How 23 Foods Get To The Grocery Store | Big Business | Insider Business

from giant Farms keeping bananas from going extinct to the factory turning out your Ben and Jerry's ice cream flavors to one of the few dairies that's certified to make creamy Gorgonzola cheese in Italy to the farm producing Beluga caviar that can cost nearly six thousand dollars we traveled the world to see how all these Foods we love buying from the grocery store actually make it there [Music] our first stop is Magdalena Colombia where we learn how farmers are protecting the world's favorite banana from a lethal fungus you probably know the Cavendish banana you can find this type of banana in every supermarket around the world they're so popular because they're yummy they look nice and they ripen as they transport it's high yielding so it's got a lot of thick skin and so it travels well and tastes pretty good comes in its own package but there's a problem they are sterile they don't have seeds No Seeds means Cavendish bananas are clones of each other so the only way to propagate them is in vitro or by taking new growths called suckers from the base of an older plant but since they're all genetic copies Cavendish are really vulnerable to disease the domino effect if you have everything wrong with just one clone one disease can kill everything plant by plant that's exactly what's happening with TR4 one of the deadliest plant diseases out there the fungus doesn't spread to humans but it does eventually kill the banana plant so no more fruit grows scientists guess the fungus probably started somewhere in Southeast Asia in the 90s and quickly spread across the globe then in 2019 it hit Latin America combined with the Caribbean that area grows 75 percent of the world's bananas is to make sure the fungus doesn't spread Farms across Colombia have implemented biosecurity measures evanorte 2 was one of the first farms in the country to detect TR4 workers wash down and disinfect the underside of any car that comes in just in case there's infected soil hiding in the treads foreign thank you Antonio's team built cement pass throughout the farm so on their way to harvest workers are walking on open soil once they've reached the area ready to be harvested workers walk through a sanitizing foot bath made of ammonium um out in the field workers measure the banana fingers to make sure they're ready to harvest they're usually ready about 12 to 13 weeks after the fruit stem shows up one worker cuts down a 65 pound bundle while the other catches it and carries it to the cable way that cableway system brings all those banana bunches to the packaging plant first workers sanitize the bunches with Quarry [Applause] then they check the bananas for quality and any signs of fusarium damage foreign they cut off and throw bushels into a huge tank that bath not only preserves the bananas but washes off any of the latex that naturally occurs on the peel the bananas get cut into smaller Bunches of five to seven foreign next Come Those famous stickers workers wrap the banana carefully so they don't bruise that wrapping has holes in it so the bananas can ripen as they travel no more than four hours after the bananas are harvested those boxes end up on pallets loaded onto trucks the bananas are trucked to the nearby Port where they're moved onto ships this shipment's headed to the U.S 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 six thousand seven hundred 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 always coming up with new flavors hundreds of flavors a year and 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 and 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 Pines 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 what we call 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 -10 degrees the pints travel along the spiral hardener a corkscrew-shaped conveyor belt inside a freezer with the wind chill 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 penicillin Roquefort the fungus is added to milk at the very beginning of the production process in a big cauldron together with enzymes rennet and yeast thank you [Music] in about 20 minutes milk becomes curd it can be transferred into molds [Music] each wheel is marked with the various identification number you can see number 60 here that's Casey featuring vernity we visited here between 450 and 500 Gorgonzola wheels are made every day to help the curds settle wheels are turned four times and then left to rest overnight then they are salted a couple of times [Music] at this stage they weigh about 18 kilos that's 40 pounds but this number will drop to 12 kilos 26 pounds at the end of the aging process a excess way is released the sultan rooms are warm and humid this is also to favor the activity of yeasts inside the cheese mild Gorgonzola Wheels stay for three days and hargo gonzola for five then they are moved again into a cold room where they are punctured a hundred times on each side [Music] this is to allow oxygen into the cheese for it to grow its signature blue veins foreign with a machine but some other emails cheeses are still punctured by hand after this step the cheese is left to age [Music] it's two months for the blue creamy gorgonzola [Music] and three months for the green pungent one [Music] surgeons take from 8 to 20 years to produce their eggs depending on their species at the top of the chain is Beluga which takes 20 years to mature when ready the belly of the fish is sliced open and the Egg Sac is removed [Music] [Music] after extraction eggs are wrapped over a metal grate foreign [Music] to remove any impurities flavors differ from fish to fish eggs from each sturgeon are packed individually [Music] the eggs are then salted following the Malo soil recipe which means there is a less than three percent salt content [Music] [Music] thank you then the eggs are packaged and will be mature and ready to be eaten in a few months depending on which sturgeon breed they come from and on customers preferences [Music] foreign sardines in olive oil sardines and tomato sauce spiced sardines in olive oil and sardines in spiced tomato sauce we follow the making of of sardines in tomato sauce and the spiced sardines in olive oil these are the fresh sardines that have arrived this morning from a matuzinus harbor and the canning process will take place in one day so everything is going to be finished by 5 PM this afternoon all the sardines are going to be thins now it's time to go and see how sardines actually canned here at pinati after the sardines arrive at the factory they are placed on a marble table and the head and the bubble of the fish are cut off by hand [Music] thank you [Music] then they're brined for about half an hour the sardines are placed on grids that are Handmade by Senor albino in his workshop at the factory [Music] then the sardines are rinsed to remove salt and steamed [Music] this is foreign all the ingredients are cut during the day and added by hand one by one each kind of spiced sardines has one pitch of black pepper carrot Laurel piri piri clove and cucumber Senora Emilia is in charge of the tomato sauce and she keeps her recipe Secret the Fisher kind in team play tins then washed and sterilized these are the only two machines at the factory [Music] these two ladies are in charge of quality control they do that by listening carefully to the sound of each thin this is the sound of a good tin and this is a bad one tins are stored for at least three to six months whenever a customer submits an order the cans have roughed by hand which by the way is not an easy job as I had the chance to wrap account myself one there first on the bottom so much space [Music] here at Brew doctor in