0:00:02 > 0:00:05When we're in a rush, we want food that's quick and easy,
0:00:05 > 0:00:08like ready-made custard and frozen pizza.
0:00:08 > 0:00:11But what do they do to these family favourites
0:00:11 > 0:00:13so that all we have to do is heat them up?
0:00:13 > 0:00:17To find out, we're going to make our own from scratch.
0:00:17 > 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 > 0:00:27How do you reckon they stop ready-made custard from going lumpy?
0:00:27 > 0:00:29- Do they put oil in it, fat? - I think they heat it.
0:00:29 > 0:00:31They stir it in some big machinery.
0:00:31 > 0:00:33I can't make my custard that smooth!
0:00:33 > 0:00:36- Do you like pizza?- I do love pizza.
0:00:36 > 0:00:40Go on, grab a little bit. Do you reckon there's any surprise ingredients in supermarket pizzas?
0:00:40 > 0:00:44- Maybe what looks like onion is not a onion.- Maybe sugar?
0:00:44 > 0:00:46Do you reckon there's any fake ingredient in there?
0:00:46 > 0:00:48Well, the cheese can't be fake.
0:00:48 > 0:00:52- You're happy with that pizza? - Well, I don't like cold pizza.
0:00:52 > 0:00:53THEY LAUGH
0:00:54 > 0:00:57I love finding out what happens to the stuff that we eat.
0:00:57 > 0:01:02But finding out what factories do to our food isn't easy.
0:01:02 > 0:01:05So to copy the big boys, I've set up my own food factory,
0:01:05 > 0:01:07here in this barn.
0:01:07 > 0:01:10To help me discover what the masters of mass production do,
0:01:10 > 0:01:12I'm going to need some factory workers.
0:01:12 > 0:01:17Clocking on for today's shift, are two of The One Show's experts,
0:01:17 > 0:01:20Lucy Siegle and Mike Dilger.
0:01:20 > 0:01:23Whose version of today's supermarket food will go in the basket
0:01:23 > 0:01:25and whose will go in the bin?
0:01:27 > 0:01:30Our shift at the Food Factory is about to begin.
0:01:50 > 0:01:53Lucy, Mike, brilliant to have you here at the barn.
0:01:53 > 0:01:57- Would you like to see what you'll be making?- Yes, please.- May we?
0:01:57 > 0:02:02- You're going to be making ready-made custard. - Oh, wow, fabulous!- I love custard.
0:02:02 > 0:02:05I'm something of a custard expert. I'm really excited about this.
0:02:05 > 0:02:08What does custard mean to you? Why is it something that you're fond of?
0:02:08 > 0:02:10It's sweet but it tastes wholesome, for some reason.
0:02:10 > 0:02:14- It's such a naughty thing to eat. - I know, I know.
0:02:14 > 0:02:17- The thing is, how hard can it be to make custard?- It must be quite easy.
0:02:17 > 0:02:21I imagine making it a smooth consistency without lumps is quite tricky.
0:02:21 > 0:02:25- I think we need to get started. Ready for your shift?- Absolutely.
0:02:25 > 0:02:28- Follow me to the barn. - Right you are.
0:02:32 > 0:02:34Mike's right to be worried,
0:02:34 > 0:02:38especially against a self-confessed custard expert.
0:02:39 > 0:02:41Making your own custard at home is quite tricky.
0:02:41 > 0:02:44It curdles really easily, which is why I think this stuff
0:02:44 > 0:02:47that comes straight out of a tub is so popular.
0:02:47 > 0:02:51- Is that why you buy it? - Yes.- Can't be bothered to make it?
0:02:51 > 0:02:54It's a convenience food, isn't it? I only like cold custard, really.
0:02:54 > 0:02:58- Really?- This is when I like it best. - You're weird. That's very peculiar.
0:02:58 > 0:03:01- I think that's normal. - Do you eat it at home, cold?
0:03:01 > 0:03:03- Yes! With bananas. Oh, no! - I think it's all over.
0:03:03 > 0:03:07Lucy's going to absolutely trounce me here. Custard maestro.
0:03:07 > 0:03:11Your challenge is to make two rival tubs of custard,
0:03:11 > 0:03:14using the same techniques that they use in a food factory.
0:03:14 > 0:03:16When you've made them,
0:03:16 > 0:03:20we'll offer them to a group of our taste testers and they will decide
0:03:20 > 0:03:23whose custard is most like the stuff you buy from the supermarkets.
0:03:23 > 0:03:27So, first of all, meet your ingredients.
0:03:27 > 0:03:31- HE CLUCKS - Your first task is to separate the whites from the yolks.
0:03:31 > 0:03:35So you need to make a machine that can do that very quickly.
