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Inside The Factory Season 10 Episode 1 - Video
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00:00Oh, Christmas.
00:06Favourite time of the year.
00:08I've got to ask, what are you putting in the kids' stockings this year?
00:11Because it's chocolate coins, oranges, lump of coal.
00:14What a treat. Yes.
00:15How about a little bit of gingerbread?
00:18Wow, what a coincidence, because we are in Market Drayton,
00:21the home of gingerbread.
00:23It's like it was planned.
00:25Merry Christmas. Merry Christmas.
00:26Come on. You paid for them?
00:28No.
00:29What a treat.
00:34It's said they've been making gingerbread
00:36in the Shropshire town of Market Drayton for hundreds of years.
00:44Everywhere you go, you're reminded of their most famous exports.
00:49And here we are at a gingerbread factory
00:52that churns out tons of the sweet stuff.
00:54In fact, they make four million biscuits every year.
00:57Let's find out how they do it.
01:00Is that all right for sound?
01:03This is a factory full of festive cheer.
01:07Can I have a good one?
01:08Absolutely.
01:09That's the best part for me.
01:11And tonight, we're joining these busy olds in a grotto of gingerbread gems.
01:20I'm actually sweating.
01:21I'm actually sweating.
01:23A magical place of sugar and spice and all things nice.
01:30That looks like raspberry sauce on ice cream.
01:32Yeah, it's called Christmas Razzle.
01:34And for a guaranteed white Christmas...
01:37Oh, wow.
01:40...I'm learning how to make snow indoors.
01:44That is one powerful machine.
01:46And Ruth settles in for a special message from history for peace on Earth.
01:53This is what Christmas in space looks like.
01:57This factory makes over 100,000 gingerbread biscuits every week on the run-up to Christmas.
02:04And today, we're going to help them.
02:06Welcome to Inside the Christmas Factory.
02:08Inside the Christmas Factory
02:38It's glistening once again
02:40Candy canes and silver lanes that glow
02:45Oh, look at that.
02:48Oh, that smells like Christmas joy.
02:50Can you smell that?
02:50Lovely bit of ginger.
02:54Oh, our name's on the board.
02:56Oh, look!
03:04Oh, no.
03:05Look at this.
03:05Those are cute, aren't they?
03:06These are a little work of art, these.
03:08Oh, wow, look at that.
03:08These are snowflakes.
03:10It's beginning to look a lot like Christmas.
03:15Right, well, we could spend all day doing this, just looking at ginger biscuits, but we've got things to do.
03:21I'm going to go that way.
03:22Which way are you going?
03:23I'm going to go that way, so it's not walk right.
03:24To that wall.
03:25Yeah.
03:25Right, just go on there.
03:26There, yeah, just film Cherry just walking.
03:29Oh, look at it.
03:32Oh, hey, you know, don't worry about that.
03:38We're just trying to make a Christmas TV show here.
03:40You nearly took me out.
03:41This is the original biscuit baker's factory, and it is busy in here.
03:49It's like Santa's workshop.
03:51Go on, carry on.
03:54They're on the final push to meet the Christmas rush, producing 20,000 ice gingerbread biscuits every day, ready to fill stockings across the country.
04:06And I'm going to be following these today, the bestseller, the Santas.
04:17And don't forget the reindeer.
04:18Oh, I'm not forgetting the reindeer.
04:21Merry Christmas.
04:22Merry Christmas, everyone.
04:25Merry Christmas.
04:26You were too late.
04:29You can't get the stuff these days.
04:31Merry Christmas.
04:32Merry Christmas.
04:36I'm kicking things off by heading outside to ingredients intake with Managing Director, Gemma Williams.
04:50Hello.
04:51Nice to meet you.
04:52Merry Christmas.
04:53Merry Christmas to you too.
04:54Look at this.
04:57Santa has come early.
04:59And he's bringing one of our most crucial ingredients, the ground ginger.
05:02Come on, get us unloaded.
05:05Oh, I like that.
05:06Assertive.
05:08Why do you use ground ginger?
05:10Ground ginger packs a real punch.
05:12It leaves a lovely warming taste in the mouth.
05:15So is that the same ground ginger that I'd have in the cupboard at home?
05:18Yes.
05:19And let me show you.
05:19I've got some right here for you.
05:21Oh, yeah.
05:21There you go.
05:22And that's what we use.
05:25Oh, yeah.
05:26That smells like Christmas.
05:27And as the ginger is loaded into the factory, by the miracle of Christmas telly...
05:38Here we go.
05:40We've got our urnets on.
05:41This is where the start of the magic happens.
05:45Yeah.
05:45The very first stage is making the gingerbread dough.
05:48So in the bowl at the moment, you've got a demerara sugar and you've got a granulated sugar.
05:52Why two different ones?
05:53So the granulated sugar is more of a neutral sweet flavour.
05:57Right.
05:57The demerara sugar, it brings in a slightly more caramelised taste.
06:01Yeah.
06:01It's got that extra depth and colour there as well.
06:04Once we've got the sugars in, we need to add a fat to it.
06:06So we use a shortening, which we've got a copy of it here.
06:09A shortening?
06:10Yes.
06:10Right, okay.
06:11So this is a mix of vegetable oils.
06:13So you were at home, you were making them with the kids or whatever.
06:15I presume it would be butter or marge.
06:17We tend to tend away from butter.
06:19We find a lot of people have dairy allergies now.
06:22And so if you'd like to do the honours and tip it in, that'd be fantastic.
06:25I'd love to.
06:26I'd love to.
06:27Look at that.
06:28What this basically does is when the biscuit's been baked and cooled,
06:32it does make it a bit more of a softer texture for it.
06:35So what we need to do at this stage is then blend these together.
06:38Okay.
06:39Lovely.
06:45That's what we're paying our licence fee for.
06:48This is what we want.
06:51Mixing on the telly.
06:54Don't worry.
06:55Everything's better with a bit of Christmas music.
06:59In go the rest of the ingredients.
07:02Black herb of soda.
07:03That helps the biscuit rise and it also gives it that nice sort of texture.
07:08A secret spice.
07:10Can we smell it?
07:11Oh, I don't know what it is, but that definitely gets the nostrils going.
07:17Love that.
07:18That can go in.