Portland Oregon the kombucha starts with three main ingredients water tea and sugar it's the same three ingredients that have made up the drink since its likely Creation in China thousands of years ago in Japan it was made with seaweed hence its name kombu cha these days Brewers start the tea with Botanicals like rose mint and lavender it's fun with these Botanicals to think about the giant Fields they come from a single batch of Kombucha needs about 85 pounds of tea to get it going that'll make 66 000 bottles in here what we do is we bring in hot water then they add sugar so essentially what we're doing here is making a big pot of sweet tea that will then get fermented into kombucha steeping takes around 40 minutes then it's pumped through this waterfall filter in all the organic material comes out and so we partner with our local municipalities to compost to ready the vat for the next batch of tea this guy crawls in to clean it out and that already brewed sweet tea heads to tanks in the fermentation room where the tea first starts to produce alcohol at half a million gallons total all the liquid in here would almost fill an Olympic-sized swimming pool the room is kept at a steamy 82 degrees Fahrenheit and it smells kind of sour that seems to be where our kombucha fermentation is happiest so we add the sweet tea into the tank where there's already a scoby a scoby is a symbiotic culture of bacteria and yeast essentially it's a living organism that kick-starts the fermentation process as the kombucha is fermenting the scoby forms and layers eventually you'll just have layer upon layer upon layer upon layer it's this guy's job to pop CO2 bubbles that form at the top of the tank the scoby's bacteria eats Up the sugar and creates carbon dioxide which makes kombucha bubbly and alcohol as long as it has sugar to feed on a scoby can grow to Epic Proportions if this tank were as wide as a swimming pool it would create a scoby the width of a swimming pool this batch has been fermenting for just over three weeks at this point Brew doctors kombucha has about three percent alcohol by volume compare that to a light beer which sits at 4.2 ABV dude it's so good with alcohol in it like no pictures every fermented food from yogurt to kimchi has Trace Amounts of alcohol you can't feed yeast sugar and not create ethanol that's natural Brew doctor pays annually for a distillery license but because Brew doctor sells its kombucha as a soft drink the team has to remove most of the natural alcohol bringing it from three percent to under the legal limit of 0.5 percent they use this machine common in the wine industry this column is heated slowly at low temperatures cones spin inside to spread out the liquid a cool Vapor evaporates carrying the small alcohol molecules with it it's a very elegant mechanical way of taking ethanol out of a liquid without affecting the nature of the liquid that fancy machine costs Matt a million dollars but now we're responsibly selling a non-alcoholic product to our consumers testing is also required by law but it's another complicated and expensive step in the process this alcohol test testing machine can cost up to forty thousand dollars each bottle gets a label warning of the Trace Amounts of alcohol at this point the alcohol is well under the 0.5 percent limit next it's packed and shipped 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 hero 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've 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 through here it builds up and then as it moves along it goes in here where there's a break and all the proof 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 Middleboro 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 and dry cranberry that's got 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 covid-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 [Music] 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 berries 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 food to the customer's specifications 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 of 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 core 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 core between all the flavors of Craisins juice and sauce Ocean Spray has more than 250 skus or product Types on shelves across the globe percent of it goes to Europe and then the rest goes to our distribution centers here in the United States first they have to find the key to this whole operation salty brine water underground they dig 30 feet into the mud to get to it digging Wells can take up to a week the families then set up these government subsidized solar panels they'll power the pumps that bring brine water to the surface foreign s build the salt pans these expansive Salt Flats the roller helps them flatten out the Earth they'll make 10 to 20 pans all by hand it's back-breaking work now working in the desert is not a joke everyone in the family pitches in to help then the farmers will release the salty brine water from the wells it flows between the pans by the last Pan the water reaches the 24 salinity needed to form big salt crystals the farmers are so skilled that they know it's the perfect salinity simply by tasting the water oh yeah minimum 300 400 salt over the next few months as the water evaporates salt crystals form foreign this rake costs 22. too expensive for many of the farmers we have to rake the salt crystals every day for the first three months they start raking early each morning to avoid the hottest part of the day foreign but working here can be really dangerous the life expectancy of a farmer is about 60 years because not only do they face extreme temperatures they are dealing with subsoil brain which is highly acidic and you also have an exposure to that subsoil brine also comes with a lot of problems in in skin foreign s become blind from years of the bright Sun reflecting off the white landscape and because they're so far from the nearest Village accessing Medical Care is often too expensive [Music] unit [Music] and uh foreign [Music] despite these conditions the agarias live and work out here until spring when the salt is finally ready they harvest three times the first produces the best quality salt they leave in April usually with over a thousand tons of salt and they'll sell it to a Trader like Rafiq rahimbaija his team picks up the Harvest with trucks once it arrives from Iran [Music] um employs 200 workers at his Factory in tikar processing and packaging salt he says he loses about 20 of the salt during the washing and draining process foreign it gets packaged and sold as edible powder salt and as crystal salt to be made into soap detergent and baking soda this whole process refines the salt and makes it more valuable so Rafiq can sell his product for upwards of 60 times what the farmers make now the process of making peeps takes just six minutes from start to finish four basic ingredients sugar corn syrup gelatin and Air they all combine to make the marshmallow base but making that marshmallow isn't easy cooking and setting it takes hours it's very important because peeps have to be a specific density when they're deposited onto the belt to make sure that the marshmallow is stable the six minutes begin when the marshmallows hit the production belt for the chicks those are just deposited for our 2D shapes it's basically like a cookie cutter there's already a thin layer of colored sugar on the Belt duskboard makes 19 colors of sugar but yellow is our most popular color for chicks and bunnies followed by Pink and then blue the sugar is colored in these giant drums the peeps move on a conveyor belt they go into an enclosed area that's covered so that