0:00:03 > 0:00:07We're a nation of food lovers, and there's more choice than ever.
0:00:08 > 0:00:14Eating in or taking away, there's always the chance that something can go wrong.
0:00:14 > 0:00:19It's a good job there's an army of people working to keep us safe.
0:00:19 > 0:00:21They're the food fighters.
0:00:44 > 0:00:48'On today's programme, from the farm...'
0:00:48 > 0:00:52- Come on, girls. - '..to a Yorkshire pudding factory.
0:00:52 > 0:00:56'We follow the food fighters protecting our humble egg.'
0:00:56 > 0:00:59What's the final safety check that we have to do?
0:00:59 > 0:01:05We would reject this type. This is the carbon from the trays.
0:01:05 > 0:01:08'Open for business, but is it ready to serve?'
0:01:08 > 0:01:12This place needs sorting out. You know that.
0:01:12 > 0:01:18'And can these junior food fighters teach us about safety in the kitchen?'
0:01:18 > 0:01:23If I don't wash my hands, then all the germs might go into the food
0:01:23 > 0:01:26and it might give other people belly ache.
0:01:30 > 0:01:34In Britain, the catering industry is worth £40 billion a year.
0:01:34 > 0:01:40It's no surprise restaurants and takeaways are opening all the time to get a slice of that pie.
0:01:40 > 0:01:44But who's checking those new businesses are fit to serve us?
0:01:44 > 0:01:50'On the front line of food safety there's a team of Environmental Health Officers across the country.
0:01:50 > 0:01:53'We've been on the road with two of them.
0:02:01 > 0:02:04'Oxford Environmental Health officer Richard Kuziara
0:02:04 > 0:02:09'is checking out a place so new he doesn't even know its name.
0:02:09 > 0:02:12'And he's not the only one.'
0:02:12 > 0:02:15- What's it called? Is it still Shisha House?- No.
0:02:15 > 0:02:19- It's just they put flag up. I don't know what it's called.- Yeah!
0:02:19 > 0:02:22It's just been here about three days.
0:02:22 > 0:02:25I'll call it the Kurdish Flag.
0:02:25 > 0:02:29'But though the flag is Kurdish, the food is more familiar -
0:02:29 > 0:02:33'baguettes and paninis stored in a fridge by the window.
0:02:35 > 0:02:40'If they're not kept properly, things can go badly wrong.
0:02:40 > 0:02:44'The fridge needs to be between five and eight degrees.
0:02:46 > 0:02:49'Time for Richard to aim his laser thermometer.'
0:02:49 > 0:02:54Temperature in here's good. It should be eight or below.
0:02:54 > 0:02:59- So the stuff in there is reading about seven.- Good?- Yeah. Good.
0:02:59 > 0:03:04'Storage of these sandwiches is OK, but prep is a different story.'
0:03:06 > 0:03:10When I need to make the panini, I have to take the meat out.
0:03:10 > 0:03:15- I not make them in here. - It's not well laid out, is it?
0:03:15 > 0:03:17No!
0:03:17 > 0:03:21'The Kurdish Flag has a fridge at one end of the cafe
0:03:21 > 0:03:24'and a kitchen at the other.
0:03:24 > 0:03:29'To Richard, that's like keeping your fridge in your living room!
0:03:29 > 0:03:33'And it can cause all sorts of food safety problems.'
0:03:33 > 0:03:36This is your poor layout again.
0:03:36 > 0:03:39This cheese... I know you're making sandwiches.
0:03:39 > 0:03:42But what would be nice, if that was here,
0:03:42 > 0:03:45then you could keep putting it away.
0:03:45 > 0:03:49Or if you had a fridge here, for example,
0:03:49 > 0:03:52you could put it away afterwards.
0:03:52 > 0:03:58'This poor setup means fillings are left to sit at room temperature.
0:03:58 > 0:04:01'This increases the risk of bacteria.'
0:04:01 > 0:04:03What have we got here, then?
0:04:03 > 0:04:09'It's not long before Richard makes another worrying discovery.'
0:04:09 > 0:04:12It says "store between six and eight". See that?
0:04:12 > 0:04:14So you need...
0:04:14 > 0:04:18Um, this is going to go off if you leave it at this temperature.
0:04:18 > 0:04:21How long's that been out there?
0:04:21 > 0:04:25- This one on top of there, yesterday. - Yesterday.
0:04:26 > 0:04:30'These yoghurt drinks have been left out for 24 hours.
0:04:30 > 0:04:35'They could be off, and could cause food poisoning.'
0:04:35 > 0:04:40- This one, I throw out. - Yeah. Throw them away.
0:04:41 > 0:04:45'The Kurdish Flag didn't get in touch with Richard before opening.
0:04:47 > 0:04:50'The new owners have to make a lot of changes.'
0:04:50 > 0:04:56What I would have liked to have seen was the owner contacting us before.
0:04:56 > 0:05:01Saying, "We're opening this place. Have a look. Tell us what we need to do."
0:05:01 > 0:05:05Instead, they've just opened it and, structurally, it's rubbish.
0:05:08 > 0:05:13'How much difference can the food fighters make to a new business?
0:05:23 > 0:05:25'200 miles away, in Preston,
0:05:25 > 0:05:31'Environmental Health Officer Simon Neighbour is giving a cafe its second inspection.
0:05:31 > 0:05:34'When this curry cafe first opened, it was dirty
0:05:34 > 0:05:39'and they were real problems about the way food was being stored.
0:05:39 > 0:05:43'It was marked just two out of five and told to clean up its act.
0:05:46 > 0:05:48'Simon's back to see if they have.'
0:05:48 > 0:05:53I hope that you got those things that Jenny put in her letter.
0:05:53 > 0:05:55- Yeah, I got everything completely. - Good.
0:05:55 > 0:06:00'Lunches & Brunches has been in business just over a year,
0:06:00 > 0:06:03'serving curry and rice to central Preston.'
