1 00:00:02,800 --> 00:00:07,720 The cereal bar. This portable snack has been refuelling us for decades. 2 00:00:07,720 --> 00:00:12,040 We unwrap over 15 million of them every week. 3 00:00:12,040 --> 00:00:17,040 Powering an industry worth over £300 million a year. 4 00:00:17,040 --> 00:00:20,640 Whether it's oat-, rice- or wheat-packed, 5 00:00:20,640 --> 00:00:23,000 the choice is staggering. 6 00:00:23,000 --> 00:00:24,320 You know what, Greg? 7 00:00:24,320 --> 00:00:28,280 I absolutely love a dried fruit and nut combo. 8 00:00:28,280 --> 00:00:30,400 In that case, Cherry, you are going to go nuts 9 00:00:30,400 --> 00:00:33,360 for the bars they make in this factory. 10 00:00:33,360 --> 00:00:34,680 Coming through! 11 00:00:34,680 --> 00:00:36,400 I'm Gregg Wallace. 12 00:00:36,400 --> 00:00:38,520 You can smell that toastiness. 13 00:00:38,520 --> 00:00:41,800 And tonight, I'm discovering the delicate balancing act 14 00:00:41,800 --> 00:00:43,800 at the heart of each bar. 15 00:00:43,800 --> 00:00:46,520 You can pour wet things over a crispy thing and it stays crispy? 16 00:00:46,520 --> 00:00:47,720 Yep, it does indeed. 17 00:00:47,720 --> 00:00:49,800 You're like a cookery magician. We are, yes. 18 00:00:49,800 --> 00:00:50,840 GREGG CHUCKLES 19 00:00:50,840 --> 00:00:52,240 CHERRY SCREAMS 20 00:00:52,240 --> 00:00:53,640 That is fun. 21 00:00:53,640 --> 00:00:55,080 I'm Cherry Healey. 22 00:00:55,080 --> 00:00:57,680 And I'll be following the astonishing journey 23 00:00:57,680 --> 00:00:59,800 these nuts go on from tree... 24 00:00:59,800 --> 00:01:02,640 Oh, wow! They look like tiny limes. 25 00:01:02,640 --> 00:01:04,440 ..to bar. 26 00:01:04,440 --> 00:01:06,720 Those nuts like to party. 27 00:01:06,720 --> 00:01:08,920 And historian Ruth Goodman... 28 00:01:08,920 --> 00:01:11,960 It's really simple, isn't it? Quite basic, yes, yes. 29 00:01:11,960 --> 00:01:13,560 ..is on the road, 30 00:01:13,560 --> 00:01:17,760 discovering the groovy origins of these handy snacks. 31 00:01:17,760 --> 00:01:21,680 It was sort of the staple food of all hippies in those days. 32 00:01:21,680 --> 00:01:23,720 Over the next 24 hours, 33 00:01:23,720 --> 00:01:28,760 this factory will transform 18 tonnes of fruit and nuts... 34 00:01:28,760 --> 00:01:32,040 ..into 400,000 cereal bars. 35 00:01:32,040 --> 00:01:34,280 Welcome to Inside The Factory. 36 00:01:54,640 --> 00:01:58,240 This the Eat Natural factory at Halstead, Essex. 37 00:01:58,240 --> 00:02:00,520 300 people work here, 38 00:02:00,520 --> 00:02:05,240 knocking out more than 90 million cereal bars every year. 39 00:02:05,240 --> 00:02:07,600 They make 22 different types. 40 00:02:08,800 --> 00:02:13,040 From protein-packed salted caramel and peanuts... 41 00:02:13,040 --> 00:02:15,320 ..to almond and apricot. 42 00:02:16,760 --> 00:02:20,560 Tonight, we're following production of one of their best-selling bars - 43 00:02:20,560 --> 00:02:23,960 dark chocolate with cranberries and macadamias. 44 00:02:23,960 --> 00:02:27,320 Packed with nuts, cranberries, coconut, sultanas 45 00:02:27,320 --> 00:02:30,360 and coated in chocolate. 46 00:02:30,360 --> 00:02:33,000 Producing these bars on a monster scale 47 00:02:33,000 --> 00:02:36,440 is a complex and challenging process, 48 00:02:36,440 --> 00:02:39,440 which begins at the intake area. 49 00:02:39,440 --> 00:02:41,520 where I'm receiving a month's supply 50 00:02:41,520 --> 00:02:46,200 of one of our most important ingredients, macadamias, 51 00:02:46,200 --> 00:02:50,840 with quality inspector and all-round nut expert, Richard Lansdown. 52 00:02:53,920 --> 00:02:55,520 Is that it? Yep, that's it. 53 00:02:55,520 --> 00:02:56,960 Sorry, I don't mean to sound rude, 54 00:02:56,960 --> 00:03:00,400 but I'm used to dirty, great big trucks full of stuff. 55 00:03:00,400 --> 00:03:02,040 So how many nuts on there? 56 00:03:02,040 --> 00:03:04,200 We've got 2,000 kilos of macadamia nuts. 57 00:03:04,200 --> 00:03:05,520 How long will that last you? 58 00:03:05,520 --> 00:03:07,320 There's enough to make a million bars there. 59 00:03:07,320 --> 00:03:08,960 Oh, really? Yeah. 60 00:03:08,960 --> 00:03:11,160 That's an important delivery for you guys, then? 61 00:03:11,160 --> 00:03:12,920 I guess it is. Let's get it unloaded. 62 00:03:20,120 --> 00:03:24,040 Macadamias are one of the priciest nuts in the world, 63 00:03:24,040 --> 00:03:27,640 and the most expensive ingredient in our bar. 64 00:03:29,680 --> 00:03:31,560 They're...they're chopped? 65 00:03:31,560 --> 00:03:33,720 This allows us to evenly distribute them in the bars. 66 00:03:33,720 --> 00:03:35,840 If they were bigger, they really wouldn't fit in. 67 00:03:35,840 --> 00:03:39,360 Why would you use macadamias as opposed to a hazelnut or a walnut? 68 00:03:39,360 --> 00:03:41,200 Well, they have a unique, mild, mellow, 69 00:03:41,200 --> 00:03:42,720 sort of faintly buttery flavour. 70 00:03:42,720 --> 00:03:47,720 Texture is crisp but soft, so it's absolutely perfect for our product. 71 00:03:49,320 --> 00:03:52,920 While these guys crack on unloading this lot, 72 00:03:52,920 --> 00:03:55,080 Cherry's exploring the challenges 73 00:03:55,080 --> 00:03:59,480 of getting these nuts from far-flung field to factory. 74 00:04:02,560 --> 00:04:06,000 I've come to the lush, mountainous region of Mpumalanga 75 00:04:06,000 --> 00:04:08,480 in northern South Africa, 76 00:04:08,480 --> 00:04:12,920 which provides the perfect climate for our factory's macadamias. 77 00:04:14,160 --> 00:04:20,000 South Africa is the largest producer of macadamia nuts in the world, 78 00:04:20,000 --> 00:04:23,680 accounting for over a quarter of the global harvest. 79 00:04:23,680 --> 00:04:27,000 Terry Haig is the farm manager at Green Farms, 80 00:04:27,000 --> 00:04:32,120 where they grow 100 tonnes a year on 48,000 trees. 81 00:04:32,120 --> 00:04:34,520 Hi, Terry, lovely to meet you. Nice to meet you, Cherry. 82 00:04:34,520 --> 00:04:37,480 So this is a macadamia nut tree? Yeah. 83 00:04:37,480 --> 00:04:40,000 Can I see some? I've never really seen a nut on a tree. 84 00:04:40,000 --> 00:04:41,280 There's some here. 85 00:04:41,280 --> 00:04:44,440 Oh, wow! They look like tiny limes. 86 00:04:44,440 --> 00:04:47,880 So this is the outer husk, and you can bite that off. 87 00:04:47,880 --> 00:04:49,200 You can bite it off? 88 00:04:50,400 --> 00:04:52,080 Oh, look at that. 89 00:04:52,080 --> 00:04:53,480 But that's not macadamia nut? 90 00:04:53,480 --> 00:04:56,000 No, the kernel is inside the shell. 91 00:04:56,000 --> 00:04:59,400 So inside there is the actual nut that we're after? Yeah. 92 00:04:59,400 --> 00:05:01,280 Can I crack open? 93 00:05:01,280 --> 00:05:02,640 You could try. 94 00:05:02,640 --> 00:05:04,920 Holy Moley. 95 00:05:04,920 --> 00:05:07,360 Argh, God. That's unbelievably tough. 96 00:05:07,360 --> 00:05:10,640 It is the toughest nut shell... ..in the world? Yeah, yeah. 97 00:05:10,640 --> 00:05:13,480 One reason this nut is so pricey 98 00:05:13,480 --> 00:05:16,280 is it can take seven years for the trees to mature 99 00:05:16,280 --> 00:05:19,160 and produce their first commercial crop. 100 00:05:19,160 --> 00:05:23,400 Harvesting and processing is a labour-intensive process. 101 00:05:23,400 --> 00:05:26,760 How do you harvest a macadamia nut? Do you pick it off a tree? 102 00:05:26,760 --> 00:05:29,880 Well, this particular variety drops their nuts when they are mature. 103 00:05:29,880 --> 00:05:31,960 The tree will let you know when it's time to harvest? 104 00:05:31,960 --> 00:05:33,560 That's right, yeah. 105 00:05:35,440 --> 00:05:39,160 I'm joining one of the farm's pickers, Julianne Makuena... 106 00:05:39,160 --> 00:05:40,480 Nice to meet you. 107 00:05:40,480 --> 00:05:42,480 ..to lend a hand. 108 00:05:42,480 --> 00:05:43,960 I'm very strong. 109 00:05:43,960 --> 00:05:46,720 I feel like I'm going to be useful on your team. OK. 110 00:05:46,720 --> 00:05:47,800 OK? 111 00:05:50,080 --> 00:05:51,640 Show me how to do it. 112 00:05:51,640 --> 00:05:53,640 Make it low for you. 113 00:05:53,640 --> 00:05:56,120 We make the sacks like this. OK. 114 00:05:56,120 --> 00:05:59,160 So then starting harvesting. OK. 115 00:06:03,240 --> 00:06:05,440 Oh, you are fast. Oh, you're fast! I see, I see. 116 00:06:07,840 --> 00:06:10,040 So quick. Yeah. Yeah. 117 00:06:10,040 --> 00:06:12,360 How many bags can you collect in one day? 118 00:06:12,360 --> 00:06:14,200 Maybe 12 or 15. 119 00:06:16,000 --> 00:06:19,680 Bags filled, time for their weigh-in. 120 00:06:19,680 --> 00:06:21,400 I'm a bit nervous about this. Yeah. 121 00:06:23,640 --> 00:06:25,280 How much was your bag? 122 00:06:25,280 --> 00:06:28,600 12.54. 12.54 kg? Yes. 123 00:06:28,600 --> 00:06:30,400 I'm not sure I can match that. 124 00:06:33,040 --> 00:06:36,960 I'm sweating so much, and it's seven kilograms. 125 00:06:39,200 --> 00:06:41,800 We empty our haul into a waiting trailer. 126 00:06:41,800 --> 00:06:44,880 One, two, three. One, two, three. Argh, go on! 127 00:06:48,760 --> 00:06:52,520 Then our tough nuts begin a hardcore workout. 128 00:06:55,000 --> 00:06:59,280 Their soft, green outer husks are stripped off, 129 00:06:59,280 --> 00:07:02,760 and the nuts are tipped into a giant hopper. 130 00:07:02,760 --> 00:07:05,040 Go! SHE SCREAMS 131 00:07:06,560 --> 00:07:09,040 Whoa! That is fun! 132 00:07:10,040 --> 00:07:11,880 That is a lot of nuts. 133 00:07:15,000 --> 00:07:17,120 Protected by their hard shells, 134 00:07:17,120 --> 00:07:20,560 they take a roller-coaster ride into vast dryers. 135 00:07:22,040 --> 00:07:26,520 The heat makes the kernels inside shrink away from their shells, 136 00:07:26,520 --> 00:07:29,960 making it easier to crack through that armour-plating. 137 00:07:29,960 --> 00:07:32,520 In the enormous nut-cracking room, 138 00:07:32,520 --> 00:07:34,840 Alex White's telling me how they do it. 139 00:07:36,280 --> 00:07:40,160 How do you crack the world's toughest nut? 140 00:07:40,160 --> 00:07:43,440 With special-designed macadamia nut crackers. 141 00:07:43,440 --> 00:07:45,680 So it just smashes the nut, basically, 142 00:07:45,680 --> 00:07:47,640 and hopefully the kernel comes out whole. 