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Inside The Factory - Season 10 Episode 5 - Breakfast Cereal
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00:00That breakfast is one of the most important meals of the day.
00:04Lovely stuff.
00:05Put it on me tab.
00:06You haven't got a tab.
00:07That's what they all say.
00:10So, what I'm working hard hosting the UK's premier factory-based TV show,
00:16I couldn't agree more.
00:17And this factory's massive, so I need to keep me strength up.
00:21Can someone throw us a couple of sausages on?
00:25In the UK, we crunch through, get this,
00:29a billion boxes of cereal every year.
00:34So, luckily, I've come to one of Europe's biggest factories
00:38that's dedicated to making the stuff.
00:44I'm going to take a big bottle of milk.
00:48Everything here is supersized.
00:51Holy granola, that is big.
00:55With massive machines.
00:57Where is everybody?
00:59And an automated process...
01:02There he gets out.
01:04..making multi-grain cereal.
01:08And while I find out exactly what goes into your breakfast bowls,
01:12Cherry's drawn the short straw because she's learning how to clean up.
01:17Oh, yeah, I'm getting down and dirty.
01:20No, no, no, no, no, no, no.
01:22Discovering the do's and don'ts of dishwashers.
01:26You don't rinse.
01:27We don't rinse plates.
01:29And historian Ruth Goodman is in search of the man from Sheffield
01:34who revolutionized spoons.
01:36So, he doesn't set out to make a better spoon.
01:41This is a man who wants to make a better gun.
01:47This factory produces 120 million boxes of cereal every year.
01:53And I'm going to show you how they make every single flake.
01:57This is Inside the Factory.
02:17Hygiene.
02:19Very important.
02:20Hygiene.
02:25Again.
02:27That's the wrong one.
02:29Where's the what?
02:30There it is.
02:30Whatever happens are just taps.
02:32Tap, you turned on.
02:34Bit of salt.
02:35Lovely.
02:36Now it's all this like that.
02:38That taps now turn into an hand dryer.
02:41What a time to be alive.
02:43And then we're going over this bit now.
02:44It's like Blackpool Funhouse.
02:45Here we go.
02:46And this is like Council Swimming Baths when you're a kid.
02:54Get your feet in there with hot verrucas and toenails.
02:57Bit more sanitiser.
02:59Give them a wipe.
03:00Through the thing.
03:02Absolutely spotless.
03:13This is the Kellogg's Factory in Rexall.
03:16And they've been making cereal here for almost half a century.
03:20That's a lot of bowls of rekkie.
03:22Wake up, it's a beautiful morning.
03:25You're a sunshine and all your eyes.
03:29This factory runs around the clock.
03:32A temple of high tech.
03:34Nice.
03:34Making many of the nation's favourite cereals like brown flakes and fruit and fibre.
03:40Wake up, wake up, wake up.
03:42But today, I'm following Special K and I'm learning how they create these 440-gram boxes.
03:52Got one.
03:53Come here.
03:54Wake up, wake up.
03:56It's a beautiful morning.
03:58There's a sunshine and falling right.
04:02And to get my morning going, I'm trekking across this massive site to ingredients intake.
04:08Wake up, it's a beautiful morning.
04:11Now, excuse all the belts and buckles.
04:15Here's Craig Williams, who's in charge, to explain all.
04:21Morning, Craig.
04:22You all right, pal?
04:23Morning, Paddy.
04:23You OK?
04:24Yeah, yeah.
04:24Well, I am OK.
04:26But I've got to be honest.
04:27I've never started a show in this kind of get-up.
04:29It's a little bit Fifty Shades of Grey.
04:31What are we doing?
04:33Well, all will be revealed.
04:34So we put all our tankers in here and this one contains rice.
04:38Which, for me, is a little bit strange because, obviously, there's certain cereals that are just rice.
04:44But I didn't think this particular cereal would contain it.
04:4747% of the flake is actually rice.
04:50Can I have a look?
04:51Yeah, that's why we're wearing these Paddy.
04:53Let's go up and have a gander's.
04:54Right, challenge Annika, this, isn't it?
05:00Are you on my bum?
05:04Right then, we'll connect one of these to the back of your harness so we don't lose you.
05:07OK, yeah.
05:08You're falling off the tanker.
05:11Turns out the harness isn't for fun, but for safety.
05:15It's like a seatbelt, isn't it?
05:16It gets you like that.
05:17Yeah, that's it.
05:19Because we're climbing on top of the tanker to take a sample of the rice delivery.
05:24Yeah.
05:24If you want to do it.
05:25Yeah, yeah, can do.
05:29Oh, that's a first for me.
05:30Give us one more.
05:33What kind of rice is that, then?
05:34It's a type of rice, if you do much cooking at home, that you'd use in a risotto.
05:38We use that because it's high in starch.
05:40So once it's cooked, it gets, like, a sticky texture.
05:43Right.
05:43And it helps bond the flake together.
05:45Right, so now we've took the sample.
05:47Yeah.
05:48We're going to give it to Paul.
05:49OK, no problem.
05:50OK.
05:51We'll do the relevant testing on it.
05:53Right.
05:53Let's make sure it meets the right specification.
05:55Yeah.
05:57First off, Paul makes sure the rice is a mix of big and small grains, which will give texture
06:03to the finished flakes.
06:08Oh, hang on.
06:09Looks like someone's peckish.
06:11It's OK, though.
06:13Apparently, it's part of the test.
06:15Paul's checking the rice hasn't picked up any natty tastes or smells.
06:19And the scores are in.
06:23How's it looking, Paul?
06:24Rice is all good, Paddy.
06:26Belting.
06:26So we can load it in now?
06:27Yeah, let's get it going.
06:29OK.
06:30Load it up!
06:30Start the clock.
06:43Breakfast is underway.
06:45To make 350,000 boxes of cereal every day,
06:52this massive factory has four 100-tonne, 30-metre-high silos.
07:01Just for the rice.
07:03And there's another three silos full of wheat.
07:06So, 47% of our flake is made up by rice, and the other's whole wheat.
07:14Around 37% whole wheat.
07:16Well, I'm glad you said that, Craig, because through the magic of telly,
07:19I've sent Cherry down to the farm to find out exactly how it's harvested.
07:23The wheat for your cereal, Paddy, needs dry weather to harvest.
07:33And the somewhat changeable British climate is making that tricky.
07:39It's been such a soggy summer.
07:41It's been raining what feels like non-stop.
07:44But I've just had the call from Farmer Stephen to say he thinks
07:46it's dry enough to harvest the wheat.
07:50Fingers crossed.
07:50I'm in Northamptonshire, meeting Stephen Evans,
07:55who runs a 1,600-acre farm.
07:58Lovely to see you.
07:59Really nice to meet you.
