but there's something
strange going on.

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It's funny. All these Bakewells
in all these bakery windows,

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and none of them have icing on.

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And they certainly don't
have a cherry on top.

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I may be in Bakewell,

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but I can't see
a Cherry Bakewell anywhere.

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Morning! Morning.

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Have you got any Cherry Bakewells?

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HE SIGHS DEEPLY

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We're actually famous
for our Bakewell puddings,
rather than our Cherry Bakewells.

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Oh, is there a difference?

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Oh, yeah. it's quite
a significant difference.

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The puddings, actually,
the sort of locals' product,

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it's got a similar sweet,
almondy flavour

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and a layer of strawberry jam at the
bottom, like your Bakewell tart,

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but no flour. So rather than
rising up like a sponge,

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it kind of sinks into a rich, gooey,
decadent, almondy,

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sort of egg custard mixture.

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It's actually the one
that's made in the town,

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and it's the one that
the town's famous for.

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I'm hoping that investigating
the origins of the pudding

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will help lead me to the
cherry-topped version.

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Oh, there's another one!

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We just keep passing places
selling Bakewell puddings.

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I've enlisted the help
of food historian Regula Ysewijn.

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I mean, how did the pudding and the
town get so closely entwined?

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Well, we're heading
to the Rutland Arms.

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And the story goes that a member of
staff was ordered to make puddings,

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and she misread the recipe

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and, by mistake, invented the
Bakewell pudding.

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Just got it wrong, and something
edible came out of it? Exactly.

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She thought, "Well, this is nice."

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"We'll just call it
a Bakewell pudding."

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And that's how Bakewell
got full of Bakewell puddings.

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When would this have been? Around
1851-1857, in between that time.

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What a great story. Yeah.

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Is it true?

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Mm...

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..it's not that easy.

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It's not that simple.

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Regula has found evidence suggesting
that something very like

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a Bakewell pudding was being made
and eaten all around Britain

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well before this date.

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There is a recipe in this book -
The Compleat Housewife.

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It was written in 1727.

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So, that's a full century earlier.

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The only difference is it's called
a sweet-meat pudding here,

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but if you look at the ingredients
and the method,

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it's exactly the same
as a Bakewell pudding.

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Its fruit layer is candied
peel, rather than jam,

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but the proof's in the pudding.

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It's good. Mm.

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The flavours are there, aren't they?

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It's just missing the name Bakewell.

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So how did this sweet-meat pudding
become associated with the town?

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I think it's because the railways
came here, and with it,

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a lot of Victorian tourists.

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And everyone went to the nearby spa
towns of Matlock Bath and Buxton,

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and people wanted a piece of the
pie - or the pudding, so to speak -

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so they kind of put Bakewell with
the pudding to lure in the tourists,

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because... Saying, "This is our
regional speciality"?

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Yes, because if you...

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If you're on holiday, you want to
eat the local specialities.

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An invented local speciality to haul
in the tourists? Yes, yes.

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I would never have guessed.

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The creation of the Bakewell pudding
was a masterstroke of marketing,

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so successful that the word
"Bakewell" became a shorthand for

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this winning combination of almond
and fruit flavours in all its forms.

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How does it become a Bakewell tart?

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00:11:03,040 --> 00:11:06,720
Well, in the recipes, there have
been some differences towards

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the 20th century,
and one particular one -

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here in Mrs Leyel's book -
is very significant, because this is

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the first time that the recipe
of a Bakewell pudding

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starts to look exactly like
a Bakewell tart.

206
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So it's getting more cakey?

207
00:11:24,080 --> 00:11:28,480
It's getting more cakey. We are
moving towards the more frangipane

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00:11:28,480 --> 00:11:31,680
version that we know today
as a Bakewell tart.

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Right.

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So, hang on now...

211
00:11:34,720 --> 00:11:37,480
..we're nearly there, but we're not
quite there, are we?

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00:11:37,480 --> 00:11:42,200
Because you're saying a Bakewell
tart, but you don't mean

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the Cherry Bakewell? Not yet?

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00:11:44,240 --> 00:11:45,920
Not yet, exactly.

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00:11:45,920 --> 00:11:52,200
This gives us a really good insight
into how food can evolve.

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We first have the sweet-meat
pudding...1727. Yeah.

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And then it moves onto a Bakewell
pudding. Yeah.

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Then we have the Bakewell tart,

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and now we have the Cherry Bakewell,

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which is the last stage
of our journey, really.

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TV AD: I saw a lot of
cherries in the bakery

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the other day, and I asked what they
were for.

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MR KIPLING: "To put on top

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"of my new Cherry Bakewells,
of course," he said.

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This is another piece
of clever marketing.

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It was invented in the 1970s.

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They made it into an iced Bakewell
tart, which you can keep for longer

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and mass manufacture, so everyone -
even outside of Derbyshire -

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can enjoy a Bakewell tart.

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Fabulous!

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The town may not claim
the cherry version as its own,

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but whether the Bakewell
in all its forms was dreamt
up here or not,

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they all have one thing in common...

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..they're very tasty.

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Back in Stoke, we're
one hour, 19 minutes in,

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and my massive 165kg batch

237
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of shortcrust pastry

238
00:13:06,920 --> 00:13:09,200
has been mixing for 90 seconds.

239
00:13:10,360 --> 00:13:14,480
Now that is a beautiful pastry mix.

240
00:13:14,480 --> 00:13:19,360
But this big ball of dough
would clog up the delivery chute,

241
00:13:19,360 --> 00:13:23,160
so it's sent through
what they call the nibblers...

242
00:13:23,160 --> 00:13:25,680
There she goes.

243
00:13:25,680 --> 00:13:30,520
..where 672 rotating teeth chew
it up into little bits.

244
00:13:31,760 --> 00:13:34,120
It doesn't take long
for it to eat that, does it?

245
00:13:34,120 --> 00:13:38,600
No, not at all. In fact, it'll eat
probably 1,000kg, actually, an hour.

246
00:13:38,600 --> 00:13:40,760
A tonne an hour?
A tonne an hour.

247
00:13:42,320 --> 00:13:46,680
From the mixing bay, gravity drops
our pastry to the floor below,

248
00:13:46,680 --> 00:13:50,600
and the start of our Cherry
Bakewell production line...

249
00:13:50,600 --> 00:13:51,920
Fabulous.

250
00:13:51,920 --> 00:13:53,840
..where I'm rejoining Mark.

251
00:13:53,840 --> 00:13:56,000
This is when it starts
to look like cakes, right?

252
00:13:56,000 --> 00:13:57,760
That's absolutely right, yeah.

253
00:13:57,760 --> 00:14:00,720
So the paste that you made
upstairs earlier,

254
00:14:00,720 --> 00:14:02,560
you placed onto the nibblers.

255
00:14:02,560 --> 00:14:05,360
It's actually now in this chute.

256
00:14:05,360 --> 00:14:08,360
At the bottom of the chute,
the pastry is divided up,

257
00:14:08,360 --> 00:14:13,760
21g at a time, ready to head
into individual baking trays.

258
00:14:15,200 --> 00:14:17,240
For the next part of
the process, we use foils.

259
00:14:17,240 --> 00:14:20,400
Are they the little foils
that are actually in the box?

260
00:14:20,400 --> 00:14:21,960
That's right, yes.

261
00:14:21,960 --> 00:14:26,560
The uncooked pastry goes straight
into the little foil

262
00:14:26,560 --> 00:14:28,480
that we take out of the box?
Correct.

263
00:14:28,480 --> 00:14:30,600
And you cook them in that? Correct.

264
00:14:30,600 --> 00:14:32,240
Now I never knew that.

265
00:14:32,240 --> 00:14:34,760
So do you grease these? No.

266
00:14:34,760 --> 00:14:36,760
Well, how does the pastry
not stick to them?

267
00:14:36,760 --> 00:14:39,960
One of the key ingredients
is margarine.

268
00:14:39,960 --> 00:14:42,600
Margarine heats up
and it releases the oils,

269
00:14:42,600 --> 00:14:46,160
so it stops the pastry
from being baked in.

270
00:14:46,160 --> 00:14:50,920
15 foils at a time are dropped
down onto the conveyor belt,

271
00:14:50,920 --> 00:14:54,160
the pastry drops in...

272
00:14:55,640 --> 00:15:00,080
..then metal punches - called dies -
press down, push up the sides

273
00:15:00,080 --> 00:15:02,720
and imprint the crimps in the top.

274
00:15:04,560 --> 00:15:07,400
Tell me, where that die
pushes down on the pastry... Yeah.

275
00:15:07,400 --> 00:15:09,040
..the pastry's sticky... Yeah.

276
00:15:09,040 --> 00:15:12,520
..why doesn't it stick to the die
when it comes back up again?

277
00:15:12,520 --> 00:15:15,760
Predominantly, because the
die's hot - it's heated.

278
00:15:15,760 --> 00:15:18,160
And the margarine causes the
separation of the die

279
00:15:18,160 --> 00:15:19,920
from the pastry case.

280
00:15:22,440 --> 00:15:26,040
Now our plain pastry
cases get tarted up...

281
00:15:28,320 --> 00:15:30,160
..with a slick of colour.

282
00:15:32,360 --> 00:15:34,440
How much jam goes in each tart?

283
00:15:34,440 --> 00:15:36,480
Five grams.

284
00:15:36,480 --> 00:15:39,920
Now, I would've thought that
would've been strawberry jam. Is it?

285
00:15:39,920 --> 00:15:43,160
No, it's a plum and
raspberry flavoured jam.

286
00:15:43,160 --> 00:15:45,560
Can I taste that? Absolutely.

287
00:15:48,680 --> 00:15:50,480
Sweet. Yeah. Little bit sharp.

288
00:15:50,480 --> 00:15:52,680
I wouldn't have tasted plum.
I'd have got raspberry.

289
00:15:52,680 --> 00:15:54,520
No-one else is going in that pot,
are they? No.

290
00:15:54,520 --> 00:15:55,760
I can have another bit.

291
00:15:55,760 --> 00:15:57,800
Why do you use plum and raspberry?

292
00:15:57,800 --> 00:16:00,640
It's readily available,
for consistency,

293
00:16:00,640 --> 00:16:03,840
and it also helps to
enhance the overall flavour.

294
00:16:03,840 --> 00:16:09,840
How do you stop the jam trickling
over the side of your tart?

295
00:16:09,840 --> 00:16:14,360
You get an injection - a pulse of
jam - with a very clear cut-off,

296
00:16:14,360 --> 00:16:16,200
so there's almost like a blower.

