Big Business Season 1 Marathon

from tiny cruise ship galleys and quarantined nba kitchens to deep caves of pink salt and cricket condos this season we took you all around the world to explore the big business of big eats our first story takes place aboard a cruise ship sailing the caribbean every week over 6 600 people vacation aboard the world's largest cruise ship and all those people need to eat three four eight times a day you have to calculate that it's breakfast lunch and dinner plus snacks blues at night plus all 24-hour food all around and that never stops ship kitchens run 24 7 manned by a culinary team of more than a thousand people they dish out over 30 000 meals every single day and they do it all from compact kitchens on a rocking ship so how does all this food make it to the plate we'll start on the loading dock on a saturday this is turnaround day when all new food is delivered to deck 2. this is basically a place that you would not like to be on on turnaround day when we are loading it's busy busy super busy that's jared he orders food for the ship's 23 different restaurants every week jared's got a one million dollar shopping budget all of that is just for seven days of food sometimes jarrett will tweak his orders based on who's coming aboard more kids means more chicken fingers that's how the operation runs so we monitor it on a daily basis what has been used what has not been used and then we adjust our orders accordingly but by and large being in miami having the same number of people it's almost the same every cruise on turnaround day 30 trucks arrive at miami port they're carrying 500 pallets worth of inventory and all that has to be loaded under the ship by 4 pm any delay in our operation can hamper the sail away of the ship which is again a big logistic requirement over 600 thousand pounds of food and drinks are provisioned for just one week of sailing once on board everything is moved along the ship's secret highway this is i-95 and it runs the entire length of the ship on deck 2. we separate all the stores to the different locations that they are supposed to go we have about 20 different store rooms divided into freezers fridges walk-in fridges and rice stores seafood meat vegetables and fruit are all divided and stored in separate fridges if you come towards the end of the cruise this box will be almost empty with a few fruits that are needed for two more days which we keep as backup stock there are also six freezers that's where the 700 pounds of ice cream that will be eaten each week are stored dry goods are stored down on deck 1. full of spices full of chocolate in this store coffee it's nice to be in this store an elevator gets the food downstairs jared's team checks all of the food for quality control every day if produce is ripening faster than expected they try to work it into another meal for example overripe broccoli could go into broccoli cheddar soup instead of being tossed once inventory is stored restaurants on upper decks put in food orders with jarrett chefs will come downstairs pick up their order and cart it away to be cooked that's where this guy comes in any food on board this beautiful shape anything you eat is my responsibility whenever you have beautiful potato fry is my rice smile pate is mine pastry is mine salad shrimp whatever you eat is my responsibility rihos team of 280 chefs run the kitchens 24 7. each chef works 10 to 12-hour dates contracts typically last four months without a single day off some of the people start working for eight o'clock in the morning all the way to two o'clock take a break come back i can find your clothes feeding by 9 30. then another group i start to walk in 10 o'clock deny all the way to 10 o'clock in the morning so we cover day and night productions chefs on board cook up nearly 100 different menus every week all the menus are developed at royal caribbean's miami headquarters and every week chefs stick to the same rotation of menus cooking up everything from racks of lamb to hand rolled sushi the food has to be diverse to match symphony of the sea's international passengers vacationing at all kinds of price points we try to please everybody to make sure everybody find what you're looking for all the cooking happens in 36 kitchens or galleys as they're called on a ship there are 12 specialty restaurants on board costing up to 50 a person and each of those restaurants has its own small galley in those tight quarters chefs crank out the same menu every day at jamie's italian it's fresh pasta at hooked it's over 2 000 oysters shocked per cruise but the largest amount of food is reserved for the main dining room which spans three decks and serves up to 6 000 people a night eating here is included in your ticket before food heads up to the main galleys it starts in one of the prep kitchens off i-95 there's a butcher shop butter good morning these are the gentlemen looking after all the meat cuts the butcher goes through about 15 000 pounds of beef and 9 700 pounds of chicken each week there's also a veggie cutting room and a fish thawing box lobster is the most popular dish in maine dining the ship goes through about 2 100 pounds of lobster tails every week finally the food heads upstairs to the main galley the ship's biggest kitchen is broken down by categories desserts bread cold food and hot food in dessert chefs whip up cakes chocolates and a hundred different types of pastries over in the bread bakery they make 40 different kinds of bread from all over the world all from scratch but the real hustle comes just before the dinner rush 6 000 hungry passengers in the main dining room remember rijo before dinner prep starts he has to approve all the dishes each dish and gives his critiques very very good ionic i only we need to put a little bit more for today you can see how yoga take a note don't forget beautiful thank you so much and thank you so much i look forward to have beautiful night tonight thank you have a beautiful day bye-bye chefs take his notes and get cooking chefs