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Every self-respecting packed lunch
has one of these - a yogurt -

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and we Brits love 'em,

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eating a whopping 500,000 tonnes
of the stuff every year.

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That's a massive yogurt
shopping bill of £1.4 billion.

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Whether you like natural or Greek,
fruity or fat-free...

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..you can find them all here.

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In a factory that produces nearly
2,500 tonnes of yogurt

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every single week.

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Come on, you beauty!

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I'm Gregg Wallace.

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Oh!
LAUGHTER

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I'm not very good, am I?

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And, tonight, I'm getting sucked
into yogurt-making,

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meeting the cows that get it
moo-ving!

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They are really scary and huge.

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And helping the humans
who keep it sweet.

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How much fruit do you go through
a day?

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11 tonnes of fruit a day.

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Mate, there's not that much fruit
in the world!

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I'm Cherry Healey...

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Whoa-ho!

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..and I'm down on the farm,
where we're harvesting

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enough blackcurrants...

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..to make a year's supply of yogurt.

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And dreams come true
for historian Ruth Goodman...

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I'd love to have a go -
I'll be honest.

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..as she takes the wheel
of a British classic...

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Woo!

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..to reveal the history of
the electric milk float.

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She's a robust little thing,
isn't she?

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Woo!
RUTH LAUGHS

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One million yogurt pots will leave
this factory every 24 hours.

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And we're going to reveal
just how they do it.

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Welcome to Inside The Factory.

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This is the Yeo Valley yogurt
factory in rural Somerset.

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Every year, they churn out
125,000 tonnes of yogurt -

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that's enough to fill 60
Olympic-size swimming pools.

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The site produces 94 different types
of yogurt.

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Tonight, I'll be learning how they
make one of their best sellers -

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the organic fruity flavours
multipack,

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made up of raspberry,
peach, strawberry

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and blackcurrant-flavoured yogurts.

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But, first, I'm taking a short
stroll to meet the crack team

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of heavyweights who get
yogurt production started.

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COWS MOO

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A herd of organic Friesian cows.

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Gabby? Hello.

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Looking after them on the factory's
very own farm is Gabby Coles.

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Rather her than me!

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This isn't my usual factory setting,
I have to say.

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But I get it, right?

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Yogurt - we need milk,
so we need cows.

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And that's it, right?
It's about the milk.

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Not quite. It all starts from
the grass

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and that starts from the soil.

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If you see what we've got here,
so we've got some clover layers,

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some rye grass, and we also have
some herbal layers mixed in.

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So these are all organic cows,
what we have here,

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so they've got to have
at least 60% grass to be organic

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and also we don't use
any fertilisers or pesticides

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or anything like that.

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So, basically, the better
the quality the grass,

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the better quality milk.

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Before we think about the milk,
we think about the grass,

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and, before that, we think about
the soil. Exactly, exactly.

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Any chance I can see these
being milked?

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In fact, is it anywhere near milking
time? It is.

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All we've got to do is get
these in first

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and then I'll show you how to
milk them.

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They're a bit scary, to be honest.

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You milk them.
I'll... I'll stand and watch.

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I'm sure I'll get you involved.
No, no, no.

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Show me where, show me where.

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Yogurt production started
on the farm back in the mid '70s,

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with just 35 cows.

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Things have changed
a bit since then

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and the herd is now 240-strong.

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What do they do in the evenings?

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Obviously there's
not cow telly to watch, is there?

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They don't watch the Evening Moos!

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The herd produces 6,000 litres
of milk a day,

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that sounds like a lot,
but, incredibly,

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it's less than 2% of
the yogurt factory's daily intake,

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with the rest coming from
a local co-op of organic farms.

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Come on.

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Milking these bulky beasts
is no tiny undertaking -

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especially for a city boy like me.

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They are really scary and huge.

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Are they supposed to be this big?

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Is that a sign of there's loads
of milk in there...?

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Full of milk, yeah.

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I'm getting the hang of
this cow lark.

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As they come into
the milking parlour,

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electronic tags on their necks
identify each cow.

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The computer then calculates
how much high-energy feed

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to give each one based
on their milk yield.

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And while they munch away happily,

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Gabby and I get busy
down the business end.

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So I've got to wipe the cows' teats?
Yeah.

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Am I likely to get a kick
in the face? Um...

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Have you had a kick in the face?

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I've been close to it.
SHE LAUGHS

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This is getting better and better,
this!

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Cleaning the teats with antiseptic
wipes gets rid of poo and dirt.

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It also replicates the sucking
action of a calf

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and stimulates the milk.

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Oh, this one's stamping its foot!

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Now, it either doesn't like me
or it wants to dance.

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Do you recognise
the back of the cows?

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Yeah, I pretty much know them
from the back end.

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So, if one came up to you in
a field and said hello,

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you wouldn't recognise it,

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but if it backed into you,
you would?

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I mean, I'd know it more
from its back end,

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but a lot of them
I still know from their face.

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Now we've got to put the units on.

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Now...
HE SIGHS, SHE LAUGHS

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The units, or clusters, attach to
the cows' udders

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and extract milk
using a gentle vacuum.

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Well, that's what you're supposed
to do with them.

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Automated milking usually takes
just six minutes per cow.

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Are you ready? Yeah.

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If I don't come out of here,
I want to be buried in Kent.

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OK, got you.

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But that doesn't include the time
it takes to get the clusters on.

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Oh!

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Do you feel the vacuum taking it on?
So... Yeah.

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Oh, she's moving, she's moving.

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Listen, it's hard enough as it is!

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Come on!

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So, I'm proud of myself there.
Look at that. Look!

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I'm really pleased I did that.

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I come from an inner city area,

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I normally get nervous
when I run out of concrete.

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I found that very scary.

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But I did it, right?
You did it.

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The clusters are finally on,
the milk is flowing

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and production of
our yogurt has begun.

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That's the happiest cow along
this line. Is it?

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Oh, yeah. Gentle, I am. See?

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There! Look at that.

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Our milk is piped, filtered
and cooled

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from the cow's body temperature
of 38.5C

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to a chilly three degrees.

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Right, so these are ready to go now.

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Big old lumps, aren't they?
Look at them.

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It's stored in a 16,000-litre
bulk tank

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before being piped into
a refrigerated truck

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and driven to the yogurt factory
a handy ten minutes up the road.

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We've been drinking good old cow's
milk for thousands of years.

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However, these days, plant-based
milk drinks are getting

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more and more popular,

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but can they ever really replace
dairy in our daily cuppa?

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Cherry's been finding out.

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It's coffee o'clock.

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I can't wait for my first sip
in the morning

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and it's got to have lots of milk.

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But lately, when we go to order
a coffee,

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we are confronted with
an array of options.

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Please, can I try
an oat cappuccino?

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Of course, no problem.

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Six in ten of us have tried
plant-based milk substitutes

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in our coffee shop drinks.

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But with so many alternatives
on the market,

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how do we know which is the right
one to use?

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And which will work best
in my coffee?

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Helping me put them to the test
is food scientist Dr Stu Farrimond.

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Hi, Dr Stu! Cherry, great to
see you. I see you came prepared.

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Talk me through my options.

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You have coconut, oat, rice,

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soya, almond,
but there's plenty more.

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So, how do we even get milk
if there is no cow?

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It's not actually milk.

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These are actually juices.

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All you do, basically, is you get
the grain, the nut,

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or whatever it is, and you soak it
or you boil it and you squeeze it.

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So much like you get an orange
to make orange juice,

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you squeeze it, and that juice that
comes out,

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that is your milk substitute.

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Cow's milk works well in coffee
because the proteins in it bind

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with the coffee's tannins,
making it less bitter.

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Plant-based alternatives come
with added ingredients like calcium

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to mimic the original,

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but can they really cut it
in my coffee?

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We're putting the top five
sellers to the test.

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First up, soy.

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Ew...! My cow's milk never curdles
like this.

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That looks really unappealing.

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What is going on in there?

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As strange as it might sound,
the protein of the soy is cooking

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in the acid of the coffee,

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causing them to bundle up
and float to the surface.

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So soy, in fact, is not
the perfect milk alternative.

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That soy isn't for your coffee,

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but we've got one here
that has added calcium.

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The calcium protects those proteins
from being cooked by the acid.

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So, will the added calcium regulate
the acidity

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and stop this soy product
from curdling?

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I have a lovely,
milky smooth coffee.

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No curdling. Lovely.

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It tastes quite nutty.

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It definitely doesn't taste
like milk. Mm.

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Next up, oat.

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It has a porridge-y tone to it...
Mm.

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..probably cos it's oats.

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Well, interestingly, oat and coffee
share a lot of flavour compounds,

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so, naturally, oat and coffee
go together very well.

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I do think it's a good team.

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So, oat is a contender.

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How will rice do?

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It doesn't taste bad.

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It almost has no flavour whatsoever.
Very neutral.

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It's weird having rice in my coffee,
but, you know, I'll go with it.

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Finally, we have almond and coconut.

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SHE COUGHS

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Both really strong flavours that,
for me, overpowered the coffee.

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I think my favourite was the oat.

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Even though it did have
a really distinct oaty flavour,

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I thought it was delicious.

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So, oat for coffee.

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But for those of us committed to
a dairy-free diet,

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which milk alternative copes best
with cooking?

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We're challenging them with

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a traditional
Yorkshire pudding recipe.

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Quick, quick, quick, quick.

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OK.

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Protein in regular milk gives
the batter strength and structure

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as the Yorkies puff up.

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Let's see if the others
will rise to the challenge.

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Yowzers! Wow, they're good.

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Never seen Yorkshire puddings
like that before, have you?

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That's an alien Yorkshire pudding.

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All right, so we have the rice,
the soya,

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the almond, the coconut,

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the milk and the oat.

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I think the whole milk one is best.
Yes, definitely.

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The almond there,
that's sort of erupted.

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This one here - the soy - isn't bad.
That's...

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I think that's pretty good.
..probably the next second best.

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I'd buy that, I'd buy that.

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The soy made a better-looking pud
than the other milk alternatives,

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but why?

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So, soy is the only one that has
anything like approaching

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the protein that you have in the
milk.

245
00:11:54,240 --> 00:11:57,640
Why is the protein so crucial
for the rise?

246
00:11:57,640 --> 00:12:01,440
As it rises, it's the protein that
catches the bubbles of steam,

247
00:12:01,440 --> 00:12:04,000
so it lifts up and you get
the lovely finish

248
00:12:04,000 --> 00:12:06,400
and, without it,
you end up with a flat pud.

249
00:12:07,600 --> 00:12:09,920
Mm!

250
00:12:09,920 --> 00:12:12,600
That's a good Yorkie.
Mm! Lovely rise.

251
00:12:12,600 --> 00:12:13,760
Crackin'!

252
00:12:13,760 --> 00:12:16,240
So, soy is the baker's friend,

253
00:12:16,240 --> 00:12:19,880
but sweeter nut and rice milks
are better for desserts.

254
00:12:19,880 --> 00:12:23,520
However, nut flavours can
overpower savoury dishes,

255
00:12:23,520 --> 00:12:27,000
so neutral-tasting oat
is probably best for them.

256
00:12:27,000 --> 00:12:31,480
Today has been really interesting...
And tasty. And tast... Very tasty.

257
00:12:31,480 --> 00:12:33,320
..because not one size fits all.

258
00:12:33,320 --> 00:12:35,840
The thing to bear in mind, Cherry,
is we're still at the stage

259
00:12:35,840 --> 00:12:38,160
where we're trying to find something
that's going to be

260
00:12:38,160 --> 00:12:39,800
an absolute replacement for milk,

261
00:12:39,800 --> 00:12:42,240
but none of these are,
as we've discovered today.

262
00:12:42,240 --> 00:12:44,840
So maybe, in the future,
we'll be able to appreciate

263
00:12:44,840 --> 00:12:47,320
that each is an individual
ingredient in their own right.