297
00:16:16,200 --> 00:16:18,520
So a little jet of air... Yeah.

298
00:16:18,520 --> 00:16:20,920
..pushes out each spoonful?
That's correct.

299
00:16:20,920 --> 00:16:22,560
Squirt, air, squirt, air... Yeah.

300
00:16:22,560 --> 00:16:23,880
..squirt, air, squirt.

301
00:16:23,880 --> 00:16:27,200
MUSIC: Jamming
by Bob Marley and The Wailers

302
00:16:27,200 --> 00:16:29,040
It's like Bob Marley...

303
00:16:29,040 --> 00:16:30,680
..Jamming.

304
00:16:30,680 --> 00:16:32,320
# Well, all right

305
00:16:32,320 --> 00:16:34,360
# We're jamming

306
00:16:34,360 --> 00:16:37,360
# I wanna jam it with you

307
00:16:37,360 --> 00:16:41,240
# We're jamming, jamming

308
00:16:41,240 --> 00:16:44,520
# I hope you like jamming too... #

309
00:16:44,520 --> 00:16:48,120
When the guys here get around to
baking these pastry cases,

310
00:16:48,120 --> 00:16:50,000
I can guarantee one thing...

311
00:16:50,000 --> 00:16:53,440
..they'll come out of the oven
with a perfectly crispy base.

312
00:16:53,440 --> 00:16:57,480
But for home bakers, like me, it's
not quite that simple.

313
00:16:57,480 --> 00:17:00,760
So how do you avoid
the dreaded soggy bottom?

314
00:17:00,760 --> 00:17:02,360
Over to Cherry.

315
00:17:06,400 --> 00:17:08,640
Whenever I buy a pie,

316
00:17:08,640 --> 00:17:13,360
the base is crispy and delicious.

317
00:17:13,360 --> 00:17:15,440
But when I make them at home,

318
00:17:15,440 --> 00:17:18,280
its way more miss than hit.

319
00:17:21,440 --> 00:17:23,320
In search of solutions,

320
00:17:23,320 --> 00:17:26,560
I'm meeting food scientist
Dr Stuart Farrimond.

321
00:17:26,560 --> 00:17:29,280
Hi, Dr Stu. Cherry, great to see
you. How are you doing?

322
00:17:29,280 --> 00:17:31,040
I'm not that great, to be honest.
OK.

323
00:17:31,040 --> 00:17:34,240
Because I have a really bad
case of soggy bottom.

324
00:17:34,240 --> 00:17:36,280
With your pie? Yes, with my pie.

325
00:17:36,280 --> 00:17:38,560
Yes, OK. Thank goodness.

326
00:17:38,560 --> 00:17:42,680
According to Dr Stu, there are five
scientific golden rules

327
00:17:42,680 --> 00:17:44,920
to help you swerve the sogginess.

328
00:17:46,240 --> 00:17:48,680
Rule number one...

329
00:17:48,680 --> 00:17:50,520
..preheat the oven.

330
00:17:50,520 --> 00:17:55,000
For our fan oven,
we're going for 180 Celsius...

331
00:17:55,000 --> 00:17:58,040
..but don't just wait
for the light to go out.

332
00:17:58,040 --> 00:18:02,320
Most people think that
they're preheating their oven,
but they're not really.

333
00:18:02,320 --> 00:18:05,120
They turn it on, and then as soon as
the light goes out,

334
00:18:05,120 --> 00:18:06,640
they put their baking in.

335
00:18:06,640 --> 00:18:10,240
But the light is there for a reason,
the light tells me it's pie time.

336
00:18:10,240 --> 00:18:13,880
It's not true. It means that the air
temperature is at the temperature

337
00:18:13,880 --> 00:18:18,960
that you set it at, but the oven
itself - the walls - are still cold.

338
00:18:18,960 --> 00:18:21,800
So leave it on at least 15 minutes,

339
00:18:21,800 --> 00:18:24,920
so that the metal walls
are up to temperature.

340
00:18:24,920 --> 00:18:28,680
You need to get that pastry cooked
quickly if you want it to be crispy.

341
00:18:30,600 --> 00:18:32,120
Rule number two...

342
00:18:32,120 --> 00:18:35,400
..maximise the heat below
your pie dish.

343
00:18:35,400 --> 00:18:36,840
Another tip for you,

344
00:18:36,840 --> 00:18:40,000
for getting the temperature
as high as possible,

345
00:18:40,000 --> 00:18:41,920
is to use a pizza stone.

346
00:18:41,920 --> 00:18:46,960
Why would you put a pizza stone
in your oven if you're making a pie?

347
00:18:46,960 --> 00:18:48,840
If we put in a pizza stone,

348
00:18:48,840 --> 00:18:52,480
or if you haven't got a pizza stone,
just use a heavy metal oven tray,

349
00:18:52,480 --> 00:18:55,200
then you have heat coming from
the bottom, which will help

350
00:18:55,200 --> 00:18:57,520
the bottom cook very quickly.

351
00:19:00,000 --> 00:19:01,800
Rule number three...

352
00:19:01,800 --> 00:19:03,840
..choose the right dish.

353
00:19:03,840 --> 00:19:05,080
OK, that's your pie dish?

354
00:19:05,080 --> 00:19:07,480
Yes. It's not great for pies.

355
00:19:07,480 --> 00:19:09,480
Why is it called a pie dish, then?

356
00:19:09,480 --> 00:19:12,320
This is a ceramic-style pie dish.

357
00:19:12,320 --> 00:19:15,720
It's got a long time to heat up,
and will cook slowly,

358
00:19:15,720 --> 00:19:18,880
some of the fats will melt and come
out, and we'll get a soggy bottom.

359
00:19:18,880 --> 00:19:20,680
If that isn't good...

360
00:19:20,680 --> 00:19:22,320
..for a pie - what is?

361
00:19:22,320 --> 00:19:25,360
We want to go for metal,
so something like this.

362
00:19:25,360 --> 00:19:27,000
You are blowing my mind today.

363
00:19:27,000 --> 00:19:28,640
A metal pie dish. Why?

364
00:19:28,640 --> 00:19:32,320
Because it will heat up quickly,
and also, you want a black dish,

365
00:19:32,320 --> 00:19:35,160
because if it's silver, it will
reflect some of that heat away.

366
00:19:35,160 --> 00:19:41,120
Another great pie dish is one
that is made out of tempered glass,

367
00:19:41,120 --> 00:19:44,480
like this one, and this is great
because if you've got your

368
00:19:44,480 --> 00:19:49,240
pizza stone or thick oven tray
underneath, then the radiated heat

369
00:19:49,240 --> 00:19:53,520
will pass straight through, and it
will help bake the bottom

370
00:19:53,520 --> 00:19:56,880
of the pastry, and you
won't have a soggy bottom.

371
00:19:56,880 --> 00:19:58,680
Which pie dish are we going
to use today?

372
00:19:58,680 --> 00:20:01,120
The black metal pie dish.

373
00:20:03,240 --> 00:20:04,680
Rule number four...

374
00:20:04,680 --> 00:20:07,840
..roll the pastry to the
correct thickness.

375
00:20:07,840 --> 00:20:11,320
How thick do I want my pastry?

376
00:20:11,320 --> 00:20:14,160
Because, I have to say...

377
00:20:14,160 --> 00:20:15,760
..I guess every time.

378
00:20:15,760 --> 00:20:20,240
Ideally, you want something
between three and five millimetres.

379
00:20:20,240 --> 00:20:22,280
I don't want to sound
like I'm not committed,

380
00:20:22,280 --> 00:20:24,640
but I don't often have
a ruler in the kitchen.

381
00:20:24,640 --> 00:20:27,680
I have a great little hack
for you. Two 20ps...

382
00:20:27,680 --> 00:20:29,760
OK.

383
00:20:29,760 --> 00:20:31,640
..on top of each other... OK.

384
00:20:31,640 --> 00:20:34,640
..will give you an ideal depth
for your pastry.

385
00:20:34,640 --> 00:20:36,640
What a brilliant tip!

386
00:20:39,360 --> 00:20:41,800
Has my pastry passed the test?

387
00:20:41,800 --> 00:20:44,120
Your pastry has passed
the two 20p test.

388
00:20:44,120 --> 00:20:45,520
Yes!

389
00:20:45,520 --> 00:20:47,280
After lining my dish with pastry,

390
00:20:47,280 --> 00:20:50,200
this is when I'd usually
bung my filling on top,

391
00:20:50,200 --> 00:20:52,360
and stick it in the oven.

392
00:20:52,360 --> 00:20:55,360
Which brings us to rule
number five...

393
00:20:55,360 --> 00:20:57,080
..blind baking.

394
00:20:58,240 --> 00:21:01,440
So, what we're doing is
part-cooking the pastry

395
00:21:01,440 --> 00:21:03,520
before we put the filling in.

396
00:21:03,520 --> 00:21:06,120
And the reason for that is that if
we don't do it,

397
00:21:06,120 --> 00:21:11,680
there's a danger that the pastry
won't be cooked by the time
that the filling is done.

398
00:21:11,680 --> 00:21:13,840
We prick the pastry with a fork,

399
00:21:13,840 --> 00:21:17,520
and cover it with greaseproof
paper, weighed down with rice,

400
00:21:17,520 --> 00:21:21,320
which stops air pockets forming
and the pastry bubbling up.

401
00:21:21,320 --> 00:21:22,560
Preheated oven. Great.

402
00:21:22,560 --> 00:21:23,960
In we go. Lovely.

403
00:21:23,960 --> 00:21:25,840
Towards the top.

404
00:21:25,840 --> 00:21:27,880
Ten minutes near the top
of the oven,

405
00:21:27,880 --> 00:21:31,400
followed by three to four minutes
without the paper and rice,

406
00:21:31,400 --> 00:21:34,040
gives us a golden brown base.

407
00:21:34,040 --> 00:21:35,560
Ah, look at it. Ah...

408
00:21:35,560 --> 00:21:37,240
On the top, that's lovely.

409
00:21:37,240 --> 00:21:43,080
Blind baking partly cooks the
pastry, which stops the gooey pie
filling seeping in.

410
00:21:43,080 --> 00:21:45,320
Lift... Go, go, go, go, go!

411
00:21:45,320 --> 00:21:46,720
Hey! Amazing.

412
00:21:46,720 --> 00:21:48,480
Yay, look at that!

413
00:21:48,480 --> 00:21:50,000
In she goes.

414
00:21:55,200 --> 00:21:59,160
30 minutes later,
the moment of truth.

415
00:21:59,160 --> 00:22:01,760
It smells good, it looks good.
It smells amazing!