can see a tally of each dish ordered up on screens the system also keeps track of how much inventory is used in the cold room salads and appetizers like carpaccio come together in the hot room chefs dish out soups sauces sides and mains we have the two kinds of chefs just working here on the line which is close to me plating up and chefs on the stove poking so everything we do is batch cooking so basically we grill a steak there we pass it over to the past the person on the process plating it up to the requested temperature that means always that the guests are getting fresh food and from an operational point we don't have any overproduction finally waiters delivered those dishes to hungry passengers out in maine dining between the chefs inventory crew waiters and dishwashers it takes a team of 1085 people to keep this massive operation going together they cook nearly 11 million meals each year and they're doing it all on a moving ship the ship is rocking then all the equipment is built to the ship rocket then in whatever moment maybe they should move somebody don't put one break in one in one trolley and you see the trolley flying away and happen that's why all the cooks always be the attention with that but if crew members are doing their job right passengers won't even know any of it's happening they'll just get back to eating their eighth meal of the day just up the road from the port of miami chefs inside this stadium are waging a different kind of culinary battle this time for the super bowl more than 215 000 people are expected to flock to miami for america's biggest sporting event and all of those fans come with big appetites we do two things here we play and we eat that's diani de la cruz or chef d the executive chef of the super bowl she's in charge of feeding everyone from the fans to the players and performers she runs an army of 3 000 culinary professionals hustling day and night leading up to the big game but they're not just serving up stadium nachos they're also whipping up complex dishes like porchetta and seafood paella and they're doing it all against the clock delivering meals across a stadium the size of well a football field we are living on this amazing adrenaline rush and it's like a bomb just blow in the middle of the kitchen it feels like we all go to work we all fight our own battles and at the end of the run we come back and we tell the stories about how we made it so how do they feed all of football's biggest fans this year miami's hard rock stadium is hosting the big game the stadium and its caterer center plate are no stranger to big events but for super bowl 54 things are taken up a notch we are doubling the building and everything that we're doing so far 50 more staff was brought in just for super bowl sunday including dishwashers line cooks inventory staff and 35 chefs flown in from all over north america but the staff has to think beyond the game there are also press events nfl executive dinners and the fan experience at miami beach convention center which means on top of the 65 000 fans squeezing into the stadium the chefs are responsible for feeding an extra 150 000 people in just one week while it wouldn't share an exact number center plate does expect millions of dollars in sales for the super bowl alone to get it all done the culinary team began planning for this event nearly four years ago but it all comes down to the 24 hours before the super bowl there is a system to the madness i know people don't believe that but it is there is there is something behind it so this is how we work super bowl everything is in order we kind of have a system we have orders we have labels inventory staff receives all incoming produce starting 36 hours before game day it's hustled into storage or divided into kitchen fridges chefs typically do most of the cooking from seven kitchens in the stadium but for super bowl sunday they had to wheel in three extra mobile kitchens and outsource cooking to local vendors in the miami beach convention center main kitchens crank out food for lounges suites and concession stands and in those stands the staff aims to keep the time between ordering your food and getting it in your hand at 45 seconds now these what we're doing is we pre-cook them and we'll finish them in the oven the day of the game i will keep them in the hot boxes at temperature and then we'll serve them kitchens are divided up into cold and hot sections in the cold kitchen they're throwing together dishes like wedge salads and ceviche in hot they're frying up heaps of plantains and chicken wings chefs line up rows of turkey sandwiches labor over vats of lamb curry and dish out gallons and gallons of baked beans for the sweets here they'll be cooking 10 000 hot dogs alone a little bit weary tons of fun i'm a football fan so go 49ers once cooked all the food is rushed down the stadium's secret highway under the stands sorry i walk fast some of you i'm gonna slow down we call this the belly of the beast we are walking through what we call our area when it comes to food and beverage i'm having a coffee macaroon so i can continue going anybody who walks on game day should have between 6 to 11 miles all this is in preparation for the biggest food rush right before kickoff food heads up to one of the 85 concession stands and carts in the concourse while some stands have small grills to finish up cooking most rely on deliveries from downstairs whenever they get close to running out let's just say that it doesn't happen often but if it does then somebody calls the radio and then somebody runs really fast but with the stadium's massive size and thousands of people clogging up the concourse deliveries can be tough it's a big giant that moves on is on sometimes today you might be selling all the flat pipe pizza tomorrow you might be selling all the burgers so it's all about readjusting and making sure that we manage the expectations upstairs are handling smaller tasks but the same amount of food we are in what we call the cold side area for suites