0:00:01 > 0:00:05Orange Squash and instant tomato soup in a cup,
0:00:05 > 0:00:08they're two of the most popular supermarket foods.
0:00:08 > 0:00:10But what do they do to the oranges and the tomatoes
0:00:10 > 0:00:13so that all we have to do is add water?
0:00:13 > 0:00:16To find out, we're going to make our own, from scratch.
0:00:16 > 0:00:19We think we know these foods,
0:00:19 > 0:00:22but how much do we really know about them?
0:00:22 > 0:00:25Do you reckon there are any real oranges in orange squash?
0:00:25 > 0:00:26There must be a few.
0:00:26 > 0:00:27No.
0:00:27 > 0:00:30If there are, I think it's a really small amount.
0:00:30 > 0:00:33How many tomatoes do you reckon are in that sachet of instant soup?
0:00:33 > 0:00:35I don't think there are any in here.
0:00:35 > 0:00:37One small tomato. THEY LAUGH
0:00:37 > 0:00:40When I was a kid I used to get in masses of trouble
0:00:40 > 0:00:43for playing with my food, but now it's what I like doing most.
0:00:43 > 0:00:47I love finding out what happens to the stuff that we eat.
0:00:47 > 0:00:51But finding out what factories do to our food isn't easy.
0:00:53 > 0:00:56So to copy the big boys, I've set up my own Food Factory
0:00:56 > 0:00:57here in this barn.
0:00:57 > 0:01:01To help me discover what the masters of mass production do,
0:01:01 > 0:01:03I'm going to need some factory workers.
0:01:04 > 0:01:08Clocking on for today's shift are two stars of Saturday night TV,
0:01:08 > 0:01:11Strictly Come Dancing's Anton Du Beke
0:01:11 > 0:01:13and I'd Do Anything winner Jodie Prenger.
0:01:13 > 0:01:17But whose version of today's supermarket food
0:01:17 > 0:01:20will go in the basket and whose will go in the bin?
0:01:20 > 0:01:23Our shift at the Food Factory is about to begin.
0:01:44 > 0:01:46Jodie and Anton, brilliant to have you here,
0:01:46 > 0:01:48thank you for coming.
0:01:48 > 0:01:52What we're going to be making today is a supermarket product, I'm going to show you what it is.
0:01:52 > 0:01:54Ooh!
0:01:54 > 0:01:56- Orange Squash!- Was this ever part of your world when you were a kid?
0:01:56 > 0:01:58- Yeah, massively.- Yes.
0:01:58 > 0:02:00School sports days, really bad memories.
0:02:00 > 0:02:02I never won the egg and spoon race.
0:02:02 > 0:02:05So you drank a lot of squash on the way?
0:02:05 > 0:02:07A lot of squash on the way. That got me through it.
0:02:07 > 0:02:10The worst days of my life, so I love you.
0:02:10 > 0:02:11It's lovely, isn't it?
0:02:11 > 0:02:14It's something that we've all grown up with, as well.
0:02:14 > 0:02:17Even now I'm partial to a little squash.
0:02:17 > 0:02:18THEY LAUGH
0:02:18 > 0:02:20- You ready for this?- BOTH: Yes.
0:02:20 > 0:02:23I think it's time to start your shift at the barn. You better follow me in.
0:02:27 > 0:02:31There's a surprise ingredient inside every bottle of squash,
0:02:31 > 0:02:33but I'm not going to tell them what it is yet.
0:02:35 > 0:02:37So...thirsty?
0:02:37 > 0:02:39- Yes.- Yes.- Yes?
0:02:39 > 0:02:42I just want you to have a little taste and explain
0:02:42 > 0:02:45what the flavour is to me, is it different from orange juice?
0:02:45 > 0:02:47- Yes.- Yes.
0:02:47 > 0:02:48In what way?
0:02:48 > 0:02:49It's sort of thinner....
0:02:49 > 0:02:52- Yes.- For a start, refreshing. Yes.
0:02:52 > 0:02:54OK.
0:02:54 > 0:02:58Your challenge is this, to make two rival bottles of orange squash
0:02:58 > 0:03:02using the same techniques that they use in a food factory.
0:03:02 > 0:03:05Then we're going to offer them to a group of Taste Testers
0:03:05 > 0:03:09and it's they who will decide whose orange squash is most like
0:03:09 > 0:03:10the ones you buy from the supermarket.
0:03:10 > 0:03:14First of all, I think you need to meet your ingredients.
0:03:14 > 0:03:16- Ah!- Make friends!- Oh. Surprise!
0:03:16 > 0:03:19Well, it is a bit of a surprise
0:03:19 > 0:03:22because orange squash does come from real oranges.
0:03:22 > 0:03:27So the first task is to extract the juice. Grab your buckets...