143 00:07:47,640 --> 00:07:50,920 Oh, wow! Just like that. Oh, and there it is. Yeah. 144 00:07:50,920 --> 00:07:56,600 Rotating steel rollers press together with 300 psi of pressure. 145 00:07:56,600 --> 00:08:00,800 It's like a baby elephant sitting on each nut. 146 00:08:00,800 --> 00:08:03,280 This smashes the shells open, 147 00:08:03,280 --> 00:08:06,040 releasing the valuable kernels inside. 148 00:08:07,960 --> 00:08:09,120 Wow! 149 00:08:09,120 --> 00:08:10,520 Those nuts like to party. 150 00:08:10,520 --> 00:08:13,560 LIVELY MUSIC PLAYS 151 00:08:14,640 --> 00:08:17,480 They head across a set of shaking sieves. 152 00:08:19,360 --> 00:08:22,440 Bits of shell and smaller nuts fall through the holes, 153 00:08:22,440 --> 00:08:25,760 and the bigger nuts head on for a visual check. 154 00:08:29,320 --> 00:08:33,520 Once given the final OK, they're vacuum sealed into foil bags 155 00:08:33,520 --> 00:08:35,760 and packed into cardboard boxes. 156 00:08:39,240 --> 00:08:43,040 The half a million macadamia nuts on this pallet 157 00:08:43,040 --> 00:08:46,760 are now ready to go to the cereal bar factory in Essex. 158 00:08:46,760 --> 00:08:48,960 I'm not carrying them all the way. 159 00:08:51,360 --> 00:08:53,240 Fortunately for Cherry, 160 00:08:53,240 --> 00:08:57,320 the nuts are driven nine hours to the port of Durban... 161 00:08:58,920 --> 00:09:01,560 ..where they're loaded onto a container ship, 162 00:09:01,560 --> 00:09:04,640 which carries them round the Cape of Good Hope 163 00:09:04,640 --> 00:09:09,120 on a 22-day voyage direct to the port of Felixstowe. 164 00:09:10,200 --> 00:09:13,360 Once they hit dry land, it's an hour's trip 165 00:09:13,360 --> 00:09:15,000 to our cereal bar factory. 166 00:09:19,200 --> 00:09:22,600 And 20 minutes after our nuts arrived, 167 00:09:22,600 --> 00:09:26,600 they make a 300 metre hop across the site to ingredients preparation... 168 00:09:28,080 --> 00:09:30,360 ..where technical manager Lisa Conning 169 00:09:30,360 --> 00:09:32,440 is checking they make the grade 170 00:09:32,440 --> 00:09:34,720 before they head into our cereal bars. 171 00:09:34,720 --> 00:09:37,520 Lisa? Yes. All right? Hi. 172 00:09:37,520 --> 00:09:40,360 How many nuts are we dealing with here? 173 00:09:40,360 --> 00:09:44,040 So we're going to deal with about 260kg per hour. 174 00:09:45,280 --> 00:09:47,240 That's a fair amount of nut, innit? Yeah. 175 00:09:47,240 --> 00:09:50,760 That's 260,000 nuts. 176 00:09:50,760 --> 00:09:54,000 I know how to check to see if an elephant's been in the bag. 177 00:09:54,000 --> 00:09:55,600 There wouldn't be any nuts left. 178 00:09:55,600 --> 00:09:57,240 Yes, true! 179 00:09:57,240 --> 00:09:59,040 MUSIC: Let's Go Surfing by The Drums 180 00:09:59,040 --> 00:10:01,880 They may have travelled 8,500 miles, 181 00:10:01,880 --> 00:10:04,360 but these nuts still have a long way to go 182 00:10:04,360 --> 00:10:07,600 to prove they're exactly right for our cereal bars. 183 00:10:12,080 --> 00:10:15,360 To pass muster, each individual nut needs to be 184 00:10:15,360 --> 00:10:19,720 exactly ten millimetres wide and perfectly creamy coloured. 185 00:10:20,920 --> 00:10:24,640 They queue up for inspection on a series of conveyors 186 00:10:24,640 --> 00:10:28,720 and drop onto a four-metre-long vibrating tray 187 00:10:28,720 --> 00:10:30,800 which separates them out, 188 00:10:30,800 --> 00:10:34,840 before bouncing towards a highly complex bit of machinery. 189 00:10:38,880 --> 00:10:41,520 Right, what am I looking at, a load of nuts coming down a slide? 190 00:10:41,520 --> 00:10:43,640 Yeah, so this is our laser sorter. 191 00:10:43,640 --> 00:10:45,840 The laser acts as the eyes. 192 00:10:45,840 --> 00:10:48,600 There's electronics in there that acts like a human brain, 193 00:10:48,600 --> 00:10:50,880 to push off any nuts that we don't want. 194 00:10:50,880 --> 00:10:52,960 And you say it acts like a human brain? Yeah. 195 00:10:52,960 --> 00:10:54,960 It doesn't want to act like my brain. 196 00:10:54,960 --> 00:10:57,160 It'll just be telling rubbish jokes all day long. 197 00:10:57,160 --> 00:10:58,960 What is it discarding? 198 00:10:58,960 --> 00:11:02,440 So this'll get rid of any darker nuts that we don't want. 199 00:11:02,440 --> 00:11:05,200 This sorter has a clever way of picking out 200 00:11:05,200 --> 00:11:08,080 any nuts which fall short of the standard. 201 00:11:08,080 --> 00:11:11,080 There's 64 air jets in there that will ping them off. 202 00:11:11,080 --> 00:11:12,600 It's shooting them off? Yes. 203 00:11:14,000 --> 00:11:18,920 The nuts drop off the edge of the vibrating shelf into the sorter. 204 00:11:18,920 --> 00:11:23,480 They fall past four lasers fired between two rotating drums. 205 00:11:25,440 --> 00:11:28,600 The lasers check every single nut 206 00:11:28,600 --> 00:11:31,800 against these specially coloured drums. 207 00:11:31,800 --> 00:11:34,680 If they don't precisely match the pre-set colour... 208 00:11:37,320 --> 00:11:40,920 ..a series of air jets fire them into a reject bin. 209 00:11:42,440 --> 00:11:45,280 But it's not the end of the road for these little fellas. 210 00:11:45,280 --> 00:11:47,360 They're sent to a specialist plant, 211 00:11:47,360 --> 00:11:49,960 where they're broken down to generate electricity. 212 00:11:51,080 --> 00:11:53,640 The super nuts that have passed their test 213 00:11:53,640 --> 00:11:55,440 continue through the machine. 214 00:11:56,840 --> 00:11:59,320 As fast as I can see the nuts falling, 215 00:11:59,320 --> 00:12:01,560 that's as fast as it can shoot them off? 216 00:12:01,560 --> 00:12:04,840 Yes, because actually it can scan up to 2,000 nuts per second. 217 00:12:06,200 --> 00:12:07,440 Say that again. 218 00:12:07,440 --> 00:12:10,480 Yeah, 2,000 nuts per second, it's incredible. 219 00:12:10,480 --> 00:12:12,720 I love this stuff, I love this stuff. 220 00:12:12,720 --> 00:12:14,760 So does this just do nuts? 221 00:12:14,760 --> 00:12:17,600 It looks at nuts but it could also look at other raw materials, 222 00:12:17,600 --> 00:12:19,640 like our sultanas and apricots. 223 00:12:19,640 --> 00:12:20,960 So how does that work? 224 00:12:20,960 --> 00:12:23,280 How does the computer know when you've changed it? 225 00:12:23,280 --> 00:12:26,480 What we have is different coloured drums for different products. 226 00:12:26,480 --> 00:12:31,000 So, right now, that's a macadamia nut coloured drum? Yeah. 227 00:12:31,000 --> 00:12:34,240 For other bars, there's also dark brown for almonds, 228 00:12:34,240 --> 00:12:37,360 green for pumpkin seeds, and white for cashews. 229 00:12:39,840 --> 00:12:41,760 What are these people here doing? 230 00:12:41,760 --> 00:12:44,880 So, even though we've got our amazing machine, 231 00:12:44,880 --> 00:12:48,040 that is 90% efficient and we still need members of our team 232 00:12:48,040 --> 00:12:50,120 to pull off the other 10%. 233 00:12:50,120 --> 00:12:52,560 So they're just doing a final visual check, 234 00:12:52,560 --> 00:12:55,880 because a single nut that's not right could affect our product. 235 00:12:55,880 --> 00:13:00,840 So as clever as that machine thinks it is, we still need humans? Yes. 236 00:13:05,360 --> 00:13:10,000 Checks complete, the nuts tumble into a 350 kilo hopper 237 00:13:10,000 --> 00:13:12,040 at the end of the line. 238 00:13:12,040 --> 00:13:14,480 Now it's time to turn up the heat. 239 00:13:14,480 --> 00:13:15,720 Can I help? 240 00:13:15,720 --> 00:13:20,160 Course you can, you can go up those stairs and open the gates, please. 241 00:13:20,160 --> 00:13:24,440 I feed the nuts into a giant four-metre gas-fired oven. 242 00:13:29,320 --> 00:13:31,120 That is a torrent of nuts. 243 00:13:33,360 --> 00:13:36,000 They pass under an adjustable bar, 244 00:13:36,000 --> 00:13:39,080 set to an exact 2.5 centimetres. 245 00:13:39,080 --> 00:13:43,120 This flattens them down, so each nut gets a perfect roasting. 246 00:13:44,080 --> 00:13:45,240 Why do you roast them? 247 00:13:45,240 --> 00:13:47,400 Why don't you just put them into the bar as they are? 248 00:13:47,400 --> 00:13:49,360 Because we want to make it even tastier 249 00:13:49,360 --> 00:13:51,480 by bringing out those lovely sweet flavours. 250 00:13:51,480 --> 00:13:54,720 Just 15 minutes at 135 degrees Celsius 251 00:13:54,720 --> 00:13:58,080 before they pop out the other end. 252 00:13:58,080 --> 00:14:00,360 You can smell that toastiness. 253 00:14:00,360 --> 00:14:03,320 What is actually happening to the nuts when you're toasting them? 254 00:14:03,320 --> 00:14:06,000 There's the chemical reaction called the Maillard reaction 255 00:14:06,000 --> 00:14:07,480 when there's heat being applied. 256 00:14:07,480 --> 00:14:10,640 And that is just the reaction between the sugars and the proteins, 257 00:14:10,640 --> 00:14:13,360 which gives the nut the final, gentle browning 258 00:14:13,360 --> 00:14:15,120 and this lovely flavour. 259 00:14:15,120 --> 00:14:16,840 I can feel a draught. 260 00:14:16,840 --> 00:14:19,280 It cools at the end of the roasting 261 00:14:19,280 --> 00:14:21,520 by blowing off all the heat. 262 00:14:21,520 --> 00:14:23,200 Why-why do you want to cool them? 263 00:14:23,200 --> 00:14:25,800 We want to make sure that we don't get any horrible sweaty nuts 264 00:14:25,800 --> 00:14:28,000 which will affect the quality of the bar. 265 00:14:28,000 --> 00:14:29,880 Yeah, I'm saying nothing. 266 00:14:31,440 --> 00:14:36,440 Roasted and ready, they're packed into to 12.5 kilo boxes. 267 00:14:38,000 --> 00:14:40,400 Our nuts are prepped and well on their way 268 00:14:40,400 --> 00:14:42,880 to becoming part of our cereal bars. 269 00:14:42,880 --> 00:14:46,760 But whose idea was it to turn a bowl of cereal into... 270 00:14:46,760 --> 00:14:48,640 ..well, into a bar? 271 00:14:48,640 --> 00:14:51,800 Ruth is investigating in Bedfordshire. 272 00:14:51,800 --> 00:14:55,760 It may surprise you to learn that it was not either the oatcake 273 00:14:55,760 --> 00:15:00,280 or the flapjack that kick-started cereal bars in Britain. 274 00:15:00,280 --> 00:15:03,800 To find out what did, we have to take a trip back in time... 275 00:15:03,800 --> 00:15:05,280 RECORD SCRATCH 276 00:15:05,280 --> 00:15:07,160 ..to 1969... 