Episode 5 Food Fighters


Episode 5

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We're a nation of food lovers, and there's more choice than ever.

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Eating in or taking away, there's always the chance that something can go wrong.

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It's a good job there's an army of people working to keep us safe.

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They're the food fighters.

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'On today's programme, from the farm...'

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-Come on, girls.

-'..to a Yorkshire pudding factory.

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'We follow the food fighters protecting our humble egg.'

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What's the final safety check that we have to do?

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We would reject this type. This is the carbon from the trays.

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'Open for business, but is it ready to serve?'

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This place needs sorting out. You know that.

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'And can these junior food fighters teach us about safety in the kitchen?'

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If I don't wash my hands, then all the germs might go into the food

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and it might give other people belly ache.

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In Britain, the catering industry is worth £40 billion a year.

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It's no surprise restaurants and takeaways are opening all the time to get a slice of that pie.

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But who's checking those new businesses are fit to serve us?

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'On the front line of food safety there's a team of Environmental Health Officers across the country.

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'We've been on the road with two of them.

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'Oxford Environmental Health officer Richard Kuziara

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'is checking out a place so new he doesn't even know its name.

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'And he's not the only one.'

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-What's it called? Is it still Shisha House?

-No.

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-It's just they put flag up. I don't know what it's called.

-Yeah!

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It's just been here about three days.

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I'll call it the Kurdish Flag.

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'But though the flag is Kurdish, the food is more familiar -

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'baguettes and paninis stored in a fridge by the window.

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'If they're not kept properly, things can go badly wrong.

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'The fridge needs to be between five and eight degrees.

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'Time for Richard to aim his laser thermometer.'

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Temperature in here's good. It should be eight or below.

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-So the stuff in there is reading about seven.

-Good?

-Yeah. Good.

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'Storage of these sandwiches is OK, but prep is a different story.'

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When I need to make the panini, I have to take the meat out.

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-I not make them in here.

-It's not well laid out, is it?

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No!

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'The Kurdish Flag has a fridge at one end of the cafe

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'and a kitchen at the other.

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'To Richard, that's like keeping your fridge in your living room!

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'And it can cause all sorts of food safety problems.'

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This is your poor layout again.

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This cheese... I know you're making sandwiches.

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But what would be nice, if that was here,

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then you could keep putting it away.

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Or if you had a fridge here, for example,

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you could put it away afterwards.

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'This poor setup means fillings are left to sit at room temperature.

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'This increases the risk of bacteria.'

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What have we got here, then?

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'It's not long before Richard makes another worrying discovery.'

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It says "store between six and eight". See that?

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So you need...

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Um, this is going to go off if you leave it at this temperature.

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How long's that been out there?

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-This one on top of there, yesterday.

-Yesterday.

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'These yoghurt drinks have been left out for 24 hours.

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'They could be off, and could cause food poisoning.'

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-This one, I throw out.

-Yeah. Throw them away.

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'The Kurdish Flag didn't get in touch with Richard before opening.

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'The new owners have to make a lot of changes.'

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What I would have liked to have seen was the owner contacting us before.

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Saying, "We're opening this place. Have a look. Tell us what we need to do."

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Instead, they've just opened it and, structurally, it's rubbish.

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'How much difference can the food fighters make to a new business?

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'200 miles away, in Preston,

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'Environmental Health Officer Simon Neighbour is giving a cafe its second inspection.

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'When this curry cafe first opened, it was dirty

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'and they were real problems about the way food was being stored.

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'It was marked just two out of five and told to clean up its act.

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'Simon's back to see if they have.'

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I hope that you got those things that Jenny put in her letter.

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-Yeah, I got everything completely.

-Good.

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'Lunches & Brunches has been in business just over a year,

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'serving curry and rice to central Preston.'

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You've got a lot of room down here!

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We cook traditional homemade food so, er...

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We make in the morning and we put it in a pot and go upstairs.

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'It's a simple system, but have the staff made the changes called for two months ago?'

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From this initial thing, you can see you've got preparation here,

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there's storage in this corner, moves round into cooking.

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You can do plating-up here and take it upstairs,

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which is a really nice progression.

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The floor's fantastic. Stainless steel, easy to tell you're on top of that.

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'The layout here is much better than the Kurdish Flag in Oxford, but it still isn't perfect.'

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It's a little dark at this end of the kitchen.

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When we clean this one, yeah, it goes brighter.

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Cleaning about three, four months, so it's gonna be brighter.