0:03:27 > 0:03:29- Thank you!- ..and get to work.
0:03:29 > 0:03:31They're not quite on their own.
0:03:31 > 0:03:34My factory foremen Marty and Tod are here to help.
0:03:34 > 0:03:38We're going to do a double mechanical juicer,
0:03:38 > 0:03:41and we're going to make it bicycle powered.
0:03:41 > 0:03:42I can't ride a bike!
0:03:42 > 0:03:46They need to get as much juice from their three dozen oranges
0:03:46 > 0:03:51as quickly as possible to funnel all the fresh flavour into their squash.
0:03:51 > 0:03:53We'll squash that down
0:03:53 > 0:03:57- using a car jack. Orange will all come beautifully flowing. - Beautifully flowing out.
0:03:57 > 0:03:59Both these methods are designed to get into the juice
0:03:59 > 0:04:02inside the orange, which is held inside it
0:04:02 > 0:04:05in these funny little blister-like things called vesicles.
0:04:05 > 0:04:08They're really hard to get out of the orange like this.
0:04:08 > 0:04:10So what I'm going to do is freeze one first.
0:04:10 > 0:04:12I'm going to do it using a super-chilly liquid,
0:04:12 > 0:04:17called liquid nitrogen - minus 196 degrees centigrade.
0:04:17 > 0:04:19One peeled orange.
0:04:23 > 0:04:25Looks like it should be ready.
0:04:26 > 0:04:28Just need to give it a light tap.
0:04:31 > 0:04:34Let's slow that right down.
0:04:34 > 0:04:37I can show you all the tiny vesicles much more clearly.
0:04:37 > 0:04:39And it's great fun.
0:04:39 > 0:04:43And there is one of the vesicles.
0:04:43 > 0:04:47Inside this little bag is lots of water,
0:04:47 > 0:04:50lots of sugar and a tiny little bit of orange oil.
0:04:50 > 0:04:52And that's where the orange gets its flavour.
0:04:52 > 0:04:55The production lines are ready to roll.
0:04:55 > 0:04:59But who can produce the most juice?
0:04:59 > 0:05:00- All set?- Let's do it.
0:05:00 > 0:05:02Please start your production line.
0:05:02 > 0:05:08Jodie and Marty have assembled a bicycle powered squeezing machine.
0:05:08 > 0:05:12The harder Jodie pedals, the faster the juicers spin,
0:05:12 > 0:05:15the more juice should flow into the bucket...
0:05:15 > 0:05:18Look at this! He's covered in orange juice.
0:05:18 > 0:05:21It's like an orange shower going on here.
0:05:24 > 0:05:26Anton and Tod's juice press
0:05:26 > 0:05:29looks more like a mediaeval torture device.
0:05:29 > 0:05:31Start your production line.
0:05:31 > 0:05:33- OK. Lower the top.- Yep.
0:05:33 > 0:05:37They're hoping to juice a dozen oranges at a time.
0:05:37 > 0:05:39The juice is supposed to flow through a hollow spike
0:05:39 > 0:05:42pierced into each orange.
0:05:42 > 0:05:44But it looks like it's flooding over the edge.
0:05:44 > 0:05:45Juice is coming out.
0:05:45 > 0:05:48Juice is coming out, you have produced some juice.
0:05:48 > 0:05:52Some? Loads! It's like a torrential rainfall of juice.
0:05:52 > 0:05:53I can smell it, as well!
0:05:53 > 0:05:57- Look, that's the smell of orange squash.- We're in production.
0:05:57 > 0:05:59- We have smell!- Smell?
0:05:59 > 0:06:02We've had have smell since....
0:06:02 > 0:06:05That's because you've been pedalling so much, love! We have orange smell!
0:06:05 > 0:06:08There's an orangey aroma
0:06:08 > 0:06:14and juice in their buckets, but who's let loose most juice?
0:06:14 > 0:06:17OK, Anton. Let's have a look at you. You got...
0:06:17 > 0:06:19- 5cm.- 4cm. Behave yourself.
0:06:19 > 0:06:22Your eyes are bad.
0:06:22 > 0:06:28And, Jodie, you got 5cm. Blimey. Now that's great.
0:06:28 > 0:06:30But what we're making here is concentrated orange squash.
0:06:30 > 0:06:34Not all of the flavour of your squash comes from orange juice,
0:06:34 > 0:06:35it comes from something else.
0:06:35 > 0:06:38- Lemons!- Lemons!- Limes!
0:06:38 > 0:06:41- It's got to be limes. - It's got to be limes. No, it hasn't.
0:06:41 > 0:06:43What?
0:06:43 > 0:06:46The clue's here. It says it's whole orange squash.
0:06:46 > 0:06:51I hope you didn't throw away any waste matter?
