Behind The Scenes Of The Most Famous Chocolate | Inside Cadbury: Unwrapped | Documentary Central

[Music] Cadbury is a National Treasure and one of the world's biggest chocolate makers in what's been an extraordinary year cameras have been around unique access inside its secretive Willy Wonka world where real-life Oompa Loompas toil away to feed Britain's insatiable appetite for chocolate the whole point we're here is to make delicious moments of Joy I know that might sound a bit corny but that's what we're here for while some production lines pump out vast quantities of old favorites I love pre-mix we make about 300 million a year others are busy creating brand new flavors strong orange smell [Music] sometimes successfully whoever invented this is a genius but not always [Music] perfect things can go wrong this year the company faces its biggest challenge for a century to dramatically cut sugar from Cadbury dairy milk you've got a brand that people are religious about and that is really really nerve-wracking they're throwing everything they've got at the problem from computers who've learned how to taste when you chew into a product this machine actually tracks what you're perceiving in your mouths to the most finely tuned human taste buds of the land can we have a show of hands though who thought it was more bitter okay that's quite a consensus there when the new version of dairy milk hits the shelves will Cadbury hold on to its place in the heart of a chocolate obsessed Nation you know when I started this project I had dark hair if I if I don't retain my health your nose is now Gray [Music] welcome to bourneville a village four miles Southeast of Birmingham [Applause] the Cadbury chocolate factory has occupied the same site here for 140 years churning out chocolate treats for a loyal British public [Music] it's still Britain's most popular chocolate maker with a dedicated fan base from chocoholics to chocolatiers Cadbury's caramel crunchy 12 cream eggs Little Egg of happiness I do really like a twirl I do like fruit in that oh yes a bit of fruit and a bit of nut in my chocolate and it's just an addiction that I never really grew out of the company's most important recipe has remained unchanged for 114 years the top secret formula for Cadbury's dairy milk but its main ingredients are not so Secret milk and cocoa so you'll have it then marry the creamy milk from Shropshire with the cocoa from Ashanti cream and brown written and Africa [Music] it's still Britain's favorite chocolate people love dairy milk for the Nostalgia of it because they were given it as a child and it was that first or very early Taste of fat and sugar and milk mixed together and once you're once you get fat and sugar mixed together with a little bit of cacao you are hooked this precious confection starts life just as it always has in a building called the chocolate block from here the liquid chocolate runs through the entire Factory like blood through its veins if you look around you have a number of stainless steel point where apocalypse river that you see in Willy Wonka our chocolate rivers are in these quite work so basically walking through it every day it's above your head or it's to this side of it any one time although the recipe for dairy milk hasn't altered not everything has stayed the same at Cadbury nearly 10 years ago the entire company was bought by an American Food Giant the factory has been massively upgraded in a bid to be one of the most efficient chocolate makers in Europe as you can see we get quite a lot of bastard every minute which turns into the tons and tons that you'll see in the shops how many of them in it roughly we roughly get about 400 Bars a minute coming out it's a lot of chocolate foreign [Music] as much as 500 tons can be made in a single day and it all comes to a massive central warehouse near Birmingham piled seven stories high with chocolatey treats [Music] staff here battle Temptation on a daily basis I do like chocolate so there's plenty of chocolate in the canteen there's plenty chocolate in the office and you can eat as much as you want most new people spend a week trying to avoid it and then they go for it and within 10 days I put half a stone on slime bulging food manufacturers like Cadbury face a problem new government guidelines mean they're now Under Pressure to provide reduced sugar products [Music] for Cadbury the challenge is huge the vast majority of its chocolate bars are more than 50 sugar a bar of dairy milk 56 grams of it per 100 is sugar it is a frightening thing it's like if I had to change something radical about my iconic product and I've got a few iconic products if I had to change one massive thing because I was forced to by Society by media and it changed it I'd be frightened if my sales would plummet so much it would be detrimental to my business the man entrusted with solving Cadbury sugar problem is chocolate scientist Adam Harris just hold on to handrails when you're coming up guys in the bourneville Factory's experimental pilot plant he's working on a hush hush project to make a version of dairy milk which is 30 percent less sugar we're now going to put some ingredients in here the top secret [Music] of course you can't look inside the