out of these two kitchens we fit about 157 suites imagine 157 small restaurants we are in the best kitchen at hard rock stadium who is the second super bowl we got two two pioneers three here they're slicing up cheese and roasting racks on racks of mushrooms imagine what you see here and cook for 600 people for me the team cranks out 400 different menu items on super bowl sunday alone and if one thing breaks well if one of them breaks it's like a dominant effect something is going to fall behind so you can't take anybody's for granted especially in such a large operation like what we have here and in this game the size is the biggest hurdle at a regular restaurant for a regular day you might order just two cases of lobster tails instead of receiving two cases on lobster tail you're receiving three thousand we just smoked about 45 400 almost 5 000 pounds of pork butts right now actually i'm bringing about 9000 cookies which is crazy i just call my vendor and i say you know i need more cookies luckily chef dee can rely on others to help make the magic happen she's hired 40 local vendors to turn out everything from 4 000 popsicles within a week to cake pops cookies and bundt cakes for the sweets working 24 hours a day i have four sheets right now i have to rent extra refrigeration this is the founder of pastries art a family-owned bakery in charge of all the desserts for the super bowl and yes she did get that call for those 9 000 cookies chef d is super funny we plan and get organized and then she said oh by the way mama just so you know i may order a little bit more cookies i'm like okay sure no problem how many more i don't know about 2500 more and i said sure no problem i got it i got it and then when i hang out the phone i'm like oh my god we have 2500 more cookies it's center plates 15th super bowl but it's chef d's first we are all of us bearing ourselves to thousands of fans out there i always tell everybody on game day find a little moment you know and look down into the bowl and find yourself thinking you know pat yourself in the back and say i did that [Music] also in the sunshine state the mba is quarantined bubble chef grant takes us inside her restricted kitchen where she's cooking for basketball's biggest stars i for the first five weeks did not take any days off i was here open sunday to sunday rocking out for our guys that's chef lex one of just 10 chefs invited to cook for players inside the nba bubble a covid free isolation zone on disney world's campus right now i'm getting brunch ready for the heat disney was initially responsible for feeding the 22 teams that made it into the bubble but after negative twitter reviews and complaints from players the nba brought in chefs like lex to live inside the bubble under strict quarantine everything that we have to do has to be at the hotel we cannot leave we cannot wander she and the other chefs whip up about 4 000 meals a week but sheflex is no stranger to star-studded clientele she's cooked for the portland trailblazers oprah winfrey kelly rowland meek mill and competed on food network's chopped we followed chef lex to see what it's really like cooking thousands of meals for players inside the nba bubble let's feed our guys the best food possible for chef lex each day inside the bubble starts at 4 30 a.m i'm just throwing on the same shirt and throwing my hair up and thank god getting on a bus there are technically two zones within the nba bubble the inner bubble houses the players and staff and the outer bubble is where the chefs live and work and they're not allowed to cross between the two zones we have these really really strict rules and if you don't follow them you have to go chef lex lives at the waldorf astoria but cooks inside the executive chef kitchen buses transport her between the two cleared areas rise and shine mr will yes my guy joy chef lex and her assistant joy run comfort kitchen a pop-up southern and caribbean restaurant that lex lunch specifically for the nba bubble all the other chefs who came into the bubble were attached to a team but shefflex came in as an individual chef i get to the kitchen and it's time to rock and roll as soon as i get there hit the ground running teams can browse her menu and place team or a la carte orders through her website but orders aren't guaranteed as teams leave it is also affecting my sales and we are all affected by the elimination but that's the name of the game chef lex receives her team orders the night before so she has a chance to order all the food she needs since she's not allowed to leave the bubble personal shoppers outside do all of her shopping thanks sis all right way to cook see y'all later masked up and with her station very clean 50 000 times today chef lex and joy get to work they start with making the traditional breakfasts right now i'm getting drunk ready for the heat they had an amazing game last night and one so we are doing turkey bacon chicken sausage follow me while i grab my cabbage beautiful it's for my catfish and grits literally the comfort food of the bubble 11 o'clock and we have one hour to get all the food out crazy but we're going to make it happen chef lex thanks for hosting this great team meal here for heat nation it was a perfect way to celebrate our win last night appreciate you it's just chef lex and her assistant joy doing all the cooking for comfort kitchen you bet joy dario is instrumental in keeping comfort kitchen open and running i mean i was able to walk away from certain parts of the cooking because i can micromanage the time together they're making all kinds of comfort food chicken and waffles shrimp chicken wings go get this jalapeno salmon all of the things that i made here are all my own recipes and also like jack i want to say 20 times stronger now than when i got here once everything's cooked it's packaged up for the journey to the inner bubble locked in focus baby almost done baby you are you almost done baby yes baby does it self-inspect order because of coven we have to make sure that