Episode 8 Food Fighters


Episode 8

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

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Whether you are eating in or taking away,

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there's always the chance that something can go wrong.

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So it's a good job there's a whole army of people

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working hard to keep us safe.

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They are the Food Fighters.

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Coming up today...

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Meals in minutes, but what goes into ensuring

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our TV dinners are completely safe to eat?

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High-risk catering at a county show.

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Got nine barbecues under cover in one place

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and customers are cooking their own food?

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-There are always raised eyebrows.

-I know.

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And from fields to our fridge.

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Will this unpasteurised cheese get the thumbs up?

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Food safety and hygiene is mega-critical here

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because I'm dealing with a raw product - raw cheese, raw milk.

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'We Brits have been buying ready-prepared meals since the late 1970s.

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'And the variety now on offer is simply staggering.

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'From Chinese are to Italian, Indian to British classics -

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'it's possible to eat our way around the world

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'with dishes cooked in minutes.'

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We all lead hectic lives,

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and when cooking something from scratch isn't an option,

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many of us reach for products from this aisle in our supermarket.

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The ready meal market is big business.

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Even though the products are convenient, they have to undergo

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rigorous hygiene checks to ensure that they're safe to eat.

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'Here at this food factory in Southall, West London,

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'they make as many as 200,000 ready meals every day.

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'On the production line for Sainsbury's supermarkets

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'is one of our national dishes - chicken tikka masala.

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'And making sure this yummy curry doesn't give us a dicky tummy

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'is this Food Fighter.

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'Alec Kyriakidis is the supermarket's head of safety.

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'Today he's conducting one of his regular inspections here,

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'to make sure the ready meals are being made safely.'

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'First stop, goods in.

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'Handling a very high-risk product.'

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All right, so chicken comes in, what do we look for?

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What does it look like, what does it smell like,

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is it slimy, blood spots - there's no blood spots on there.

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You are looking for things you wouldn't want such as gristle or bone.

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We certainly don't want any bone in a product.

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'The chicken pieces are also weighed here to ensure they are the right size.

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'To big and the chicken might not be thoroughly cooked,

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'increasing the risk of food poisoning.'

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Chicken has been subject to many health scares over the years.

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The main dangers from a piece of raw chicken are what?

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Most people know that raw chicken is something you need to handle very carefully.

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The two key microbiological safety concerns

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are salmonella and campylobacter.

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Salmonella is a lot lower than it ever has been in raw poultry

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but it still can be there.

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Campylobacter is there quite frequently,

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therefore we all know it has to be cooked properly

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and you have to make sure that you don't cross-contaminate

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between the raw chicken and the cooked chicken.

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'Spices are the key ingredient in any curry,

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'so I'm following my nose to the most aromatic room in the factory.'

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Ah! Look at this!

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This is glorious.

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The smell in here is fantastic.

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You get cloves, cardamom, cumin, coriander, garam masala,

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lovely cinnamon bark in there, dried chillies. It's just beautiful.

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'But while you might imagine these would be very low risk,

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'the vibrant colours could signal danger.'

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I suppose that because all of these spices are imported

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then there are still health and safety issues here.

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Absolutely. I think you can't take anything for granted.

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You might remember many years ago the issue with Sudan 1,

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where people were adding illegal dyes to some of the spices.

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You can see the vivid colours here, there is the risk

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that people could actually try for example to add Sudan 1

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to really make that red more vibrant.

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These will be subject to testing particularly for chemical

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and microbiological hazards

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that could be present associated with them.

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Now I've got all of these in front of me and they are all going to be measured, I want to get cooking now.

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Let's go through and see how it's all brought together in the pan.

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'I absolutely love cooking curry,

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'and how they create the tikka masala ready meal

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'isn't so different to how I'd make it.

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'For the marinade I'd add my spice mix and yoghurt... '

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' ..before adding my chicken.'

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'But obviously one thing I don't do

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'is make curry on such an industrial scale,

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'and here they're using a catering cement mixer to do it.'

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The whole idea is to really maximise the interaction

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between the marinade and the chicken,

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because what that does is it helps you absorb all that flavour into the chicken very quickly.

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What's happening temperature-wise at this point?

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When the chicken comes in raw, keeping that temperature down is so important.

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-Are we still fairly cold at this point?

-Absolutely.

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They tumble for about half-an-hour maximum.

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They'll go back into the chiller, they'll be held there just to stabilise for another half-hour

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and then they'll be straight on the line to be cooked.

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Once the chicken is marinated it's flame-grilled in one of these huge ovens.

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When it comes out the other side its core temperature is monitored

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to make sure it's cooked through.

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'Elsewhere in the factory, the masala sauce is being cooked up.

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'But it's in the pilau rice where the next food poisoning nasty could be lurking.'

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Rice is one of those things I think a lot of people don't realise

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how dangerous it can be in terms of getting food poisoning.

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Yes. There are inherent risks with rice, particularly when you are cooking it on a large scale.

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Most people think you are cooking it, you are boiling it,

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and therefore nothing is a problem afterwards, everything is killed.

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But there are some spore-forming bacteria that can remain.