416
00:22:01,760 --> 00:22:04,800
But what we're really here to see
is whether it has a soggy bottom.

417
00:22:04,800 --> 00:22:06,760
Yep.

418
00:22:06,760 --> 00:22:08,920
Wow! Look at that!

419
00:22:08,920 --> 00:22:12,440
My first-ever pie that doesn't
have a soggy bottom!

420
00:22:15,400 --> 00:22:16,960
Mm-mm! Mm-mm!

421
00:22:16,960 --> 00:22:19,160
That's a good pie. It is, isn't it?

422
00:22:29,480 --> 00:22:33,280
Back in Stoke, on our industrial
pie production line,

423
00:22:33,280 --> 00:22:37,520
I've been sent to a high-security
zone to collect the next ingredient.

424
00:22:38,960 --> 00:22:40,160
Hey.

425
00:22:40,160 --> 00:22:41,320
Khalid? Ey-up.

426
00:22:41,320 --> 00:22:42,400
All right, good. Great.

427
00:22:42,400 --> 00:22:44,040
I've come to get me almonds, right?

428
00:22:44,040 --> 00:22:47,720
I'm meeting mixing bay
operative Khalid Hussain.

429
00:22:47,720 --> 00:22:50,560
Why are they in a cage here?
Why are they locked away?

430
00:22:50,560 --> 00:22:52,920
Well, we keep them separate
cos it's a nut product.

431
00:22:52,920 --> 00:22:55,640
We don't want it to cause
contamination with anything else.

432
00:22:55,640 --> 00:22:58,680
Because people have nut allergies,
right? Yeah. I gotcha, I gotcha.

433
00:22:58,680 --> 00:23:01,320
So we're getting the ingredients
together for the frangipane.

434
00:23:01,320 --> 00:23:05,160
Frangipane, of course,
is an almond flavoured cream. Yeah.

435
00:23:05,160 --> 00:23:06,800
It goes into lots of cakes.

436
00:23:06,800 --> 00:23:09,320
It's one of my favourite flavours
in the world, actually.

437
00:23:09,320 --> 00:23:11,880
So, how much of that do we need?

438
00:23:11,880 --> 00:23:13,320
Two kilograms.

439
00:23:13,320 --> 00:23:16,360
Right. And it's important to be
precise, right? Yeah.

440
00:23:16,360 --> 00:23:19,400
We've got our beautiful almonds -
where do we go now?

441
00:23:19,400 --> 00:23:22,760
From here, they go to the sieve
area to get sieved.

442
00:23:26,520 --> 00:23:31,200
Our ground almonds are shaken
through a 2.5mm mesh,

443
00:23:31,200 --> 00:23:35,400
and passed over a strong magnet to
make sure the batch is clear

444
00:23:35,400 --> 00:23:39,080
of any fragments of shell or metal.

445
00:23:39,080 --> 00:23:41,520
That's it.

446
00:23:41,520 --> 00:23:42,760
Now what?

447
00:23:42,760 --> 00:23:45,400
Now we take it
to make the frangipane.

448
00:23:46,800 --> 00:23:48,240
From the nut room,

449
00:23:48,240 --> 00:23:51,800
I'm taking my ground almonds
back to the mixing bay,

450
00:23:51,800 --> 00:23:57,160
where Dave Alcock is as nutty as
I am about this fragrant filling.

451
00:23:57,160 --> 00:23:58,840
I've got the sieved almonds.

452
00:23:58,840 --> 00:24:01,200
What's this? Have you started making
the mix without me?

453
00:24:01,200 --> 00:24:02,440
Yeah. What's in there?

454
00:24:02,440 --> 00:24:06,280
Flour, water, fat, sugar, egg.

455
00:24:06,280 --> 00:24:07,720
We're just waiting for yours now.

456
00:24:07,720 --> 00:24:10,800
Just tip it in, yeah? Yeah.

457
00:24:10,800 --> 00:24:14,240
You can't have frangipane without
almonds, can you? No.

458
00:24:14,240 --> 00:24:15,800
But there's still more to go in,

459
00:24:15,800 --> 00:24:19,080
including an unexpected ingredient.

460
00:24:19,080 --> 00:24:21,160
So, what's this? Coconut.

461
00:24:21,160 --> 00:24:22,800
Coconut? Yeah.

462
00:24:22,800 --> 00:24:24,480
Why coconut?

463
00:24:24,480 --> 00:24:28,080
It's like the almonds, for the
texture and the flavour.

464
00:24:28,080 --> 00:24:31,000
Coconut also helps thicken
up our mix.

465
00:24:32,520 --> 00:24:34,440
Now there's just the flavour
to go in.

466
00:24:34,440 --> 00:24:36,160
Almond essence? Yeah.

467
00:24:36,160 --> 00:24:37,920
I've got almond essence at home,

468
00:24:37,920 --> 00:24:39,840
in a little glass jar like that.

469
00:24:39,840 --> 00:24:42,280
That doesn't all go in there,
does it? Yeah.

470
00:24:42,280 --> 00:24:45,080
What, all of that? Yeah. All that.

471
00:24:45,080 --> 00:24:51,080
655g will flavour all 148kg of mix.

472
00:24:51,080 --> 00:24:53,200
Strong, isn't it?
Yeah, but it's beautiful.

473
00:24:53,200 --> 00:24:55,240
I could spoon that out now.

474
00:24:56,480 --> 00:24:59,920
Or...maybe it's better that we get
it mixed first?

475
00:25:02,200 --> 00:25:06,640
A quick 60-second blast transforms
it into a smooth paste.

476
00:25:07,880 --> 00:25:10,680
Now the challenge is getting
it from this big tub

477
00:25:10,680 --> 00:25:12,760
to our little tarts.

478
00:25:12,760 --> 00:25:15,200
Hang on a minute, hang on a minute,
hang on a minute...

479
00:25:15,200 --> 00:25:18,120
So what is that? Is that going to go
through the floor?

480
00:25:18,120 --> 00:25:21,880
Yeah, it's a delivery pipe down to
the hoppers underneath on the line.

481
00:25:21,880 --> 00:25:24,720
Just through a hole in the floor?
Yeah.

482
00:25:24,720 --> 00:25:28,160
How do you know it's in the right
place? Look.

483
00:25:28,160 --> 00:25:30,760
You literally have a look?
It doesn't clamp in place? No.

484
00:25:30,760 --> 00:25:33,160
So if we start pouring and we move
that, we are going to have

485
00:25:33,160 --> 00:25:34,800
an almighty mess? Yeah.

486
00:25:34,800 --> 00:25:36,920
If you just want to slowly
open the valve?

487
00:25:36,920 --> 00:25:38,240
I'm a bit nervous.

488
00:25:38,240 --> 00:25:40,440
That'll do. Ho-ho-ho!

489
00:25:40,440 --> 00:25:42,360
Oh!

490
00:25:42,360 --> 00:25:43,960
Dave, what's that?

491
00:25:43,960 --> 00:25:46,440
It's the inspection hatch.

492
00:25:46,440 --> 00:25:49,080
Oh!

493
00:25:49,080 --> 00:25:52,120
It's quite incredible that this goes
through a hole in the floor.

494
00:25:52,120 --> 00:25:54,880
It's even more incredible that you
can see it below. Yeah.

495
00:25:56,600 --> 00:26:00,840
Our gloopy almond mix flows
down a pipe and into a hopper

496
00:26:00,840 --> 00:26:02,880
on the main production line.

497
00:26:05,760 --> 00:26:07,840
One hour, 34 minutes in,

498
00:26:07,840 --> 00:26:12,840
and I'm following my filling
downstairs to catch up with Mark.

499
00:26:12,840 --> 00:26:14,520
Mark. Hi, Gregg.

500
00:26:14,520 --> 00:26:16,920
That's my frangipane. That's right.

501
00:26:16,920 --> 00:26:20,120
That goes into there, and then it
comes through these pipes.

502
00:26:20,120 --> 00:26:21,440
How many of them? 15.

503
00:26:21,440 --> 00:26:25,200
And squeezes just the right
small amount into each tart?

504
00:26:25,200 --> 00:26:26,680
Yeah.

505
00:26:26,680 --> 00:26:30,080
How much frangipane
into each of these tarts?

506
00:26:30,080 --> 00:26:31,760
Nine grams.

507
00:26:31,760 --> 00:26:35,400
And that batch that I made
upstairs - how long will that last?

508
00:26:35,400 --> 00:26:37,320
20 minutes.

509
00:26:37,320 --> 00:26:39,840
Just 20 minutes? 20 minutes.

510
00:26:39,840 --> 00:26:42,920
Now our Cherry Bakewells
have their pastry case,

511
00:26:42,920 --> 00:26:46,200
jam layer and frangipane filling...

512
00:26:46,200 --> 00:26:49,240
..it's time to step things
up a bit...

513
00:26:49,240 --> 00:26:52,240
..on this strange-looking
contraption.

514
00:26:59,000 --> 00:27:02,800
Right, what's happening here? They
seem to be lifted up - row by row.

515
00:27:02,800 --> 00:27:05,560
It's a Franklin transfer system.

516
00:27:05,560 --> 00:27:09,960
This whole set-up was designed
by one of our project engineers

517
00:27:09,960 --> 00:27:11,480
some 40 years ago.

518
00:27:11,480 --> 00:27:13,760
His name was Franklin? Yeah.

519
00:27:13,760 --> 00:27:18,640
This complex system of cogs and
levers is doing a very simple job,

520
00:27:18,640 --> 00:27:22,880
transferring our tarts from one
conveyor belt to another.

521
00:27:24,760 --> 00:27:28,440
It's so clever how it
lifts them at the front,

522
00:27:28,440 --> 00:27:30,440
but keeps on lifting them
at the middle and the back,

523
00:27:30,440 --> 00:27:32,680
and placing them gently down.

524
00:27:35,120 --> 00:27:38,560
Are you absolutely sure
this is necessary?

525
00:27:38,560 --> 00:27:41,640
We haven't managed to find anything
that will replicate this

526
00:27:41,640 --> 00:27:44,680
in a consistent and
an efficient fashion.

527
00:27:44,680 --> 00:27:47,120
That's got to be the oven, right?
That's right.

528
00:27:47,120 --> 00:27:48,800
That's going in to baking? Yeah.

529
00:27:48,800 --> 00:27:51,800
But you haven't got the cherry
on it, or the icing?

530
00:27:51,800 --> 00:27:54,440
Not at this stage, not pre-bake.

531
00:27:54,440 --> 00:27:58,400
That's cos the icing and the cherry
doesn't need cooking, right?