07:19And finally, there'd be no gingerbread Santas without the ground ginger.
07:26I can't get enough of that.
07:27It comes from India and contains a compound called gingerol that activates heat receptors on our tongs,
07:36literally tickling our taste buds.
07:40Already, I want to get a finger in there.
07:43And just give it...
07:44Oh, love that.
07:45Wait till this is baked.
07:46Right, okay.
07:47It'll be a lot nicer.
07:47All right, then.
07:54Go on, I'll do that one.
07:56Oh, blimey, you made that look like it was light.
08:00Right, on there, like that.
08:02Oh, yes.
08:05Gingerbread has been a treat since medieval times.
08:08It's even mentioned in Shakespeare and was often bought at furs and eaten for good luck.
08:15Let's hope it brings me some today.
08:17I'm baking, I'm cooking, I'm making.
08:22Next in, a mix of water and mouth-watering golden syrup.
08:29Gorgeous.
08:30Absolutely gorgeous.
08:32What does the golden syrup add?
08:34It's that luxury sort of taste you get from it.
08:36It's like those childhood memories.
08:38Even at school, you used to make, like, flapjacks and gingerbread men.
08:41You'd have the golden syrup there.
08:43Love that.
08:44Gemma's got special childhood memories of gingerbread.
08:50Her mum and dad started the company when she was just a kid.
08:54So, my parents had a bakery to begin with.
08:57So, back in those days, as well as gingerbread, we made cakes, we made breads, made pasties and all those things.
09:03I'll just give you some pictures over here.
09:05Who's this little rapscallion?
09:06Look at that.
09:07Oh, my days.
09:09Is that you, Jibber?
09:09Back in the days.
09:10Oh.
09:11Are they ginger?
09:12They are large gingerbread sheep.
09:14I was used as a lovely marketing prop there.
09:17Oh, I love that.
09:19And what started as a small family business, no employs over 70 people.
09:35Right, that's all mixed up now, Gemma.
09:37What we need to do now is actually store it in the chiller for 24 hours.
09:42Because if you try and use it straight away, it's too soft and crumbly.
09:45Right.
09:45It also helps bring out the flavour of the spices.
09:48It infuses more deeply in it.
09:50Send them off.
09:51Speaking of chiller, you met Cherry earlier, didn't you?
09:55I met Cherry.
09:55She's gone to the biggest ever chill room you've ever seen.
10:00Let's go and get a cup of tea.
10:01For some lucky people, Christmas means a getaway to snowy alpine slopes.
10:28But this is inside the factory.
10:30So, no, I'm not in St. Moritz.
10:32I'm in a giant snow factory in Milton Keynes.
10:40This is the snow zone, one of Europe's largest indoor ski centres.
10:47It's a winter paradise all year round.
10:51But how did they create the Alps?
10:54Slap, bang, in the middle of Milton Keynes.
10:57How do you think they make the snow for that slope?
11:03I think they're a little bit too plastic.
11:05How would you describe it?
11:07It's not like the snow that you'd get when it actually snows.
11:09What do you think it's made of?
11:11Ice, I guess.
11:13I don't know.
11:13It feels icy, but then to look at and to ski down...
11:17It feels like snow when you see it.
11:18It feels like snow?
11:19Yeah.
11:21To unlock the mystery of making snow indoors is the centre's head of snow.
11:27Matt!
11:28Refrigeration engineer Matt McKenzie.
11:31Nice to meet you.
11:32How do you make an alpine mountain in the middle of Milton Keynes?
11:37So we've got massive metal plates that run 170 metres from top to bottom.
11:42Then on top of that, we have an 8 centimetre block of ice.
11:46Wow.
11:47Underneath the slab of ice to keep it nice and cold, we've got pipes with glycol, which is an antifreeze.
11:54Oh, I see.
11:55So it keeps it really cold all the way through the block of ice.
11:57Then on top of that, we have 6 centimetres of snow.
12:00So you've got the opposite of underfloor heating, you've got underfloor cooling.
12:04Correct.
12:06When the centre was constructed in 2000, pipes were laid, through which the antifreeze glycol runs,
12:14chilled at minus 10 degrees Celsius to prevent the ice and snow above from melting.
12:21And thick insulated walls keep this giant room at a chilly minus 4 degrees.
12:27And then two to three times a week, we make snow.
12:32So we're continuously getting rid of old, new, old, new, and then we've got a lovely new snow for the slope.
12:42But how do they make the snow?
12:44All is revealed when the centre closes, and Matt and his team get ready for a night of snowfall.
12:53First job, smoothing the slope with a snowplough called a pieced basher,
12:58which pushes dirty snow into heated pits where it melts away into the drainage system.
13:04Then it's time for Matt and me to take a look at his pride and joy.
13:13Oh, it's quite a hike, isn't it? It's better be worth it.
13:16The snow cannon.
13:19How does this machine produce snow?
13:22So we push water through the hose at a high pressure.
13:26We chill this water to zero degrees.
13:29It comes out of these little nozzles, just like an aerosol, and they're little tiny balls.
13:35And as they travel through the air, just before they hit the ground, they turn into little crystals,
13:40and that's what makes our snow.
13:41So I assumed that this snow would have lots of chemicals in it.
13:45No.
13:45But it's just water.
13:45Completely natural.
13:47Can I turn her on?
13:48Let's do it.
13:49Press this phone.
13:50She's gone green, but we'd better step away.
13:53OK, come on. Run away.
14:00For the cannon to create a snowy landscape, the air temperature is lowered to a chilly minus 10 degrees Celsius.
14:10I mean, look at it.
14:12That is one powerful machine.
14:14As the water meets the freezing air, it creates a man-made blizzard.
14:21She's only been on for a few minutes, and already it's like a winter wonderland.
14:25It's so beautiful.
14:27Oh, it's fantastic, isn't it?
14:28How is it different to the snow on the mountains outside?
14:31Because outside, droplets come from the clouds.
14:34They turn into a beautiful snowflake, which looks similar to this.
14:38Beautiful.
14:39Look at it up close.
14:40Isn't that gorgeous?
14:41And then inside here, the snow we make, it comes out like this.
14:47So it's little droplets.
14:48So instead of being a snowflake, it's like a little snow ball.