264
00:12:49,960 --> 00:12:53,680
Let's face it, finding a direct
substitute for cow's milk

265
00:12:53,680 --> 00:12:56,800
was never going to be easy.

266
00:12:56,800 --> 00:12:59,240
But if you do want to try
the alternatives,

267
00:12:59,240 --> 00:13:01,040
you might want to invest

268
00:13:01,040 --> 00:13:02,440
in a bigger fridge.

269
00:13:03,680 --> 00:13:05,120
COW MOOS

270
00:13:07,440 --> 00:13:11,720
Four hours into production,
all 240 cows are milked

271
00:13:11,720 --> 00:13:16,560
and our tanker has made the
short trip from farm to factory.

272
00:13:16,560 --> 00:13:20,440
So, with hair net on, I'm heading to
the milk intake area

273
00:13:20,440 --> 00:13:23,360
to meet supply manager Adam Fry.

274
00:13:23,360 --> 00:13:25,480
Adam, this is my milk.

275
00:13:25,480 --> 00:13:28,120
I want you to take
special care of this, OK?

276
00:13:28,120 --> 00:13:29,360
Of course.

277
00:13:29,360 --> 00:13:30,760
How much milk is on here?

278
00:13:30,760 --> 00:13:33,360
So there's 28,000 litres
on this tanker. Wow!

279
00:13:33,360 --> 00:13:35,480
That's a serious amount of milk,
right?

280
00:13:35,480 --> 00:13:38,640
To keep yogurt production
moving 24/7,

281
00:13:38,640 --> 00:13:42,800
12 of these monster tankers
deliver organic milk every day

282
00:13:42,800 --> 00:13:47,680
from the factory's own farm nearby
and others within 20 miles.

283
00:13:47,680 --> 00:13:50,800
Then it's stored
in these giant silos.

284
00:13:50,800 --> 00:13:53,520
All these silos are full of milk,
right? Yes.

285
00:13:53,520 --> 00:13:55,680
So how many litres of milk
do you have here?

286
00:13:55,680 --> 00:13:58,200
On site we hold around about
350,000 litres of milk.

287
00:13:58,200 --> 00:13:59,640
How long would that last you?

288
00:13:59,640 --> 00:14:02,280
If you didn't get another delivery
in, how long would that last you?

289
00:14:02,280 --> 00:14:03,880
That's a day's worth of production.

290
00:14:03,880 --> 00:14:06,720
You go through 350,000 litres
a day? Every day.

291
00:14:06,720 --> 00:14:08,160
Give me an idea. What is that?

292
00:14:08,160 --> 00:14:10,600
That would be around about
600 bathtubs in a silo.

293
00:14:10,600 --> 00:14:13,440
Bathtubs? 600 bathtubs in each silo?

294
00:14:13,440 --> 00:14:15,280
And you've got six of them?
Six of them.

295
00:14:15,280 --> 00:14:17,240
I think even Cleopatra
would be happy with that.

296
00:14:17,240 --> 00:14:18,600
I think she would.

297
00:14:18,600 --> 00:14:24,160
Each of the silos stores enough milk
to make 154,000 pots of yogurt.

298
00:14:24,160 --> 00:14:26,440
Put all six silos together

299
00:14:26,440 --> 00:14:30,760
and we've got milk to make
more than 900,000 pots.

300
00:14:30,760 --> 00:14:34,040
But before a drop of my milk
can leave the tanker,

301
00:14:34,040 --> 00:14:36,920
Adam has to take
a sample for testing.

302
00:14:36,920 --> 00:14:40,120
I find that incredibly comforting,
that you still use a bucket.

303
00:14:40,120 --> 00:14:42,080
So, we take the sample.

304
00:14:42,080 --> 00:14:45,200
Mate, that's going to be a very
small bowl of breakfast cereal.

305
00:14:45,200 --> 00:14:48,160
I don't think that one would keep
you happy in the mornings.

306
00:14:48,160 --> 00:14:49,480
Time for a test, right?

307
00:14:49,480 --> 00:14:51,640
Time for a test.
These are ready now.

308
00:14:51,640 --> 00:14:55,280
As we stand by, my milk whizzes up
to the factory's lab,

309
00:14:55,280 --> 00:14:58,800
which deals with up to
250 samples every day.

310
00:15:00,560 --> 00:15:02,640
What exactly are we testing for?

311
00:15:02,640 --> 00:15:05,240
So, we're testing now for
the fat content of the milk

312
00:15:05,240 --> 00:15:08,280
to ensure that it's
between 3.6% and 4.6%.

313
00:15:08,280 --> 00:15:11,040
That gives us the average amount
of fat that you'd see in cow's milk.

314
00:15:11,040 --> 00:15:13,480
If it was outside of that,
there would be something wrong.

315
00:15:13,480 --> 00:15:16,400
Ah, I see! That's the average
fat in milk anyway, right?

316
00:15:16,400 --> 00:15:18,840
That's the average fat that
you would see in milk. Ah, OK!

317
00:15:22,120 --> 00:15:24,120
When will I know
whether my milk's OK?

318
00:15:24,120 --> 00:15:26,600
That process takes five minutes
to complete.

319
00:15:26,600 --> 00:15:28,840
What if he's gone off to have
a cup of tea and a biscuit?

320
00:15:28,840 --> 00:15:31,640
With 4.6% milk,
I think I'd have coffee.

321
00:15:33,480 --> 00:15:36,440
But if the milk fails the test,

322
00:15:36,440 --> 00:15:41,600
the entire 28,000-litre tanker
will be sent back to the farm.

323
00:15:41,600 --> 00:15:44,640
Results are zapped from the lab
to the loading bay.

324
00:15:44,640 --> 00:15:46,280
And there you can see it on
the screen.

325
00:15:46,280 --> 00:15:48,520
It's just come through now
that it's ready to go. Fine.

326
00:15:48,520 --> 00:15:50,840
So it's passed all of our tests.
We can unload, right?

327
00:15:50,840 --> 00:15:52,680
Yep, we're ready to unload
The milk's good!

328
00:15:52,680 --> 00:15:55,600
I knew it anyway. Milk's good!
You can unload.

329
00:15:55,600 --> 00:15:59,160
Pumping at a rate of 250kg
per minute,

330
00:15:59,160 --> 00:16:02,360
my milk is then moved to
the raw milk blend area...

331
00:16:04,120 --> 00:16:07,800
..where it is mixed
with cream and skimmed milk powder.

332
00:16:09,000 --> 00:16:10,840
Are we finally making yogurt?

333
00:16:10,840 --> 00:16:12,520
So, this is us making yogurt.

334
00:16:12,520 --> 00:16:14,680
How much are we making?
How much is a batch?

335
00:16:14,680 --> 00:16:16,520
So, we're making
a 25,000-litre batch.

336
00:16:16,520 --> 00:16:20,520
25,000 litres...? 25,000 litres.

337
00:16:20,520 --> 00:16:22,240
How many pots is that, please?

338
00:16:22,240 --> 00:16:25,280
That would make around about
150,000 pots.

339
00:16:25,280 --> 00:16:27,920
Right. So, what are we doing here?

340
00:16:27,920 --> 00:16:30,240
So, here we would be adding dry
ingredients,

341
00:16:30,240 --> 00:16:33,360
such as protein powders or,
in this case, organic sugar.

342
00:16:33,360 --> 00:16:36,840
The sugar comes
in hefty 25-kilo bags.

343
00:16:36,840 --> 00:16:38,480
And you've got to tip them
in there?

344
00:16:38,480 --> 00:16:39,880
Yeah, they've got to go into here.

345
00:16:39,880 --> 00:16:41,320
Sounds easy enough!

346
00:16:42,360 --> 00:16:45,800
The sugar's sucked through a funnel
and a spaghetti junction of pipes

347
00:16:45,800 --> 00:16:47,440
to the mixing tank,

348
00:16:47,440 --> 00:16:49,840
where it's blended with
the liquid ingredients.

349
00:16:49,840 --> 00:16:51,280
ENGINE WHIRS
Oi-oi!

350
00:16:51,280 --> 00:16:53,080
It's like a rocket's going
to take off!

351
00:16:53,080 --> 00:16:54,520
Oh...!

352
00:16:54,520 --> 00:16:57,200
How many bags are we putting
in here?

353
00:16:57,200 --> 00:17:01,640
So there'll be 36 bags in total
going into a 25,000-litre vat.

354
00:17:01,640 --> 00:17:05,640
Sugar makes up just 3%
of the yogurt's ingredients,

355
00:17:05,640 --> 00:17:09,400
but it's still
a backbreaking 900 kilos.

356
00:17:09,400 --> 00:17:12,240
This isn't an easy job after all.

357
00:17:12,240 --> 00:17:13,720
Oh, it's going down now.

358
00:17:13,720 --> 00:17:17,680
# Clap your hands
if you're working too hard... #

359
00:17:17,680 --> 00:17:20,560
The sugar's got to go through at
a steady pace.

360
00:17:20,560 --> 00:17:22,600
If the flow slows, air will get in

361
00:17:22,600 --> 00:17:25,000
and the yogurt recipe will be
ruined.

362
00:17:25,000 --> 00:17:26,400
It won't rip!

363
00:17:26,400 --> 00:17:28,160
It won't rip and it's emptying!

364
00:17:28,160 --> 00:17:29,920
Quick, you get in there!

365
00:17:29,920 --> 00:17:31,880
Adam to the rescue.

366
00:17:31,880 --> 00:17:34,080
You rip, I'll put the bags on.

367
00:17:34,080 --> 00:17:35,640
GREGG GROANS

368
00:17:35,640 --> 00:17:36,760
Crikey!

369
00:17:36,760 --> 00:17:39,240
That's 25 kilos... 25 kilos.

370
00:17:39,240 --> 00:17:41,880
That's the same weight
as a bag of spuds.

371
00:17:41,880 --> 00:17:44,680
Making yogurt shouldn't be
this physical, should it?

372
00:17:46,520 --> 00:17:48,000
I'm sugared!

373
00:17:49,760 --> 00:17:51,600
But there's no time to rest.

374
00:17:51,600 --> 00:17:53,840
It's bucket time!

375
00:17:53,840 --> 00:17:57,880
Before my newly blended mix of milk,
cream, skimmed milk powder and sugar

376
00:17:57,880 --> 00:18:01,920
can move on,
there's another trip to the lab.

377
00:18:01,920 --> 00:18:03,760
So that's ready now to be
off and tested

378
00:18:03,760 --> 00:18:05,200
to make sure it hits specifications.

379
00:18:05,200 --> 00:18:06,440
You lead on.

380
00:18:06,440 --> 00:18:07,680
What about your bucket?!

381
00:18:07,680 --> 00:18:08,840
I'll get it.

382
00:18:12,320 --> 00:18:15,160
OK, how many tests will these guys
be doing?

383
00:18:15,160 --> 00:18:18,000
So, these guys will be doing
three tests in total.

384
00:18:18,000 --> 00:18:20,840
They will test this for
its fat content, its total solids

385
00:18:20,840 --> 00:18:22,640
and for its pH.

386
00:18:22,640 --> 00:18:26,320
That means my milk mix has got
to have the right creaminess,

387
00:18:26,320 --> 00:18:29,040
thickness and acidity
to make yogurt.

388
00:18:30,400 --> 00:18:31,840
How long is it going to be?

389
00:18:31,840 --> 00:18:33,440
It's going to be around about
ten minutes.

390
00:18:33,440 --> 00:18:35,480
I've got a deck of cards.

391
00:18:35,480 --> 00:18:37,840
Let's hope the odds are stacked
in our favour

392
00:18:37,840 --> 00:18:39,760
because if any of the tests fail,

393
00:18:39,760 --> 00:18:44,080
it's game over for
my 25,000-litre batch.

394
00:18:44,080 --> 00:18:47,840
Have you finished? How'd we get on?
A pass. Yeah!

395
00:18:47,840 --> 00:18:50,680
My milk mix has come up trumps,

396
00:18:50,680 --> 00:18:53,720
so it's piped across to
milk base processing

397
00:18:53,720 --> 00:18:56,120
for more high-tech treatment.