buckets because that's where the secret lies [Music] medal for two years with a sacred recipe and thinks his congenital solution replacing sugar with fiber Sugar's in chocolate for sweetness it also provides like a scaffolding within the chocolate you take that scaffolding away the chocolate falls down you have to replace it with something else and we're replacing that with fiber Adam may have managed to replace the sweetness of sugar it's a mouthful of fiber doesn't sound quite so appetizing the really critical step in the process is about how it feels in the mouth so if you have Beats if you had a spoonful of sugar put that in your mouth you feel the grittiness um versus a spoonful of icing sugar in your mouth which is quite smooth and what we're trying to do is get to that nice smooth texture with reduced sugar chocolate that's even more critical if we don't get this right that when you eat this chocolate it isn't going to melt in the mouth how you'd expect it to melt launch date looming Adam's new recipe is now ready to go into its final testing phase this is a baby right that me and the team have been working on for over two years and um you know with any baby you want to look after it and make sure you take it through and and allow it to grow up in the right and proper way it's currently in the nursery and we're just about to release it to the big school and as any parent knows that's a really like scary thing to be doing hopefully my babies are going to grow up nicely and be loved by everybody in the marketplace if it's not I may have some nights of crying while Adam is busy removing sugar from dairy milk production of one of the sugary treats that Cadbury makes is running at Full Tilt [Music] a million cream eggs roll off the line every day I don't know where they go you mean if you look at the belt just it's just like a waterfall Cascada wings but I'm glad they do keeps me in a jump formation of the legendary Creme Egg is another process normally shrouded in secrecy the yolk is actually part of the cream so it's exactly the same cream but with a bit of coloring basic look so I only put the yolk on one half when the molds close together we get a continuous show Center foreign we make about 300 million a year so I think that I would say it's about six for every person within the country so somebody eats a lot of cream eggs cream eggs are best eaten when they've been in the fridge I hear that oh I've got it all over this I mean I've definitely in a whole box you know when they did the six box definitely in 911 setting a child who puts away one of these in two or three minutes is consuming their entire ration of sugar for the day it's an enormous instant sugar bomb and it's really best not to think about it while the same tiny sugar bomb is being wolfed down around the country in a small town in the Midlands it's undergoing a strange transformation [Music] it was quite manic for a while people were going absolutely mad for us I had a customer coming and I was telling me how nice they were and there was like I was come on trying one so they tried well in about 10 minutes later to come back and there was working in a Ware restaurant in the top 10. basically you were muff it roll it in the flower dip it in the butter and then drop it as gently as you can into the pan about the Snickers but it's like a coverage payment you think it's just completely spoiling it but it doesn't it works better if it's double dipped it just gives it that extra little bit of firmness on the outside when it's done makes it a little bit easier to eat as well without it squishing all over your arms and everything I think that's basically it when it's cooked cream eggs dumbbell I haven't actually tried on myself I just kind of thought they might be a bit too sickly foreign [Music] [Music] [Music] in the bourneville factories pilot plant chocolate scientist Adam Harris has spent over two years struggling to reinvent Cadbury dairy milk by taking out 30 percent of its sugar we're working on something massive that is very very new for the Chocolate World this is by far one of the most difficult things I've ever had to deliver in my career you know you've got a brand that people are religious about you know until people are buying this in the marketplace I'm going to be worrying about it there's just one more ingredient to add to his secret formula this is beautiful cocoa butter a couple of gallons of pure fat while Adam's team cook up a 30 less sugar prototype although Oompa Loompas have been given nearly 5 million pounds to put Cadbury products under the microscope unfeed them into computers [Music] in one lab a researcher samples chocolate and breathes out chalky fumes into a state-of-the-art machine capable of measuring what she's tasting when you chew into a product in your mouth you sense it through your nose this machine actually you know you can breathe into it and it tracks what you're perceiving in your mouth [Music] upstairs is the Department of mouth feel where Dr Chi hey masticates for a living so the average consumer chewing times around 20 seconds Dr Haye has a PHD in the science of chewing thank you most people will fight at the beginning and then changing side using town from side to