277 00:15:07,160 --> 00:15:09,240 MUSIC: Purple Haze by Jimi Hendrix 278 00:15:09,240 --> 00:15:11,280 ..and the heyday of hippies... 279 00:15:16,360 --> 00:15:19,400 ..when a 20-year-old drummer from England called Bill Jordan 280 00:15:19,400 --> 00:15:23,240 was touring the west coast of California with his blues rock band. 281 00:15:25,480 --> 00:15:28,120 # Excuse me, while I kiss the sky. # 282 00:15:29,600 --> 00:15:32,560 Once he was out there, he started experimenting with something 283 00:15:32,560 --> 00:15:34,200 that all the hippies were doing. 284 00:15:34,200 --> 00:15:37,600 Not drugs, but an oaty cereal called granola. 285 00:15:40,920 --> 00:15:44,400 50 years down the road, Bill still remembers the breakfast 286 00:15:44,400 --> 00:15:47,160 that changed his life, and our eating habits. 287 00:15:48,640 --> 00:15:51,280 So what did you think of this stuff when you first ate it? 288 00:15:51,280 --> 00:15:54,120 Well, I mean, if you're used to sort of normal breakfast cereals, 289 00:15:54,120 --> 00:15:56,160 this was amazing, it was whole grains, 290 00:15:56,160 --> 00:15:59,200 it was a different texture, a lot of different flavours, 291 00:15:59,200 --> 00:16:02,440 a lot of different ingredients, it was very different stuff. 292 00:16:02,440 --> 00:16:07,480 A mix of whole oats, nuts and seeds, granola was baked hard with honey. 293 00:16:07,480 --> 00:16:11,400 It was sort of the staple food of all hippies in those days. 294 00:16:12,840 --> 00:16:17,680 Young Bill was convinced there was a market for granola in Britain. 295 00:16:17,680 --> 00:16:20,080 After his year living the rock and roll dream, 296 00:16:20,080 --> 00:16:21,920 he returned home to Bedfordshire... 297 00:16:23,400 --> 00:16:26,640 ..and the mill where his family had been producing white flour 298 00:16:26,640 --> 00:16:27,640 for 70 years. 299 00:16:29,480 --> 00:16:31,240 What a fabulous place! 300 00:16:31,240 --> 00:16:32,920 Yeah, lovely old mill, isn't it? 301 00:16:32,920 --> 00:16:35,360 So this is what you were coming back to? 302 00:16:35,360 --> 00:16:38,560 That's right. It's been here since 1899, this mill. 303 00:16:38,560 --> 00:16:40,840 And you brought back the granola here, then. Yeah. 304 00:16:40,840 --> 00:16:42,480 At, what, 20 years of age? 305 00:16:42,480 --> 00:16:44,280 Yeah, we just thought it was a good idea. 306 00:16:44,280 --> 00:16:46,520 Liked the stuff, we got a bit of abuse from the family. 307 00:16:46,520 --> 00:16:49,000 They sort of said, you know, "Whole grains?" 308 00:16:49,000 --> 00:16:51,440 Dad said he couldn't even sell it to animals, 309 00:16:51,440 --> 00:16:54,040 and he didn't fancy our chances selling it to humans. 310 00:16:56,000 --> 00:16:59,120 The family's Victorian watermill was struggling to compete 311 00:16:59,120 --> 00:17:02,400 with new-fangled electric-powered flour mills. 312 00:17:03,680 --> 00:17:06,680 But Bill knew the older technology was perfect 313 00:17:06,680 --> 00:17:11,120 for slow rolling the wholegrain cereals needed in the granola. 314 00:17:13,000 --> 00:17:16,440 His sister, Lindsay, got in on the act. 315 00:17:16,440 --> 00:17:18,680 Well, we weren't really that keen to start with. 316 00:17:18,680 --> 00:17:21,080 We always looked at it, looked a bit strange, 317 00:17:21,080 --> 00:17:23,720 but once we started giving people it to try, 318 00:17:23,720 --> 00:17:26,240 then they loved it, tastes delicious. 319 00:17:26,240 --> 00:17:29,760 They came up with a unique mobile marketing approach. 320 00:17:29,760 --> 00:17:32,280 As you can see, it was called Original Crunchy G. 321 00:17:32,280 --> 00:17:34,680 We started off and did the first three Glastonburys. 322 00:17:34,680 --> 00:17:36,680 So you were sort of on tour, really? 323 00:17:36,680 --> 00:17:39,200 Sounds much better than it was, but, yeah, we were on tour. 324 00:17:39,200 --> 00:17:40,360 RUTH LAUGHS 325 00:17:40,360 --> 00:17:42,800 And, after that, we took the show to the county shows. 326 00:17:42,800 --> 00:17:45,720 I mean, that would be memorable, if you turned up at a county show. 327 00:17:45,720 --> 00:17:47,680 I mean, look at you all! 328 00:17:47,680 --> 00:17:49,000 It was a while ago! 329 00:17:49,000 --> 00:17:50,320 THEY LAUGH 330 00:17:50,320 --> 00:17:53,760 It's a real '70s, new... Hippies. 331 00:17:53,760 --> 00:17:55,800 Hippies, yeah. We were all hippies. 332 00:17:58,280 --> 00:18:01,880 As well as at festivals, their new Jordan's brand of granola 333 00:18:01,880 --> 00:18:05,360 proved popular in 1970s health food shops, 334 00:18:05,360 --> 00:18:09,400 and soon they branched out into an entirely new product. 335 00:18:09,400 --> 00:18:11,040 So how on earth did you move 336 00:18:11,040 --> 00:18:13,280 from making granola to making cereal bars? 337 00:18:13,280 --> 00:18:15,320 We got a lot of distressed people writing, 338 00:18:15,320 --> 00:18:17,760 saying they liked eating granola in the car 339 00:18:17,760 --> 00:18:20,560 and it got behind the seat or down their trousers or whatever. 340 00:18:20,560 --> 00:18:22,400 So what on earth did you do? 341 00:18:22,400 --> 00:18:25,280 Ah. That's the difficult bit. We tried for a lot of time, 342 00:18:25,280 --> 00:18:27,280 but the job is to try and get granola 343 00:18:27,280 --> 00:18:29,120 in a sort of form where there's... 344 00:18:29,120 --> 00:18:31,200 Well, as you can sort of tell from this. 345 00:18:31,200 --> 00:18:33,160 You've got the sort of fruit and the nuts, 346 00:18:33,160 --> 00:18:35,200 but it holds together. 347 00:18:35,200 --> 00:18:40,720 This was the UK's first cereal bar, and it launched in 1981... 348 00:18:40,720 --> 00:18:43,240 MUSIC: Just Can't Get Enough by Depeche Mode 349 00:18:43,240 --> 00:18:47,080 ..ready to ride a wave of '80s consumerism... 350 00:18:47,080 --> 00:18:48,920 # When I'm with you, baby 351 00:18:48,920 --> 00:18:50,840 # I go out of my head... # 352 00:18:50,840 --> 00:18:54,400 ..and a health and fitness boom. 353 00:18:54,400 --> 00:18:57,760 The market just went crazy and it took us something like - 354 00:18:57,760 --> 00:19:00,840 ooh, crikey - six months to do the first million bars. 355 00:19:00,840 --> 00:19:04,160 Wow! And the market grew so fast, you know, two years later 356 00:19:04,160 --> 00:19:06,440 we were doing three million bars a week. 357 00:19:06,440 --> 00:19:08,600 That is really fast! Yeah, yeah. 358 00:19:08,600 --> 00:19:10,560 JAWS-LIKE MUSIC 359 00:19:10,560 --> 00:19:11,800 CRUNCH! 360 00:19:11,800 --> 00:19:13,240 With such rapid growth, 361 00:19:13,240 --> 00:19:15,760 it wasn't long before others joined the party. 362 00:19:15,760 --> 00:19:17,480 CRUNCH! 363 00:19:17,480 --> 00:19:21,160 In 1982, Quaker warned us to watch out for squirrels 364 00:19:21,160 --> 00:19:22,760 if you ate their bars. 365 00:19:24,800 --> 00:19:27,200 ECHOING: Tracker... Tracker... Tracker... Tracker... 366 00:19:27,200 --> 00:19:31,040 And in 1987, confectioner Mars used an association 367 00:19:31,040 --> 00:19:33,720 with the great outdoors to promote their version. 368 00:19:37,560 --> 00:19:44,120 Today, the global cereal bar market is worth over £10 billion. 369 00:19:44,120 --> 00:19:47,640 But here in Britain, we may not have taken them to heart 370 00:19:47,640 --> 00:19:51,880 if it had not been for a miller's son touring West Coast America 371 00:19:51,880 --> 00:19:53,600 in the psychedelic '60s. 372 00:20:01,160 --> 00:20:05,200 We're 48 minutes into the production process 373 00:20:05,200 --> 00:20:08,040 and the macadamia nuts for our cereal bars 374 00:20:08,040 --> 00:20:11,200 have been sorted, roasted and boxed. 375 00:20:11,200 --> 00:20:12,520 OK. Come on, then. 376 00:20:13,720 --> 00:20:17,640 Lisa and I are carrying them to the mixing area, 377 00:20:17,640 --> 00:20:21,240 where the building blocks of our cereal bars come together. 378 00:20:23,080 --> 00:20:24,600 What are we doing with these? 379 00:20:24,600 --> 00:20:28,720 So we're going to decant them on to here. Decant them? Yes. 380 00:20:28,720 --> 00:20:32,400 Is there a special technique? Tip them out. 381 00:20:32,400 --> 00:20:34,680 Hey! 382 00:20:39,320 --> 00:20:43,000 The ingredients will be combined in five metal trollies 383 00:20:43,000 --> 00:20:46,200 to make it easier to process further down the line. 384 00:20:46,200 --> 00:20:48,440 Beautiful! Ooh, they're still warm! 385 00:20:48,440 --> 00:20:51,480 First up is 30 kilos of macadamias. 386 00:20:51,480 --> 00:20:54,160 Is there a reason why you don't just tip it straight into the bin? 387 00:20:54,160 --> 00:20:56,000 Yes. We like to also do another check, 388 00:20:56,000 --> 00:21:00,440 just to make sure that they're exactly what we want. 389 00:21:00,440 --> 00:21:02,880 GREGG CHUCKLES 390 00:21:02,880 --> 00:21:04,280 This is great! 391 00:21:04,280 --> 00:21:08,160 Macadamias will make up 6% of our finished bar, 392 00:21:08,160 --> 00:21:11,600 along with macadamia powder from the same suppliers. 393 00:21:11,600 --> 00:21:12,840 Whoa! 394 00:21:12,840 --> 00:21:15,120 I'm just like a kid in an edible sandpit. 395 00:21:17,120 --> 00:21:20,960 These powdered nuts help to glue the other ingredients together, 396 00:21:20,960 --> 00:21:24,880 making sure there are no big gaps in the finished bars. 397 00:21:24,880 --> 00:21:26,240 How many sultanas do we need? 398 00:21:26,240 --> 00:21:29,280 We need nine boxes, which is 120 kilos. 399 00:21:29,280 --> 00:21:32,520 These will form 16% of our bars. 400 00:21:32,520 --> 00:21:35,080 Raisin' the bar here, ain't we? 401 00:21:35,080 --> 00:21:39,640 Now 64kg of pre-weighed dried cranberries join the party... 402 00:21:39,640 --> 00:21:41,040 Whoa! 403 00:21:42,520 --> 00:21:46,360 ..to add colour and sharp, sweet flavour. 404 00:21:46,360 --> 00:21:47,560 Hai-yah! 405 00:21:47,560 --> 00:21:49,400 Oof! LISA LAUGHS 406 00:21:49,400 --> 00:21:51,120 It's a real beauty 407 00:21:51,120 --> 00:21:54,320 to have all these products just out on a bench in front of you. 408 00:21:54,320 --> 00:21:56,680 Look at the vivid colour. It's lovely. 409 00:21:58,160 --> 00:22:02,800 Last of all, coconut, which makes up a fifth of the bar. 410 00:22:02,800 --> 00:22:04,240 Why do we need coconut? 