we servant wrap the container which is a really important step all bags are then labeled and staple clothes that's one of the most important parts next to sedan wrapping because it's how everybody identifies their food and i'll be keeping this in the hotdogs until it's time to go because chef lex isn't allowed to enter the inner bubble she has to hand off the food to runners for you my dear you got nugget this one is for nba staff then the relay race begins the first runner can only go as far as the security point for the inner bubble there it's picked up by a second runner on the other side that person finally delivers it to the players chef's done it again my food is here this is my boyfriend french toast bacon and eggs appreciation then it's back to the hotel to rest up and get ready to do it all over again working in a situation where i am not able to directly hand off food to my client was really hard and a huge like relinquish of power for me because i like my food to get there and be as beautiful as it was when i sent it out but i have a lot of repeat customers so that means that my runners have been doing a fantastic job this has been probably the hardest work that i have done in quite a few years the most work ever but i swear i'm feasting i'm really proud of myself i feel like such a boss thank you for asking me to do this shout out to the nba in the bubble and all the guys here from buckets of chicken wings to lines of ice cream pints our next stop takes us to an iconic vermont creamery scooped up across 38 countries and up to 75 flavors ben jerry's is no pint-sized operation it's two vermont factories run 24 7 operated by hundreds of flavor makers together they pump out nearly a million pints a day from classic flavors like cherry garcia and half baked to flavors on a mission for criminal justice reform and refugee rights and all those flavors have to be delicious our minimum run size once we get the flavor to the factory is eighty thousand pints so not only do we have to love it but eighty thousand fans i'm just hundred two we visited the saint albans plant in northern vermont to see how these famous pints flip their way to our freezers ben cohen and jerry greenfield started ben and jerry's homemade ice cream in 1978 from a renovated gas station in burlington vermont they launched a brand based on sustainable ice cream making and advocating for causes they believed in and it worked today ben jerry's is the best selling single brand ice cream label in the us to pump out its iconic flavors first it starts with ingredients ben jerry's partners with 250 farms globally to source everything from vanilla bean to milk milk comes from the saint albans cooperative creamery just a mile and a half from the factory once the milk's at the plant it heads to one of these massive 6 000 gallon silos but before it can be made into ice cream everyone involved has to suit up including us gowns hair nets caps and boots to make the ice cream base the milk heads to the blend tank cream milk and lots of sugar are churned together the factory goes through 6 700 gallons of cream every single day every ice cream flavor starts with either a sweet cream base or a chocolate base next the mix master will pour in eggs stabilizers and cocoa powder if it's a chocolate base then it's piped into the pasteurizer you can't see it happening but hot steel plates are heating up the mix to kill any harmful bacteria the newly pasteurized milk is stored in the tank for four to eight hours so the ingredients can really get to know each other after making the two bases they'll head to one of the 20 flavor vats to get a flavor boost we're always coming up with new flavors hundreds of flavors a year and we usually narrow it down to about three or four we really love to bring our social mission values into our naming process for example empowerment to talk about voting rights before ben and jerry's famous chunks can be added the mix has to get to below freezing temperatures it's pumped through this giant freezing barrel and when it gets to the front it's finally ice cream along the way it's quality tested meaning lucky factory floor workers get to taste the ice creams then it goes into the first of two freezer visits when it comes out it's 22 degrees and somewhere between the consistency of a milkshake and soft serve now for the best part the chunks founder ben actually didn't have a great sense of smell which meant he couldn't taste much either so his big thing was texture that's why ben jerry's has some of the biggest chunks in the ice cream industry these chunks end up in flavors like half baked chubby hubby or the one we're making chocolate therapy workers dump in add-ins through the chunk feeder from brownie bites and cookie dough globs to chocolate chunks fruits and nuts they let us give it a try but it's not as easy as it looks then it's finally time to pack those pints workers stack the empty containers into the automatic filler the machine drops the pints into position and perfectly pumps in ice cream it can fill up 270 pints a minute the pints are pushed towards the litter and sealed tight at this point six pints every hour are pulled off the line for quality testing quality assurance personnel first cut pints open they're making sure the ingredients are symmetrical and there aren't any big air bubbles there is a small gap but that's called what we call a functional void if we saw large woods it would be concerning it's actually quite the workout as you can tell they also measure the weight and volume of pints to ensure that the right amount of ice cream makes it into each container so we know the weight of the ice cream and anything below 460 is not passable [Music] now back to the factory line it's now time for the pints to take a second spin in the freezer the ice cream has to get even colder down to minus 10 degrees the pints travel along the spiral hardener a corkscrew-shaped conveyor belt inside a freezer with the windchill it can get up to minus 60 degrees in there after three