side and other people put the chocolate in their mouth and let it melt [Music] by seeing how the globules of fat sugar and cocoa arrange themselves on his slide can Dr Haye unlock the secret to the perfect mouth feel that will make Cadbury products irresistible and irresistibility is what Cadbury has been selling us for decades from bribing naughty school children [Music] deductive women enjoying chocolaty mouth feel [Music] to cream eggs being used to resolve a sticky situation [Music] we advertise crew make every year because you need to remind people that it's back it's a product that's only a market from January until Easter every year so it's important that when people are going into the shops they're like oh yeah I remember that I'm gonna pick one up and try it again haven't had one in a while this year the crem egg campaign is a glorified Nationwide Easter egg hunt using white chocolate eggs some with golden tickets worth up to ten thousand pounds it's kind of like the lottery like I don't think that I would ever actually win it I don't go out specifically with the hope of getting the white Cream Egg I mean it's always in back of my mind obviously because oh maybe this time I mean obviously somebody has to but the chance of actually finding it I think is is pretty low pull every brush off actually buying a lottery ticket right so we'll get the chocolate on first for the white Cream Egg Hunt 5 000 eggs will be needed Maggie and parmesheets have been given the task of producing them we can't make them in the factory because the production run will be too small everyone is individually made in this little room this is the fondant the sticky gooey stuff that goes in the middle all right that looks about they're very sweet yeah the filling is mainly sugar [Music] like their milk chocolate twin handmade white eggs are one of the most sugar dense treats Cadbury produce they're also one of the trickiest to make you do the white one okay I'll do the yolk Palms my Sorcerer's Apprentice even though she's worked with chocolate she hasn't actually handmade them [Music] oh we need the hair dryer pump after an hour of meticulous crafting the final touches are added before parmesit can attempt the trickiest part of the process line it up properly marrying the two halves together [Laughter] disaster that's a definite disaster so that's 36 out the window now 36 and gone now yeah [Applause] that's it turn it turn it an hour later I'm there ready to try again yeah get it closer to get quick [Music] that's it only swarm [Music] even when it goes well there are still casualties on the battlefield you're constantly counting eggs just to see how far you are it's like am I near that 5 000 yet well Maggie's careful eye ensures only Flawless eggs will leave her kitchen in the factory the human quality control team has been replaced with the BD red eye of a laser scanner [Music] he is amazing it will never let where are we good [Music] it's just about a tiny little that if I was looking at it I wouldn't have spotted it because they're going too quick so I wouldn't have spotted it but even with the new technology expensive mishaps can still occur [Music] a pile up on the floor at the moment so things can go wrong on this line it's it's not perfect things can go wrong but just gotta clean that's not supposed to happen we'll clean it all up and then we'll empty it all out and we'll start again okay sounds like a plan this is a lot of money going in the bin it's obviously it's fourways so obviously can't go anywhere then the customer so into the red bin and the pigs will be happy [Applause] [Music] though machines can be fallible Cadbury's owners American Food Giant Mondelez have invested heavily in them spending 75 million pounds automating and improving the bourneville site Now it only takes four people to turn out 400 Bars a minute [Music] equipment it's good but we have less people on the plants you know it's back in the day we had more people and nowadays around 2 000 people work at bourneville [Music] in the 1950s there were five times that number to accommodate its Workforce the Cadbury family built bornville Village a kind of chocolate box Utopia with schools shops parks and homes the dentist they had a physiotherapy department they had a doctor they had a nurse they look after you so well I think the magic was everybody that came in was welcomed into the family yes and it sort of Drew you in I think you you failed like this magnetic pull it came from the top that people were important and the people were what made cadburys it became your life cadburys became your life on my shift alone there was 24 people per shift that was not including management that was just us little worker bees actually making the stuff that he turned out now it's you know across the other side of the rumors and other bloke working and if you want to talk to them you've got to get on the phone because he's too far away to talk to Mr mondele or however it is the chief of the whole company would like to walk in press a button and at the end of the day all the chocolates come out but and that's what it's getting to we have had to change the older people have had to change uh it's a change or leave yes we got taken over