532
00:27:58,400 --> 00:28:02,160
As they begin their journey
through the 38-metre oven,

533
00:28:02,160 --> 00:28:05,160
things are hotting up for
our pastry cases.

534
00:28:05,160 --> 00:28:07,320
Why is it so long?

535
00:28:07,320 --> 00:28:10,040
To enable us to bake the products
as quickly as we do,

536
00:28:10,040 --> 00:28:12,320
and as thoroughly as we do.

537
00:28:12,320 --> 00:28:17,440
Inside, our tarts head through
a series of different heat zones.

538
00:28:17,440 --> 00:28:20,640
They regulate from 195 degrees
in the first burner,

539
00:28:20,640 --> 00:28:22,880
going up to 210
for burners two and three,

540
00:28:22,880 --> 00:28:25,120
and back down to 195.

541
00:28:25,120 --> 00:28:29,520
This variable temperature baking
ensures the pastry cooks evenly

542
00:28:29,520 --> 00:28:32,000
and crisps up on the bottom.

543
00:28:32,000 --> 00:28:35,440
How long does it take from one end
of the oven to the other?

544
00:28:35,440 --> 00:28:38,120
It's eight minutes, 24 seconds.

545
00:28:38,120 --> 00:28:40,680
And in that time,
there's 6,000 Cherry Bakewells

546
00:28:40,680 --> 00:28:43,040
going through that oven as we're
looking at it now.

547
00:28:43,040 --> 00:28:44,800
Whenever I'm in a factory,

548
00:28:44,800 --> 00:28:49,160
it always amazes me that
we must be consuming them

549
00:28:49,160 --> 00:28:51,160
as fast as you're making them!

550
00:28:57,200 --> 00:29:00,880
The tarts in the oven wouldn't
be the same without their
almond filling...

551
00:29:00,880 --> 00:29:05,280
..but where and when did it get that
strange name - frangipane?

552
00:29:06,960 --> 00:29:10,080
Ruth headed across
the Channel to find out.

553
00:29:11,800 --> 00:29:13,600
Ah, Paris...

554
00:29:13,600 --> 00:29:15,600
..home to the Eiffel Tower,

555
00:29:15,600 --> 00:29:17,840
the Arc de Triomphe...

556
00:29:17,840 --> 00:29:20,720
..and, of course, sweet pastries.

557
00:29:21,960 --> 00:29:25,000
If you step into any French
patisserie, the first thing

558
00:29:25,000 --> 00:29:27,840
that hits you - besides the
beautiful array of cakes

559
00:29:27,840 --> 00:29:30,440
and pastries - is the smell...

560
00:29:30,440 --> 00:29:33,920
..a great waft of sugar and almonds.

561
00:29:33,920 --> 00:29:35,560
Or frangipane.

562
00:29:38,840 --> 00:29:42,320
To discover the origins
of this aromatic filling,

563
00:29:42,320 --> 00:29:45,320
I'm meeting French
food historian David Downie...

564
00:29:45,320 --> 00:29:47,880
David! Nice to see you.

565
00:29:47,880 --> 00:29:51,760
..who has brought
an unusual gift for me.

566
00:29:51,760 --> 00:29:53,880
Ooh, a lovely new pair of
red gloves!

567
00:29:53,880 --> 00:29:56,920
But what on earth has that got
to do with frangipane?

568
00:29:56,920 --> 00:29:59,400
Now, these are perfumed gloves.
Oh, really?

569
00:29:59,400 --> 00:30:02,440
Yes. Sniff. Oh, yeah! They are
perfumed, aren't they?

570
00:30:02,440 --> 00:30:04,440
And what do they smell of?
They smell of almonds.

571
00:30:04,440 --> 00:30:06,520
They smell of almonds.
Very strongly of almonds.

572
00:30:06,520 --> 00:30:10,280
And they were the rage in
the 17th century,

573
00:30:10,280 --> 00:30:11,960
when this square was built.

574
00:30:13,560 --> 00:30:17,400
At that time, Paris was
a rather different place.

575
00:30:17,400 --> 00:30:23,120
For one thing, the population
density was about 20 times
what it is today.

576
00:30:23,120 --> 00:30:24,560
Wow!

577
00:30:24,560 --> 00:30:29,640
Almost half a million people
were crammed into a city
without sewers.

578
00:30:29,640 --> 00:30:32,680
So there was a certain tang
to the air,

579
00:30:32,680 --> 00:30:35,400
I believe you say "pong"
in your country.

580
00:30:35,400 --> 00:30:40,600
And the nobility, who could afford
it, wore perfumes. Right.

581
00:30:40,600 --> 00:30:45,280
They wore it on their clothes and,
specifically, on their gloves.

582
00:30:45,280 --> 00:30:47,880
Now, here's the recipe
for making those gloves,

583
00:30:47,880 --> 00:30:50,560
from the royal perfumer, a book.

584
00:30:50,560 --> 00:30:54,560
And if we look at them, they are
called frangipane gloves.

585
00:30:54,560 --> 00:30:56,640
Oh, goodness!

586
00:30:56,640 --> 00:30:59,280
So who on earth was
this...Frangipane?

587
00:30:59,280 --> 00:31:05,120
There is a Marshal of France
named Pompeo Frangipani.

588
00:31:05,120 --> 00:31:07,840
A favourite of Louis XIII,

589
00:31:07,840 --> 00:31:12,480
Pompeo Frangipani was a perfumer
whose name became synonymous

590
00:31:12,480 --> 00:31:16,280
with the fashionable almond
fragrance he perfected.

591
00:31:16,280 --> 00:31:19,480
But how does that
translate into food?

592
00:31:19,480 --> 00:31:25,680
Legend has it that his maggiordomo -
his butler - took the name of

593
00:31:25,680 --> 00:31:30,600
his master, and applied
it to this much older recipe

594
00:31:30,600 --> 00:31:33,400
for the almond-filled tart. Ah...

595
00:31:33,400 --> 00:31:37,960
So we've got the same name being
applied to a particular tart.

596
00:31:37,960 --> 00:31:41,800
And the pair of them, the gloves
and the tart, have a similar smell.

597
00:31:41,800 --> 00:31:43,760
Smells like frangipane.

598
00:31:43,760 --> 00:31:46,920
A fashionable scent becomes
a fashionable flavour.

599
00:31:50,280 --> 00:31:53,320
To get a taste of 17th-century Paris
for myself,

600
00:31:53,320 --> 00:31:56,240
David's helping me cook up the very
earliest written recipe

601
00:31:56,240 --> 00:31:58,560
for frangipane.

602
00:31:58,560 --> 00:32:00,640
Oh, I see you've got everything
here!

603
00:32:00,640 --> 00:32:03,240
Look. Marvellous! Ready to go.

604
00:32:03,240 --> 00:32:05,280
So, this is our recipe?

605
00:32:05,280 --> 00:32:06,920
Yes.

606
00:32:06,920 --> 00:32:10,840
It's from La Varenne's
Le Cuisinier Francois,

607
00:32:10,840 --> 00:32:13,640
which dates back to 1651.

608
00:32:13,640 --> 00:32:18,240
So, take some flour and cook it
in your milk.

609
00:32:19,840 --> 00:32:24,200
The ingredients of this 370-year-old
recipe are similar

610
00:32:24,200 --> 00:32:27,120
to those you'd use in a modern
frangipane.

611
00:32:27,120 --> 00:32:30,280
Now, you'll notice that this is
very scientific

612
00:32:30,280 --> 00:32:32,280
and it has all the measurements
and the weights...

613
00:32:32,280 --> 00:32:33,920
Yeah, none of them! Right.

614
00:32:33,920 --> 00:32:36,720
None of them, that's the way I like
cooking, no measurements. Exactly!

615
00:32:36,720 --> 00:32:39,440
No spelling, no measurements.

616
00:32:39,440 --> 00:32:42,640
I've put in about two tablespoons
of sugar.

617
00:32:42,640 --> 00:32:44,800
Would you put in more, or...?

618
00:32:44,800 --> 00:32:47,520
1653, at the price of sugar -
no, I wouldn't!

619
00:32:47,520 --> 00:32:48,920
SHE LAUGHS

620
00:32:52,840 --> 00:32:55,480
I'm leaving the beautifying to you.
OK.

621
00:32:55,480 --> 00:32:58,280
I can't be trusted with anything
that has to look pretty!

622
00:33:01,920 --> 00:33:05,000
25 minutes later, it's cooked.

623
00:33:05,000 --> 00:33:07,040
Ooh, look at that!

624
00:33:09,280 --> 00:33:11,680
Now, that does look good,
doesn't it? Mm!

625
00:33:11,680 --> 00:33:14,320
And it smells like gloves!

626
00:33:14,320 --> 00:33:16,120
SHE LAUGHS

627
00:33:20,040 --> 00:33:23,880
The fashion for perfumed gloves was
a short-lived craze.

628
00:33:23,880 --> 00:33:26,960
Mm, oh, that's nutty!

629
00:33:26,960 --> 00:33:31,840
But thanks to this fragrant filling,
Frangipane's name has lasted longer.

630
00:33:31,840 --> 00:33:34,480
Cake is king! Absolutely.

631
00:33:43,760 --> 00:33:46,800
Almost three hours in,
our Cherry Bakewells

632
00:33:46,800 --> 00:33:49,360
are looking suitably regal.

633
00:33:49,360 --> 00:33:52,680
Eight and a half minutes in the oven
has firmed up the frangipane

634
00:33:52,680 --> 00:33:55,600
and crisped up the pastry.

635
00:33:55,600 --> 00:34:00,080
They march out 15 at a time with
their new all-over tans.

636
00:34:03,920 --> 00:34:06,960
Do you feel good about that?
Yeah, they look really good, yeah.

637
00:34:06,960 --> 00:34:08,760
I could eat them without the icing,
to be honest!

638
00:34:08,760 --> 00:34:10,240
HE LAUGHS

639
00:34:10,240 --> 00:34:13,080
Before we can allow them to continue
their journey,

640
00:34:13,080 --> 00:34:16,560
we need to check they're
fully cooked.

641
00:34:16,560 --> 00:34:18,760
So, with a hand-held temperature
probe,

642
00:34:18,760 --> 00:34:20,800
and what we're looking to achieve
at this point

643
00:34:20,800 --> 00:34:23,920
is a temperature of a minimum of
95 degrees.

644
00:34:23,920 --> 00:34:27,280
The reason it's 95 degrees,
is we're looking to ensure

645
00:34:27,280 --> 00:34:29,520
that the Cherry Bakewells
are food safe,

646
00:34:29,520 --> 00:34:31,960
that the baking profile has been
achieved.