0:03:35 > 0:03:36Please, get cracking.
0:03:36 > 0:03:39In the bucket are 60 eggs,
0:03:39 > 0:03:43but it's only the yolks they need to make their custard creamy.
0:03:43 > 0:03:47My factory foremen, Marty and Tod, are here to help.
0:03:47 > 0:03:51- Marty.- Yes.- It's custard. The mission is, we've got five dozen eggs...- Yes.
0:03:51 > 0:03:55..we've got to crack them as quickly as possible, separating the whites from yellows.
0:03:55 > 0:03:57We're going to take the eggs and take a blade
0:03:57 > 0:04:00- and we'll go tweak, and chop the bottoms off...- Right.
0:04:00 > 0:04:04..and we'll separate them out but - and this is the good bit -
0:04:04 > 0:04:08- we're going to do them all at once. - You're joking.- One hit.
0:04:08 > 0:04:11Tod's plan is a little more modest.
0:04:11 > 0:04:13Separate the two, classic way of doing it,
0:04:13 > 0:04:17it's almost like a cattle grid, you slide it down some thin rods,
0:04:17 > 0:04:21and the yolk will just slide over the top and skid down into one pot.
0:04:21 > 0:04:24- Clever.- Yeah, and the whites will drop through the cattle grid...
0:04:24 > 0:04:27- I'm liking this. - ..and go into another pot. - OK. Let's do it, I like that idea.
0:04:27 > 0:04:31Cracking and separating the eggs is only the first step
0:04:31 > 0:04:34towards the really big challenge - making lump-free custard.
0:04:34 > 0:04:36For proper top-quality custard,
0:04:36 > 0:04:39the supermarkets use up to 10% egg yolk.
0:04:39 > 0:04:42That's three egg yolks in a tub like this.
0:04:42 > 0:04:45Tod and Marty have come up with two mechanical methods
0:04:45 > 0:04:48to crack and separate their eggs.
0:04:48 > 0:04:50They're both copying real factory methods.
0:04:50 > 0:04:55The eggshell is delicate, so it requires some precision engineering.
0:04:57 > 0:04:59Tod, what is this for?
0:04:59 > 0:05:03- It's our egg separator. Obviously. - It's a clothes drier.
0:05:03 > 0:05:05At the moment.
0:05:05 > 0:05:08Foods we prefer to buy ready-made
0:05:08 > 0:05:10are the ones which are tricky to make at home.
0:05:10 > 0:05:13Once they've cracked those eggs open,
0:05:13 > 0:05:16they've got to make custard with no lumps,
0:05:16 > 0:05:18and that can be quite difficult.
0:05:18 > 0:05:21Now, egg is traditionally the key ingredient in custard.
0:05:21 > 0:05:24It has an amazing thickening effect.
0:05:24 > 0:05:29So, in there is egg and sugar, and I'm going to pour in some hot milk.
0:05:31 > 0:05:35All you do is put it back on the heat,
0:05:35 > 0:05:37gently stir,
0:05:37 > 0:05:39and it should begin to thicken.
0:05:39 > 0:05:42This is also the tricky bit.
0:05:42 > 0:05:45If you get it wrong, heat it up too quickly, the whole lot curdles.
0:05:45 > 0:05:47You have to chuck it away and start again.
0:05:49 > 0:05:51It's curdled a bit.
0:05:51 > 0:05:53That's curdled a lot!
0:05:55 > 0:05:59So, this is what happens if you cook it too quickly.
0:05:59 > 0:06:03Scrambled egg in milk. Not nice.
0:06:03 > 0:06:08This is why it's so much easier to buy custard ready-made.
0:06:10 > 0:06:13So now it's time to separate the egg yolks from the egg whites,
0:06:13 > 0:06:17making sure no shell ends up in the custard.
0:06:18 > 0:06:21What on earth is going on here?
0:06:21 > 0:06:24It's very exciting. We've got this suction thing here,
0:06:24 > 0:06:26where we're holding the eggs in place,
0:06:26 > 0:06:27so we're not going to get the shell
0:06:27 > 0:06:31- when we've separated the eggs down here.- Ah, OK.
0:06:31 > 0:06:34Then they come through here, and incredibly efficiently,
0:06:34 > 0:06:36we are going to slice the eggs.
0:06:36 > 0:06:39Then the egg fluids, if you will, comes down here,
0:06:39 > 0:06:40and this is our separator,
0:06:40 > 0:06:45which was formerly a kind of clothes drier.
0:06:45 > 0:06:47Please start your production line.
0:06:49 > 0:06:53Go, go, go, go, go!
0:06:59 > 0:07:02There we go, the egg innards are speeding down.
0:07:02 > 0:07:03Yes! Go on.