398
00:18:56,120 --> 00:18:59,000
First, it's homogenised by
distributing

399
00:18:59,000 --> 00:19:02,760
the milk's fat content evenly
to make it silky smooth.

400
00:19:04,480 --> 00:19:09,240
The homogeniser forces the liquid
through tiny three-millimetre holes

401
00:19:09,240 --> 00:19:14,480
at high pressure, smashing the fat
globules into minuscule particles,

402
00:19:14,480 --> 00:19:17,680
mixing them through
the milk for a glossy finish.

403
00:19:19,360 --> 00:19:21,200
Then it's on to pasteurisation -

404
00:19:21,200 --> 00:19:25,240
the process of killing off
harmful bacteria through heating.

405
00:19:25,240 --> 00:19:30,800
Flowing through the pasteuriser
at a rate of 15,000 litres per hour,

406
00:19:30,800 --> 00:19:35,200
the milk blend is warmed to 98C
for around three minutes,

407
00:19:35,200 --> 00:19:40,280
leaving me with a food-safe mix
that's ready to be made into yogurt.

408
00:19:40,280 --> 00:19:44,680
Now, when I was a kid, I remember
our milk appearing as if by magic

409
00:19:44,680 --> 00:19:46,040
at the crack of dawn.

410
00:19:46,040 --> 00:19:48,800
We never heard the milkman arriving.

411
00:19:48,800 --> 00:19:52,200
Ruth's been looking back at the
ground-breaking electric vehicles

412
00:19:52,200 --> 00:19:55,440
they used to get
the job done very quietly.

413
00:19:58,160 --> 00:20:00,400
The whir of an electric motor,

414
00:20:00,400 --> 00:20:03,360
the glow of headlights on
a crisp morning

415
00:20:03,360 --> 00:20:06,000
and the clink of glass bottles.

416
00:20:09,640 --> 00:20:13,040
50 years ago, such sights and sounds
were synonymous

417
00:20:13,040 --> 00:20:16,240
with the daily delivery of milk
to your front door.

418
00:20:16,240 --> 00:20:19,080
BOTTLES CLINK

419
00:20:19,080 --> 00:20:22,200
And the fleet of milk floats
delivering predawn pints

420
00:20:22,200 --> 00:20:23,680
became a British icon.

421
00:20:25,200 --> 00:20:28,200
To find out their origins,
I'm meeting Denis Chick

422
00:20:28,200 --> 00:20:30,840
at the Wythall Transport Museum.

423
00:20:32,200 --> 00:20:34,200
So, when did the electric milk float
start?

424
00:20:34,200 --> 00:20:35,680
1920s. OK.

425
00:20:35,680 --> 00:20:38,760
Up until then, horses were pulling
the milk floats.

426
00:20:38,760 --> 00:20:41,840
The problem was the horses
were becoming not very practical.

427
00:20:41,840 --> 00:20:44,560
Milk sales went up, loads went up,

428
00:20:44,560 --> 00:20:47,400
horses started to complain
about the loads

429
00:20:47,400 --> 00:20:49,720
and an alternative was needed,

430
00:20:49,720 --> 00:20:51,960
so the electric float was developed.

431
00:20:51,960 --> 00:20:54,200
And when was this? 1923.

432
00:20:56,040 --> 00:20:59,080
But this wasn't
the first electric vehicle.

433
00:20:59,080 --> 00:21:00,560
As early as the 1880s,

434
00:21:00,560 --> 00:21:03,560
electric cars were powered
by rechargeable batteries.

435
00:21:05,240 --> 00:21:07,000
But, by the turn of the century,

436
00:21:07,000 --> 00:21:09,280
they were being overtaken
by petrol cars,

437
00:21:09,280 --> 00:21:11,720
which were faster
and travelled further.

438
00:21:13,720 --> 00:21:16,960
But the sturdy little
electric milk float endured

439
00:21:19,400 --> 00:21:22,440
Why on Earth did the milk industry
not go with petrol?

440
00:21:22,440 --> 00:21:25,240
Petrol was expensive to run, petrol
or diesel engines

441
00:21:25,240 --> 00:21:28,320
needed maintaining, and it's cheap
to run with electricity,

442
00:21:28,320 --> 00:21:31,320
cheap to maintain and did exactly
the job it was needed to do in a day

443
00:21:31,320 --> 00:21:32,920
on a full charge of electricity.

444
00:21:32,920 --> 00:21:34,640
And then you charge it again
overnight,

445
00:21:34,640 --> 00:21:36,680
and off you go the next day
for another day's work.

446
00:21:38,040 --> 00:21:40,440
And, of course, the electric floats
were quiet

447
00:21:40,440 --> 00:21:42,880
for those predawn deliveries.

448
00:21:42,880 --> 00:21:45,880
As the British thirst for pints
on the doorstep grew,

449
00:21:45,880 --> 00:21:48,720
the '50s and '60s saw
a milk float boom.

450
00:21:48,720 --> 00:21:52,920
And by the 1970s, there were 50,000
on our roads -

451
00:21:52,920 --> 00:21:57,600
the most extensive use of electric
vehicles in the world.

452
00:21:57,600 --> 00:22:00,640
And I have a very personal link
to them.

453
00:22:00,640 --> 00:22:05,080
Do you know, way back in 1925, this
is what my grandfather was doing?

454
00:22:05,080 --> 00:22:07,960
Aged 14, he was in charge
of milk deliveries.

455
00:22:07,960 --> 00:22:10,800
Really? 14?! 14 years old...
Oh, my goodness.

456
00:22:10,800 --> 00:22:12,920
..on the public road,
blind in one eye.

457
00:22:12,920 --> 00:22:15,800
As well?! Yeah!
I'm glad I wasn't around!

458
00:22:15,800 --> 00:22:17,560
I'd love to have a go -
I'll be honest.

459
00:22:17,560 --> 00:22:20,160
You can't drive this one. This is
a museum exhibit, I'm afraid.

460
00:22:20,160 --> 00:22:22,160
But there are still a few
on the road. Oh, really?

461
00:22:22,160 --> 00:22:25,640
You should seek one out.
Yes, it's great fun. Hmm...

462
00:22:25,640 --> 00:22:28,240
I think that this could be
in my blood.

463
00:22:28,240 --> 00:22:33,640
MUSIC: Peer Gynt Suite No.1 Op.46:
Morning Mood by Edvard Grieg

464
00:22:33,640 --> 00:22:37,000
So I've set my alarm for 5am
to meet Paul Cartmell,

465
00:22:37,000 --> 00:22:39,240
who's been a milkman for 40 years,

466
00:22:39,240 --> 00:22:43,920
but his electric milk float has been
in the business even longer.

467
00:22:43,920 --> 00:22:48,080
Built in 1975, it's still delivering
every day.

468
00:22:49,360 --> 00:22:53,920
Hi, Paul! Hiya! Good morning!
How long have you been up?

469
00:22:53,920 --> 00:22:55,320
Since two o'clock.

470
00:22:55,320 --> 00:22:57,320
Since two?! Yeah. Good grief!

471
00:22:57,320 --> 00:22:58,840
I don't want to get in your way,

472
00:22:58,840 --> 00:23:00,600
but if there's anything
I can do to help...

473
00:23:00,600 --> 00:23:03,600
You can drive it, if you want.
Really? Yeah. Can I really? Yeah.

474
00:23:03,600 --> 00:23:05,160
I'll show you how to get it going.

475
00:23:05,160 --> 00:23:06,560
What a thrill!

476
00:23:06,560 --> 00:23:10,520
Finally behind the wheel
of a working electric milk float.

477
00:23:10,520 --> 00:23:13,080
Let's hope me and the bottles make
it through in one piece!

478
00:23:14,480 --> 00:23:18,040
The only thing you need to know
is you've got two pedals. Yeah.

479
00:23:18,040 --> 00:23:20,880
The small one is to go...
And that one's to stop? It is.

480
00:23:20,880 --> 00:23:23,640
Take your handbrake off... OK.
..and press that pedal.

481
00:23:23,640 --> 00:23:25,960
Oh, God. Woo!

482
00:23:27,520 --> 00:23:29,400
Where am I going?

483
00:23:29,400 --> 00:23:32,280
MUSIC: Riding On My Bike
by Madness

484
00:23:34,760 --> 00:23:38,120
Woo! She's a robust little thing,
isn't she?

485
00:23:38,120 --> 00:23:40,720
It might not go fast, but, woo!

486
00:23:40,720 --> 00:23:42,600
SHE LAUGHS

487
00:23:42,600 --> 00:23:44,600
A bit more, a bit more,
a bit more...

488
00:23:48,920 --> 00:23:52,360
God, this is a fun little thing
to drive!

489
00:23:52,360 --> 00:23:55,840
Electric floats like this delivered
90% of our milk

490
00:23:55,840 --> 00:23:57,840
right up until the 1980s,

491
00:23:57,840 --> 00:24:00,080
when cheaper supermarket prices

492
00:24:00,080 --> 00:24:03,680
almost killed off
the morning milk round.

493
00:24:03,680 --> 00:24:08,400
These days, just 3% of the UK's milk
arrives on our doorsteps.

494
00:24:08,400 --> 00:24:11,360
But, in recent years, the service
has been thrown a lifeline

495
00:24:11,360 --> 00:24:14,280
from an unlikely rescuer.

496
00:24:14,280 --> 00:24:16,520
It's been a steady decline
for a long time

497
00:24:16,520 --> 00:24:18,560
and then we saw a nice increase

498
00:24:18,560 --> 00:24:21,160
when they did the
David Attenborough programme

499
00:24:21,160 --> 00:24:23,000
about plastics in the sea.

500
00:24:24,680 --> 00:24:28,240
After Blue Planet highlighted
plastic pollution in our oceans

501
00:24:28,240 --> 00:24:35,200
in 2017, Paul's milk supplier
saw orders increase by 30%.

502
00:24:35,200 --> 00:24:38,880
A lot of people
who were using plastics

503
00:24:38,880 --> 00:24:41,720
then chose to go on glass,
which is good.

504
00:24:41,720 --> 00:24:43,760
I know it costs a little bit more,

505
00:24:43,760 --> 00:24:48,000
but every single bottle gets used
over and over and over again.

506
00:24:49,240 --> 00:24:52,000
In fact, the empty bottles
that Paul returns to the dairy

507
00:24:52,000 --> 00:24:56,160
are reused an incredible
30 times before they're recycled.

508
00:24:58,400 --> 00:25:01,640
Here we are,
well into the 21st century,

509
00:25:01,640 --> 00:25:06,920
using a 45-year-old milk float and
delivering milk in glass bottles.

510
00:25:06,920 --> 00:25:11,680
And yet, suddenly, this outdated
method is looking rather

511
00:25:11,680 --> 00:25:14,520
like a sustainable solution
for the future.

512
00:25:21,120 --> 00:25:25,200
Back in Somerset, it's been eight
hours since cow-milking commenced.

513
00:25:26,800 --> 00:25:31,080
My 25,000 litres of milk blend
has been mixed,

514
00:25:31,080 --> 00:25:33,840
tested, homogenised and pasteurised.

515
00:25:35,160 --> 00:25:37,800
So it's pumped to
the incubation hall,

516
00:25:37,800 --> 00:25:41,800
where I'm meeting the factory's
technical scientist - Chris Coggins.

517
00:25:41,800 --> 00:25:44,280
Chris. All right?
Good to meet you.

518
00:25:44,280 --> 00:25:45,920
What are you doing in that freezer

519
00:25:45,920 --> 00:25:47,600
and what has it got
to do with my yogurt?

520
00:25:47,600 --> 00:25:49,360
I'm getting the cultures out.

521
00:25:49,360 --> 00:25:51,000
What are cultures?

522
00:25:51,000 --> 00:25:53,120
Cultures are a collection
of bacteria

523
00:25:53,120 --> 00:25:56,080
that have been specially selected
to make yogurt.