411 00:22:04,240 --> 00:22:07,280 Cos it gives a lovely, oily quality to our bar. 412 00:22:07,280 --> 00:22:10,120 The fragrance is unbelievable. 413 00:22:10,120 --> 00:22:13,800 That is floating away on a sea of coconut essence. Yeah. 414 00:22:13,800 --> 00:22:15,400 That is beautiful. 415 00:22:17,560 --> 00:22:19,720 I've never been in a factory like this. 416 00:22:19,720 --> 00:22:21,280 Everything is done by hand. 417 00:22:21,280 --> 00:22:23,600 It just allows us to make sure that, at every stage, 418 00:22:23,600 --> 00:22:25,680 we can make sure that the ingredients are right. 419 00:22:25,680 --> 00:22:28,200 Don't ever get a machine for this bit, OK? No. 420 00:22:28,200 --> 00:22:31,840 This has been my most enjoyable process in any factory. 421 00:22:37,360 --> 00:22:42,240 I've now got five containers of nearly 400kg of ingredients, 422 00:22:42,240 --> 00:22:45,600 so I'm letting a machine take the strain from here. 423 00:22:45,600 --> 00:22:47,240 Shall I? Yeah. 424 00:22:48,920 --> 00:22:51,960 LISA LAUGHS Ahem! What are you laughing at? 425 00:22:51,960 --> 00:22:54,000 That's not very encouraging, is it, laughing? 426 00:22:54,000 --> 00:22:56,320 Do you laugh at all your trainees like that? Yes! 427 00:22:56,320 --> 00:22:58,680 I'll go to the HR department if you laugh at me again. 428 00:22:58,680 --> 00:23:00,080 That's it! Perfect. 429 00:23:00,080 --> 00:23:03,160 With the push of a button, a hydraulic lift 430 00:23:03,160 --> 00:23:08,400 tips our bins of dry mix into this giant 900-litre mixer. 431 00:23:11,480 --> 00:23:13,080 Oh, look at that. 432 00:23:13,080 --> 00:23:15,120 HE LAUGHS 433 00:23:15,120 --> 00:23:17,560 Oh, I'm enjoying this. 434 00:23:17,560 --> 00:23:20,000 The mixer gently combines them, 435 00:23:20,000 --> 00:23:23,040 but I can't help thinking there's something missing. 436 00:23:23,040 --> 00:23:25,520 Right. Are we now adding some cereal to it? 437 00:23:25,520 --> 00:23:28,240 That's going to come in a bit, when we go to the production line. 438 00:23:28,240 --> 00:23:30,760 Are you sure there is cereal in your cereal bar? Yeah, I'm sure. 439 00:23:30,760 --> 00:23:33,200 You've seen the recipe, have you? Yes! 440 00:23:33,200 --> 00:23:35,840 I'll have to take Lisa's word for it. 441 00:23:37,040 --> 00:23:42,320 Our cereal-less cereal bar mix travels along a series of conveyors 442 00:23:42,320 --> 00:23:44,080 and is sealed into boxes... 443 00:23:45,600 --> 00:23:49,960 ..each one holding enough to make up 480 bars. 444 00:23:54,800 --> 00:23:57,240 The sultanas we've added to our mix 445 00:23:57,240 --> 00:24:00,800 play a very important role in our cereal bars, 446 00:24:00,800 --> 00:24:03,680 adding both texture and sweetness. 447 00:24:03,680 --> 00:24:05,520 Cherry's back in South Africa, 448 00:24:05,520 --> 00:24:08,960 learning just what makes a sultana a sultana. 449 00:24:11,160 --> 00:24:14,840 I'm in the vineyards of Upington in the Northern Cape Province, 450 00:24:14,840 --> 00:24:16,880 where it's harvest time. 451 00:24:19,240 --> 00:24:21,720 I've often wondered what the difference is 452 00:24:21,720 --> 00:24:24,280 between a raisin and a sultana. 453 00:24:24,280 --> 00:24:28,640 I'm hoping Pieter Roos from Carpe Diem can come to my aid. 454 00:24:28,640 --> 00:24:30,520 Hi, Pieter. Lovely to meet you. 455 00:24:30,520 --> 00:24:34,200 Hi, Cherry. Nice to meet you. What a gorgeous bunch of grapes. 456 00:24:34,200 --> 00:24:36,760 Those are absolutely amazing. 457 00:24:36,760 --> 00:24:39,040 They're so juicy. 458 00:24:39,040 --> 00:24:41,840 This variety is the Thompson seedless, 459 00:24:41,840 --> 00:24:44,080 also known as the sultana grape. 460 00:24:45,520 --> 00:24:47,680 Do you just leave these grapes on the vine 461 00:24:47,680 --> 00:24:50,360 and they'll dry and - boom! - you'll have a sultana? 462 00:24:50,360 --> 00:24:55,040 No, actually, if you leave them on the vines, you get a raisin. 463 00:24:55,040 --> 00:24:56,680 You get a raisin? A raisin. 464 00:24:56,680 --> 00:24:59,720 But with the same grapes, you can actually make sultanas. 465 00:24:59,720 --> 00:25:03,000 All my life, I've believed that sultanas come from white grapes 466 00:25:03,000 --> 00:25:04,920 and raisins come from red grapes. 467 00:25:04,920 --> 00:25:07,520 And that's not true at all. No, it's not. 468 00:25:07,520 --> 00:25:11,480 Sultanas and raisins both start life as white grapes. 469 00:25:11,480 --> 00:25:12,920 It's the way they're treated 470 00:25:12,920 --> 00:25:15,560 that determines which dried fruit they become. 471 00:25:15,560 --> 00:25:18,160 So how do you make a sultana? 472 00:25:18,160 --> 00:25:20,280 You spray it with a mixture. 473 00:25:20,280 --> 00:25:22,960 We've got a mixture here so I can show you. 474 00:25:22,960 --> 00:25:26,160 On this farm, when the grapes are ripe in March, 475 00:25:26,160 --> 00:25:29,600 they spray them with a solution of water, vegetable oil 476 00:25:29,600 --> 00:25:34,040 and a baking powder-like ingredient called potassium carbonate. 477 00:25:35,720 --> 00:25:40,320 How does it turn these grapes into sultanas? 478 00:25:40,320 --> 00:25:45,120 The potassium will actually damage the skin, forming cracks on the skin 479 00:25:45,120 --> 00:25:47,640 to get the moisture evaporating quicker 480 00:25:47,640 --> 00:25:51,360 and turning it to a golden brown sultana. 481 00:25:51,360 --> 00:25:54,760 The sprayed bunches of grapes are cut off the vines 482 00:25:54,760 --> 00:25:58,840 and, just like washing, they're hung out on a line to dry. 483 00:25:58,840 --> 00:26:02,880 They lose 80% of their moisture, which makes them sweeter, 484 00:26:02,880 --> 00:26:05,800 and shrinks them by a quarter. 485 00:26:05,800 --> 00:26:09,000 Just four weeks later, they're finished sultanas. 486 00:26:10,240 --> 00:26:14,560 But in the field next door, Pieter's crop looks very different. 487 00:26:14,560 --> 00:26:16,920 OK. So this is the raisins. 488 00:26:16,920 --> 00:26:18,960 So these haven't been sprayed. No. 489 00:26:18,960 --> 00:26:21,240 How do you start the drying process? 490 00:26:21,240 --> 00:26:24,000 So, for raisins, you wait a little bit longer 491 00:26:24,000 --> 00:26:26,640 to get the sugar content a little bit higher. 492 00:26:28,320 --> 00:26:31,320 These grapes are left on the plant for two weeks longer, 493 00:26:31,320 --> 00:26:33,760 so they're riper before they're cut. 494 00:26:35,520 --> 00:26:39,560 They're not sprayed, but allowed to dry naturally in the sun. 495 00:26:39,560 --> 00:26:42,400 They're left for six weeks, making them darker 496 00:26:42,400 --> 00:26:44,760 and more caramelly than sultanas. 497 00:26:47,440 --> 00:26:49,600 Is that like when you leave something in the oven, 498 00:26:49,600 --> 00:26:52,800 the longer you leave it, the darker and crispier it becomes? 499 00:26:52,800 --> 00:26:53,880 Exactly. 500 00:26:55,000 --> 00:26:58,560 Both crops are harvested and processed in the same way, 501 00:26:58,560 --> 00:27:03,640 simply washed, dried and packed, ready to be sent all over the world. 502 00:27:06,480 --> 00:27:09,720 Oh, there's a reason to be happy! 503 00:27:09,720 --> 00:27:12,080 Those are some beautiful raisins. Wow. 504 00:27:12,080 --> 00:27:14,480 You can really tell the difference. You see the difference. 505 00:27:14,480 --> 00:27:17,000 You really can. So the sultana is a lovely golden brown, 506 00:27:17,000 --> 00:27:19,680 whereas the raisins are a really deep, intense brown. 507 00:27:19,680 --> 00:27:21,920 Shall we have a taste test? Yes. OK. 508 00:27:21,920 --> 00:27:23,120 So sultanas first? 509 00:27:24,800 --> 00:27:27,400 Kind of a zing to it. It's quite citrussy. Now a raisin. 510 00:27:28,600 --> 00:27:32,400 I think it's much more intense, much richer. Smoother. 511 00:27:32,400 --> 00:27:34,960 Smoother. And sweeter. Very sweet. 512 00:27:34,960 --> 00:27:37,200 It's amazing how much difference it makes. Yeah. 513 00:27:37,200 --> 00:27:39,120 So that intensity is really striking. 514 00:27:39,120 --> 00:27:42,240 So now you've unfolded the mystery of sultana versus raisin. 515 00:27:42,240 --> 00:27:43,680 I have one more for you. 516 00:27:43,680 --> 00:27:45,040 What is a currant? 517 00:27:45,040 --> 00:27:47,560 Does that come from the same grape? 518 00:27:47,560 --> 00:27:49,360 Do you just leave it on there for 1,000 years? 519 00:27:49,360 --> 00:27:50,400 THEY CHUCKLE 520 00:27:50,400 --> 00:27:53,840 No, currants is a totally different grape, mainly from Greece. 521 00:27:53,840 --> 00:27:56,520 So this is a different grape. Yes, yes. OK. 522 00:27:56,520 --> 00:27:59,880 It's a red grape called a Black Corinth. 523 00:27:59,880 --> 00:28:02,920 It's much less sweet, much less intense. Yeah. 524 00:28:02,920 --> 00:28:05,040 I imagine that's why it's mainly used for cooking, 525 00:28:05,040 --> 00:28:07,200 for currant buns. Bakeries. Yeah. Yeah. 526 00:28:07,200 --> 00:28:08,760 Well, whichever one you prefer, 527 00:28:08,760 --> 00:28:09,880 any RAISIN for a snack. 528 00:28:11,280 --> 00:28:13,520 Cheers. Cheers to that. 529 00:28:24,480 --> 00:28:28,280 Back in Essex, our sultanas and other dried fruit and nuts 530 00:28:28,280 --> 00:28:29,960 are ready to roll. 531 00:28:29,960 --> 00:28:31,640 With no time to waste, 532 00:28:31,640 --> 00:28:35,760 they take a quick forklift ride over to the production area. 533 00:28:35,760 --> 00:28:38,960 This is the heart of our factory, where all the ingredients 534 00:28:38,960 --> 00:28:43,520 will finally be transformed into cereal bars. 535 00:28:43,520 --> 00:28:46,360 In charge of this precise operation 536 00:28:46,360 --> 00:28:49,080 is production manager Leanne Taylor. 537 00:28:49,080 --> 00:28:51,840 Leanne. How are you doing? 538 00:28:51,840 --> 00:28:54,560 I'm good. How are you? Happy. Good. Right. 539 00:28:54,560 --> 00:28:58,040 This is my batch. Right? Or your batch. Our batch. Our batch. 540 00:28:58,040 --> 00:29:00,680 But we do need to add one final ingredient to it first. 541 00:29:00,680 --> 00:29:02,280 Cereal? Cereal. 542 00:29:02,280 --> 00:29:06,120 You're finally putting cereal in your cereal bar? We are indeed. 