0:07:03 > 0:07:06Am I allowed to just give it a little push?
0:07:06 > 0:07:09It'll get there. Don't worry. Right, come on, next lot.
0:07:09 > 0:07:10No time to wait for them.
0:07:10 > 0:07:13Cracking just six eggs at a time,
0:07:13 > 0:07:16it's more like mess production than mass production.
0:07:18 > 0:07:19Mike and Marty are very excited.
0:07:19 > 0:07:22They're hoping to crack all their eggs in a oner.
0:07:25 > 0:07:30You can see this tray we've created with the eggs' bottoms sticking out.
0:07:30 > 0:07:34My job is to close this, and all the bottoms will be cut off.
0:07:34 > 0:07:38- Eggs will flood out into this channel here.- Then I think you can work out what those holes are for,
0:07:38 > 0:07:40because the yolks will be intact. They'll sit in the tray,
0:07:40 > 0:07:44and then all the whites will drizzle through this beautiful structure
0:07:44 > 0:07:49that Marty has lovingly created, and that should be a yolk-free zone.
0:07:49 > 0:07:53I can't see any way on earth that this is going to work. But here we go.
0:07:53 > 0:07:55Mustn't stifle innovation in the workplace. Are you ready?
0:07:55 > 0:07:59- Three, two... - Please start you production line.
0:07:59 > 0:08:00..one, go!
0:08:01 > 0:08:02Oh, that felt good!
0:08:02 > 0:08:05Look! Come on!
0:08:05 > 0:08:07That's astounding. I'm properly impressed.
0:08:07 > 0:08:09Fantastic!
0:08:09 > 0:08:12That's a sea of egg yolks, that's exactly what I wanted.
0:08:12 > 0:08:15Marty, we have just vaguely impressed Stefan!
0:08:15 > 0:08:18'Let's enjoy that EGGS-travaganza again!
0:08:20 > 0:08:24Slice, slide, separate!
0:08:24 > 0:08:26Genius!
0:08:26 > 0:08:31Lucy and Tod still haven't EGGS-actly cracked it,
0:08:31 > 0:08:33while Mike and Marty have EGG-celled themselves!
0:08:33 > 0:08:36OK. Please stop your production lines.
0:08:36 > 0:08:37It's time for quality control.
0:08:37 > 0:08:40Let's see how well you've separated yolks. Bring them over.
0:08:42 > 0:08:43- There we go.- Wow! Pretty good.
0:08:43 > 0:08:46- Here's my yolks.- Pretty...- Average!
0:08:46 > 0:08:47Less good.
0:08:47 > 0:08:51- There's a slight difference to the quantity here, isn't there?- Yeah.
0:08:51 > 0:08:55- Lucy, how many egg yolks do you have here?- I have 24.
0:08:55 > 0:08:5924. 24 out of 60. Mike, how many yolks do you have?
0:08:59 > 0:09:0353. A few broke in the tray, but we got 53, intact, out.
0:09:03 > 0:09:05A few eggshells in there?
0:09:05 > 0:09:08Um, no, pretty eggshell-free as well, I think you'll find, Lucy.
0:09:08 > 0:09:11Now you need to build an industrial-scale blender.
0:09:11 > 0:09:16The silky smoothness of your custard will all depend on how well it works.
0:09:16 > 0:09:19So, please take your eggs and get back to work.
0:09:25 > 0:09:30While Lucy and Mike attempt to guarantee their custard has no lumps,
0:09:30 > 0:09:33I'm about to reveal a surprise ingredient
0:09:33 > 0:09:36sprinkled on the top of some frozen pizza.
0:09:36 > 0:09:39One of these cheeses is a fake cheese.
0:09:39 > 0:09:41Grab that little flag there
0:09:41 > 0:09:44and put it into the cheese that you think is fake.
0:09:45 > 0:09:48- That isn't actually the fake cheese. - Oh, OK.
0:09:48 > 0:09:50You reckon that's a fake? OK.
0:09:50 > 0:09:52You reckon that's a fake?
0:09:52 > 0:09:54Neither of those are fake cheeses.
0:09:54 > 0:09:57- That one there?- Oh, no, that feels quite real, actually.
0:09:57 > 0:09:59THEY LAUGH
0:09:59 > 0:10:02- I'm going to go with that one. - Hey! Very well done. That is it.
0:10:02 > 0:10:05Would you find fake cheese in a cheese sandwich,
0:10:05 > 0:10:07on a cracker or on a pizza?
0:10:07 > 0:10:10- Pizza.- You reckon pizza? - Cracker.- Cracker?
0:10:10 > 0:10:12Mum's got it right! Ah, no!
0:10:12 > 0:10:15I was hoping you'd get this one. Mums are always right!
