Introduction: Chocolate: Inside the Factory—How Our Food Is Made (Series 1) (02:00)
In the UK, the average person consumes 266 chocolate bars each year, created from the 70,000 tons of cocoa delivered annually. See excerpts from this film on how candy is made on a large scale.
Cocoa Bean Delivery (02:58)
The Nestlé Factory in York employs 800 people. One truck delivers 28 tons of beans. After harvesting, cocoa beans from West Africa are dried in the sun for seven days before they are shipped to the UK.
Beans: Cleaning, Shelling, Roasting (02:22)
A grate is used to remove debris from the cocoa. Rollers crush the shell to release the nib. Clean nibs are roasted in giant ovens and then milled to create cocoa liquor.
Making Milk Chocolate (01:37)
Eight tons of cocoa liquid is piped over to the factory; after mixing it with other ingredients, it becomes a coarse chocolatey powder. The powder is mixed in a conche for eight hours.
Chocolate's Individual Aroma Molecules (02:59)
Healey meets with a food scientist to learn about the connection between our senses of smell and taste. Using an olfactometer, she is able to smell single compounds in chocolate.
Kit Kat's Unique Chocolate Recipe (03:04)
Liquid chocolate is pumped from conches to 28 ton vats. Wallace has a sample. The factory makes 16 different chocolate recipes. In a taste test, Wallace learns that not just any chocolate recipe will work on the Kit Kat.
Making the Vanilla Truffle (04:21)
At the UK's largest British owned chocolate manufacturer viewers learn how vanilla truffles are made. Mixed chocolate is cut into pieces (55,000 per hour), coated in chocolate, tempered, and coated again in white chocolate.
Hand-Decorating Truffles (01:39)
Healey works on a production line with an employee who has 21 years of experience.
Packing Variety Box Trays (01:37)
A variety of hand-decorated chocolates are packed into shaped trays by lightning-fast robots.
Making Kit Kat Wafer (03:29)
Forty pounds of batter are made every minute from flour, butter, water, and other ingredients. Huge waffle irons create batter squares that are browned in ovens before being spread with a cocoa and sugar filling. Robots stack the finished wafers.
Creating Chocolate's Mass Market (01:34)
Before the 1930s, chocolate was an expensive treat for the wealthy. Improved living conditions changed British buying habits. Cheaper processing costs meant chocolate was affordable to 90 percent of the country.
Chocolate Wars (03:12)
In 1932, Mars was the first to create a chocolate bar with a core. Chocolate bars developed during this competitive decade are still popular today. See archival footage of a cinema advertisement by Rowntree and hear how Cadbury enticed new customers.
Kit Kat Assembly (04:45)
Chocolate is deposited into molds followed by cut-to-size wafers. Wallace feeds the wafer loading machine. A camera detects any missing pieces. After the top layer of chocolate is applied, bars are cooled and de-molded.
Making Hollow Easter Eggs (02:33)
At Thornton's, Healey gets a lesson in filling molds and rotating them on a spinner until the chocolate is evenly dispersed and hardened.
Kit Kat Quality Control (01:54)
Bars that do not meet standards are removed and re-purposed into filling for future product.
Rowntree Factory History (02:32)
An historian tells Ruth Goodman that Rowntree workers enjoyed good conditions, benefits, and additional perks. Known for manufacturing a quality product, Quakers become the top chocolate makers. See archival footage of working conditions.
End of an Era (02:55)
A couple sits down with Goodman and discusses what it was like to work at Rowntree in the mid-1900s. Eddy spots himself in an archival clip of factory operations. In the 1980s, demand for cheaper chocolate meant the end of Rowntree's hand-made chocolates.
Kit Kat Wrapping and Packing (02:41)
Three and a half million bars are individually foil and paper wrapped. Wallace works on boxing the final product.
Chocolate and Patriotism (01:28)
Chocolate has been the preferred sweet treat for over 200 years. It makes people feel happy and nostalgic. Chocolate flavors are tailored to the palate of the originating country.
Chocolate Taste Test (04:03)
Young and Healy melt chocolate from four different countries into identical shapes and test the public to see if they prefer British chocolate. American chocolate is only preferred by Americans and has a component of vomit.
Self-Managed Building (03:55)
Visit a building, the size of two soccer fields, where 30 foot robots control the chocolate inventory from stacking and storing to sending it to the loading area. Wallace goes along for a ride.
Credits: Chocolate: Inside the Factory—How Our Food Is Made (Series 1) (00:43)
Credits: Chocolate: Inside the Factory—How Our Food Is Made (Series 1)
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