hours the pints are finally frozen and ready to be packaged they're flipped over and shrink-wrapped into groups of eight together they make a gallon but you'll never actually see a gallon tub of ben and jerry's ice cream because the company never wants its ice cream going bad sitting in the back of your fridge once the pints are packaged they're ready to be shipped across the globe halfway across the world from deep inside this dangerous mountain comes most of the world's supply of pink himalayan salt himalayan salt doesn't actually come from the himalayas it's mined 186 miles away in pakistan thanks to its pink hue and supposed health benefits the salt has exploded in popularity since the late 2000s today it's turned into lamps statues and of course table salt but extracting the coveted salt means descending into dark caves then blasting and carrying heavy rocks sizes blocks we went inside the mine turning this mountain into four hundred thousand tons of pink salt each year the kayode salt mine here in the punjab region of pakistan is the second largest salt mine in the world the pink salt comes from remnants of ancient seabeds that crystallized 600 million years ago legend has it it was actually alexander the great's horse that first discovered these salt rocks when it stopped to take a lick then under british rule salt mining ramped up in the 1870s today it's a popular tourist destination and a working mine producing the majority of the world's pink salt all the mining starts here at the train station this train takes miners deep into the mountain here tunnels stretch for 25 miles and it's always 64 degrees fahrenheit level is miners work these dark chambers they've used many of the same mining tools for over a century pickaxes hand drills and gunpowder subsequently sorry foreign only half of the mountain salt is actually mined the rest is used for structural support so the chambers don't collapse tractors haul the mine salt out of the mountain each day miners excavate over a thousand tons of salt or about the weight of 157 elephants outside they search for blocks with the best shape and coloring to send to manufacturers once picked the blocks are loaded up on trucks either by hand or crane and sent across pakistan historically pakistan couldn't process this raw pink salt so much of it was exported to india cheaply india would treat the salt label it as made in india and sell it at a premium pakistan saw little of the profits npr reported that a ton of salt sold to india for 40 could fetch 300 in europe in 2019 a social media campaign calling for the end of salt exports to india went viral that same year the pakistani government banned all assault exports to india the goal returning the profits to pakistan 23 percent uh rock salty uh manufacturing production pakistan but some pakistani salt exporters suffered they didn't speak english and couldn't meet europe's tough import standards only about a dozen exporters saw an opportunity to sell products under pakistani labels directly to europe muhammad was one of them every month he purchases 300 tons of salt from the mine for his company himalayan decor international event [Music] hamari factory defense eating most of the work is done by hand but drills and saws have sped up the process in three to 5 kg 9 to 12 12 to 15 kg ranges basically blocks are fed into the grinder and broken down into smaller grains workers bag and weigh a thousand of these pouches of pink salt every hour like mohammed's factory rm salt also makes lamps and other specialty products after the raw material we get we convert it with a different shape as per our order like you can see in the cutting machine he is cutting different sizes on this saw water prevents dust from flying up but on the grinders it's not possible which is why muhammad's staff wore masks even before the pandemic over at rm salt as you can see this facility we have installed a vacuum through which we can uh absorb the dust this is the order of usa one of our clients we are making these goods for them the moon shape and the hardship as well double drill give us a washing the lamps are then coated with the gel to prevent humidity from interacting with the salt and then they're shrink wrapped arm salt ships 30 containers of products every month muhammad exports about 80 percent of his products primarily to western countries like the us uk and spain where demand has spiked in the last decade because of the alleged health benefits however it's such a very small percentage of the salt it makes up these minerals you are highly unlikely to get any real benefit or any trace of them in your regular serving of salt itself but nutritionally it's pretty much similar to regular salt it's also pretty similar tasting to sea salt but others claim himalayan salt has healing powers whether inhaled used in spa treatments or in lamp form there's a lot of different homeopathic remedies that can seem very very appealing but actually they're not grounded in evidence and it's these false health claims that have driven the price up himalayan salt can cost up to 20 times the price of normal table salt normally your price starts manufacturing sell but that money doesn't always make it back to the miners they take home less than 1500 rupees a day not much more than the cost of this bag of himalayan sea salt at walmart and those salaries have stayed the same even though pakistan has severed its salty relationship with india and the pink salt is seeing growing demand abroad luckily the mountain won't run out of salt anytime soon it's estimated only about 220 million tons of salt have been excavated here nothing compared to the nearly 6.7 billion tons left [Music] while pink salt may seem expensive these giant tuna have even more impressive price tags this bluefin tuna is 363 pounds it's known as the king of sushi in japan for its color and texture some of the highest quality bluefin are auctioned for millions of dollars at the toyosu market in tokyo at almost 4 million square feet the market is a