0:06:03 > 0:06:06You've got a lot of room down here!
0:06:07 > 0:06:11We cook traditional homemade food so, er...
0:06:11 > 0:06:16We make in the morning and we put it in a pot and go upstairs.
0:06:16 > 0:06:23'It's a simple system, but have the staff made the changes called for two months ago?'
0:06:23 > 0:06:27From this initial thing, you can see you've got preparation here,
0:06:27 > 0:06:31there's storage in this corner, moves round into cooking.
0:06:31 > 0:06:34You can do plating-up here and take it upstairs,
0:06:34 > 0:06:37which is a really nice progression.
0:06:37 > 0:06:43The floor's fantastic. Stainless steel, easy to tell you're on top of that.
0:06:43 > 0:06:49'The layout here is much better than the Kurdish Flag in Oxford, but it still isn't perfect.'
0:06:49 > 0:06:52It's a little dark at this end of the kitchen.
0:06:52 > 0:06:56When we clean this one, yeah, it goes brighter.
0:06:56 > 0:07:00Cleaning about three, four months, so it's gonna be brighter.
0:07:00 > 0:07:04- With steam and oil... - Yeah. They'll collect on there.
0:07:04 > 0:07:07This end, you know, it's a little bit dark.
0:07:07 > 0:07:13It's harder to see how the cleaning's going, if you're doing any checks for signs of mice.
0:07:13 > 0:07:15No problem. We'll do that.
0:07:16 > 0:07:20'It's time for Simon to shine his light.
0:07:20 > 0:07:24'Will anything unwelcome be lurking in the dark?
0:07:25 > 0:07:30'He's looking for bits of food on the floor and for signs of rodents.'
0:07:30 > 0:07:32If you can get a pen through a gap
0:07:32 > 0:07:36a mouse will be able to squeeze through that size hole.
0:07:36 > 0:07:40Mice can carry diseases. Rats carry diseases.
0:07:40 > 0:07:44Mice are urinally incontinent. They dribble urine everywhere they go.
0:07:44 > 0:07:47They can jump onto a worktop,
0:07:47 > 0:07:49dribble urine, scamper off.
0:07:49 > 0:07:56That urine will dry out but it can leave behind salmonella and other bugs that make you poorly.
0:07:56 > 0:07:59'Thankfully, there's not a mouse in sight.'
0:07:59 > 0:08:03- Have you got a pest control contract?- Yes.
0:08:03 > 0:08:07'In fact, though dark, this kitchen is pretty clean.'
0:08:07 > 0:08:10This is after this morning's preparation.
0:08:10 > 0:08:12There's no accumulation here.
0:08:12 > 0:08:16There's odd bits and pieces but, it sounds silly, it's fresh.
0:08:16 > 0:08:19It's not old. It's not accumulated.
0:08:19 > 0:08:22And the thing is, when we close at half past three,
0:08:22 > 0:08:27before we go home, we clean out everything and mop it every time.
0:08:27 > 0:08:30This is nice and clean, nice and tidy.
0:08:31 > 0:08:35'Vital advice about cleaning has clearly got through to Muhammad.'
0:08:35 > 0:08:39- I'm very strict about cleaning on my staff.- OK.
0:08:39 > 0:08:43I am not allowing any single thing, "Oh, just leave it till tomorrow."
0:08:43 > 0:08:47I say, "No. You have to finish your work, as simple as that."
0:08:50 > 0:08:52'The setup here is good,
0:08:52 > 0:08:56'but next comes a crucial part of the inspection -
0:08:56 > 0:09:00'the area the manager was told he must improve.
0:09:03 > 0:09:09'Will Muhammad have improved the way he stores his food?'
0:09:09 > 0:09:13Right in the middle there, that's still warm.
0:09:13 > 0:09:17'And straight-talking from the next generation of food fighters.'
0:09:17 > 0:09:21If I found a hair in my food, I'd feel awful and disgusted.
0:09:21 > 0:09:24I'd order a refund.
0:09:31 > 0:09:36The humble egg is something most of us eat every day in some form.
0:09:36 > 0:09:41From cakes to pies, mayonnaise to sauces, or simply boiled or poached.
0:09:41 > 0:09:45It's a huge industry and needs to be carefully monitored
0:09:45 > 0:09:48because it's by no means risk-free.
0:09:53 > 0:09:57'The UK food industry was on red alert.'
0:09:57 > 0:10:02Supermarkets are clearing shelves of products that could contain contaminated eggs from Germany
0:10:02 > 0:10:07following reports of animal feed being contaminated with chemicals.
0:10:08 > 0:10:14'In large quantities, the chemicals are thought to cause infertility and cancer in humans.
0:10:15 > 0:10:20'These contaminants would not have been destroyed by pasteurisation
0:10:20 > 0:10:23'or cooking.'
0:10:23 > 0:10:27Products were made using imported liquid egg, 14 tonnes of it!
0:10:27 > 0:10:32'Despite initial concerns, the dioxin levels in this case
0:10:32 > 0:10:34'weren't high enough to pose a risk,
0:10:34 > 0:10:39'but served as a reminder of how easily our food chain can be contaminated.'
0:10:44 > 0:10:47Thankfully, here in the UK, our egg industry is well protected.
0:10:47 > 0:10:54From the farms to our supermarkets and dinner plates, an army of people safeguard the eggs we eat.
0:10:54 > 0:10:58It's a journey that we followed on food fighters.
0:10:59 > 0:11:02'North Yorkshire, and this free range farm
0:11:02 > 0:11:06'produces 1.9 million eggs every year.
0:11:06 > 0:11:11'They're sent to shops, caterers and manufacturers all over the country.
0:11:11 > 0:11:16'This is a lot of responsibility on the shoulders of farmer Andy Hall.
0:11:16 > 0:11:20'Andy's been running his free range farm for two years.