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Once the rice is then cooked,

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if you leave it for too long it stays warm and moist.

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-Perfect conditions for bacteria.

-Perfect conditions.

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Those spores germinate and grow, and as a consequence you can be ill.

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'To stop bacteria growing, the rice is spread evenly on these trays

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'before being whisked through to the massive blast chiller.'

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The aim of the blast chiller is actually to blow cool air over it

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to take the heat out of it very quickly

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and to get it to a temperature where those bacteria aren't going to grow.

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So does that mean now, because this is now a cooked product,

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that the next stage for us is to move into the high-risk side?

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Absolutely. Let's go and get changed into high-risk kit.

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I love a bit of danger, Alec, I love a bit of danger.

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Coming up...

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Vital advice at the County Show.

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I normally sacrifice one burger, breaking it open to make sure

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it's cooked all the way through and the juices are running clear.

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Very important, because if it's pink, it's trouble.

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'But first, despite the recent credit crunch, eating out is more popular than ever in the UK.

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'But even if a restaurant is recommended by a newspaper or website review,

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'it's worth knowing if it hits the highs when it comes to hygiene.

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'So we've been following environmental health officers up and down the country.

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'And it's their job to make sure your evening out won't buy you

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'a case of food poisoning.'

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'Leigh-on-Sea, Essex.

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'In a one-time working boatyard sits The Boatyard restaurant.

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'It offers a fine dining experience with estuary views,

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'and goes down well with locals and tourists.

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'Today, Environmental Health Officer Steve Ramm has sailed in

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'to make sure there's no chance of anyone getting sick.'

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On the website that gives scores for restaurants we find this one is

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giving the highest number of hits, so that's a sign of how popular it is.

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When it received its last inspection about a year ago,

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despite its popularity on the ratings

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it only got a description of broadly compliant, which is not alarming

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but we'd like to think it could do better than that.

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-Hello there.

-'Steve meets head chef John.'

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That's right, Steve Ramm, Southend Council, how do you do?

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'The last inspection here didn't go well.

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'So John has been working hard to steer this restaurant in the right direction.'

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'John takes Steve to the main food prep area.

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'There's plenty of space at The Boatyard.

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'Steve thinks he could use it better.'

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Yes, in the past we've said if you do raw food on a worktop

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and then later on you're doing ready-to-eat food, make sure you sanitise.

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That's what we've been saying for a long time.

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The new guidance says you ought really to have a separate area, designate a separate area.

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I would think you've got...

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You've got two sides of a stainless-steel worktop, that should be quite easy.

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'Cross-contamination is one of the most common causes of food poisoning.

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'Making sure no bugs from raw meat find their way to

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'the ready-to-eats means safer food on the punters' plates.'

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'By the same token, when raw meat is stored

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'it should be kept at the bottom,

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'so juices don't drip down on to other food.'

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-Cooked meats.

-Yeah.

-Sauces.

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So once again you've thought about the fact we've got raw meats at the bottom where they should be,

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cooked meats at the top where they should be, and sauces in the middle.

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-Everything is separate.

-OK.

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'The fridge temperature should be no higher than eight degrees Celsius.

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'Anything higher would allow harmful bacteria to grow.

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'Steve is happy with all but one fridge.'

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I'm actually getting eight and nine, which is what this is saying.

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'This fridge is more of a storage space for low risk foods, so it's not a major issue.'

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But you do need to keep an eye to make sure you bring it back to below eight.

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'Steve has to use all his findings to come up with an overall score.

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'The food fighters grade every outlet from 0 - 5.'

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I think I've seen all I need to see today.

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'At its last inspection The Boatyard just kept its head above water with a two.

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'John is desperate to climb the ladder.'

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I've been as honest and as positive as I possibly can.

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I've played by the books, I've done everything they've told me to do

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and I hope that reflects in the report.

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'Moment of truth time.'

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-This is my report form.

-'Will The Boatyard have won a few more stars?'

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And it confirms, as we've discussed as we've gone around,

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that you have made some improvements since the last inspection.

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You've gone from a two to a four, which is described as good.

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'So it's four for The Boatyard, and with a few more improvements

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'this restaurant could easily achieve five.'

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I'm pretty happy. We've got four stars, a score of four.

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It's a massive improvement to when she last come in,

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which was pretty shocking.

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But obviously the next step is now five stars,

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and that's what I'm looking forward to getting.

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'From Essex to one of the world's foremost learning institutions -

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'Oxford University.'

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'In the new biochemistry building,

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'there's a popular cafe serving hungry science students.

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'Students and good food don't normally go together,

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'but like any restaurant, this one will have to make the grade.'

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How you doing?

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'So Food Fighter Richard Kuziara is taking a trip down memory lane.'

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I always enjoyed being a student.

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It's coming back to me now.

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Good. Want a job?

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'Catering manager Karen fills him in on what they do here.'

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We have at least one or two hot other choices.

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Today, we've got cannelloni and we've got fish.

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OK. And again, that's all prepared on the day.

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-That's all prepared fresh every day.

-OK. Great. Nice.

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'Health inspections can be as nerve-wracking as exams, but Karen's calm.'

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I've had no problems about this. You know, everyone was saying "Oh, they're coming."