14:54When it snows outside, ice crystals fall through the freezing air, gathering more water droplets,
15:01which freeze to form the snowflake's beautiful hexagonal structure.
15:05But here, the cannon creates snow almost instantly, producing frozen droplets that are more solid than a natural flake,
15:18giving the piste a denser surface for skiing.
15:23You're actually starting to look a bit like a snowman.
15:25I am.
15:27Should we give that a chance to do its thing?
15:28Yeah, I think so.
15:29All right, let's go.
15:29Let's go.
15:30The snow cannon works away throughout the night, taking six hours to produce three tons of snow.
15:45Let it snow, snow, snow, let it snow, let it snow, let it snow, let it snow.
15:51Then the pieced basher comes out again to smooth it all over.
15:56Snow, snow, snow, snow.
15:58And hey, presto.
16:00Our ski slope has been transformed.
16:05Oh, wow.
16:08It's like Christmas morning.
16:10It's great, doesn't it?
16:11It's perfect.
16:13Isn't that stunning?
16:15Is that it now?
16:16Is it finished?
16:16Is it ready?
16:17Yeah, really happy with that.
16:18Can I be the first person to ski on this slope?
16:20Yeah.
16:21No way.
16:21Will you come with me?
16:23Well, I can't actually ski.
16:25What?
16:26You don't ski?
16:27I don't ski, no.
16:27But my job is to make the snow for you skiers and snowboarders.
16:31We're lucky to have you.
16:32You're a Christmas gift.
16:34I may not make it to the Swiss slopes this Christmas, but skiing on brand new snow is a fabulous first for me.
16:51Whee!
16:51There she goes.
16:54Always on the piste.
17:00One sleep to go.
17:02I'm getting that buzz.
17:04This candy-coated Christmas feels like it should.
17:09And ba-ba-ba-ba-bing sings the love.
17:11Morning.
17:13Morning.
17:13Morning.
17:15Back in Market Drayton, I'm having a lovely chilled out time too.
17:20Oh, I have to do it in here.
17:21Who's it to, love?
17:23With me new factory friends.
17:26We can do this on Christmas episodes, you see.
17:29It's a bit more relaxed.
17:31Merry Christmas as well.
17:33Can I have a cuddle?
17:34Absolutely.
17:35That's the best part for me.
17:37There you are.
17:38Doing the bats.
17:38I'm not a machine.
17:45Tell you what, you don't get this without them deck.
17:48They won't do this.
17:52While I'm distracting the ladies in the decorating room,
17:56Gemma's grafting, feeding the gingerbread paste into a machine called a sheeter.
18:02The door passes between two rollers, forming sheets one centimetres thick
18:07that are cut ready to make the gingerbread shapes.
18:12I'd better catch her up.
18:15You all right, Gemma?
18:16You all right?
18:17Yeah.
18:17You come to see the next stage?
18:19Yes, I am, yeah.
18:20So, gingerbread dough's been cut into sheets, which gives a nice flat surface.
18:24Yeah.
18:24And now we're going to create them into Santa's.
18:26OK.
18:26So, are you ready to work?
18:28Shit, I am.
18:28I'm going to pass you some trays in a minute.
18:30Yes, I am.
18:30OK, wonderful.
18:32Let's get started.
18:41Here they come.
18:46Oh, yes.
18:47Merry Christmas, everybody.
18:50There you go.
18:51Get on there, you.
18:52This is where I feel pressure here, Gemma, because as soon as they start, that's it.
18:57They're not stopping, are they?
18:58They're not stopping.
19:00This is the first time I've seen the actual Santas coming out.
19:03Weirdly, I know it's because they're not baked yet.
19:05They look quite rough, Gemma.
19:07Yeah, when they come through, they both start looking a bit like that,
19:10but as it bakes, they create a smooth shape.
19:13Fun festive fact for you.
19:15In Elizabethan times, gingerbread was believed to cure flatulence.
19:22Could come in handy after the sprouts on Christmas Day.
19:27So, they're going in, sheets on top, they're coming out, magic little Santas.
19:32How is that actually happening?
19:34Just lift this up.
19:35Oh.
19:36So, as you can see, we've got a roller there that's going to the machine.
19:40So, the paste is coming through, travelling on the rollers underneath it.
19:43So, it's turning round.
19:44You've got the imprint of the Santa, which then cuts out the Santa shape.
19:48And that can just be taken in and out, depending on the time of year.
19:51Yeah, absolutely.
19:52If you're doing anything else, round Halloween, Christmas, whatever.
19:55We've got some different rollers here.
19:57So, these are the reindeers.
19:58Oh, yeah.
19:59These are little antlers, ears, face.
20:06All right.
20:08Off to the oven.
20:09Two hundred and forty Santas are loaded onto baking trays and wheeled to one of two special ovens.
20:19Inside, the racks rotate to give the gingerbread an even bathe.
20:30So, there's Santa.
20:32Where's his reindeers?
20:33Those are in that oven over there.
20:35Ah, reindeers are in that oven.
20:37Santa's in there.
20:38For anyone just joining us, especially the kids, we're not slow-roasting Santa and his reindeers.
20:45Just putting that out there.
20:46Don't want anyone having nightmares.
20:48After 25 minutes at 163 degrees Celsius...
20:55..the baked Santas are ready to come out into the cold.
21:03Here they are.
21:06Now, I've been here a while.
21:08Yeah?
21:09I've been thinking it.
21:10I've not said it out loud.
21:11Can I have a taste?
21:13Absolutely.
21:13Go for it.
21:14Merry Christmas.
21:20Oh, I love that.
21:21Oh, they're nice and soft as they've just come out of the oven.
21:23Get on that.
21:26Oh.
21:31Soft with a little bit of a crunch around the edge.
21:34Oh, that's good.
21:35You get, like, a smooth sort of velvet-ness.
21:37Oh, yeah.
21:38That is cool from the golden syrup.
21:39And just the right amount of heat in that.
21:41Are you still here?
21:46Go and film something.
21:47You want fun?
21:49Go on.
21:50That's your wages for today.
21:52Yeah.
21:58Every day, 20,000 gingerbread figures are wheeled through here to cool.
22:03And Gemma and I...
22:06There we go.
22:07Great.