524
00:25:56,080 --> 00:25:59,320
I can't help but think that bacteria
might be a bad thing.

525
00:25:59,320 --> 00:26:03,040
No, you have good bacteria
and you have bad bacteria.

526
00:26:03,040 --> 00:26:05,600
It's good bacteria,
not bad bacteria.

527
00:26:05,600 --> 00:26:11,280
So what part does bacteria
play in our yogurt-making?

528
00:26:11,280 --> 00:26:16,800
The bacteria will live off of the
natural milk sugars, lactose,

529
00:26:16,800 --> 00:26:20,680
it will break that lactose
down into lactic acid,

530
00:26:20,680 --> 00:26:22,680
which is what makes yogurt acidic,

531
00:26:22,680 --> 00:26:25,720
and it will also give the yogurt
thickness as well.

532
00:26:25,720 --> 00:26:28,120
Can I see them?
Yes, of course you can.

533
00:26:29,760 --> 00:26:32,760
Oh! Not what I expected.

534
00:26:32,760 --> 00:26:36,040
They actually look like
little frozen sweets. Yeah.

535
00:26:36,040 --> 00:26:40,520
That much there is probably
getting on for a billion bacteria.

536
00:26:40,520 --> 00:26:42,800
That's ridiculous, isn't it?

537
00:26:42,800 --> 00:26:45,440
And how many of these do
we need for our batch of yogurt?

538
00:26:45,440 --> 00:26:47,280
We need seven bags of this.

539
00:26:47,280 --> 00:26:50,080
So billions and billions
and billions of bacteria? Yeah.

540
00:26:50,080 --> 00:26:51,320
Amazing.

541
00:26:51,320 --> 00:26:54,400
My bacteria may be
the microscopic magicians

542
00:26:54,400 --> 00:26:56,920
that turn my milk mixture to
yogurt...

543
00:26:56,920 --> 00:26:59,120
Come on, then. Oh, he's just put
them in a shopping bag.

544
00:26:59,120 --> 00:27:01,080
It's like Bacteria R US.

545
00:27:01,080 --> 00:27:03,720
..but if you want to make yogurt
on a massive scale,

546
00:27:03,720 --> 00:27:06,080
you need some serious hardware.

547
00:27:09,200 --> 00:27:11,240
This is the incubation hall.

548
00:27:11,240 --> 00:27:14,480
It contains 12 giant
stainless steel tanks.

549
00:27:16,120 --> 00:27:20,040
They've got a combined capacity of
a quarter of a million litres

550
00:27:20,040 --> 00:27:24,840
and are the colossal cooking pots
where 90 million litres of milk

551
00:27:24,840 --> 00:27:28,040
turns to yogurt every year.

552
00:27:28,040 --> 00:27:29,720
So, this is our tank.

553
00:27:29,720 --> 00:27:31,160
Whoa!

554
00:27:31,160 --> 00:27:33,120
It's a little bit warm at the
moment.

555
00:27:33,120 --> 00:27:34,120
Yeah, it's hot.

556
00:27:35,760 --> 00:27:38,040
This is your milk base
going in here now.

557
00:27:38,040 --> 00:27:41,080
Right, and now I have
to empty these into there?

558
00:27:41,080 --> 00:27:44,800
So now we've got to add the bacteria
so that we can produce yogurt.

559
00:27:44,800 --> 00:27:46,920
This is getting very interesting.

560
00:27:46,920 --> 00:27:49,200
Would you let me do it?
I don't see why not.

561
00:27:49,200 --> 00:27:51,840
Have they actually got names,
these different bacteria? Yes.

562
00:27:51,840 --> 00:27:54,320
There are three different
bacteria in there -

563
00:27:54,320 --> 00:27:56,120
streptococcus thermophilus...

564
00:27:56,120 --> 00:27:58,520
GREGG LAUGHS

565
00:27:58,520 --> 00:28:01,560
..lactobacillus acidophilus... No!

566
00:28:01,560 --> 00:28:04,240
..and bifidobacterium.

567
00:28:04,240 --> 00:28:08,000
My tongue-twisting bacteria occur
naturally on plants,

568
00:28:08,000 --> 00:28:09,560
but, for yogurt production,

569
00:28:09,560 --> 00:28:12,600
they're grown under controlled
conditions in a lab

570
00:28:12,600 --> 00:28:15,000
and it takes just 3.5 kilos of them

571
00:28:15,000 --> 00:28:18,640
to turn my 25,000-litre milk mix
to yogurt.

572
00:28:20,080 --> 00:28:23,560
Do you know roughly how many
bacteria I'm putting in here?

573
00:28:23,560 --> 00:28:27,920
Yes. Every gram will be
about 100 million.

574
00:28:27,920 --> 00:28:30,640
This is beyond my comprehension.

575
00:28:30,640 --> 00:28:33,440
This tank is kept at 42 degrees C

576
00:28:33,440 --> 00:28:36,840
to encourage the bacteria
to multiply.

577
00:28:36,840 --> 00:28:39,760
Go on, kids! Have a whale of a time!

578
00:28:39,760 --> 00:28:41,000
Bye!

579
00:28:41,000 --> 00:28:42,400
They seem happy to me.

580
00:28:43,960 --> 00:28:46,880
The bacteria doubles every 30
minutes

581
00:28:46,880 --> 00:28:51,760
until there are 100 billion friendly
bacteria for every gram of yogurt.

582
00:28:51,760 --> 00:28:54,360
To check it's working,
after six and a half hours,

583
00:28:54,360 --> 00:28:58,080
a sample is taken
for lab test number three.

584
00:28:58,080 --> 00:29:01,520
Now, that looks like yogurt.
That looks good.

585
00:29:01,520 --> 00:29:04,160
Right, how do I test this now?

586
00:29:04,160 --> 00:29:05,560
Right, take the probes

587
00:29:05,560 --> 00:29:07,720
and now place them in the yogurt...

588
00:29:07,720 --> 00:29:10,440
..and that will tell you
what the pH is.

589
00:29:10,440 --> 00:29:14,520
Our pH is currently below 4.6,

590
00:29:14,520 --> 00:29:16,480
so it's now safe to eat.

591
00:29:16,480 --> 00:29:19,120
Right, OK. So now what do we do?

592
00:29:19,120 --> 00:29:22,440
All we've got to do
is initiate the cooling.

593
00:29:22,440 --> 00:29:25,040
There you are. Away it goes.

594
00:29:25,040 --> 00:29:27,880
The tank is cooled
for another four hours

595
00:29:27,880 --> 00:29:31,280
to slow the action
of that busy bacteria.

596
00:29:31,280 --> 00:29:36,880
And while my mix cools, it's on to
the next vital ingredient - fruit!

597
00:29:36,880 --> 00:29:39,360
My multipack yogurts need
strawberries, raspberries,

598
00:29:39,360 --> 00:29:43,160
peaches and apricots,
which all come from Europe.

599
00:29:43,160 --> 00:29:47,160
But the blackcurrants are harvested
right here, in the UK.

600
00:29:47,160 --> 00:29:49,240
Cherry went to give them a hand.

601
00:29:51,480 --> 00:29:53,960
I've been up since the crack of dawn

602
00:29:53,960 --> 00:29:55,760
and I'm here, in South
Herefordshire,

603
00:29:55,760 --> 00:30:00,440
to help out with the biggest
blackcurrant harvest in the UK.

604
00:30:00,440 --> 00:30:04,120
In a very short window
of about six weeks,

605
00:30:04,120 --> 00:30:08,920
an entire year's supply of
these little juicy currants

606
00:30:08,920 --> 00:30:11,440
need to be picked and stored,

607
00:30:11,440 --> 00:30:13,720
so I should probably...get moving!

608
00:30:15,080 --> 00:30:18,480
Overseeing the harvest
is farm owner Anthony Snell.

609
00:30:19,520 --> 00:30:21,360
Hello, Anthony! Hi, Cherry.

610
00:30:21,360 --> 00:30:23,200
Nice to meet you. Nice to meet you.

611
00:30:23,200 --> 00:30:25,840
What a beautiful field!

612
00:30:25,840 --> 00:30:29,160
The bushes are absolutely dense with
blackcurrants

613
00:30:29,160 --> 00:30:32,280
and they do look very big
and juicy and beautiful.

614
00:30:32,280 --> 00:30:34,240
So, these are ready to be harvested?

615
00:30:34,240 --> 00:30:38,360
Yes, and, as soon as they're ready,
we check the natural sugar levels

616
00:30:38,360 --> 00:30:39,840
and we inspect them daily

617
00:30:39,840 --> 00:30:42,680
to make sure that there's
no green or red fruits.

618
00:30:42,680 --> 00:30:44,880
When do you start your day,
is it pretty early?

619
00:30:44,880 --> 00:30:47,960
We wait until the bushes are nice
and dry in the morning,

620
00:30:47,960 --> 00:30:50,680
otherwise, if you start harvesting
very early in the morning

621
00:30:50,680 --> 00:30:53,920
when they're wet, you get slugs
and snails up the bushes.

622
00:30:53,920 --> 00:30:55,280
So it's thanks to the snails

623
00:30:55,280 --> 00:30:57,480
that you don't have to get up
at the crack of dawn.

624
00:30:57,480 --> 00:31:00,480
That's right. Thanks, snails!
That's convenient.

625
00:31:00,480 --> 00:31:02,480
I wish someone had told me that!

626
00:31:03,600 --> 00:31:06,440
With only one week left
to finish this entire harvest,

627
00:31:06,440 --> 00:31:09,280
Anthony's son James needs
an experienced driver

628
00:31:09,280 --> 00:31:10,840
for one of the harvesters...

629
00:31:11,920 --> 00:31:14,160
..but he's got me instead.

630
00:31:14,160 --> 00:31:16,400
Hello, James. Oh, hi, Cherry.

631
00:31:16,400 --> 00:31:18,120
Can I come aboard? Yes, of course.

632
00:31:18,120 --> 00:31:22,480
Wow! This is a big machine.

633
00:31:22,480 --> 00:31:25,480
The farm has
almost 300 acres of blackcurrants -

634
00:31:25,480 --> 00:31:28,600
around half of that is devoted
to organic cultivation.

635
00:31:28,600 --> 00:31:30,320
ENGINE STARTS
Whoa-ho!

636
00:31:30,320 --> 00:31:33,280
There we are. That was really fun.

637
00:31:33,280 --> 00:31:38,560
Each of the two harvesters gathers
in 15 to 25 tonnes of fruit a day.

638
00:31:38,560 --> 00:31:41,600
Is that right? Yeah, that's good,
that's good.

639
00:31:41,600 --> 00:31:45,440
Inside the harvester, the berries
are shaken off the branches,

640
00:31:45,440 --> 00:31:47,880
conveyor belts catch
the falling fruit

641
00:31:47,880 --> 00:31:52,360
and take them to a team of sorters
boxing up the berries at the back.

642
00:31:52,360 --> 00:31:53,720
There's so much to do.

643
00:31:53,720 --> 00:31:57,640
I mean, I'm so conscious
that, if I lose concentration,

644
00:31:57,640 --> 00:32:01,000
I could wipe out the whole row of
bushes.

645
00:32:01,000 --> 00:32:04,280
In this short six-week harvest,
James and the team will collect

646
00:32:04,280 --> 00:32:07,920
a massive 650 tonnes
of blackcurrants -

647
00:32:07,920 --> 00:32:10,680
the same weight as
half a dozen blue whales.

648
00:32:11,880 --> 00:32:15,320
And this year, almost 10% of that
is going to yogurt production

649
00:32:15,320 --> 00:32:17,120
at our factory.

650
00:32:17,120 --> 00:32:20,400
So, reluctantly, I need to let
the professionals get back to work.

651
00:32:20,400 --> 00:32:23,040
I'll give you your captain's hat
back. Thank you very much.

652
00:32:23,040 --> 00:32:25,320
Good luck with the rest
of the harvest. Thank you.