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I said, "Don't worry about it. Do what you do.

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"If you're doing something wrong, we'll find out

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"and we can put it right."

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'And Richard's giving it a big tick so far.'

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The whole thing just is like really bright and airy and lovely, isn't it?

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'Especially when he gets a load of the supersized butties.'

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That's a sandwich and a half, that, isn't it?

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Definitely a man's sandwich. Excellent.

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You've got stuff for the skint students as well. That's all good.

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'Time for some science, then, in the biochemistry building.

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'Richard aims his laser to check fridge temperatures.'

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The temperature inside, yeah, is good.

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'It's full marks so far for front of house.'

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-This looks really nice.

-Thank you.

-I wasn't expecting it to be quite such nice home-prepared stuff.

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I thought, well, you know, it's... yeah, yeah.

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'But when Richard heads into the kitchen... '

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-Right. You want to come round this way?

-Yeah, please.

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'Will the raw elements pass the test?'

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-Later...

-You can't wash your hands in it. It's too hot.

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'Will Oxford University's cafe make the grade?'

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You do need hot water, but you don't want it too hot.

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If it's too hot, it's going to scald your hands.

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'Now, most milk and cheese that we buy has been pasteurised.

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'This extreme heating kills off any dodgy lurking bacteria,

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'but some cheese makers believe that unpasteurised or raw milk can give a better flavour.

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'Now that might be true, but how can we be sure that this cheese is safe to eat?'

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'This is Mrs Kirkham's Dairy near Preston in Lancashire.

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'Here they handle every stage of cheese production.'

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'From the cows in the field...

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'to milking in the parlours...

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'to the final big cheese.'

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'The boss here is a firm believer in using unpasteurised milk.'

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My name's Graham Kirkham, and I make a raw milk unpasteurised Lancashire cheese.

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Food safety and hygiene is megacritical here,

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because we're dealing with a raw product. Raw cheese, raw milk.

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'But aren't Graham's methods of cheese-making risky?

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'Well, today he should find out because a Food Fighter has come calling.

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'Simon Neighbour is an Environmental Health Officer from Preston Council,

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'and he's here to inspect the dairy.'

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-Hey, Graham.

-'Before the inspection begins,

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'it's vital the pair don't introduce any contaminants into the dairy.'

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As we've come up the path earlier on, there could have been

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anything on the path that picks up contaminations.

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So stick the wellies on, they'll go through the foot bath more easily,

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and you just make sure the footwear is sanitised and don't introduce any bacteria into the processing area.

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'Wellied up, they can enter.

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'The cheese-making at Mrs Kirkham's is very hands-on.

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'So the first critical step for Simon

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'is to check that hand-washing is up to scratch.'

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So here we're just making sure we've got

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hot and cold or appropriately mixed water. So that's a nice temperature.

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If it's too cold, you tend not to wash your hands for very long.

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Soap, obviously.

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Something you can then dry your hands on.

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You've then got an alcohol gel,

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which is excellent for giving a final clean and sanitise the hands.

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'Now it's time to inspect the key areas.

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'Once the cows are milked, their milk passes through a big tank into this room.

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'It's here that the cheese-making magic begins.'

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We add a culture, called starter, which looks like a natural yoghurt.

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That goes in, then 20 minutes later you put a rennet in,

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which basically sets the milk.

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Looks like a blancmange. Which creates this sort of a thing.

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Makes it set like that.

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The curds will sink and the whey will come to the top.

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In about another hour's time, we'll drain all this off

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and we'll just be left with the curds in the bottom.

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'The whey is simply a byproduct, and can now be used as animal feed.

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'The remaining curd is the stuff that will eventually become cheese.'

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'So Simon must ensure the curd-making methods are safe.'

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OK, so just looking at the structure,

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and the cleanliness on this, and the state of repair, that's all fine.

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There's nothing looking like it's going to flake or be dropping into the milk.

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All the welding's good.

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'Simon's checks are crucial in keeping cheese-eaters safe from danger microorganisms.'

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Those organisms don't affect how the product looks or tastes or smells,

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so it could look absolutely fine,

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taste fine when you're eating it, no off odours, but those pathogens

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can cause illness 12-36 hours later.

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With listeria, there's an incubation time of 70 days

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between eating the product and it actually making you ill.

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So it's keeping an eye on the process,

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making sure the cheese develops as you would expect it to do.

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'There's no pasteurisation process to kill germs in the milk.

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'This makes it all the more important nothing contaminates the milk flow.

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'The best way of keeping things clean is thorough, regular test swabs.'

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The whole dairy's swabbed, actually, on a weekly basis now.

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Tap end. Corners in this vat.

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Floor, drains, you know.

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'Graham's anti-contamination efforts look thorough.

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'They should help stop this curd picking up germs

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'before it enters the next stage, the curd bin.'

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The purpose of this is to drain more of the whey off,

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so we cut this up and we break it to help drainage.

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Then we press it again, and we do this sort of three times,

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and then it's left till the following morning.

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'But draining isn't the only thing going on here.

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'Lactic acid is now produced by the live culture in this curd.