one-stop shop for fish from all over the world here tuna is sliced packaged and sold to high-end clientele and grocery stores alike but before it's sold experts must first bid on the top tier tuna which can go for millions in 2019 a japanese restaurant chain paid over three million dollars for a 612 pound tuna and at the center of this action are expert tuna scouters like takayuki shinoda he's a naka aroshi or intermediate wholesaler his job is to select the best tuna from around the world for his customers [Music] but the future of takayuki's job is in jeopardy the population of bluefin tuna is down 97 over the last decade which means there will be less of a need for naka oroshi like takayuki for him work starts at 4 30 a.m at toyota market there's no such thing as a normal business day octopus and squid arrive a day earlier fresh fish like horse mackerel and sardines come in before midnight and truckloads of tuna are dropped off every hour without that's almost 13 million and tuna is the market's most popular product each day the fish make their way from the boat decks to the auction floor but it's more than just the type of tuna you find in a can there's big eye tuna ideal for sushi and sashimi yellowfin tuna perfect for grilling at restaurants due to its high fat content but most bitters are here for the bluefin between 3 and 5 a.m wholesale employees lay out tuna one by one bidders like takayuki have about 15 minutes to evaluate dozens of fresh tuna before the auction begins sushi restaurants supermarkets and department stores all depend on nakairoshi like him takayuki looks at the quality and cost of [Music] any sort of nick or flesh wound can lower the price by thousands of dollars when tuna is reeled in it can wriggle and ride causing a chemical reaction in the muscles the movement speeds up decomposition and makes tuna sour soggy and less tasty he is when the bell rings the bidding begins [Music] a range of hand signals known as tayati are used to place bids an index finger for one and two fingers for two but whether that's eleven hundred yen a pound or twelve thousand depends on the type of fish being auctioned in just ten minutes the auction's over and winning bidders claim their prizes the tuna then makes its way from the auction floor to the intermediate wholesale building for filleting toyosu keeps the temperature between 50.9 and 77 degrees fahrenheit to slow decomposition wholesalers also rely on a fleet of small trucks known as tade they zip through winding corridors to minimize how long the fish are exposed to air body to move the heavy tuna onto the cutting table to prepare the tuna for cutting first they wash it then remove the ice a customers care about two things when it comes to raw bluefin tuna color and taste it but [Music] it's then brought inside the shop where it's divided in fillet customers show up early to get the first pick [Music] yeah not a single part of the tuna is wasted even its eyes customers have relied on the market's high quality fish products for decades before the market moved to its new location and was renamed toyotu it was known as the tsukiji market was the epicenter of seafood its success spurred demand for all types of fish fishing for bluefin tuna in the western atlantic rose by over 2 000 in 1970 but it was difficult for the market to keep up with meanwhile japanese tuna consumption was growing significantly [Music] japan has since placed a quota on the number of bluefin tuna caught but it's a double-edged sword for wholesalers like takayuki [Music] our next stop takes us to a waterlogged farm in massachusetts where these cranberries are exploding in demand thanks to a tick-tock video all of these cranberries end up as sauce craisins or in juice bottles like this one made famous by this viral tick tock since it was posted on september 25th the video has been viewed over 70 million times and soon it was copied by celebrities and tick talkers across the globe it was so popular that retailers struggled to keep ocean spray crane raspberry juice on shelves but just as the video took off ocean spray farms across the northeast were heading into their busiest season harvest and holiday prep fall harvest is a wonderful thing but it's our most busy time of the year by far the company has only six weeks to harvest a hundred billion cranberries all of that sudden demand and a pandemic made an already rushed harvest even harder so how did ocean spray do it hey mike hi allison how are you honey awesome how are you well it all starts here in the bog you might recognize it from those commercials hi we're ocean spray cranberry growers and this is our 100 juice starting in the middle of september the gilmore family begins preparing its hundred acres of bogs for the wet harvest normally the bogs look like this come right on dry fields you can walk on this and not damage it the cranberries grow just like this in a layer of sand peat gravel and clay we use water to harvest the cranberries but they don't grow submerged in water some of the cranberry vines here on the bog are almost 90 years old when it's time to harvest allison will flood the bog with about a foot of water once we add the water the cranberries start to float on the vine cranberries have four pockets of air inside to knock the berries off those vines farmers use a cranberry harvesting machine you can fairly easily take them right off the harrow that ben is using he actually built that the berries pop off and float to the top then for the fun part farmers strap on some waders and trudge out into the water the cranberries are all floating to the top and we're standing on top of the vines there isn't anything quite like the experience of standing in a bog but it does feel like i'm being hugged by all the cranberries i do love that as you can see this is a wide open space and we have put in place all the cdc guidelines we are socially distanced by the nature of when we are farming and we've put in masks from inside the bog farmers use what's called a boom to corral all