22:08...have the latest batch.
22:10So, the next thing we need to do is take the biscuits off the baking trays...
22:14Yeah.
22:14...and put them onto a decorating tray.
22:17Gemma, I've got to be honest.
22:19You were talking then.
22:20I were totally distracted by that poster with them hands on.
22:24I've never been in a factory where we have to do hand stretches.
22:26Why is that?
22:27Well, it's when you're piping and icing all day.
22:29Yeah.
22:30It can be quite tough on your hands.
22:31So, it's good to stretch your fingers out a little bit...
22:34Yeah.
22:34..so that it's not too much pressure on your hands.
22:36What a job that is, being a hand-stretching model.
22:39Well, actually, it's one of our employees here that did it for us.
22:43It's Bev's.
22:43Are you yours?
22:44Mm-hmm.
22:45Bev?
22:46Bev?
22:47I'm here.
22:47Get your hands down here.
22:50Get your hands down here.
22:52Not just a pretty face.
22:53Right.
22:55Talk us through these, then.
22:56Right, this one's really good.
22:58Do you want to pray with me?
22:59Yes, I do.
23:01Spread your fingers.
23:03Yeah.
23:03And then go like that, and that's a really good stretch.
23:06Ooh.
23:12When you first took my hand on a cold Christmas Eve
23:16You promised me Broadway was waiting for me
23:18You were pretty queen of New York City
23:22When the band finished playing
23:23They held up for more
23:25And
23:26They do this with the wrist
23:28That with the wrist
23:29That way
23:29So you don't realise it
23:31When you pick your gingerbreads off off the shelves
23:33What goes into it?
23:34Look at all this
23:35And it does help
23:36It really does help
23:37Right
23:41Let's go
23:43While I'm limbering up
23:46Let's check in on Ruth
23:47Who's enjoying a 1960s Christmas
23:50Loveliness
23:51Go on, Jen
23:52Off we go
23:53And for some reason
24:01She appears to be in a space museum
24:04For as long as humans have gazed up at the sky
24:14We have been fascinated by space exploration
24:17And in December 1968
24:20There was one very special mission
24:22That gave three astronauts a Christmas never to forget
24:27Who better to reveal this incredible festive story than Helen Sharman
24:34Hello, Ruth
24:35Hello
24:36Nice to see you
24:36Nice to see you too
24:38In 1991
24:40She became Britain's first astronaut
24:42And the first woman ever to visit the Mir space station
24:46We're meeting at the Science Museum in London
24:51You actually have been in space
24:55Yeah
24:55So I was in low Earth orbit
24:57Where the International Space Station is now actually
24:59About 250 miles above the Earth's surface
25:01But when you think about going further away from Earth's orbit
25:05I mean that is just something else
25:07In the mid-1950s
25:13The race began to do just that
25:15The USA and the Soviet Union
25:20Were engaged in a bitter Cold War
25:22And both superpowers
25:25Had set their sights on space superiority
25:28Still by 1968
25:31No humans had gone higher than low Earth orbit
25:37And there was this big race
25:38America wanted to go to the moon before the Soviets
25:41And Apollo 8 was a spacecraft that was ready to do that
25:45Three astronauts were chosen
25:51Jim Lovell
25:53Bill Anders
25:55And Frank Borman
25:56Their mission
25:58To be the first space crew
26:01To reach the moon's orbit
26:0210
26:0310
26:039
26:05We have ignition sequence start
26:07And on the 21st of December 1968
26:112
26:121
26:130
26:13We have liftoff
26:20Apollo 8 launched
26:23Apollo 8, you're looking good
26:26Roger
26:27Well this is a command module
26:31Now this actual one is Apollo 10's
26:34But for their entire mission
26:35The Apollo 8 crew
26:37Spent their time in this type of a spacecraft
26:39Or just this one small little piece
26:42Yeah
26:42Can you imagine?
26:43Just a few days before Christmas
26:44They were living
26:45They were sleeping
26:46Going to the toilet
26:47Eating
26:47I mean everything had to happen
26:49Inside this spacecraft
26:50Back on Earth
26:56People were preparing
26:57For a very special Christmas
26:58As Apollo 8
27:02Approached the moon's orbit
27:04Armed with TV cameras
27:06The crew were tasked
27:08With documenting this historic moment
27:11Oh my goodness
27:14So what
27:14This is inside the module
27:16Quite fun isn't it
27:18So you get an idea
27:19Of how cramped they were
27:21Wow
27:22This is what Christmas in space
27:24Looks like
27:25It's taken almost three days
27:32To get there
27:32But they've travelled
27:33240,000 miles
27:36To the moon
27:37And they were getting
27:38Into the moon's orbit
27:40On Christmas Eve
27:42Itself
27:43Then
27:48At 2.34
27:49On Christmas morning
27:51The astronauts
27:52Broadcast live
27:53To the world
27:54We are
27:56Now approaching
27:58Lunar sunrise
27:59And
28:01For all the people
28:02Back on Earth
28:04The crew of Apollo 8
28:05Has a message
28:07That we would like
28:07To send to you
28:08In the beginning
28:12God created
28:14The heaven and the earth
28:15And darkness
28:16Was upon the face
28:17Of the deep
28:18And God said
28:20Let there be light
28:22A lot of thought
28:24Went into what they
28:25Were going to say
28:26They knew people
28:27All around the world
28:27Would be tuning in
28:28We think now
28:30It's estimated
28:30That about a billion
28:32One billion people
28:33Watched this broadcast
28:35So about a quarter
28:36Of all people alive
28:38No
28:39Good gracious
28:43So everybody's
28:44Getting ready for Christmas
28:45They're hanging up
28:45Their stockings
28:46They're doing their thing
28:47And they're watching
28:48The moon from close up
28:50What a Christmas
28:52And NASA
28:56Had even provided
28:57The astronauts
28:58With their very own
28:59Christmas dinner
29:00Santa Claus brought us
29:03Some turkey and gravy
29:04Cranberry sauce
29:06Great lunch
29:07Outstanding
29:09Glad to hear it
29:11We're down here
29:13Eating cold coffee
29:14And bologna sandwiches
29:15Having gathered
29:20Vital information
29:21For future
29:22Apollo voyages
29:23The mission
29:24Proved a huge success
29:26While delivering
29:27One final
29:29Christmas miracle
29:30As they came
29:33Around the moon
29:33There was this
29:35Most amazing
29:36Earth
29:37Rising
29:38Above the surface
29:40Of the moon
29:40Like the moon rise
29:41You've got the earth
29:42Earth rise
29:43Got a colour film
29:44Jim
29:44Oh that's a beautiful shot
29:46And it became
29:50This iconic photograph
29:51Bill Anders
29:52Described it
29:53Later on
29:54As being like
29:55A fragile
29:55Christmas tree
29:57Bauble
29:57The only part
29:59Of colour
29:59In the whole
30:00Of this black
30:01Space
30:02Wow
30:05It is such
30:08An iconic image
30:09That isn't it
30:09And I suppose also
30:11It's not just
30:12Earth rise
30:13It's
30:13Earth at Christmas
30:15And from the crew
30:17Of Apollo 8
30:18We close with
30:20Good night
30:20Good luck
30:22A Merry Christmas
30:23And God bless
30:25All of you
30:26All of you
30:27On the good earth
30:28That's the Christmas
30:38Spirit right there
30:40Bless us one and all
30:41You better watch out
30:43You better not cry
30:45You better not pout
30:46I'm telling you why
30:48Why?
