Cereals: Inside the Factory—Introduction (02:05)
People in Britain consume over 1.5 million bowls of cornflakes every day. Gregg Wallace and Cherry Healey will visit the largest cereal factory in Europe and learn about wheat production. Ruth Goodman will investigate the history of breakfast foods.
The Manchester factory is the largest producer of breakfast cereal in Europe. Once a month, farmers in Argentina ship 30,000 tons of corn to the U.K. Wallace helps Paul Davies offload a truckload of corn into a silo.
Cooking Hall (02:59)
The hall contains 26 industrial sized pressure cookers that steam one ton of corn at a time. Conveyor belts transport the cooked corn to start the drying process.
Skipping Breakfast (05:22)
Approximately 1 in 10 people do not eat breakfast. Louise Dye and Katie Adolphus explain the benefits of eating breakfast and what happens when you do not. They conduct an experiment to support their claims.
Drying and Milling (03:28)
The corn kernels travel along a looped conveyor belt through a dual level dryer for 2.5 hours. The mill flattens and elongates the kernels into the cornflake shape.
Victorian Breakfast Foods (03:56)
Seren Charrington reveals common items served at breakfast. In 1863, Dr. James Caleb Jackson developed granola, the first commercially available breakfast cereal. In 1894, Dr. John Kellogg and William Keith attempted to make granola and created the wheat flake.
Rice Cereals (02:55)
Kellogg's produces several types of cereal, all of which are fortified with vitamins and minerals. Wallace learns how Arborio rice becomes Rice Krispies and Coco Pops.
Sunshine Vitamin (03:52)
Prof. Adrian Martineau explains the effects of Vitamin D on the common cold. Angelique Panagos explains the relationship between people, Vitamin D, and the sun in the U.K. Healey tests her levels and learns sources for Vitamin D.
Toasting Hall (02:43)
Machines dry and salt the flakes at a rate of 10 bowls per second; the flakes will become one of three types of cereal. Wallace makes a phone call to divert some of the flakes for Crunchy Nut processing.
Healey learns how experts make the most popular cereal in the U.K.; the factory produces 250,000 biscuits an hour. Robert Barnes supplies the factory with enough wheat for approximately 150 million wheat biscuits.
Coating Hall (02:27)
Wallace learns how the factory turns plain cornflakes into Crunchy Nut cereal; the peanuts and honey come from the Americas.
Appeal of Porridge (05:58)
Scottish oatmeal, jumbo rolled oatmeal, and pre-cooked oatmeal are the three best-selling types of oats. Healey asks early morning commuters to taste test three types of porridge.
Packing Hall (04:42)
Computer controlled hoppers weigh the cereal to deliver the correct combination for a 500 gram packet. Machines turn flat-pack into boxes and insert the cereal bags. Jim Carney conducts quality control every two hours.
Cereal Dominates Breakfast (03:21)
Approximately 87% of British adults eat a bowl of cereal every day. After WWII, television advertising and a shift in family dynamics boosted cereal sales. Goodman visits a cafe that serves only cereal; the owners describe why cereal is special.
Distribution Hall (04:12)
Every box of cereal receives a bar code before being wrapped for delivery. Jeff Bolton explains automated distribution; three operators and one craftsman oversee the process. Wallace reviews his trip to the cereal factory.
Credits: Cereals: Inside the Factory—How Our Food Is Made (Series 2) (00:34)
Credits: Cereals: Inside the Factory—How Our Food Is Made (Series 2)
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