the berries bobbing on the surface one of the things that is surprisingly difficult is pulling the boom it's heavy 100 of ocean sprays cranberries are grown sustainably but not only is wet harvest environmentally friendly it's also efficient allison's family can harvest up to 10 acres a day we are harvesting in all different weather we work every day for six seven weeks whatever it takes eight weeks sometimes the berry pump right over here we can come over here and see and as you can see we're paddling and gently pushing the cranberries into that pump that's right there the paddle helps to control the rate of which the cranberries are going into the pump and the pump gently takes the cranberries up into a truck called the berry washer the fruit is coming up through here it builds up and then as it moves along it goes in here where there's a break and all the fruit gets washed and it goes into the back of the truck those trucks say goodbye to gilmore farm and head out to the receiving station just up the road here trucks coming from massachusetts and rhode island line up by the dozens waiting their turn to unload once in front they back up and get locked into this giant lift hydraulics lift the front end up and all the berries tumble out the back the berries are cleaned again to get rid of the rest of the leaves and vine bits then they're boxed and sent to one of the manufacturing plants one and a half million barrels will be processed here in just over a month it'll take the manufacturing plants a year to go through all those berries over at the plant in middleborough massachusetts berries are turned into the products we see on the shelves we process all the fruit freeze it and then when it's frozen we can slice it to make that optimal sweet dry cranberry that's scott head of engineering here we're gonna go out to our fruit delivery area and see where the fruit comes in and we kick start the process it's gonna be very loud so we'll be wearing ear protection and ppe to continue operating under covet 19 restrictions ocean spray had to implement temperature checks mandatory masks and social distancing in its factories after suiting up we followed scott into the freezer we store 3.1 million pounds in our local freezer which is about two days of production the berries chosen for craisins juice or sauce have to be frozen first once it's frozen it breaks down the cellular structure inside the cranberry and allows the juice to be released and processed after they're frozen the berries are spiked to break them up frozen fruit comes into the process then we slice it we defrost it and then we extract those juice from the berry this is where we're extracting the juice once they've got the juice it's sent here to become a concentrate that concentrate heads to another facility where the water juices and other ingredients are added in to become the now very famous juice about 4 400 cranberries go into a typical bottle of cranberry juice but after the juice gets extracted those leftover berries don't just get thrown away they become the dried cranberries called craisins as the fruit enters the dryer it's a 210 foot dryer that has three stages where we dry the fruit to the customer's specification once there's no liquid left the dried cranberries can get flavorings today we're running strawberry on our production line it smells like strawberry shortcake in the facilities now for the sauce ocean spray's first product introduced back in 1930. this year ocean spray expects americans to buy nearly 60 million cans of the stuff for the holidays the berries get ground up into a puree about 200 berries along with sweeteners go into each can of jellied sauce the process hasn't changed so much some of the equipment we use and some of the training that's required the personnel has but the general concept has not changed in almost 90 years once all the products are finished they're packaged up and this robot does all the boxing this is our finished goods cooler where we store product that's waiting to go out to the customer we have 3 500 pallet spots in here and a total of 5 500 at the site so less than three weeks we turn all the inventory over here in the cooler between all the flavors of craisins juice and sauce ocean spray has more than 250 skus or product types on shelves across the globe 50 of it goes to europe and then the rest goes to our distribution centers here in the united states due to the demand from the viral tick tock and the harvest season ocean sprite says the plants are operating more than normal the south harbor receiving center and the middleborough plant had to hire over 230 seasonal employees while ocean spray has increased production the company says it's too soon to tell how the tick tock actually affected sales i think everybody enjoyed it i think a lot of us attempted at home or had family members that saw it it was really fun it was nice to be able to bring some good vibes to everyone finally we visit a farm in canada that's making big money off an unexpected insect there are about 15 million crickets in this room here they'll live out their lives freely until they're transformed into food the purpose of the condos is to give the crickets somewhere to live and so generally they are resting inside the condos they'll come up have a drink of water have some food and then go back down to rest again it's difficult to perceive how many crickets are actually in a room like this because of course they were all living inside their happy little condos we just take the condo give it a bang and all the crickets come out most of these crickets will be milled into a powder that can be used like flour it's good you can't even taste it yet or you can snack on them whole like chips this one is barbecue flavored though you may be thinking this is a strange choice for food crickets actually contain more protein than beef without any of the environmental damage a lot of manufacturers and entrepreneurs were looking for safer more sustainable protein sources to add to their product