647
00:34:31,960 --> 00:34:34,160
The next part of the bake check
is to ensure that there is

648
00:34:34,160 --> 00:34:36,000
no soggy bottom.

649
00:34:36,000 --> 00:34:38,680
Yeah, that's what I want to see.
Come on, then.

650
00:34:42,080 --> 00:34:45,560
That has not stuck to the tin,
like I thought it would. No.

651
00:34:45,560 --> 00:34:47,800
And that is a perfectly dry,

652
00:34:47,800 --> 00:34:50,960
cooked all the way through,
tart bottom. Yeah!

653
00:34:50,960 --> 00:34:53,240
Come on, I'll nibble this if you're
not looking!

654
00:34:53,240 --> 00:34:54,680
HE CHUCKLES

655
00:34:55,960 --> 00:35:00,400
Test passed, the tarts are allowed
some time to chill out.

656
00:35:00,400 --> 00:35:05,280
As they saunter along 22 and a half
metres of conveyors,

657
00:35:05,280 --> 00:35:11,560
their temperature gradually drops
from 75 Celsius, down to 45.

658
00:35:11,560 --> 00:35:15,840
This ensures the pastry hardens
without cracking.

659
00:35:15,840 --> 00:35:17,680
Come on, I know you see this
every day.

660
00:35:17,680 --> 00:35:19,880
Tell me you're not impressed by
this - that's fantastic.

661
00:35:19,880 --> 00:35:21,720
No, it's good.

662
00:35:21,720 --> 00:35:26,000
The conveyor then passes through
this big yellow fridge,

663
00:35:26,000 --> 00:35:31,080
where our tarts enjoy a six
minute blast of cool air.

664
00:35:31,080 --> 00:35:34,520
When they emerge, they're at
a comfortable handling temperature,

665
00:35:34,520 --> 00:35:37,480
ready for another step class.

666
00:35:37,480 --> 00:35:39,760
FUNKY MUSIC PLAYS

667
00:35:45,680 --> 00:35:48,320
They drop six at a time
into the trays

668
00:35:48,320 --> 00:35:50,520
that they'll leave the factory in.

669
00:35:53,680 --> 00:35:58,080
I can't believe that you actually
bake the whole thing in its tin,

670
00:35:58,080 --> 00:36:00,720
and I can't believe you put the
icing on once it's in the plastic.

671
00:36:00,720 --> 00:36:02,760
Don't tell me - you put the
cherry on once you've got it

672
00:36:02,760 --> 00:36:04,080
inside the box!

673
00:36:04,080 --> 00:36:05,320
HE LAUGHS

674
00:36:05,320 --> 00:36:07,640
We're not that good!

675
00:36:07,640 --> 00:36:10,040
These tarts are still a little
underdressed

676
00:36:10,040 --> 00:36:11,640
for the outside world...

677
00:36:13,480 --> 00:36:15,920
..so, I'm heading to the factory's
icing room,

678
00:36:15,920 --> 00:36:17,880
to sort out their topping.

679
00:36:19,200 --> 00:36:21,200
Hello, Gregg. Are you John?

680
00:36:21,200 --> 00:36:23,160
I am, it's me. How do I get up?

681
00:36:23,160 --> 00:36:25,000
Round the corner.

682
00:36:25,000 --> 00:36:28,240
I'm meeting icing technician,
John Harding.

683
00:36:28,240 --> 00:36:30,800
Hello, Gregg.
All right, John. Morning!

684
00:36:30,800 --> 00:36:33,320
Right, we're making icing, right?
Fondant icing, yeah.

685
00:36:33,320 --> 00:36:35,000
Where do we make that?

686
00:36:35,000 --> 00:36:36,960
We're going to use this machine
today.

687
00:36:36,960 --> 00:36:39,480
Right, OK, the great big witches'
cauldron. Does that open up?

688
00:36:39,480 --> 00:36:41,560
Yes, I'll show you.

689
00:36:41,560 --> 00:36:44,160
And I thought I had a big mixer
at home!

690
00:36:44,160 --> 00:36:46,400
This one's 1,000 litres!

691
00:36:47,720 --> 00:36:49,880
Yeah, take the hose into there.

692
00:36:49,880 --> 00:36:55,160
We're mixing up a batch of luxurious
soft fondant icing.

693
00:36:55,160 --> 00:37:00,040
And the first ingredient is 96 kilos
of glucose syrup.

694
00:37:00,040 --> 00:37:02,280
Will this automatically stop
when it's had enough?

695
00:37:02,280 --> 00:37:04,680
No, no, you turn it off,
same as you turn it on.

696
00:37:04,680 --> 00:37:08,840
How many Cherry Bakewells will this
icing mix cover?

697
00:37:08,840 --> 00:37:12,400
So, it'll probably last the plant
around one hour 30,

698
00:37:12,400 --> 00:37:16,560
and it will cover 64,000 cakes.

699
00:37:16,560 --> 00:37:18,720
Why is this not done automatically?

700
00:37:18,720 --> 00:37:21,560
Because if you take your eye off the
ball, you're going to mess it up.

701
00:37:21,560 --> 00:37:23,560
You don't take your eye off the
ball!

702
00:37:23,560 --> 00:37:27,120
94, 95, 96. That'll do, that'll do.

703
00:37:27,120 --> 00:37:29,240
How long have you been icing
Cherry Bakewells, John?

704
00:37:29,240 --> 00:37:31,040
Er, 42 years.

705
00:37:31,040 --> 00:37:32,720
42 years! 42 years.

706
00:37:32,720 --> 00:37:34,440
Has the recipe changed in that time?

707
00:37:34,440 --> 00:37:35,760
No.

708
00:37:35,760 --> 00:37:38,000
The size of the mix, yes.

709
00:37:38,000 --> 00:37:39,920
The mix itself, no.

710
00:37:39,920 --> 00:37:41,840
What do you like about working here?

711
00:37:41,840 --> 00:37:44,520
It's a challenge every day,

712
00:37:44,520 --> 00:37:46,720
to make sure that they don't
run out.

713
00:37:46,720 --> 00:37:48,480
As quick as they make cakes...

714
00:37:48,480 --> 00:37:50,120
They want it, we've got to make it.

715
00:37:50,120 --> 00:37:52,200
You pride yourself in always
giving them the icing.

716
00:37:52,200 --> 00:37:54,840
Correct!
You are the icing on the cake.

717
00:37:54,840 --> 00:37:56,680
That's the one!

718
00:37:56,680 --> 00:37:58,520
THEY LAUGH

719
00:38:00,520 --> 00:38:05,000
Liquid ingredients in, we close the
lid before we call for the dry ones.

720
00:38:07,000 --> 00:38:11,520
So, what we need to do now,
take this and tap on that pipe

721
00:38:11,520 --> 00:38:14,360
above you, the metal part.

722
00:38:14,360 --> 00:38:17,640
So that it will drop down the
sugar, into the bowl.

723
00:38:17,640 --> 00:38:19,880
He's waiting for me to tap it? Yes.

724
00:38:19,880 --> 00:38:22,440
All this million pounds' worth of
industry,

725
00:38:22,440 --> 00:38:24,760
and I've got to get the sugar by
tapping on a pipe?

726
00:38:24,760 --> 00:38:27,920
That's the most important tool
of all.

727
00:38:27,920 --> 00:38:29,440
What's your normal tap?

728
00:38:29,440 --> 00:38:31,000
Just two taps.

729
00:38:31,000 --> 00:38:32,840
That's the one.

730
00:38:36,960 --> 00:38:38,640
Here's your sugar now.

731
00:38:38,640 --> 00:38:40,720
432 kilos.

732
00:38:40,720 --> 00:38:43,000
That's probably about five
cups of tea for me!

733
00:38:45,960 --> 00:38:48,520
There we go, he's knocked on there
to tell you that it's all in.

734
00:38:48,520 --> 00:38:50,920
I only did two knocks,
he's playing a tune.

735
00:38:53,840 --> 00:38:56,840
OK, start the machine.

736
00:38:56,840 --> 00:39:00,160
It simmers in this heated
mixer for 20 minutes,

737
00:39:00,160 --> 00:39:02,680
reducing down and thickening up.

738
00:39:04,480 --> 00:39:08,640
Once it's cooled, we add
another ingredient.

739
00:39:08,640 --> 00:39:13,280
This is egg white, sugar - mixed
up into a marshmallow product.

740
00:39:13,280 --> 00:39:15,320
It's like a meringue mix.
Yes.

741
00:39:15,320 --> 00:39:18,720
This will help our icing
set and make it shiny.

742
00:39:18,720 --> 00:39:20,200
Wahey!

743
00:39:20,200 --> 00:39:23,960
Our next ingredient is also
upstairs.

744
00:39:23,960 --> 00:39:25,920
That'll do.

745
00:39:25,920 --> 00:39:27,680
This will be condensed milk.

746
00:39:27,680 --> 00:39:29,320
Condensed milk? Condensed milk.

747
00:39:29,320 --> 00:39:31,920
What, like you get in a tin?
Exactly.

748
00:39:31,920 --> 00:39:34,000
That will give your texture,
taste.

749
00:39:34,000 --> 00:39:36,480
When you're eating it,
it tastes quite creamy, yeah?

750
00:39:36,480 --> 00:39:38,840
So that's why we add that.
Creamy and rich!

751
00:39:38,840 --> 00:39:40,640
Yes.

752
00:39:41,720 --> 00:39:44,920
Another good mix for 30 minutes
and it's ready.

753
00:39:46,600 --> 00:39:50,480
We're going to tip it out
and if you can stand here,

754
00:39:50,480 --> 00:39:53,320
I'll give you that.

755
00:39:53,320 --> 00:39:55,560
Do I need to be scared
of this, John?

756
00:39:55,560 --> 00:39:57,960
There's quite a lot of topping
coming out.

757
00:39:57,960 --> 00:40:00,000
MUSIC: Ride Of The Valkyries
by Wagner

758
00:40:06,880 --> 00:40:08,920
Whoa!

759
00:40:08,920 --> 00:40:11,160
Look at that!

760
00:40:11,160 --> 00:40:12,960
HE LAUGHS EXCITEDLY

761
00:40:18,480 --> 00:40:20,560
Now, work the scraper.

762
00:40:20,560 --> 00:40:23,520
Now, all you're doing is scraping
the lip off.

763
00:40:23,520 --> 00:40:25,760
What, here? All the way on the edge.

764
00:40:25,760 --> 00:40:27,600
On the edge.

765
00:40:27,600 --> 00:40:29,640
This is a good job.