0:11:20 > 0:11:22'Things are going extremely well.
0:11:22 > 0:11:28'Unlike the eggs in the German case, these have been awarded the British Lion stamp.
0:11:28 > 0:11:32'It's a mark we recognise from our supermarket shelves,
0:11:32 > 0:11:38'designed to give consumers like you and I the confidence that what we're buying is safe.
0:11:38 > 0:11:41'Just being awarded the stamp is not enough.
0:11:41 > 0:11:45'Andy has to prove his standards haven't slipped.
0:11:45 > 0:11:50'He's audited every 18 months, and today is inspection day.'
0:11:50 > 0:11:52My name's Malcolm.
0:11:52 > 0:11:56My job is to make sure that the eggs you buy are safe to eat.
0:11:56 > 0:12:00'Many of Andy's customers insist on the British Lion stamp.
0:12:00 > 0:12:04'If he didn't have it, he would lose a huge amount of business.
0:12:04 > 0:12:07'Clearly, today is a very important day.
0:12:07 > 0:12:11'For the farm to keep its status, Malcolm needs to be convinced
0:12:11 > 0:12:15'that every stage of the process is up to scratch.'
0:12:15 > 0:12:20If we couldn't get the stamp, it would be a very restricted market.
0:12:20 > 0:12:24I don't know what the financial implications would be,
0:12:24 > 0:12:27whether you could even find anyone to take the eggs.
0:12:29 > 0:12:31Right, good morning, girls.
0:12:31 > 0:12:33'Malcolm is on the front line
0:12:33 > 0:12:37'in the battle to stop harmful substances entering the food chain.
0:12:37 > 0:12:40'As well as dioxins,
0:12:40 > 0:12:44'he's also fighting to protect us against salmonella.
0:12:44 > 0:12:50'Salmonella is the second most common food poisoning in the UK.
0:12:50 > 0:12:54'It's caused by infected faeces on the exterior of the shell.
0:12:54 > 0:12:58'These can be absorbed through the shell and into the egg itself.
0:12:58 > 0:13:02'Salmonella can cause vomiting, diarrhoea and fever.'
0:13:03 > 0:13:07Salmonella is a major threat to the egg industry.
0:13:07 > 0:13:12The programme is to ensure that eggs do not have salmonella on the shell
0:13:12 > 0:13:15or within the contents of the egg.
0:13:16 > 0:13:20'Malcolm takes samples using swabs attached to his feet
0:13:20 > 0:13:22'to test for signs of the bacteria.'
0:13:22 > 0:13:24Come on, girls!
0:13:28 > 0:13:32'Dioxins got into the eggs in the German case through feed,
0:13:32 > 0:13:37'so Malcolm wants to see exactly what these chickens are eating.'
0:13:37 > 0:13:42The press has been full of feed scares over a number of years.
0:13:42 > 0:13:46One of the favourite chemicals mentioned is dioxins.
0:13:46 > 0:13:49Dioxins have got into the feed chain.
0:13:49 > 0:13:52They would transmit through into the egg,
0:13:52 > 0:13:56so it's very important that the feed is of the required quality
0:13:56 > 0:14:00to make sure they don't present a problem to the egg itself.
0:14:00 > 0:14:05'All the feed here must be above board, because what a chicken eats
0:14:05 > 0:14:08'eventually gets into our eggs.
0:14:08 > 0:14:14'So Malcolm gets CRACKING looking at the paperwork and the food itself.'
0:14:14 > 0:14:1616th. 5th April.
0:14:16 > 0:14:191st February.
0:14:19 > 0:14:21OK.
0:14:21 > 0:14:23Thank you very much.
0:14:23 > 0:14:26'Final stop, the printing machine.
0:14:26 > 0:14:33'Each egg is given a unique code so we can tell where it's come from and when it should be used by.
0:14:33 > 0:14:36'This code must be clearly visible.'
0:14:36 > 0:14:391UK 21214.
0:14:39 > 0:14:42- Yeah. It's a good job.- Yeah.
0:14:42 > 0:14:45Fine. That's all I'm looking for.
0:14:45 > 0:14:51'There's been no stone left unturned here and now it's crunch time.
0:14:51 > 0:14:54'Will Andy's eggs continue to carry the Lion stamp,
0:14:54 > 0:14:59'which clearly means so much to businesses like this?'
0:14:59 > 0:15:01I've not found any problems,
0:15:01 > 0:15:06so I'm proposing that you be approved within the Lion scheme.
0:15:08 > 0:15:10And that's us done.
0:15:10 > 0:15:16'Andy's CRACKED it. His eggs can carry on being sold with the British Lion stamp.
0:15:16 > 0:15:19'Many will go straight off to our supermarkets.
0:15:19 > 0:15:23'Others will be off to the food factories.'
0:15:27 > 0:15:30Many eggs like Andy's are used to make this.
0:15:30 > 0:15:32It's liquid egg.
0:15:32 > 0:15:36It's used in a whole range of products we buy from our shops.
0:15:36 > 0:15:40It's used in restaurants like mine up and down the country.
0:15:40 > 0:15:45Without a shell to protect it, can we be sure it's not contaminated?
0:15:45 > 0:15:49Let's meet the food fighters who keep it safe.
0:15:51 > 0:15:56'This is Ready Eggs near Enniskillen, Northern Ireland.
0:15:58 > 0:16:03'The factory produces four tonnes of liquid egg every hour.
0:16:03 > 0:16:06'It could end up on a plate near you.
0:16:06 > 0:16:10'Kerry Campbell is the plant's technical manager.
0:16:10 > 0:16:17'Eggs used have that all-important stamp, so Kerry knows they're safe.
0:16:20 > 0:16:22'There's plenty that can go wrong.
0:16:22 > 0:16:28'A shell is like a shield, so once it's gone, bacteria could invade.