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-With steam and oil...

-Yeah. They'll collect on there.

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This end, you know, it's a little bit dark.

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It's harder to see how the cleaning's going, if you're doing any checks for signs of mice.

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No problem. We'll do that.

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'It's time for Simon to shine his light.

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'Will anything unwelcome be lurking in the dark?

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'He's looking for bits of food on the floor and for signs of rodents.'

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If you can get a pen through a gap

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a mouse will be able to squeeze through that size hole.

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Mice can carry diseases. Rats carry diseases.

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Mice are urinally incontinent. They dribble urine everywhere they go.

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They can jump onto a worktop,

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dribble urine, scamper off.

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That urine will dry out but it can leave behind salmonella and other bugs that make you poorly.

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'Thankfully, there's not a mouse in sight.'

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-Have you got a pest control contract?

-Yes.

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'In fact, though dark, this kitchen is pretty clean.'

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This is after this morning's preparation.

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There's no accumulation here.

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There's odd bits and pieces but, it sounds silly, it's fresh.

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It's not old. It's not accumulated.

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And the thing is, when we close at half past three,

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before we go home, we clean out everything and mop it every time.

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This is nice and clean, nice and tidy.

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'Vital advice about cleaning has clearly got through to Muhammad.'

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-I'm very strict about cleaning on my staff.

-OK.

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I am not allowing any single thing, "Oh, just leave it till tomorrow."

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I say, "No. You have to finish your work, as simple as that."

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'The setup here is good,

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'but next comes a crucial part of the inspection -

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'the area the manager was told he must improve.

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'Will Muhammad have improved the way he stores his food?'

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Right in the middle there, that's still warm.

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'And straight-talking from the next generation of food fighters.'

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If I found a hair in my food, I'd feel awful and disgusted.

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I'd order a refund.

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The humble egg is something most of us eat every day in some form.

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From cakes to pies, mayonnaise to sauces, or simply boiled or poached.

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It's a huge industry and needs to be carefully monitored

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because it's by no means risk-free.

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'The UK food industry was on red alert.'

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Supermarkets are clearing shelves of products that could contain contaminated eggs from Germany

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following reports of animal feed being contaminated with chemicals.

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'In large quantities, the chemicals are thought to cause infertility and cancer in humans.

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'These contaminants would not have been destroyed by pasteurisation

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'or cooking.'

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Products were made using imported liquid egg, 14 tonnes of it!

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'Despite initial concerns, the dioxin levels in this case

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'weren't high enough to pose a risk,

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'but served as a reminder of how easily our food chain can be contaminated.'

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Thankfully, here in the UK, our egg industry is well protected.

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From the farms to our supermarkets and dinner plates, an army of people safeguard the eggs we eat.

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It's a journey that we followed on food fighters.

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'North Yorkshire, and this free range farm

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'produces 1.9 million eggs every year.

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'They're sent to shops, caterers and manufacturers all over the country.

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'This is a lot of responsibility on the shoulders of farmer Andy Hall.

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'Andy's been running his free range farm for two years.

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'Things are going extremely well.

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'Unlike the eggs in the German case, these have been awarded the British Lion stamp.

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'It's a mark we recognise from our supermarket shelves,

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'designed to give consumers like you and I the confidence that what we're buying is safe.

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'Just being awarded the stamp is not enough.

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'Andy has to prove his standards haven't slipped.

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'He's audited every 18 months, and today is inspection day.'

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My name's Malcolm.

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My job is to make sure that the eggs you buy are safe to eat.

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'Many of Andy's customers insist on the British Lion stamp.

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'If he didn't have it, he would lose a huge amount of business.

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'Clearly, today is a very important day.

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'For the farm to keep its status, Malcolm needs to be convinced

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'that every stage of the process is up to scratch.'

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If we couldn't get the stamp, it would be a very restricted market.

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I don't know what the financial implications would be,

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whether you could even find anyone to take the eggs.

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Right, good morning, girls.

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'Malcolm is on the front line

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'in the battle to stop harmful substances entering the food chain.

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'As well as dioxins,

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'he's also fighting to protect us against salmonella.

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'Salmonella is the second most common food poisoning in the UK.

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'It's caused by infected faeces on the exterior of the shell.

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'These can be absorbed through the shell and into the egg itself.

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'Salmonella can cause vomiting, diarrhoea and fever.'

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Salmonella is a major threat to the egg industry.

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The programme is to ensure that eggs do not have salmonella on the shell

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or within the contents of the egg.