08:01And grows 2,000 tonnes of wheat a year,
08:04half of which goes to the cereal factory.
08:07And today, there's just one field left to harvest.
08:12Has the rain been a total pain?
08:14It's been a horrible year.
08:15It's made life very difficult.
08:17Why can't you harvest when it's just rained?
08:19The grain, if it's too wet, will go mouldy in the shed.
08:22I mean, how much money do you lose if that happens?
08:24It'll be tens of thousands across the farm.
08:27So we've invested everything and we really need this.
08:30Oh, my gosh.
08:33More rain is on the horizon.
08:36But the last few sunny days means this 25-acre field
08:39should be dry enough to harvest.
08:41We just need to do a moisture test and see if it's good to go.
08:45The stakes are really high.
08:47There's a lot riding on this.
08:48So this is our electronic moisture tester.
08:50So we need the moisture of this grain to be 15 or less.
08:5315% moisture or less, or we're in trouble today.
08:56That's right.
08:5714.9.
09:02So is it go time?
09:03I think we'd better go.
09:04With the weather forecast threatening, it's a race against time.
09:08But the 15-tonne combine harvester is ready for action.
09:16It's absolutely amazing.
09:18It's just the most enormous, loudest monster of a machine I've ever seen.
09:26Yeah, 10 metres wide.
09:28It's amazing what they'll process.
09:31I've seen a few farm machines in my time,
09:34but this one is on another level.
09:36Yeah.
09:37Woo-hoo!
09:40To make sure the valuable crop is gathered before the rain comes,
09:45Stephen calls in another harvester from a neighbouring farm.
09:50Today, it's all hands on deck.
09:53Here we are.
09:53Take a seat.
09:54Look at this.
09:56So we'll put the front header in gear.
10:00Look at those teeth.
10:01So that's the knife.
10:02That will cut the crop.
10:04That is one hell of a knife.
10:07All right, here it goes.
10:08Whoa, look at that.
10:10So we're off.
10:10So this rotating wheel is then pulling it all into the body of the machine,
10:17which is like a mini factory back there.
10:18Oh, it is.
10:20A combine harvester gets its name
10:23because it combines the three stages of harvesting.
10:27First, reaping, where the front header cuts the stalks of wheat.
10:32Next, threshing, to shake the ears from the stalks.
10:36And finally, winnowing,
10:39to separate the wheat from the chaff, the unwanted husks.
10:44The straw and the chaff fly out the back
10:47to fertilise the field for next year.
10:51The grain, which will be used for cereals,
10:53is filling up the tank behind us.
10:55How much are you collecting in one go?
10:57This machine currently is doing about 30 tonnes per hour,
11:02so that's a lot of bowls of cereals.
11:05In fact, it's enough to produce nearly 2 million bowls of our cereal.
11:11And we've got two of these monster machines
11:14working flat out to get the harvest finished.
11:18I hope Paddy appreciates how much work has gone into this.
11:20So do I.
11:24It's about time we emptied.
11:26Once the grain tank is full...
11:30Oh, here he comes!
11:30There he is.
11:31There we go. Hello.
11:32So, looks like Frank is good at catching.
11:35It needs to be emptied as quickly as possible.
11:38And we don't need to pause the harvest to unload.
11:41Absolutely nailed it.
11:43Because the trailer comes to us.
11:45It's like someone's just turned the tap on, Max.
11:51That can go into the store.
11:52Off he goes.
11:53With two combine harvesters,
11:57it takes just an hour and a half
11:59to gather 90 tonnes of wheat from this final field.
12:07We've dodged the rain...
12:08..and the freshly harvested crop is taken to a dry barn.
12:13Is this everything done?
12:17Have you finished the harvest?
12:18We're finished now.
12:19We're over the line.
12:20It's such a relief.
12:21The weather won't affect us any more.
12:25The wheat will be sent to the cereal factory
12:27to be transformed into 72 million servings of breakfast flakes.
12:33Paddy, I've got 800 tonnes of wheat for you.
12:36I hope it's enough.
12:37I think that should keep us ticking over, Cherry.
12:51Mind you, I'm still getting to grips with the size of this place.
12:55It's a whopping 52,000 square metres.
12:59And using the traditional TV measuring system,
13:03that's bigger than seven football pitches.
13:06Feeling fitter already.
13:09I'm definitely getting my steps in.
13:11We've had to put a wide-angle lens on the drone
13:15just to get this shot.
13:17From the huge silos intake,
13:20I'm following our rice and wheat to the mini silos.
13:25Where I've been told to look out
13:27for factory food designer Lizzie waiting.
13:31You all right, Lizzie?
13:32Hi, Paddy, how are you doing?
13:33Keeping busy?
13:34Oh, just about.
13:34I just did a rhyming thing, it's all right.
13:36No, listen, for the good licence fee paying people at home,
13:40what are we doing here?
13:41So, this room is where all of the grains come to
13:45after they've just been offloaded.
13:47So, above us, on all the silos,
13:48there's about 80 tonnes of the four key ingredients
13:50that go into the multigrain cereal.
13:52So, we've got the rice that you've just seen.
13:53Yeah.
13:54We've got the wheat, and we've got two types of barley.
13:57So, this is the wheat,
13:59which is really important for the structure of the flake.
14:01It holds it all together, but it's a whole grain,
14:03so it adds fibre, it's really good for your heart
14:05and digestive system.
14:06Oh, OK.
14:07Now, that's definitely changed from when I saw it
14:09with cherry, what's been done to it?
14:12This is cracked wheat.
14:13It's been taken to a mill,
14:15and then it's been cleaned to get rid of any impurities,
14:17and then those kernels are moistened a little bit,
14:20and then they're just cracked a little bit.
14:22Random question, how do you clean wheat?
14:25Just with water and...
14:27So, it's just like how you clean yourself
14:29at home, you get in the bath.
14:30Do you have a little bit of a scrub?
14:32Yeah, exactly.
14:33Just no shower gel.
14:34All right.
14:35The other two main ingredients are kibbled barley,
14:41which are crushed whole grains...
14:42It's almost like tiny little stones.
14:46It's quite hard.
14:47..and finer textured malted barley flour.
14:51From here, our cereals rush along pipes
14:54into one of four enormous cookers.
14:57Whoa, this is massive.
15:03Stand back.
15:09Holy granola, that is big.
15:12Stand back.
15:15Lizzie, quick question.
15:1714 cookers, massive room.
15:19Where is everyone?
15:21So, these are quite self-sufficient.
15:23We've got them all pre-set to make sure
15:24that as one cook finishes,
15:26another one's still going,
15:27and there's a continuous feed of cereal
15:29going to the next part of the process.
15:33In one cook?
15:35How much cereal is that?
15:37Around about 740 kilos.
15:40That's about 1,500 boxes of cereal.