0:16:28 > 0:16:32'The British Lion food fighters want to make sure that's not happening.'
0:16:32 > 0:16:38If the auditor finds anything untoward, it would have a big impact on our business.
0:16:38 > 0:16:44We are making sure that we're aware of all the risks posed to the consumer
0:16:44 > 0:16:48because of the risks such as salmonella.
0:16:49 > 0:16:56My name's Kevin Carlisle. It's my job to make sure liquid egg is safe for consumption.
0:16:56 > 0:16:59'Just like on the farm, this is a crucial inspection.
0:16:59 > 0:17:02'If Kerry loses the British Lion stamp
0:17:02 > 0:17:07'it will be almost impossible to sell the product in the UK.
0:17:07 > 0:17:12'First, Kevin checks if she knows where her eggs have come from.'
0:17:12 > 0:17:14Can you tell me when they were laid?
0:17:14 > 0:17:20Yes. This pallet would have been laid at the tail end of March, 26 and 27 March,
0:17:20 > 0:17:23which is the date of lay.
0:17:23 > 0:17:28- What's the maximum time you hold them here?- Before we process them, a maximum of 28 days.
0:17:28 > 0:17:30'This is a two-fold check.
0:17:30 > 0:17:34'Kevin needs to be convinced the eggs are approved.
0:17:34 > 0:17:40'He also needs to be sure any problems down the food chain can be traced back to the source.'
0:17:43 > 0:17:471UK obviously stands for the fact that the eggs are free range.
0:17:47 > 0:17:50This four-digit code relates to the producer.
0:17:50 > 0:17:53'Kevin continues his meticulous inspection.
0:17:53 > 0:18:00'This is the breaking room, where eggs are cracked and separated.
0:18:00 > 0:18:03'It's vital that no shell gets into the product.'
0:18:03 > 0:18:08You can see the yolk coming down one lane and the white down another.
0:18:12 > 0:18:18'Next, probably the most important part of the process, pasteurisation.
0:18:18 > 0:18:23'By law, liquid egg has to be heated to over 65 degrees
0:18:23 > 0:18:25'to kill off any bacteria.
0:18:26 > 0:18:32'It must then be blast-chilled in a high-care area to remain safe.
0:18:34 > 0:18:38'A failure here could lead to dodgy bacteria winging its way
0:18:38 > 0:18:40'onto our dinner plates.
0:18:43 > 0:18:48'After an exhaustive inspection, it's time for Kevin's verdict.'
0:18:48 > 0:18:51Well, we've had a good look through everything.
0:18:51 > 0:18:54Hygiene standards were very good.
0:18:54 > 0:18:59Working practices, traceability, record keeping all very good.
0:18:59 > 0:19:04- So I'm pleased to say that you've retained your certification. - Thank you very much.
0:19:04 > 0:19:11'It's a great relief for Kerry, and means she can continue her business with the British Lion backing.'
0:19:11 > 0:19:15We'll see each other again in a year's time.
0:19:15 > 0:19:21'So, from the farm to this factory, our egg's been heavily scrutinised,
0:19:21 > 0:19:24'but it's not over yet.
0:19:24 > 0:19:29'For the next part of the journey, we need to head to Yorkshire.
0:19:33 > 0:19:35'The lengths food fighters go to
0:19:35 > 0:19:39'to make sure this Sunday lunch favourite is safe to eat.'
0:19:39 > 0:19:45I didn't imagine that at the end of this process I'd find a metal detector!
0:19:49 > 0:19:54As a kid I didn't need much of an excuse to get into the kitchen,
0:19:54 > 0:20:00but in recent years, skills that should have been handed down seem to have gone missing.
0:20:00 > 0:20:02Bad news for our dinner plates.
0:20:02 > 0:20:06It also means there's more risk of food poisoning from our kitchens.
0:20:06 > 0:20:11A national network of cooking clubs is set to change all that.
0:20:14 > 0:20:17'In days gone by, cooking and hygiene
0:20:17 > 0:20:20'was a huge part of the school curriculum.
0:20:20 > 0:20:25'Although home economics wasn't the breeding ground for sexual equality,
0:20:25 > 0:20:28'lessons played a key role in educating youngsters
0:20:28 > 0:20:30'about food safety.
0:20:30 > 0:20:33'As home economics has disappeared,
0:20:33 > 0:20:38'whole generations have missed out on that safety message - until now.'
0:20:43 > 0:20:48Morning, everyone. There's your aprons. One, two, three...
0:20:50 > 0:20:56'These future cooks and chefs have embarked on a mission to learn about food safety.
0:20:56 > 0:20:59'The message is already getting through.'
0:20:59 > 0:21:01Whoa! If I ate bad food,
0:21:01 > 0:21:05it would probably give me food poisoning
0:21:05 > 0:21:07and make me ill.
0:21:07 > 0:21:10It would give me stomach ache and make me very ill.
0:21:10 > 0:21:15It'll give me food poisoning and I'll have to go in hospital.
0:21:15 > 0:21:19'Let's Get Cooking is a national network of cooking clubs.
0:21:19 > 0:21:24'Today, trainer Rebecca Popple is at Overthorpe School in Dewsbury.'
0:21:26 > 0:21:29And...cross-contamination.
0:21:29 > 0:21:31Wow!
0:21:31 > 0:21:37'Rebecca uses fun games like this to show kids how germs can spread.'
0:21:37 > 0:21:41That germ would pass from your hand to the next person,
0:21:41 > 0:21:44onto the next person, onto the next person.
0:21:44 > 0:21:49People aren't aware of the high levels of food poisoning out there.
0:21:49 > 0:21:53'People generally tend to think that it's from some dodgy takeaway
0:21:53 > 0:21:56'or from eating out in cafes and restaurants,'
0:21:56 > 0:22:01and aren't aware that a large number of cases are caused in the home.