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'Malcolm takes samples using swabs attached to his feet

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'to test for signs of the bacteria.'

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Come on, girls!

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'Dioxins got into the eggs in the German case through feed,

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'so Malcolm wants to see exactly what these chickens are eating.'

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The press has been full of feed scares over a number of years.

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One of the favourite chemicals mentioned is dioxins.

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Dioxins have got into the feed chain.

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They would transmit through into the egg,

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so it's very important that the feed is of the required quality

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to make sure they don't present a problem to the egg itself.

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'All the feed here must be above board, because what a chicken eats

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'eventually gets into our eggs.

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'So Malcolm gets CRACKING looking at the paperwork and the food itself.'

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16th. 5th April.

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1st February.

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OK.

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Thank you very much.

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'Final stop, the printing machine.

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'Each egg is given a unique code so we can tell where it's come from and when it should be used by.

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'This code must be clearly visible.'

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1UK 21214.

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-Yeah. It's a good job.

-Yeah.

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Fine. That's all I'm looking for.

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'There's been no stone left unturned here and now it's crunch time.

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'Will Andy's eggs continue to carry the Lion stamp,

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'which clearly means so much to businesses like this?'

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I've not found any problems,

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so I'm proposing that you be approved within the Lion scheme.

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And that's us done.

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'Andy's CRACKED it. His eggs can carry on being sold with the British Lion stamp.

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'Many will go straight off to our supermarkets.

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'Others will be off to the food factories.'

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Many eggs like Andy's are used to make this.

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It's liquid egg.

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It's used in a whole range of products we buy from our shops.

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It's used in restaurants like mine up and down the country.

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Without a shell to protect it, can we be sure it's not contaminated?

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Let's meet the food fighters who keep it safe.

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'This is Ready Eggs near Enniskillen, Northern Ireland.

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'The factory produces four tonnes of liquid egg every hour.

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'It could end up on a plate near you.

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'Kerry Campbell is the plant's technical manager.

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'Eggs used have that all-important stamp, so Kerry knows they're safe.

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'There's plenty that can go wrong.

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'A shell is like a shield, so once it's gone, bacteria could invade.

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'The British Lion food fighters want to make sure that's not happening.'

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If the auditor finds anything untoward, it would have a big impact on our business.

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We are making sure that we're aware of all the risks posed to the consumer

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because of the risks such as salmonella.

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My name's Kevin Carlisle. It's my job to make sure liquid egg is safe for consumption.

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'Just like on the farm, this is a crucial inspection.

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'If Kerry loses the British Lion stamp

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'it will be almost impossible to sell the product in the UK.

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'First, Kevin checks if she knows where her eggs have come from.'

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Can you tell me when they were laid?

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Yes. This pallet would have been laid at the tail end of March, 26 and 27 March,

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which is the date of lay.

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-What's the maximum time you hold them here?

-Before we process them, a maximum of 28 days.

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'This is a two-fold check.

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'Kevin needs to be convinced the eggs are approved.

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'He also needs to be sure any problems down the food chain can be traced back to the source.'

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1UK obviously stands for the fact that the eggs are free range.

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This four-digit code relates to the producer.

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'Kevin continues his meticulous inspection.

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'This is the breaking room, where eggs are cracked and separated.

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'It's vital that no shell gets into the product.'

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You can see the yolk coming down one lane and the white down another.

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'Next, probably the most important part of the process, pasteurisation.

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'By law, liquid egg has to be heated to over 65 degrees

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'to kill off any bacteria.

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'It must then be blast-chilled in a high-care area to remain safe.

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'A failure here could lead to dodgy bacteria winging its way

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'onto our dinner plates.

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'After an exhaustive inspection, it's time for Kevin's verdict.'

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Well, we've had a good look through everything.

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Hygiene standards were very good.

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Working practices, traceability, record keeping all very good.

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-So I'm pleased to say that you've retained your certification.

-Thank you very much.

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'It's a great relief for Kerry, and means she can continue her business with the British Lion backing.'

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We'll see each other again in a year's time.

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'So, from the farm to this factory, our egg's been heavily scrutinised,

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'but it's not over yet.

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'For the next part of the journey, we need to head to Yorkshire.

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'The lengths food fighters go to

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'to make sure this Sunday lunch favourite is safe to eat.'

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I didn't imagine that at the end of this process I'd find a metal detector!

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As a kid I didn't need much of an excuse to get into the kitchen,

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but in recent years, skills that should have been handed down seem to have gone missing.