0:10:17 > 0:10:21This is fake cheese.
0:10:21 > 0:10:24Fake cheese is an artificial cheesy substance.
0:10:24 > 0:10:27It's much quicker and cheaper to make than real cheese.
0:10:27 > 0:10:30It looks like cheese, feels like cheese...
0:10:32 > 0:10:37..but there's absolutely no flavour at all - it's really weird.
0:10:37 > 0:10:40You may wonder why you've never spotted "fake cheese"
0:10:40 > 0:10:43written on frozen pizza packaging.
0:10:43 > 0:10:46That's because pizza makers call it "cheese analogue" -
0:10:46 > 0:10:50to put it another way, like cheese, but not cheese.
0:10:50 > 0:10:53So to find out what's in this cheap and cheerful cheesy cousin
0:10:53 > 0:10:58and how it can hide on some frozen pizza, I'm going to make my own.
0:10:58 > 0:11:02So what are the ingredients for fake cheese?
0:11:02 > 0:11:08This is pure milk protein powder. And it's completely fat free.
0:11:08 > 0:11:12It's the first vital ingredient for making fake cheese.
0:11:12 > 0:11:16Full of milk protein but no milk fat,
0:11:16 > 0:11:19whole full-fat milk is used to make real cheese.
0:11:19 > 0:11:22It's expensive, so the cream is reserved for premium foods
0:11:22 > 0:11:24like cream cakes.
0:11:24 > 0:11:29So to make fake cheese, they use fat from vegetables instead.
0:11:29 > 0:11:34And here's the second crucial ingredient - solid vegetable fat.
0:11:34 > 0:11:37Weight for weight, it's about half the price of solid milk fat -
0:11:37 > 0:11:39otherwise known as butter.
0:11:39 > 0:11:43Just the job. Now I'm ready to start faking it.
0:11:44 > 0:11:48Now I've got my two main ingredients - vegetable fat and milk protein -
0:11:48 > 0:11:54I need a contraption to cook up this cost-cutting commodity.
0:11:54 > 0:11:58Perfect! Apart from that bit!
0:11:58 > 0:12:00I'm using kettle elements to heat the tub
0:12:00 > 0:12:02which I'm going to fill with water.
0:12:04 > 0:12:09That'll do it - it's my cheese vat. Or at least it's my fake cheese vat.
0:12:16 > 0:12:20My cheese counterfeit job begins by melting down the vegetable fat.
0:12:28 > 0:12:29Now for the milk protein powder.
0:12:31 > 0:12:35The milk protein powder and vegetable fat are both cheap ingredients.
0:12:35 > 0:12:37But now something even cheaper -
0:12:37 > 0:12:39water.
0:12:39 > 0:12:43And adding something called an emulsifier
0:12:43 > 0:12:47will help mix all these ingredients into a smooth, cheesy goo.
0:12:49 > 0:12:52Something is beginning to happen here.
0:12:52 > 0:12:53At the sides of the pan,
0:12:53 > 0:12:58it's starting to turn a little bit whiter and go a little bit gluey.
0:12:58 > 0:13:02Ah! Look at that!
0:13:02 > 0:13:06It's like alien matter. Whoo!
0:13:15 > 0:13:17It all looks so wrong.
0:13:17 > 0:13:21Once it's set, it's time for a cheese-tastic tasting.
0:13:23 > 0:13:26Mm!
0:13:26 > 0:13:29I've got to taste this, haven't I?
0:13:31 > 0:13:36Mm. It doesn't taste of anything. It's like rubbery polystyrene.
0:13:37 > 0:13:40It's got everything good about cheese except for the cheesiness.
0:13:40 > 0:13:44But that's fine, because this stuff is never really eaten on its own.
0:13:52 > 0:13:59Some ready-made frozen pizzas use this stuff as a "cheese extender".
0:13:59 > 0:14:03The fake fromage adds some extra chewy texture to the topping.
0:14:03 > 0:14:06There's a helping of real cheese for flavour
0:14:06 > 0:14:11and to act as cheese camouflage. But how good is my forged formaggio?
0:14:17 > 0:14:22It's cheesy - maybe it's mild - it's a little bit bland,
0:14:22 > 0:14:25but all the other ingredients give the taste as well.
0:14:25 > 0:14:29Yeah, it's weird but that's a normal pizza.
0:14:31 > 0:14:36My very own ready-made fake-cheese pizza.
0:14:36 > 0:14:39But only our taste testers can decide whether mine
0:14:39 > 0:14:42is as good as the shop-bought stuff.
0:14:42 > 0:14:44OK, it's pizza time!
0:14:44 > 0:14:48So any guesses as to what topping I made out of that pizza?
0:14:48 > 0:14:50- Could it be the tomato? - Not the tomato.- The cheese?