653
00:32:25,320 --> 00:32:27,960
Woo! That was fun.

654
00:32:27,960 --> 00:32:30,720
Just glad to be contributing
to the nation's yogurts.

655
00:32:32,760 --> 00:32:34,440
But I'm not finished yet.

656
00:32:34,440 --> 00:32:37,440
To maintain freshness,
the blackcurrants get from field

657
00:32:37,440 --> 00:32:40,520
to freezer in less than an hour.

658
00:32:40,520 --> 00:32:44,160
And this massive unit stores
a year's supply.

659
00:32:44,160 --> 00:32:47,800
I mean, it is absolutely freezing
in here!

660
00:32:47,800 --> 00:32:51,640
I'm wearing my ski things and
I'm still really cold.

661
00:32:51,640 --> 00:32:53,480
What's the temperature in here?

662
00:32:53,480 --> 00:32:56,160
So, it's a minimum of minus 18.

663
00:32:56,160 --> 00:32:57,960
Are these all blackcurrants?
They are.

664
00:32:57,960 --> 00:33:00,760
That's incredible.

665
00:33:00,760 --> 00:33:02,840
How long do they stay in
this freezer

666
00:33:02,840 --> 00:33:04,800
before they go to make yogurts?

667
00:33:04,800 --> 00:33:07,160
We just supply
when the customer demands them.

668
00:33:07,160 --> 00:33:09,920
So you actually hold on to them
until they need them?

669
00:33:09,920 --> 00:33:12,400
Yeah. That's the beauty of
a freezing process like this,

670
00:33:12,400 --> 00:33:15,440
is that you can store products
for up to two years,

671
00:33:15,440 --> 00:33:18,680
just exactly the same quality
as when they're fresh.

672
00:33:18,680 --> 00:33:21,120
You can have British fruit
all year round.

673
00:33:23,040 --> 00:33:28,240
This freezer holds 300 tonnes
of fruit on 1,000 pallets

674
00:33:28,240 --> 00:33:30,800
in subarctic conditions.

675
00:33:30,800 --> 00:33:34,320
This is what it feels like to be
a fish finger in my freezer. Yeah.

676
00:33:34,320 --> 00:33:37,160
Just hours since they were shaken
from their bushes,

677
00:33:37,160 --> 00:33:41,080
my blackcurrants are now sorted,
boxed and frozen solid.

678
00:33:42,240 --> 00:33:44,280
And now they'll wait patiently
in the freezer

679
00:33:44,280 --> 00:33:47,000
until they're ready
to be sent off to Gregg.

680
00:33:52,440 --> 00:33:56,040
Back at the factory, I'm nine hours
into production.

681
00:33:56,040 --> 00:33:58,080
My milk blend has been mixed
with bacteria

682
00:33:58,080 --> 00:34:01,960
to make a 25,000-litre batch
of plain yogurt.

683
00:34:01,960 --> 00:34:04,960
And while it cools in
a giant incubation tank,

684
00:34:04,960 --> 00:34:07,560
I'm heading 42 miles down the road

685
00:34:07,560 --> 00:34:10,560
to the processing plant
at Crewkerne,

686
00:34:10,560 --> 00:34:14,720
where they make the four fruity
conserves for my yogurt.

687
00:34:14,720 --> 00:34:18,800
A whopping 20 tonnes of Cherry's
frozen blackcurrants

688
00:34:18,800 --> 00:34:20,440
have just arrived.

689
00:34:20,440 --> 00:34:23,120
Team manager Matt Pullen
takes charge of them from here.

690
00:34:23,120 --> 00:34:24,880
Matt, right? Yep. All right, Gregg?

691
00:34:24,880 --> 00:34:27,560
And these are our Cherry's currants?
Blackcurrants, yep.

692
00:34:27,560 --> 00:34:30,320
And we're going to be sorting
them on the sorting table today.

693
00:34:30,320 --> 00:34:32,440
Can I have a go? Yeah, of course you
can. Come on round.

694
00:34:34,280 --> 00:34:37,360
What do I do? So, you need to bang
the box on the table -

695
00:34:37,360 --> 00:34:40,640
that will break up any lumps of
frozen blackcurrants inside the box.

696
00:34:40,640 --> 00:34:43,400
Oh, this is great fun!
Can I have another go? Yeah.

697
00:34:43,400 --> 00:34:45,000
There you go.

698
00:34:45,000 --> 00:34:47,880
OK. So, now remove the tape.

699
00:34:47,880 --> 00:34:50,640
Whoa! They're lovely.

700
00:34:50,640 --> 00:34:52,280
Ooh, look at them.

701
00:34:52,280 --> 00:34:53,960
It feels like cold marbles.

702
00:34:55,920 --> 00:34:58,640
Most of the stalks are removed back
at the farm,

703
00:34:58,640 --> 00:35:01,440
but an eight-metre-long
conveyor carries the blackcurrants

704
00:35:01,440 --> 00:35:03,080
through one final check.

705
00:35:04,920 --> 00:35:07,120
Have you ever been pulled
along by a strong currant?

706
00:35:08,560 --> 00:35:13,440
My river of blackcurrants flows
at a rate of 600 kilos an hour,

707
00:35:13,440 --> 00:35:16,360
so you need eyes out on stalks
for this job.

708
00:35:16,360 --> 00:35:17,920
Right, what are we looking for?

709
00:35:17,920 --> 00:35:20,360
So we're looking for anything
that shouldn't be there.

710
00:35:20,360 --> 00:35:23,280
Bits of stalk, bits of leaf,
misformed blackcurrants.

711
00:35:23,280 --> 00:35:24,840
So that? Yep.

712
00:35:24,840 --> 00:35:27,880
You wouldn't want that in your
yogurt, would you? A shrivelled one.

713
00:35:27,880 --> 00:35:30,640
Because they're frozen, does that
help them keep their shape?

714
00:35:30,640 --> 00:35:32,520
It will help them throughout
our process.

715
00:35:32,520 --> 00:35:34,760
We try to retain as much
of the fruit ID as we possibly can.

716
00:35:34,760 --> 00:35:37,760
Fruit ID? Yeah. Fruit ID?

717
00:35:37,760 --> 00:35:40,880
And does the fruit have to carry its
ID with it wherever it goes

718
00:35:40,880 --> 00:35:43,520
in case it's stopped by
a yogurt policeman?

719
00:35:46,600 --> 00:35:50,840
Identities intact, the blackcurrants
line up for a final check

720
00:35:50,840 --> 00:35:53,000
at the metal detector.

721
00:35:53,000 --> 00:35:55,920
Then we head upstairs to turn
some of Cherry's berries

722
00:35:55,920 --> 00:35:58,760
into fruity conserve for my yogurt.

723
00:35:58,760 --> 00:36:00,040
Coming through!

724
00:36:00,040 --> 00:36:01,480
Got your currants!

725
00:36:02,720 --> 00:36:05,440
This cooking area has
six giant vessels

726
00:36:05,440 --> 00:36:09,080
that churn out 20 tonnes
of fruit conserve every day.

727
00:36:10,840 --> 00:36:14,400
We're making the one-tonne
blackcurrant batch.

728
00:36:14,400 --> 00:36:18,800
First, 238 kilos of water
is added to the pot...

729
00:36:21,520 --> 00:36:24,360
..before Cherry's frozen
blackcurrants are tipped in

730
00:36:24,360 --> 00:36:26,960
by the 100-kilo bucket-load.

731
00:36:26,960 --> 00:36:28,760
How many of those have
we got to get in there?

732
00:36:28,760 --> 00:36:32,280
Another four. Five in total.
500 kilos of fruit?

733
00:36:32,280 --> 00:36:34,320
How much fruit do you go through
a day?

734
00:36:34,320 --> 00:36:38,280
11 tonnes of fruit a day.
11 ton...?! Every day?!

735
00:36:38,280 --> 00:36:41,160
Mate, there's not that much fruit
in the world!

736
00:36:41,160 --> 00:36:45,640
That's the blackcurrant equivalent
of seven family cars.

737
00:36:45,640 --> 00:36:47,960
But even on this massive scale,
nothing's wasted.

738
00:36:47,960 --> 00:36:51,000
What are you going to do with that,
get the ice off your windscreen?

739
00:36:51,000 --> 00:36:53,400
Scraping stray currants into a vat?

740
00:36:53,400 --> 00:36:56,160
That can't be BERRY hard!

741
00:36:56,160 --> 00:36:58,880
I think I've got some blackcurrants
up my sleeve!

742
00:36:58,880 --> 00:37:02,160
Outsmarted by frozen fruit -
that's got to be a first.

743
00:37:02,160 --> 00:37:04,680
THEY LAUGH

744
00:37:06,200 --> 00:37:09,400
Even I can't go too far wrong with
the next ingredient...

745
00:37:09,400 --> 00:37:10,600
Wahey!

746
00:37:10,600 --> 00:37:12,480
..sugar!

747
00:37:12,480 --> 00:37:13,920
Sweet!

748
00:37:13,920 --> 00:37:18,960
Into the frozen fruit and water
goes 142 kilos of cane sugar

749
00:37:18,960 --> 00:37:21,240
to sweeten the blackcurrants.

750
00:37:21,240 --> 00:37:24,240
# Sweet dreams are made
of these... #

751
00:37:24,240 --> 00:37:26,720
It's like an alpine snow scene!

752
00:37:26,720 --> 00:37:28,680
You could ski on that...

753
00:37:28,680 --> 00:37:29,960
..if I could ski.

754
00:37:32,080 --> 00:37:35,640
The vessel is heated and the sugary
fruit is cooked with starch,

755
00:37:35,640 --> 00:37:38,640
lemon juice and blackcurrant
flavouring.

756
00:37:38,640 --> 00:37:41,960
It is just like making jam at home,
but on a massive scale.

757
00:37:41,960 --> 00:37:45,400
An hour later, my conserve
is complete.

758
00:37:45,400 --> 00:37:47,200
Right, let's have a go.

759
00:37:51,440 --> 00:37:53,880
All the flavour of the fruit
is there, but that is sharp.

760
00:37:53,880 --> 00:37:56,960
You're going to need some yogurt
to take the sharpness away.

761
00:37:56,960 --> 00:38:00,120
The conserve is pumped directly
from cooking vessel

762
00:38:00,120 --> 00:38:02,880
to a vertical form fill sealer.

763
00:38:02,880 --> 00:38:07,000
Yep, that's a bagging machine
to you and me.

764
00:38:07,000 --> 00:38:09,840
The 9kg blackcurrant bags
are air-cooled

765
00:38:09,840 --> 00:38:13,240
and loaded onto trucks
bound for the yogurt factory.

766
00:38:14,920 --> 00:38:18,080
Of course, conserve is just a posh
word for jam

767
00:38:18,080 --> 00:38:21,600
and, in my opinion, the best
accompaniment to jam

768
00:38:21,600 --> 00:38:26,200
is clotted cream, dolloped on top of
a freshly baked scone,

769
00:38:26,200 --> 00:38:30,280
but where and when did this famous
combo first come together?

770
00:38:30,280 --> 00:38:33,720
Ruth has dared to take
on this contentious debate.

771
00:38:36,200 --> 00:38:40,440
On July 1st 1904,
a six-carriage locomotive left

772
00:38:40,440 --> 00:38:43,360
London Paddington en route
to Devon and Cornwall,

773
00:38:43,360 --> 00:38:45,880
marketed as a high-speed rail link

774
00:38:45,880 --> 00:38:49,320
from the capital to
the West Country.

775
00:38:49,320 --> 00:38:52,840
This new route became known
as the Cornish Riviera Express.

776
00:38:52,840 --> 00:38:58,040
and suddenly the southwest became
an even more popular destination.

777
00:38:59,360 --> 00:39:04,400
Visitor numbers boomed, and a part
of that holiday experience

778
00:39:04,400 --> 00:39:07,680
in the West Country was
this culinary indulgence -

779
00:39:07,680 --> 00:39:09,200
the cream tea.