0:22:03 > 0:22:09'The lesson shows that what seems like the most basic thing is our biggest weapon against germs.'
0:22:09 > 0:22:13If you have your sweatshirts on, push them right up.
0:22:13 > 0:22:16'Most food poisoning occurs in our homes.
0:22:16 > 0:22:18'Dirty hands are often to blame.'
0:22:18 > 0:22:24Take a squirt. I want you to rub it in your hands, OK?
0:22:24 > 0:22:30'The pupils are told to imagine this gel is full of germs.
0:22:30 > 0:22:34'Then they have to wash away as many as they can.
0:22:34 > 0:22:37'Under a UV light, they see how much they've missed.'
0:22:37 > 0:22:39Uh-oh!
0:22:39 > 0:22:44Where can you see that there would be bacteria gathered there?
0:22:44 > 0:22:46All the way around your nail beds.
0:22:47 > 0:22:53'And here's a lesson for all of us - how to scrub up properly.'
0:22:53 > 0:22:59You need to make sure you go to the backs, fronts, in between, nails.
0:22:59 > 0:23:01'If I don't wash my hands,'
0:23:01 > 0:23:04all the germs might go into the food
0:23:04 > 0:23:08and it might give other people belly ache.
0:23:10 > 0:23:12'The final game is a big hit.'
0:23:12 > 0:23:16We're now going to play a game called "dissect my pie"!
0:23:16 > 0:23:20'Inside these pies are a few nasty surprises.'
0:23:20 > 0:23:25I want you to chop into it and, as you cut into it,
0:23:25 > 0:23:30dig out what you find and put it onto the edge of your plate.
0:23:30 > 0:23:32'It's supposed to get them thinking
0:23:32 > 0:23:36'about hairs and fingernails could get into their dinner.'
0:23:36 > 0:23:38What did you find in your pie?
0:23:38 > 0:23:43- A ring.- How did it get there? - It must have slipped off someone's finger.
0:23:43 > 0:23:47'And how we can avoid this happening in our own kitchens.'
0:23:47 > 0:23:49What would you do to stop that?
0:23:49 > 0:23:54- Let no jewellery in the kitchen. - That's right.
0:23:54 > 0:23:57- Ew! Ew! - I feel... Ugh!
0:23:57 > 0:24:00- I feel...- Disgusted.
0:24:00 > 0:24:03- Ugh! - Can you imagine swallowing that?
0:24:05 > 0:24:09Have you ever eaten something and found a hair in your mouth?
0:24:09 > 0:24:11I think most of us have.
0:24:11 > 0:24:15If I found a hair, I'd feel awful and disgusted.
0:24:15 > 0:24:17- Would you be angry?- Yeah.
0:24:18 > 0:24:21- A bit.- A lot!
0:24:21 > 0:24:23I'd order a refund.
0:24:23 > 0:24:25What would we do to prevent that?
0:24:25 > 0:24:29- If you've got long hair, tie it back.- Spot on!
0:24:31 > 0:24:34- I'd report them. - I'd never go back to that place.
0:24:34 > 0:24:37- What would you like? - Chicken, please.
0:24:37 > 0:24:43'Then it's into the dinner hall for these junior food fighters.
0:24:43 > 0:24:47'It's reassuring to know that they've learnt some vital lessons
0:24:47 > 0:24:50'to take back home and into their own kitchens.
0:24:55 > 0:24:58'Verdict time for the new takeaways.'
0:24:58 > 0:25:02I'm not going to be generous. The structure's rubbish.
0:25:07 > 0:25:10The Yorkshire pudding, a Sunday lunch favourite.
0:25:10 > 0:25:12Everyone has their own recipe.
0:25:12 > 0:25:17My secret - very hot oil before you even put the batter in.
0:25:17 > 0:25:20But when you're making up to 20 million a week,
0:25:20 > 0:25:24how do you guarantee they're made well and made safely?
0:25:24 > 0:25:29I'm, where else, but Yorkshire, to meet the food fighters protecting our puds.
0:25:31 > 0:25:35'At Aunt Bessie's in Hull, they produce a range of food
0:25:35 > 0:25:37'from roly-poly to fruit pie,
0:25:37 > 0:25:42'but they're particularly famous for their Yorkshire puddings.
0:25:42 > 0:25:44'Now, you can't make yorkies without eggs.
0:25:44 > 0:25:46'Here, they use tonnes of them,
0:25:46 > 0:25:50'all brought in from British Lion approved suppliers.
0:25:52 > 0:25:56'As we've seen, it's already faced dozens of checks.
0:25:56 > 0:26:01'Nevertheless, staff here can't afford to count their chickens.'
0:26:02 > 0:26:08This is where the raw materials come in - whey powder, milk powder, flour, sugar.
0:26:08 > 0:26:11Every single product has to be tested further.
0:26:11 > 0:26:13And that's through here.
0:26:13 > 0:26:20My name is Anne Garner. It's my job to check that all ingredients that come in are safe to use.
0:26:20 > 0:26:23- Hi, Anne. How are you? - Fine, thank you.
0:26:23 > 0:26:27- This is where we test everything that comes into the factory?- It is.
0:26:27 > 0:26:30The thing I'm intrigued by is liquid egg.
0:26:30 > 0:26:36We've seen it start as an egg, turned into liquid egg and all the tests that go on.
0:26:36 > 0:26:42- When you get it, what happens now? - I check for the pH level.
0:26:42 > 0:26:46If the pH was too high, it could indicate bacteria in there.
0:26:46 > 0:26:50Obviously, we wouldn't use that until we were sure that it was OK.
0:26:50 > 0:26:54'Anne tests a sample of the raw egg for acidity
0:26:54 > 0:27:00'and is looking for target pH between 7.6 and 8.4.
0:27:00 > 0:27:03'Anything outside this would be condemned.'
0:27:03 > 0:27:06- Has that ever happened? - I've never known it.