0:14:50 > 0:14:55It's the cheese - top man! Now what does this cheese taste like to you?
0:14:55 > 0:14:57- It tastes like normal cheese. - It tastes nice and making it fake
0:14:57 > 0:15:00doesn't make it taste any different.
0:15:00 > 0:15:03Guys, can you sense that there's any fake cheese on there?
0:15:03 > 0:15:06No, not really. It just tastes like normal dairy cheese.
0:15:06 > 0:15:09I think that's a success for me, then!
0:15:15 > 0:15:19Back in the barn, One Show experts Lucy and Mike
0:15:19 > 0:15:24are attempting their version of supermarket ready-made custard.
0:15:24 > 0:15:28We want custard with no lumps, so now they've cracked their eggs,
0:15:28 > 0:15:32they've got to mix all their ingredients very carefully.
0:15:32 > 0:15:34Those ingredients are cream...
0:15:34 > 0:15:36- There we go. - In it goes, in it goes.
0:15:36 > 0:15:42..sugar, corn flour to thicken, and vanilla for flavour.
0:15:42 > 0:15:46You won't find any lumps in ready-made custard.
0:15:46 > 0:15:49That's because at the factory they use a special process
0:15:49 > 0:15:54to blast all the ingredients. It's called "homogenising".
0:15:54 > 0:15:58That's the process Lucy and Mike will need their machines to copy.
0:15:58 > 0:16:03Lucy and Tod have cannibalised a colander to blast their custard mix.
0:16:03 > 0:16:08- Have a look at that. - OK. It's working! It's happening!
0:16:08 > 0:16:12Now Mike and Marty need an ingenious idea
0:16:12 > 0:16:14to keep their custard lump free.
0:16:14 > 0:16:17We've just got to make it all nice and smooth and we'll use two,
0:16:17 > 0:16:22- not one, but two of these beasts. - Is it like a vacuum cleaner or something?
0:16:22 > 0:16:24No, what it is, is this is for emptying your swimming pool.
0:16:24 > 0:16:27- This goes in there. The whole thing.- Really?
0:16:27 > 0:16:31Yeah, we put the whole thing. Ploop. And it'll suck it in here -
0:16:31 > 0:16:34spinning plate inside, which will make it all smooth.
0:16:34 > 0:16:36Let's get pumping and beating, then.
0:16:36 > 0:16:39- OK. Start your production lines. - Right, are you ready?
0:16:39 > 0:16:42- I don't know!- Right, here goes.
0:16:42 > 0:16:45Lucy and Tod's spinning colander contraption
0:16:45 > 0:16:49uses centrifugal force to suck the custard through tiny holes
0:16:49 > 0:16:51and smash up all the lumps.
0:16:51 > 0:16:54Look at that - it's a proper custard fountain!
0:16:54 > 0:16:56- It's beautiful.- That's stunning.
0:16:56 > 0:17:01Custard tastes silky-smooth when the globules of milk fat are deliciously small and slippery,
0:17:01 > 0:17:06but if the milk fat clumps into lumps, it's 'orrible.
0:17:06 > 0:17:09Lucy and Mike have come up with two wildly different approaches
0:17:09 > 0:17:11to making sure their custard is lump free.
0:17:11 > 0:17:14I've no idea which one will work best.
0:17:14 > 0:17:16Three, two, one, go.
0:17:16 > 0:17:18Homogenising doesn't remove the lumps,
0:17:18 > 0:17:22but it makes them really small by blasting them to smithereens,
0:17:22 > 0:17:25spreading them evenly through the whole mix.
0:17:25 > 0:17:28- Oh, look at that! - Yes. We have custard.
0:17:28 > 0:17:32It does look like we're in a dairy. So should that one be going at the same time to bring it back?
0:17:32 > 0:17:35Well, we'll wait until it's all in and then we'll flip it back.
0:17:35 > 0:17:38- There we go, that's all through. - It's like a game of custard tennis.
0:17:38 > 0:17:41Yes, it's coming through!
0:17:41 > 0:17:44Custard tennis? I quite like the sound of that.
0:17:44 > 0:17:48So, whose process will produce the smoothest result?
0:17:48 > 0:17:50Will Mike's pumps leave him swimming in lumps?
0:17:50 > 0:17:55Has Lucy's colander contraption saved a custard catastrophe?
0:17:55 > 0:17:57It's time for quality control.
0:17:57 > 0:18:01- Stop production, please, and bring me your custard mix.- Heavy!
0:18:01 > 0:18:06That's the biggest bucket I've ever seen in my life!
0:18:06 > 0:18:08With the smallest amount of custard - there's hardly anything in there.