when the sugar blows around it's contained it's very quick any sugar that doesn't stick it's recycled for the next batch on the Belt and peeps aren't exactly known for their nutritional value each chick has 6.8 grams of carbs and six of those come from sugar then it's on to the most important part peeps become peeps when they get their decorations so when they're chicks and they get their eyes added when they're bunnies and they get their nose added that's when I would say they officially become peeps the decorations are made with edible wax then squirted onto the peeps with Precision we have an entire QA team that checks everything frequently throughout the entire production process we also have Associates who checked for decoration and making sure that their eyes are in the right spot we manufacture peeps all year long we produce the most peeps for Easter season but because they're on shelves starting really in January we are producing them in the summer and fall but there's a reason Easter is the Brand's time to shine Acme smoked fish is a fourth generation family-owned Smoked Fish Company based in Brooklyn you've probably seen Acme products in well-known markets like Whole Foods and zabars but what you might not know is that they also sell anonymously to some of the most famous bagel shops and specialty stores in the city meaning if you've ever ordered lox on your bagel in NYC there's a decent chance it came from Acme you realize how New York City would not exist for smoked fish if it wasn't for this place the hundred-year-old business produces about 15 million pounds of smoked fish products every year to see how acne makes its legendary products I met up with Adam caslow the company's fourth generation co-ceo that's so gross Adam joined the business in 2006 along with his cousins and sister my great grandfather became a smoke fish wagon jobber in 1906 and was just competing for that American Dream his dream was to one day open up his own Smokehouse and he did that at the very end of his career today we're in the fourth generation of Acme and so the four of us are keeping the family Legacy alive and well over the years Acme has significantly expanded its inventory with products like Whitefish salad and poke bowls but there's one thing that really put them on the map they're classic smoked Nova salmon the salmon is expertly trimmed and scraped so that it can fully absorb the salt during the brining stage it will brine for about seven days before ultimately undergoing Acme's signature smoking process the origins of the smoking fish are really around preserving food for a later date so in Europe people in the 1600s would would salt their fish to keep it for extended periods of time now the origins of smoked fish are a little bit Up For Debate as some people say that as the fish were hanging out to to dry the smoke from the campfire gave it this added flavor but it's unconfirmed it's a really nice story we don't know if it's true but it's a good story it's a good story the salt gives it about a 30 day shelf life and the smoke really adds that flavor [Music] so this oven is has been the original smoker that we've had at Acme since its existence back in the day they would just light fires on the floor of the SmokeHouse that sounds very safe it was not safe but the the principles of smoking really haven't changed we're gonna turn these fans on they're gonna blow air throughout the oven dry out the the fish and after about three to four hours we'll turn on the smoker and fill this room with wood Burn smoke after smoking most products are packaged and shipped out to stores across the country welcome to Otis tofu I get here at 2 30 in the morning Monday through Saturday make tofu and start the day the night before workers pull out giant bags of soybeans sourced from Iowa and they're dried soybeans so they're very hard you could hardly break it with a hammer and we soak them the night before then they become really soft it takes 10 hours of soaking depending on the temperature of the outside we tend to soak them longer if it's colder or shorter if it's hotter we want that pure white in the soybeans yeah these are still pretty good Cooks transferred the soft soybeans to one of two grinders we grind the soybeans make a really a slush and we put it into our cookers which cook to about a hundred degrees Celsius then the mixture flows through a giant pipe into a filtering bag in the pressing machine this machine squeezes out the soy milk the milk comes out the other end and drops into another filter so we double filter it to get as pure of soy milk as we can okay this is hot what's left is a byproduct called okada basically the leftover bits from the beans like the shells so this nylon that catches the rest of the okada people use it in like baking recipes and stuff like that but also we give it to Farmers to feed their cows and pigs some of the soy milk gets bottled by hand it's sold across Portland but the rest gets turned into tofu our tofu is made out of three ingredients soybeans water and wagulant the mixture first gets a splash of coagulant so we use our nigari traditional Japanese coagulant we can adjust the amount of coagulant that we use to make the firmness that we want I will actually make a firm so I'm going to add some more coagulant because it could be separated from the curds in the water a little bit more it's kind of like making cheese right like in cheese the coagulant separates the Whey or liquid from the proteins which Clump up into curds that takes about 15 minutes so this is what it looks like after it's curded so these curds are actually nice and like fluffy and soft that scrambled egg looking mixture is spooned into molds Jason hand shapes it using a cheesecloth now we just got to press them into the firmness that we worn it's pretty soft almost like a water bed we make medium firm and extra firm it's depending on how much water we squeeze out the curds on the firm and the extra firm Are finer and harder so it's easier to get water out the medium's nice and soft a hydraulic press then helps squeeze out the water after it's pressed Jason carefully flips the tofu into a giant bath he slices it along the lines from the molds tofu headed to restaurants is placed in buckets some of it gets fried into what's called Hage so he is a master at Chopsticks yeah that is not easy to do with the flimsy tofu blocks Bound for stores get fished from the water and put in boxes some soaked soybeans the final product probably about an hour everything else is really controlled by hand before that coffee gets poured into someone's cup it gets harvested from a coffee plant like this one harvesting is a labor-intensive process with a countdown once the coffee cherries ripen we have to do something with it immediately it only lasts 24 hours when coffee cherries ripen they are hand-picked and loaded into 100 pound bags the majority of Lou's coffee cherries go into What's called the washed process where they are converted into parchment basically entails going through a flotation tank from there it's going to get sucked up into the pulper that's where we remove the skin in the pulp from there it goes into a demusler once it goes through the denuclear we have removed all that slimy pectin layer goes into another flotation tank and then it's going to be transported over to the drying deck when it comes out of that process comes out of the wet Mill it's 46 moisture you got to dry that down to 9 to 12 percent after drying in the open overnight the parchment is loaded into a mechanical dryer for 24 hours then we can move it into our warehouse Lou estimates that he has approximately ninety thousand pounds of coffee parchment in his Warehouse waiting for