543 00:29:06,120 --> 00:29:07,600 Yes. 544 00:29:07,600 --> 00:29:10,360 I was beginning to wonder whether it was ever going to happen. 545 00:29:10,360 --> 00:29:11,840 What is the cereal? 546 00:29:11,840 --> 00:29:14,480 The cereal that we're going to add is puffed rice. 547 00:29:14,480 --> 00:29:17,720 Is that the same puffed rice that we get in breakfast cereals? 548 00:29:17,720 --> 00:29:19,360 Pretty much. 549 00:29:19,360 --> 00:29:24,000 Puffed rice is made by mixing rice flour with water and sugar. 550 00:29:24,000 --> 00:29:27,000 It's then moulded into rice-shaped pieces, 551 00:29:27,000 --> 00:29:29,960 dried, and toasted till crispy. 552 00:29:29,960 --> 00:29:32,320 That has got a sweet... 553 00:29:32,320 --> 00:29:34,240 ..breakfast cereal smell, hasn't it? 554 00:29:34,240 --> 00:29:37,200 It has. Cor! I want to get a spoon and a bowl of milk! 555 00:29:37,200 --> 00:29:38,640 Why puffed rice? 556 00:29:38,640 --> 00:29:41,280 So we use the puffed rice to add some texture to the bar, 557 00:29:41,280 --> 00:29:43,320 and it also keeps the bar quite light. 558 00:29:43,320 --> 00:29:45,960 The fruit and nut mix that you've made is quite heavy. 559 00:29:45,960 --> 00:29:49,800 So the puffed rice actually balances out and keeps it nice and light. 560 00:29:49,800 --> 00:29:52,840 The rice makes up 9% of our bar, 561 00:29:52,840 --> 00:29:56,920 and I need 6.2 kilos of these airy grains. 562 00:29:56,920 --> 00:29:59,120 About a third of a kilo each shovel. 563 00:30:00,960 --> 00:30:02,800 You got a bigger shovel, love? 564 00:30:02,800 --> 00:30:04,400 You're just slow. 565 00:30:05,680 --> 00:30:08,480 I'm one of the quickest rice shovellers in the business. 566 00:30:13,560 --> 00:30:15,080 YES! 567 00:30:15,080 --> 00:30:18,280 6.2 kilos on the nose. 568 00:30:20,360 --> 00:30:23,760 The dry ingredients for our cereal bars have come together. 569 00:30:25,120 --> 00:30:27,440 Where's it going, boss? Mixing area. 570 00:30:27,440 --> 00:30:30,240 Coming through! Stand by, mixing area! 571 00:30:30,240 --> 00:30:32,000 Round the corner. 572 00:30:32,000 --> 00:30:33,080 Into the hoist. 573 00:30:34,880 --> 00:30:36,120 Excellent. 574 00:30:37,520 --> 00:30:39,520 Here we go. 575 00:30:39,520 --> 00:30:44,840 The 14 paddles on this magic mixer turn at 40 revs per minute, 576 00:30:44,840 --> 00:30:47,320 slowly mixing the ingredients together, 577 00:30:47,320 --> 00:30:51,160 just like you would at home with a wooden spoon. 578 00:30:51,160 --> 00:30:54,280 But I can't yet see how all these yummy stuff 579 00:30:54,280 --> 00:30:56,240 is going to stick together. 580 00:30:56,240 --> 00:30:58,800 That isn't bound at all. No. 581 00:30:58,800 --> 00:31:02,200 So there's one more ingredient that you need to go and get. Where? 582 00:31:02,200 --> 00:31:03,800 Over there. And bring it back? 583 00:31:03,800 --> 00:31:05,160 Yep. I'll see you in a bit. 584 00:31:06,440 --> 00:31:08,600 To track down my missing ingredient, 585 00:31:08,600 --> 00:31:10,840 I'm meeting Harriet Gregory. 586 00:31:13,480 --> 00:31:14,920 Harriet? Hello. 587 00:31:14,920 --> 00:31:17,320 Is that what's going to bind my bars? Yes. 588 00:31:17,320 --> 00:31:19,760 This is our lovely honey mix. 589 00:31:19,760 --> 00:31:23,640 So we've got a mixture of two honeys, a dark honey 590 00:31:23,640 --> 00:31:27,720 and a light honey, which is a little bit more acidic, 591 00:31:27,720 --> 00:31:29,360 slightly spicy, maybe. 592 00:31:36,240 --> 00:31:38,080 That really is quite sharp. Yeah. 593 00:31:38,080 --> 00:31:40,720 What did the bees go? A lemon tree? 594 00:31:40,720 --> 00:31:42,320 And then try the darker one. 595 00:31:47,600 --> 00:31:50,880 That is thick and luxurious. 596 00:31:50,880 --> 00:31:55,320 And almost like a like a chocolate bar. But quite strong. 597 00:31:55,320 --> 00:31:58,960 So I think you need the two, just to level things out a little bit. 598 00:31:58,960 --> 00:32:02,840 I don't know whether people realise that, actually, different honey 599 00:32:02,840 --> 00:32:05,480 comes from different flowers, different pollen. 600 00:32:05,480 --> 00:32:07,520 It's wherever the bees go. Right? 601 00:32:07,520 --> 00:32:09,880 Exactly. So this one is where they've been having 602 00:32:09,880 --> 00:32:11,520 really scented flowers. 603 00:32:11,520 --> 00:32:14,520 And this one is where they've been in woodlands and forest. 604 00:32:14,520 --> 00:32:16,320 The honeys taste great to me. 605 00:32:16,320 --> 00:32:18,400 But, surprisingly, Harriet's mix 606 00:32:18,400 --> 00:32:21,320 also contains two-thirds liquid glucose. 607 00:32:22,560 --> 00:32:24,840 Why have we got to add glucose? 608 00:32:24,840 --> 00:32:28,400 Because it helps form a crystal structure within the bar. 609 00:32:28,400 --> 00:32:32,760 And so when you bite into the bar, that lovely crunch that you have 610 00:32:32,760 --> 00:32:35,320 is caused by the crystals of the glucose. 611 00:32:35,320 --> 00:32:36,880 Without the glucose, 612 00:32:36,880 --> 00:32:39,640 you just end up with something that will fall apart. 613 00:32:39,640 --> 00:32:42,280 They'd just have a bit of a mild chew? 614 00:32:42,280 --> 00:32:44,680 To be honest, it would be quite soggy. 615 00:32:44,680 --> 00:32:46,360 Why not just make it from glucose? 616 00:32:46,360 --> 00:32:48,560 The bar would literally be so hard, 617 00:32:48,560 --> 00:32:51,800 it would almost break like glass and you wouldn't want to eat it. 618 00:32:51,800 --> 00:32:55,040 So different honeys give it flavour. Yeah. 619 00:32:55,040 --> 00:32:59,280 They also give the bar a certain softness. Exactly. 620 00:32:59,280 --> 00:33:03,080 The glucose actually dilutes the honey flavour, 621 00:33:03,080 --> 00:33:05,400 which is a bit too strong. A little bit, yeah. 622 00:33:05,400 --> 00:33:08,640 And also helps the bars stick together. 623 00:33:08,640 --> 00:33:10,440 Exactly. You've got it. 624 00:33:12,480 --> 00:33:13,920 Oh-ho! 625 00:33:13,920 --> 00:33:16,600 This honey mix will make up about a fifth of my bar. 626 00:33:17,600 --> 00:33:19,760 And I need a whole bucketful, 627 00:33:19,760 --> 00:33:24,320 heated to 80 degrees Celsius so it's runny honey. 628 00:33:24,320 --> 00:33:26,960 I'm happier than Winnie the Pooh. 629 00:33:26,960 --> 00:33:28,720 Do you know what I want to do with that now? 630 00:33:28,720 --> 00:33:30,480 What do you want to do? I want a bath in it. 631 00:33:32,080 --> 00:33:34,280 Oh, look at that. Ha-ha! 632 00:33:37,120 --> 00:33:41,640 30 seconds of gentle mixing sweetens this lot up nicely. 633 00:33:44,000 --> 00:33:46,040 I don't believe that's going to stick together. 634 00:33:46,040 --> 00:33:48,400 Come and have a look at this. Does that look right to you? 635 00:33:48,400 --> 00:33:50,840 Oh, it looks perfect. Really? Yeah. 636 00:33:54,160 --> 00:33:57,080 Don't these crispy bits of rice now get soggy? 637 00:33:57,080 --> 00:33:59,840 No. They actually work really well to help make it nice and crisp. 638 00:33:59,840 --> 00:34:02,680 You can pour wet things over a crispy thing and it stays crispy? 639 00:34:02,680 --> 00:34:05,200 Yep. It does. You're like a cookery magician. 640 00:34:05,200 --> 00:34:06,520 We are, yes. 641 00:34:09,400 --> 00:34:11,200 Take it away? Take it away. 642 00:34:13,280 --> 00:34:16,360 I'm telling you, that's not sticky enough. We'll see. 643 00:34:16,360 --> 00:34:18,560 An hour and 40 minutes in, 644 00:34:18,560 --> 00:34:24,840 and with 55 kilos of mix to now turn into 1,440 cereal bars, 645 00:34:24,840 --> 00:34:28,920 it's all hands on deck, quite literally. 646 00:34:28,920 --> 00:34:33,280 The sticky mixture is weighed into 920-gram portions. 647 00:34:34,360 --> 00:34:36,280 What are they doing? 648 00:34:36,280 --> 00:34:39,760 We are now putting our mix into the baking trays. 649 00:34:39,760 --> 00:34:42,640 1,440 bars... Yeah. 650 00:34:42,640 --> 00:34:45,800 ..is baked in little things that would fit in your oven at home? 651 00:34:45,800 --> 00:34:47,000 Yes. 652 00:34:47,000 --> 00:34:50,840 And just like at home, each steel tray is lined with greaseproof paper 653 00:34:50,840 --> 00:34:52,640 to stop it sticking. 654 00:34:52,640 --> 00:34:55,920 Is this just for me, cos I'm here? Or is this actually how you make...? 655 00:34:55,920 --> 00:34:58,360 This is how we make every single bar. 656 00:34:58,360 --> 00:34:59,960 By hand? By hand. 657 00:35:04,840 --> 00:35:09,400 What's this gentleman here doing? He's doing what we call massage. 658 00:35:11,560 --> 00:35:15,080 Yes. He's massaging the product to make it nice and even, 659 00:35:15,080 --> 00:35:18,480 so that we don't get holes or gaps in the bars. 660 00:35:18,480 --> 00:35:21,520 We need to make sure it's in the corners of the baking tray. 661 00:35:21,520 --> 00:35:23,840 Are you a good fruit and nut bar massager? 662 00:35:23,840 --> 00:35:26,600 I am good, but not as good as these guys. 663 00:35:28,200 --> 00:35:30,080 Feel free to have a go. 664 00:35:30,080 --> 00:35:31,360 Yeah. 665 00:35:31,360 --> 00:35:33,560 Now, I love a good massage, 666 00:35:33,560 --> 00:35:35,640 but I'm normally on the receiving end. 667 00:35:35,640 --> 00:35:36,920 How hard can it be? 668 00:35:40,680 --> 00:35:42,240 Don't push it down, Gregg. 669 00:35:42,240 --> 00:35:45,400 You want to massage it, not compact it. 670 00:35:45,400 --> 00:35:47,480 Ah! Don't push it down. 671 00:35:47,480 --> 00:35:48,720 Spread it out. 672 00:35:48,720 --> 00:35:50,760 Being careful not to crush the ingredients 673 00:35:50,760 --> 00:35:52,600 is a delicate business. 674 00:35:52,600 --> 00:35:54,160 Sorry. 675 00:35:54,160 --> 00:35:56,920 That took me 20 seconds to do one, 676 00:35:56,920 --> 00:35:58,640 and there's 60 to do! 677 00:35:58,640 --> 00:36:01,920 Gregg, you've only got 20 minutes to do this. You're getting behind. 678 00:36:01,920 --> 00:36:04,040 Hard work, this is. 679 00:36:04,040 --> 00:36:08,080 Next up is pinning, named after the rolling pin, 680 00:36:08,080 --> 00:36:11,680 which gently flattens the mix to 1.5 centimetres - 681 00:36:11,680 --> 00:36:14,720 the exact depth of the tray. 682 00:36:14,720 --> 00:36:17,480 Can I have a go at pinning, now? Pinning looks easier. 