0:06:51 > 0:06:52No. Got buckets.
0:06:52 > 0:06:53Buckets of it, excellent.
0:06:53 > 0:06:56THEY LAUGH
0:06:56 > 0:06:59So some of the orangey flavour in your squash
0:06:59 > 0:07:01will come from orange peel.
0:07:01 > 0:07:05Have a little taste. Just a little nibble, at the side.
0:07:05 > 0:07:07- So what does that taste like? - It tastes zingy.
0:07:07 > 0:07:10- Uh-huh.- Quite sharp.- Pleasant?- No.
0:07:10 > 0:07:13It's quite bizarre that you need to put peel in your squash.
0:07:13 > 0:07:16But of course you can't hide that in squash,
0:07:16 > 0:07:18so you need to come up with some machines.
0:07:18 > 0:07:20You need machines which will pulp your peel.
0:07:20 > 0:07:23Back to work please, team!
0:07:23 > 0:07:26More work! I hope it's not another bike!
0:07:26 > 0:07:28I hope you have a space hopper this time!
0:07:28 > 0:07:32Come on, come on. No time to muck about. Take that with you.
0:07:32 > 0:07:34What are they like?
0:07:40 > 0:07:43While Anton and Jodie search for the secrets of squash,
0:07:43 > 0:07:48I'm going to find out what soup-in-a-cup makers really use
0:07:48 > 0:07:51to put the tomato flavour in powdered soup.
0:07:51 > 0:07:54- Do you think there are any tomatoes in a dry...?- No
0:07:54 > 0:07:56- ..tomato soup?- Sadly not.
0:07:56 > 0:07:57I really hope so!
0:07:57 > 0:07:59There should be, but I sincerely doubt there is.
0:07:59 > 0:08:02I guess you'd like to think they were somehow dried
0:08:02 > 0:08:05and condensed and there was loads of them in there,
0:08:05 > 0:08:09but probably something horrifying like quarter of a tomato or less!
0:08:09 > 0:08:13Loads of us have this stuff on standby.
0:08:13 > 0:08:15Instant tomato soup in a cup.
0:08:15 > 0:08:19Just add water and the powder magically transforms
0:08:19 > 0:08:20into steaming soup.
0:08:20 > 0:08:23And amazingly, it really does start with tomatoes.
0:08:23 > 0:08:24Aah!
0:08:24 > 0:08:28Honest. But what does the factory do to turn them into powder?
0:08:28 > 0:08:31Well, first there's something they have to get rid of.
0:08:33 > 0:08:35Here we go!
0:08:35 > 0:08:37Water. There's lots of it.
0:08:37 > 0:08:41About 95% of a tomato's weight is water.
0:08:44 > 0:08:48Oh-ho! Look at all that liquid.
0:08:49 > 0:08:53But the thing is, all this liquid has got to go,
0:08:53 > 0:08:56it's got to go, leaving behind a bone dry powder.
0:08:56 > 0:09:00As well as water, tomatoes contain lots of seeds.
0:09:00 > 0:09:04No-one wants seeds in their sachet of soup.
0:09:04 > 0:09:07So I'm rigging up a filter to get rid of them.
0:09:12 > 0:09:15I give you...the spatulator!
0:09:18 > 0:09:21This is my version of what they use in the factory.
0:09:21 > 0:09:26So down here I've got a bit of mesh, and hopefully when I spin this,
0:09:26 > 0:09:30these spatulas will push all of my tomato pulp through that,
0:09:30 > 0:09:34leaving behind all the bits of peel and all those seeds.
0:09:35 > 0:09:36See if it works.
0:09:42 > 0:09:46It's working, it's coming through! it's coming through!
0:09:46 > 0:09:50Right, let's see if we can crank this up to factory speed.
0:09:50 > 0:09:52HE LAUGHS
0:09:53 > 0:09:55The answer's no.
0:09:58 > 0:10:00Oooh! Look at that!
0:10:00 > 0:10:06Lovely liquid and no pips, but still way too watery to go in a sachet.
0:10:06 > 0:10:09But if I boil it up, some of the water will evaporate
0:10:09 > 0:10:13and I'll be left with nice, thick concentrated juice.
0:10:13 > 0:10:17But then soup in-a-cup makers do something clever
0:10:17 > 0:10:19to turn it into powder.
0:10:25 > 0:10:27Here's my version.
0:10:27 > 0:10:30No, it's not a rocket, this is my spray drier.
0:10:30 > 0:10:33And this is how it's going to work, heat guns.
0:10:33 > 0:10:37We're going to put one heat gun in here and one in here,
0:10:37 > 0:10:39and they're going to heat up this drum.