the final steps we store it until we need to Mill it into green bean when Lou is ready to convert the parchment into green bean it heads to the dry Mill that dry Milling process does several things so first it's going to Hull it it's going to polish it then it goes into a classifier which pulls out all the different sizes from there the green bean heads to the gravity table beans that are too light because they are over ripe under ripe or damaged by pests float to the top and are discarded the rest of the top grade product continues onto the optical sorter which removes any remaining impurities coffee is one of those products that any little defect is going to throw off your cup this is what will eventually get roasted and become what we know as coffee in a normal season Kahu coffee mill will produce close to 160 thousand pounds of green bean which gets sold to coffee shops and Roasters throughout the state and internationally flower blooms for just one day a year [Music] Raza fin Salama works alone and can pollinate up to 500 orchids a day it takes about nine months for a pod to grow the price of this vanilla bean has skyrocketed in recent years due to Rising demand and the destruction of crops by Cyclones in 2018 vanilla hit a high of nearly 600 dollars per kilo more than the value of silver it's since dropped to 250 a kilo but that's still a lot and those prices are really attractive to thieves foreign [Music] so many farmers in the region are arming themselves patrolling their fields at night when thieves usually strike thieves stole 20 kilograms of farmer Berlin ronorees Harvest leaving his vines bare [Music] um foreign in 2018 officials estimated 10 of the year's Harvest was lost to theft [Music] Auto he often sleeps out here overnight foreign and because farmers only get one vanilla Harvest annually [Music] some of the thieves are actually children driven to steal because of poverty they were held in overcrowded and unhygienic prisons in the northeast of the country for years without trial [Music] Farmers have started branding their vanilla beans with identifying codes making the crops easier to track if they do get stolen another protective measure some Farmers pick their beans before they're completely ripe to beat thieves to harvest and so the quality goes down a lot this year Raza fin Salama was able to wait until his beans were completely mature Farmers have to move quickly because the pods start fermenting immediately once they're picked they pack the vanilla pods in 40 pound bags ah and haul the loads for Miles along dirt roads to the market [Music] foreign [Applause] middlemen called comicionea bought these beans in their raw Green State and they held a lot of negotiating power over the farmers since the beans spoiled quickly the middlemen are definitely making a lot more money they can kind of tell people whatever price they want so some years farmers walk away happy in other years they can barely make ends meet I have heard Farmers say things like you have to have courage to plant vanilla because it may not be worth it at the end you may not get anything nowadays Raza finsalama sells his pods directly to a Cooperative called sahana Representatives check the bean quality and the brand on the bean and pay the farmers directly in cash cutting out the middleman and promising a consistent price today rosafin Salama earns about 17 for a kilo of raw green vanilla foreign takes the beans to one of its processing facilities employing thousands of workers across Madagascar but even these large operations still have to protect against thieves the facility has electric fences surveillance cameras and private security patrolling at night [Music] but it'll still be another three months of painstaking work before the vanilla is export ready [Music] first work ER have to sort the beans by quality and size next they wash each Bean to remove any impurities foreign s get dunked in hot water to release the compound vanillin that's what creates the distinct vanilla flavor is [Music] the beans need less than a minute depending on how ripe they are [Music] [Music] [Music] my English they have to run the bean baskets so they don't lose the heat from cooking workers move the cooked beans to boxes or they'll sit for 48 hours when they take the beans out they'll be Brown [Music] [Music] [Music] there the beans will stay for 15 to 30 days depending on the moisture inside come on [Music] the name is [Music] in the packaging room they massage the beans to release the oils and the vanilla fragrance careful not to damage the beans they group The pods in bunches then they check that there are no stray metals like nails hidden inside [Music] workers then weigh the boxes [Music] package them for shipping the electricity vanilla beans end up with american-based food processor Archer Daniels Midland ers Larry's a fifth generation farmer in Fort Meade Florida we've been growing citrus in my family since the 1850s when I first started in the industry Citrus occupied over 900 000 acres in the State of Florida in fact some years we had too much fruit and market prices were depressed just 15 years ago his family packed a million orange cartons a year mostly Valencia oranges the big sweet juicy kind he planted a Grove expecting that to last for multiple Generations the first case of citrus Greening was reported in China back in 1918. it quickly spread across the continent devastating Citrus Groves in India and Saudi Arabia as well no one knows exactly how the Asian citrus psyllid made it to Florida but in 1998 it showed up on an orange jasmine plant in a backyard in Palm Beach County and it quickly spread throughout the state on Infected root stocks but it would take another seven years before Florida's orange trees showed signs of Greening it spreads throughout the state before you even know it's present and in 2005 Larry found his first infected tree it was a real Challenge and an eye-opening for us we knew what a thread it could beat our operation and we were fearful there were more infected trees that just had not been detected at first Larry tried removing all the sick trees but the insect moved faster soon infecting too many to control when a solid munches on a citrus tree it leaves behind the bacteria that causes Greening here in the vascular tissue the bacteria replicates and blocks this important Highway for moving nutrients underground the root system's thin and die out above ground you notice the yellow pattern the dark green spots if you can see me that means this bearing oranges for a few years the fruit essentially never ripens you see it's small in size it remains green and when I cut this fruit you see a nod shape you can still eat the fruit it's just not as sweet the orange juice from this fruit has lower sugar content or bricks than normal fruit but there's nothing wrong with the juice it's awful and 40 of those oranges fall off the tree sooner than usual the bacteria is actually starving and kills the tree over time today researchers estimate 90 of all orange trees in the state have the bacteria no longer do you see citrus trees abundant in the landscape Larry has kept his trees alive in producing for 15 years using a combination of Horticultural techniques developed by scientists at the University of Florida some of our work that is going on right now is finding ways to keep those trees that do have the disease still producing fruit that are usable you guys want to see what some salads look like all right so they're very small oh there's an escapee actually they're small they kind of jump around a little bit so we use this thing called a an aspirator or the more fun term we use with children is Pooter we just suck them up it's basically