by the Americans and now they've made their mark on the plants and they want to do it their way [Music] over in the pilot plant the reduced sugar team has managed to produce a new version of dairy milk in liquid form [Music] Adam can he get it to form into solid bars [Music] so in the first one so on here the chocolate hasn't quite flow to the corners and we've got a few air bubbles the team adjusts the temperature then crank up the vibration to try and get the new recipe to spread the shot is not flowing I would like it to flow in the mold which means you've got lots of crystals in there I don't believe it's the chocolate that's causing information but it's a new and different chocolate so you know we're learning by doing foreign from anybody else [Music] Cadbury's constant drive to keep people buying their products has this year taken a new turn a colorful televised ad campaign promoting a competition for the public to come up with flavor combinations for a new chocolate bar Melanie Fuller a primary school teacher from Manchester is one of the finalists I entered the competition back in the summer and when I got an email saying it'd be shortlisted I actually thought oh maybe we're going to get a chocolate bar in the post um and then all of a sudden I've got having a phone call from somebody from Cadbury's and they're saying they're gonna make my chocolate this is a huge thing you know I am going to go to bourneville like Charlie and the Chocolate Factory um and go and have my chocolate bar made we had 220 000 views amazing into the competition and obviously went through a kind of judging process and got a very finalists of what you are one in a few months time the public will vote to decide if Melanie's recipe is the winning flavor it's meant an awful lot because when I entered the competition I was doing it by my mum's bedside my mum was very poorly we were talking about the different flavors the raspberry my mum really wanted the raspberry because that was her favorite fruit and we talked about how there wasn't any other chocolate bars we could think of that she had raspberry in there I love the school it's a small school getting the packaging right will be crucial to the success of the raspberry bar I've been kind of um wanting to get some little hidden details in there that you you know you kind of know about not necessarily everybody would see my mum was her favorite color was purple hence purple butterfly that was the third thing you know it would be great to have some things you know that I can say to people well you know this smile and look can you see that it's good that we can get a bit of her in this hopefully it's gonna come out yes it is a prototype of Melanie's bar has been confected in The Factory Kitchen [Music] it's yeah it's really it's really that you're happy with what I'm very happy yes I'm very very happy to have a winner oh yeah thank you make it really well oh in the pilot plant Adam's having more success molding his bar was it won't be ready to try until it's been through the cooling tunnel [Music] this is a bit like waiting for your baby to be born you know it's going to come out it's just an offshore way it's not so bad they got a nice they've got a nice really nice shine to them on the surface we've got a good snap it's got the aroma that's reminiscence we can be dairy milk so that's that's great you gotta love chocolate try something nice snap it's good that's good it's good now Phil that's all you want someone to say that's good it's good it's not just Adam's colleagues who are enjoying the finished article in the labs of the computerized tasting machine is also rather enjoying his new bar so 30 less and this is the standard dairy milk the profiles are consistent so we've definitely managed to retain the signature flavor that you would expect we think we've got the perfect profile now good free Indulgence but what does guilt-free indulgence look like in London Cadbury's design agency is hard at work creating a wrapper for the sugar light bar the challenge for lead designer ASA cook is how to make less seem like more design is Limitless it's infinite you can do anything and in this case we believe the right thing to do is all of the Indulgence with none of the compromise so you're not getting less you're not getting a diet product I want something with all the Indulgence um but with an additional benefit I'm not taking away I'm giving you more each time Acer creates a Cadbury wrapper he seeks inspiration with a pilgrimage to the purple Palace when you work on a run like this you feel a responsibility to understand the thoughts of the people that have gone before you really and it's figuring out what are those elements in the kind of DNA of the brand that you've got to keep [Music] Keeper of the Cadbury archive is Sarah foden in here we've got some of the very early Camry dairy milk packaging that's actually a recreation then or is this the original from 1913 yeah tracklist to edible no do you want to crack it open no I'm not going to try it that flowing shape has always been there the whole time right in the you know from the scroll originally which kind of denotes quality to something which represents milk um and kind of give standout and