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Bad news for our dinner plates.

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It also means there's more risk of food poisoning from our kitchens.

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A national network of cooking clubs is set to change all that.

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'In days gone by, cooking and hygiene

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'was a huge part of the school curriculum.

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'Although home economics wasn't the breeding ground for sexual equality,

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'lessons played a key role in educating youngsters

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'about food safety.

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'As home economics has disappeared,

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'whole generations have missed out on that safety message - until now.'

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Morning, everyone. There's your aprons. One, two, three...

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'These future cooks and chefs have embarked on a mission to learn about food safety.

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'The message is already getting through.'

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Whoa! If I ate bad food,

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it would probably give me food poisoning

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and make me ill.

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It would give me stomach ache and make me very ill.

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It'll give me food poisoning and I'll have to go in hospital.

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'Let's Get Cooking is a national network of cooking clubs.

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'Today, trainer Rebecca Popple is at Overthorpe School in Dewsbury.'

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And...cross-contamination.

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Wow!

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'Rebecca uses fun games like this to show kids how germs can spread.'

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That germ would pass from your hand to the next person,

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onto the next person, onto the next person.

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People aren't aware of the high levels of food poisoning out there.

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'People generally tend to think that it's from some dodgy takeaway

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'or from eating out in cafes and restaurants,'

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and aren't aware that a large number of cases are caused in the home.

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'The lesson shows that what seems like the most basic thing is our biggest weapon against germs.'

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If you have your sweatshirts on, push them right up.

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'Most food poisoning occurs in our homes.

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'Dirty hands are often to blame.'

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Take a squirt. I want you to rub it in your hands, OK?

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'The pupils are told to imagine this gel is full of germs.

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'Then they have to wash away as many as they can.

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'Under a UV light, they see how much they've missed.'

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Uh-oh!

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Where can you see that there would be bacteria gathered there?

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All the way around your nail beds.

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'And here's a lesson for all of us - how to scrub up properly.'

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You need to make sure you go to the backs, fronts, in between, nails.

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'If I don't wash my hands,'

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all the germs might go into the food

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and it might give other people belly ache.

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'The final game is a big hit.'

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We're now going to play a game called "dissect my pie"!

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'Inside these pies are a few nasty surprises.'

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I want you to chop into it and, as you cut into it,

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dig out what you find and put it onto the edge of your plate.

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'It's supposed to get them thinking

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'about hairs and fingernails could get into their dinner.'

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What did you find in your pie?

0:23:360:23:38

-A ring.

-How did it get there?

-It must have slipped off someone's finger.

0:23:380:23:43

'And how we can avoid this happening in our own kitchens.'

0:23:430:23:47

What would you do to stop that?

0:23:470:23:49

-Let no jewellery in the kitchen.

-That's right.

0:23:490:23:54

-Ew! Ew!

-I feel... Ugh!

0:23:540:23:57

-I feel...

-Disgusted.

0:23:570:24:00

-Ugh!

-Can you imagine swallowing that?

0:24:000:24:03

Have you ever eaten something and found a hair in your mouth?

0:24:050:24:09

I think most of us have.

0:24:090:24:11

If I found a hair, I'd feel awful and disgusted.

0:24:110:24:15

-Would you be angry?

-Yeah.

0:24:150:24:17

-A bit.

-A lot!

0:24:180:24:21

I'd order a refund.

0:24:210:24:23

What would we do to prevent that?

0:24:230:24:25

-If you've got long hair, tie it back.

-Spot on!

0:24:250:24:29

-I'd report them.

-I'd never go back to that place.

0:24:310:24:34

-What would you like?

-Chicken, please.

0:24:340:24:37

'Then it's into the dinner hall for these junior food fighters.

0:24:370:24:43

'It's reassuring to know that they've learnt some vital lessons

0:24:430:24:47

'to take back home and into their own kitchens.

0:24:470:24:50

'Verdict time for the new takeaways.'

0:24:550:24:58

I'm not going to be generous. The structure's rubbish.

0:24:580:25:02

The Yorkshire pudding, a Sunday lunch favourite.

0:25:070:25:10

Everyone has their own recipe.

0:25:100:25:12

My secret - very hot oil before you even put the batter in.

0:25:120:25:17

But when you're making up to 20 million a week,

0:25:170:25:20

how do you guarantee they're made well and made safely?

0:25:200:25:24

I'm, where else, but Yorkshire, to meet the food fighters protecting our puds.