0:18:08 > 0:18:13- Back off. OK, that is a lot of custard.- That's too much.
0:18:13 > 0:18:15Let's see if there's any lumps in the mix.
0:18:15 > 0:18:18- Delve deeply.- Yeah, all right.
0:18:18 > 0:18:22Let's see how much of this is foam and how much is lumps.
0:18:22 > 0:18:24- That's a lump-free zone. - I think you're right.
0:18:24 > 0:18:28I think that's lump free. I think you've done very well.
0:18:28 > 0:18:31- OK, Lucy. Let's see.- I don't think there's any lumps in there.
0:18:33 > 0:18:36Foamy again, a little bit foamy, but lump free.
0:18:36 > 0:18:39So the next stage is all about temperature control.
0:18:39 > 0:18:42And if you get this wrong, your custard won't be fit to sell in the supermarket.
0:18:42 > 0:18:47- I had no idea it was this complicated.- Oh, yeah. OK, back to work.
0:18:47 > 0:18:48HE STRAINS
0:18:54 > 0:18:58Lucy and Mike's custard still isn't cooked,
0:18:58 > 0:19:01so while they get to work, a Food Factory first -
0:19:01 > 0:19:04I'm going to discover the secret to a ready-made food
0:19:04 > 0:19:07I bet you've never eaten.
0:19:07 > 0:19:09Would you ever eat dog food?
0:19:09 > 0:19:12- No. - THEY LAUGH
0:19:12 > 0:19:13No, never even consider it.
0:19:13 > 0:19:17Did you know that dog food has to be fit for human consumption, by law?
0:19:17 > 0:19:20Well, I'd have to be very hungry to eat it.
0:19:21 > 0:19:24- Would you be prepared to have a little try of it yourself? - Yeah, go on, then.
0:19:26 > 0:19:29It's a bit like a digestive biscuit.
0:19:34 > 0:19:37Every good food factory needs a discerning panel of taste testers.
0:19:39 > 0:19:40This factory is no different,
0:19:40 > 0:19:44but the taste testers here don't use a show of hands.
0:19:44 > 0:19:48Oh, no - they have their own special way of letting the boss know
0:19:48 > 0:19:50what they think of the food.
0:19:54 > 0:19:57So, Stefan, what do you think, on a scale of one to five?
0:19:57 > 0:20:01On a scale of one to five that's horrible. It's a poo!
0:20:01 > 0:20:04This doggy doo-doo diagram tells the bosses
0:20:04 > 0:20:07just how healthy the dog's diet is.
0:20:07 > 0:20:11It's between three and four. It's formed, it's well formed...
0:20:11 > 0:20:13It might look like a number two,
0:20:13 > 0:20:16but this poo rates an excellent number four.
0:20:16 > 0:20:20And that's this taste tester's special way of telling
0:20:20 > 0:20:24Chris Fletcher from Crown Pet Foods his recipe is just right.
0:20:24 > 0:20:27But surely all this poo analysis is unnecessary -
0:20:27 > 0:20:31we all know dogs are served up really disgusting meat.
0:20:31 > 0:20:34So we're just going to take a sample of one of the ingredients
0:20:34 > 0:20:38that goes into the dog food. I'm really not looking forward to this,
0:20:38 > 0:20:41because it could be utterly, utterly gruesome.
0:20:44 > 0:20:47- WOMAN SCREAMS - Eh?
0:20:47 > 0:20:49- It's a pile of rice!- It is.
0:20:49 > 0:20:53I was expecting a massive load of carcasses of dead animals!
0:20:53 > 0:20:58We all know dogs love to eat meat, so why have I only seen rice?
0:20:58 > 0:21:01Wherever they're hiding it, it can't be prime cuts -
0:21:01 > 0:21:04after all, this is a dog food factory.
0:21:05 > 0:21:07Oh, my...
0:21:07 > 0:21:09Is it horsemeat?
0:21:09 > 0:21:11Or is it dried blood or something?
0:21:11 > 0:21:13Try a smell.
0:21:15 > 0:21:18- That's bizarre.- It certainly doesn't smell like meat, does it?
0:21:18 > 0:21:21It doesn't smell meaty. It's kind of fragrant.
0:21:21 > 0:21:23- Is that carrot? - It certainly is carrot.
0:21:23 > 0:21:26Come on - show me the meat.
0:21:26 > 0:21:30There must be some off-cuts hidden around here somewhere.
0:21:30 > 0:21:33- What on earth is that? - This is pure turkey
0:21:33 > 0:21:36and all the meat that goes into pet foods has to be from animals
0:21:36 > 0:21:39which have been fit for human consumption.
0:21:39 > 0:21:41So it's from the animals that you're getting your meat.