683 00:36:17,480 --> 00:36:18,600 Yep. 684 00:36:22,040 --> 00:36:24,200 Oh, this is an easy job! 685 00:36:24,200 --> 00:36:26,320 Easy job! 686 00:36:26,320 --> 00:36:28,360 Oh, whoa! Whoa! 687 00:36:29,960 --> 00:36:31,400 There we go, look. 688 00:36:31,400 --> 00:36:33,840 No, no, no, no, no, no. 689 00:36:33,840 --> 00:36:36,520 That can't go on. Why? What's wrong with it? 690 00:36:36,520 --> 00:36:38,920 Look how wavy your bar is. Feel it. 691 00:36:38,920 --> 00:36:43,440 If not rolled out flat, our bars won't bake evenly. 692 00:36:43,440 --> 00:36:45,280 Look at that. 693 00:36:45,280 --> 00:36:47,000 How's that? Perfect. 694 00:36:48,200 --> 00:36:51,960 Where do they go then? They need to be loaded into the trolley. 695 00:36:53,760 --> 00:36:58,840 180 trays an hour are loaded onto these movable racks. 696 00:36:58,840 --> 00:37:03,080 My 60 trays take up a whole trolley. 697 00:37:03,080 --> 00:37:04,640 You get there eventually, don't you? 698 00:37:04,640 --> 00:37:06,920 I mean, look, I'm actually... Can I tell you something? 699 00:37:06,920 --> 00:37:08,560 I'm actually quite proud of myself. 700 00:37:08,560 --> 00:37:10,720 You should be, that's really, really good. 701 00:37:12,240 --> 00:37:14,040 A-ha-ha! 702 00:37:14,040 --> 00:37:16,240 Next stop is the baking area. 703 00:37:16,240 --> 00:37:18,880 MUSIC: Spinning Around by Kylie Minogue 704 00:37:18,880 --> 00:37:21,600 We wheel our trays, trolley and all, 705 00:37:21,600 --> 00:37:24,960 straight into a 2.5 metre high walk-in oven 706 00:37:24,960 --> 00:37:27,840 with a special design feature. 707 00:37:27,840 --> 00:37:29,560 It's turning round! 708 00:37:29,560 --> 00:37:32,120 # I'm spinning around 709 00:37:32,120 --> 00:37:34,560 # Move out of my way 710 00:37:34,560 --> 00:37:37,800 # I know you're feeling me Cos you like it like this. # 711 00:37:37,800 --> 00:37:39,560 Why's it turning round? 712 00:37:39,560 --> 00:37:43,120 So we can get a nice, even distribution of heat 713 00:37:43,120 --> 00:37:45,760 through the trolley and all of the trays. 714 00:37:45,760 --> 00:37:50,400 The trolleys sit on a turntable built into the floor of the oven, 715 00:37:50,400 --> 00:37:54,680 which spins them a sedate two revolutions per minute. 716 00:37:54,680 --> 00:37:57,520 Some ovens, all ovens - even ovens at home - have got hot spots, 717 00:37:57,520 --> 00:37:59,760 which is why sometimes the corner of your pie's burnt. 718 00:37:59,760 --> 00:38:01,760 Yeah, so there'll be no burnt edges on this, 719 00:38:01,760 --> 00:38:03,960 because it's rotating constantly. 720 00:38:03,960 --> 00:38:05,920 It's getting a nice, even bake in there. 721 00:38:06,880 --> 00:38:08,680 I like it here. 722 00:38:08,680 --> 00:38:11,600 This great bit of kit edges the temperature 723 00:38:11,600 --> 00:38:13,760 up to 180 degrees Celsius. 724 00:38:15,600 --> 00:38:18,000 The heat reduces the moisture in the bars, 725 00:38:18,000 --> 00:38:21,280 concentrating the sugars in the honey mix, 726 00:38:21,280 --> 00:38:23,480 changing the crystal structure, 727 00:38:23,480 --> 00:38:28,200 which helps bind our ingredients together to make solid bars. 728 00:38:30,040 --> 00:38:33,960 After their 17-minute spin class, they're nice and warm. 729 00:38:33,960 --> 00:38:36,160 Whoa! Careful! 730 00:38:36,160 --> 00:38:38,760 Something hot in the kitchen. 731 00:38:38,760 --> 00:38:40,520 And he's carrying some bars! 732 00:38:41,800 --> 00:38:44,480 Time for them to chill out. 733 00:38:44,480 --> 00:38:45,880 Really? Yep. 734 00:38:45,880 --> 00:38:48,280 You just stick it in front of a wall of fans? Yes. 735 00:38:48,280 --> 00:38:50,040 And that's it? 736 00:38:50,040 --> 00:38:52,360 But these are no ordinary fans. 737 00:38:57,560 --> 00:39:00,400 These six industrial beasts 738 00:39:00,400 --> 00:39:04,320 turn at an impressive 1,330 revs per minute. 739 00:39:04,320 --> 00:39:05,960 Whoa, it's...! 740 00:39:05,960 --> 00:39:07,120 Whoosh! LEANNE LAUGHS 741 00:39:07,120 --> 00:39:08,200 Whoosh! 742 00:39:14,280 --> 00:39:15,720 That was great. 743 00:39:15,720 --> 00:39:19,360 It will take just ten minutes for our trays to cool down 744 00:39:19,360 --> 00:39:22,640 from 75 degrees Celsius to room temperature. 745 00:39:25,240 --> 00:39:29,440 Of course, cereal bars are just one way of keeping us fuelled on the go. 746 00:39:29,440 --> 00:39:31,440 Ruth has been delving into the history 747 00:39:31,440 --> 00:39:33,600 of one of the original energy bars. 748 00:39:37,400 --> 00:39:40,120 I've come to the wild moors and rolling hills 749 00:39:40,120 --> 00:39:41,640 of the Lake District. 750 00:39:42,760 --> 00:39:47,800 A hiker's paradise and home to Kendal Mint Cake - 751 00:39:47,800 --> 00:39:51,080 super-sugary, super-minty. 752 00:39:51,080 --> 00:39:57,360 Why is it so synonymous with mountaineering and explorers? 753 00:39:58,520 --> 00:40:01,400 To find out, I'm meeting Mollie Hughes... 754 00:40:01,400 --> 00:40:02,560 Hello! 755 00:40:05,280 --> 00:40:07,760 ..who researched the history of this sugary snack 756 00:40:07,760 --> 00:40:11,760 while preparing for her successful ascent of Everest. 757 00:40:11,760 --> 00:40:13,200 On top of the world! 758 00:40:13,200 --> 00:40:15,880 So what's so good about Kendal Mint Cake, then? 759 00:40:15,880 --> 00:40:18,280 So, Kendal Mint Cake has all these compact sugars. 760 00:40:18,280 --> 00:40:21,920 Really high energy and, especially on Everest and at high altitude, 761 00:40:21,920 --> 00:40:24,200 your body finds it hard to digest food, 762 00:40:24,200 --> 00:40:26,360 so these kind of simple sugars are really great. 763 00:40:26,360 --> 00:40:28,280 And I guess I know from my own expeditions, 764 00:40:28,280 --> 00:40:29,680 you burn so many calories - 765 00:40:29,680 --> 00:40:32,320 like, between maybe 6,000 and 7,000 calories a day... 766 00:40:32,320 --> 00:40:34,720 Wow! ..as you're heading to the summit. Crazy amounts. 767 00:40:34,720 --> 00:40:35,960 So this kind of thing, 768 00:40:35,960 --> 00:40:38,160 this high-energy, easy-to-eat food is great. 769 00:40:38,160 --> 00:40:39,800 It doesn't freeze in low temperatures. 770 00:40:39,800 --> 00:40:41,320 It doesn't even melt in the sun. 771 00:40:41,320 --> 00:40:44,880 So it's really great for these high-altitude expeditions. 772 00:40:44,880 --> 00:40:48,160 Kendal Mint Cake was invented in 1869, 773 00:40:48,160 --> 00:40:52,520 in the town that gives it its name, by confectioner Joseph Wiper. 774 00:40:55,040 --> 00:40:57,720 I'm going to Romney's - one of the top producers of the bar - 775 00:40:57,720 --> 00:41:00,320 where managing director John Barron... 776 00:41:00,320 --> 00:41:03,400 John, hi! Hello, Ruth. Hey. Pleased to meet you. 777 00:41:03,400 --> 00:41:06,840 ..is letting me in on the secrets of this sweet treat. 778 00:41:06,840 --> 00:41:08,280 What's in Kendal Mint Cake? 779 00:41:08,280 --> 00:41:11,680 Basically, sugar. Sugar with glucose and water 780 00:41:11,680 --> 00:41:13,920 and then we add peppermint oil, obviously, 781 00:41:13,920 --> 00:41:15,760 to get the mint flavour, yeah. 782 00:41:15,760 --> 00:41:19,120 That's really simple, isn't it? Quite basic, yes, yes. 783 00:41:19,120 --> 00:41:21,040 Basic it may be... 784 00:41:21,040 --> 00:41:23,880 OK, so we'll get this poured out. 785 00:41:23,880 --> 00:41:28,760 ..but this sugary bar is the success story that nearly never was. 786 00:41:28,760 --> 00:41:30,760 How Kendal Mint Cake came about - 787 00:41:30,760 --> 00:41:33,800 somebody was actually trying to make a clear mint. 788 00:41:33,800 --> 00:41:36,760 And what they've done is they've taken the boiling off too early, 789 00:41:36,760 --> 00:41:40,560 and then stirred it and it went cloudy and they poured it out 790 00:41:40,560 --> 00:41:42,960 and thought, "Oh, dear, this is no good." 791 00:41:42,960 --> 00:41:46,840 But, when it set, thought, "Hey, we've got something here." 792 00:41:46,840 --> 00:41:50,000 The cloudy mixture is ladled into moulds. 793 00:41:51,720 --> 00:41:53,960 I'll make sure it goes to the corners. There you go. 794 00:41:53,960 --> 00:41:57,200 So nice and liquid. That's it. Self-levelling. 795 00:41:57,200 --> 00:42:01,280 After just ten minutes, the solid cake is turned out 796 00:42:01,280 --> 00:42:05,120 and broken into bar-sized pieces, and wrapped. 797 00:42:06,560 --> 00:42:11,920 Although the first bars were sold locally to Victorian tourists, 798 00:42:11,920 --> 00:42:14,120 they quickly established a reputation 799 00:42:14,120 --> 00:42:17,040 as the explorer's energy snack of choice 800 00:42:17,040 --> 00:42:20,280 when, in 1914, Ernest Shackleton 801 00:42:20,280 --> 00:42:22,800 took mint cake with him to Antarctica. 802 00:42:24,960 --> 00:42:29,400 But one event cemented its place in mountaineering history. 803 00:42:30,760 --> 00:42:33,960 So Kendal Mint Cake's most famous moment came at 11:30am 804 00:42:33,960 --> 00:42:36,200 on the 29th of May, 1953. 805 00:42:36,200 --> 00:42:39,200 And this was when Sir Edmund Hillary and Tenzing Norgay, 806 00:42:39,200 --> 00:42:41,720 they reached the summit of Mount Everest. 807 00:42:41,720 --> 00:42:44,360 This was the first time anyone had succeeded 808 00:42:44,360 --> 00:42:47,560 in reaching the highest peak in the world. 809 00:42:47,560 --> 00:42:49,880 So Tenzing Norgay is quoted on the packet. 810 00:42:49,880 --> 00:42:51,560 He says, "We sat down in the snow 811 00:42:51,560 --> 00:42:54,000 "and looked out at the country far below us. 812 00:42:54,000 --> 00:42:56,120 "We nibbled the Kendal Mint Cake." 813 00:42:56,120 --> 00:42:59,160 So how much Kendal Mint Cake did Sir Edmund Hillary take? 814 00:42:59,160 --> 00:43:01,880 I've actually got the original order here with us. 815 00:43:01,880 --> 00:43:04,240 It says, "We would like to incorporate it 816 00:43:04,240 --> 00:43:06,280 "in our special high-altitude rations. 817 00:43:06,280 --> 00:43:08,480 "We will require 300 such bars." 818 00:43:09,520 --> 00:43:11,760 This was a big ask. 819 00:43:11,760 --> 00:43:15,120 Sugar was still in short supply after Second World War rationing 820 00:43:15,120 --> 00:43:17,640 had restricted distribution. 821 00:43:17,640 --> 00:43:19,720 But it made all the difference to them, 822 00:43:19,720 --> 00:43:22,880 and to the popularity of mint cake. 823 00:43:22,880 --> 00:43:26,720 So we know that Edmund Hillary had quite a large stock. 