0:10:39 > 0:10:43Then, we're going to put my tomato liquid into this paint sprayer
0:10:43 > 0:10:45and spray it through this hole in the top.
0:10:45 > 0:10:48Hopefully, all of the water will turn instantly to steam
0:10:48 > 0:10:49and come out of the top,
0:10:49 > 0:10:52and my delicious tomatoey powder will all fall to the bottom.
0:10:54 > 0:10:59Here goes, it's 120 degrees centigrade inside the drum,
0:10:59 > 0:11:02so no copying at home, this is risky!
0:11:02 > 0:11:07Paint sprayer, with tomato juice, that looks pretty good.
0:11:07 > 0:11:11At this high temperature, the water in my concentrated juice
0:11:11 > 0:11:14should turn to steam and evaporate instantly.
0:11:14 > 0:11:17Hopefully, the magic is all going on inside.
0:11:17 > 0:11:18If it's not hot enough,
0:11:18 > 0:11:21the concentrate will simply fall to the bottom.
0:11:21 > 0:11:25But crank the heat too high, it'll burn and ruin the flavour.
0:11:25 > 0:11:28It's a really fine balance but I haven't a clue if it's working.
0:11:28 > 0:11:33So will there be a lovely dusting of red tomato powder at the bottom?
0:11:37 > 0:11:40Oh, it's like a really thick liquid!
0:11:40 > 0:11:42That's a bit of a disaster.
0:11:42 > 0:11:44The temperature at the top was about 120.
0:11:44 > 0:11:49Maybe if I really push it up lot higher, get it up to 160-180,
0:11:49 > 0:11:51maybe that would do the trick.
0:11:51 > 0:11:55Improved spray drier, Mark Two!
0:11:55 > 0:11:57Now with twice the power!
0:11:58 > 0:12:03It's now over 180 degrees centigrade. Here goes.
0:12:08 > 0:12:11I'm getting some really strong tomato smells, but I don't know
0:12:11 > 0:12:15if that's a wonderful dried tomato or if it's burnt tomato.
0:12:18 > 0:12:21OK, let's open it up and see what I've got.
0:12:28 > 0:12:29Ha-ha! Yes!
0:12:29 > 0:12:31That is tomato powder.
0:12:33 > 0:12:39Ha-ha! It might look like rust but it tastes like delicious tomato.
0:12:39 > 0:12:43So proof, that there are real tomatoes in instant soup,
0:12:43 > 0:12:46roughly one or two in each sachet.
0:12:48 > 0:12:51But there's lots of other stuff in there too.
0:12:51 > 0:12:54At the factory, they add more vegetable powders,
0:12:54 > 0:12:59potato starch to thicken it, dried onions and herb for flavour.
0:12:59 > 0:13:04They even add some extra red colour from this beetroot extract.
0:13:04 > 0:13:09And it's not finished yet, in go sugar and salt, vegetable fat,
0:13:09 > 0:13:13and here's a surprise - milk powder, to make it creamy.
0:13:15 > 0:13:18It looks like beef soup at the moment.
0:13:26 > 0:13:28That is quite strange.
0:13:28 > 0:13:32It's like a tomato-vegetable soup I guess. But really good.
0:13:32 > 0:13:34I think that's pretty decent.
0:13:36 > 0:13:39My very own tomato soup-in-a-cup.
0:13:39 > 0:13:42But only our Taste Testers can decide
0:13:42 > 0:13:45whether mine's as good as shop-bought stuff.
0:13:45 > 0:13:47Ho, ho, ho, do I have a treat for you!
0:13:47 > 0:13:49What sort of taste do you think it has?
0:13:49 > 0:13:53Quite salty...gravy granule taste.
0:13:53 > 0:13:54Doesn't taste of a huge amount.
0:13:54 > 0:13:56That's not bad, actually.
0:13:56 > 0:13:58Hey, my man! Thank you very much!
0:13:58 > 0:14:03It's got tomato and a bit of herbs.
0:14:03 > 0:14:04Yes.
0:14:12 > 0:14:16Back in the barn, Anton and Jodie have discovered
0:14:16 > 0:14:19the secret inside every bottle of orange squash.
0:14:19 > 0:14:23It's something we would normally throw away. The peel.
0:14:23 > 0:14:25- Now we've got to turn this...- Yeah.
0:14:25 > 0:14:27- ..to make that more concentrated. - Right.
0:14:27 > 0:14:31So what's so special about an ingredient which tastes so bad,
0:14:31 > 0:14:35yet it gives squash such a powerful punch?
0:14:35 > 0:14:37Orange peel tastes horrible
0:14:37 > 0:14:40because it lacks all the sugar that's in the flesh.
0:14:40 > 0:14:44However, it's also rammed with a potent orange flavour.
0:14:44 > 0:14:47Take a look at this. Put this under the microscope.