0:25:240:25:29

'At Aunt Bessie's in Hull, they produce a range of food

0:25:310:25:35

'from roly-poly to fruit pie,

0:25:350:25:37

'but they're particularly famous for their Yorkshire puddings.

0:25:370:25:42

'Now, you can't make yorkies without eggs.

0:25:420:25:44

'Here, they use tonnes of them,

0:25:440:25:46

'all brought in from British Lion approved suppliers.

0:25:460:25:50

'As we've seen, it's already faced dozens of checks.

0:25:520:25:56

'Nevertheless, staff here can't afford to count their chickens.'

0:25:560:26:01

This is where the raw materials come in - whey powder, milk powder, flour, sugar.

0:26:020:26:08

Every single product has to be tested further.

0:26:080:26:11

And that's through here.

0:26:110:26:13

My name is Anne Garner. It's my job to check that all ingredients that come in are safe to use.

0:26:130:26:20

-Hi, Anne. How are you?

-Fine, thank you.

0:26:200:26:23

-This is where we test everything that comes into the factory?

-It is.

0:26:230:26:27

The thing I'm intrigued by is liquid egg.

0:26:270:26:30

We've seen it start as an egg, turned into liquid egg and all the tests that go on.

0:26:300:26:36

-When you get it, what happens now?

-I check for the pH level.

0:26:360:26:42

If the pH was too high, it could indicate bacteria in there.

0:26:420:26:46

Obviously, we wouldn't use that until we were sure that it was OK.

0:26:460:26:50

'Anne tests a sample of the raw egg for acidity

0:26:500:26:54

'and is looking for target pH between 7.6 and 8.4.

0:26:540:27:00

'Anything outside this would be condemned.'

0:27:000:27:03

-Has that ever happened?

-I've never known it.

0:27:030:27:06

-Which is satisfying.

-Oh, yes. Most definitely.

0:27:060:27:09

-But we still always check.

-Course.

-There could be just that one time.

0:27:090:27:14

-So, until you sign it off, none of that product can be used?

-No.

0:27:140:27:18

-So we're on 8.14, well within our parameters.

-Absolutely.

0:27:180:27:22

'It's not just egg that Anne keeps an eye on.

0:27:240:27:28

'Another key ingredient here is fruit,

0:27:280:27:33

'used to make thousands of sweet puddings every week.'

0:27:330:27:37

What things do you check for?

0:27:370:27:39

That there's nothing that shouldn't be in there, the colour's correct,

0:27:390:27:44

the size is correct.

0:27:440:27:46

Every ingredient that we receive has an agreed spec.

0:27:460:27:50

With the fruit, a lot of that is a visual check, then?

0:27:500:27:53

There's nothing that's contaminated it in there.

0:27:530:27:57

-The colour and the size is right.

-It is with that particular fruit.

0:27:570:28:02

There are different fruits we have, for example, apples,

0:28:020:28:06

that I check for the size.

0:28:060:28:08

We check for any excessive pips or peel or anything like that.

0:28:080:28:13

-The fruit looks beautiful.

-It is. It's really nice.

0:28:130:28:17

-So far today, happy day.

-Yeah.

-Brilliant.

0:28:170:28:21

'It's Yorkshire puddings I'm really interested in.

0:28:240:28:27

'With the raw materials given the green light, the baking can begin.'

0:28:270:28:32

This is where it all starts. Lynne Campbell is quality manager.

0:28:320:28:36

My name's Lynne Campbell.

0:28:370:28:39

It's my job to make sure that the Yorkshire puddings are safe to eat

0:28:390:28:43

and the best quality possible.

0:28:430:28:46

Good to see you. What have we got here, then?

0:28:460:28:49

This is an egg tanker, how our liquid egg is delivered onto site.

0:28:490:28:55

It is then pumped into the factory and held in a sealed unit.

0:28:550:28:59

-Are there any checks at this point?

-We make sure that the temperature's correct.

0:28:590:29:04

That everything is to the specification required.

0:29:040:29:07

'This tanker holds 25 tonnes, equivalent to half a million eggs.

0:29:070:29:12

'Just like the puds I make, the other main ingredient is flour.

0:29:140:29:18

'Here, it has a set of safety checks all of its own.'

0:29:180:29:22

-Wow! This is clearly flour.

-It is.

0:29:220:29:25

This is the bulk flour silo,

0:29:250:29:27

where all our flour's stored ready to call for the factory.