766
00:40:29,640 --> 00:40:31,840
I like this. This is a great job!

767
00:40:35,960 --> 00:40:40,560
I love icing and iced cakes -
and I'm not the only one.

768
00:40:40,560 --> 00:40:45,480
Last year, we spent over £2 billion
on birthday and wedding cakes.

769
00:40:45,480 --> 00:40:50,400
Cherry is steadying her hand at one
of the country's biggest producers.

770
00:40:50,400 --> 00:40:56,640
Oldham, Greater Manchester,
is home to Park Cakes,

771
00:40:56,640 --> 00:41:01,320
where 60 specialist decorators
top over eight million cakes a year

772
00:41:01,320 --> 00:41:04,000
for Marks & Spencer.

773
00:41:04,000 --> 00:41:06,640
Hi, Riz, lovely to meet you.
Hi, lovely to meet you.

774
00:41:06,640 --> 00:41:09,560
Production manager Riz Ali is
challenging me to have a go

775
00:41:09,560 --> 00:41:12,280
at some of her bestsellers.

776
00:41:12,280 --> 00:41:14,480
First up, it's the tulip cake.

777
00:41:16,040 --> 00:41:20,080
Andrea Grady makes it look easy,
and I can't wait to get started!

778
00:41:21,280 --> 00:41:24,800
What is the secret to a perfect
tulip?

779
00:41:24,800 --> 00:41:29,400
There's three things - the texture
of the buttercream. Mm-hm.

780
00:41:29,400 --> 00:41:31,920
The nozzle. The nozzle? Yeah.

781
00:41:31,920 --> 00:41:33,880
So, that gives you a lovely tulip...
Yeah.

782
00:41:33,880 --> 00:41:35,440
..shape, OK, what else?

783
00:41:35,440 --> 00:41:37,520
And the holding of the bag.

784
00:41:37,520 --> 00:41:39,720
That hand there, that hand there.
OK, great start!

785
00:41:39,720 --> 00:41:41,880
And then, do that. OK, here we go.

786
00:41:41,880 --> 00:41:43,800
In the middle. In the middle.

787
00:41:43,800 --> 00:41:45,440
Lift.

788
00:41:45,440 --> 00:41:47,880
That's the saddest tulip
I've ever seen!

789
00:41:47,880 --> 00:41:49,960
Instead of pushing down,
just bring it up.

790
00:41:49,960 --> 00:41:51,920
Oh, OK.

791
00:41:51,920 --> 00:41:54,160
Oh, look! There you go.
That's a good one!

792
00:41:54,160 --> 00:41:57,000
You've just got to do it lightly.
Hello, there!

793
00:41:57,000 --> 00:41:59,200
Shame about the other
ones, never mind!

794
00:42:03,880 --> 00:42:05,760
Oh, look at that! There you go.

795
00:42:05,760 --> 00:42:08,760
If you close your eyes a little bit,
then it looks amazing.

796
00:42:10,640 --> 00:42:12,680
But what does Riz think?

797
00:42:12,680 --> 00:42:15,400
Would that get past quality control?
It wouldn't.

798
00:42:15,400 --> 00:42:18,440
Do you think I'd be sent home to
have a day off? I think so, yes.

799
00:42:18,440 --> 00:42:20,720
Sort myself out? Yes!

800
00:42:22,320 --> 00:42:24,880
My next challenge is
another flower,

801
00:42:24,880 --> 00:42:28,280
a blush rose for one of their
wedding cakes.

802
00:42:28,280 --> 00:42:32,160
Shamima Akhtar is showing
me how to make one.

803
00:42:32,160 --> 00:42:34,760
I can see you've layered them, and
then you've twisted them round.

804
00:42:34,760 --> 00:42:36,320
Yeah.

805
00:42:36,320 --> 00:42:39,880
A special ingredient called
tragacanth gum makes this icing

806
00:42:39,880 --> 00:42:42,880
pliable enough to shape into
delicate petals.

807
00:42:44,240 --> 00:42:46,160
So, it's really just a millimetre
thick. Yeah.

808
00:42:46,160 --> 00:42:48,160
That's incredibly thin!

809
00:42:48,160 --> 00:42:52,040
But it quickly starts to go hard,
so I've got to work fast.

810
00:42:54,720 --> 00:42:57,320
Well, it does look like a rose,
at least.

811
00:42:57,320 --> 00:42:59,480
It does look like a flower.

812
00:43:01,000 --> 00:43:05,040
Now we airbrush on the blush effect,
using a dye made of beetroot.

813
00:43:05,040 --> 00:43:08,640
So, now these are ready, where do we
take them? To the wedding room.

814
00:43:08,640 --> 00:43:11,280
Take them into the wedding room?
Take them into the wedding room.

815
00:43:11,280 --> 00:43:14,000
Do you play Abba in there? No!

816
00:43:14,000 --> 00:43:18,040
# I do, I do, I do,
I do, I do...#

817
00:43:19,280 --> 00:43:21,320
Christine, I hear you're the woman
to talk to about

818
00:43:21,320 --> 00:43:23,720
assembling a wedding cake. Yes.

819
00:43:23,720 --> 00:43:27,200
I've brought one for you specially.

820
00:43:27,200 --> 00:43:29,840
Look, that can be your first rose,
to go on the cake.

821
00:43:29,840 --> 00:43:31,680
No!

822
00:43:32,760 --> 00:43:34,880
I don't think Riz would accept that!

823
00:43:34,880 --> 00:43:37,560
So, here's a much nicer one.

824
00:43:37,560 --> 00:43:41,000
How on earth do you get this
rock-solid rose,

825
00:43:41,000 --> 00:43:43,240
that's quite heavy, to stick
precariously

826
00:43:43,240 --> 00:43:45,280
onto the side of a cake?

827
00:43:45,280 --> 00:43:47,920
Just this icing. OK, just the icing?
Yeah.

828
00:43:47,920 --> 00:43:50,320
What's that icing? Royal icing.
Royal icing.

829
00:43:50,320 --> 00:43:52,400
Why do you use royal icing?

830
00:43:52,400 --> 00:43:54,960
Because it sets hard.
So, it's like cement. Yeah.

831
00:43:54,960 --> 00:43:57,680
Edible cement. Edible cement!

832
00:43:57,680 --> 00:44:00,680
A mix of icing sugar, egg whites
and lemon juice -

833
00:44:00,680 --> 00:44:03,400
royal icing got its name after it
was used to decorate

834
00:44:03,400 --> 00:44:07,000
Queen Victoria's wedding cake
in 1840.

835
00:44:07,000 --> 00:44:08,840
Ta-da, it's finished!

836
00:44:08,840 --> 00:44:11,280
That's really good. Isn't that
amazing? What do you think?

837
00:44:11,280 --> 00:44:13,000
You've done a good job, yeah.

838
00:44:14,080 --> 00:44:16,920
But now for my ultimate challenge!

839
00:44:18,040 --> 00:44:20,760
So, this is our Chocolate Caramel
Dribble Cake.

840
00:44:20,760 --> 00:44:23,800
We don't have long to decorate this.
Why? So, the key is...

841
00:44:23,800 --> 00:44:26,480
Because the chocolate sets and then
the chocolate components

842
00:44:26,480 --> 00:44:28,240
don't stick to the cake, basically.

843
00:44:28,240 --> 00:44:30,720
Are we revving things up a bit?
So, we're revving it up now.

844
00:44:30,720 --> 00:44:32,360
We've come to extreme icing.

845
00:44:32,360 --> 00:44:34,240
Extreme speed!

846
00:44:35,600 --> 00:44:39,680
Three fountains keep our molten
chocolate at 40 degrees Celsius.

847
00:44:41,520 --> 00:44:43,320
OK, ready?

848
00:44:45,160 --> 00:44:47,400
Is that enough? Yeah, let's go.

849
00:44:48,720 --> 00:44:50,520
OK. Is that enough? Yeah.

850
00:44:50,520 --> 00:44:51,920
OK, now wiggle.

851
00:44:51,920 --> 00:44:53,960
So, you're going to give it
a little shake,

852
00:44:53,960 --> 00:44:56,440
so the chocolate falls down
the sides.

853
00:44:56,440 --> 00:44:58,360
Why won't it go?!

854
00:44:58,360 --> 00:45:00,080
A little bit faster, so you can...

855
00:45:00,080 --> 00:45:02,240
It's all in the wiggle!

856
00:45:04,960 --> 00:45:08,120
It's a race against time to get
all my chocolaty baubles

857
00:45:08,120 --> 00:45:10,720
on the top before it sets.

858
00:45:12,400 --> 00:45:14,880
Of all of the cakes that I've iced
today,

859
00:45:14,880 --> 00:45:20,080
this is probably the least bad,
but I did not dribble well.

860
00:45:20,080 --> 00:45:23,800
No, and that's another one doesn't
pass quality control, I'm afraid.

861
00:45:23,800 --> 00:45:25,760
Are you saying I have to go home
with this one?

862
00:45:25,760 --> 00:45:27,840
I don't know about that! Oh, go on!

863
00:45:27,840 --> 00:45:29,880
Go on, then.

864
00:45:29,880 --> 00:45:32,760
Well, I think I can safely say that
I'm better at eating cake

865
00:45:32,760 --> 00:45:35,760
than decorating them,
but I can live with that!

866
00:45:43,600 --> 00:45:44,800
PIPES CLANG

867
00:45:47,960 --> 00:45:52,400
We're three hours, 35 minutes
into production of my cakes.

868
00:45:52,400 --> 00:45:57,720
I'm hooking my 841 kilos of
sweet fondant icing

869
00:45:57,720 --> 00:46:01,320
up to a delivery tank,
because Mark is waiting for it

870
00:46:01,320 --> 00:46:03,400
on the main production line.

871
00:46:03,400 --> 00:46:05,600
Hello again, mate. Hi, Gregg.
You all right?

872
00:46:05,600 --> 00:46:07,480
Hey, my beautiful icing!

873
00:46:07,480 --> 00:46:11,920
The way that's going on there,
and not dripping over the pastry,

874
00:46:11,920 --> 00:46:14,600
must be the same principle
as the jam?

875
00:46:14,600 --> 00:46:17,360
Yes, it's exactly the same.
Eh, I'm learning!

876
00:46:17,360 --> 00:46:20,160
So, there's a little bit of air
in between each squirt.

877
00:46:20,160 --> 00:46:21,680
That's right.

878
00:46:21,680 --> 00:46:24,680
That stops anything dripping over
the side.

879
00:46:24,680 --> 00:46:28,600
These precision dollopers are
dishing out 13g

880
00:46:28,600 --> 00:46:32,240
of my precious icing
onto each tart.