824 00:43:26,720 --> 00:43:28,720 We know that they were eating it on the summit. 825 00:43:28,720 --> 00:43:32,640 And then that information is part of the advertising and marketing 826 00:43:32,640 --> 00:43:34,640 for Kendal Mint Cake for years. 827 00:43:34,640 --> 00:43:37,480 Yep, absolutely. I think any mountaineer and hiker in the UK 828 00:43:37,480 --> 00:43:39,400 knows Kendal Mint Cake and has eaten it 829 00:43:39,400 --> 00:43:41,200 at one point or another on a mountain. 830 00:43:46,000 --> 00:43:49,080 This is the original British energy bar. 831 00:43:49,080 --> 00:43:53,480 And 150 years after it was first invented in the Lake District, 832 00:43:53,480 --> 00:43:58,440 it still provides a high-energy boost to hikers all across Britain. 833 00:44:06,680 --> 00:44:08,920 In the flatlands of Essex, 834 00:44:08,920 --> 00:44:11,240 our chilled-out trays of baked cereal mix 835 00:44:11,240 --> 00:44:13,680 are ready for the next leg of their journey. 836 00:44:15,000 --> 00:44:16,560 Right. 837 00:44:16,560 --> 00:44:19,440 I am as chilled as the bars. Yes, you are. 838 00:44:19,440 --> 00:44:23,040 What are we going to do? So now we need to cut the baking tray. 839 00:44:23,040 --> 00:44:25,840 So this is the point our bars really start to look like bars. 840 00:44:25,840 --> 00:44:27,200 Fantastic. 841 00:44:27,200 --> 00:44:28,840 Yeah. At last. At last. 842 00:44:28,840 --> 00:44:31,440 Is this the cutting machine? It is, yes. Right. 843 00:44:31,440 --> 00:44:34,040 Can I do it? Yeah, you can. So take a baking tray out. 844 00:44:39,000 --> 00:44:40,880 That was complicated, wasn't it? 845 00:44:40,880 --> 00:44:42,600 Very technical. 846 00:44:42,600 --> 00:44:44,040 Slide it underneath. 847 00:44:46,360 --> 00:44:48,680 Both hands on the thing. Do I have to slam it? 848 00:44:48,680 --> 00:44:51,680 No. Just bring it down nice and gently. 849 00:44:51,680 --> 00:44:53,120 With this fancy cutter, 850 00:44:53,120 --> 00:44:56,880 the factory can chop 360 trays an hour. 851 00:44:56,880 --> 00:44:58,800 Behind the safety guard, 852 00:44:58,800 --> 00:45:02,240 a dozen blades apply 12 tonnes per square inch of pressure 853 00:45:02,240 --> 00:45:06,120 to the mix, cutting it into 24 tidy bars. 854 00:45:06,120 --> 00:45:08,320 There they are. There they are. 855 00:45:08,320 --> 00:45:10,800 All packed full of nuts, bar none. 856 00:45:10,800 --> 00:45:14,240 Exactly. I've got other 59 trays to cut, right? You have, 857 00:45:14,240 --> 00:45:15,840 and you've got ten minutes to do that 858 00:45:15,840 --> 00:45:18,320 and that'll be our 1,440 bars. 859 00:45:24,400 --> 00:45:26,440 My bars are nearly complete, 860 00:45:26,440 --> 00:45:28,880 but they're looking a bit underdressed. 861 00:45:30,000 --> 00:45:33,400 Tipped out from their trays, they're lined up like soldiers - 862 00:45:33,400 --> 00:45:35,960 nine across - on a conveyor belt. 863 00:45:35,960 --> 00:45:39,200 Again, by hand? Again by hand. Are they ready now? 864 00:45:39,200 --> 00:45:41,320 Are they ready to get wrapped up and gone? 865 00:45:41,320 --> 00:45:43,960 No, we've got one final ingredient to add - 866 00:45:43,960 --> 00:45:46,080 a little bit of indulgence. 867 00:45:46,080 --> 00:45:48,160 It's the chocolate, innit? It's the chocolate. 868 00:45:48,160 --> 00:45:51,000 So I need you to go and get me some chocolate. 869 00:45:51,000 --> 00:45:54,240 No way! Yeah. A bucket of chocolate?! A bucket of chocolate. 870 00:45:54,240 --> 00:45:57,520 I might be a while. No, you won't, cos I'm coming with you. 871 00:45:59,560 --> 00:46:02,000 The dark chocolate which will coat our bars 872 00:46:02,000 --> 00:46:05,280 arrives at the factory in giant button form 873 00:46:05,280 --> 00:46:08,080 and is melted to 45 degrees Celsius 874 00:46:08,080 --> 00:46:11,960 in huge 2,000-litre tanks. 875 00:46:11,960 --> 00:46:15,080 13 kilos is just enough for our batch. 876 00:46:15,080 --> 00:46:16,800 I got to taste the honey. 877 00:46:16,800 --> 00:46:18,960 Do I get to taste the chocolate? No. 878 00:46:18,960 --> 00:46:20,640 But maybe later on a bar. 879 00:46:21,880 --> 00:46:23,720 Sorry. Come on, let's go. 880 00:46:23,720 --> 00:46:25,040 Whoa-ho-ho! 881 00:46:25,040 --> 00:46:26,560 Ho-ho-ho! 882 00:46:26,560 --> 00:46:28,800 It's 3 hours, 42 minutes since 883 00:46:28,800 --> 00:46:31,680 our macadamia nuts arrived at the factory 884 00:46:31,680 --> 00:46:35,440 and it's time for our bars to have their finishing touch. 885 00:46:35,440 --> 00:46:39,560 Some jobs you do that are an absolute delight. 886 00:46:39,560 --> 00:46:40,840 Yeah. 887 00:46:40,840 --> 00:46:44,240 My melted chocolate pours straight into a small tray 888 00:46:44,240 --> 00:46:45,840 on this enrobing machine. 889 00:46:45,840 --> 00:46:47,400 That'll do lovely. 890 00:46:47,400 --> 00:46:48,920 Yeah? Yeah. 891 00:46:48,920 --> 00:46:51,960 Look at that. Oh. Clean. You kept your hands clean, too. 892 00:46:51,960 --> 00:46:53,160 Well done. 893 00:46:54,280 --> 00:46:56,800 It's pumped into a heated reservoir 894 00:46:56,800 --> 00:47:00,840 and a series of rollers feed it up towards a wire conveyor. 895 00:47:03,960 --> 00:47:07,800 As the bars march across this melty chocolate sea, 896 00:47:07,800 --> 00:47:11,440 the rollers push the chocolate up through the wire conveyor, 897 00:47:11,440 --> 00:47:15,680 coating my battalion with nine grams of the lovely stuff. 898 00:47:17,360 --> 00:47:20,160 It takes just six minutes to have their chocolaty bath. 899 00:47:20,160 --> 00:47:23,400 But they need to cool off quickly before they're wrapped up. 900 00:47:25,040 --> 00:47:27,680 They've got chocolate on the bottom. Where are they going now? 901 00:47:27,680 --> 00:47:31,280 What's this? So this is a cooling tunnel. Ah. Yeah. 902 00:47:31,280 --> 00:47:33,680 So is this just one big refrigerator? 903 00:47:33,680 --> 00:47:35,040 Pretty much, yes. 904 00:47:35,040 --> 00:47:37,760 That bottom cooling - which is where the chocolate is - 905 00:47:37,760 --> 00:47:39,480 will be around five degrees. 906 00:47:39,480 --> 00:47:42,520 And we've a top cooling, which is around eight degrees. 907 00:47:42,520 --> 00:47:44,480 So what's it for - just to set the chocolate? 908 00:47:44,480 --> 00:47:46,280 Just to set the chocolate. Yeah. 909 00:47:47,600 --> 00:47:49,440 In their final push, 910 00:47:49,440 --> 00:47:55,160 my troops are paraded through this 18-metre fan-cooled tunnel. 911 00:47:55,160 --> 00:47:59,360 3 hours and 48 minutes since our nuts arrived at the factory, 912 00:47:59,360 --> 00:48:01,600 my bars are complete. 913 00:48:06,280 --> 00:48:07,920 That's it, right? That's it. 914 00:48:07,920 --> 00:48:10,240 That's our finished bar. It is, yes. 915 00:48:10,240 --> 00:48:14,120 Honey mix, dried fruit, toasted nuts and a bit of chocolate. 916 00:48:14,120 --> 00:48:17,520 Perfect. And I've had a hand in every single little bit. 917 00:48:22,760 --> 00:48:26,000 Nice little bar, that. It is, yeah. 918 00:48:26,000 --> 00:48:29,600 While they form an orderly queue for the next stage, 919 00:48:29,600 --> 00:48:32,240 Cherry's delving into the secrets of the nuts 920 00:48:32,240 --> 00:48:34,320 at the heart of them down in Cornwall. 921 00:48:38,520 --> 00:48:43,280 I've come to this balmy biome to unravel a botanical puzzle. 922 00:48:44,840 --> 00:48:48,960 Because it's harder to spot a nut than you might think. 923 00:48:48,960 --> 00:48:52,320 And, to kick things off, I've got a cracking game for the visitors 924 00:48:52,320 --> 00:48:56,200 at the Eden Project. It's called Nut Or No Nut. 925 00:48:56,200 --> 00:48:57,560 Hazelnut. 926 00:48:57,560 --> 00:48:58,680 Cashew nut. 927 00:48:58,680 --> 00:49:00,320 And peanut. 928 00:49:00,320 --> 00:49:03,560 The rules are simple - is it a nut or not? 929 00:49:08,240 --> 00:49:09,840 All three are nuts. Really? 930 00:49:09,840 --> 00:49:11,160 Really. You sure? Quite sure. 931 00:49:11,160 --> 00:49:12,720 I know that's a nut. Yes. 932 00:49:12,720 --> 00:49:14,280 Cos I grow them at home. 933 00:49:14,280 --> 00:49:17,040 Nut. Nut? Don't want to phone a friend? 934 00:49:17,040 --> 00:49:19,400 No, no, I'm convinced all three are nuts. 935 00:49:19,400 --> 00:49:22,080 What kind of nut? Not sure. 936 00:49:22,080 --> 00:49:24,120 They're nuts. Peanuts. Hazelnut. 937 00:49:24,120 --> 00:49:26,120 They're nuts. Cashews. But they're not. 938 00:49:27,800 --> 00:49:29,480 Game over. 939 00:49:29,480 --> 00:49:31,280 Time for the results. 940 00:49:31,280 --> 00:49:33,120 Did you know that only one of these is a nut? 941 00:49:33,120 --> 00:49:35,280 I didn't know that, no. 942 00:49:35,280 --> 00:49:36,840 That's right. 943 00:49:36,840 --> 00:49:41,280 We may call them all nuts, but only one is a true botanical nut - 944 00:49:41,280 --> 00:49:43,800 the hazelnut. 945 00:49:43,800 --> 00:49:45,600 # Nuts, nuts to you! # 946 00:49:47,640 --> 00:49:53,440 So if our other two nuts aren't nuts, what are they? 947 00:49:53,440 --> 00:49:57,400 Horticulturist Catherine Cutler has brought me to a cashew tree 948 00:49:57,400 --> 00:49:59,640 to help me understand. 949 00:49:59,640 --> 00:50:03,680 Why is a cashew nut not an actual nut? 950 00:50:03,680 --> 00:50:06,520 It's not actually a nut, because it's a drupe. 951 00:50:06,520 --> 00:50:10,000 So... What is a drupe? A drupe. It's a botanical term. 952 00:50:10,000 --> 00:50:12,720 Perhaps, as a layperson, you'd normally use the word fruit. 953 00:50:12,720 --> 00:50:15,360 But it's like almonds, walnuts - they're all fruits, 954 00:50:15,360 --> 00:50:17,480 which have got a seed inside. 955 00:50:17,480 --> 00:50:21,280 And so this we call a cashew apple, or cashew pear. 956 00:50:21,280 --> 00:50:23,480 That is the weirdest-looking thing. 957 00:50:23,480 --> 00:50:26,080 The cashew drupe is clearly visible 958 00:50:26,080 --> 00:50:29,400 below the yellow, swollen stem of the plant. 959 00:50:30,480 --> 00:50:34,000 Walnuts, almonds and pecans are also drupes, 960 00:50:34,000 --> 00:50:37,040 and some consider the macadamia to be one, too. 961 00:50:37,040 --> 00:50:39,760 They all have a fleshy outer layer. 