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'The acid not only adds flavour, but prevents the growth of bad bacteria.'

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This is what we made yesterday.

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Sort of rubbery curd, no whey left in it.

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Nice and dry, nice and squidgy.

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-OK.

-Plenty of acidity.

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1.4 or 14 on the acidity, so that's high, that's really good.

0:20:110:20:15

Nice milky smells coming off it. It's good. That's how we want it.

0:20:150:20:19

'These high acidity levels are good for the taste -

0:20:190:20:23

'and good for safety too.

0:20:230:20:25

'What's more, as cheese matures, acidity levels rise.

0:20:250:20:30

'This produces an ever-increasing defence against bad bacteria.'

0:20:300:20:34

'But the danger of contamination remains throughout.

0:20:360:20:40

'These are the cheese presses.

0:20:400:20:41

'Used to, well, press cheese, really.

0:20:410:20:44

'And they're next on Simon's checklist.'

0:20:440:20:48

Because it's a really moist environment, quite steamy,

0:20:480:20:51

rust develops quite quickly, but these are in good condition.

0:20:510:20:55

Blue is a good colour, because if any of the paint did flake off and got through the covering,

0:20:550:21:00

you'd be able to pick it up straight away.

0:21:000:21:03

'And here we are at the very end of the cheese journey and Simon's inspection. The storage room.'

0:21:030:21:09

So cheese is turned every few weeks.

0:21:090:21:13

'Key for Simon here is the labelling, and of course those all-important temperature checks.'

0:21:130:21:18

We keep this room at about 12-14 degrees,

0:21:180:21:22

so it's quite warm in some respects.

0:21:220:21:24

-We need that bit of warmth, because that's what keeps the starter culture working.

-Sure.

0:21:240:21:28

Which keeps all the pathogens at bay, which builds up the acidity,

0:21:280:21:32

and we also need it to be able to get this rind growth.

0:21:320:21:35

If it's too cold we won't get this nice white mould growing.

0:21:350:21:39

'And at the end of his inspection, it's feedback time.'

0:21:390:21:42

You slightly improved your score on last time.

0:21:420:21:45

Pretty much as good as you can get now. Keep doing that.

0:21:450:21:47

Keep doing what we're doing.

0:21:470:21:49

'Graham may only have a small dairy...'

0:21:490:21:52

All right, cheers.

0:21:520:21:54

'but when it comes to food safety, he really is a big cheese.'

0:21:540:21:58

Yeah, sure, it's a good inspection,

0:21:580:22:01

and I hope that the next one will be the same, if not even better.

0:22:010:22:04

That's how it is. That's how it has to be. That's how it has to be.

0:22:040:22:08

I have to say, this has been one of the hardest things

0:22:140:22:16

I've had to do on Food Fighters, because curry is my thing,

0:22:160:22:20

and if I'm honest with you, if they sold lager in here, I'd never leave.

0:22:200:22:24

When it comes to eating red meat, many people like to eat it rare.

0:22:290:22:32

But there's a clear distinction that must be made

0:22:320:22:36

between burgers and steak.

0:22:360:22:38

Bacteria like E-coli, survive on the outside of the meat

0:22:380:22:41

so as long as you cook the outside of the steak or roast beef,

0:22:410:22:44

you're going to be OK.

0:22:440:22:45

But burgers are a completely different story.

0:22:470:22:49

Because they're made of minced beef,

0:22:490:22:52

it means that every single grain of the burger has been exposed to those food poisoning nasties.

0:22:520:22:57

It's therefore vital that burgers are cooked through.

0:22:570:23:00

'It's the second day of the Devon County Show.

0:23:050:23:08

'And the crowds are pouring in to sample the local produce.

0:23:080:23:12

'There's a lot of high risk outdoor cooking going on here

0:23:120:23:15

'but if any vendor plans to cut corners, they'd better think again.

0:23:150:23:21

'There's a Food Fighter here

0:23:210:23:23

'with a name to strike fear into the heart of any rogue trader.

0:23:230:23:27

BUGLE CALL

0:23:270:23:29

My name is Dick Turpin

0:23:310:23:32

and it's my job to maintain food standards at open-air events.

0:23:320:23:36

# Stand and Deliver, your money or your life. #

0:23:360:23:43

'Catering steward Dick Turpin needs to check every stall here'

0:23:430:23:46

'but it's the red meat and burgers that's his priority.'

0:23:460:23:49

We're going to get 90,000 people in three days to feed,

0:23:490:23:54

and we take that very seriously.

0:23:540:23:57

You're running at 78, when you only need 75. That's all right.

0:23:570:24:02

'Dick knows a lapse in standards today would not only be a public health calamity,

0:24:020:24:06

'it would also be an economic disaster for the whole Devon Show.'

0:24:060:24:11

And that's what? 77? 78? Very good.

0:24:110:24:15

One bad bit of publicity on food safety, overnight,

0:24:150:24:19

could affect the number of visitors the following day.

0:24:190:24:22

'Right, let's get started.'

0:24:250:24:27

'At this stand, they don't deliver, but they do bacon, burgers, sausages and beef.

0:24:270:24:33

'And it's burgers that Dick needs to keep a keen eye on today.