780
00:39:13,160 --> 00:39:16,520
Now, there have been very
many mysteries investigated

781
00:39:16,520 --> 00:39:18,760
and solved on steam trains,

782
00:39:18,760 --> 00:39:23,080
but there's one mystery that's still
hotly debated round here.

783
00:39:24,120 --> 00:39:26,880
Where did the cream tea come
from in the first place?

784
00:39:28,160 --> 00:39:30,600
I'm meeting food historian
Dr Annie Gray

785
00:39:30,600 --> 00:39:34,640
to find some answers
to this culinary controversy.

786
00:39:34,640 --> 00:39:37,360
Annie! Hello! Hello!

787
00:39:37,360 --> 00:39:39,760
Well, this all looks
very scone-like to me.

788
00:39:39,760 --> 00:39:42,200
Well, over there you've got scones,
it's true.

789
00:39:42,200 --> 00:39:45,280
But over here, what I'm doing
is I'm starting off with a thing

790
00:39:45,280 --> 00:39:48,040
called a split, which is a bit more
like a bun

791
00:39:48,040 --> 00:39:50,320
with a sort of enriched dough -
almost like a brioche -

792
00:39:50,320 --> 00:39:52,160
which is really what people
would've had

793
00:39:52,160 --> 00:39:54,160
with their cream
and their jam and their tea

794
00:39:54,160 --> 00:39:56,560
before the scone came along.

795
00:39:56,560 --> 00:40:00,080
So, it was the soft and sweet yeast
bun known as the split

796
00:40:00,080 --> 00:40:03,440
that had been a speciality
in the southwest for generations.

797
00:40:04,720 --> 00:40:08,880
But the new trains that brought
the tourists also brought new food,

798
00:40:08,880 --> 00:40:12,040
including the scone, from Scotland.

799
00:40:13,680 --> 00:40:16,760
Scones, which was originally
poverty food, started to spread out

800
00:40:16,760 --> 00:40:20,840
from Scotland, just because you've
got now the means to transport that.

801
00:40:20,840 --> 00:40:22,840
And people are
travelling everywhere -

802
00:40:22,840 --> 00:40:25,440
servants are travelling,
aristocrats are travelling,

803
00:40:25,440 --> 00:40:27,080
middle classes are travelling.

804
00:40:27,080 --> 00:40:29,600
Everyone is everywhere, going,
"What's this? This is great.

805
00:40:29,600 --> 00:40:32,480
"I'm having some of that back
in my own county."

806
00:40:32,480 --> 00:40:35,520
By the middle of the 20th century,
the scone had become

807
00:40:35,520 --> 00:40:37,920
a firm favourite in
the West Country's growing number

808
00:40:37,920 --> 00:40:40,120
of cafes and tea rooms

809
00:40:40,120 --> 00:40:43,320
and the split fell out of favour.

810
00:40:43,320 --> 00:40:46,400
So, why did a Scottish thing
take over?

811
00:40:46,400 --> 00:40:49,440
So, what's happening is you've got
a lot of people wanting something

812
00:40:49,440 --> 00:40:52,160
in the afternoon which needs
to be cheap, cheerful

813
00:40:52,160 --> 00:40:53,360
and easy to prepare,

814
00:40:53,360 --> 00:40:56,640
and the scone just lends itself
so much better to that.

815
00:40:56,640 --> 00:41:00,960
So, what is the major difference,
then, between a split and a scone?

816
00:41:00,960 --> 00:41:03,200
Essentially, this has yeast
in it as its rising agent,

817
00:41:03,200 --> 00:41:05,200
so it's going to take a couple
of hours to rise.

818
00:41:05,200 --> 00:41:07,400
You bake it like a bread,
it eats like a bread.

819
00:41:07,400 --> 00:41:10,800
A scone has baking powder in,
it's quick, it's easy,

820
00:41:10,800 --> 00:41:13,000
it doesn't really require
any time to rise.

821
00:41:13,000 --> 00:41:14,960
You bake it - job done.

822
00:41:14,960 --> 00:41:16,480
So, this is my dough for the split.

823
00:41:16,480 --> 00:41:18,280
If I give you that...

824
00:41:18,280 --> 00:41:21,120
Ah! I knew I'd be doing something.

825
00:41:21,120 --> 00:41:24,680
So, it seems Scottish scones
became the basis of the cream tea

826
00:41:24,680 --> 00:41:26,680
purely for convenience.

827
00:41:26,680 --> 00:41:31,920
So, if we're thinking of this not
as a traditional regional dish,

828
00:41:31,920 --> 00:41:38,280
but rather as a regional solution
to commercially feeding tourists,

829
00:41:38,280 --> 00:41:40,840
it's one controversy after another,
isn't it, really?

830
00:41:40,840 --> 00:41:43,040
Yeah, and we haven't even got on
to jam and cream yet.

831
00:41:43,040 --> 00:41:44,240
Oh, dear.

832
00:41:46,520 --> 00:41:48,960
While the simple and convenient
scones go in the oven

833
00:41:48,960 --> 00:41:51,000
and the splits prove before baking,

834
00:41:51,000 --> 00:41:54,720
there's just enough time
to get one thing straight.

835
00:41:54,720 --> 00:41:56,880
Tell me that at least
the clotted cream

836
00:41:56,880 --> 00:41:59,120
is actually a West Country thing.

837
00:41:59,120 --> 00:42:02,760
Clouted cream, as it was known,
was made across Britain.

838
00:42:02,760 --> 00:42:04,680
But because the milk was
so good here -

839
00:42:04,680 --> 00:42:06,200
the cream was particularly good -

840
00:42:06,200 --> 00:42:09,240
it does have a definite claim
to be a proper West Country product.

841
00:42:09,240 --> 00:42:11,120
So, it's not an exclusive product?

842
00:42:11,120 --> 00:42:13,720
It's merely that West Country
clotted cream

843
00:42:13,720 --> 00:42:16,200
is some of the best clotted cream.
Yes.

844
00:42:16,200 --> 00:42:18,040
So, that's the cream cleared up.

845
00:42:18,040 --> 00:42:21,480
But, as we sit down to our freshly
baked scones and splits,

846
00:42:21,480 --> 00:42:24,080
we hit the ultimate
cream tea conundrum.

847
00:42:25,320 --> 00:42:27,360
And, of course, we're back
to controversy.

848
00:42:27,360 --> 00:42:29,440
Is it the jam first,
or the cream first?

849
00:42:29,440 --> 00:42:32,000
Turns out we've gone
for the two opposite options.

850
00:42:32,000 --> 00:42:33,920
I've gone jam first,
you've gone cream first.

851
00:42:33,920 --> 00:42:35,920
Which of us is Devon
and which of us is Cornwall?

852
00:42:35,920 --> 00:42:37,480
Am I Devon? I think I might be
Devon.

853
00:42:37,480 --> 00:42:39,680
I think it all tastes the same
when you do this.

854
00:42:42,560 --> 00:42:45,560
But what about the split
versus scone debate?

855
00:42:45,560 --> 00:42:48,360
Is a split worth the extra weight?

856
00:42:49,880 --> 00:42:52,120
The split's interesting.
I like it.

857
00:42:52,120 --> 00:42:54,080
It's not so rich as a scone.

858
00:42:54,080 --> 00:42:56,800
The texture of a split,
to me, is better.

859
00:42:56,800 --> 00:42:59,240
But if you've got to feed
the ravening hordes

860
00:42:59,240 --> 00:43:02,280
at the drop of a hat,
scones all the way. Yep. Or sc-ones.

861
00:43:02,280 --> 00:43:06,920
And enjoy arguing about whether
it's Scottish, Devon or Cornwall!

862
00:43:06,920 --> 00:43:10,000
Or some sort of grand mix
of the three!

863
00:43:10,000 --> 00:43:12,640
THEY LAUGH

864
00:43:12,640 --> 00:43:15,280
But wherever it comes from,
one thing is certain -

865
00:43:15,280 --> 00:43:19,360
the cream tea is a very tasty
Great British invention.

866
00:43:19,360 --> 00:43:23,200
And with a glorious view
like this, you can't beat it.

867
00:43:30,080 --> 00:43:32,720
I'm back at my West Country
yogurt factory

868
00:43:32,720 --> 00:43:36,200
and the blackcurrant conserve
has arrived, too.

869
00:43:36,200 --> 00:43:40,400
18 hours into production and
my bacteria-rich plain yogurt mix

870
00:43:40,400 --> 00:43:42,720
is cooling and thickening.

871
00:43:42,720 --> 00:43:44,600
So, back in the incubation hall,

872
00:43:44,600 --> 00:43:47,840
I'm catching up
with supply manager Adam.

873
00:43:47,840 --> 00:43:50,240
Good to see you again.
Hello again, Gregg.

874
00:43:50,240 --> 00:43:52,800
Are we ready? We are now ready.

875
00:43:52,800 --> 00:43:55,920
So, the base has now cooled down to
below 23 degrees

876
00:43:55,920 --> 00:43:57,560
and it is ready to be drawn off

877
00:43:57,560 --> 00:43:59,560
into one of the smaller
mobile vessels.

878
00:43:59,560 --> 00:44:02,200
Right. Shall we do it?
We can do it. We're ready to start.

879
00:44:02,200 --> 00:44:03,840
It's ready to go at the touch of
a button.

880
00:44:05,680 --> 00:44:09,920
As it's decanted from the towering
incubation tanks to smaller vessels,

881
00:44:09,920 --> 00:44:14,680
my 25,000 litres of yogurt passes
through a superfine filter

882
00:44:14,680 --> 00:44:17,720
with holes smaller than
a fifth of a millimetre,

883
00:44:17,720 --> 00:44:20,200
making it much smoother.

884
00:44:20,200 --> 00:44:23,480
And what you'll see here is the
final product, when it comes out,

885
00:44:23,480 --> 00:44:25,960
has a nice polished sheen
on the top of it.

886
00:44:25,960 --> 00:44:28,400
Wow. Why polished? Cos it's shiny?

887
00:44:28,400 --> 00:44:30,720
Cos it's shiny, yeah.
That's incredible.

888
00:44:30,720 --> 00:44:32,880
So the filter not only gets rid
of the lumps,

889
00:44:32,880 --> 00:44:34,680
but it makes it shiny - or polished.

890
00:44:34,680 --> 00:44:36,320
And makes it more appealing.

891
00:44:36,320 --> 00:44:39,440
Next time I open a pot of yogurt,
I'm going to tell my wife

892
00:44:39,440 --> 00:44:41,760
that this one is polished.

893
00:44:41,760 --> 00:44:47,120
The buffed-up yogurt is finally
ready for my fruity conserve.

894
00:44:47,120 --> 00:44:50,280
Now, look at them. They are a thing
of absolute beauty.

895
00:44:50,280 --> 00:44:51,360
What are we going to do?

896
00:44:51,360 --> 00:44:53,360
Are we going to put them in the pot
with the yogurt?

897
00:44:53,360 --> 00:44:56,200
They can't go straight in the tank.
First, we need to give them a bath.

898
00:44:56,200 --> 00:44:58,080
What?! Seriously? Seriously.

899
00:44:58,080 --> 00:45:00,920
So, what we have here,
we have a fruit bath

900
00:45:00,920 --> 00:45:03,680
and, in here, each of these
fruit bags go in as they are.

901
00:45:03,680 --> 00:45:05,400
They don't need to be opened.

902
00:45:05,400 --> 00:45:08,440
What we don't want is any
unfortunate bad bacteria

903
00:45:08,440 --> 00:45:10,440
to be added back into the product,

904
00:45:10,440 --> 00:45:13,480
so it's actually sterilising
the outside edge of the bag.

905
00:45:13,480 --> 00:45:16,120
So the bacteria that make it
into your yogurt

906
00:45:16,120 --> 00:45:18,720
is not inside my currants -
it may be on the bag?

907
00:45:18,720 --> 00:45:20,800
It is purely the outside of the bag.