0:21:43 > 0:21:47All the ingredients are ground up together then cooked
0:21:47 > 0:21:49and shaped into dried pellets.
0:21:49 > 0:21:52Now it's almost ready for the taste testers.
0:21:52 > 0:21:55Are you going to have a taste of it now?
0:22:00 > 0:22:02It's a bit like bran flakes.
0:22:02 > 0:22:05So these pellets contain so much more than meat.
0:22:05 > 0:22:08In fact, they contain all the nutrition a dog needs.
0:22:08 > 0:22:11It can eat them for every meal, every single day of its life
0:22:11 > 0:22:14and want for nothing else. They seem to like it,
0:22:14 > 0:22:19and I can't think of any ready-made foods that will do the same for us.
0:22:26 > 0:22:30Back in the barn, One Show experts Lucy Siegle
0:22:30 > 0:22:34and Mike Dilger are making two rival tubs of ready-made custard.
0:22:34 > 0:22:37They've cracked and separated their eggs,
0:22:37 > 0:22:42and blasted their mix at high pressure to remove all the lumps.
0:22:42 > 0:22:43Here it comes.
0:22:43 > 0:22:46But now they need to cook and cool the custard
0:22:46 > 0:22:47ready for the supermarket.
0:22:47 > 0:22:50This stage is critical for food safety.
0:22:51 > 0:22:54We all love custard, don't we?
0:22:54 > 0:22:57Well, so do bacteria, and if we leave food out in the open
0:22:57 > 0:22:59the bugs quickly multiply.
0:22:59 > 0:23:00Take a look at this.
0:23:00 > 0:23:04This one's been enjoying the sunshine for a few days.
0:23:04 > 0:23:08Bacteria multiply quickly in warm conditions.
0:23:08 > 0:23:09Oh-ho-ho!
0:23:09 > 0:23:13That's why ready-cooked food factories have to be very careful
0:23:13 > 0:23:15about temperature control.
0:23:15 > 0:23:17Urgh, it stinks.
0:23:18 > 0:23:22There's probably loads of bugs in there and if you eat it,
0:23:22 > 0:23:24it could well make you sick.
0:23:25 > 0:23:29The factory can't destroy all the bacteria,
0:23:29 > 0:23:32but they can reduce them to a very low safe level
0:23:32 > 0:23:37by using heat to kill them, and cold to stop them multiplying again.
0:23:37 > 0:23:42Mike and Lucy's custard mix, which contains milk and raw eggs,
0:23:42 > 0:23:45must be gently cooked to reduce the bacteria to a safe level.
0:23:45 > 0:23:48OK, Mike, so how are you going to cook your custard?
0:23:48 > 0:23:50We're going to use two methods,
0:23:50 > 0:23:54the little gas stove down here and this is a wallpaper stripper
0:23:54 > 0:23:58which Marty's done a special Heath Robinson-esque adaption here.
0:23:58 > 0:24:01This is a copper tubing with lots of tiny holes.
0:24:01 > 0:24:03We're going to cook this up like a kettle.
0:24:03 > 0:24:05Steam will come out of there, heat it internally.
0:24:05 > 0:24:08Just one thing - what about chilling it later?
0:24:08 > 0:24:10Come over here, sir. Liquid nitrogen.
0:24:10 > 0:24:13I've got some very special gloves.
0:24:14 > 0:24:17Look at that. I can't wait to play with that.
0:24:17 > 0:24:22This process of precise heating and cooling is called pasteurising.
0:24:22 > 0:24:24Lucy and Tod have lined up a hot tub and an ice bath.
0:24:24 > 0:24:27Not that high-tech.
0:24:27 > 0:24:31OK, Lucy, what's your plan to make this custard safe to eat?
0:24:31 > 0:24:36OK, so I'm going to ladle the custard into our contraption here.
0:24:36 > 0:24:42The contraption is going into here and then we're going to rapidly cool
0:24:42 > 0:24:47in this fabulous heat exchange situation, that I like to call it.
0:24:47 > 0:24:50OK, please start your production lines.
0:24:50 > 0:24:53Pasteurising won't kill all the bacteria,
0:24:53 > 0:24:57but it will knock enough out to make it safe to eat.
0:24:57 > 0:25:00Only superheating would kill them all
0:25:00 > 0:25:02but that would ruin the flavour.
0:25:02 > 0:25:0381.7 - that's perfect.
0:25:03 > 0:25:06Heat, heat...
0:25:06 > 0:25:08Lucy's desperate to impress with her custard prowess,
0:25:08 > 0:25:12but she's spotted a tiny problem.
0:25:12 > 0:25:16- Oh, what are they?- It's lumpy. - It's lumpy!- How did that happen?
0:25:16 > 0:25:18I don't know.