then you know the idea of that representing the milk has kind of been embraced but you see it recurring so much through the entire history of the brand so that's why that flowing shape is essential I think foreign [Music] Cadbury have been so confident about Dairy milk's appeal they even run a surreal ad where they didn't mention the bar at all relying instead on a purple background to tell viewers what it is they're selling [Music] but the new on tried reduced sugar version is going to need all the help it can get in London Acer and his team are trying to make the bar feel irresistible to health-conscious chocoholics this is an area where we started to think about inverting the whole pack and it goes into a white bar with a purple mark you can clearly see that it's better for you it feels a bit more kind of Milky if you like which is you know an important element at dairy milk but is it two diets is there something missing does it feel indulgent enough do you show cues of sugar in order to talk about the sugar reduction that's not the right thing to do you're focusing too much on the bit that you're taking out after three months work and hundreds of versions the new bar is looking as appealing as they can make it we've refined the shape of the curve to be more sympathetic to the dairy milk curve the teal color that we came to in the end connects to something slightly more natural which works for what this product is I'm going to be upset [Music] uh yeah [Music] oh one rapper that's definitely not revealing what's inside is the one wrapped around the 5 000 cream eggs that Maggie and Parmesan have finally made they're transported 150 miles to an undercover operative whose job it is to hide them as you would expect it's the same weight and size as a regular egg and then inside there will be a congratulations you have found a winning white egg and in this case this person has won a hundred pounds okay team cheers what a lovely day to be dropping eggs like a cross between Willy Wonka and the Easter Bunny Jeremy Stern travels Incognito up and down the country depositing prize eggs in supermarkets and Corner shops [Music] the practice has been dubbed reverse shoplifting thank you well we've done thousands and we've never been caught because of their main worry is people stealing somebody putting an extra 65 PS worth of chocolate on their shelves uh can't rank highly in their in in their priorities let's do it yeah in London the country invents a new chocolate bar is reaching its Climax and Melanie's campaign to win the public vote is in full swing the winning bar will become a permanent fixture on shop shelves [Music] that's that is so cool I really like that I really like that picture you see I've not seen one this big and so close because I've had so many pictures from friends going I've seen you on a bus stop I've seen you out in town and uh but look [Music] that's so cool do you know I sometimes I do go in supermarkets and accidentally go past the chocolate I almost say and just go and see how they're doing really quite exciting when I did the competition I actually did it with my mum when she was in hospital and she was a butterfly person she was purple and so we bought these and said in the eulogy I said you know be like Bob be positive be happy and so I told cadburys about the butterfly and obviously I'll wear them all the time and a couple of weeks after I'd been to bourneville I got a phone call from somebody at Cadbury's and they said you know we we listen to you and and what they've done is they've put a little tiny butterfly on the back there and it's hidden it's behind the city behind the fold so it's secret and it's there for my mum and and I can't you know every time I see that it just makes me feel really really happy um it's very very special meanwhile on an industrial estate in the outskirts of reading a showdown is about to take place it's time for Adam to offer up his bar to a panel of expert tasters the comparison they're making today is um Cadbury dairy milk against the new 30 less Capri dairy milk Cadbury's iconic bar has been the nation's favorite for 114 years Ken Adam's new version really match up a disaster would be you know if we saw massive differences um away from Calvary dairy milk the tasting panel are a hand-picked group of ordinary people with extraordinary taste buds [Music] right welcome ladies um so your first sample is one three one [Music] their verdict will decide if Adam's prototype will ever see the fluorescent light of a supermarket Shelf foreign 's reduced sugar dairy milk prototype is being blind tested against the original panel don't know which one is which so what do we think of that sample what were the most outstanding attributes did you find sweet for me it was very milky anything else small smooth so the texture of an icing sugar in the mouth and you're on the agreement with that it's a language that we'd expect to hear for that product so we'll see if we hear the same sort of things for the next product what do you think of these sample ladies I thought the texture was different yeah yeah in what way Michelle I thought it's more adhesive okay a little bit just stuck to your palette yeah right okay [Music] so can we have a show