30:48Santa Claus is coming to town
30:51Gather on
30:53Do you know what I love about Christmas?
30:56Those unexpected yet thoughtful Christmas presents
30:59One year
31:01One year
31:01My aunt got me a pink bath mat
31:03And I was ten
31:03Pink
31:04That's my worst present I've ever had
31:06When I was younger
31:07Midi hi-fis had just come out
31:10Oh
31:10And I was like
31:11I'd love her
31:11I thought
31:12No chance
31:13Anyhow
31:13Christmas day
31:14I was up
31:15First thing
31:16Straight in the front room
31:17So excited
31:18Ripped the box open
31:20And it was a
31:21Cleral foot spa
31:22So
31:23Hoping for better luck this year
31:28At this family run factory
31:33I've mixed, baked and cooled Santas and reindeer
31:36But the gingerbread is only half the story
31:39Ah
31:42Naked these ones
31:45Nothing on them yet
31:47Yep
31:48All ready for decorating
31:50The kids and girls in Boyland
31:53Will have a jubilee
31:55They're gonna build a toy land town
31:59All around the Christmas tree
32:01This is where the magic of the factory happens
32:05The heart of Santa's grotto
32:08Where plain and simple gingerbread shapes
32:11Are transformed into colourful Christmas creations
32:14And to adorn their biscuits
32:17The factory gets through 30 kilos of icing a day
32:21Love that
32:23It makes you smile
32:24The gingerbread is decorated with two types of icing
32:28Runny royal icing for intricate details
32:32And sugar paste shapes for larger areas
32:35He sees you when you're sleeping
32:38And in all the way
32:39Cherry's off to make the next batch for our Sansa
32:42It's like Christmas magic in here
32:45How good do those look?
32:48He needs it for his lovely red waistcoat
32:51He's coming to town
32:54Her guide to sugar paste perfection
33:00Is baking operative Steph
33:03Hey Steph, lovely to meet you
33:05So what's in here?
33:06What are the ingredients?
33:07So we've got icing sugar
33:08The xanthan gum
33:10And sugar gum in there
33:11I know what icing sugar is
33:12What is xanthan gum?
33:14So xanthan gum
33:15It helps with the consistency in the shelf life
33:17Xanthan gum is a plant-based thickener
33:21And sugar gum is made from glucose syrup
33:24Sugar, oil
33:25And another syrup called glycerin
33:28They bind the icing together
33:30Giving it a firm, flexible texture
33:33Perfect to mould into shapes
33:35We've got a red colouring to add in now
33:37And that's just that one over there
33:39Can I do the honours?
33:40Absolutely
33:41Ready?
33:42Yeah
33:42Ready?
33:43Get it?
33:43Red is...
33:44That is so beautiful
33:50That looks like raspberry sauce on ice cream
33:52Yeah, it's called Christmas red
33:54The colour we actually put in
33:55Is that done?
33:59That's it done now
34:00Hey presto
34:02Can I touch it?
34:03Absolutely
34:04It's so thick
34:05It is just like modelling
34:06Yeah
34:07So without this
34:09Santa would be naked
34:10So this is a really important element
34:12To the biscuit
34:14It really is
34:15Fabulous job
34:16Nice one, Cherry
34:21My turn to load your icing
34:23Into this sheeter machine
34:24Where it's rolled out
34:26To just three millimetres thick
34:28Then a stamper
34:33Cuts out the waistcoat shapes
34:35Santa baby
34:38Just slip a sable
34:40Under the train
34:42For me
34:43So hurry down
34:45That you'll need
34:46Tonight
34:47Santa's waistcoat
34:53Is ready for some detail
34:54And for that
34:55The clever factory elves
34:57Use the runny
34:58Royal icing
34:59It's a mix of
35:02Icing sugar
35:03Egg white
35:04Glucose syrup
35:05Xanthan gum
35:06And corn flour
35:08With glycerin
35:09So it doesn't set rock hard
35:11And if you think
35:13Royal icing sounds posh
35:15Get this
35:16In the middle ages
35:18Gingerbread would sometimes
35:20Be decorated
35:20With gold leaf
35:22Not on our budget
35:24I've got to be honest
35:26It's the first time
35:27I've filled a piping bag
35:28Gemma
35:28Oh there it is
35:30Get that in there
35:31Look at that
35:32That's it
35:33You don't want to dribble too much
35:35Story of my life
35:38Gemma
35:38Gemma herself
35:42Comes up with the designs
35:43And the ladies here
35:45Are wizards at reproducing them
35:47They are
35:50Icing artists
35:52How long have you been doing that?
35:55I've been in ten years now
35:56They're quick
35:57Who's the fastest icer?
35:59Beth, yeah
36:00How many gingerbreads
36:01Do you think you've iced?
36:03Millions
36:04Four billions
36:05Billions?