15:43Or 24,500 bowls of cereal.
15:46Wowzers!
15:47So, the cook is in three stages.
15:50For the first stage,
15:51you have the cookers rotating,
15:52so all the ingredients are mixed together.
15:54And we add in lots of hot steam.
15:59A jet of steam is blasted into the cooker
16:03at 125 degrees Celsius,
16:06adding moisture to the mix
16:08and starting the cooking process.
16:10Give me steam.
16:12I'm how you feel, come make it real.
16:15Real as any place you'd be.
16:19Get away.
16:20It's very similar to if you were making a risotto at home.
16:27You have your stock and your rice.
16:28Right.
16:28You mix and heat it,
16:29and it gets thicker,
16:30and it starts to swell.
16:32That's the same process that we've got going on in here.
16:34So, when I'm looking at a cereal,
16:45it's very, very dry and flaky.
16:47Surely, we don't want to be adding more moisture to it.
16:50Is it not going to keep making it soggy?
16:52Well, actually, Paddy,
16:54we need to add even more moisture to it.
16:56So, at this stage,
16:57we actually add in about a third extra moisture.
17:01Oh, no, no, no.
17:02I'm not a medical person,
17:04but someone needs to drink more water.
17:08This is, in fact,
17:09the flavour solution we added after the pre-scene.
17:12So, in here, we have malt,
17:13we have sugar, salt, and water.
17:15Can I smell that?
17:16Yes, you can smell it.
17:18Have a little...
17:19It's almost like a sweet and sour smell, that.
17:25The flavouring is added to the cooker,
17:28which slowly revolves for an hour,
17:31mixing all the ingredients thoroughly as they cook.
17:37If we go around now,
17:38we can go and take a little look at it.
17:40Thought you'd never ask.
17:41Come on, then.
17:46Three hours after the rice was delivered,
17:48our mix is cooked,
17:50and we've taken the first step
17:51towards breakfast cereal heaven.
17:55Beautiful.
17:57All of this has just been dumped out of that cooker,
18:00and it's coming along these Archimedes screws.
18:02Dumped?
18:02Yes, it's not the most...
18:04Placed. Placed.
18:05It's not the most romantic word,
18:06but we go with it.
18:08It's been glovingly placed
18:10into this Archimedes, too.
18:13Still looks nothing like cereal that I recognise.
18:17No, so the most important part about this
18:19is it's now cooked.
18:20So that means it's ready to get all that moisture back out.
18:22So we put it in,
18:23and now we need to take it back out again.
18:24It does smell lovely, though.
18:25Yes, yes.
18:26That's all those cooked flavours coming through.
18:28So to save your fingers,
18:29I've brought you some,
18:30so you can have a little closer look at it.
18:32All right, that's that.
18:33That is that, yes.
18:34Oh, that is hot.
18:35Yes, yes.
18:36It's not very wet,
18:38but there's definitely still quite a bit of moisture in there.
18:41It's all moist now,
18:42but the next stage of the process
18:43is to try and get all that moisture out
18:45to get to that lovely crunchy cereal.
18:46I'd love to try that,
18:48but I'm missing one key ingredient.
18:52Spoons!
18:54And that, viewers,
18:56is my clever link
18:57to everyone's favourite historian, Ruth Goodman.
19:01She's visiting somewhere that makes the best of them.
19:08Sheffield, the steel city.
19:12Fed by iron ore and coal mined from the Pennines,
19:16Sheffield's metalworks put the city on the map,
19:19and they were particularly famous for their cutlery.
19:25But it's one very specific piece of cutlery
19:29that I'm in Sheffield to find out about.
19:32Not just any old spoon,
19:34but the stainless steel spoon.
19:39I'm at the Kellam Island Museum,
19:42a historic industrial site,
19:44to meet curator of industry and metalwork,
19:47Emma Paragreen.
19:50So Sheffield has a really long history
19:53of cutlery making, doesn't it?
19:55It does indeed.
19:56It goes right back to the 13th century.
19:59OK.
19:59And then Chaucer talks about a Sheffield swivel,
20:02which is an early knife.
20:03OK.
20:04But where do spoons come into it?
20:07Spoons have been around for millennia.
20:09Spoons made in bone, wood,
20:12even glass and ceramics.
20:14In terms of a metal spoon,
20:16we're talking really the Tudor period
20:19and then into the Elizabethan age.
20:20And what sort of metal were they?
20:22A lot of them were pewter.
20:24It's quite heavier, isn't it?
20:26Mm.
20:27And of course, pewter tastes.
20:29Yeah.
20:29You can smell it,
20:31you can taste it.
20:32There'll be a lead content as well.
20:34Which is really poisonous.
20:36OK.
20:36I'll give you that back.
20:37So maybe silver is a better option.
20:40OK.
20:41This is going into the 17th, 18th century.
20:44So solid silver.
20:45Solid silver.
20:46It's not exactly going to be
20:47in your poor man's cupboard then, is it?
20:49No.
20:50So a lot more expensive.
20:52You always know if you're eating off a silver spoon,
20:54you can taste it on the food.
20:56Yeah.
20:56The bad taste you get when eating off pewter or silver
21:00is due to the metal reacting with acids
21:03in the food and with our saliva.
21:07But steel, an alloy of iron, carbon and other elements,
21:12had the potential to react in a different way.
21:16By the mid-19th century,
21:18Sheffield was producing 85% of British steel
21:21for everything from knives and forks to railway tracks.
21:26But in 1913, just before the First World War,
21:32a revolution in cutlery production
21:34came from a surprising source.
21:38This gentleman, Harry Rearley,
21:41was looking for different alloys
21:43to make a gun barrel that wouldn't rust.
21:47So he doesn't set out to make a better spoon.
21:49This is a man who wants to make a better gun.
21:51Yes.
21:53In search of a metal that wouldn't rust or corrode,
21:57Harry began to experiment with steel alloys
21:59containing chromium,
22:01which has a high melting point,
22:03ideal for use in gun barrels.
22:08To find out more,
22:10we're visiting the factory of Sheffield cutlery makers,
22:13David Mellor,
22:14to look at some of Harry's experiments.
22:19So we've got some early samples
22:21of some of the tests that Harry Rearley
22:24had been working on with his gun barrels,
22:26and then he discovers
22:28that actually this might be useful for something else.
22:32On the 13th of August, 1913,
22:39Harry discovered a form of steel
22:41that was not only rust-proof,
22:44but had another revolutionary property.
22:49So he discovers this rustless steel,
22:53stainless steel,
22:55and metal with no taste.
22:57Oh, really?
22:58No, so if you imagine,
23:00this is the first time
23:01that a metal hasn't really had that aftertaste.
23:04So out of rifle barrels comes cutlery?
23:08Yeah, definitely.