908
00:45:20,800 --> 00:45:23,560
Do you know what? I never really
trusted that bag.

909
00:45:23,560 --> 00:45:26,840
The blackcurrant bags spend
two minutes relaxing in the bath

910
00:45:26,840 --> 00:45:30,760
before being cut open and
the fruit squeezed into the yogurt.

911
00:45:30,760 --> 00:45:33,680
Come on, you beauty, Come on.

912
00:45:33,680 --> 00:45:36,040
Ah, ah... Ah-ha-ha.

913
00:45:38,960 --> 00:45:40,920
Look at that.

914
00:45:40,920 --> 00:45:43,560
Oh...! Watch your...! Ah...!

915
00:45:43,560 --> 00:45:46,680
I've got a feeling I could end up
in a right mess here.

916
00:45:46,680 --> 00:45:48,640
HE LAUGHS

917
00:45:51,880 --> 00:45:53,840
Did you not want to put
them in the tank?

918
00:45:53,840 --> 00:45:55,880
Yeah. This is fun.

919
00:45:57,040 --> 00:45:59,960
What's the total weight of fruit
going into our yogurt?

920
00:45:59,960 --> 00:46:03,280
So, in an ideal world, 71 kilos.

921
00:46:03,280 --> 00:46:05,840
The way you were fruiting that,
around about 68.

922
00:46:07,720 --> 00:46:09,760
I'm not very good, am I?

923
00:46:09,760 --> 00:46:12,600
With just enough conserve
in my yogurt...

924
00:46:13,840 --> 00:46:17,720
..it heads off on a nifty
little forklift to blending.

925
00:46:17,720 --> 00:46:20,960
Let's see if I can give this job
its just deserts.

926
00:46:22,080 --> 00:46:25,000
So this is where you mix it?
So this is where we mix it.

927
00:46:25,000 --> 00:46:26,640
With that? With that.

928
00:46:26,640 --> 00:46:28,880
That looks like,
you know, like a stick blender

929
00:46:28,880 --> 00:46:31,720
you get at home, in the kitchen -
just an enormous one of them, right?

930
00:46:31,720 --> 00:46:32,920
Just a giant hand blender.

931
00:46:36,520 --> 00:46:37,720
Oh-ho-ho!

932
00:46:37,720 --> 00:46:41,440
So imagine you're now on
a grabber machine at the fair.

933
00:46:41,440 --> 00:46:43,520
No prize for me yet.

934
00:46:43,520 --> 00:46:45,720
It's got a mind of its own! Yep.

935
00:46:45,720 --> 00:46:47,000
Hang on, hang on, hang on.

936
00:46:47,000 --> 00:46:50,160
Come on! Come on! Ah...!

937
00:46:50,160 --> 00:46:51,520
You better do this.

938
00:46:51,520 --> 00:46:54,440
Is this a two-man job normally?
No. It is, innit?

939
00:46:54,440 --> 00:46:56,720
It's not. It is, innit? It's not.

940
00:46:56,720 --> 00:46:58,120
It so is.

941
00:46:58,120 --> 00:47:01,000
Well, someone here has mastered
these tricky mixers

942
00:47:01,000 --> 00:47:04,600
because the factory blends
a mouthwatering 120 tonnes

943
00:47:04,600 --> 00:47:06,760
of fruit yogurt every day.

944
00:47:06,760 --> 00:47:08,880
Is that done now, then?
Yeah, that's done.

945
00:47:08,880 --> 00:47:10,920
Oh, come on, let's have a look
at it. All right, OK.

946
00:47:10,920 --> 00:47:14,960
That has got a lovely pink-purple
tinge to it, hasn't it?

947
00:47:16,800 --> 00:47:19,160
Am I allowed to taste it?
You can, yes.

948
00:47:19,160 --> 00:47:21,960
Well, I mean, I've been there
through every stage of its life.

949
00:47:23,160 --> 00:47:24,480
It's got a fine nose.

950
00:47:30,000 --> 00:47:32,480
Very creamy, a little sour,

951
00:47:32,480 --> 00:47:35,240
but a big fruity hit finish,
most certainly.

952
00:47:35,240 --> 00:47:36,920
A little bit of sharpness as well.

953
00:47:39,760 --> 00:47:41,880
Have I got a bit on my nose?
You have.

954
00:47:41,880 --> 00:47:44,000
It's all right - it matches
my apron.

955
00:47:44,000 --> 00:47:45,440
Very true.

956
00:47:48,080 --> 00:47:51,520
Despite my messy dabbling,
my blackcurrant yogurt

957
00:47:51,520 --> 00:47:54,360
is miraculously ready to move on
to the filling area...

958
00:47:56,160 --> 00:47:58,440
Mags! Hey, Gregg!
Nice to meet you.

959
00:47:58,440 --> 00:48:00,080
I'm coming up to see you.

960
00:48:00,080 --> 00:48:01,680
OK.

961
00:48:01,680 --> 00:48:05,640
..where shift manager Mags Gourley
is ready to, well, manage me.

962
00:48:07,600 --> 00:48:09,240
Hi, Gregg. Hey.

963
00:48:09,240 --> 00:48:12,680
These must be our yogurt pots,
right? They are our yogurt pots.

964
00:48:12,680 --> 00:48:15,840
How many of these do you go through?

965
00:48:15,840 --> 00:48:18,760
We pack 28,800 pots an hour.

966
00:48:18,760 --> 00:48:21,400
That is seriously, seriously fast.

967
00:48:21,400 --> 00:48:23,840
This looks like something
I could master.

968
00:48:23,840 --> 00:48:25,600
GREGG LAUGHS

969
00:48:25,600 --> 00:48:27,000
Feed it in.

970
00:48:27,000 --> 00:48:28,280
Oh...!

971
00:48:28,280 --> 00:48:29,880
Or...maybe not.

972
00:48:30,960 --> 00:48:33,680
Um... Are you going to jam up
my machine, Gregg?

973
00:48:33,680 --> 00:48:36,200
Um... There you are.

974
00:48:36,200 --> 00:48:37,440
Whoa!

975
00:48:37,440 --> 00:48:41,120
This side doesn't work properly.
OK, try that side, then.

976
00:48:41,120 --> 00:48:44,880
Um... They are joined together.
They're twin pots.

977
00:48:44,880 --> 00:48:47,480
You've got to be fast!
Whoa, whoa, whoa!

978
00:48:47,480 --> 00:48:48,800
Drop them down.

979
00:48:51,040 --> 00:48:54,920
Once my stack falls into the feeder,
individual pots are released

980
00:48:54,920 --> 00:48:59,720
into a slatted conveyor
with precise, pot-shaped holes.

981
00:48:59,720 --> 00:49:04,440
A laser sensor then checks
there are containers in every slot

982
00:49:04,440 --> 00:49:06,680
before the yogurt is dispensed.

983
00:49:12,760 --> 00:49:15,680
So, you'll see the pots
being filled here.

984
00:49:15,680 --> 00:49:18,680
What's happening right now
it all the yogurts passing through

985
00:49:18,680 --> 00:49:21,920
some pipe work into a device that
we call the cock valve

986
00:49:21,920 --> 00:49:25,360
and that individually deposits
120g into each pot.

987
00:49:25,360 --> 00:49:27,800
How many of those every minute?

988
00:49:27,800 --> 00:49:30,280
Every minute? 480.

989
00:49:30,280 --> 00:49:32,720
How absolutely beautiful.

990
00:49:32,720 --> 00:49:35,560
You must, every now and again,
get a mishap

991
00:49:35,560 --> 00:49:37,960
and the whole thing is
just smothered in yogurt?

992
00:49:37,960 --> 00:49:40,400
All over. Not very often,
but it has happened.

993
00:49:40,400 --> 00:49:41,720
Has it happened? Yeah.

994
00:49:41,720 --> 00:49:44,480
And is it just, like, everywhere?
Everywhere.

995
00:49:44,480 --> 00:49:46,080
Can you give me a call when
it happens?

996
00:49:46,080 --> 00:49:47,880
Honestly, I'll make the journey.

997
00:49:47,880 --> 00:49:52,120
One pair of pots is filled
with raspberry and strawberry,

998
00:49:52,120 --> 00:49:55,840
the other with peach and apricot,
and my blackcurrant.

999
00:49:55,840 --> 00:49:59,280
Then the lids are heated sealed
at 200 C.

1000
00:50:00,600 --> 00:50:03,960
They're date coded and lifted
to a conveyor belt which separates

1001
00:50:03,960 --> 00:50:07,640
the pairs of flavours and sends
them through a metal detector,

1002
00:50:07,640 --> 00:50:09,880
and then onto the packing hall.

1003
00:50:11,480 --> 00:50:15,720
Soon all plastic pots in the UK,
like these, will be required

1004
00:50:15,720 --> 00:50:18,680
to be more environmentally friendly.

1005
00:50:18,680 --> 00:50:22,440
So, what does it take to make
ground-breaking plastic pots

1006
00:50:22,440 --> 00:50:24,240
that are better for the planet?

1007
00:50:24,240 --> 00:50:26,120
Cherry's been finding out.

1008
00:50:28,160 --> 00:50:29,920
"Widely recycled."

1009
00:50:29,920 --> 00:50:31,600
"Not yet recyclable."

1010
00:50:31,600 --> 00:50:35,240
I really do try to do my bit
when it comes to recycling.

1011
00:50:36,840 --> 00:50:38,320
Absolutely no idea.

1012
00:50:38,320 --> 00:50:41,120
But there are so
many different plastics used,

1013
00:50:41,120 --> 00:50:44,000
knowing what to recycle
and how to recycle

1014
00:50:44,000 --> 00:50:46,440
can be quite confusing.

1015
00:50:46,440 --> 00:50:50,160
It doesn't help that the rules
differ depending on where you live.

1016
00:50:50,160 --> 00:50:54,040
Currently, we recycle less than half
of the 1.5 million tonnes

1017
00:50:54,040 --> 00:50:57,200
of plastic packaging
we consume every year.

1018
00:50:57,200 --> 00:50:59,960
But, from April 2022,

1019
00:50:59,960 --> 00:51:02,480
a tax is going to be levied on
any plastic packaging

1020
00:51:02,480 --> 00:51:06,080
that contains less than
30% recycled plastic.

1021
00:51:06,080 --> 00:51:08,360
So, not only do we need to do our
bit at home,

1022
00:51:08,360 --> 00:51:11,400
but the companies who make the
packaging are also going to have

1023
00:51:11,400 --> 00:51:13,680
to do their bit
to look after the planet.

1024
00:51:13,680 --> 00:51:18,720
There is some 100%-recycled plastic
food packaging on the market,

1025
00:51:18,720 --> 00:51:22,280
but much of the rest still uses
a layer of new plastic

1026
00:51:22,280 --> 00:51:25,040
to stop the food touching
recycled material.

1027
00:51:25,040 --> 00:51:29,880
But packaging manufacturer Faerch
is making food-safe yogurt pots

1028
00:51:29,880 --> 00:51:33,160
with 100% recycled plastic.

1029
00:51:33,160 --> 00:51:35,880
Hi, Chris! Nice to meet you!

1030
00:51:35,880 --> 00:51:39,360
Site manager Chris Plant
is showing me around.

1031
00:51:39,360 --> 00:51:41,520
Chris, what have you just
had delivered?

1032
00:51:41,520 --> 00:51:47,080
So, we've just taken receipt of 27
tonnes of recyclable PET material.

1033
00:51:47,080 --> 00:51:50,680
And, essentially, what that is
is chopped up water bottles,

1034
00:51:50,680 --> 00:51:54,800
food trays that can be regenerated
and reused.

1035
00:51:54,800 --> 00:51:56,280
What does it look like?

1036
00:51:56,280 --> 00:51:58,120
Let's go and have a look. OK.

1037
00:51:59,160 --> 00:52:01,600
PET stands for...
SHE INHALES

1038
00:52:01,600 --> 00:52:04,840
..polyethylene terephthalate.