36:06Flipping heck
36:08They are accurate
36:09I feel like you get it spot on every time
36:12With the concentration of ninjas
36:16And today
36:18There's a nervous new apprentice
36:20In the house
36:21Now we're on to the main stage
36:25We're going to decorate these
36:26To look exactly like Father Christmas
36:28Are you ready to give it a go?
36:29Let's give it a go
36:30Absolutely
36:31And I've got two experts with me today
36:33I've got Rachel and Charlie
36:34And they are going to show you
36:35Everything that you need
36:37To be able to decorate a Santa
36:38Right, let's do it
36:39Okay, so your first part
36:41Is his face
36:43Two round then
36:45A little squeedle in the middle
36:46God, that is so much difficult
36:53Than you make it look
36:54Right, okay
36:56I'll tell you what
36:57I'm feeling it already
36:58In my hands
36:58You're feeling it?
36:59Yeah
36:59You're stretching
37:00So it's his hands next
37:05I reckon this is going to be the trickiest part
37:07It is a bit tricky
37:08Okay, so squeeze
37:10And drag
37:11Right
37:12Squeeze
37:15And drag
37:16Squeeze and drag
37:17I think I put ears
37:25Where his hands should be
37:26We've got the hard bit to go
37:29Yeah
37:29I'm going to do the hat now
37:33Oh my
37:36And it doesn't help
37:39That I can feel
37:40All the eyes are on me
37:41What?
37:44I'm actually sweating
37:45I'm having no stress like it
37:48Mine's got all lumps
37:51Of yours
37:51He's dead smooth
37:52Hello
37:55Have a look
37:55Which one did you?
37:57Well, I take a guess
37:58Yeah, I know
38:00Oh, it's so good
38:01You're a natural
38:02I don't think she means that
38:04Well done
38:05God, you're working hard on that
38:07Er, there's reindeers
38:09Be frosted or whatever
38:11Good luck
38:12Have a good'em
38:13Thank you
38:14Lovely to see you
38:15Merry Christmas
38:17Gemma's family have been in business
38:20For nearly 40 years
38:22Surely one man can't bring it down in a day
38:25Right, will I get to grips with this masterpiece?
38:29Cherry's down in Cornwall
38:30Looking at scented candles
38:32I'm actually still here
38:33Telling it
38:34All right, don't worry about it
38:36This is the St. Evel factory near Newquay
38:47Where they've been making festive candles for over 30 years
38:52Using traditional techniques and cutting-edge technology
39:00Like the gingerbread factory
39:02They're in full swing for Christmas
39:04I'm meeting Chief Exec Ian Greaves
39:09Hi Ian
39:11Hi Jake
39:11Who's overseeing a Yuletide treat
39:14Can I just thank you so much for having the best smelling factory of all time?
39:19Thank you
39:19And you always go home smelling so nice as well
39:21Do you?
39:22Yes
39:22What are we making today?
39:24Today we're making an advent calendar
39:26An advent calendar?
39:27Not with chocolate
39:27With candles
39:28The advent calendar contains 24 scented tea lights
39:35So each window has a different scent
39:38Oh wow
39:39These small candles were originally used to keep teapots warm in Japanese tea ceremonies
39:45Today I'm making the scented tea light behind door 20
39:51Orange and cinnamon
39:53Orange and cinnamon
39:54Warm and tangy with a hint of spice
39:56It's lovely
39:58Oh yeah
39:59That is Christmas Day in a candle
40:01It is
40:01Exactly that
40:02But before we make our festive tea lights
40:09I want to understand the science of scent
40:12What different things are you looking for when it comes to scent in a candle?
40:17Well there's two types of throw in a candle
40:19What is the throw?
40:21It's how far you can get that fragrance to throw
40:23So can you smell it close up?
40:25Can you smell it far away?
40:25So that's the throw
40:26We talk about a hot throw and a cold throw
40:28When you walk into the room and the candle's not lit
40:31You can often smell a candle
40:33And that's called the cold throw because it's not light
40:35Even before it's lit
40:38Fragrance molecules are released from the surface of the candle
40:42When these molecules hit scent receptors in our noses
40:46We smell the aroma
40:47And that effect is enhanced when the candle is lit
40:52Why does lighting it encourage the fragrance to leave the candle?
40:56When the wax becomes a liquid
40:58The fragrance can then evaporate much quicker
41:01We can then smell it from a distance
41:04Because it's releasing much more fragrance
41:05So once you've got that throw nailed
41:08That scent is all over the place
41:10And it's really gorgeous
41:11What do you do next?
41:13Down to production
41:14Mix some wax and fragrance
41:15Let's make some candles
41:16Production manager Joe Shalders is in charge of the wax
41:24What is this wax made of?
41:27So this is a vegetable mineral blend
41:29And what is mineral wax?
41:30So that element of it is paraffin
41:33So it gives us a really good scent throw
41:35And it's a really clean burn
41:37The slabs of wax are melted overnight at 80 degrees Celsius
41:44Then cooled to 61 degrees
41:47Ready to add the all-important scent
41:50Each of our candles has got its own recipe
41:54This is what we need to make the orange and cinnamon candle
41:56Right
41:57Can I?
41:58You can
41:58The scent is a mix of essential oils
42:02Extracted from plants and spices
42:04Plus synthetic fragrance
42:07Oh the smell that's coming off that Joe
42:09Yeah
42:10It's absolutely Christmassy heaven
42:13The small tea lights contain a high proportion of scent
42:17To achieve that all-important hot throw
42:20And after a good mix
42:24The fragranced wax is sent to the high-tech part of the factory
42:28This is the pouring line
42:31Where all the elements of the tea light come together
42:34The aluminium cases are loaded onto a computer-controlled conveyor belt
42:40The cotton tea light wick is fed in from a wick reel
42:47Along with the metal holders which keep the wicks upright
42:50The cases come down through here
42:55And then this fancy piece of kit cuts the wick to the right length
43:00And then glues it into the case
43:03Hidden inside this machine
43:07Called a wicking head
43:08A little dot of glue fixes the wicks in place
43:12And when they're all lined up and standing to attention
43:16We're ready to pour our scented liquid wax
43:19Please tell me there's a button
43:20There is a button
43:21Just this one here
43:22Oh easy
43:22Off she goes
43:23Gosh look at this
43:31It's so beautiful
43:32The fragrance wax gets released down
43:35Into the cup
43:37Filling them
43:3822 in a row
43:40All in one go
43:41That smells absolutely delicious
43:43The pouring machine dispenses 18 grams of scented wax into each case
43:50Over six hours a full tank of 250 litres of wax
43:55Can fill 14,000 tea lights
43:59So can you now tick December 20th off your list?