0:14:47 > 0:14:51See all these little dots, well, these are the oil glands
0:14:51 > 0:14:53and they contain the zest or the essential oil of the orange.
0:14:53 > 0:14:55It's under pressure in here.
0:14:55 > 0:14:57And if you squeeze the peel,
0:14:57 > 0:15:00it squirts out like you're squeezing a spot.
0:15:00 > 0:15:06In fact, there's 50 times more essential oil in the peel
0:15:06 > 0:15:07than the flesh.
0:15:07 > 0:15:10It's highly flammable too - set it alight
0:15:10 > 0:15:13and you can see just how much oil there really is.
0:15:13 > 0:15:17The peel is a massive source of flavour.
0:15:17 > 0:15:21It would be a crime not to put the peel in.
0:15:21 > 0:15:23That's why they call it whole orange squash.
0:15:23 > 0:15:26It's got the whole orange in it, but you didn't notice
0:15:26 > 0:15:30because on the ingredients list, they call the peel "comminute",
0:15:30 > 0:15:33comminuted orange.
0:15:33 > 0:15:38Now Anton and Jodie have to work out how to comminute their peel
0:15:38 > 0:15:40to transform it from waste into extra taste.
0:15:40 > 0:15:43That's the first thing that sprung to my mind, as well.
0:15:43 > 0:15:45Did that come to your mind, as well?
0:15:45 > 0:15:48I want to smash something up, I'm going to get a lawnmower.
0:15:48 > 0:15:51Jodie hopes the upturned lawnmower
0:15:51 > 0:15:54will unleash all the extra flavour in her peel.
0:15:54 > 0:15:58Anton and Tod have souped-up a shredder.
0:15:58 > 0:16:02Woooo! Power!
0:16:02 > 0:16:06And cannibalised a cement mixer to completely crush their peel.
0:16:08 > 0:16:10Is that, is that a caravan wheel?
0:16:10 > 0:16:12- Yes. It is.- OK!
0:16:14 > 0:16:17The pulpier the peel, the easier it'll be to mix it
0:16:17 > 0:16:19into their orange juice.
0:16:19 > 0:16:22Ah, it looks like cornflakes.
0:16:22 > 0:16:25But whose method has produced the smoothest looking pulp?
0:16:25 > 0:16:29I'd say one is slightly more successful than the other.
0:16:29 > 0:16:31Jodie's is very nicely broken down.
0:16:31 > 0:16:34I'd say, Anton, you're a bit lumpen.
0:16:34 > 0:16:35Why don't we have a little taste?
0:16:36 > 0:16:39It's actually not as bad as I thought.
0:16:39 > 0:16:41THEY LAUGH
0:16:41 > 0:16:43OK, so that is loads and loads of flavour in there.
0:16:43 > 0:16:45So you've already got your juice.
0:16:45 > 0:16:48You've now pulped your peel into comminute.
0:16:48 > 0:16:51Now you need to work out how to mix it all together
0:16:51 > 0:16:53into a lovely sweet orange squash,
0:16:53 > 0:16:55like the one you buy from the supermarket.
0:16:55 > 0:16:57Before they can do that,
0:16:57 > 0:17:01Anton and Jodie must make their juice super strong.
0:17:01 > 0:17:04So they've got to get some of the water out of their juice.
0:17:04 > 0:17:08But get it wrong and they'll ruin the whole day's work.
0:17:16 > 0:17:22For factories, taking the water out of some of our most popular foods
0:17:22 > 0:17:23is a mighty challenge.
0:17:23 > 0:17:26There's one food we need everyday
0:17:26 > 0:17:29which arrives in buckets of the stuff.
0:17:29 > 0:17:32How many buckets of sea water do you reckon goes into making
0:17:32 > 0:17:34this pack of sea-salt?
0:17:34 > 0:17:35About a 1,000.
0:17:35 > 0:17:38- What, one pack that size? - One pack, that size.- 20?- 20?
0:17:38 > 0:17:40- 30.- 30?
0:17:40 > 0:17:41That's a lot of water.
0:17:41 > 0:17:43Well, that's a lot of salt.
0:17:43 > 0:17:47- It's actually three.- Really? - Yes. Not 3,000, three buckets.- Wow.
0:17:49 > 0:17:56Yes, it only takes 15 litres of sea water to produce one 500g pack.
0:17:56 > 0:18:01The Cornish Sea Salt Company gets their main ingredient for free.
0:18:01 > 0:18:05They simply suck it out of the sea.
0:18:05 > 0:18:09They heat up sea water to get sea-salt out.
0:18:09 > 0:18:10How hard can that be?
0:18:14 > 0:18:1915 minutes later and hey, presto, free sea salt!