0:29:270:29:31

When this arrives, what do you check for from a health and safety point of view?

0:29:310:29:37

We have to check the tanker that's arrived is in good condition,

0:29:370:29:41

we're happy with its integrity.

0:29:410:29:43

It's then pumped into here through a sieve.

0:29:430:29:47

'Like me, they sift their flour before making a yorkie.

0:29:470:29:51

'They do it for a very important reason.'

0:29:510:29:54

This is to make sure that there's no contamination through any of the systems.

0:29:540:30:00

-So anything that's a contamination in terms of foreign bodies?

-Yes.

0:30:000:30:05

-Then that's going to be ejected.

-It is.

0:30:050:30:07

Any hard wheat husk or any hard flour, anything that shouldn't be in there.

0:30:070:30:13

-Any contamination, it will catch it.

-Where does the flour go from here?

0:30:130:30:17

It is piped through into the factory. They call it straight into the mixing.

0:30:170:30:23

-Straight through the pipework?

-Yes.

0:30:230:30:26

'I'm astounded by all the work that goes into making a simple Yorkshire pudding.

0:30:260:30:31

'And when you mix a whole load of eggs with a whole load of flour,

0:30:320:30:37

'you get more batter than I've ever seen.'

0:30:370:30:41

It passes through this filter, another critical test

0:30:410:30:44

to make sure we haven't got any contaminants in the mixture

0:30:440:30:48

before it's baked.

0:30:480:30:50

-Then oil as well?

-Yes.

0:30:500:30:52

The key to a good yorkie - hot trays, hot oil, batter.

0:30:520:30:55

The oil goes in heated into the hot trays, which is what we can see?

0:30:550:31:00

Yes.

0:31:000:31:01

The oil is deposited from this hopper.

0:31:010:31:04

The batter is deposited on top of the oil, forms a nice ring

0:31:040:31:08

and goes straight into the trays into the oven.

0:31:080:31:13

'When I've got the family over for Sunday dinner, I've sometimes wished

0:31:150:31:20

'I had a bigger oven.

0:31:200:31:22

'These are something else. They're half the size of a football pitch.'

0:31:220:31:27

When I'm cooking a Yorkshire pudding at home,

0:31:270:31:31

it's nice and hot, constant.

0:31:310:31:33

-Is it the same in this process?

-No, it's not.

0:31:330:31:38

This is a far bigger scale.

0:31:380:31:40

'They couldn't be more different.

0:31:400:31:43

'These massive ovens are split into different temperature zones,

0:31:430:31:48

'designed to get the puds to rise.'

0:31:480:31:51

What safety checks are done? It's a long time to leave the product.

0:31:510:31:56

Baking time is approximately 15 minutes.

0:31:560:31:59

We monitor the batter, time and temperature in the holding tanks

0:31:590:32:03

to make sure it hasn't had any time for microbes to grow.

0:32:030:32:07

Through the baking process, we've validated the oven to reach the temperatures needed.

0:32:070:32:14

At the end, a critical point, we take the bake temperature to ensure it's baked safely.

0:32:140:32:20

'I just can't resist taking a sneaky look inside this super-sized oven.'

0:32:210:32:27

Wow! These are massive, massive ovens!

0:32:270:32:31

'Time to see if the puds have risen,

0:32:310:32:34

'or if opening that door has caused a bit of a flop.

0:32:340:32:38

'Thankfully, they look perfect.'

0:32:400:32:43

Now that they've cooked, what's the final safety check we have to do?

0:32:430:32:49

We take a tray and look that they've baked correctly.

0:32:490:32:52

The right height, the right shape.

0:32:520:32:54

From a foreign body point of view, we would reject this

0:32:540:32:58

because this is the carbon from the trays.

0:32:580:33:02

We would reject that.

0:33:020:33:04

'Bacteria can grow when food is below 63 degrees.

0:33:040:33:08

'So making sure the yorkies are hot enough is critical.'

0:33:080:33:13

If it didn't hit temperature, what would the implications be?

0:33:130:33:18

-We would have to throw away the full oven.

-Right.

0:33:180:33:21

We couldn't let it go any further so the whole oven would be thrown away.

0:33:210:33:27

'For most of us, yorkies go straight from the oven onto the plate.

0:33:290:33:34

'Here, they need to be frozen, packed, then passed through one last checkpoint.'

0:33:340:33:40

I didn't imagine that, at the end, I'd find a metal detector.