of hands so who thought it was more beef so okay that's quite a consensus there so would you say that this second sample differed quite a lot um thank you ladies I think that one that went well um I guess as I expected to go so we saw some differences between the two products which you know we'd expected to see you know you see a slight difference in sweetness a slight difference in in texture and that's what happens when you take away some of the sugar so these are the things I didn't hear anything that I didn't expect to hear which is which is always a good story to have I think and which one did they try first James I think it's quite quite exciting I really want the consumer is to find that out when they when they try it you know um so I'm going to leave that hanging with you hello welcome to the typical lovely spiritual the white Cream Egg campaign has started to produce lucky winners fantastic um so when was it that you purchased you've eaten it all good stuff was it was it delicious so I just got back home from school um from a long bike ride Against the Wind I collapsed on my um chair Toby comes in and brings me two cream eggs why did you do that because he's a very nice brother yeah and he got me those two cream eggs and so I opened one it was an ordinary um chocolate yeah I ate it and then I opened the next and I go Mom Dad a white Cream Egg and then there's a thing around her mum was like there's something around it we unravel it and there's this and we read out loud and under the front in big words says you have one 50 pounds on the show of both of my brothers because I just want to be a nice brother just as he was a nice brother to me thanks to Cadbury winners like Fred will be 50 pounds better off the lucky few will be ten thousand pounds better off but the biggest winner of all has been Cadbury themselves where do you want everybody it's been a record-breaking year [Music] the white egg campaign has achieved more sales this year than any other since cream eggs were first produced over 50 years ago so really good results I think we absolutely smashed and I'm really glad you said that but yeah guys [Applause] while sprinting's gobbling down more high sugar cream eggs than ever before a Cadbury HQ the new 30 less sugar wrapper has won the approval of the marketing team whenever I Look to buy a tree it's got a look tasty and it's got to look nice and if it doesn't look any of those things then you wouldn't buy into it I would say this is probably the biggest piece of innovation that we've ever had in cabra's history because you don't change the recipe because it is so important but the requirements today some consumers are looking to really cut down their sugar levels so it's important for us to be able to offer a choice to them after extensive testing with expert tasting panels the new reduced Sugar Bar is finally ready for launch there's 90 odd pallets in the warehouse today depending on how well the launch goes I'm expecting it to be flooding in and flooding back out again ubar is Bound for supermarkets up and down the country [Music] is over there is it very excited first time the seat on the Shelf Adam and his team are going to see how their offspring is doing now it's out in the real world yes beautiful try the place that's amazing [Music] look at that it's wicked you know it looks great yeah it does doesn't it you feel a bit of relief slightly emotional are you gonna cry now no I'm not gonna I'm not gonna cry but it's not that emotional and is it 30 less calories as well as 30 less sugar that's the reason that there isn't that there's a small calorie reduction sort of a slimming bar no this is this isn't about um this is about giving our consumers Choice um to allow them to have less sugar in their their diet if they say cheese well Adam and his team are a glow with parental Pride very satisfied what do chocolate super fans make of the new bar it smells exactly the same [Music] similar texture um it's not disgusting and it's got a sugar in it so it's better for me what I know is less sugar if you happen to tell me possibly not [Music] oh it is better but I would say this it is yeah you could make money you can make money to Cabbage yeah so the sugar inside the chocolate is reduced what about the calories no so the calories a little bit is only just a little bit so how does that make sense well you would assume it means it's more healthier but if it contains the same amount of calories but less sugar I don't get it I don't get it [Music] look it's like that's so cool [Music] thank you [Music] [Applause] [Music] [Applause] foreign

Channel: Documentary Central

Views: 1,976,385

Keywords: Doco, Documentaries, Documentary, Episode, Movie, Movies, Online, Series, TV, chocolate factory, how to make chocolate, cadbury factory, cocoa powder, cadbury chocolate, cadbury chocolate factory, cadbury world, easy recipe, kitchen secrets, business insider, series to watch, insider, food insider, food wars, cadbury, chocolate, dessert, candy, sweets, indian cuisine, english cuisine, food, comparison, cultural food, eating, eats, chocolate factory song, dairy milk, Christmas Chocolate, easter

Id: 75apltxdrCE

Length: 46min 36sec (2796 seconds)

Published: Sun Sep 10 2023