23:09Originally known as rustless steel,
23:12in 1921,
23:13Harry teamed up with a local firm
23:15to produce cutlery
23:17which they marketed as stainless steel.
23:21So this is a mass-market product.
23:23It's cheap in comparison to what went before.
23:25Yeah, very much so.
23:26And as it says on the box,
23:28neither rusts, tarnishes, nor stains.
23:32Cutlery made from this steel
23:33is unaffected by food acids
23:35and is, in consequence,
23:37a universal boon.
23:39A universal boon!
23:42Guaranteed!
23:48And here, David Mellor,
23:50they've been making stainless steel spoons
23:52since the 1960s.
23:54Today, David's son, Corinne,
23:57is the company's creative director.
24:01So what's so great about stainless steel for spoons, then?
24:05It's indestructible.
24:07It's incredibly resilient.
24:10Lasts forever.
24:11And there is nothing, really,
24:13to substitute good old stainless steel.
24:15I mean, it simply is the best material
24:19to make a spoon out of.
24:21A hundred odd years on,
24:22it's just part of life.
24:24Absolutely part of life.
24:25It's there every morning for your cereal, isn't it?
24:27And you just use it.
24:28Spot on, that, Ruth.
24:37Back at the factory,
24:38I'm making a cereal fit
24:40for the best of spoons.
24:43It's like the Beatles.
24:45What a beautiful time
24:47Hi, hi, I'm the king of all time
24:51Bloody noisy!
24:54Nothing is impossible
24:55In my own house or mine
24:58What we've got so far
25:01is nothing like flakes yet.
25:04So I'm in search of
25:08Head of Operations,
25:10Ian Selle.
25:11You all right, Ian?
25:12How are you, pal?
25:13You all right?
25:14OK, thanks.
25:15Ian, I tell you,
25:16everything in this factory
25:17is supersized.
25:19Yeah, it's a really big plant.
25:20Oh, my word, is it?
25:22No, I've just left Lizzie.
25:24All that cereal's not quite cereal.
25:27Yeah.
25:27It's still very moist.
25:28I believe you're the man
25:29to dry it out.
25:30I sure am, Paddy.
25:31So we've been through
25:32the cooking process.
25:33Everything that we're going to see
25:34in the next few stages
25:35is about how we're going to
25:36transform that
25:37into the crispy cereal
25:39that we know.
25:39OK.
25:41It starts with the granulator,
25:43a fierce-looking bit of kit
25:46which forces the mixture
25:47through a mesh.
25:49This essentially is a box now
25:51with a steel conveyor inside.
25:53Right.
25:53And it will hold roughly
25:54three cooks at any one time,
25:56which is about
25:57two tonnes of food.
25:58My word.
25:59And we're just trying
26:00to break it up,
26:00trying to make it more
26:01even more free-flowing
26:02in order that we can
26:03take moisture out.
26:04Got it.
26:05And off we go,
26:10following the mix
26:11to a massive
26:1230-metre-long dryer.
26:15Keep going, Ian.
26:16Where the temperature
26:17reaches 100 degrees Celsius.
26:20As it travels along,
26:22the mix loses
26:23a third of its moisture,
26:25starting the transformation
26:26from soggy
26:27to crunchy.
26:29What have we got here, Ian?
26:30So these are our
26:32pellet mills, Paddy.
26:33Right.
26:34Yeah.
26:34And what you can see there
26:35is that's the cooked mix
26:36coming down through that tube
26:38and we'll put it
26:39between two rollers.
26:40We're going to make
26:41little tiny dough balls
26:42with it.
26:46One of the metal rollers
26:48is covered in
26:49hundreds of dimples.
26:51It looks a bit like
26:52bubble wrap.
26:53When the cooked cereal
26:55passes between the rollers,
26:56the mix is pushed up
26:58into the dimples,
26:59moulding it
27:00into little balls of dough
27:01called pellets.
27:03I can see the little balls
27:06that are dropping, yeah.
27:09Behave, Ian.
27:10Thank God.
27:15Each pellet will eventually
27:16become one flake of cereal.
27:21So they've still got
27:22a little bit of moisture in them, yeah?
27:24They still need to hold
27:25quite a lot of moisture
27:26in order that we can get them
27:27to form together
27:28now to make them little balls.
27:29These little pellets
27:34don't look like cereal flakes yet
27:36but they look over the moon
27:39to be on the way.
27:41Oh, look at these
27:42cheeky little scamps.
27:45Having a right little bounce about.
27:47So at this point now
27:52we've put the product
27:52through a mesh
27:53so those that have
27:54made it into a pellet
27:55small enough
27:56drop through that mesh.
27:58Those that don't make it
28:12through there
28:12so you can see
28:13there are some lumps
28:14that go over the top
28:15and over the end
28:15they return back
28:17into the process.
28:18How much is coming
28:20through here now, Ian?
28:21So each pellet mill paddy
28:22produces about
28:2348,000 pellets
28:26a minute.
28:27Wow.
28:30We multiply that
28:31by the amount
28:31of pellet mills
28:32we've got on
28:32that's 10
28:33it'll equate
28:34to about
28:344,000 bowls
28:36of cereal
28:36a minute.
28:38Hey,
28:38sometimes
28:39when I'm doing this show
28:40people tell me
28:41facts and figures
28:42I can't get my head
28:44round it
28:44and that's one of them
28:45I mean
28:45just how's that
28:47even possible?
28:49It really is amazing
28:50it really is
28:53amazing to see.
28:57Want to try one paddy?
28:59Absolutely.
29:00At this point
29:00oh
29:02still very moist
29:03still very moist
29:05at this point
29:05you've got to put
29:08a lot in your mouth
29:09to get that cereal
29:11taste
29:12they're chewy
29:14but
29:14it's not unpleasant
29:15but it's definitely
29:18not
29:18what I know
29:19that taste to be.
29:25After four and a half
29:27hours
29:28we're leaving
29:28the pellets behind
29:29and we've got
29:30a hundred metres
29:31to cover
29:32to get to the
29:33flake making.
29:36And here we are.
29:37Ha ha ha!
29:39That looks a little bit
29:40more familiar now.
29:42Go on Ian
29:42reveal the flakes.
29:47It's like playing
29:48the tastiest
29:49tuppany nudger
29:50on the pier
29:51as your grandparents.
29:54We've only gone
29:55and won the flaky
29:56jackpot.
29:58So Paddy
29:59this is one of our
29:59flaky mills.
30:01This is very similar
30:02to a pellet mill
30:02two steel rolls
30:04but without the dimple
30:05and as you can see
30:07there
30:07that becomes
30:07the plate.
30:14Would you like to
30:15take a sample?
30:15Yes sir.
30:16Pull the handle
30:17there and we'll
30:18take a sample.
30:20My God!
30:22That's floppy!
