Introduction: Bread: Inside the Factory—How Our Food Is Made (Series 1) (02:08)
The British consume 12 million loaves of bread daily. This segment orients viewers to bread production in the UK and hidden killers that were once found in bread with excerpts from the program.
Wheat Production and Storage (03:24)
Allied Bakery produces millions of baked goods every week. Silos store 420 tons of flour from mills across the country. A variety of previously stored wheat arrives at the bakery and is tested for quality and impurities before being unloaded.
Separating the Wheat Kernel (02:28)
Cornet Mill combines a variety of wheat to make over a hundred types of flour. To make white flour, kernels are soaked and then repeatedly ground through steel rollers to produce the silky powder.
Flour Delivery Process (02:50)
Trucks are grounded to prevent combustion of flour dust; ventilators prevent it from escaping. A truck's 28 ton load will produce 60,000 loaves of bread. See flour unloaded at a bakery.
Readying Ingredients for Dough (02:26)
A computerized mixer orders ingredients from all over the factory. Flour is delivered at 4.4 lbs per second. Kibble gives bread texture and soya enhances color. The bakery uses two full tankers of cream yeast weekly.
What is Yeast? (02:10)
Dr. Ian Roberts discusses the microscopic fungus found throughout nature. Experts research the adaptable ancient fungi for its UV protective properties.
Mass Produced Yeast (03:22)
Over four days, experts us six massive fermenters and 42 tons of sugar syrup to produce 66,000 pounds of yeast. Dehydrated yeast is compressed into bricks.
Chorleywood Bread Process (02:21)
Gregg Wallace adds dough conditioners to the giant mixer. The three minute mixing stage is a precisely monitored process; 20 hourly batches result in 350 loaves.
Dough: Resting/Shaping (03:56)
Long conveyor belts give dough balls 30 seconds to rest. Balls are then flattened, rolled, cut in four, and turned 90° to give bread loaves a stronger texture. Wallace butters a slice to demonstrate bread strength.
Symbolism of Social Division (04:15)
In medieval times, workers ate bread made from local grains. The wealthy enjoyed white bread and the loaf's "upper crust." In the mid-1800s cheap wheat was imported from America's prairies and milled through steel rollers creating finer flour.
Bread: Proving (02:30)
Within 7 minutes of beginning the process, loaves are put in a giant prover to rise. Feeding on the starch, yeast produces bubbles of carbon dioxide held in by gluten.
Bread: Baking/Cooling (03:12)
Loaves are ready for the oven one hour and 24 minutes after the flour was delivered. Heat kills the yeast and refrigeration readies the bread for slicing and packaging.
Bread Waste in Birmingham (03:13)
Healey visits families to see how much bread they throw out. Emma Marsh offers tips for rescuing stale bread; toss any bread with mold.
Bread Storage Tips (03:01)
Keep bread visible to reduce waste. Refrigerating bread causes the starches to harden, hastening deterioration. Freeze bread to make it last longer.
English Muffin Inspection (02:42)
People in the UK purchase 146 million muffins annually. From the cooler, muffins are dropped onto a divided packing line at the rate of 18,000 an hour.
Bread: Slicing/Bagging (02:29)
Cooled loaves are put through a slicer, which cuts them in 18 or 20 pieces. Hear how the high-speed bagger works. Bagged bread is checked for contamination in a metal detector.
Adulterated Victorian Bread (04:08)
Food tampering in the 19th century was common. Women advised each other on ways to inspect flour and bread for contaminants.
Food Adulteration Act of 1860 (01:13)
Scientist Arthur Hill Hassall tested 2,000 foods for contamination. He is credited with the adoption of many laws and codes leading to publicly regulated food safety.
Dispatching Warehouse (02:29)
The 62,000 sq ft facility processes as many as 1 million bread loaves per day. Bread is ready for supermarkets 3.5 hours after flour arrices at the bakery.
Filling Supermarket Orders (03:32)
A voice-activated computer collates orders for packers. Today, 30,000 baskets need to be filled by hand; Wallace gets a lesson. Bread reaches store shelves within 24 hours of flour delivery to bakeries.
Credits: Bread: Inside the Factory—How Our Food Is Made (Series 1) (00:43)
Credits: Bread: Inside the Factory—How Our Food Is Made (Series 1)
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