and for us it's been quite a boon to our business as a result we went inside canada's entimo farms to see how they turn crickets from bugs to brunch for most of us crickets are just the soundtrack of our summer nights but darren golden and his brothers thought they could be used to create a new source of sustainable and nutritious food just reimagining how we can feed a population of 9 or 10 billion people on an overcrowded planet now they harvest about 50 million crickets a week and they're aiming to triple production within the year the trickiest thing is that there's no real manual in terms of this kind of scale and density there's no manual let's figure it out as you go nobody's ever done free-range cricket farming on this kind of a scale before [Music] it all starts here where the crew covers boards with a mixture of damp soil and peat moss making mud pies and the pregnant females flock to lay their eggs it may look like just dirt and some grains of rice but actually there's probably thousands and thousands of cricket eggs in there and in this room about 15 million eggs the 900 different species darren could choose from he chose the tropical house cricket because of its simple feed requirements it's a cricket that does well in high densities grows really fast and is a super delicious cricket every single part of this cricket is edible plus they have nutrients like fiber iron and calcium after roughly nine days the eggs hatch and they'll hang in the nursery for about two weeks crickets definitely require a nice warm environment being cold-blooded animals their metabolisms controlled by temperatures so if you keep them on the warmer end of their preferred temperature they grow faster and then once they're big enough and ready to handle life in the big grow room then we transfer them from the nursery into the grow room it only takes a crew of five to maintain this colony of millions the crickets here eat a mixture of corn soy and some flax on average the crickets die on almost a thousand pounds of feed a day that's often staggering for people because you think of crickets as such tiny little animals but of course when you got 10 or 15 million of them they consume a fair amount of feed to put it in human terms 15 million crickets is nearly twice the population of new york city but growing all these crickets is still more sustainable than farming pigs poultry or cattle to produce just one kilogram of kami takes a staggering 22 000 liters of water and to produce that same amount of protein from a cricket only a few hundred liters growing crickets also has other advantages so one of the interesting things about insects is that there's very very few diseases that are transferable from insects to humans which is very different from farming mammals or chickens and crickets do not have any known viruses or the species that we produce has no known viruses that can affect them and of course certainly no zoonotic viruses or viruses that can cross species the three entomo barns can produce nine 000 pounds of protein a week enough to fill the daily protein requirements of about 80 000 people by and large most of our customers are either integrating it into a finished good like a dog kibble a dog treat or selling it as cricut powder under a different brand or putting it in something like a superfood smoothie mix baking it into other baked goods and other snacks even their poop is a usable product and as you can see the floor is covered with cricket manure it's called frass and it's a great fertilizer the farm can produce about six thousand pounds of manure per harvest these crickets will live out their full lifespan before they're turned into food so from the time egg hatches to harvest is about six weeks the big difference is that at six weeks a cricket is fully mature it's lived out its life its bred and laid eggs for us and essentially it would be dying within a few days anyway and now it's time to see them turned into food so this is our raw receiving room all of the crickets come in from the farm the insects are rinsed then sorted to make sure there's no debris from the farm in the mix next they're evenly spread onto trays and slipped into ovens to roast so in order to make the powder the moisture has to be below a certain percentage we find that if it's above that percentage it's really difficult to grind it while some are left whole and sent for seasoning and packaging the majority will go into this industrial grinder until they look like coffee it's then manually packed into boxes of 25 pounds each every day they turn 15 000 crickets into 500 pounds of powder the secret sauce is really in the metrics it's in in exactly how your setup is done your ratio of eggs surface area of feed and it's it's kind of like a big giant recipe and everything does have to be perfect for it to function the way that we function but there's still room for improvement right now the process at entimo is mostly manual and that needs to change if they want to ramp up production and so we're looking at more automated solutions which will allow us to actually produce three to four times what we are capable of doing now entomo farms hopes this will also help bring costs down and make their products more affordable qriket flower sells for roughly twelve dollars for every four ounces which is 45 times the price of all-purpose flour but it's not really the price that's holding back some customers perception in north america around insect as food is certainly a challenge and it's one that we are striving to rise up against in asia cricket's already a popular food and darren is confident the appetite for crickets is only going to grow super exciting thing about insect farming is scale up is super fast each cricket lays 600 eggs or so and so in a crisis event if we needed to scale up our production we can do it really really fast

Channel: Insider Business

Views: 1,563,748

Keywords: Business Insider, Business News

Id: pbG3EeYnXQ0

Length: 59min 56sec (3596 seconds)

Published: Sun May 23 2021