44:04Yes I can
44:04Only 23 more to go
44:07All 24 candles of various scents are hand packed into the advent calendar
44:16Winter time
44:19Ready for dispatch around the country
44:22It's quite satisfying to know that someone's going to open all these little doors on the run up to Christmas
44:27And enjoy their Christmas candles
44:29Happy Christmas guys
44:30Thank you
44:31I hope you've got one of those for me Cherry
44:35It may surprise you but I love a hot soak in the tub with a scented candle
44:40Back in Market Drayton there's no time to relax when there are Santas to decorate
44:52And Cherry's back from Cornwall already
44:57That was quick
44:59Gingerbread coming through
45:01Make way
45:02Thank you so much
45:03It's her job to decorate our second Christmas biscuit
45:08Come on my little reindeer friends
45:11Let's make you fancy
45:12And luckily she's got some expert help from operative Danny
45:17Hi Danny
45:19Hi
45:19Lovely to meet you
45:20Lovely to meet you
45:21It's very quiet here
45:23Have you scared everyone off?
45:24Yes
45:24Well unlike the Santas
45:25We don't decorate these by hand
45:27We decorate it with a robot
45:30Oh my god you've gone high tech
45:31The robot floods the face of the reindeer with royal icing
45:39Their little ears and antlers would be too fiddly to cut from sugar paste sheets
45:45How quickly can it ice a biscuit?
45:50There's 21 pieces on a tray and it takes 9 minutes a tray
45:53The whole tray?
45:54The whole tray
45:54So it's really speedy
45:55Oh yeah much quicker than us
45:57And it doesn't complain about our make?
45:58No definitely not
45:59How does it know where the biscuit is to get the icing exact?
46:03So when it takes the tray in it takes a picture of the camera
46:06And it maps where the biscuits are on the tray
46:09And it's pre-programmed the design
46:12So then it will just see where the biscuit is and trace it on top
46:15But just when I thought I'd got the easy icing job
46:19Turns out these little fellas also get their finishing touches by hand
46:25Serves me right for laughing at Paddy
46:27Like twisty round
46:30Oh that's weird
46:32Oh it looks like a croissant
46:34Okay this one's going to be great
46:36This one's good
46:37Oh no!
46:41That's what I was talking to
46:42It's basically got a nosebleed
46:45Not so easy is it?
46:50Mine looks like it's been in some kind of accident
46:51Oh she's struggling
46:53It looks like he's sticking his tongue out now
46:55These experts can ice a gingerbread in 105 seconds
47:02I've taken a bit longer than that
47:06Right Paddy just the last thing to do now
47:09Create his face for us
47:10Lovely
47:11Here we go
47:12I think you're coming into your own now Paddy
47:16I'm happy with that one
47:24He's got his own charm about him there you see
47:26You see I'm not a perfect Santa but you know I'll still taste nice
47:31Right so I'm going to take mine too
47:35To Cherry and see how it compares with her reindeers
47:39Thanks very much for that
47:40No worries
47:40See you in a bit
47:41Come on you two
47:43So it's the ultimate Christmas competition
47:51Santa versus his reindeer
47:53But which of us has won the icing crown?
47:59Let's see yours
48:00Can I just say
48:01Don't you think?
48:02Lovely glazing
48:04Yes
48:04Actually that bit was done by a robot
48:06We're never going to agree on this are we
48:08So let's get the expert eye in
48:10Gem
48:11Where are you?
48:13Here we are
48:14Right Gemma
48:14How are we getting on?
48:15Well let's have a look
48:16Whose do you think is the best?
48:18Wow
48:19I think there's some good effort sir
48:21That is a very good reindeer
48:23It's very close
48:23Thank you so much
48:24Oh it's a reindeer
48:25Right okay
48:27Unfortunately I don't think either of them
48:30Are going to pass our quality standards
48:32But
48:32You are more than welcome to have them
48:35And take them away
48:35Can I have one of your garden gnomes?
48:39Yes you can
48:39Yes yes can I have one of your bull mastiffs?
48:42Yeah there we go
48:43Thank you
48:43How about that?
48:44One eight
48:44Wonderful
48:45Happy Christmas
48:46See you in a bit
48:46Garden gnomes
48:48The cheek of it
48:50Once the icing's dried
48:53The gingerbread is ready to be pint
48:55We're placing the santas
49:02We're placing the santas individually down the flow wrapper
49:03So each one goes in its own little section
49:06Love this
49:06And it's pushed along
49:07And it's taken it down to the flow wrapping section there
49:10The santas are sealed in their see-through packages
49:19At the rate of 50 a minute
49:21As we go round
49:25You'll see them coming out of the other side
49:28All individually packed
49:29Yes
49:30All them little santas
49:34Off to make someone's Christmas
49:36Very special
49:37Off to stockings around the country
49:40Beautiful
49:40Then it's into the boxes
49:43Eight in each
49:45Good night everyone
49:48Where Santa is united with his reindeers
49:52Well
49:57Cherry's alright at packing boxes
50:00But how does she go on with wrapping presents?
50:02Let's find out
50:03Now I adore giving gifts
50:13But wrapping them is a whole world of pain
50:18Please tell me that I am not the only one
50:21That leaves my wrapping to the last minute
50:23You can never find the scissors
50:24You can't find the end of the tape
50:26There's never enough paper
50:27And then it looks like this
50:29There's got to be a better way to do this
50:33Here to grant my Christmas wish
50:36Is expert mathematician Bobby Seagull
50:39Bobby
50:41Happy Christmas
50:42Happy Christmas
50:43Come in
50:45Who uses maths to achieve present wrapping perfection
50:49Bobby
50:52Welcome to the annual Christmas wrapping disaster
50:56This is ineffective
50:58There's far too much wrapping paper
50:59It's wasted
51:00On this one here
51:01The corners aren't covered
51:02Because the paper's too weak
51:03You're not covering the surface area
51:05This is a mathematical Christmas disaster
51:07Can maths save Christmas?