30:23There's still a lot
30:24of moisture
30:25at this phase.
30:26Yeah!
30:27I thought they were
30:28going to come out
30:29totally solid
30:30and crispy.
30:31So at this point
30:32we've taken out
30:33about 40% moisture.
30:35There's still moisture
30:36in there
30:36because if we dried
30:37it out completely
30:37at this point
30:38we wouldn't be able
30:39to get it through
30:40that flaky mill
30:40and it would
30:41probably disintegrate
30:42into a powder.
30:44I don't know
30:44if it's a
30:45psychological thing
30:46but because it's
30:47a bit more
30:47like a plate
30:48I'm getting the
30:49flavour a bit more
30:50now.
30:51Possibly yeah.
30:53But seeing those
30:54floppy flakes
30:55makes me think
30:56of one of my
30:57pet aids.
30:58Soggy bits of
30:59breakfast stuck
31:00on the dishes.
31:02It's the
31:03eternal debate.
31:05What's the best
31:06way to stack
31:06those dirty
31:07cereal bowls
31:08in your dishwasher
31:09and get them
31:10spotlessly clean?
31:11Well luckily
31:13for us
31:13Sherry Ely
31:14is about
31:15to give us
31:16the answer.
31:19Endeavor the
31:20professional
31:21she's brought
31:22her own prop
31:23along.
31:24Looks heavy
31:25that Sherry.
31:26In most
31:27households
31:28it would seem
31:29there is one
31:30person who
31:30stacks the
31:31dishwasher
31:31with the
31:32precision of
31:33a Scandinavian
31:34architect
31:34and there is
31:35another
31:36who takes
31:37more of a
31:37cram it in
31:38approach.
31:40So I'm
31:42in Bristol
31:42to dish
31:43the dirt
31:44on this
31:44dishwashing
31:45divide.
31:48Cutlery first.
31:49No, do the
31:50plate.
31:51No, please.
31:52No, cutlery first.
31:54You are cutlery first,
31:55you are plates first.
31:57There's always an argument
31:57isn't there?
31:58This is the wrong way.
31:59This is wrong
32:00because there should be
32:01no pots up there.
32:02Who is the stacker
32:05and who is the
32:05shover?
32:06I'm the stacker.
32:07Does he sometimes
32:08just shove the
32:08dishes in?
32:09Occasionally and
32:09then I have to
32:10take it out and
32:10redo it.
32:13What do you think
32:14about this stacking?
32:15How does it make
32:16you feel?
32:16I'm tied to it.
32:18Looks like
32:18something out of a
32:19door.
32:20That would drive me
32:21nuts.
32:22I would have to
32:22take it all out
32:23and restack.
32:23It seems there's
32:26only one conclusion.
32:28Everyone thinks
32:29they're right.
32:31Time to clear it up
32:33once and for all.
32:36Back in my very own
32:37kitchen, my family's
32:39dirty breakfast bowls
32:40are waiting for some
32:41expert treatment.
32:43Hi, Andrew.
32:44I'm Cherry.
32:44Nice to meet you.
32:45Nice to meet you.
32:46From Andrew Lachlan,
32:47dishwasher guru and
32:49principal researcher at
32:50consumer organisation
32:51WITCH.
32:53Is there anything
32:54that causes more
32:55domestic arguments
32:56than stacking the
32:57dishwasher?
32:58I would say no.
32:59They cause a lot of
33:00arguments but hopefully
33:01we can settle a few
33:02arguments today.
33:04But before Andrew
33:06gives me a masterclass
33:07in stacking, I need to
33:09rinse my very dirty
33:10plates.
33:12No, no, no, no, no,
33:13no, no, no, Sherry.
33:14Oh, what?
33:14That's...
33:15Sherry, Sherry, Sherry.
33:15Oh, it's gross though.
33:17We don't.
33:18You don't rinse?
33:19We don't rinse plates.
33:21You can actually mess up
33:22how the machine works
33:24by doing it because
33:25on most machines
33:26auto-program, it has
33:27what's called a
33:28turbidity sensor.
33:29A turbidity sensor?
33:31It senses in that
33:32pre-wash cycle how
33:34cloudy the water is.
33:35And what it's looking
33:36for is how dirty
33:38your dishes are.
33:39So imagine if you
33:40cleaned all this stuff,
33:41put it all in, the
33:41machine's going to go,
33:43hold a minute, this is
33:43just clean dishes.
33:44I'll adjust the
33:45temperature and lower
33:46it accordingly.
33:46So if you want
33:47your dishes really
33:48clean, make sure
33:50they're dirty.
33:51The dishwasher
33:52wants to clean.
33:54Let it.
33:57Instead of rinsing,
33:59scrape leftovers
34:00into your food waste
34:02bin and regularly
34:03clean the dishwasher
34:04filter.
34:07And when stacking,
34:09face everything
34:09towards the centre
34:11of the machine
34:11for the best
34:12performance.
34:13As a rule of
34:14thumb, typically
34:16if you eat out of
34:17it, it goes on
34:18the lower rack.
34:19If you drink out of
34:20it, it goes on
34:20the upper rack.
34:21Right.
34:22And make sure no
34:23items are touching
34:24so the water can
34:25flow and wash
34:26effectively.
34:29Nonstick cookware,
34:30sharp knives and
34:31wood should never
34:33go in the dishwasher
34:34as high temperatures
34:35and water pressure
34:36could damage them.
34:38Oh my God, are you
34:39restacking?
34:40No.
34:41It's like a
34:43natural thing.
34:44Is it because some
34:45of them weren't
34:45quite even?
34:46Well, you know,
34:48it is my job, you
34:49know, to be a
34:49slight pedant.
34:53Particular placement
34:54might be important,
34:55but with this next
34:56lot, Andrew's got
34:57his work cut out.
34:58These are two of
34:59the worst offenders.
35:00Cereal-based anything
35:02and scrambled eggs.
35:04Yeah, what you've
35:05got here is carbs,
35:06sugar and starch,
35:07and protein with the
35:08egg.
35:09They take a bit more
35:09time to break down.
35:11When left behind,
35:13the starches and
35:14proteins on the
35:15bowls form bonds
35:16with each other
35:17and start to
35:18harden.
35:19The longer the food
35:20sits, the more
35:21cement-like it
35:22becomes.
35:23By adding moisture,
35:25the dishwasher
35:25breaks these bonds.
35:27So what we want
35:28to do with this
35:29one is put it in
35:30the middle where
35:31the intensity is
35:31highest.
35:32I'll be stunned
35:33if that comes off.
35:35We'll see.
35:36Time to put
35:38Andrew's tips
35:39to the test.
35:41Right, in the
35:42tablet goes.