881
00:46:32,240 --> 00:46:36,560
What happens if, say one batch of
the frangipane hasn't risen

882
00:46:36,560 --> 00:46:39,960
as much as it normally does,
then your icing won't go

883
00:46:39,960 --> 00:46:41,960
to the top of the tart?

884
00:46:41,960 --> 00:46:43,440
No, that's right.

885
00:46:43,440 --> 00:46:47,240
What we'd end up having to do is put
more of the fondant icing in,

886
00:46:47,240 --> 00:46:49,520
to achieve the correct fill level.

887
00:46:49,520 --> 00:46:51,920
Just by turning it up a little bit,
like a tap, is that right?

888
00:46:51,920 --> 00:46:53,160
That's right, yeah.

889
00:46:53,160 --> 00:46:54,920
That's all right, it's not an issue,
is it?

890
00:46:54,920 --> 00:46:57,000
The fondant icing is the most
expensive bit

891
00:46:57,000 --> 00:46:58,840
of the Cherry Bakewell.

892
00:46:58,840 --> 00:47:01,600
Is it? It is.

893
00:47:01,600 --> 00:47:04,720
No need to turn the tap up today,
as we've got our proportions

894
00:47:04,720 --> 00:47:06,600
spot on.

895
00:47:06,600 --> 00:47:09,600
Stage one of their beautification
complete,

896
00:47:09,600 --> 00:47:12,080
the cheeky final touch is...

897
00:47:12,080 --> 00:47:14,040
..the cherry on top!

898
00:47:15,560 --> 00:47:19,160
French glace cherries are washed
clean of their sticky syrup.

899
00:47:21,760 --> 00:47:23,880
Kirsty, cherries, yeah?
Yes, cherries.

900
00:47:23,880 --> 00:47:26,080
Can I help? Of course you can!

901
00:47:26,080 --> 00:47:28,880
Then they're given a once-over by
cherry checker,

902
00:47:28,880 --> 00:47:30,320
Kirsty Meakin.

903
00:47:30,320 --> 00:47:32,160
What have I got to do?

904
00:47:32,160 --> 00:47:34,000
We basically have to sort through
them.

905
00:47:34,000 --> 00:47:36,400
We have to take the bad ones out.

906
00:47:36,400 --> 00:47:38,400
Tip it there.

907
00:47:38,400 --> 00:47:40,880
They'll come on the...
Hang on, hang on, that's too fast!

908
00:47:40,880 --> 00:47:43,440
Can we slow the machine down? No.

909
00:47:43,440 --> 00:47:45,960
I'm going to miss bits.
I'm sure you won't.

910
00:47:45,960 --> 00:47:48,440
I will. If you've got an eagle eye.

911
00:47:48,440 --> 00:47:51,200
But someone's going to get
a Bakewell tart with only a quarter

912
00:47:51,200 --> 00:47:53,680
of a cherry and they're going to
think I'm responsible!

913
00:47:53,680 --> 00:47:55,520
I'm sure they won't.

914
00:47:55,520 --> 00:47:59,040
What happens to the cherries
we're discarding?

915
00:47:59,040 --> 00:48:01,440
They go upstairs, they go in the
flapjack.

916
00:48:01,440 --> 00:48:04,280
Right, they don't get thrown away?
No, no waste.

917
00:48:04,280 --> 00:48:06,520
I don't suppose you know, do you,
how many cherries

918
00:48:06,520 --> 00:48:08,080
you go through here?

919
00:48:08,080 --> 00:48:10,520
260 tonnes a year.

920
00:48:10,520 --> 00:48:13,200
I wouldn't have imagined there were
that many cherries in the world.

921
00:48:13,200 --> 00:48:14,920
I know!

922
00:48:14,920 --> 00:48:16,800
You'd be surprised.

923
00:48:22,160 --> 00:48:24,960
Hey, I've got cherries!

924
00:48:24,960 --> 00:48:27,080
Can I put them down?
They're heavy!

925
00:48:27,080 --> 00:48:31,440
A team of 12 places each individual
half cherry by hand.

926
00:48:33,280 --> 00:48:34,920
They're not wearing any gloves.

927
00:48:34,920 --> 00:48:37,120
No, that's right, Gregg.
Have you washed your hands?

928
00:48:37,120 --> 00:48:39,200
Mate, I haven't stopped washing my
hands in here.

929
00:48:39,200 --> 00:48:42,040
All our staff regularly wash
their hands.

930
00:48:42,040 --> 00:48:46,120
Now I want to get stuck in,
and Sue Lawton is showing me how.

931
00:48:46,120 --> 00:48:49,360
Get a handful of cherries,
go all the way along,

932
00:48:49,360 --> 00:48:52,200
but make sure you're putting them
in the middle.

933
00:48:52,200 --> 00:48:54,840
Here, surely you can get a machine
to do this, right?

934
00:48:54,840 --> 00:48:58,120
Um, no, we haven't found a machine
yet that'd be able to put

935
00:48:58,120 --> 00:49:02,120
the cherries on the right way round,
with them being half cherries.

936
00:49:02,120 --> 00:49:04,200
Oh, I see.

937
00:49:04,200 --> 00:49:06,200
You've got a massively quick
technique,

938
00:49:06,200 --> 00:49:08,040
you're kind of like a double hander.

939
00:49:08,040 --> 00:49:11,160
I don't do it like the others do it,
I prefer doing it my way.

940
00:49:11,160 --> 00:49:13,280
How long have you been on here,
doing the cherries?

941
00:49:13,280 --> 00:49:15,560
About 13 years now. 13!

942
00:49:15,560 --> 00:49:17,160
Since you were 12.

943
00:49:17,160 --> 00:49:19,240
I wish!

944
00:49:19,240 --> 00:49:21,240
How long have you been here?
12 years.

945
00:49:21,240 --> 00:49:23,200
12 years? Yeah.

946
00:49:23,200 --> 00:49:25,360
Do you like it? I love it!

947
00:49:25,360 --> 00:49:29,320
Why? It's good fun, nice people,
easy job.

948
00:49:29,320 --> 00:49:32,000
Is there a song you sing
to go with it?

949
00:49:38,440 --> 00:49:40,920
# It's cherry pink

950
00:49:40,920 --> 00:49:46,000
# And apple blossom white

951
00:49:46,000 --> 00:49:50,080
# When your true lover comes
your way

952
00:49:50,080 --> 00:49:54,320
# It's cherry pink and
apple blossom white

953
00:49:54,320 --> 00:49:57,160
# The poet says...

954
00:49:57,160 --> 00:49:59,520
There's certainly something to sing
about -

955
00:49:59,520 --> 00:50:02,280
all my Bakewells baked well!

956
00:50:02,280 --> 00:50:05,440
# The story goes that once a cherry
tree... #

957
00:50:05,440 --> 00:50:08,080
These tarts were a nostalgic
favourite,

958
00:50:08,080 --> 00:50:11,080
but the basis of their filling is
flavour of the month.

959
00:50:11,080 --> 00:50:14,240
Almonds are big business,
with sales shooting up

960
00:50:14,240 --> 00:50:16,520
over the last year.

961
00:50:16,520 --> 00:50:20,880
Cherry couldn't resist checking out
how you turn nuts into butter.

962
00:50:23,400 --> 00:50:26,680
I'm visiting Petrow Foods, near
Cambridge,

963
00:50:26,680 --> 00:50:31,880
where they make 350 tonnes of almond
butter for Pip and Nut each year.

964
00:50:31,880 --> 00:50:34,600
Pippa Murray is guiding me through
the process.

965
00:50:34,600 --> 00:50:36,360
Hi, Pip. Hey, Cherry.

966
00:50:36,360 --> 00:50:38,400
Lovely to meet you.
So nice to meet you too.

967
00:50:38,400 --> 00:50:40,040
Boy, oh, boy!

968
00:50:40,040 --> 00:50:42,080
That is a big bag of nuts.

969
00:50:42,080 --> 00:50:45,240
About 16 bags of almonds sitting
right here.

970
00:50:45,240 --> 00:50:47,760
Millions and millions of almonds.
Yeah.

971
00:50:47,760 --> 00:50:49,360
Where do these almonds come from?

972
00:50:49,360 --> 00:50:51,400
These almonds are from California.

973
00:50:51,400 --> 00:50:54,640
If you look at it when it's on the
tree, it has a green outer shell,

974
00:50:54,640 --> 00:50:57,040
which is soft, and then inside,
you've got the almond,

975
00:50:57,040 --> 00:50:58,920
which is a seed.

976
00:50:58,920 --> 00:51:01,640
So, an almond isn't really a nut?

977
00:51:01,640 --> 00:51:07,480
No, technically part of a fruit, and
the inside of the almond is a seed,

978
00:51:07,480 --> 00:51:11,160
even though we classify it as a nut,
if you buy it.

979
00:51:11,160 --> 00:51:14,160
80% of the world's almonds come
from California,

980
00:51:14,160 --> 00:51:16,680
where they are harvested by
a machine which is very logically

981
00:51:16,680 --> 00:51:19,000
called a tree shaker.

982
00:51:21,600 --> 00:51:23,720
They are sun-dried...

983
00:51:23,720 --> 00:51:25,560
..collected up...

984
00:51:25,560 --> 00:51:28,040
..then graded and shipped out.

985
00:51:29,440 --> 00:51:32,320
At the factory, today's delivery
is getting a once-over.

986
00:51:33,680 --> 00:51:35,400
So, what is this machine?

987
00:51:35,400 --> 00:51:38,680
So, this is the optical sorter,
which is a fancy word for saying

988
00:51:38,680 --> 00:51:41,600
a laser machine.

989
00:51:41,600 --> 00:51:45,680
This hi-tech machine scans each
almond with lasers,

990
00:51:45,680 --> 00:51:48,880
weeding out any damaged or
discoloured nuts.

991
00:51:48,880 --> 00:51:51,800
So, there's two lasers that detect
any bad almonds,

992
00:51:51,800 --> 00:51:55,160
and they use air to shoot them out,
and they'll come down

993
00:51:55,160 --> 00:51:57,880
and into this bucket, but all the
good ones get passed down

994
00:51:57,880 --> 00:52:01,480
onto this belt and they go into
a very big bag.

995
00:52:03,760 --> 00:52:06,880
A tonne of graded nuts heads to
the roaster.

996
00:52:08,600 --> 00:52:11,240
Right, are we ready to release the
nuts? Yeah.

997
00:52:11,240 --> 00:52:13,480
Into the wild!

998
00:52:13,480 --> 00:52:15,760
With the simple pull of a tag...

