0:34:50 > 0:34:57.
0:35:02 > 0:35:05Have you noticed how some snack foods seem to melt in your mouth?
0:35:05 > 0:35:06Here are two of my favourites.
0:35:06 > 0:35:09Cheesy puffs and chocolate-covered honeycomb.
0:35:09 > 0:35:12But why do they melt in your mouth?
0:35:12 > 0:35:15To find out, we're going to make our own from scratch.
0:35:15 > 0:35:17We think we know these foods,
0:35:17 > 0:35:20but how much do we really know about them?
0:35:20 > 0:35:22OK, budge up there.
0:35:22 > 0:35:23One, two, three, go!
0:35:23 > 0:35:25Oh, yes!
0:35:25 > 0:35:27Have a taste and tell me what you think.
0:35:27 > 0:35:30Crispy at first and then it just dissolves in your mouth.
0:35:30 > 0:35:33- What goes on in your mouth? - It dissolves on your tongue.
0:35:33 > 0:35:36- Do you like these honeycomb bars? - Yes.- Why?
0:35:36 > 0:35:38It's the softness of the chocolate
0:35:38 > 0:35:41and yet the hardness, crunchiness of the honeycomb centre.
0:35:41 > 0:35:44Can you grab a piece of the honeycomb bar?
0:35:44 > 0:35:45Why do you think it's so light?
0:35:45 > 0:35:48It's obviously got air bubbles inside it, hasn't it?
0:35:49 > 0:35:53When I was a kid, I used to get into trouble for playing with my food.
0:35:53 > 0:35:55But now that's what I like doing most.
0:35:55 > 0:35:59I love finding out what happens to the stuff that we eat.
0:35:59 > 0:36:04But finding out what factories do to our food isn't easy.
0:36:04 > 0:36:09So to copy the big boys, I've set up my own food factory here in this barn.
0:36:09 > 0:36:12To help me discover what the masters of mass production do,
0:36:12 > 0:36:15I'm going to need some factory workers.
0:36:15 > 0:36:19Clocking on for today's shift are consumer champion Esther Rantzen
0:36:19 > 0:36:22and her daughter Becca Wilcox, the Watchdog reporter.
0:36:22 > 0:36:26But whose version of today's supermarket food
0:36:26 > 0:36:29will go in the basket and whose will go in the bin?
0:36:29 > 0:36:30LAUGHTER
0:36:30 > 0:36:33Our shift at the Food Factory is about to begin.
0:36:33 > 0:36:36MUSIC: "Rubber Biscuit" by The Chips
0:36:54 > 0:36:57- Brilliant to see you. Thank you for coming.- Our pleasure.
0:36:57 > 0:37:01- Do you like chocolate?- Puts me in a good mood.- Fantastic. Becca?
0:37:01 > 0:37:05- I can't say I do.- How do you raise a child who doesn't like chocolate? Brilliant idea!
0:37:05 > 0:37:08Well, it means more for me. THEY LAUGH
0:37:08 > 0:37:12- I will eat it, especially if there's competition involved. - THEY LAUGH
0:37:12 > 0:37:16- This is what we're going to be making.- Oh, wow! I haven't had this
0:37:16 > 0:37:20since I was about 12.
0:37:20 > 0:37:21Mm!
0:37:21 > 0:37:23- Mm!- Mm!
0:37:23 > 0:37:27Now, what we need to do is find out what this strange centre is made of
0:37:27 > 0:37:31and how they get all of the bubbles inside it.
0:37:31 > 0:37:33- Wow!- Too late to go home.
0:37:37 > 0:37:40Making these melt-in-the-mouth snack bars
0:37:40 > 0:37:42is much harder than it looks.
0:37:42 > 0:37:44Becca's not going to be going home for a while yet.
0:37:44 > 0:37:48- OK, you all set for this? - Yep.- Yes.- Excellent!
0:37:48 > 0:37:52- So your challenge is to make two rival bars.- OK.
0:37:52 > 0:37:55But using the same techniques that they use in a factory.
0:37:55 > 0:37:59And then we're going to take your efforts outside
0:37:59 > 0:38:03and offer them to some taste testers who will decide which one's best.
0:38:03 > 0:38:04Those poor people!
0:38:04 > 0:38:06HE LAUGHS
0:38:06 > 0:38:10So, the whole journey...starts here.
0:38:10 > 0:38:11- Ah!- Ooh, yum!
0:38:11 > 0:38:13- Meet your ingredients.- Chocolate.
0:38:13 > 0:38:17Lots of chocolate, obviously. It's a chocolate bar. Lots of sugar.
0:38:17 > 0:38:20But then...we have some mystery ingredients.
0:38:20 > 0:38:25- Oh!- Strange gloopy, globby stuff.
0:38:26 > 0:38:30And this...mystery white powder.
0:38:30 > 0:38:33So the first task you've got is to make the honeycomb centre.