a little vacuum in my hand here Lauren diepenbrock can study the solids movement to learn what might keep them off a citrus tree using the aspirator is actually a really efficient way to collect psyllids she's figured out a few things that detract solids first this pink clay it's sprayed on the trees to hide the leaves from the insect which uses light wavelengths to see one study showed the clay was more effective than insecticides the second thing Lauren is researching is these eight foot wide sheets of plastic called reflective mulch the idea is that it should make it where the solid can't find the host plant it could be that it blinds them or causes a visual deterrent does it work uh someone we do get psyllids we do get them but we do get them at a reduced rate a few years ago Farmers discovered that putting plastic bags around baby trees could help them grow stronger before infection Lauren's now studying how effective these individual protective covers or ipcs actually can be so this is IPC mesh and as you can see there's little holes in it you can see my hand very clearly wind Sun rain it all gets through here the goal is to really keep that Asian citrus psyllid off the tree and then if you look underneath this is our irrigation the baby trees will grow in the ipcs for two years so you can see the trees aren't perfect we're still going to have some stuff on them we do have some pest issues in here but you know they look really good compared to what's in the open field and this will actually give our trees a Fighting Chance once they're out in the environment and they could potentially get infected with sea Lass scientist tripty vashish thinks the key is in the soil we have been learning that the trees need these nutrients to fight infection the citrus trees because of this disease have very small roots or fewer Roots so they are not very efficient in picking up the nutrients it's like a job of 10 people needs to be done by one person same with the roots she figured out that giving smaller doses of fertilizer and water more frequently helps the sick Roots absorb nutrients better and it's similar like us at six small meals each day rather than three big meals are better same as with the fertilizer and irrigation smaller doses are better than big doses Larry uses fertilizer custom designed for his trees he's also planting more young ones one of our strategies for dealing with Greening is to plant The Groves at higher densities we're planting 300 trees per acre compared to 140 to 150 trees per acre before we were dealing with the disease so if he knows all the trees will get infected with more planted hopefully some Will Survive Growers have also tried releasing Predator wasps and spraying insecticides while there's no Silver Bullet in combination these short-term Solutions have sort of worked you can slow down the decline we've been battling Citrus Greening for 15 years and while the industry is not thriving we're definitely surviving but the problem is all these approaches acre onto production costs for Growers our revenues are down by more than half on an individual growth basis Growers are losing money and many couldn't swallow the losses by early 2022 half of Florida's orange growers had left the industry so while he waits for a long-term solution Larry's taking the hit so he can keep harvesting the same way his family always has workers quickly pick the oranges and drop them into bags once they've got a good batch Pickers dump them into baskets in the Grove workers then truck the oranges to the packing facility just down the road we have eight digital cameras that takes a picture of each piece of fruit as it travels through the packing line we use an electronic sorter to divide the crop by color if they're orange enough the fruit gets cleaned and hit with a layer of natural wax it preserves the fruit extends its shelf life today because of hlb Larry packs half as many boxes as he did 17 years ago if the oranges are a bit too green Larry knows they'll be hard to sell on the Fresh side so he sends them to get Juiced at the Florida's natural plant in Lake Wales Larry owns the juicing plant along with other local Growers as part of the company's Cooperative about 90 percent of the fruit grown in the steak goes to orange juice but just like Growers the factory has been getting fewer oranges so less efficiency in the plant with a lower fruit volume the factory had to shut down one of its three processing lines nowadays sixty thousand boxes of oranges arrive at the plant from Cooperative Farms across central Florida that's about thirty thousand fewer than before hlb within 24 hours of harvesting the we juice the fruit this machine squeezes the juice out of every orange we pull out any seeds and we also collect the pulp where we can add that back to whatever degree will want to do that the juice gets pasteurized and then pumped into cartons but remember greeting affects Orange's natural sugar content so Florida's natural has to blend infected oranges with sweeter ones from different regions or even Seasons it still tastes like orange juice it's just not quite as sweet today the factory pumps out about a third less than pre-greening they need a home for their fruit where they can get maximum value that hopefully can sustain their operations until a solution to Greening is found many scientists believe the long-term solution lies with re-engineering nature either genetically changing the bug itself or naturally breeding citrus trees ultimately a tree that's resistant or tolerant to the disease will be key that's the project Fred gemitter and his team are working on at the University of Florida they're trying to breed for an hlb resistant orange variety meaning even if the disease shows up the tree won't get sick to do that he takes two different types of trees maybe one with yummy oranges and one that's resistant and essentially has the mate and their kid will hopefully still taste good but won't get hlb that's really the Holy Grail of of citrus screening research but that's not easy finding a resistant orange is like looking for a genetic needle in a haystack it's extremely difficult to breed new oranges we know of some kinds of trees related to oranges that are resistant and we're trying to access the genetics of those resistant types by making crosses Fred says it could take more than a decade so it's long term there's always an element of serendipity in this but armed with that miracle-resistant tree they could be better prepared to tackle future diseases it's a global interconnected world we live in people and plant diseases move about pretty freely and so there will be another problem another disease come along I believe science will continue to deliver new tools that will make growing citrus easier over time I look forward to those days I'm sure we'll have other challenges that we'll face in time but today Citrus screening is here to stay this is John vigliata he began his career on the water when he was 13 years old I started putting oysters in cages in 1995. this Aquaculture farm sprawls over 884 Acres the size of over 147 Roman coliseums it includes a hatchery nursery and part of Virginia's mobjack bay farming an oyster begins in the Hatchery here biologist Chris Smith puts 3 000 adult oysters into a shallow tank called a spawning table then he artificially creates the conditions that cause oysters to spawn we're controlling the temperature in the tank specifically it's the all-you-can-eat buffet getting them ready to spawn when the oysters spawn they release their eggs and sperm directly into the water the eggs and sperm are put into tanks where they turn into oyster larvae 1 billion oyster babies are produced in these tanks