0:33:400:33:45

If you think about our process, all the batter and the puddings

0:33:450:33:49

travel through lots and lots of stainless steel and machinery.

0:33:490:33:53

-One of the major hazards would be metal contamination.

-Of course.

0:33:530:33:57

We make sure the product's free from metal.

0:33:570:34:00

So they'd be rejected. What physically happens to the product?

0:34:000:34:05

The metal detector registers that there's metal in the pack.

0:34:050:34:09

That sends a signal to an air blast to blast them into a reject bin

0:34:090:34:13

which is locked and kept secure.

0:34:130:34:16

'Bits of metal in your Yorkshire pud would be dangerous.

0:34:170:34:21

'So I'm keen to see if this machine works.

0:34:230:34:26

'Every hour, metal rods are attached to packaging.

0:34:260:34:30

'When they're detected, the bag is rejected.'

0:34:300:34:34

Brilliant. That proves that it's working properly.

0:34:340:34:38

-We can safely get the packaging out and distributed.

-Yes.

-Brilliant.

0:34:380:34:43

'It's been a journey that started on the farm

0:34:450:34:48

'and has been scrutinised every step of the way.

0:34:480:34:52

'Finally, these yorkies can be packed off to our supermarkets in time for Sunday lunch.'

0:34:520:35:00

If you're planning on grabbing a takeaway today, you'll want to be reassured that the food is safe.

0:35:050:35:11

Let's rejoin our two food fighters.

0:35:110:35:14

At the opposite ends of the country, their mission is the same - to put safety at the top of the menu.

0:35:140:35:21

'At the Kurdish Flag in Oxford, it's not been a great inspection.

0:35:250:35:31

'Environmental Health Officer Richard Kuziara

0:35:310:35:34

'is concerned about the distance between prep and storage areas.

0:35:340:35:38

'And drinks that should have been in the fridge have been left out.'

0:35:380:35:42

I'll have a look down here.

0:35:420:35:45

'Downstairs, things aren't much better.'

0:35:450:35:48

-This is more chicken, isn't it?

-Yes.

0:35:480:35:51

You can see we've got blood and things in there.

0:35:510:35:55

'Raw chicken can be a source of campylobacter,

0:35:550:35:59

'the most common form of food poisoning in the UK.

0:35:590:36:03

'So blood sitting on a fridge shelf is a serious food safety issue.'

0:36:030:36:08

So the actual chicken is going to be OK,

0:36:080:36:12

IF you wash your hands when you open that.

0:36:120:36:15

I know you've only just moved in,

0:36:150:36:17

but stuff like that, you need to clean it.

0:36:170:36:21

'For Richard, these problems should have been sorted out before opening.

0:36:240:36:29

'There are potential risks in every corner.'

0:36:290:36:32

One of the issues here,

0:36:320:36:34

we've got paint peeling.

0:36:340:36:38

Got open food below it.

0:36:400:36:43

There's a risk of contamination. It's not great.

0:36:430:36:46

And, you know, what is up here? Who knows?

0:36:460:36:51

'The Kurdish Flag has structural problems.

0:36:550:36:58

'Not just the condition of the ceiling, but the layout, too.

0:36:580:37:02

'So it's time for Richard to give his verdict.'

0:37:040:37:08

Because of your stock rotation and your temperature control,

0:37:080:37:12

the overall picture I'm going to put you as "fair".

0:37:120:37:15

I'm being a bit generous, but I'm not going to be generous with the structure.

0:37:150:37:21

The structure's rubbish. You know that. I know that.

0:37:210:37:25

'The marks are totted up to produce a star rating between zero and five.

0:37:250:37:30

'These scores are very important to food businesses, especially new ones.'

0:37:300:37:36

As it is today, this is a one-star business, yeah?

0:37:360:37:40

It's mostly down to the structure

0:37:400:37:43

and...my confidence in the management.

0:37:430:37:47

'It's a poor score, so the duty manager begs for a follow-up visit in three days' time.'

0:37:470:37:54

-Friday you come, 100% everywhere.

-Right.

0:37:540:37:57

-Everything 100%.

-So, on Friday, this place is going to be immaculate?

-For sure.

0:37:570:38:03

Friday, you will see everything is clean.

0:38:030:38:06

-If it's right on Friday...

-Yeah.

0:38:060:38:10

..I can move you up to two stars if you do everything you say you'll do.

0:38:100:38:15

'Richard will be back to check if these promises have been kept.

0:38:170:38:21

'What about his fellow food fighter, Simon?