0:38:33 > 0:38:35- Let's get to work.- Indeed.
0:38:35 > 0:38:40'It's not easy to unlock the secret of those honeycomb bubbles,
0:38:40 > 0:38:45'so my two trusty factory foremen, Marty and Tod, are here to help.'
0:38:45 > 0:38:49This really is chemistry. We've got to weigh the right amount of sugar,
0:38:49 > 0:38:51- the right amount of syrup, glucose syrup.- OK.
0:38:51 > 0:38:54Add some water and boil that up in a pan.
0:38:54 > 0:38:56- We'll put all the sugary stuff in there.- OK.
0:38:56 > 0:38:59And then we're going to use this beast...
0:38:59 > 0:39:02- flame gun...- Love it!
0:39:02 > 0:39:04..to heat it up.
0:39:04 > 0:39:05And then we'll do the chemistry.
0:39:05 > 0:39:08- Do the chemistry? Just do the chemistry.- Do the chemistry!
0:39:08 > 0:39:10We're making an item of confectionary,
0:39:10 > 0:39:14so of course there's a bucketful of sugar to melt.
0:39:14 > 0:39:18And yes, we'll also need some clever chemistry.
0:39:18 > 0:39:20Now, to get this honeycomb stuff right,
0:39:20 > 0:39:23they need to mix up lots of sugar together with this stuff.
0:39:23 > 0:39:25It's called glucose syrup. You really need that
0:39:25 > 0:39:28to be able to get your honeycomb to set very, very hard.
0:39:28 > 0:39:32This syrup is too watery
0:39:32 > 0:39:36so they need to boil it to get rid of some of that water.
0:39:36 > 0:39:38Come on, come on.
0:39:38 > 0:39:40Yeah. Pour a bit out, Esther, come on.
0:39:40 > 0:39:42Come on, stuff.
0:39:42 > 0:39:45Esther and Becca have to heat up the sugar and glucose
0:39:45 > 0:39:48to just the right temperature. This is really important
0:39:48 > 0:39:52otherwise their munch bars won't have any crunch.
0:39:52 > 0:39:56We need to get it up to the hard ball temperature.
0:39:56 > 0:39:59- Which is?- 150 degrees.
0:39:59 > 0:40:02It's where the mixture will take on a particular gloopiness.
0:40:02 > 0:40:05- That's the technical term?- Yes.
0:40:05 > 0:40:09When the temperature reaches 150 degrees centigrade,
0:40:09 > 0:40:11they can add the next ingredient.
0:40:11 > 0:40:14And it's a bit of a surprise.
0:40:14 > 0:40:17This is bicarbonate of soda.
0:40:17 > 0:40:21It's the key to getting the bubbles in your honeycomb just right,
0:40:21 > 0:40:25because when you heat this stuff up, it gives off gas.
0:40:25 > 0:40:27Lots of it. Watch this.
0:40:36 > 0:40:41Let's see what happens when I heat up the bicarbonate of soda.
0:40:46 > 0:40:48Whoa!
0:40:48 > 0:40:49LAUGHTER
0:40:49 > 0:40:51- It went.- It went.
0:40:51 > 0:40:54When bicarbonate of soda gets hot,
0:40:54 > 0:40:57it creates bubbles of carbon dioxide.
0:40:57 > 0:41:00But it's not that easy to control this chemical reaction.
0:41:02 > 0:41:07You've got your molten sugar at the perfect critical temperature. Start those production lines!
0:41:08 > 0:41:10The big challenge facing Esther and Becca
0:41:10 > 0:41:13is can they make these bubbles just right?
0:41:13 > 0:41:15- All systems go now.- Are you ready?
0:41:15 > 0:41:17- Here we go.- Here we go.
0:41:17 > 0:41:20- Do you have to stir it? - We've got to stir it.
0:41:20 > 0:41:23Oh, look! It's going really fizzy-bubbly!
0:41:23 > 0:41:26Watch out. I'm going to be pouring that in a moment.
0:41:26 > 0:41:29Ooh!
0:41:29 > 0:41:32- Shouldn't there be bubbles? - Oh, there will. Just watch.
0:41:32 > 0:41:34- The masterpiece!- Chemistry over.
0:41:34 > 0:41:36Becca's cock-a-hoop with her result.
0:41:36 > 0:41:39But it hasn't gone so well for Esther.
0:41:39 > 0:41:41What's happened?
0:41:41 > 0:41:45Well, we think probably that most of the carbon...whatever it's called
0:41:45 > 0:41:49- stuck to the bottom of the spoon. - It's still there.- It's still there.
0:41:49 > 0:41:55So while I was expecting this massive eruption of bubbles,
0:41:55 > 0:41:58- what we got was that. - You don't know what's inside there.
0:41:58 > 0:42:01If there's a fizz of bubbles underneath the surface,
0:42:01 > 0:42:05- it might be salvageable. Good luck. - Thank you.