51:09Maths will have to save Christmas
51:11Definitely this Christmas
51:12Luckily I have a whole raft of rolls to choose from
51:17Think about the paper you're using
51:20It shouldn't have glitter or that shiny foil
51:23Because these are non-paper additives
51:25That can't be recycled
51:26Don't be on the naughty list
51:28Because of your wrapping paper
51:29No, Santa is not going to be pleased with you
51:31No, okay
51:31In the UK
51:34It's estimated we throw away
51:36Around 200,000 miles of wrapping paper a year
51:41So if you can
51:42It's important to choose fully recyclable paper
51:45To avoid waste
51:48I'm hoping Bobby's maths
51:50Can help me achieve perfectly wrapped presents
51:53Let's start with this
51:56A box of chocolates
51:57Well, maths can definitely help
51:59So if you look at this
52:00It's a square prism
52:02It's got a square on one side
52:05And it's the same dimensions all the way through
52:07Before we begin wrapping
52:12We calculate how much paper we need
52:14To cover our square prism
52:16So X presents the sides of this square
52:21Yes
52:21And L represents the length
52:23Good
52:23I'm not at one with maths
52:25But I'm following you
52:26Now it's time to measure
52:29Okay
52:30The width of the square
52:33Yes
52:33Is 6 centimetres
52:35Okay
52:36Good
52:36The length is 19 centimetres
52:39Plus we have a third measurement
52:42To allow for a half centimetre paper overlap
52:45When wrapping
52:45Okay, so Y equals 0.5
52:49Time to calculate the total area of paper needed
52:55First, the width
52:58All the way round
52:59Right
52:59There's how many lots of X
53:014
53:02So the width of the wrapping we needed is 4X plus Y
53:06So 4 times 6 is 24
53:09Plus the half centimetre paper overlap
53:1324.5
53:15Yes
53:1624.5
53:17To work out the length of paper
53:21It's the length of the box
53:23Plus one side of the square end
53:2519 plus 6
53:30Which is 25
53:31Spot on
53:32Calculations complete
53:38Next, measure and cut
53:40That is not enough wrapping paper
53:46Trust the maths
53:48We're using paper-based sticky tape
53:53That can be recycled
53:54Along with the wrapping paper
53:56Thanks to that half centimetre overlap
54:00Our paper joins up perfectly
54:03Ta-da!
54:06I told you
54:07Look at that
54:08Nothing is wasted
54:10Everything is used
54:11And the same principle even applies
54:16To wrapping a bottle of festive fizz
54:19Instead of the square at the base
54:21It's now a circle
54:23To work out the width of paper
54:25Measure the diameter of the bottle
54:27And times it by a figure known as pi
54:30And pi is roughly 3.14
54:33Plus half a centimetre overlap
54:37The length of the wrapping
54:38Is the diameter of the bottle
54:40Plus the height
54:41The classic bottle
54:45Wrapped
54:46And it's beautiful
54:47Bobby's halfway to saving Christmas
54:50But can he pass my final fiendish challenge?
54:57Can you deal with the big boss of wrapping?
55:00Which is?
55:01A ball
55:02It's difficult to wrap spheres perfectly
55:05But there is a way around this
55:07We can actually create a petal-like structure
55:09To wrap around the football
55:11So you can have four, five or six petals
55:18It might take a bit of time to cut out the petals
55:21But once that's done
55:23It takes seconds
55:24To wrap it
55:27Look at that
55:28Santa's smiling all the way to the North Pole
55:31I can hear the elves singing their favourite Christmas song
55:34And they're not the only ones humming a happy tune
55:39With Bobby's help
55:41My Christmas wish has been fulfilled
55:43Look how beautiful they look
55:46I think it's fair to say
55:47That you are the saviour of Christmas
55:49Look at you
55:51Like a Christmas elf
55:52Merry Christmas
55:53That is officially a wrap
55:56I've got to say
56:03That box looked great
56:05The ball
56:06Not so much
56:08Our boxed up gingerbread
56:31Has been loaded onto pallets
56:33And it's taken outside
56:36Where I'm headed
56:37Jacket on
56:38Her net off
56:39To see it on its way
56:40Oh, loading them up
56:42You alright Gemma?
56:42Hi Paddy
56:43Hello Paddy
56:44This is my mum's
56:45Sarah Paddy
56:46Oh, nice to meet you Sarah
56:47So, you set this business up
56:49All those years ago
56:50Did you imagine
56:51It were going to grow into something as big as this
56:54Because it's very impressive
56:55Thank you
56:56No, not at all
56:57Absolutely not
56:57No, we had a little bread shop
56:58And, you know, it's a dream come true
57:00You start a business
57:01And you never expect it to go
57:02To where it is today
57:04And I'm very proud
57:05From a lot of hard work
57:06And a great team behind us
57:08Hard work pays off
57:09How many gingerbreads are on there?
57:11Well, there's 26 pallets on there
57:13Which is just shy of 100,000 pieces
57:15100,000 gingerbreads
57:17Waiting to go out
57:18To keep everyone happy
57:19Around the nation
57:20Right
57:20That's loaded up
57:21We'll close the doors
57:22Send them on the way
57:23I'm going to get my colleague
57:25Out of there
57:26Cherry
57:26Because no doubt
57:27She'll be snaffling up
57:28All the gingerbreads
57:28Merry Christmas
57:29Merry Christmas
57:31Take care
57:32From Market Drayton
57:43The British home of gingerbread
57:45Our Santas and reindeers
57:48Travel across the country
57:49Ready to drop down the chimneys
57:51Of well-behaved biscuit lovers
57:53Everywhere
57:54Oh, look at us
58:02In the boss's office
58:03Living the life
58:04Nice cup of tea
58:05Thank you
58:06Oh, look at these beauties
58:08Do you want one?
58:09I'd love one
58:10Cheers
58:11Merry Christmas, everyone
58:14Have a lovely time
58:16Oh
58:17Well, I wish it could be Christmas
58:21Every day
58:24When the kids start singing
58:27And the band begins to play
58:30Oh, I wish it could be Christmas
58:35So let the band ring out
58:42For Christmas
58:44Oh, look at all, let the band ring out
58:59Peace
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