0:38:210:38:24

'In Preston, Lancashire, Simon has been checking up on curry cafe Lunches & Brunches.

0:38:250:38:32

'The cafe received two stars on its first inspection, but improvements seem to have been made.

0:38:320:38:38

'Simon is yet to poke his nose into the important stuff, the food.'

0:38:380:38:43

I'll pop it in the rice.

0:38:450:38:47

'In the middle of the fridge, Simon spots a problem.

0:38:520:38:55

'There are some tubs of food that are still warm.'

0:38:550:38:58

That's come out at a comfy 40 degrees there.

0:39:000:39:04

Cos right in the middle there, that's still warm.

0:39:040:39:08

-If you put your hand under there, that's quite pleasant!

-It's warm.

0:39:080:39:12

Before it's cooled down, don't put it in the fridge, yeah?

0:39:120:39:17

Leave it out for maybe an hour, hour and a half.

0:39:170:39:20

'The warm food can heat up the rest of the fridge's content and this can open the door for bacteria.

0:39:220:39:31

'Muhammad must ensure that only fully cooled food is in the fridge.'

0:39:310:39:36

Cos it's a catering fridge, a proper industrial refrigerator,

0:39:360:39:41

once you let it cool a bit longer it will cope with that

0:39:410:39:44

and take those temperatures down.

0:39:440:39:47

A domestic one wouldn't work so well.

0:39:470:39:50

'A mark against the takeaway, but Muhammad knows what should be done,

0:39:500:39:55

'and that goes for use-by dates, too.'

0:39:550:39:59

If it's not finished by three days, should throw. Don't need to ask me.

0:39:590:40:03

You can ask my staff, but I told them don't ask me. Throw it straight away.

0:40:030:40:10

Really good.

0:40:100:40:12

'And now it's the verdict.

0:40:130:40:16

'Will Muhammad improve on his two-star score?'

0:40:160:40:21

The hygiene practices, things that you talked me through,

0:40:210:40:25

the stuff you told me without prompting, that's really good.

0:40:250:40:29

The structure is lovely, really impressed with that.

0:40:290:40:34

-That would give you a five-star certificate.

-Thank you very much.

0:40:340:40:38

That's genuinely really good.

0:40:380:40:40

So we'll get you the certificate next week.

0:40:400:40:43

Out of our 1,200 businesses, you're in the top 100.

0:40:430:40:47

-Thank you very much.

-I'm impressed with that.

0:40:470:40:51

It's really nice when you find a business that started out,

0:40:530:40:57

not been open long, lots of advice given to start with

0:40:570:41:01

and the results are really good.

0:41:010:41:03

It's a well-deserved mark, that.

0:41:030:41:06

-Cheers. See you later.

-Thank you.

0:41:100:41:12

'Muhammad is delighted with his result.'

0:41:120:41:15

It's amazing.

0:41:150:41:17

I've got a five star now so I'm really happy and very, very...

0:41:170:41:23

I can't help my feelings!

0:41:230:41:25

So I'm happy now, but I'm still going to be very strict on my staff!

0:41:250:41:31

'It's a brilliant improvement, but can the Kurdish Flag in Oxford

0:41:340:41:38

'pull off a similar transformation?

0:41:380:41:40

'Richard DID go back three days later but found the shop shut up.

0:41:400:41:45

'So, a few months later, he's back again.'

0:41:460:41:49

Hello, Hassan.

0:41:490:41:51

'There's a huge change this time.

0:41:510:41:54

'The Kurdish Flag now has a name and a new owner, Hassan.

0:41:540:41:57

'This is the shop's third owner in as many months.

0:41:570:42:02

'He may be new, but Hassan still needs to follow the old advice.

0:42:020:42:08

'While the food prep area is all in one place with a wash basin,

0:42:080:42:13

'there is room for improvement.'

0:42:130:42:15

It's a little bit warm. You've got about 11.5 there.

0:42:150:42:20

It should be below eight.

0:42:200:42:22

'All in all though, Richard's happy with the progress that's been made.'

0:42:220:42:27

That's classic small business stuff, three months, three owners.

0:42:270:42:31

The new owner seems to be the best so far.

0:42:310:42:35

He has gone some way to rectifying the problems.

0:42:350:42:38

What I've got there is a business that is a lot better.

0:42:380:42:42

Hopefully, with a bit of looking after, he'll go on to improve.

0:42:420:42:47

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0:43:090:43:12

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0:43:120:43:15

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