0:18:19 > 0:18:22Let's see what it tastes like.
0:18:23 > 0:18:27Ugh! Well, it's very salty,
0:18:27 > 0:18:31but it's got some other weird taste sensations there, as well.
0:18:31 > 0:18:34It's quite bitter, quite a nasty kick to it.
0:18:34 > 0:18:39So what I want to know is, when we buy sea-salt in the shops,
0:18:39 > 0:18:42do they just boil the water away, or is there something more to it?
0:18:42 > 0:18:49Philip Tanswell produces salt from sea water on a very big scale.
0:18:54 > 0:18:57And here we have, down below, our main sea water feed pipe.
0:18:57 > 0:19:02It's able to pump 80,000 litres of sea-water per hour, so it's...
0:19:02 > 0:19:04So you really don't want to be swimming past that!
0:19:04 > 0:19:07All that sea water ends up in these tanks.
0:19:07 > 0:19:10That's a lot of water to boil off.
0:19:10 > 0:19:13You can't do that with a camping stove.
0:19:13 > 0:19:16You need one of these, a steam evaporator!
0:19:16 > 0:19:20So, Phil, this is what I made this morning. That's my salt.
0:19:20 > 0:19:21Oh, dear!
0:19:21 > 0:19:24Is all this kit basically just doing this, but on a bigger scale?
0:19:24 > 0:19:28What you've done there is you've made salt, fairly poorly may I say!
0:19:28 > 0:19:30- But there we go.- What are you saying? - Look at it.
0:19:30 > 0:19:33There's no structure there, there's no flaky crunchy bits in there.
0:19:33 > 0:19:35My camping stove boiled ALL the water away.
0:19:35 > 0:19:39But this is a very clever bit of kit,
0:19:39 > 0:19:41it doesn't evaporate ALL the water.
0:19:43 > 0:19:47It stops at the crucial moment.
0:19:47 > 0:19:52The water now contains 25% salt, it's super salty brine.
0:19:52 > 0:19:54It's as salty as brine can get.
0:19:54 > 0:19:57Any more salty and it'll start to form the crystals.
0:19:57 > 0:20:00The highly concentrated brine is then transferred
0:20:00 > 0:20:02to these evaporation tanks
0:20:02 > 0:20:06just before the salt crystals have a chance to form.
0:20:06 > 0:20:10So this is where the magic happens. You can actually watch them growing.
0:20:10 > 0:20:12If you look really closely,
0:20:12 > 0:20:14there's a little speck where it's just started,
0:20:14 > 0:20:17and they kind of seem to team up with other crystals.
0:20:17 > 0:20:19It's almost better than television, isn't it?
0:20:19 > 0:20:25These lamps produce a gentle heat that slowly evaporates the water.
0:20:25 > 0:20:28The sodium chloride that's already dissolved in the water
0:20:28 > 0:20:33is eventually forced out, forming crystals of salt.
0:20:33 > 0:20:37We want nice big flaky crystals to form on the surface of the brine.
0:20:37 > 0:20:40You can see the salt dropping down through.
0:20:40 > 0:20:42Which sort of shows it's time for some harvesting, I think.
0:20:42 > 0:20:44Excellent. So we've got to dig it out?
0:20:44 > 0:20:46Yes, let's go and get some shovels and dig it out.
0:20:49 > 0:20:52As the sea water evaporates other minerals,
0:20:52 > 0:20:56including calcium and magnesium, start to crystallise, too.
0:20:56 > 0:20:58But they'll spoil the taste of the salt.
0:20:58 > 0:21:01So this is the critical moment.
0:21:01 > 0:21:05The salt crystals must be scooped out of the water now.
0:21:05 > 0:21:07If we were to evaporate the water all the way down onto that salt,
0:21:07 > 0:21:09it would leave a very bitter taste.
0:21:09 > 0:21:12So the stuff I made on the beach probably had all the bits
0:21:12 > 0:21:16the magnesium and calcium left behind, and that's why it didn't taste so good?
0:21:16 > 0:21:17Exactly.
0:21:17 > 0:21:22The salt is left to drain, and then it's dried, ready for packaging.
0:21:22 > 0:21:24Next stop, my chips!
0:21:30 > 0:21:34The big question though - is this any better than the stuff I made?
0:21:34 > 0:21:36Let's have a little go.
0:21:39 > 0:21:41Oh, yeah!
0:21:49 > 0:21:53Back at the barn, Anton Du Beke and Jodie Prenger are discovering
0:21:53 > 0:21:56getting all the extra flavour into orange squash
0:21:56 > 0:22:00is far from easy squeezy!