0:27:06 > 0:27:09- Which is satisfying. - Oh, yes. Most definitely.
0:27:09 > 0:27:14- But we still always check.- Course. - There could be just that one time.
0:27:14 > 0:27:18- So, until you sign it off, none of that product can be used?- No.
0:27:18 > 0:27:22- So we're on 8.14, well within our parameters.- Absolutely.
0:27:24 > 0:27:28'It's not just egg that Anne keeps an eye on.
0:27:28 > 0:27:33'Another key ingredient here is fruit,
0:27:33 > 0:27:37'used to make thousands of sweet puddings every week.'
0:27:37 > 0:27:39What things do you check for?
0:27:39 > 0:27:44That there's nothing that shouldn't be in there, the colour's correct,
0:27:44 > 0:27:46the size is correct.
0:27:46 > 0:27:50Every ingredient that we receive has an agreed spec.
0:27:50 > 0:27:53With the fruit, a lot of that is a visual check, then?
0:27:53 > 0:27:57There's nothing that's contaminated it in there.
0:27:57 > 0:28:02- The colour and the size is right. - It is with that particular fruit.
0:28:02 > 0:28:06There are different fruits we have, for example, apples,
0:28:06 > 0:28:08that I check for the size.
0:28:08 > 0:28:13We check for any excessive pips or peel or anything like that.
0:28:13 > 0:28:17- The fruit looks beautiful. - It is. It's really nice.
0:28:17 > 0:28:21- So far today, happy day.- Yeah. - Brilliant.
0:28:24 > 0:28:27'It's Yorkshire puddings I'm really interested in.
0:28:27 > 0:28:32'With the raw materials given the green light, the baking can begin.'
0:28:32 > 0:28:36This is where it all starts. Lynne Campbell is quality manager.
0:28:37 > 0:28:39My name's Lynne Campbell.
0:28:39 > 0:28:43It's my job to make sure that the Yorkshire puddings are safe to eat
0:28:43 > 0:28:46and the best quality possible.
0:28:46 > 0:28:49Good to see you. What have we got here, then?
0:28:49 > 0:28:55This is an egg tanker, how our liquid egg is delivered onto site.
0:28:55 > 0:28:59It is then pumped into the factory and held in a sealed unit.
0:28:59 > 0:29:04- Are there any checks at this point? - We make sure that the temperature's correct.
0:29:04 > 0:29:07That everything is to the specification required.
0:29:07 > 0:29:12'This tanker holds 25 tonnes, equivalent to half a million eggs.
0:29:14 > 0:29:18'Just like the puds I make, the other main ingredient is flour.
0:29:18 > 0:29:22'Here, it has a set of safety checks all of its own.'
0:29:22 > 0:29:25- Wow! This is clearly flour.- It is.
0:29:25 > 0:29:27This is the bulk flour silo,
0:29:27 > 0:29:31where all our flour's stored ready to call for the factory.
0:29:31 > 0:29:37When this arrives, what do you check for from a health and safety point of view?
0:29:37 > 0:29:41We have to check the tanker that's arrived is in good condition,
0:29:41 > 0:29:43we're happy with its integrity.
0:29:43 > 0:29:47It's then pumped into here through a sieve.
0:29:47 > 0:29:51'Like me, they sift their flour before making a yorkie.
0:29:51 > 0:29:54'They do it for a very important reason.'
0:29:54 > 0:30:00This is to make sure that there's no contamination through any of the systems.
0:30:00 > 0:30:05- So anything that's a contamination in terms of foreign bodies?- Yes.
0:30:05 > 0:30:07- Then that's going to be ejected. - It is.
0:30:07 > 0:30:13Any hard wheat husk or any hard flour, anything that shouldn't be in there.
0:30:13 > 0:30:17- Any contamination, it will catch it. - Where does the flour go from here?
0:30:17 > 0:30:23It is piped through into the factory. They call it straight into the mixing.
0:30:23 > 0:30:26- Straight through the pipework?- Yes.
0:30:26 > 0:30:31'I'm astounded by all the work that goes into making a simple Yorkshire pudding.
0:30:32 > 0:30:37'And when you mix a whole load of eggs with a whole load of flour,
0:30:37 > 0:30:41'you get more batter than I've ever seen.'
0:30:41 > 0:30:44It passes through this filter, another critical test
0:30:44 > 0:30:48to make sure we haven't got any contaminants in the mixture
0:30:48 > 0:30:50before it's baked.
0:30:50 > 0:30:52- Then oil as well?- Yes.
0:30:52 > 0:30:55The key to a good yorkie - hot trays, hot oil, batter.
0:30:55 > 0:31:00The oil goes in heated into the hot trays, which is what we can see?
0:31:00 > 0:31:01Yes.
0:31:01 > 0:31:04The oil is deposited from this hopper.
0:31:04 > 0:31:08The batter is deposited on top of the oil, forms a nice ring
0:31:08 > 0:31:13and goes straight into the trays into the oven.
0:31:15 > 0:31:20'When I've got the family over for Sunday dinner, I've sometimes wished
0:31:20 > 0:31:22'I had a bigger oven.
0:31:22 > 0:31:27'These are something else. They're half the size of a football pitch.'
0:31:27 > 0:31:31When I'm cooking a Yorkshire pudding at home,
0:31:31 > 0:31:33it's nice and hot, constant.
0:31:33 > 0:31:38- Is it the same in this process? - No, it's not.
0:31:38 > 0:31:40This is a far bigger scale.
0:31:40 > 0:31:43'They couldn't be more different.
0:31:43 > 0:31:48'These massive ovens are split into different temperature zones,
0:31:48 > 0:31:51'designed to get the puds to rise.'
0:31:51 > 0:31:56What safety checks are done? It's a long time to leave the product.
0:31:56 > 0:31:59Baking time is approximately 15 minutes.