0:42:05 > 0:42:07Not a chance.
0:42:07 > 0:42:09- Becca!- I know!
0:42:09 > 0:42:11- That looks brilliant! - Are you impressed?
0:42:11 > 0:42:13The big question is what's it like inside?
0:42:13 > 0:42:15You've got these big bubbles on the top.
0:42:15 > 0:42:19If they're inside, it won't be like the ones you buy in the shops.
0:42:19 > 0:42:21- And that's what we're after. - It's a slight worry.
0:42:21 > 0:42:24- We'll only find out when we start cutting it.- Well done.
0:42:24 > 0:42:29Now they need to turn this bubbly swamp into bars of Crunch 'n' Munch.
0:42:29 > 0:42:31OK, pretty good so far.
0:42:31 > 0:42:34But now you need to cool it and cut it. And I want standardised shapes.
0:42:34 > 0:42:37They've all got to be exactly the same size bars.
0:42:37 > 0:42:40Because this is a factory line, not a kitchen, OK?
0:42:40 > 0:42:42# Bow-bow-bow-bow
0:42:42 > 0:42:46# Bow-bow, ooo-ooo-ooo-ooh. #
0:42:46 > 0:42:51Will Esther and Becca be able to make a bar our taste testers can munch?
0:42:51 > 0:42:54I'll leave them to it while I search for the secret
0:42:54 > 0:42:57inside another melt-in-the-mouth snack.
0:42:57 > 0:42:59Are you two fans of the cheesy puff?
0:42:59 > 0:43:01We are fans of the cheesy puff.
0:43:01 > 0:43:04- Quite light. Don't weigh you down. - Crunchy at the same time.
0:43:04 > 0:43:08They start off nice and crispy, then the moisture in your mouth melts them to nothing.
0:43:08 > 0:43:10It's a melt-in-the-mouth sensation.
0:43:10 > 0:43:12I think the way it dissolves or disintegrates
0:43:12 > 0:43:15is what makes it different from other crisps.
0:43:15 > 0:43:19Why do you think they make it so that they melt in your mouth?
0:43:19 > 0:43:21So you want more.
0:43:21 > 0:43:23But what are they made from?
0:43:23 > 0:43:26And why do they melt in the mouth?
0:43:26 > 0:43:30To melt down the secrets of cheesy puffs, I'm going to make my own.
0:43:31 > 0:43:35Cheesy puffs are made out of this stuff, maize.
0:43:35 > 0:43:39Grind up these kernels and you end up with this.
0:43:40 > 0:43:43Eurgh! It's like eating sand.
0:43:43 > 0:43:45So, how do you turn it...
0:43:45 > 0:43:46into cheesy puffs?
0:43:48 > 0:43:49Boil it up, maybe.
0:43:49 > 0:43:51Nope.
0:43:51 > 0:43:53Roast it?
0:43:53 > 0:43:56Nope.
0:43:56 > 0:43:57Fry it?
0:43:57 > 0:43:59No!
0:43:59 > 0:44:04To transform unappetising maize into light, airy cheese puffs,
0:44:04 > 0:44:07they cook it in a way that no domestic kitchen can copy.
0:44:10 > 0:44:12We're about to discover a bit of kit
0:44:12 > 0:44:16which makes weird and wonderful food shapes possible.
0:44:16 > 0:44:20Meet the extruder.
0:44:20 > 0:44:24It was patented 70 years ago by a cattle-feed company.
0:44:24 > 0:44:30The raw maize goes inside and a tightly-fitting spiral compacts it.
0:44:30 > 0:44:34As the spiral turns, it forces the maize down towards the end.
0:44:34 > 0:44:37And the force gets harder and harder and creates heat,
0:44:37 > 0:44:39so much heat that when the maize
0:44:39 > 0:44:42finally gets squeezed out of this tiny little hole here,
0:44:42 > 0:44:46it's so hot that it cooks it and you get corn puffs.
0:44:47 > 0:44:51But the spiral needs to spin very fast
0:44:51 > 0:44:53to force the maize through the hole.
0:44:53 > 0:44:56I'll never get up enough puff.
0:44:56 > 0:44:59That's hard work. I need more power.
0:45:13 > 0:45:14This should do it!
0:45:17 > 0:45:22The output at the back of the tractor will power my extruder.
0:45:28 > 0:45:31The spiral's up to speed
0:45:31 > 0:45:34so if I ladle in the maize, I should get puffs out.
0:45:37 > 0:45:40Look at them coming out! Oh, they're a little bit wiggly.
0:45:40 > 0:45:42A bit more stringy than puffy.
0:45:45 > 0:45:47That's disgusting!
0:45:47 > 0:45:48It's like worms!
0:45:48 > 0:45:53But now the shaft's getting hotter and the maize is going gooey inside.