0:24:330:24:36

'Burgers rank amongst the most high-risk food.

0:24:390:24:42

'That's because minced beef could contain E-coli.

0:24:420:24:46

'E-coli causes sickness, diarrhoea, fever, and can even prove fatal.

0:24:460:24:53

'So, your burgers must be cooked throughout

0:24:530:24:56

'to kill off this food-poisoning nasty.'

0:24:560:24:58

Let's have a look at the burgers today.

0:25:020:25:04

Probably the biggest seller on the whole thing.

0:25:040:25:07

'Back at the Devon burger stall,'

0:25:070:25:10

'and Dick wants to see how they're standing up to the regulations.'

0:25:100:25:14

-How often do you do temperature control?

-I try and do them regular.

0:25:140:25:19

Also, in terms of cooking them, I do like to probe

0:25:190:25:21

to check the temperature.

0:25:210:25:23

If I cook one batch,

0:25:230:25:24

I normally sacrifice one burger,

0:25:240:25:26

breaking it open to make sure

0:25:260:25:28

it's cooked through

0:25:280:25:29

and the juices are running clear.

0:25:290:25:31

Very important. If it's pink, it's trouble.

0:25:310:25:33

'Now Dick wants to know that burgers aren't left sitting around.'

0:25:350:25:39

They come in stacks of eight.

0:25:390:25:40

We cook two or three stacks, depending on how busy we are,

0:25:400:25:43

serve them, and once they're going really low,

0:25:430:25:46

new batch, so that the food's always getting rolled over,

0:25:460:25:50

and nothing's getting kept there for too long.

0:25:500:25:53

'That's music to Dick's ears, because quick turnover'

0:25:530:25:55

'means less opportunity for harmful bacteria to grow.'

0:25:550:25:59

OK, we'll just go round to the store, there.

0:25:590:26:01

'Before leaving, Dick has a quick butcher's at the storage tent.'

0:26:010:26:05

OK, Paul, this is the ambient storage, isn't it?

0:26:050:26:08

Any ambient foods are well clear of the floor,

0:26:080:26:12

because of vermin or anything else.

0:26:120:26:14

OK, Paul, any problems this morning, staffing or anything?

0:26:170:26:20

No, everyone's here nice and early, food cooking, ready for a good day at the show. Hopefully.

0:26:200:26:26

OK, well, make sure you cook those burgers well.

0:26:260:26:28

-Thanks very much.

-I'll see you later on. Bye-bye.

0:26:280:26:31

'This stall is given the OK to carry on grilling, so Dick can move on.

0:26:320:26:36

'With more than 50 vendors operating here today,

0:26:410:26:43

'Dick has his work cut out.

0:26:430:26:45

'But it's the meat stall that poses the biggest risks.

0:26:450:26:48

'And, whereas Dick can be happy that most know how to cook a burger properly,'

0:26:480:26:53

'there's one that isn't cooking them at all.'

0:26:530:26:56

This is the thing, you know,

0:26:570:26:59

it's the first time I've ever seen our visitors cooking their own food.

0:26:590:27:03

We're actually serving raw meat to the general public,

0:27:030:27:06

to cook themselves.

0:27:060:27:07

For all Health and Safety executives coming onto the site new,

0:27:070:27:10

for the first time, seeing what we do,

0:27:100:27:12

there are always raised eyebrows, as they look round and they think,

0:27:120:27:17

"Hang on a minute, we've got nine barbecues, undercover,

0:27:170:27:21

"in one place and customers are cooking their own food."

0:27:210:27:24

And it slightly puts the fear of God into them.

0:27:240:27:28

Once we explain how we manage it, what we do,

0:27:280:27:31

what our practices are, they then go away, relaxed.

0:27:310:27:35

'The customers are cooking their own dinner.

0:27:370:27:40

'Dick wants to know how they do this, safely.'

0:27:400:27:44

Run me through it, what happens, if I sit down as a customer,

0:27:440:27:48

and have a look at a menu.

0:27:480:27:50

OK, so, we do provide guidance to people,

0:27:500:27:52

on how to cook their food, we do advise customers that

0:27:520:27:56

they should be cooking their burgers until juices run clear.

0:27:560:27:58

The burgers, we don't actually probe test.

0:27:580:28:01

What we do, burgers we simply do a break test on the burger,

0:28:010:28:05

use a set of tongs and just part the meat slightly,

0:28:050:28:08

and as soon as the juices run clear, that's then good to serve.

0:28:080:28:12

A misnomer amongst people in cooking burgers

0:28:120:28:17

is that it's OK to have raw,

0:28:170:28:19

but in fact, minced meat has been exposed to the environment

0:28:190:28:22

and you can actually get bacteria on the inside.

0:28:220:28:25

'So, that's the cooking, but with all this raw meat around,

0:28:270:28:31

'failure to keep temperature records would be truly criminal.'

0:28:310:28:35

For every show we go to, we record all of our cold food,

0:28:370:28:40

and our cooked food temperatures, we record them on this,

0:28:400:28:43

to make sure that we keep the right record.

0:28:430:28:46

We've got salad bar temperatures, we're allowed to go up to eight,

0:28:460:28:49

so five is good, normally, everything else, we keep that four.