35:46A pre-wash
35:47sprays jets of
35:48cold water between
35:49the carefully spaced
35:50plates and cutlery,
35:51knocking off excess
35:52foods before the
35:53main cycle begins.
35:58But perfect
35:59stacking's not the
36:00only thing required
36:02for my dishes to
36:03sparkle.
36:04What about
36:04tablets?
36:05Is that important?
36:06Absolutely, yeah.
36:07They are designed to
36:09break down all the
36:10dirt and the food
36:10waste and start the
36:12cleaning process.
36:13Most tablets
36:14contain enzymes
36:16which attack
36:17protein-based foods
36:18like my scrambled
36:19eggs, as well as
36:20the starchy residue
36:21of breakfast cereal.
36:24They also have
36:25something else in
36:26them, which is a
36:27surfactant.
36:28It basically stops
36:30water from forming
36:31droplets and it makes
36:32it spread more easily.
36:33You want to add
36:34detergent to have
36:35maximum coverage and
36:36the water is the
36:37vehicle to get that
36:38there.
36:40Another addition,
36:41rinse aid,
36:42disperses the water on
36:44the surface of the
36:44dishes, helping them
36:46to dry at the end of
36:47the cycle.
36:49And to run
36:50efficiently, special
36:51dishwasher salt softens
36:53the water, preventing
36:54limescale build-up and
36:56those horrid white
36:57marks on glasses.
36:57which is so annoying.
37:01Every household has a
37:03cloudy glass.
37:04Yeah, that would be
37:05because you've not kept
37:06up with your salt.
37:07And with the cycle over,
37:09it's time to see if my
37:10impeccably stacked
37:12dishwasher has done its
37:13job.
37:13No.
37:22Oh, no!
37:24It dealt with the cereal.
37:27Dealt with the egg.
37:28Even the egg.
37:29Even the egg.
37:31So the cutlery is
37:32sparkling.
37:34Yeah.
37:34So does that mean that
37:35stacking properly works?
37:36Yep.
37:37Don't pre-wash.
37:38Stack properly the first
37:39time and you'll get good
37:41results every time.
37:42I'm sorry I didn't wear
37:43sunglasses because that
37:44is some good-looking
37:45cutlery.
37:48So we've learnt how to
37:50get the best out of our
37:51dishwasher.
37:52Now all that remains is
37:54the battle of whose turn
37:56it is to empty it.
38:12I'm going to take a big
38:13bottle of milk.
38:19Just like everything in
38:21this factory, we've now
38:22got super-sized bowls of
38:25cereal.
38:26But these flakes are still
38:27missing that all-important
38:28crunch.
38:30So I'm on the hunt for
38:31Ian again.
38:33Is it that way?
38:35I'm not sure where I'm
38:36going from here now.
38:36I want to find out how
38:39flakes go from floppy to
38:41fabulous.
38:44There he is.
38:46Good to see you again,
38:47Ian.
38:48How are you, pal?
38:49I'll tell you what, it's
38:51toasty here.
38:52Oh, it's really warm here.
38:53The heat coming off that.
38:55Flipping heck.
38:56Woo!
38:57We've arrived at the
38:58toasting machine.
39:00That explains a lot.
39:01So this is the part where
39:02we generate the really
39:03crispy, crunchy flake.
39:05Okay.
39:06So what you can see at the
39:07point coming off the
39:07in-feed, we've still got
39:09the floppy flakes.
39:10Yeah, I can see someone
39:11go over the side there.
39:12Yep.
39:14So there's still a
39:15significant amount of
39:15moisture in there.
39:16Yeah.
39:16And what they're going to
39:17do now, they go into
39:18our toaster.
39:19Right.
39:19It's very similar to a
39:21toasting machine that
39:22you get in a hotel.
39:24So if you think about one
39:24where you load the bread
39:25and the conveyor the
39:26cluster.
39:26I was going to say, you
39:27might be wasting your
39:28money there to get a new
39:29machine.
39:29Because I have never
39:31used a hotel toaster.
39:33That toast the bread
39:34just comes out warm.
39:35This is significantly
39:37different.
39:37This is proper.
39:38What temperature is in
39:39there, Ian?
39:40So this is way in
39:41excess of 200 degrees.
39:42Oh, my word.
39:43That's proper.
39:44So we're now going to
39:45put these floppy flakes
39:47inside the oven.
39:49Inside there is a
39:50conveyor, but it's a
39:51vibrating conveyor.
39:52Yeah.
39:53And it's bouncing the
39:54flake up and down.
39:55And we're going to
39:56really reduce that
39:57moisture.
39:59The bouncing helps
40:00the evaporation process
40:02and stops them
40:04sticking together.
40:07Look at that.
40:14I've got to say,
40:15they're definitely a
40:16nicer colour now.
40:17What you're seeing now
40:19is 6.3 tonnes an hour
40:20here.
40:21Wow.
40:21So that's the equivalent
40:22of about 12,500 boxes an
40:25hour.
40:25It's bonkers, isn't it?
40:27You know, it's amazing to
40:30me, the amount of stuff
40:32that's going out of
40:33factories every single
40:35day, the product, the
40:36ingredients, the work,
40:38it's mind-blowing.
40:39Yeah.
40:40I'm getting them lovely
40:41aromas, Ian.
40:43So what's happening
40:44within there is something
40:45called the Maillard reaction.
40:48That's where you get a
40:49browning effect and it also
40:50really fetches out the
40:52aromas and the flavours.
40:53It was French chemist
40:56Louis Maillard who
40:58discovered that heating
40:59amino acids and sugars
41:01gives cooked food that
41:02taste we love.
41:05We're talking barbecued
41:06meat, roasted coffee and
41:08of course, the toasty
41:10flavour of cereal.
41:12So when I'm on the beach
41:13in Tenerife on my sun
41:15lounger, I'm getting the
41:17Maillard effect.
41:18Probably, yeah.
41:19Oh.
41:19Also, what's happened
41:22through the toaster is
41:23we've enhanced the
41:25surface texture of it.
41:26You'll see where the rice
41:27grain has expanded.
41:29Yeah, it's popped.
41:30See, the textures look
41:31much different.
41:32And that's the wheat,
41:33the kibble barley, the
41:34rice all coming together
41:35now.
41:36Now it'll be really
41:37crunchy.
41:38What we left moisture-wise,
41:39at this stage now, we've
41:41taken out 90%
41:43of the moisture.
41:45Can I try one?
41:47You can.
41:47Or two.
41:50Extremely hot.
41:51My God, they're
41:53roasting.
41:55I mean, you would be
41:56hot, wouldn't you, if
41:56you'd come out of an
41:57oven, to be fair.
41:58Wow.
42:00Right.
42:04Ah.
42:06Lovely bit of crunch
42:07there now, Ian.
42:08That's lovely.
42:11I'm just not quite
42:12getting the full flavour,
42:14Ian.