0:45:53 > 0:45:56It's beginning to puff just a little bit.
0:45:56 > 0:46:00I can feel the heat off it. It's its own cooker.
0:46:03 > 0:46:05Whoo! Ha-ha!
0:46:05 > 0:46:06It's shooting them out.
0:46:06 > 0:46:08Blimey! It's really fast!
0:46:08 > 0:46:11As the hot, squidgy maize pops out,
0:46:11 > 0:46:13the moisture turns to steam
0:46:13 > 0:46:16and the maize magically puffs up.
0:46:16 > 0:46:17It's a-maizing!
0:46:18 > 0:46:21Look at that! That is absolutely brilliant!
0:46:23 > 0:46:26Look! I've got puffs!
0:46:26 > 0:46:30Maize is the only ingredient.
0:46:30 > 0:46:33What really makes these melt-in-the-mouth snacks possible
0:46:33 > 0:46:35is the machine.
0:46:39 > 0:46:42It's time for quality control.
0:46:43 > 0:46:48Some of them look a bit weird and gnarly.
0:46:48 > 0:46:51Some of them are short and bally.
0:46:51 > 0:46:53Some of them are...
0:46:53 > 0:46:54a bit mad.
0:46:56 > 0:46:58THAT is a brilliant corn puff.
0:46:58 > 0:47:01Look at it! It's got the right shape.
0:47:02 > 0:47:04Oh! Ah-ha-ha!
0:47:04 > 0:47:06It's got the right texture.
0:47:06 > 0:47:09Beautiful aerated little centre.
0:47:09 > 0:47:12THAT is brilliant!
0:47:14 > 0:47:17The puff is up to 90% air.
0:47:17 > 0:47:19That's why they melt in the mouth.
0:47:19 > 0:47:21The thing is...
0:47:22 > 0:47:24..at this stage, they don't taste of anything
0:47:24 > 0:47:27and that's cos they're naked corn puffs.
0:47:28 > 0:47:31But wait till I coat them in this stuff.
0:47:31 > 0:47:33Cheese-flavoured powder.
0:47:33 > 0:47:35It's about 7% cheese.
0:47:35 > 0:47:39And if I mix it with oil to make a paste,
0:47:39 > 0:47:41it should stick to my puffs.
0:47:43 > 0:47:46Got my corn puffs, I've got my flavouring.
0:47:46 > 0:47:49In the factory, they put these together in a huge rotary oven
0:47:49 > 0:47:51which tumbles them all around, heats them up
0:47:51 > 0:47:54and coats the puff with all the flavouring.
0:47:56 > 0:47:58I've got a tumble dryer.
0:48:02 > 0:48:04Now the flavouring.
0:48:04 > 0:48:08If this doesn't make them cheesy, I'll chuck my socks in as well.
0:48:12 > 0:48:16After they're baked in this lovely cheesy paste,
0:48:16 > 0:48:19they should be ready to eat. Take a look.
0:48:21 > 0:48:24Fantastic! They're all covered with a little film of flavouring.
0:48:28 > 0:48:32Not quite as cheesy and not quite as fluffy as the real thing,
0:48:32 > 0:48:36but considering what it's been through, I'm well chuffed with that.
0:48:36 > 0:48:41My very own melt-in-the-mouth cheesy puffs.
0:48:42 > 0:48:44But only our taste testers can decide
0:48:44 > 0:48:47whether they're as good as the shop-bought ones.
0:48:47 > 0:48:50Dig in, grab yourself a handful of those.
0:48:50 > 0:48:53What's the magic going on inside your mouth right now?
0:48:53 > 0:48:55- It's quite plain.- Ha!
0:48:55 > 0:48:58- And what's the texture? - Nothing.- Nothing!
0:48:58 > 0:49:00- Air.- Air, yeah. It's mostly air.
0:49:00 > 0:49:04- Is the texture right? - Yes. I reckon so.- I'll take that!
0:49:04 > 0:49:08- It sort of melts in your mouth. - That's exactly what I'm after!
0:49:08 > 0:49:09# Bow-bow-bow-bow
0:49:09 > 0:49:14# Bow-bow, ooo-ooo-ooo-ooh. #
0:49:14 > 0:49:17Back in the barn, mum and daughter Esther and Becca
0:49:17 > 0:49:20are making rival Crunch 'n' Munch bars.
0:49:20 > 0:49:23The hot honeycomb slab has been cooled down
0:49:23 > 0:49:28using some industrial-inspired ingenuity.
0:49:28 > 0:49:29LAUGHTER
0:49:31 > 0:49:34Oh, dear! Making Crunch 'n' Munch bars
0:49:34 > 0:49:36is proving trickier than expected.
0:49:36 > 0:49:40- This is what we meant to happen, is it?- Yeah, this is good.
0:49:40 > 0:49:43The honeycomb is now cold enough to cut.
0:49:43 > 0:49:46But can they produce finger-shaped bars?