999
00:52:15,760 --> 00:52:17,880
Ah! Woohoo!

1000
00:52:17,880 --> 00:52:19,560
SHE LAUGHS

1001
00:52:19,560 --> 00:52:22,040
Whoa!

1002
00:52:22,040 --> 00:52:24,640
The almonds pour into the hopper
below...

1003
00:52:26,120 --> 00:52:28,720
..then travel into the 15 metre
long oven,

1004
00:52:28,720 --> 00:52:31,360
where they're roasted at a low
temperature.

1005
00:52:33,640 --> 00:52:35,200
Why do you roast the almonds?

1006
00:52:35,200 --> 00:52:37,040
Why not just take them
in their raw state

1007
00:52:37,040 --> 00:52:38,720
and create the butter from those?

1008
00:52:38,720 --> 00:52:42,160
The roasting process brings out all
the flavours within the almond,

1009
00:52:42,160 --> 00:52:44,520
specifically it's a special reaction
that happens,

1010
00:52:44,520 --> 00:52:48,240
called the Maillard reaction, which
is where the sugars and the proteins

1011
00:52:48,240 --> 00:52:52,520
react with each other and it creates
new flavour compounds,

1012
00:52:52,520 --> 00:52:55,960
which really enhances, like, the
nuttiness in the almonds.

1013
00:52:55,960 --> 00:52:58,160
The roast takes two hours.

1014
00:52:59,280 --> 00:53:01,640
They took their time. Yeah.
Was it worth it?

1015
00:53:03,520 --> 00:53:06,080
Oh, it's gorgeous! Yeah, exactly.

1016
00:53:06,080 --> 00:53:07,960
You can really see the difference.

1017
00:53:07,960 --> 00:53:11,560
It's very intense,
it tastes all toasted.

1018
00:53:11,560 --> 00:53:14,160
Yeah. And nutty and sweeter.
Yeah.

1019
00:53:16,080 --> 00:53:20,120
As well as intensifying the flavour,
roasting dries out the nuts -

1020
00:53:20,120 --> 00:53:23,160
ready for milling.

1021
00:53:23,160 --> 00:53:25,640
So, this right here is our mill.

1022
00:53:25,640 --> 00:53:28,880
So, right inside there we have
these two stones.

1023
00:53:28,880 --> 00:53:31,520
This one actually sits on top of it,
like that?

1024
00:53:31,520 --> 00:53:34,160
Yeah, exactly, and what you can see
is that it's got a really

1025
00:53:34,160 --> 00:53:37,480
thin gap between the two stones.
Right.

1026
00:53:37,480 --> 00:53:41,480
And it's that tiny gap which the
almonds are being pressed through,

1027
00:53:41,480 --> 00:53:46,160
and eventually get turned into
kind of, like, liquid.

1028
00:53:46,160 --> 00:53:50,160
The mill pulverises the almonds
into a smooth paste.

1029
00:53:52,600 --> 00:53:56,560
Oh, yeah, look at that!

1030
00:53:56,560 --> 00:53:59,320
What's so incredible is when you see
it roasted,

1031
00:53:59,320 --> 00:54:02,160
roasted for two hours, it looks like
the driest thing on Earth.

1032
00:54:02,160 --> 00:54:03,360
I know.

1033
00:54:03,360 --> 00:54:06,000
And then, here, it's liquid.

1034
00:54:06,000 --> 00:54:10,480
The natural oiliness of the nuts is
crucial to this transformation.

1035
00:54:10,480 --> 00:54:13,760
When you look at an almond, you
can't automatically see the oil.

1036
00:54:13,760 --> 00:54:16,160
Yeah. And then give them a little
grind.

1037
00:54:16,160 --> 00:54:18,480
Yeah. And out it comes.

1038
00:54:18,480 --> 00:54:20,680
Yeah, and it's all good fat,
so it's, like,

1039
00:54:20,680 --> 00:54:24,320
completely rich in
monounsaturated fat.

1040
00:54:24,320 --> 00:54:28,640
Butter created, there's only one
other ingredient for our huge batch,

1041
00:54:28,640 --> 00:54:30,400
0.4% of salt.

1042
00:54:31,840 --> 00:54:34,680
So, is that it? Yeah.

1043
00:54:34,680 --> 00:54:37,520
Just almonds and salt
and nothing else?

1044
00:54:37,520 --> 00:54:40,520
Yeah, for almond butter,
that's all we do.

1045
00:54:43,000 --> 00:54:45,960
Two ingredients and eight hours of
processing

1046
00:54:45,960 --> 00:54:50,320
have transformed six tonnes of nuts
into 30,000 jars

1047
00:54:50,320 --> 00:54:53,040
of gooey almond butter.

1048
00:55:04,120 --> 00:55:07,160
In Staffordshire, it's been three
hours and 49 minutes

1049
00:55:07,160 --> 00:55:09,400
since our flour delivery.

1050
00:55:11,960 --> 00:55:15,920
Our completed Cherry Bakewells take
one final journey

1051
00:55:15,920 --> 00:55:19,680
towards the packing area,
on an elevated conveyor high up

1052
00:55:19,680 --> 00:55:22,000
in the factory's rafters.

1053
00:55:23,600 --> 00:55:26,280
Mark, that's quite a long walk.

1054
00:55:26,280 --> 00:55:29,520
Why do those Cherry Bakewells
have to travel so far?

1055
00:55:29,520 --> 00:55:32,600
The layout of the factory and the
distance that we've walked

1056
00:55:32,600 --> 00:55:35,960
actually enables us to assure
that the topping is set.

1057
00:55:35,960 --> 00:55:39,000
That's why it travels so far, just
to give the icing time to set?

1058
00:55:39,000 --> 00:55:41,720
It helps us with that, yeah.

1059
00:55:41,720 --> 00:55:45,240
After their 70 metre stroll,
our tarts have arrived

1060
00:55:45,240 --> 00:55:49,480
at the packing department,
where we're picking up the pace.

1061
00:55:51,880 --> 00:55:55,480
Each tray of six is wrapped in
a film to help keep them fresh.

1062
00:55:59,000 --> 00:56:01,800
But are the robots getting
carried away?

1063
00:56:02,960 --> 00:56:05,040
I'm getting worried my beautiful
Bakewells

1064
00:56:05,040 --> 00:56:08,000
are going to take a bashing.

1065
00:56:08,000 --> 00:56:09,880
Those suckers seem to be
coming down there

1066
00:56:09,880 --> 00:56:11,400
with a fair amount of force.

1067
00:56:11,400 --> 00:56:14,280
I'm surprised they actually
don't dent the tarts.

1068
00:56:14,280 --> 00:56:18,640
What the suckers are doing is coming
down and sucking on the tray.

1069
00:56:18,640 --> 00:56:21,480
Ah, they're hitting those bits?

1070
00:56:21,480 --> 00:56:24,080
That's correct. Gotcha!

1071
00:56:25,200 --> 00:56:28,040
Now, the tarts slide into their
red boxes

1072
00:56:28,040 --> 00:56:31,240
and then into cardboard cases,
ten at a time...

1073
00:56:34,920 --> 00:56:37,560
..before racing to the distribution
area,

1074
00:56:37,560 --> 00:56:40,400
where I'm meeting factory manager,
Steve Morton.

1075
00:56:43,480 --> 00:56:45,520
Are those my Cherry Bakewells?
They are.

1076
00:56:45,520 --> 00:56:48,960
Right, is that truck going to be
completely full of my tarts?

1077
00:56:48,960 --> 00:56:51,160
Full of Cherry Bakewells by the
end of the day.

1078
00:56:51,160 --> 00:56:52,680
How many pallets on there?

1079
00:56:52,680 --> 00:56:54,440
There'll be 52 pallets when
it's full.

1080
00:56:54,440 --> 00:56:56,040
How many cases, how many boxes?

1081
00:56:56,040 --> 00:56:58,280
That'll be 4,200 boxes.

1082
00:56:58,280 --> 00:57:01,560
I don't suppose you know how many
individual Cherry Bakewells?

1083
00:57:01,560 --> 00:57:05,480
265,000 individual Cherry Bakewells.

1084
00:57:05,480 --> 00:57:07,600
265,000?!

1085
00:57:07,600 --> 00:57:09,080
Yes.

1086
00:57:11,080 --> 00:57:13,360
That's today's quota and more.

1087
00:57:14,760 --> 00:57:19,280
It's taken a touch under four hours
to make our Cherry Bakewells.

1088
00:57:19,280 --> 00:57:23,200
Now, it's time to ship them out to
our shops and supermarkets.

1089
00:57:24,920 --> 00:57:27,920
From this factory, they head as far
afield as Spain,

1090
00:57:27,920 --> 00:57:30,400
and even Australia!

1091
00:57:30,400 --> 00:57:33,640
While back in the UK, northerners
are the keenest consumers,

1092
00:57:33,640 --> 00:57:36,160
closely followed by southerners.

1093
00:57:38,040 --> 00:57:39,920
I've met some great people here.

1094
00:57:39,920 --> 00:57:43,720
I mean, this is a very big factory,
full of hi-tech equipment,

1095
00:57:43,720 --> 00:57:48,640
but what surprised me is, they bake
the pastry inside the tinfoil case

1096
00:57:48,640 --> 00:57:52,040
and they put the icing on when
it's in the tray,

1097
00:57:52,040 --> 00:57:56,640
but they still put every single
cherry on top by hand.

1098
00:58:00,640 --> 00:58:01,840
Next time...

1099
00:58:03,080 --> 00:58:05,120
That's obviously supposed to
happen, right? Yes.

1100
00:58:05,120 --> 00:58:07,600
..I'm helping transform raw
cotton...

1101
00:58:07,600 --> 00:58:10,880
Oh, you can feel the power of it!

1102
00:58:10,880 --> 00:58:13,360
..into waxed jackets.

1103
00:58:13,360 --> 00:58:16,880
And here's my moleskin pocket. Yep.

1104
00:58:16,880 --> 00:58:18,120
CHERRY SHRIEKS

1105
00:58:18,120 --> 00:58:20,320
Cherry soaks up the science of
staying dry...

1106
00:58:20,320 --> 00:58:22,160
So, that is my waterproof jacket?
Yeah.

1107
00:58:22,160 --> 00:58:24,040
That's breathable? That's it.

1108
00:58:24,040 --> 00:58:26,760
..and Ruth sniffs out the history of
waterproofing.

1109
00:58:26,760 --> 00:58:28,440
Oh, smells like linseed oil!

1110
00:58:28,440 --> 00:58:29,800
SHE LAUGHS