0:28:490:28:55

-Yes.

-And that's showing four there, so that's fine.

0:28:550:28:59

'This stall is selling cooked as well as raw meat.

0:29:000:29:03

'Dick needs to be convinced there's no cross-contamination. 'This means taking a look out back.'

0:29:030:29:10

You're doing well on this storage in the fridge,

0:29:100:29:13

you haven't got any food down at floor level.

0:29:130:29:15

Well done you. All the best. Thanks.

0:29:150:29:18

'It's an ambitious idea,

0:29:180:29:20

'but the stall is handling the risks well,

0:29:200:29:22

'and Dick thinks they have risen to the outdoor catering challenge.'

0:29:220:29:27

Firstly, I was impressed with the computerised recording of the temperatures.

0:29:290:29:35

He had the right numbers, and the fact that he keeps a back-up,

0:29:350:29:38

so that's all good news.

0:29:380:29:41

In terms of how the actual inspection went, very relaxed,

0:29:410:29:44

he had no complaints or issues with what we're doing,

0:29:440:29:46

so as far as I'm concerned, it's a clean bill of health

0:29:460:29:50

and we're good to go.

0:29:500:29:51

As the day draws to a close in Devon,

0:29:590:30:01

this food fighter is satisfied that the show has been a runaway success.

0:30:010:30:06

Thanks to Dick Turpin, knight of the roadshow,

0:30:080:30:10

customers can rest assured whether it's their money, or their life, it's in safe hands.

0:30:100:30:17

I'm in a food factory discovering how ready-meal curries

0:30:230:30:26

are manufactured for Sainbury's.

0:30:260:30:28

Their head of safety Alex

0:30:280:30:31

has been showing how the dinners are made.

0:30:310:30:34

But now I'm about to enter the danger zone.

0:30:340:30:36

For the fashion conscious, might I recommend food factory live?

0:30:390:30:42

We're in the high risk area and I have natty new footwear

0:30:420:30:46

and, as you can all see, I think I'm a redhead.

0:30:460:30:49

Here we move from industrial cooking to something we'd all recognise as being in a factory.

0:30:510:30:56

The production line.

0:30:560:30:58

What are the risks we've got now then?

0:31:000:31:03

Essentially we've cooked all of these products.

0:31:030:31:06

We now have to treat them as a true ready to eat product.

0:31:060:31:09

What we're trying to do is avoid any contamination at this point.

0:31:090:31:12

The ladies are wearing gloves,

0:31:120:31:14

they have appropriate covering on their hair

0:31:140:31:16

and all of this is designed to manufacture this in a hygienic way.

0:31:160:31:21

Preventing cross-contamination between low and high risk areas

0:31:230:31:26

is crucial in a place like this.

0:31:260:31:29

And, to stop germs moving between the two zones,

0:31:290:31:32

there's also an invisible food fighter at work.

0:31:320:31:35

It's called positive air flow.

0:31:350:31:37

I've heard a lot about the positive air flow, what does that mean?

0:31:370:31:42

We're trying to push the micro-organisms from here into there.

0:31:420:31:46

High risk into low risk?

0:31:480:31:49

We don't want anything from the low risk when we've been handling raw chicken.

0:31:490:31:53

-We don't want any coming here.

-How do you know it works, then?

0:31:530:31:56

Well, I'll show you, watch this bit of paper.

0:31:560:31:59

Ah...

0:32:000:32:02

You can see how the air is blowing everything out of this room

0:32:030:32:06

and stopping anything coming back from the other room.

0:32:060:32:10

Impressive, Alex. Impressive.

0:32:100:32:12

The packaged meals are also passed through a metal detector

0:32:140:32:17

to check no nuts or bolts have gone into the curry.

0:32:170:32:20

It's almost the end of the line.

0:32:200:32:22

I think there's something quite exciting about production lines.

0:32:220:32:26

I like the way it's all pieced together.

0:32:260:32:28

The logistical side of being a chef, it's exciting when you piece

0:32:280:32:32

a meal together, whether it be here or in the restaurant.

0:32:320:32:35

There we go, look at that. Perfect.

0:32:370:32:40

We've got rice, chicken, and sauce on there.

0:32:400:32:43

This has been one of the hardest things I've had to do

0:32:430:32:46

on food fighters because curry is my thing.

0:32:460:32:48

If I'm honest with you, if they sold lager in here, I'd never leave.

0:32:480:32:52

Before these Indian meals can be enjoyed with a pint,

0:32:590:33:02

they're labelled up

0:33:020:33:04

and sent off to the supermarket in temperature-controlled trucks.

0:33:040:33:07

But some of them won't be hitting the shelves.

0:33:080:33:12

Instead they'll be subject to even more scrutiny

0:33:120:33:14

to ensure their fellow curries are safe for us to eat.

0:33:140:33:17

So yesterday I got involved in making a chicken tikka masala curry ready meal.

0:33:170:33:21

Today I've come to an independent laboratory that tests the cooking instructions on the packet

0:33:210:33:27

to ensure that the product is safe to eat.