0:49:46 > 0:49:48I think we can use a red-hot wire
0:49:48 > 0:49:51that will just melt its way through the sugar.
0:49:51 > 0:49:54- Brilliant. Am I going to do that? - Yeah.- Good.
0:49:54 > 0:49:56Let's restart those production lines.
0:49:56 > 0:49:59Tod's cunning plan is based on a car battery,
0:49:59 > 0:50:02electric current and copper wire.
0:50:02 > 0:50:04- OK.- So no copying now.
0:50:04 > 0:50:06Oh, wow!
0:50:06 > 0:50:09The wire heats up and burns through the sugar.
0:50:09 > 0:50:11Brilliant or bonkers?
0:50:11 > 0:50:14Bonkers.
0:50:14 > 0:50:18If at first you don't succeed, hit it with a hammer.
0:50:18 > 0:50:20Yeah, it's not really working, is it?
0:50:20 > 0:50:22SHE LAUGHS
0:50:23 > 0:50:27Becca and Marty are taking a much more obvious approach,
0:50:27 > 0:50:29a big saw.
0:50:29 > 0:50:31SHE SCREAMS
0:50:31 > 0:50:33Oh, no!
0:50:34 > 0:50:40- Oh, no! Oh, no!- It's cracking.
0:50:40 > 0:50:42It's fine, it's fine.
0:50:42 > 0:50:46If in doubt eat the mistake, no-one will know.
0:50:46 > 0:50:49I'll allow a few extra minutes of production
0:50:49 > 0:50:51for Esther and Becca to salvage what they can.
0:50:51 > 0:50:56Let's see how well they've done in making the honeycomb centres for their chocolate bars.
0:50:56 > 0:50:59Esther, Becca, bring 'em on over.
0:50:59 > 0:51:01It's quality control time.
0:51:01 > 0:51:04- You're smiling. You're smiling. That's a good thing.- I am.
0:51:04 > 0:51:07Can we actually extract some of the machinery to get to your...
0:51:07 > 0:51:10Oh, there is some. Oh, brilliant! OK. OK.
0:51:10 > 0:51:12That doesn't look very nice.
0:51:12 > 0:51:16OK. So this is real serious quality control here.
0:51:16 > 0:51:17THEY LAUGH
0:51:17 > 0:51:19Oh, my good...
0:51:19 > 0:51:22We're looking for uniformity here.
0:51:22 > 0:51:25OK. 11.5, 12.
0:51:25 > 0:51:27Esther...
0:51:27 > 0:51:29Well, that one's seven.
0:51:29 > 0:51:32That one's...
0:51:32 > 0:51:35- Shall we taste them?- Yes.- What we need is a nice bit of crunch.
0:51:35 > 0:51:37Lightness and crunch, I think.
0:51:38 > 0:51:40SHE LAUGHS
0:51:40 > 0:51:41Oh!
0:51:41 > 0:51:43SHE GASPS What went?
0:51:43 > 0:51:46It's all right, it wasn't my tooth this time! Crunchy.
0:51:46 > 0:51:50Not very airy. But very delicious.
0:51:50 > 0:51:53That's not bad. Looks a bit rubbish but not bad.
0:51:53 > 0:51:55OK. Becca.
0:51:59 > 0:52:02Ah, now you have pulled off something special there.
0:52:02 > 0:52:06That does have a lightness that Mum really didn't achieve.
0:52:06 > 0:52:07She has overdone the bubble.
0:52:07 > 0:52:13I cannot believe you're criticising from there. Look at that!
0:52:13 > 0:52:17Now what you need to do is pretty quickly get this honeycomb and enrobe it.
0:52:17 > 0:52:20It's got to be covered in a beautiful layer of chocolate.
0:52:20 > 0:52:22This is important, not just for the taste,
0:52:22 > 0:52:24but because if you don't do it quickly,
0:52:24 > 0:52:28this stuff is all going to go very gooey. OK?
0:52:28 > 0:52:30Now I hate to sound bossy, but get to work!
0:52:32 > 0:52:35HE SCATS
0:52:35 > 0:52:38# Mm! Do that again! Bow-bow-bow-bow. #
0:52:38 > 0:52:42While Esther and Becca work out how to finish their Crunch 'n' Munch bars
0:52:42 > 0:52:46I'm off to discover how to make another melt-in-the-mouth favourite.
0:52:48 > 0:52:52I've snuck into the secret research room
0:52:52 > 0:52:55here at the Cadbury's chocolate factory in Bourneville.
0:52:55 > 0:52:58In here, conditions are perfectly tuned
0:52:58 > 0:53:01to concentrate on chocolatey-ness.
0:53:01 > 0:53:04My job is to compare two different samples.
0:53:04 > 0:53:05Mm-hmm.
0:53:05 > 0:53:11OK, that one's much lighter, seems to be much more creamy,
0:53:11 > 0:53:15and the chocolate flavour seems to melt really quickly in the mouth.