0:25:18 > 0:25:20It doesn't look that lumpy,
0:25:20 > 0:25:24but now it must be supercooled fast to stop any bacteria multiplying.
0:25:24 > 0:25:28Mike and Marty are using super-chilly liquid nitrogen
0:25:28 > 0:25:32at minus 195 Centigrade to cool their custard.
0:25:32 > 0:25:35- In it goes.- Whoa, look at that!
0:25:36 > 0:25:39Lucy and Tod are pumping theirs through a bucket of ice.
0:25:41 > 0:25:42Argh!
0:25:42 > 0:25:46It's one custard calamity after another for Lucy and Tod.
0:25:46 > 0:25:49Now they're suffering an embarrassing spillage.
0:25:49 > 0:25:52So 50% is on the floor or your trousers?
0:25:52 > 0:25:54- Yeah. It's not a look I was going for.- No, no.
0:25:56 > 0:26:00- I feel I'm making a witch's potion here.- Ow, this is hot.
0:26:00 > 0:26:03Stop laughing or crying or whatever you're doing.
0:26:03 > 0:26:05- Go, go, go. - Pull yourself together, Tod!
0:26:06 > 0:26:10Mike, Lucy, please package up your products and bring them over here.
0:26:10 > 0:26:12It's quality control time.
0:26:19 > 0:26:22I'm really looking forward to this one.
0:26:22 > 0:26:24Here we go. Oh, my word.
0:26:24 > 0:26:26What I'm going to do is pour some into a bowl
0:26:26 > 0:26:28and see what it's like as it comes out.
0:26:28 > 0:26:31- It's a little bit warm. - We think people like it like that.
0:26:31 > 0:26:34- OK, OK.- Consistency wise?
0:26:34 > 0:26:38Whoa! She pours well. I like that.
0:26:38 > 0:26:41- She's a good pourer.- Let's have a little look at this one.
0:26:42 > 0:26:45That is a lot thicker.
0:26:45 > 0:26:48OK, let's have a little try of Mike's custard.
0:26:50 > 0:26:54Ooh. Tastes very eggy. Not particularly vanilla-like.
0:26:54 > 0:26:59It's got a nice consistency. I think you've pulled something off there.
0:26:59 > 0:27:00Lucy. So...
0:27:04 > 0:27:06- It's unbearable. - It's disconcertingly warm.
0:27:06 > 0:27:09In a food factory, you need to get this chilled really quickly
0:27:09 > 0:27:13to stop bacterial growth. Do you know what? That tastes fantastic.
0:27:13 > 0:27:15But it's not my decision.
0:27:15 > 0:27:18It's time to serve this to our taste testers.
0:27:18 > 0:27:20APPLAUSE
0:27:23 > 0:27:26May I ask you what you think of that?
0:27:26 > 0:27:29- I think it tastes like melted ice cream.- Really nice.- Oh, good, good.
0:27:29 > 0:27:31I think it's got a lovely, delicate vanilla favour.
0:27:31 > 0:27:35- It's a good custard.- That's music to my ears.- What do you think?
0:27:35 > 0:27:37Oh, the texture's good. Really good.
0:27:37 > 0:27:40It tastes subtle, I think the word would be subtle.
0:27:40 > 0:27:43- And it tastes nice. - Thank you so much.
0:27:43 > 0:27:45That's the nicest compliment yet!
0:27:45 > 0:27:48OK, Mike and Lucy, let's have you, please. It's decision time.
0:27:48 > 0:27:51Who thinks that Mike's custard
0:27:51 > 0:27:55is most like the custard you buy in the supermarket?
0:27:55 > 0:27:58Please raise your hands. 10, 11, 12,
0:27:58 > 0:28:0113. 13 votes for Mike's custard.
0:28:01 > 0:28:05So, if you think that Lucy's custard is most like the custard
0:28:05 > 0:28:10you buy in the supermarket, raise your hands, please. OK, 10, 11, 12.
0:28:10 > 0:28:14- Oh! Gutted! Gutted!- Oh, my word.
0:28:14 > 0:28:19- Lucy, I'm afraid your custard needs to go in the bin.- What a waste.
0:28:19 > 0:28:22Mike, you did brilliantly and your custard goes in the basket.
0:28:22 > 0:28:27- Guys, a big round of applause for them.- Thank you very much. Cheers. - APPLAUSE
0:28:29 > 0:28:34Mike's custard was just that little bit smoother than Lucy's so he clinched it,
0:28:34 > 0:28:37and what a fantastic egg-cracking machine that was.
0:28:37 > 0:28:39From ready-made pizzas to dog food,
0:28:39 > 0:28:42they do all the hard work so we don't have to.
0:28:51 > 0:28:54Subtitles by Red Bee Media Ltd