every year they remain there for about three weeks feeding on algae and growing shells we grow about seven different species of algae to create a menu for our oysters and clams it's amazing to see the algae kind of Bloom and then to watch the oysters and clams grow in our facility it's very gratifying when the oysters get to be about a quarter inch long they are placed outside in upweller tanks and it's a system which allows a large quantity of water to be flown past the oysters giving them a super abundant amount of food after about two months of feeding staff check on the size of the oysters we'll take these oysters here that are larger and they'll go in a cage to go overboard and then these oysters here will go back into the system for further grow out to where they can get to be this size and eventually go in a cage the cage is full of oysters are then tossed into the mobjack bay we have about 2500 to 3 000 cages contained in all the cages that we have out in the mob Jack Bay you probably have somewhere around 30 million oysters that is a lot of oysters if all of them were harvested at once and put into your freezer you could eat over 800 oysters every day for 100 years and you would still have leftovers nicely done Farmers monitor the weather closely excessive rainfall can dilute the salt in the water which could kill the oysters and water temperature is also a factor oysters grow best between 60 degrees Fahrenheit and 80 degrees if you go above that it just gets so hot that they will stop growing or slow down significantly if it goes below that they go dormant if all goes well after six months the cages are removed from the water and the oysters are brought to a separator this machine sorts them by size if they are not big enough to sell they go back in the water oysters can take around one to two years to go from Hatchery to Market after separation Market sized oysters are washed tagged with order information and boxed once the oysters come out of the bay the clock starts ticking the team has to harvest the oysters transport them to the shop add ice package them and place them in the cooler within two hours to meet FDA guidelines the boxes are put into a refrigerated truck and shipped to Distributors across the U.S who pay around 40 cents per oyster in Virginia wild caught oysters actually sell for Less around 30 cents we probably sell our Market oysters to 10 or 15 different states in the country but our oysters end up everywhere and occasionally for local orders John delivers himself and then you have the tag here all right thank you very much okay customers say that they're fresh they're delicious since 1996 they've gone from farming 100 000 oysters per year to 3.5 million in 2019. besides selling oysters to eat the company also sells around 70 million baby oysters each year to Farmers up and down the East Coast aquaculture is one of the fastest growing food production sectors in the world while the amount of seafood caught in the wild has not increased by much since the 1980s demand is up nearly 150 percent aquaculture is filling the gap [Music] it is predicted that by 2030 60 of the fish available for human consumption will come from aquaculture Virginia has made a big bet and doubled down on farming oysters today the state is the largest oyster producer on the East Coast but the pandemic has hurt business like no natural disaster that we've ever had oysters market value and restaurant orders plummeted so we're getting hit both with reduced orders and a reduced price for the product that we do so and on top of that after a stellar 2019 John stocked the bay hoping for an abundant future we have a record amount of product in the water and our sales are off almost 50 percent while 2020 was a roller coaster ride for Ward Oyster Company sales have finally started to pick up John is optimistic about the future no matter what happens he plans to be on the water I love being out on the water my office is on the water you can't get it much better than that and salt water is in my veins workers can Harvest about 2 000 limes in a day they load them onto trucks headed to the packaging facility [Music] this machine dumps lines onto the processing line each one gets washed with a detergent disinfectant and hit with a spray of palm wax it's not just to make the limes look shiny is throughout their journey in the factory the lives will get sorted multiple times some stations do it by hand others with fancy Tech isando using those pictures the machine separated them based on their size ones that aren't the right size will go directly to Mexico's juicing industry the perfectly sized ones will head on to get exported but first there's quality control is foreign test the limes are ready for packaging and shipping the majority of the limes produced in this region end up in the United States demand for limes has been increasing for decades as Latin American and Asian Cuisines became more popular but in 1994 after a new Free Trade Agreement went into effect the floodgates for Mexican limes opened now the U.S is the biggest importer of limes globally doubling the amount it purchased from Mexico in the last 10 years to keep up with demand Mexico increased its production 50 percent in the same decade these trucks can come up to three times a day to load up the supply of fresh milk and transport it to the Cabot plant here it will become either butter cottage cheese sour cream yogurt or of course cheese cheddar cheese it takes Cabot about 10 gallons of milk to make just one pound of cheese to make Cabot's signature cheddar first the milk is pasteurized the milk is then poured into a huge bat where a starter culture of bacteria and the special enzyme called rennet are added in this combo jump starts the process of curdling the milk into cheese and as the cheese is formed big steel wires break it down into small curds and a liquid known as whey once the cheese curds are cooked through the Whey and the curds head to the finishing table here the way is drained out salt is added in to cut some of that acidity this is also the point where Cabot can add in herbs and other ingredients to make their specialty flavors like super spicy habanero and the cheese for us weaker heatseekers the pepper jack after that everything's mixed together next the cheese curds are squeezed together to form massive 40 or 60 pound blocks those blocks are then sent to the Aging room where they're left in a temperature controlled space to mature these folks are the cheese graters the people responsible for making sure cabbage cheese is aging up to their world's best standard on average in our inventory we have close to 70 million pounds of cheese that we repeatedly will sample on an everyday basis some days we're evaluating up to 150 samples or Vats a day when the cheese finally makes it to the Aging room the cheese graters take a plug or a sample out of each block foreign it's a good monterey jack a little salty monterey jack is typically a shortage Chase younger cheese it's got moisture added to it the unique profile as the cheddar gets older the flavors that develop become more intense every batch tastes a little bit different a thousand different Farms I mean the mix is always going to be a little bit different cheese is a living organism creators like Gina and Ted determine when a cheese block is ready to be cut the blocks head back to the factory for the finishing touches an industrial slicer breaks those puppies down to a more edible eight ounce block then it's sealed in plastic and boxed up in crates those boxes of cabbage signature cheese and all 50 of their other flavors will end up in stores across all 50 states this is definitely one of the landmarks Chicago Staples