1039
00:52:04,840 --> 00:52:08,400
In layman's terms, it's a type
of recyclable plastic.

1040
00:52:08,400 --> 00:52:12,560
Gregg's containers are made
from 30% recycled PET,

1041
00:52:12,560 --> 00:52:17,440
but here they're making yogurt pots
from 100% recycled material.

1042
00:52:17,440 --> 00:52:20,520
The first step is to heat
the shredded confetti-like plastic

1043
00:52:20,520 --> 00:52:22,800
to 300 degrees until it melts.

1044
00:52:22,800 --> 00:52:25,760
Can I have a look? Yes, you can.
Just round here.

1045
00:52:28,400 --> 00:52:29,760
Oh, I've got it!

1046
00:52:29,760 --> 00:52:32,040
Oh, is that liquid? It is liquid.

1047
00:52:32,040 --> 00:52:36,520
And then, as it drops down, it goes
through a series of chilled rollers

1048
00:52:36,520 --> 00:52:40,240
which takes it from 300 degrees
down to ambient,

1049
00:52:40,240 --> 00:52:43,600
and therefore you can see the sheet
that's produced afterwards.

1050
00:52:44,720 --> 00:52:48,320
These sheets made from PET have
undergone a process

1051
00:52:48,320 --> 00:52:51,400
called super-cleaning,
where heat and pressure remove

1052
00:52:51,400 --> 00:52:53,320
any contaminating chemicals,

1053
00:52:53,320 --> 00:52:56,360
making it safe to put next to food.

1054
00:52:56,360 --> 00:53:01,720
The result is the UK's first yogurt
pot made from 100% recycled plastic.

1055
00:53:01,720 --> 00:53:04,560
So, if that is possible,
to make something that is made

1056
00:53:04,560 --> 00:53:08,200
of 100% recycled plastic,
why not make everything out of that?

1057
00:53:08,200 --> 00:53:10,240
The first point is cost,

1058
00:53:10,240 --> 00:53:12,680
so the additional processing
that needs to happen

1059
00:53:12,680 --> 00:53:14,720
takes the cost up of the material.

1060
00:53:14,720 --> 00:53:17,760
And the other key point is that
there isn't enough

1061
00:53:17,760 --> 00:53:19,960
recycled PET material out there

1062
00:53:19,960 --> 00:53:24,920
to allow us to move all of
the products over to 100% recycled.

1063
00:53:24,920 --> 00:53:27,960
Chris, when I'm at home
and I'm tired and I'm thinking,

1064
00:53:27,960 --> 00:53:29,960
"Can I be bothered to wash this
out?"

1065
00:53:29,960 --> 00:53:32,800
I will think, "Chris needs this
PET."

1066
00:53:32,800 --> 00:53:34,360
Thank you very much.

1067
00:53:35,640 --> 00:53:37,240
Every little helps.

1068
00:53:37,240 --> 00:53:40,080
Back on the production line,
our recycled plastic is ready

1069
00:53:40,080 --> 00:53:43,160
to be turned into yogurt pots.

1070
00:53:43,160 --> 00:53:45,760
So the material is being threaded
through,

1071
00:53:45,760 --> 00:53:49,480
it's transported through a heating
zone, top and bottom,

1072
00:53:49,480 --> 00:53:52,880
to the point where we're forming
the product.

1073
00:53:52,880 --> 00:53:54,760
How many yogurt pots does it
create in one hour?

1074
00:53:54,760 --> 00:53:57,800
Roughly, about 21,000 pots,

1075
00:53:57,800 --> 00:54:01,920
which'll give you
about 400,000 in 24 hours.

1076
00:54:01,920 --> 00:54:03,680
Do we really eat that much yogurt?

1077
00:54:03,680 --> 00:54:05,520
We must do!

1078
00:54:05,520 --> 00:54:10,120
And that's for just one variety
of yogurt made in Gregg's factory!

1079
00:54:10,120 --> 00:54:11,800
Once these pots are formed,

1080
00:54:11,800 --> 00:54:15,440
they're slipped into
a cardboard sleeve.

1081
00:54:15,440 --> 00:54:17,680
Very smart. Look at that.

1082
00:54:17,680 --> 00:54:22,880
Is that the first-ever yogurt pot
to be 100% from recycled materials?

1083
00:54:22,880 --> 00:54:24,200
Yes, it is.

1084
00:54:24,200 --> 00:54:27,840
This combination is the first
to market.

1085
00:54:27,840 --> 00:54:31,880
So...that yogurt pot
is a bit of a trailblazer.

1086
00:54:33,760 --> 00:54:36,640
Soon, Gregg's multipack
will be switching to this kind

1087
00:54:36,640 --> 00:54:39,080
of recycled material, too.

1088
00:54:39,080 --> 00:54:43,800
There's still a long way to go with
plastic food packaging, but...

1089
00:54:43,800 --> 00:54:48,360
..this 100%-recycled
and recyclable pot

1090
00:54:48,360 --> 00:54:50,600
is a step in the right direction,

1091
00:54:50,600 --> 00:54:55,080
and I hope that one day, somehow,
this little fella will end up

1092
00:54:55,080 --> 00:54:57,920
back here, ready to be reborn.

1093
00:55:05,840 --> 00:55:08,160
21 hours into production.

1094
00:55:08,160 --> 00:55:11,160
At the factory, my four fruity
flavours are potted,

1095
00:55:11,160 --> 00:55:14,360
sealed, dated and screened,

1096
00:55:14,360 --> 00:55:17,840
and they're on their way
to the cavernous packing hall.

1097
00:55:17,840 --> 00:55:20,040
Mags is showing me around.

1098
00:55:20,040 --> 00:55:22,680
OK, Gregg, so we've just
been through there,

1099
00:55:22,680 --> 00:55:25,320
we've seen our pots filled,
and they're now coming down here,

1100
00:55:25,320 --> 00:55:28,040
where they're going to be separated
into two lanes.

1101
00:55:28,040 --> 00:55:30,560
One lane carries raspberry
and strawberry,

1102
00:55:30,560 --> 00:55:33,160
the other blackcurrant
and peach and apricot.

1103
00:55:33,160 --> 00:55:36,560
The pots are jostled into position
by white screw-like fixtures

1104
00:55:36,560 --> 00:55:38,520
called worms.

1105
00:55:38,520 --> 00:55:42,200
I can honestly watch this stuff
for hours. I love it.

1106
00:55:42,200 --> 00:55:46,240
The worms space the pots
and sensors signal to robotic arms

1107
00:55:46,240 --> 00:55:48,560
that the yogurts
are ready for packing.

1108
00:55:48,560 --> 00:55:51,920
Then they swoop down, picking up
16 pots at a time,

1109
00:55:51,920 --> 00:55:54,360
placing them
in their cardboard sleeves

1110
00:55:54,360 --> 00:55:57,040
at a rate of 480 a minute.

1111
00:55:57,040 --> 00:55:58,920
Absolutely mesmerising.

1112
00:55:58,920 --> 00:56:01,960
Are you sure there are four
different flavours coming down here?

1113
00:56:01,960 --> 00:56:03,320
Absolutely sure.

1114
00:56:03,320 --> 00:56:06,040
Cos there seems to be a lot of pink.
There is a lot of pink.

1115
00:56:06,040 --> 00:56:08,800
However, we have a scanner that side
that tells us

1116
00:56:08,800 --> 00:56:11,040
that we've got the right flavour
in the right pot.

1117
00:56:11,040 --> 00:56:14,480
So, raspberry, strawberry,
peach and blackcurrant is flowing

1118
00:56:14,480 --> 00:56:18,120
down here in absolutely the correct
order and the correct time?

1119
00:56:18,120 --> 00:56:21,400
Yes. That's outstanding.
I can't do that with a fruit salad!

1120
00:56:23,240 --> 00:56:27,440
The factory packs one million pots
of yogurt every day

1121
00:56:27,440 --> 00:56:31,720
and it takes this machine
just five hours to box up my batch.

1122
00:56:31,720 --> 00:56:33,760
It's a pretty sight, isn't it?
It is.

1123
00:56:33,760 --> 00:56:34,840
A bit like me.

1124
00:56:38,240 --> 00:56:43,200
Once pallets are stacks
with 3,840 pots of my yogurts,

1125
00:56:43,200 --> 00:56:47,320
they're ready for
the 1,400-square-metre chiller...

1126
00:56:47,320 --> 00:56:48,760
Come on, Gregg!

1127
00:56:48,760 --> 00:56:51,400
Do you want me to push it on?
Yes, please.

1128
00:56:51,400 --> 00:56:54,880
..where they're stored for six hours
at five degrees C

1129
00:56:54,880 --> 00:56:58,760
to thicken to the final perfect
yogurty consistency.

1130
00:56:58,760 --> 00:57:00,800
Very good. Oh, yeah!

1131
00:57:00,800 --> 00:57:03,840
Do you know how long I've been
working in yogurts? How long?

1132
00:57:03,840 --> 00:57:05,040
It's a couple of hours.

1133
00:57:10,560 --> 00:57:15,040
23 hours since production started
back in the milking parlour,

1134
00:57:15,040 --> 00:57:17,640
our pasteurised, potted
and packed yogurts

1135
00:57:17,640 --> 00:57:20,280
finally make it to factory dispatch.

1136
00:57:22,520 --> 00:57:24,360
Is that our truck? Yep.

1137
00:57:24,360 --> 00:57:26,600
He's putting the yogurt
on the lorry.

1138
00:57:26,600 --> 00:57:29,040
So, how many of these trucks
are leaving every day?

1139
00:57:29,040 --> 00:57:33,080
So, over a 24-hour period,
we have 16 lorries leave us

1140
00:57:33,080 --> 00:57:35,400
carrying over a million pots
of yogurt.

1141
00:57:35,400 --> 00:57:37,280
Right, shall we get
the last pallet on?

1142
00:57:37,280 --> 00:57:39,240
Let's do it. Come on, my friend!

1143
00:57:42,640 --> 00:57:46,280
The east of England is home
to the nation's biggest yogurt fans,

1144
00:57:46,280 --> 00:57:47,920
followed by the Midlands

1145
00:57:47,920 --> 00:57:49,800
and southern England.

1146
00:57:49,800 --> 00:57:51,160
I like that, you know?

1147
00:57:51,160 --> 00:57:53,720
I knew them yogurts when
they were still inside the cow.

1148
00:57:56,440 --> 00:57:59,680
24 hours after my clumsy milking,

1149
00:57:59,680 --> 00:58:01,960
the fruity favourites are on their
way

1150
00:58:01,960 --> 00:58:04,360
to feed Britain's yogurt-hungry
hordes.

1151
00:58:05,560 --> 00:58:07,040
I am really impressed.

1152
00:58:07,040 --> 00:58:10,480
Honestly, I can't believe how much
work goes into making

1153
00:58:10,480 --> 00:58:13,080
a pot of yogurt and getting
it on the shelf.

1154
00:58:13,080 --> 00:58:14,840
I've loved the lot.

1155
00:58:14,840 --> 00:58:16,160
Come on, you beauty.

1156
00:58:16,160 --> 00:58:17,960
The messy mixing...

1157
00:58:17,960 --> 00:58:20,640
Oh...! Watch your...!
THEY LAUGH

1158
00:58:20,640 --> 00:58:23,080
..and the clever chemistry.

1159
00:58:23,080 --> 00:58:26,040
Do you know how many bacteria
I'm putting in here?

1160
00:58:26,040 --> 00:58:28,960
Every gram will be 100 million.

1161
00:58:28,960 --> 00:58:30,360
That's ridiculous, isn't it?

1162
00:58:30,360 --> 00:58:32,040
But do you know
what really impressed me?

1163
00:58:32,040 --> 00:58:33,720
Do you know what I really honestly
loved?

1164
00:58:33,720 --> 00:58:36,680
It's where it all started -
those cows.

1165
00:58:36,680 --> 00:58:39,640
COWS MOO