0:53:15 > 0:53:18It floods your mouth with this sensation of chocolate.
0:53:18 > 0:53:22So what's the difference between the two samples?
0:53:22 > 0:53:26They're both chocolate but they melt differently.
0:53:26 > 0:53:30Chocolate boffin Joe O'Shea knows the secret.
0:53:30 > 0:53:32That's solid chocolate, you even heard it snap.
0:53:32 > 0:53:35So the solid chocolate, when you're tasting it,
0:53:35 > 0:53:37it melts very slowly in your mouth.
0:53:37 > 0:53:40When you break open the second one you can see that it has
0:53:40 > 0:53:43thousands and thousands of little bubbles on the inside.
0:53:43 > 0:53:45The bubbles have very, very thin walls,
0:53:45 > 0:53:47so when you bite through the bubbles
0:53:47 > 0:53:49you get a very fast melt of the chocolate on your tongue.
0:53:49 > 0:53:52That's what's unique about this bubbly chocolate.
0:53:52 > 0:53:55But how do they get the bubbles into the chocolate?
0:53:55 > 0:53:59Can the answer really be outside in the car park?
0:54:01 > 0:54:04Come on, you can shake it better than that. Give it some welly!
0:54:04 > 0:54:06HE GROANS
0:54:06 > 0:54:11Now I want you to go over there, put it on the ground and open it.
0:54:11 > 0:54:13- And this is a good idea, is it? - Yes, it's a good idea.
0:54:15 > 0:54:16HE LAUGHS
0:54:18 > 0:54:21What you've got here is lemonade, which is water, essentially,
0:54:21 > 0:54:25with dissolved gas, carbon dioxide gas inside.
0:54:25 > 0:54:26It's already under pressure.
0:54:26 > 0:54:29When you shook the bottle you put it under more pressure.
0:54:29 > 0:54:33And that is exactly the same principle that we use
0:54:33 > 0:54:36to get the bubbles into our chocolate.
0:54:36 > 0:54:41Here at the factory, they dissolve carbon dioxide gas in the chocolate.
0:54:41 > 0:54:42It makes it fizzy.
0:54:42 > 0:54:47So this really is like the bottle of lemonade? It is fizzy chocolate?
0:54:47 > 0:54:49What we've got in this pipe is chocolate
0:54:49 > 0:54:51with gas dissolved in the chocolate.
0:54:51 > 0:54:53It's like opening the bottle, the gas gets released
0:54:53 > 0:54:56and you get beautiful bubbles formed in the chocolate.
0:54:56 > 0:54:59So if it comes out as basically fizzy chocolate,
0:54:59 > 0:55:02why doesn't a bar feel fizzy?
0:55:02 > 0:55:05The gas is gone by the time you eat the chocolate.
0:55:05 > 0:55:09So what you're feeling is the structure and the lightness that you get from the bubbles.
0:55:09 > 0:55:11- Left behind from the fizzy foam. - Yeah, yeah.
0:55:18 > 0:55:21What's left when the chocolate's cooled isn't the carbon dioxide gas,
0:55:21 > 0:55:25but the bubble it formed before it escaped.
0:55:25 > 0:55:30Like your footprint left in wet sand, the shape is still there
0:55:30 > 0:55:32but your foot is long gone.
0:55:32 > 0:55:37These bubbles are the reason this chocolate melts faster on your tongue,
0:55:37 > 0:55:40so it tastes more chocolatey.
0:55:44 > 0:55:46# Bow-bow-bow-bow
0:55:46 > 0:55:49# Bow-bow, ooo-ooo-ooo-ooh. #
0:55:50 > 0:55:54Back in the barn, I've challenged Esther Rantzen
0:55:54 > 0:55:56and her daughter Becca Wilcox
0:55:56 > 0:55:59to make two rival Crunch 'n' Munch bars.
0:55:59 > 0:56:03Now they've got to cover them in chocolate.
0:56:03 > 0:56:07But they must work quickly to keep the crunch in the honeycomb.
0:56:07 > 0:56:11Right, so we're about to pour the chocolate into the spray paint guns.
0:56:11 > 0:56:14The honeycomb is then going to travel through
0:56:14 > 0:56:17- on this little conveyor belt, get sprayed in this box...- Yeah.
0:56:17 > 0:56:19..and hopefully come out covered.
0:56:19 > 0:56:23Go into the dry ice box, cool down. At the other end
0:56:23 > 0:56:26we quickly pick them up and put them through again on the other side.
0:56:26 > 0:56:30- Flip them, to double coat them? - Well, just to coat the other side.
0:56:30 > 0:56:33On a scale of one to ten, how confident are you?
0:56:33 > 0:56:35I would say a really good six.
0:56:35 > 0:56:38Perhaps Esther's more optimistic?