0:31:59 > 0:32:03We monitor the batter, time and temperature in the holding tanks
0:32:03 > 0:32:07to make sure it hasn't had any time for microbes to grow.
0:32:07 > 0:32:14Through the baking process, we've validated the oven to reach the temperatures needed.
0:32:14 > 0:32:20At the end, a critical point, we take the bake temperature to ensure it's baked safely.
0:32:21 > 0:32:27'I just can't resist taking a sneaky look inside this super-sized oven.'
0:32:27 > 0:32:31Wow! These are massive, massive ovens!
0:32:31 > 0:32:34'Time to see if the puds have risen,
0:32:34 > 0:32:38'or if opening that door has caused a bit of a flop.
0:32:40 > 0:32:43'Thankfully, they look perfect.'
0:32:43 > 0:32:49Now that they've cooked, what's the final safety check we have to do?
0:32:49 > 0:32:52We take a tray and look that they've baked correctly.
0:32:52 > 0:32:54The right height, the right shape.
0:32:54 > 0:32:58From a foreign body point of view, we would reject this
0:32:58 > 0:33:02because this is the carbon from the trays.
0:33:02 > 0:33:04We would reject that.
0:33:04 > 0:33:08'Bacteria can grow when food is below 63 degrees.
0:33:08 > 0:33:13'So making sure the yorkies are hot enough is critical.'
0:33:13 > 0:33:18If it didn't hit temperature, what would the implications be?
0:33:18 > 0:33:21- We would have to throw away the full oven.- Right.
0:33:21 > 0:33:27We couldn't let it go any further so the whole oven would be thrown away.
0:33:29 > 0:33:34'For most of us, yorkies go straight from the oven onto the plate.
0:33:34 > 0:33:40'Here, they need to be frozen, packed, then passed through one last checkpoint.'
0:33:40 > 0:33:45I didn't imagine that, at the end, I'd find a metal detector.
0:33:45 > 0:33:49If you think about our process, all the batter and the puddings
0:33:49 > 0:33:53travel through lots and lots of stainless steel and machinery.
0:33:53 > 0:33:57- One of the major hazards would be metal contamination.- Of course.
0:33:57 > 0:34:00We make sure the product's free from metal.
0:34:00 > 0:34:05So they'd be rejected. What physically happens to the product?
0:34:05 > 0:34:09The metal detector registers that there's metal in the pack.
0:34:09 > 0:34:13That sends a signal to an air blast to blast them into a reject bin
0:34:13 > 0:34:16which is locked and kept secure.
0:34:17 > 0:34:21'Bits of metal in your Yorkshire pud would be dangerous.
0:34:23 > 0:34:26'So I'm keen to see if this machine works.
0:34:26 > 0:34:30'Every hour, metal rods are attached to packaging.
0:34:30 > 0:34:34'When they're detected, the bag is rejected.'
0:34:34 > 0:34:38Brilliant. That proves that it's working properly.
0:34:38 > 0:34:43- We can safely get the packaging out and distributed.- Yes.- Brilliant.
0:34:45 > 0:34:48'It's been a journey that started on the farm
0:34:48 > 0:34:52'and has been scrutinised every step of the way.
0:34:52 > 0:35:00'Finally, these yorkies can be packed off to our supermarkets in time for Sunday lunch.'
0:35:05 > 0:35:11If you're planning on grabbing a takeaway today, you'll want to be reassured that the food is safe.
0:35:11 > 0:35:14Let's rejoin our two food fighters.
0:35:14 > 0:35:21At the opposite ends of the country, their mission is the same - to put safety at the top of the menu.
0:35:25 > 0:35:31'At the Kurdish Flag in Oxford, it's not been a great inspection.
0:35:31 > 0:35:34'Environmental Health Officer Richard Kuziara
0:35:34 > 0:35:38'is concerned about the distance between prep and storage areas.
0:35:38 > 0:35:42'And drinks that should have been in the fridge have been left out.'
0:35:42 > 0:35:45I'll have a look down here.
0:35:45 > 0:35:48'Downstairs, things aren't much better.'
0:35:48 > 0:35:51- This is more chicken, isn't it?- Yes.
0:35:51 > 0:35:55You can see we've got blood and things in there.
0:35:55 > 0:35:59'Raw chicken can be a source of campylobacter,
0:35:59 > 0:36:03'the most common form of food poisoning in the UK.
0:36:03 > 0:36:08'So blood sitting on a fridge shelf is a serious food safety issue.'
0:36:08 > 0:36:12So the actual chicken is going to be OK,
0:36:12 > 0:36:15IF you wash your hands when you open that.
0:36:15 > 0:36:17I know you've only just moved in,
0:36:17 > 0:36:21but stuff like that, you need to clean it.
0:36:24 > 0:36:29'For Richard, these problems should have been sorted out before opening.
0:36:29 > 0:36:32'There are potential risks in every corner.'
0:36:32 > 0:36:34One of the issues here,
0:36:34 > 0:36:38we've got paint peeling.
0:36:40 > 0:36:43Got open food below it.
0:36:43 > 0:36:46There's a risk of contamination. It's not great.
0:36:46 > 0:36:51And, you know, what is up here? Who knows?
0:36:55 > 0:36:58'The Kurdish Flag has structural problems.
0:36:58 > 0:37:02'Not just the condition of the ceiling, but the layout, too.
0:37:04 > 0:37:08'So it's time for Richard to give his verdict.'
0:37:08 > 0:37:12Because of your stock rotation and your temperature control,
0:37:12 > 0:37:15the overall picture I'm going to put you as "fair".
0:37:15 > 0:37:21I'm being a bit generous, but I'm not going to be generous with the structure.
0:37:21 > 0:37:25The structure's rubbish. You know that. I know that.
0:37:25 > 0:37:30'The marks are totted up to produce a star rating between zero and five.
0:37:30 > 0:37:36'These scores are very important to food businesses, especially new ones.'