42:14Just a summit missing
42:16though.
42:16But that's because,
42:17Paddy, we're going to
42:18add a little bit more
42:19flavour in in the next
42:20phase.
42:21OK.
42:21We should have a
42:21coating plant.
42:23Lead on, Ian.
42:25Tell you what.
42:27Boorish, then.
42:28Very nice.
42:29The breakfast flakes travel on
42:47through the vast factory, up this spiral elevator, which uses vibration alone to jiggle them upwards.
42:55In the morning, as they head towards the enormous coating drum.
43:00Oh, my word, they're coming out of that tube so quick, they don't even look like flakes till they hit the drum.
43:18It's staged now, believe it or not, believe it or not, we'll actually put a little bit of moisture back in.
43:21Right.
43:22Only a very, very low level.
43:23And so we're putting a coating syrup on here.
43:26So that contains sugar, salt, water, and we put some vitamins in at this point.
43:31Inside the drum, the sugary liquid is sprayed onto the flakes from above, and the drum keeps moving them, so the syrup doesn't make them all clump together.
43:52Then, after a trip through yet another dryer, my flakes emerge looking good enough to eat.
44:00Again.
44:03There they are.
44:04Now, straight away there, Ian, I can see that little bit of sheen on them.
44:08So that's the coating or the flavour that we've added.
44:10Yeah.
44:11Now we've been through the dryer.
44:13Now that's the final product in its final finished state.
44:16You know what I'm going to ask, don't you?
44:17I do, Paddy.
44:18Yeah, you scoop in there, Ian.
44:20Let's have a look.
44:22Right.
44:22Here we go.
44:23Big moment.
44:27Oh.
44:29Instantly, I get that sweetness, which is amazing, because if I'd have had that without trying it before, I wouldn't have recognised that.
44:36Yeah.
44:37And at the end, when you swallow it, it's still sort of there in your mouth.
44:40But, yeah, it makes all the difference, that, doesn't it?
44:43We're really fetching the flavours out now.
44:44Yeah.
44:45This is exactly what I recognise now.
44:47This is what I pour out the box, into the bowl, splash of milk, job's a good'em.
44:53So now they're ready to go off to packing, which is where I'm heading, Ian.
44:57Me and you will have to say goodbye.
44:59I have absolutely loved having our all-day breakfast together.
45:03Put the handshake away.
45:04Come on.
45:05Thanks for looking after me today, Ian.
45:07Take care, pal.
45:07Take care.
45:08Of course, this lot would be nothing without one thing.
45:16Milk.
45:18Which brings us to Ruth, who's down on the farm.
45:21For centuries, our countryside has been blessed with miles of rolling pastureland and grazing cows.
45:31But much like today, the history of dairy farming has been a troubled one,
45:37as farmers battle the challenges of wavering demand and falling prices for their milk.
45:42Back in the 1930s, there was an organisation that set out to give farmers a better deal.
45:53And one of their aims was to get the British public to fall back in love with drinking a lot more milk.
46:02All right with you girls?
46:06Hello!
46:07Hi!
46:07Historian Amy Swainston knows a thing or two about the milk industry.
46:15They do look happy.
46:17Just being fed.
46:20I'm meeting her at this dairy farm in Dorset to find out why farmers needed help 100 years ago.
46:29So, what was going on for dairy farmers in the 1920s then?
46:33Well, in the late 1800s, many farmers had turned to dairy as a way to make money
46:39because it was seen as quite a stable product to sell.
46:43But by the 1920s, milk production far exceeded the demand for milk.
46:48So, essentially, there was a surplus.
46:50Exactly.
46:50Just not enough people buying what they were making.
46:54As supply outstripped demand,
46:57most dairy farmers were struggling to get a fair deal for their milk.
47:01Farms were a lot smaller back then.
47:04You'd have about 14 cows in a herd, whereas today it's about 200 to 300.
47:09They would sell their milk to the creameries, which were a lot bigger.
47:14So, all these little tiny farmers have got to deal with this middleman.
47:17Yes, yeah.
47:18And it's the creameries that would dictate the prices to the farmers.
47:21Across the country, creameries processed the milk and made butter and cheese.
47:28To fight their control over the market, the farmers decided to band together.
47:34The decision was taken in 1933 to set up a cooperative between farmers
47:39to help them to sell their milk at a reasonable price to buyers.
47:42They called themselves the Milk Marketing Board,
47:47and they were a cooperative that was run by farmers for farmers.
47:51So that instead of the power being with these middlemen,
47:54the power should actually sit with the producers, the farmers.
47:58Yeah.
47:59So that they could get a fair price.
48:01Farmers no longer had to accept the prices offered by the creameries.
48:06Instead, each month, the board set the price for the milk they supplied.
48:11Hello.
48:12And paid the money straight back to the farms.
48:15Oh, we're in the half election now.
48:20It ensured 70,000 farmers across the UK could maintain a steady income.
48:29And as well as negotiating a fair deal for farmers,
48:32the board was also responsible for popularising dairy products.
48:37Over the following decades, their marketing team got busy,
48:43making milk not just a favourite of children,
48:46but a drink that appealed to adults too.
48:50So here we've got a milk bar.
48:55The Milk Marketing Board opened up quite a few milk bars throughout the country,
48:58and you can see the photos of trying to persuade young women.
49:03This is a trendy thing to do.
49:06It's particularly young women, isn't it? Beautifully dressed.
49:09And they didn't stop there.
49:13In 1958, they sponsored the tour of Britain's cycle race,
49:17renaming it the Milk Race.
49:21Oh, and we've got footballers here as well.
49:23Footballers, yeah.
49:25Really associating it with physical fitness, with youth, vitality.
49:30And there were advertising campaigns that came along with this,
49:35so they were spending about 1.7 million on marketing per year by the mid-60s,
49:39which is about 30 million today.
49:42The investment paid off.
49:45Throughout the 60s and 70s, the British public fell in love with milk.
49:50And by the early 1980s, as football's league cup was rebranded the Milk Cup,
49:58annual sales of the white stuff peaked at nearly 13 billion litres,
50:05compared to 4 billion in the 1930s.
50:08But it didn't last.
50:12So there is no Milk Marketing Board anymore.
50:16What happened?
50:17Well, in 1994, the MMBs actually shut down for good by the government,
50:22and that's because the Milk Marketing Board has a monopoly over the dairy industry.
50:27Ah, yeah.
50:28The government wanted to increase competition,
50:31but with the break-up of the Milk Marketing Board,
50:35the farmers lost their power to set the best price.
50:39So from the mid-90s, dairy farmers were on their own.
50:43Yeah, so where before they'd had that assurance on prices,
50:47now there wasn't any.
50:49With retailers driving prices down,
50:52and the costs of farming going up,
50:55many dairy farms couldn't survive.