0:56:38 > 0:56:40This is the bottomer, the roller.
0:56:40 > 0:56:42Which does the bottom as the name implies.
0:56:42 > 0:56:44Very good. Bottom roller.
0:56:44 > 0:56:46Meanwhile I'm on the Portaloo pump.
0:56:46 > 0:56:49The chocolate goes straight up the tube
0:56:49 > 0:56:53and gushes down and this wonderful enrobement happens.
0:56:53 > 0:56:56- Fantastic. Are you feeling confident now?- Totally.
0:56:56 > 0:57:00- This is a bit more Heath Robinsony, old-style British engineering. - Heath Robinsony?- Yeah.
0:57:00 > 0:57:03This is the white heat of honeycomb enrobement.
0:57:03 > 0:57:05- Cutting edge.- Cutting edge.
0:57:05 > 0:57:09While Becca and Esther make a few last-minute adjustments,
0:57:09 > 0:57:14let's see why it's so important to cover the honeycomb in chocolate.
0:57:14 > 0:57:18The chocolate coating on these honeycomb bars is delicious
0:57:18 > 0:57:20but it's also there for a very practical reason.
0:57:20 > 0:57:22The honeycomb is crunchy
0:57:22 > 0:57:27because when it's cooked all the moisture is removed.
0:57:27 > 0:57:31The thing is though, this honeycomb wants all of that moisture back.
0:57:31 > 0:57:33Normally, if you leave them out,
0:57:33 > 0:57:35it will find that moisture in the air around us.
0:57:35 > 0:57:38I can show you by using a wallpaper steamer.
0:57:40 > 0:57:42This'll speed things up a bit!
0:57:43 > 0:57:46It's amazing, it's just disintegrating.
0:57:46 > 0:57:48All those little beautiful bubbles...
0:57:48 > 0:57:51just turning back into mush.
0:57:51 > 0:57:55The only time you want that to happen is when you put one in your mouth
0:57:55 > 0:57:59and the saliva all gets sucked up by that honeycomb and melts.
0:57:59 > 0:58:04That's why it's vital to get the crunchy honeycomb middle
0:58:04 > 0:58:07covered in chocolate, to keep the moisture out.
0:58:09 > 0:58:11Becca, Marty, start your production line!
0:58:11 > 0:58:15The choco paint sprayers look a bit mad-cap
0:58:15 > 0:58:20but this is the method used by the makers of some posh chocolates.
0:58:20 > 0:58:23But I'm sure the chocolate should spray onto the bars, not the box!
0:58:23 > 0:58:27It's all falling apart at the seams. I'm getting covered in chocolate.
0:58:27 > 0:58:29Turn them off!
0:58:29 > 0:58:31Terrific!
0:58:31 > 0:58:32SHE LAUGHS
0:58:36 > 0:58:38Well, some chocolate came out. That's a start.
0:58:38 > 0:58:41It just didn't go over the chocolate bar. Oh, it did a bit.
0:58:41 > 0:58:43- It's beautiful.- Look, enrobed.
0:58:43 > 0:58:47- That is so funny.- See?
0:58:47 > 0:58:50- What more do you want? - What a beautiful theory.
0:58:50 > 0:58:52Do you think that needs a little bit of tweaking?
0:58:52 > 0:58:54- Right, well...- We're so close.
0:58:54 > 0:58:58Esther and Tod want to create a curtain of chocolate.
0:58:58 > 0:59:03They hope to rescue their earlier mishap by making bite-size snacks.
0:59:03 > 0:59:07Well, your side of the factory is pumped with confidence. Ready?
0:59:07 > 0:59:09- Yes.- Start the production line.
0:59:09 > 0:59:12It will be done. The chocolate, Tod.
0:59:13 > 0:59:16You can start pumping.
0:59:16 > 0:59:19It will be quite hard work, slow and sure.
0:59:19 > 0:59:21And here we go, Niagara!
0:59:21 > 0:59:26Esther's all pumped up with Tod's chocolate coating machine.
0:59:26 > 0:59:28Oh, we're so good at this.
0:59:28 > 0:59:30It's completely brilliant!
0:59:30 > 0:59:31Can I just say?
0:59:31 > 0:59:36I had no confidence in you, Tod, and I was completely wrong!
0:59:36 > 0:59:40The bars aren't quite ready to wrap. The chocolate is still too soft.
0:59:40 > 0:59:42They need to cool it fast.
0:59:42 > 0:59:46Becca and Marty are close to calamity.
0:59:46 > 0:59:49Their bars have frozen to their super-cooled box!
0:59:49 > 0:59:51- Oops.- Agh!
0:59:51 > 0:59:56Fired up with the success of her chocolate-coating machine,
0:59:56 > 0:59:59Esther's hoping to extinguish any chance Becca's bar might be best.
0:59:59 > 1:00:04She's spraying frozen carbon dioxide everywhere!