0:33:270:33:29

Road testing some of our favourite ready meals falls to this food fighter.

0:33:290:33:33

My name is Sue White.

0:33:340:33:36

My job is to make sure the cooking instructions on these ready meals make them safe and tasty.

0:33:360:33:42

The cooking instructions on this say, "Place on a non-metallic plate,

0:33:430:33:48

"microwave on full power for four minutes, after piercing the lid several times."

0:33:480:33:52

And into the microwave.

0:33:520:33:54

The first stage is four minutes. One, two, three, four.

0:33:540:34:00

-Away we go.

-Because the overall time is going to be six and a half.

-That's correct.

0:34:000:34:04

With chicken, what kind of things can go wrong at this stage?

0:34:040:34:08

Occasionally we've had problems with chicken bursting,

0:34:080:34:12

chicken exploding, but it doesn't often happen.

0:34:120:34:15

-Just from some suppliers.

-Why does that happen?

0:34:150:34:19

Maybe a high fat sauce, a korma sauce, high fat content.

0:34:190:34:25

The microwave reacts all over the place.

0:34:250:34:28

We usually rewrite the cooking instructions.

0:34:280:34:30

Often add an extra stir so we do it in short, sharp bursts.

0:34:300:34:35

Now I must stress exploding poultry is incredibly rare

0:34:350:34:39

and with Sue here they'll be no chance of this happening in our homes.

0:34:390:34:43

But, as instructed, we give the curry a good stir

0:34:430:34:46

and cook for a further two-and-a-half minutes.

0:34:460:34:50

Fantastic. OK.

0:34:500:34:52

Next stage, it's time to test

0:34:520:34:54

if this microwave meal is hot enough to eat and I don't mean spicy.

0:34:540:34:58

So we have a set of probes here that we insert into the product.

0:34:580:35:04

If I put this into the piece of chicken,

0:35:040:35:08

this will test the temperature.

0:35:080:35:10

What has to happen from a health and safety point of view,

0:35:100:35:12

-we have to hold a minimum of 72 for two minutes.

-Yes.

-OK.

0:35:120:35:17

If the food does this, any harmful bacteria will be eliminated.

0:35:180:35:23

-This is holding up really well.

-It is, yes.

0:35:230:35:26

It looks as if the cooking instructions are spot on for this curry

0:35:260:35:29

but that's not always the case.

0:35:290:35:32

Why would that maybe not happen? Not sufficient cooking time?

0:35:320:35:36

Probably insufficient cooking time.

0:35:360:35:38

Sometimes adding half a minute can add several degrees.

0:35:380:35:42

You can adjust it up and down,

0:35:420:35:45

it's not always as logical as you would imagine it to be.

0:35:450:35:48

With the test over, how's our tikka masala measured up?

0:35:480:35:52

You can see on this particular product

0:35:520:35:54

that the lowest temperature was 78.

0:35:540:35:56

So we've met our criteria of 72 for two minutes.

0:35:560:36:00

But there's one final test to ensure this curry is fit for you to eat.

0:36:000:36:04

There's a plate, just dive in.

0:36:060:36:08

Do you know what? I'm going to dive in.

0:36:080:36:10

-It's tender, succulent?

-Mmm.

-Nice and moist?

0:36:130:36:16

-I'm happy with that, are you?

-I think that's excellent.

0:36:160:36:19

OK, you can go now. There's nothing to see here.

0:36:230:36:27

There you have it, start to finish, it's now on the supermarket shelf.

0:36:310:36:35

Look, hundreds of ready meals

0:36:350:36:36

and now you can rest assured that every single time you pick one off the shelf,

0:36:360:36:40

the tests that its gone through means it's going to be safe and delicious to eat.

0:36:400:36:44

With more than 30,000 restaurants in the UK,

0:36:520:36:56

many people are spoilt for choice.

0:36:560:36:58

But when you can't see the food being prepared, or cooked,

0:36:580:37:01

how can you be sure that a restaurant or cafe's hygiene standards are up to scratch?

0:37:010:37:05

Thankfully, food fighters up and down the country are ensuring that they make the grade.

0:37:050:37:10

We're back at Oxford University.

0:37:130:37:15

It's produced prime ministers, Nobel Prize winners and Olympic champions.

0:37:150:37:21

And in the new biochemistry building,

0:37:220:37:25

it's producing some pretty decent grub.

0:37:250:37:27

That's a sandwich and half, isn't it?

0:37:270:37:30

That's what environmental health officer, Richard, thinks so far.

0:37:320:37:36

I do like a little bit of Bakewell tart.

0:37:370:37:39

Now he's looking behind the scenes and his first concern here is the hot water.

0:37:410:37:46

You can't wash your hands in it, it's too hot.

0:37:470:37:50

It's coming out at 60 degrees.

0:37:500:37:53

Great to blast bacteria but not great for us.

0:37:530:37:56

Hand washing is one of the most important ways of avoiding cross-contamination in the kitchen.

0:37:560:38:01

You do need hot water but you don't want it too hot.

0:38:010:38:04

If it's too hot, it's going to scald your hands.

0:38:040:38:07

Having to put the plug in, put the cold water in, put the hot water in.