962 00:50:41,480 --> 00:50:45,280 And what about my other nutty impostor? 963 00:50:45,280 --> 00:50:48,080 Peanuts form under the ground. 964 00:50:48,080 --> 00:50:50,640 So peanuts aren't true nuts, either. 965 00:50:50,640 --> 00:50:53,840 This a much more closely related to beans and to peas. 966 00:50:53,840 --> 00:50:56,080 So what are they, then? They're legumes. 967 00:50:57,240 --> 00:51:01,000 Legumes form in a pod, just like the garden pea. 968 00:51:01,000 --> 00:51:03,000 So even its name is a lie. 969 00:51:03,000 --> 00:51:05,680 It's not a peanut. It's a pea legume. 970 00:51:05,680 --> 00:51:10,960 The hazelnut, by contrast, is defined as a true botanical nut, 971 00:51:10,960 --> 00:51:14,480 because its hard shell doesn't release the seed inside naturally 972 00:51:14,480 --> 00:51:16,840 when it's ready to be picked. 973 00:51:16,840 --> 00:51:20,080 But however these nuts, drupes and legumes grow, 974 00:51:20,080 --> 00:51:22,120 the one thing they have in common 975 00:51:22,120 --> 00:51:26,360 is that the nutty part we eat is the seed of the plant. 976 00:51:26,360 --> 00:51:29,160 I'm meeting dietician Azmina Govindji 977 00:51:29,160 --> 00:51:33,280 to uncover what that means for their nutritional value. 978 00:51:33,280 --> 00:51:36,160 Foods that we commonly consider to be nuts are broadly similar 979 00:51:36,160 --> 00:51:39,800 in nutritional breakdown, because a nut is the seed of the plant 980 00:51:39,800 --> 00:51:42,520 that's responsible for reproduction. 981 00:51:42,520 --> 00:51:45,720 So the nutrients and the energy that's in that tiny seed 982 00:51:45,720 --> 00:51:49,000 is enough to make it grow into a brand-new plant. 983 00:51:49,000 --> 00:51:53,160 And it's this that makes them such dietary heroes. 984 00:51:53,160 --> 00:51:55,480 I've always thought that nuts were healthy. Is that true? 985 00:51:55,480 --> 00:51:57,680 Yeah, they're great. They're low in sugar. 986 00:51:57,680 --> 00:52:00,400 They're mostly high in fibre and they're high in fat. 987 00:52:00,400 --> 00:52:02,360 All right. So that's a hazelnut. 988 00:52:02,360 --> 00:52:06,120 Right. And more than half of the weight of that hazelnut is fat. 989 00:52:06,120 --> 00:52:08,400 That seems like a lot of fat. 990 00:52:08,400 --> 00:52:10,280 That's surely not that good for us. 991 00:52:10,280 --> 00:52:13,960 Well, you're right. Excess saturated fat isn't good for us, 992 00:52:13,960 --> 00:52:16,320 Cos it's been linked with high blood cholesterol. 993 00:52:16,320 --> 00:52:19,360 But the good news is that the type of fat in nuts 994 00:52:19,360 --> 00:52:21,840 is polyunsaturated and monounsaturated, 995 00:52:21,840 --> 00:52:23,680 and these types actually help 996 00:52:23,680 --> 00:52:26,080 to maintain a healthy blood cholesterol. 997 00:52:26,080 --> 00:52:27,520 I'm going to have one right now. 998 00:52:27,520 --> 00:52:30,880 Can I do a pick and mix? That's the best, because, actually, 999 00:52:30,880 --> 00:52:33,160 although they're similar in nutrients, 1000 00:52:33,160 --> 00:52:35,440 there are variations between different nuts. 1001 00:52:35,440 --> 00:52:37,520 So, for example, cashews... Yeah. 1002 00:52:37,520 --> 00:52:42,240 ..have got twice the carbohydrate as hazelnuts and much less fibre, 1003 00:52:42,240 --> 00:52:44,560 but they're a good source of iron and zinc. 1004 00:52:45,840 --> 00:52:49,240 But if you after fibre and its healthy gut benefits, 1005 00:52:49,240 --> 00:52:52,520 the hazelnut is one of the best options, 1006 00:52:52,520 --> 00:52:55,360 while peanuts are packed with protein, 1007 00:52:55,360 --> 00:52:58,120 making them a perfect post-workout snack. 1008 00:52:58,120 --> 00:53:02,080 However, Brazils are the king of nuts. 1009 00:53:02,080 --> 00:53:06,200 So Brazil nuts are the richest dietary source of selenium. 1010 00:53:06,200 --> 00:53:07,520 What is selenium? 1011 00:53:07,520 --> 00:53:10,800 Selenium is needed to maintain a normal immune function. 1012 00:53:10,800 --> 00:53:15,560 Just by having one Brazil nut a day, you get your daily selenium needs. 1013 00:53:15,560 --> 00:53:19,680 So even though not all nuts are technically botanical nuts, 1014 00:53:19,680 --> 00:53:23,080 they are, in their own way, really, really good for us. 1015 00:53:23,080 --> 00:53:24,360 Absolutely. 1016 00:53:36,680 --> 00:53:38,360 At the factory... 1017 00:53:40,520 --> 00:53:42,160 ..my cereal bar soldiers 1018 00:53:42,160 --> 00:53:45,120 have reached the last stage of their journey 1019 00:53:45,120 --> 00:53:48,040 and are lining up for a final inspection. 1020 00:53:48,040 --> 00:53:50,520 What am I watching here - high-speed bars? 1021 00:53:50,520 --> 00:53:53,120 This is the last point we get to have a check of the bar 1022 00:53:53,120 --> 00:53:55,080 before it goes into the wrapper. 1023 00:53:55,080 --> 00:53:59,880 After all that handcrafting, it's about to get fully automated. 1024 00:54:02,120 --> 00:54:05,800 This nifty scanner uses three laser sensors 1025 00:54:05,800 --> 00:54:08,320 to check our bars as they zoom past. 1026 00:54:10,360 --> 00:54:14,320 If they're broken or stuck together, they won't make it past this point. 1027 00:54:17,000 --> 00:54:19,440 Any rejects are blown off the belt 1028 00:54:19,440 --> 00:54:22,880 by a super-fast, six-millisecond jet of air. 1029 00:54:24,480 --> 00:54:26,160 But they do get a second chance. 1030 00:54:26,160 --> 00:54:30,080 The rejects are sent back through the scanner one last time, 1031 00:54:30,080 --> 00:54:32,480 with less than 1% going to waste. 1032 00:54:34,880 --> 00:54:36,720 So if I was a bit mischievous here, 1033 00:54:36,720 --> 00:54:40,160 and I put one bar on top of another, would it notice? Yeah. 1034 00:54:40,160 --> 00:54:41,160 Excuse me. 1035 00:54:41,160 --> 00:54:42,800 I can't resist a challenge. 1036 00:54:47,080 --> 00:54:48,880 GREGG LAUGHS 1037 00:54:48,880 --> 00:54:50,120 Scanner wins. 1038 00:54:52,800 --> 00:54:56,200 My little squadron has made the grade, 1039 00:54:56,200 --> 00:54:58,040 and this lot needs wrapping up now. 1040 00:54:58,040 --> 00:54:59,600 And, with no time to lose, 1041 00:54:59,600 --> 00:55:03,080 they hurtle on towards a hi-tech wrapping robot. 1042 00:55:06,960 --> 00:55:11,240 The bars are separated by 2.5cm 1043 00:55:11,240 --> 00:55:14,040 and a wrapper is folded around each one. 1044 00:55:14,040 --> 00:55:16,640 They're then sealed and cut at each end. 1045 00:55:22,000 --> 00:55:24,480 Well, this is the fastest-moving thing in the factory, this is. 1046 00:55:24,480 --> 00:55:25,840 It is, yeah. 1047 00:55:27,280 --> 00:55:29,400 My wrapped little beauties 1048 00:55:29,400 --> 00:55:32,960 channel, nine at a time, into a slotted conveyor. 1049 00:55:34,960 --> 00:55:37,920 It's almost as if they're loading up a gun belt. 1050 00:55:37,920 --> 00:55:39,960 That's what we call our turbo train. 1051 00:55:43,160 --> 00:55:48,600 A synchronised robot arm with nine suction cups gently lifts the bars 1052 00:55:48,600 --> 00:55:52,040 and places them in threes on another conveyor. 1053 00:55:54,520 --> 00:56:00,600 It takes just seven minutes to wrap and box my 1,440 bars. 1054 00:56:08,720 --> 00:56:11,720 I see lots of packing, but I still think it's my favourite bit, 1055 00:56:11,720 --> 00:56:13,360 cos everything happens so quickly. 1056 00:56:13,360 --> 00:56:16,680 It's great to watch, innit? It is. It's fantastic. Thank you. 1057 00:56:16,680 --> 00:56:19,840 You're very welcome. I had a lovely, lovely time. 1058 00:56:19,840 --> 00:56:22,520 I've had so much fun. It's been great. Thank you for your help. 1059 00:56:24,160 --> 00:56:25,800 At the end of the line, 1060 00:56:25,800 --> 00:56:31,280 my boxed-up batch joins 5,760 other bars on pallets 1061 00:56:31,280 --> 00:56:34,680 and the whole pile is wrapped in cellophane. 1062 00:56:36,400 --> 00:56:39,000 The pallets are driven from the production area 1063 00:56:39,000 --> 00:56:42,080 100 metres down the road to distribution. 1064 00:56:44,400 --> 00:56:49,360 After just four hours of sorting, roasting, mixing and cooling, 1065 00:56:49,360 --> 00:56:50,960 our cereal bars are ready 1066 00:56:50,960 --> 00:56:54,040 to be set free in the world. 1067 00:56:54,040 --> 00:56:58,640 Company co-founder Praveen Vijn is overseeing the operation. 1068 00:57:01,320 --> 00:57:02,760 Praveen. 1069 00:57:02,760 --> 00:57:04,960 Hello, my friend. How are you? Good. 1070 00:57:04,960 --> 00:57:08,360 Listen, my batch. 1,440 bars. Yeah. 1071 00:57:08,360 --> 00:57:10,280 There's more than that on there, surely? 1072 00:57:10,280 --> 00:57:14,080 Got 115,000 on that vehicle today. Is there really? There is, yeah. 1073 00:57:14,080 --> 00:57:16,960 And how many of these trucks leave the factory every day? 1074 00:57:16,960 --> 00:57:18,800 About five to ten go out every day. 1075 00:57:18,800 --> 00:57:21,840 So how many bars leave the factory every week? 1.9 million. 1076 00:57:21,840 --> 00:57:23,880 Serious amount of bars. It's quite a bit. 1077 00:57:23,880 --> 00:57:26,720 Where's the furthest you go? One is in Tahiti. 1078 00:57:26,720 --> 00:57:28,960 And also we have this beautiful little post office 1079 00:57:28,960 --> 00:57:32,240 in northern Norway. It's just inside the Arctic Circle. 1080 00:57:32,240 --> 00:57:35,880 So these little bars from Essex basically go all over the world? 1081 00:57:35,880 --> 00:57:37,280 From Halstead to the world. 1082 00:57:40,240 --> 00:57:45,640 37 countries across the globe take delivery of these bars. 1083 00:57:45,640 --> 00:57:47,840 But their biggest fans are in the UK, 1084 00:57:47,840 --> 00:57:49,880 where Londoners eat the most. 1085 00:57:53,080 --> 00:57:55,800 Well, this isn't one of the biggest factories I've ever visited, 1086 00:57:55,800 --> 00:57:58,320 that's for sure, but it is one of the friendliest. 1087 00:58:00,280 --> 00:58:02,920 What surprised me is a lot of the ingredients 1088 00:58:02,920 --> 00:58:05,120 are added to the bar by hand, 1089 00:58:05,120 --> 00:58:07,520 and I can clearly see them through the wrapper. 1090 00:58:11,840 --> 00:58:13,840 But, most of all, do you know what? 1091 00:58:13,840 --> 00:58:15,800 I've had a lot of fun.