1:00:04 > 1:00:06Esther and Becca, your time is nearly up.
1:00:06 > 1:00:09Can you please wrap up your honeycomb chocolate bars?
1:00:18 > 1:00:20It's time for quality control.
1:00:20 > 1:00:24OK. Let's give it a try. So Crunch 'n' Munch.
1:00:24 > 1:00:27Oh, it's quite cold inside there.
1:00:28 > 1:00:30Oh, my word.
1:00:30 > 1:00:32It was looking quite disastrous earlier on,
1:00:32 > 1:00:34but I think you've come good. That's not bad.
1:00:34 > 1:00:37Oh, that's very sweet, because that looks terrible.
1:00:37 > 1:00:40There's an element of rubbish to it, granted,
1:00:40 > 1:00:42but these things are difficult to make.
1:00:42 > 1:00:44OK. Let's see if it has a crunch to it.
1:00:45 > 1:00:48- Argh!- That's not bad. - That is not bad.
1:00:48 > 1:00:50That's not bad at all. Look at that.
1:00:50 > 1:00:52That is not bad.
1:00:52 > 1:00:55The question is what does it feel like in the mouth and how does it taste? OK.
1:00:57 > 1:01:00- MUMBLES:- Nearly lost another tooth there.- Pardon?
1:01:00 > 1:01:02He said it was wonderful and it wins.
1:01:02 > 1:01:05Quite an even coating of chocolate. Pretty good.
1:01:05 > 1:01:07Melts nicely in your hands.
1:01:07 > 1:01:11So...Esther's.
1:01:14 > 1:01:15SHE LAUGHS
1:01:15 > 1:01:18- No, I am...- And?- These are really difficult to make.
1:01:18 > 1:01:22- That's a much better covering of chocolate than Becca's.- Thank you.
1:01:22 > 1:01:24Pretty good. That's all I'm saying.
1:01:24 > 1:01:26Now wish me luck.
1:01:26 > 1:01:27THE BAR CRUNCHES
1:01:27 > 1:01:31That was a very interesting noise. And still is.
1:01:31 > 1:01:34He's learned. He takes it on the back teeth now.
1:01:34 > 1:01:37It's delicious. But it's not me that's going to decide.
1:01:37 > 1:01:44It's our taste testers. So grab those. Come outside.
1:01:44 > 1:01:45Oh, dear.
1:01:46 > 1:01:47APPLAUSE
1:01:50 > 1:01:51Try this.
1:01:54 > 1:01:56Do you happen to have your own teeth...still?
1:01:56 > 1:01:59- What do you think? - Really nice, perfect.
1:01:59 > 1:02:00Perfect? Perfect
1:02:00 > 1:02:03Harsh on the fillings for the older...
1:02:03 > 1:02:06For the older muncher. I suggest sucking the chocolate off?
1:02:06 > 1:02:08Sort of sugary, caramelly.
1:02:08 > 1:02:11- That's right, yes.- Is that what you intended?- Definitely.
1:02:11 > 1:02:14Here's something to take the taste away of that disaster earlier on.
1:02:14 > 1:02:17I like the chocolate very much. It's good.
1:02:17 > 1:02:20- It's actually quite impressive. - I'm sorry, what did you just say?
1:02:20 > 1:02:23- They're actually quite impressive. - Did we catch that?
1:02:23 > 1:02:25Esther, Becca, moment of truth.
1:02:25 > 1:02:28What I want here is a show of hands
1:02:28 > 1:02:31and what you're judging is not how good it tasted but how close it was
1:02:31 > 1:02:34to the chocolate honeycomb bar you'd buy in the shops.
1:02:34 > 1:02:36So first of all, a show of hands,
1:02:36 > 1:02:40who preferred Esther's honeycomb chocolate bar?
1:02:40 > 1:02:43One, two, three, four, five.
1:02:43 > 1:02:46Hands up if you preferred Becca's chocolate bar.
1:02:48 > 1:02:50Well, I'm really sorry to say it
1:02:50 > 1:02:53but, Esther, your chocolate bar is going in the bin.
1:02:53 > 1:02:55SHE GROANS
1:02:55 > 1:02:59Which means, Becca, your chocolate bar goes in the basket.
1:02:59 > 1:03:01Well done! Round of applause, guys.
1:03:05 > 1:03:07That was great fun.
1:03:07 > 1:03:10Unfortunately Esther didn't get enough bubbles in her honeycomb
1:03:10 > 1:03:13but Becca's had the perfect chocolatey crunch.
1:03:13 > 1:03:15Now, we all love the sensation
1:03:15 > 1:03:18when snack foods magically melt in our mouths,
1:03:18 > 1:03:20but as we've discovered, making cheesy puffs
1:03:20 > 1:03:23and chocolate honeycomb bars can be really difficult.
1:03:35 > 1:03:38Subtitles by Red Bee Media Ltd