50:59So today, we actually have around 10,000 dairy farms left,
51:03which is the lowest it's been in living memory.
51:06And now supermarkets are the main seller of milk.
51:09Yeah, so all the power is with them.
51:10Yeah.
51:12The Milk Marketing Board had its detractors,
51:15but for 60 years, it provided stability in an unstable industry.
51:22It was a sort of organisation of a different era, wasn't it?
51:25Quite revolutionary at its time.
51:27Yeah.
51:27In many ways, it seems that we need something similar today.
51:38Oh, send a bottle of milk my way, Ruth.
51:41I've got a lot of flakes to get through here.
51:43But you can't have breakfast cereal without a box to put it in.
51:57First, exactly 440 grams of cereal is weighed and dropped into a bag.
52:04They're sealed and fall onto a vibrating conveyor
52:08that shakes the contents flat.
52:15I'm meeting project lead Donna Jenkins
52:18to find out more about how the bags get into the boxes.
52:23Hi, Paddy.
52:24How are you? Nice to meet you. You OK?
52:26Yeah, welcome to packing.
52:27So talk me through it. What's happening now?
52:29So we loaded the boxes onto the carter
52:32and it's got a conveyor mechanism
52:33and they work their way up the conveyor here.
52:35So each of those flat boxes are pulled down by the suction cups.
52:39As you can see, there's suction cups extracting them.
52:42Yeah.
52:42But they work their way into the guides
52:44and the front box is being pushed open.
52:46Really clever.
52:47Yeah, it is clever.
52:50Amazing.
52:51Someone has sat down and invented a machine
52:55that takes a flat box and flips it up.
52:59Someone's sat down and thought about that.
53:01That's bonkers.
53:03We'll work our way down.
53:04So what's happening now?
53:06Hold on. Don't worry.
53:07I know how to handle these situations.
53:10Yeah.
53:10You're going to be impressed by this.
53:11Shut it!
53:15That's how you do it.
53:16And then resume.
53:18So we apply glue to the top and the bottom of the box.
53:21Right.
53:21We have what we call as a pusher.
53:23It's getting the food.
53:24So it's pushing the food into the open box.
53:27Oh, I can see it.
53:27Yeah, I can see it.
53:28And it makes its way along the conveyor.
53:32It's now going to seal the boxes shut.
53:35So clever.
53:36It is.
53:36Go and use my arms.
53:39Go and use my face.
53:41Go and use my style.
53:44Go and use my sideship.
53:46Go and use my fingers.
53:48The machine turns out 150 boxes a minute.
53:52That's more than two a second.
53:58So what I've always wanted to know is, what's the care for on special care?
54:04Come on, Paddy.
54:05Kellogg's!
54:06I'm special, so special, I gotta help some of you.
54:12Don't film me, I'm embarrassed.
54:15Come on, don't pretend you knew that as well.
54:24Moving on, me and Donna are leaving packing and heading to distribution.
54:30And, you've guessed it, it's mega-sized.
54:33This is like having a little stroll in the old breakfast cereal future.
54:43And I can see what looked like a load of dodge-ums, but with no drivers.
54:49How many of these little rascals are here?
54:51Hey, get out.
54:53So we have 25 of these.
54:55They call it automated guided vehicles, Paddy.
54:58They just operate themselves.
54:59And what their job is, is to actually take all the finished boxes, either into storage
55:03on site, or they load it onto the auto bay, and it'll get fed onto a truck.
55:07All by itself.
55:09Are you not worried about being taken out by one of these?
55:12They're everywhere.
55:13No, Paddy.
55:13They're actually really intelligent.
55:15If you look at the top, it's got a scanner.
55:17Yeah.
55:17So what that's doing is talking to a control system, which is in the heart of the warehouse
55:21here.
55:21Oh, right, OK.
55:22They're actually that clever.
55:23It'll actually detect obstacles in front of them, and it'll stop.
55:27Shall we give it a go?
55:28Let's give it a go, yeah.
55:30What have we got here?
55:31Is this a specialist robotic stopperator machine?
55:34No, bog-standard blue carton.
55:36It's a blue box.
55:37All right.
55:37As good as any of them.
55:40Right.
55:41I'll give it a whirl.
55:42Here we go.
55:43So can you pop it on the floor there?
55:47Let's see.
55:51Oh!
55:53Runk right bumper, we like that.
55:54Yeah.
55:55It'll now detect if it's safe.
55:56Right.
55:57And then it'll start off again.
55:58Brilliant.
56:00Amazing.
56:01Very, very clever little things.
56:04It doesn't have to be a blue box.
56:06No.
56:07It could be any object.
56:07It could be you, Paddy.
56:09Wow.
56:10Here we are.
56:12Oh!
56:13Oh!
56:14That...
56:15Close.
56:16That was that.
56:17Look at that.
56:18Look at how close that were.
56:20But to be fair, I jumped out in front of it.
56:21I took it by surprise.
56:22Yeah, you did, yeah.
56:23It was just going about its everyday microchip business then and then.
56:27And it still kept the same.
56:32Off you go.
56:33Very clever.
56:35Way too fast.
56:37Don't slow down, you're gonna crash.
56:40You should watch, watch your steam.
56:43Don't look out, gonna break your neck.
56:45So shut, shut your mouth.
56:48He's all right, listen to any of you.
56:51Amazing!
56:52That's fantastic.
56:53Go on, you little rascals.
56:54I love that.
56:58Oh, I could hang about here all day.
57:01But apparently, we haven't finished filming yet.
57:04Don't worry about stopping in front of the camera, lads.
57:07Just mow them straight over.
57:13Seven hours after the delivery of rice,
57:16my boxes of cereal are about to leave the factory.
57:21Well, there they are there, Donna.
57:22Well, we've got around about 19,000 finished boxes on there, Paddy.
57:2619,000 boxes.
57:2719,000.
57:28A lot of cereal.
57:31And every day, 40 trucks leave the factory.
57:34So, we best get this one loaded up and on its way.
57:40There they go.
57:41Families across the nation will be enjoying them very soon.
57:46All this talk of breakfast and cereals,
57:49you know what I'm in the mood for?
57:51Full English breakfast.
57:52Good girl.
57:53Come on, Donna.
57:58From the factory in Wrexham,
58:01cereal is sent to all corners of the country
58:03to fill the bowls of hungry souls the nation over.
58:09And 30 million boxes are exported from here right across Europe.
58:16Bon appetit.
58:17So, there you go.
58:22We've finally got boxes of crunchy flakes without a drop of moisture inside.
58:28Well, not until they get in your breakfast bowl.
58:30Right.
58:31Get me some milk.
58:37Global Glamazon's Runway Ready on BBC Three.
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58:44A school in crisis on BBC One.
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