of food that you have to thrive here in town there's usually a line out the door popcorn starts off with a hybrid of butterfly and mushroom kernels which are grown just for the company the kernels are then air popped which means no oil is necessary once air popped the kernels are set aside while the caramel Heats to an optimal temperature there are a total of seven ingredients in the caramel crisp flavor Garrett Popcorn wouldn't tell us all of them but it did say two were water and caramel while the other five can be found in most pantries and refrigerators the smell of the caramel is overwhelming and it's beautiful and it's taking all my willpower not to just grab the piece of that caramel crisp I'm really surprised that none of the popcorn itself is being crushed by the weight of the caramel that's because the caramel crisp begins with butterfly kernels and Butterfly kernels as the name to notes have wings on them so when mixed in with the caramel the larger surface area on each and every kernel allows for more caramel to be glazed on top without crushing it next the vat of coated popcorn is poured onto a cooling tray oh my God it smells so good and we're doing this not to make it Clump right am I doing a good job good I was booted out so Eric here stepped in because we only have a small window until the caramel crisp cooled off and we needed to separate it enough so that when I cooled off there was no pumps and we have to do this so lightly so that we don't crush the popcorn next comes the cheese corn it's made with mushroom kernels that are round and fluffy after popping they're smothered with a mouth-watering cheddar cheese sauce but beware Garrett's cheese corn has a reputation for staining your fingers it all starts in the fields machines called vibradoras Shake ripened olives out of the trees this method doesn't damage the branches or the tree trunk it just makes the ripe olives fall to the ground Benito says he's never harvested so few olives in a season satellite images show just how dry this area has become winter precipitation was down by more than a third trees that don't get enough water are tougher to farm it's harder to pull the olives off the branches because in 2019 Benito would gather around 8 000 kilos of olives in a day some days this season he barely gets a thousand kilos it's also stiflingly hot important Benito says Winters are also less severe and without enough water the trees won't grow energy area the damage to the trees gets worse every year of the drought here's what happens to the olives that do survive Farmers unload their crops in processing facilities run by diku and a conveyor belt carries thousands of raw olives an hour they're gently washed to remove any remaining dirt from The Groves but the value of their crop isn't set the olives have to be taste tested first extra virgin olive oil is the least processed it's extracted not through the use of heat or chemicals but by grinding the olives and pressing out the oil that's what makes extra virgin the most expensive type of olive oil but it's also considered healthier because it retains all of its natural vitamins and antioxidants first machines blend the olives into a thick paste um foreign then massive decanters extract the oil out of the mush they also keep the olive waste called Al peruco after it's composted it's used as fertilizer or fuel is high standards for quality and Francisco aguado tries to make sure every bottle leaving this Factory is perfect the new olive oil is stored in huge stainless steel tanks nitrogen fills the Gap at the top of the canister to keep the oil fresh it's kept in the dark at a constant temperature decoup has the biggest olive oil storage facility in the world it can hold 300 000 metric tons that's one-third of an oil tanker the tanks can keep oil fresh for up to two years each batch of Olives has a distinct fragrance finally the olive oil is poured into bottles and sealed now it's ready to be delivered all over the world workers gather early in the morning and they pass around handfuls of cocoa leaves then they call to pachamama or Mother Earth to help them get the job done quickly Ignacio says the plant acts as a mild stimulant that gives them strength Ignacio and his family sow the seeds after the soil has been harrowed and fertilized about seven months later they harvest the crop by hand is then they cut the branches and removed the edible parts of the grain Aquino foreign to remove any leftover dirt and then transfer the quinoa to a small Warehouse about a decade ago Ignacio and his family would have traveled across the country to sell their quinoa is no but that's now the job of copain Cabana a Cooperative that represents more than 600 farmers in southern Peru foreign representatives from cooperatives like eusebio visit the Farms to inspect the grains the cooperatives pay Farmers like Ignacio about a dollar fifty per kilo about 1200 tons of quinoa are processed every year at the cooperatives facilities once the quinoa reaches their warehouse workers thoroughly wash it twice to remove a bitter chemical called saponin OS is they split the quinoa into categories remove any impurities and then package it [Music] 'll make its way overseas The Cooperative says it exports to the U.S the European Union and Japan workers load up their dinghies they commute 10 miles along the hayudo spaces then they hike into the rain forest Avenue morima is the president of the piaka tribe foreign [Music] s bury the Fallen paths to eat later so when the rolling has a bad memory there will be a new tree if a rolling is eaten by a Jaguar there will be a new tree the Brazil nut trees can live in years old they reach 100 high five feet tall as high as a 50 -story building and their trunks over six feet wide because they are usually above every other trees the canopies collectors wait for the pots to drop naturally between November and may that's what makes this such a sustainable knot each tree drops about 300 pods every season and they can come down at 50 miles per hour you are down there and one of these things fall in your head you're dead foreign foreign they make their way back this time carrying bags that are roughly a hundred pounds workers will spread them out on beds to dry them in the hot sun is once numbered in the tens of thousands but they haven't had an easy past facing massacres persecution epidemics and enslavement from rubber tappers and now there's less than a thousand apiaka left in the 1900s they started selling and exporting nuts to Europe they depended on middlemen from big cities who made the trip to their remote Village to buy nuts for just six cents a kilo much it wasn't lucrative enough and many families left the industry altogether we collapse we collapse big time and the price of nuts is so low then it is not an incentive to people to harvest it while agricultural cooperatives aren't A New Concept environmental technician Antonio Vieira gimelo thought it might work for the apiaka so he joined four tribes across Mata Grosso into one Cooperative called kopama The Collectors would then sell directly to the Cooperative cutting out the middlemen completely and the idea saved the local nut industry that's about 1.64 a kilo it may not sound like much but it's more than a two thousand percent increase from The Sixth Sense collectors made before workers then transport the dry nuts to a processing Factory in the town of zuruena once the nuts arrive workers transfer them to the dryer they'll stay here for 10 to 12 hours foreign to last the six months of the off season they're dried again for four days to extend the shelf life then they had to get steamed to loosen up the shell um [Music] here in New York City juniors is