0:22:00 > 0:22:02They've juiced three dozen oranges,
0:22:02 > 0:22:04and turned the peel into an unpleasant puree,
0:22:04 > 0:22:06now they need to come up with a recipe
0:22:06 > 0:22:09to turn all of these ingredients into something that's delicious,
0:22:09 > 0:22:13orangey and refreshing when you pour it into a glass and just add water.
0:22:13 > 0:22:16But before they can mix up the ingredients,
0:22:16 > 0:22:19they need to make their juice extra strong.
0:22:19 > 0:22:23To do this they've got to boil some of the excess water out.
0:22:23 > 0:22:26- Oh, that smells so nice. - It is good, isn't it?
0:22:26 > 0:22:29- We need to warm it up, but not too warm.- OK.
0:22:29 > 0:22:32By now you'd think the best way to get the water out
0:22:32 > 0:22:34would be to boil the juice.
0:22:34 > 0:22:36But that will spoil the flavour.
0:22:36 > 0:22:38So they need to use a clever trick.
0:22:38 > 0:22:43Here's a cup of tea. Just been made with boiling water.
0:22:43 > 0:22:45Put a bit of milk in now, so the temperature's dropped.
0:22:45 > 0:22:47It's probably about 80, 90 degrees.
0:22:48 > 0:22:51I'm going to put it in this jar.
0:22:53 > 0:22:55There we go.
0:22:55 > 0:22:57Put a cork on the top.
0:22:57 > 0:23:02And this little hand pump is going to suck the air out of it.
0:23:04 > 0:23:08Still only about 80 or 90 degrees in there. Look, look. Can you see that?
0:23:08 > 0:23:11It's starting to boil all over again.
0:23:11 > 0:23:15Water usually boils at 100 degrees centigrade.
0:23:15 > 0:23:18But by sucking the air out I've reduced the pressure inside
0:23:18 > 0:23:22and made it easier for the water to turn into steam,
0:23:22 > 0:23:25so it's boiling at a much lower temperature.
0:23:25 > 0:23:29It's very weird, but it's very useful for food factories.
0:23:29 > 0:23:33This means the flavour of the juice won't be spoiled.
0:23:33 > 0:23:35That's the trick Anton and Jodie must copy
0:23:35 > 0:23:38to concentrate their juice.
0:23:38 > 0:23:41I can't help thinking that this looks a little bit rudimentary.
0:23:41 > 0:23:44You've got a pan and some fire.
0:23:44 > 0:23:47- Yes.- How are you going to go about this?
0:23:47 > 0:23:50We're going to put a lid on it and we're going to reduce the pressure.
0:23:50 > 0:23:54This is my favourite bit. We're going to use a vacuum cleaner.
0:23:54 > 0:23:56- Very good. OK. - Not so rudimentary now.
0:23:56 > 0:23:59No, no. I like it. That's practically technology!
0:23:59 > 0:24:02Even with a lid on and the vacuum on full suck,
0:24:02 > 0:24:06I think there's a real risk Anton's juice is going to burn.
0:24:06 > 0:24:09Jodie's done something clever to stop it burning,
0:24:09 > 0:24:14she's got her juice inside a hot water bath, away from direct flame.
0:24:14 > 0:24:1766 degrees. So you're boiling something.
0:24:17 > 0:24:20This is properly ingenious. I like the work here.
0:24:20 > 0:24:22Well, I hope it goes down to the right consistency.
0:24:22 > 0:24:26I guess, the trick is to stop before there's nothing left.
0:24:27 > 0:24:31This stage is crucial, burn the juice and it'll taste horrible,
0:24:31 > 0:24:34but leave behind too much water
0:24:34 > 0:24:36and the juice won't be concentrated enough.
0:24:36 > 0:24:39OK, it's quite a high temperature, isn't it?
0:24:39 > 0:24:42There's an ever so slight smell of sort of orangey toffee going on.
0:24:42 > 0:24:46I'll kill the vacuum. It should stop boiling immediately.
0:24:46 > 0:24:48MACHINE BUZZES
0:24:48 > 0:24:51- Oh, no! It's putting water back... - It's pulling water back in.- Ahh.
0:24:51 > 0:24:56Terrible! Have we just destroyed all the work we've done?
0:24:56 > 0:24:57Some.
0:24:57 > 0:24:58SHE LAUGHS
0:24:58 > 0:25:00That's unfortunate!
0:25:00 > 0:25:02Some of the water they boiled off has leaked back in.
0:25:02 > 0:25:07Anton's looks a bit burnt to me. Although he seems thrilled...
0:25:07 > 0:25:08Ooh!
0:25:08 > 0:25:11Isn't that beautiful?
0:25:11 > 0:25:15Anton and Jodie are both staring a squash disaster in the face.
0:25:15 > 0:25:17But how does it taste?
0:25:17 > 0:25:18HE LAUGHS
0:25:20 > 0:25:22It's got that, hasn't it?