0:37:36 > 0:37:40As it is today, this is a one-star business, yeah?
0:37:40 > 0:37:43It's mostly down to the structure
0:37:43 > 0:37:47and...my confidence in the management.
0:37:47 > 0:37:54'It's a poor score, so the duty manager begs for a follow-up visit in three days' time.'
0:37:54 > 0:37:57- Friday you come, 100% everywhere. - Right.
0:37:57 > 0:38:03- Everything 100%. - So, on Friday, this place is going to be immaculate?- For sure.
0:38:03 > 0:38:06Friday, you will see everything is clean.
0:38:06 > 0:38:10- If it's right on Friday...- Yeah.
0:38:10 > 0:38:15..I can move you up to two stars if you do everything you say you'll do.
0:38:17 > 0:38:21'Richard will be back to check if these promises have been kept.
0:38:21 > 0:38:24'What about his fellow food fighter, Simon?
0:38:25 > 0:38:32'In Preston, Lancashire, Simon has been checking up on curry cafe Lunches & Brunches.
0:38:32 > 0:38:38'The cafe received two stars on its first inspection, but improvements seem to have been made.
0:38:38 > 0:38:43'Simon is yet to poke his nose into the important stuff, the food.'
0:38:45 > 0:38:47I'll pop it in the rice.
0:38:52 > 0:38:55'In the middle of the fridge, Simon spots a problem.
0:38:55 > 0:38:58'There are some tubs of food that are still warm.'
0:39:00 > 0:39:04That's come out at a comfy 40 degrees there.
0:39:04 > 0:39:08Cos right in the middle there, that's still warm.
0:39:08 > 0:39:12- If you put your hand under there, that's quite pleasant!- It's warm.
0:39:12 > 0:39:17Before it's cooled down, don't put it in the fridge, yeah?
0:39:17 > 0:39:20Leave it out for maybe an hour, hour and a half.
0:39:22 > 0:39:31'The warm food can heat up the rest of the fridge's content and this can open the door for bacteria.
0:39:31 > 0:39:36'Muhammad must ensure that only fully cooled food is in the fridge.'
0:39:36 > 0:39:41Cos it's a catering fridge, a proper industrial refrigerator,
0:39:41 > 0:39:44once you let it cool a bit longer it will cope with that
0:39:44 > 0:39:47and take those temperatures down.
0:39:47 > 0:39:50A domestic one wouldn't work so well.
0:39:50 > 0:39:55'A mark against the takeaway, but Muhammad knows what should be done,
0:39:55 > 0:39:59'and that goes for use-by dates, too.'
0:39:59 > 0:40:03If it's not finished by three days, should throw. Don't need to ask me.
0:40:03 > 0:40:10You can ask my staff, but I told them don't ask me. Throw it straight away.
0:40:10 > 0:40:12Really good.
0:40:13 > 0:40:16'And now it's the verdict.
0:40:16 > 0:40:21'Will Muhammad improve on his two-star score?'
0:40:21 > 0:40:25The hygiene practices, things that you talked me through,
0:40:25 > 0:40:29the stuff you told me without prompting, that's really good.
0:40:29 > 0:40:34The structure is lovely, really impressed with that.
0:40:34 > 0:40:38- That would give you a five-star certificate.- Thank you very much.
0:40:38 > 0:40:40That's genuinely really good.
0:40:40 > 0:40:43So we'll get you the certificate next week.
0:40:43 > 0:40:47Out of our 1,200 businesses, you're in the top 100.
0:40:47 > 0:40:51- Thank you very much. - I'm impressed with that.
0:40:53 > 0:40:57It's really nice when you find a business that started out,
0:40:57 > 0:41:01not been open long, lots of advice given to start with
0:41:01 > 0:41:03and the results are really good.
0:41:03 > 0:41:06It's a well-deserved mark, that.
0:41:10 > 0:41:12- Cheers. See you later.- Thank you.
0:41:12 > 0:41:15'Muhammad is delighted with his result.'
0:41:15 > 0:41:17It's amazing.
0:41:17 > 0:41:23I've got a five star now so I'm really happy and very, very...
0:41:23 > 0:41:25I can't help my feelings!
0:41:25 > 0:41:31So I'm happy now, but I'm still going to be very strict on my staff!
0:41:34 > 0:41:38'It's a brilliant improvement, but can the Kurdish Flag in Oxford
0:41:38 > 0:41:40'pull off a similar transformation?
0:41:40 > 0:41:45'Richard DID go back three days later but found the shop shut up.
0:41:46 > 0:41:49'So, a few months later, he's back again.'
0:41:49 > 0:41:51Hello, Hassan.
0:41:51 > 0:41:54'There's a huge change this time.
0:41:54 > 0:41:57'The Kurdish Flag now has a name and a new owner, Hassan.
0:41:57 > 0:42:02'This is the shop's third owner in as many months.
0:42:02 > 0:42:08'He may be new, but Hassan still needs to follow the old advice.
0:42:08 > 0:42:13'While the food prep area is all in one place with a wash basin,
0:42:13 > 0:42:15'there is room for improvement.'
0:42:15 > 0:42:20It's a little bit warm. You've got about 11.5 there.
0:42:20 > 0:42:22It should be below eight.
0:42:22 > 0:42:27'All in all though, Richard's happy with the progress that's been made.'
0:42:27 > 0:42:31That's classic small business stuff, three months, three owners.
0:42:31 > 0:42:35The new owner seems to be the best so far.
0:42:35 > 0:42:38He has gone some way to rectifying the problems.
0:42:38 > 0:42:42What I've got there is a business that is a lot better.
0:42:42 > 0:42:47Hopefully, with a bit of looking after, he'll go on to improve.
0:43:09 > 0:43:12Subtitles by Red Bee Media Ltd
0:43:12 > 0:43:15E-mail subtitling@bbc.co.uk