0:38:070:38:12

It's going to take ages, it's not conducive to easy hand washing.

0:38:120:38:17

So I'm going to recommend, this is purely a recommendation,

0:38:170:38:21

that they have a single lever mixer tap on.

0:38:210:38:24

They can knock up with the back of a hand and the water will come out something like 43 degrees.

0:38:240:38:30

Now Richard turns to the temperature of the food.

0:38:320:38:35

What happens, Sam, if you don't get the temperature you want?

0:38:360:38:40

-Put it back in.

-Put it back in. Fine.

0:38:400:38:42

Top marks to the chef and the storage area is also first class.

0:38:440:38:48

The swankiest storeroom I've seen in a while, this.

0:38:490:38:54

It's nice you've got the space, isn't it?

0:38:540:38:55

It's one of the problems I perennially see in Oxford.

0:38:550:39:00

All the space gone at the front and then no room out the back at all.

0:39:000:39:04

-This is just your freezer, is it?

-Yes.

-Good.

0:39:040:39:07

It should be minus 18 or colder.

0:39:090:39:12

For Richard, this is all cool. In fact, too much so.

0:39:130:39:17

I'm happy with that. It's too cold to stay in here too long.

0:39:190:39:22

We stay in the warm, nice places when we're doing visits.

0:39:220:39:25

Now it's results time. Richard will award a score out of five.

0:39:280:39:32

Your systems and procedures are good, your food safety management stuff's good.

0:39:340:39:38

You've done your hygiene training. There are no contraventions.

0:39:380:39:42

-You'll be pleased to know you've got five stars.

-Wow!

0:39:420:39:45

The highest one you can get. Thank you very much. It's a lovely kitchen.

0:39:450:39:50

What's more important is the way you're running it.

0:39:500:39:52

If it was badly run, you'd still only be...

0:39:520:39:56

You could still get zero stars on a brand new kitchen like this.

0:39:560:40:00

-Thank you.

-Thank you very much.

-Much appreciated.

0:40:000:40:03

I'm going to buy a sandwich off you. I'm absolutely starving.

0:40:040:40:07

Over in Westcliff-on-Sea in Essex is The Estuary.

0:40:090:40:14

This restaurant serves up salads and grills.

0:40:140:40:16

On this promenade, a good safety reputation

0:40:160:40:19

could make the difference when it comes to pulling in the punters.

0:40:190:40:23

Steve is in the middle of his inspection with his head chef.

0:40:230:40:27

I can see stainless steel, which is good.

0:40:290:40:31

It's quite well organised,

0:40:310:40:33

you've got a hand basin close to the preparation surfaces.

0:40:330:40:36

To minimise the risk of spreading germs,

0:40:370:40:39

it's best to use paper towels.

0:40:390:40:41

If you've got this roll of towel, which is very good,

0:40:430:40:45

what are these cloths used for?

0:40:450:40:48

-I just use these to hold the trays and stuff.

-OK.

0:40:480:40:53

I haven't got any problem using it to hold hot handles,

0:40:530:40:55

or even cleaning the floor,

0:40:550:40:58

but I'm a bit concerned to see it on this stainless steel top because that's not a good place to keep it.

0:40:580:41:03

Despite the hiccup, this kitchen is pretty clean.

0:41:060:41:10

Yeah, you show me.

0:41:120:41:13

And the chef is very much a spray, wipe and throw-away man.

0:41:130:41:17

Take it out, wipe it, yeah. Just a little tip about that.

0:41:170:41:22

If you read what it says on these things, you need to give it contact time.

0:41:220:41:26

Yeah, I know.

0:41:260:41:28

This means the amount of time you leave the spray to work

0:41:280:41:32

against bacteria before wiping.

0:41:320:41:34

When you've got a bit of time to leave this on,

0:41:350:41:38

five or ten minutes if you can. But if you haven't got that time,

0:41:380:41:42

still use it because half a minute or so is better than not using it.

0:41:420:41:46

Now Steve wants to see Refki's ingredients.

0:41:480:41:52

-The Cajun chicken.

-Right, that's got a flavouring, it's marinating.

0:41:540:41:59

-It's marinating. The date is there.

-Right.

0:41:590:42:04

When it comes to cross-contamination from raw meat, the risks are low here.

0:42:040:42:09

When you go to use these, what would happen

0:42:090:42:12

when you come to use one of these?

0:42:120:42:15

-I put it on the grill.

-On the grill from there.

-You want me to put on?

-No, no.

0:42:150:42:20

-There's almost no preparation with chicken happening on these worktops.

-No, no, no.

0:42:200:42:24

No, that's good. That's good.

0:42:240:42:25

-Inspection over.

-I think I'm satisfied that I've seen enough.

0:42:270:42:32

-Now it's just a question of those scores.

-Five, very good.

0:42:320:42:35

-So, hopefully, you'll like to put that in the window.

-Thank you very much.

0:42:350:42:39

So a good set of inspections all round.

0:42:400:42:42

It's certainly great to know, that regardless of what restaurant reviews you read,

0:42:420:42:47

the food fighters have been there first.

0:42:470:42:49

Bye.

0:42:500:42:52

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