0:25:22 > 0:25:24It needs water.
0:25:24 > 0:25:27Now they need to mix up all their ingredients.
0:25:27 > 0:25:31The pulped peel provides all that surprise orangey flavour.
0:25:31 > 0:25:34The concentrated juice is ever so sharp,
0:25:34 > 0:25:38so they need six times more sugar syrup than juice.
0:25:38 > 0:25:42And a sprinkle of citric acid gives squash that special zing.
0:25:42 > 0:25:44Just bung it all in. Bung it in?
0:25:44 > 0:25:47- Ah?- Too late, in.
0:25:47 > 0:25:50And after all that work, we're almost done.
0:25:50 > 0:25:53Can you please package up your products!
0:26:01 > 0:26:03It's time for quality control.
0:26:03 > 0:26:05Yours looks out of date!
0:26:05 > 0:26:06Feeling confident, are we?
0:26:06 > 0:26:08No!
0:26:08 > 0:26:10Du Beke squash. Here we go.
0:26:13 > 0:26:15Perfect.
0:26:15 > 0:26:18OK, so what's your usual? You tell me when to stop.
0:26:18 > 0:26:20Keep going. Keep going. Stop. Stop.
0:26:21 > 0:26:22Stop.
0:26:22 > 0:26:25OK.
0:26:30 > 0:26:32Do you know what? That's very nice.
0:26:32 > 0:26:34- I know.- It's really nice.
0:26:34 > 0:26:35- Thank you.- It's a little bit weak.
0:26:35 > 0:26:38- Did you put much of the comminute in?- Not so much.
0:26:38 > 0:26:40It's a little bit weak but it is a lovely drink.
0:26:40 > 0:26:44- Jodie. Bright orange. It's ever so slightly scary.- Day-glow!
0:26:47 > 0:26:51Ah, OK. I would say more of the comminute?
0:26:51 > 0:26:54They are both lovely and very refreshing drinks.
0:26:54 > 0:26:56- But...- Yes.
0:26:56 > 0:26:58- It's not for me to decide.- Ah!
0:26:58 > 0:27:00What we need to do is take this to our Taste Testers
0:27:00 > 0:27:04and they are the people who will decide whose orange squash
0:27:04 > 0:27:06is most like the one you buy in the shops.
0:27:06 > 0:27:10So grab your bottle, follow me.
0:27:13 > 0:27:15Put that back!
0:27:15 > 0:27:16THE CROWD APPLAUD
0:27:16 > 0:27:18Oh!
0:27:18 > 0:27:21It's very, very orangey...
0:27:21 > 0:27:25because it's made of oranges.
0:27:25 > 0:27:29Now, this is the moment of truth. What do you think?
0:27:29 > 0:27:31- It tastes really orangey. - I would buy it.
0:27:31 > 0:27:32It's fantastic.
0:27:32 > 0:27:35- Try a bit of this.- More like freshly squeezed orange juice.
0:27:35 > 0:27:38Yes, that's exactly what I did, I squeezed my oranges.
0:27:38 > 0:27:39Move up, who's your favourite dancer?
0:27:39 > 0:27:41- You.- Me?
0:27:41 > 0:27:42It was amazing.
0:27:42 > 0:27:44One of the best orange juices I've ever tasted.
0:27:44 > 0:27:46Group hug, group hug.
0:27:46 > 0:27:49OK, Anton and Jodie, come over here, please.
0:27:49 > 0:27:54Now, you lovely people, you need to vote on whose orange squash
0:27:54 > 0:27:56was most like the ones you buy in the supermarket.
0:27:56 > 0:27:59Raise your hands for Anton.
0:28:00 > 0:28:02Now, please raise your hands
0:28:02 > 0:28:06if you thought that Jodie's orange squash was the best.
0:28:06 > 0:28:07Raise those hands, please!
0:28:07 > 0:28:08Yeah!
0:28:10 > 0:28:11OK, come here!
0:28:11 > 0:28:15I have to say, Anton, your orange squash is going in the bin.
0:28:15 > 0:28:18Jodie, yours is going in the basket,
0:28:18 > 0:28:21but please give them a round of applause - they've worked so hard!
0:28:21 > 0:28:23THE CROWD APPLAUD
0:28:26 > 0:28:28Anton should have added more peel
0:28:28 > 0:28:32because that's the secret ingredient that contains all the extra flavour.
0:28:32 > 0:28:35Now, squeezing all of that flavour into a bottle of squash
0:28:35 > 0:28:37is a huge challenge for the factory,
0:28:37 > 0:28:39but it means that when we're thirsty,
0:28:39 > 0:28:42all we need to do is just add water.
0:28:50 > 0:28:53Subtitles by Red Bee Media Ltd