an institution but its cheesecakes aren't actually made in the city anymore in 2015 the company moved to this New Jersey Plan we took took over this building because we didn't have the space to do it at greens 240 workers whip up millions of cheesecakes and layer cakes here every year not surprisingly every batch starts with the most important ingredient this year we'll probably go through about seven million pounds of cream cheese Juniors partners with Kraft Heinz the maker of Philadelphia cream cheese workers unwrap each of those giant blocks of cream cheese and tip them into the mixing bowl so far we have cream cheese we have sugar we have eggs eggs some heavy cream some vanilla and I think that's just about it it's kind of simple workers roll these giant mixing bowls over to the assembly line to speed up production Allen added automatic depositors it gets pumped up here into here this is going to meter out exactly the right amount first workers drop a slice of vanilla cake not graham cracker crust into each pan we use cake on the bottom because this is a recipe that my grandfather created in 1950. it's a lot of work just to make the bottom slowly the pump works its way through the entire batch of batter plopping perfect dollops into each pan then this guy knocks out any excess air on this line they're making strawberry swirl cheesecake the swirl used to be piped by hand but this robot took over the gig in 2017. next the cakes head to baking but this step also has a unique twist a lot of bakeries use rack ovens where you just slide the whole Rack in and Slide the whole rack out it doesn't work for our cheesecake his team bakes the dense cakes in a water bath spreads the heat evenly the bottoms of the cakes don't burn they rise up like a souffle you can see how the cakes are literally above the pan when they're golden brown workers pull out the trays and pour out leftover water then they test the internal temperature they take temperatures for food safety but I can see with my eyes after they've rested the cakes aren't jiggly anymore we don't do jiggly we do juniors using this repurposed Pizza Oven Bakers can heat the pans just enough to release the settled cakes [Music] Allen keeps it at a balmy zero degrees inside but it's not just plain or swirl cheesecakes in this freezer the company whips up dozens of different flavors of cheesecakes layer cakes and desserts the chocolate mousse cheesecake is hit with a heaping pile of moose doused in a waterfall of chocolate and covered in mini chocolate chips there's also the pumpkin layer cake cheesecake robots and Bakers work together to ice it leftover cake tops are ground up to make the crumb that goes around the edges all the finished and chilled cakes Converge on the packaging line from the pumpkin cheesecake to the 24 mini cheesecake variety pack Bound for Costco workers Place each cake in a box slap on a label and put it in an even bigger box that all heads to the freezer a second time this will all be gone within 30 days right now it's enough space but I can see maybe next year us needing even more space this is going around the whole country most of the six inch cheesecakes end up in one of the 12 000 supermarkets supplied by Juniors Wegmans to Kroger Publix Stop and Shop ShopRite tomato ketchup is one of the world's most popular condiments and it can be found in many households around the world we have it with burgers fries and just about anything that we can think of to complement our meals Heinz is one of the market leaders in ketchup selling over 650 million bottles of ketchup around the world every year we visited its European Factory in the Netherlands to see how the world famous condiment is made foreign else we make sauces for the craft Heinz company our main product is ketchup that's 70 of what we do we make about 1.8 million bottles a day and that relates to about 175 000 tons of ketchup a year the ketchup making process starts here where crates of tomato paste weigh in 1 300 kilograms are transported from the Heinz Warehouse using automated forklifts the crates are opened and then go to the paste dumper where these huge Ronin pins squeeze the pace out of the package [Music] after the paste has been extracted it sits in a storage bin where it's mixed with water to give it a smoother consistency this makes it easier to transport to the storage tank where it will sit until moving on to the ketchup kitchen [Music] actually produce the tomato ketchup ketchup is made of five ingredients sugar vinegar tomato paste Brine and secret spices the spices are those by hand we dose everything we mix it and afterwards goes into our process the process is mainly about heating the ketchup and then cooling it down afterwards we fill it into the bottles but before any ketchup can be shipped each batch must be rigorously tested through this contraption which Heinz calls the quantifier this is our quantifier it's a method where we measure viscosity of our Heinz tomato ketchup it's a methodology that we use in all our ketchup factories so that we compare the ketchup quality for all the factories what we do is we put a certain amount of ketchup inside the quantifier we release it and we measure how fast it has traveled after 10 seconds all right 10.5 within range it's a special method designed by Heinz the ketchup cannot move faster than 0.028 miles per hour if it has traveled too far we have to block it you cannot sell it if it's within the range we can release it [Music] foreign Ty bottles they go into the filler we have 70 filling heads it's a filler that works by weight so a bottle comes in we check the weight of the empty bottle we fill it to the proper weight with ketchup and then we check again if we reached the filling weight the boxes with caps are emptied at the bottom floor by the operator and transported upstairs upstairs we make sure the Caps are put in the right position and go to a single row of cap so that we can position them properly on the bottle in the filling machine [Music] and for this bottle we have three labels so we have a neck label a back label and a front label these labels are self-adhesive so we don't need any glue for it after the labeler we go to a trade Packer where we get a tray from the bottom we fold it around the bottles after that put a shrink wrap around it and make sure the bottles are tight and packed in in the tray from the straight back we go to the pelletizer where a robot puts the trays in the right position and from the right position we make layer for layer on a pellet after that we put a shrink wrap around it [Music] now that we've seen how its iconic ketchup is made how did Heinz become the prominent brand it is today Heinz was founded in Pittsburgh in 1869 by a 25 year old named Henry John Hines who began his business by selling his mother's horseradish recipe over the years Heinz expanded his catalog selling pickles vinegar and eventually tomato ketchup which launched in 1876 [Music] it was a roaring success and in 1886 the company began shipping the source to the UK following the overwhelming popularity of Heinz Ketchup High started producing 13 million bottles a year and exported them all over the world which explains why you're never too far from a bottle of Heinz tomato ketchup foreign [Music]

Channel: Insider Business

Views: 3,670,656

Keywords: Business Insider, Business News, grocery stores, grocery shopping, bananas, Ben and Jerry's ice cream, Gorgonzola cheese, caviar, sardines, kombucha, cranberries, salt, Peeps, Smoked salmon, tofu, coffee, vanilla, oranges, oysters, limes, cheddar cheese, popcorn, olive oil, quinoa, Brazil nuts, cheesecake, ketchup

Id: 4ArVvrhhnyI

Length: 95min 59sec (5759 seconds)

Published: Sun Apr 09 2023