There's no colorful candy, more classic than
a jelly bean. And when you're craving a bean with some of
the truest taste and far out flavors, nothing is more. Iconic than a dimple. Shaped jelly belly. With more than 100 over the top flavors,
including everything from draught beer and chili, mango to Tabasco and even stinky
socks, jelly belly jelly beans stand out in a sea of, well, jelly beans. Jelly bellies are starch molded candies,
which means they begin as a liquid in the case of a jelly belly. The liquid is made up
of. Four main ingredients water. Sugar, corn syrup and starch, which are all
piped in from giant silos outside the factory. Most jelly bean companies only add
flavor to the candy shell, but not here. Jelly belly flavors the inside as well. We wanted to have an engaging, interactive
flavor where people would take a bite of this and just go, Wow. To achieve that flavor packed punch. Next, they add the first round of flavors
like sour, orange and coconut. Once mixing is complete, the warm flavored
mixture runs through pipes to the mogul machine, where a series of precise nozzles
fill the 160 spots in each starch covered tray. That is the candy that sets up and becomes
the center of the jelly belly. Once the trays are full, they're stacked 45
high before traveling along a series of indoor tracks to a heated drying room that
holds. 10. Million beans at a time. Here, they'll sit for 24 hours to harden and
set. The next day, a conveyor carries a centers
to a steam bath that removes the starch residue as they start to cool the beans
centers, then showered with sugar to prevent them from sticking together. After the centers are fully dusted with just
the right amount of sweetness to complement the fruity flavor, the centers drop into
large trays as they make their way across the factory. If you try this jelly bean right now, it's
really chewy and will stick to your teeth. That's why we need it to rest. Before we move on to the next step. Then crane robots come in to grab three £25
trays at a time and send them off for another round of hard. But not everything here is
automated. As the bean centers move on down the line,
the candy makers unload them by hand into large spinning vats. The next step is called panning. This is the part of the process where the
cells are created. As the beans tumble in a pan, the pan
operators add sugar and syrup, as well as additional flavoring and color to create the
hard outer shell. This is really where the artistic value comes
in. Each pan could be a little bit different
depending on how it's running that day. You know, jelly bellies commitment to
authenticity can be found not only in the flavor of the beans, but also in their
appearance. Let's take pear, for example. We make it with a green shell on it, and
then we put a little dabs of dark sugar crystals on there that actually make the
specks that you may see on a pair. The dark crystals are a variety of sugar
called black shirt that includes both molasses and minerals. In addition to creating the spots on the
candy, its complexity adds to the bold flavor of the jelly belly beans. Then it's on to the polishing room where the
beans take a tumble with a confectionery glaze that gives them a glass like vinegar. Those beans come out, they shine. At this point, the Kennedys have reached the
pinnacle of fruity freshness or sumptuous sweetness and are ready to eat. But they wouldn't be jelly bellies without
the famous stamp. Well, stamp each individual bean with a jelly
belly logo. The beans move in trays under a roller that
is coated with the same food coloring used to make the bright white color of marshmallows. Then it's on to packaging. We have this long, long, large belt, which we
call a river of beans, and we will put every single flavor on that belt. The belt holds all 49 varieties of jelly
beans at a time and sends them into a cylinder that tumbles them all together. The machine then drops the beans into the
proper size bags, seals them, and then sends them down the line to be boxed. Two deliciously creative words come to mind
when workers describe the Butterfinger bar. There are crispy and crunchy, crispy,
crunchy. Butterfinger is all about crispy, crunchy,
chocolatey experience. At the Nestle factory in Franklin Park,
Illinois. They make more than 10 million Butterfingers
every day. If we lined all the bars up end to end that
we make on this line alone in one week, when we make enough bars to stretch from Chicago
to Las Vegas. Which is 1700. Miles, we make an incredible amount of
Butterfinger in this factory. I've worked here for 52 years and I still
love. Butterfingers have been around since the late
1920s. Back then, a candy company went to the
public for help with a name. The Curtis Candy Company held a public
contest and the winning name was Butterfinger. At the time, it was a name
that referred to an athlete, a sports player who could not keep his hand on a ball. All these years later, many calls come in to
Nestlé about the mystery orange center. Primarily, what is it. The center of a Butterfinger candy bar is
really what makes Butterfinger. Butterfinger. It's rich, it's flaky, it's
made with a creamy peanut butter and from peanuts that we actually roast at the
factory. More than £100,000 of peanut butter mix in
giant bats, along with another ingredient that just might surprise you. People may not realize that one. The ingredients we use in Butterfinger is
corn flakes. You heard right, Corn flakes. As you can see, these corn flakes are much
different than what you would have for breakfast at home. We add these in. They're a lot lighter in
texture and they add the depth to the peanut butter to give the crispy, crunchy texture
from a butterfinger you'd expect. Meanwhile, in another kettle, they work on a
mixture of molasses, corn syrup, sugar and water. Then the mix gushes through pipes to
a cooking chamber below. Check this out. The hot sugary mix pours onto a cooling
wheel, then spreads out. Bringing that temperature back down is what
gives us that crystallization process. The better we manage that under certain time
and temperature. This is what gives us that unique texture
that we need. Next, a ribbon of peanut butter lines, the
middle and the whole thing takes on a taffy like consistency. Then it gently needs and folds on a slow
moving conveyor. The way it comes together is top secret that
we cannot show today. We've got to keep it under wraps. The Butterfinger flattens and forms into long
ropes, then cuts down to individual sizes. Next, the bars take a ride through a series
of cooling tunnels that are a quarter mile long. Slide to the cooling tunnels. Those bars are then going through a process
where they go through a waterfall of coating, chocolatey coating, to give us that unique
flavor that we need out of a Butterfinger. After a good chocolatey shower, the bars
cool, then march like a small army off the packaging. The entire process from start to
finish takes about one hour. Butterfinger is very popular not just today,
but it has been for years. People have really enjoyed the unique one of
a kind taste of Butterfinger. They've shared it with their friends, with
their children through the generations. When it comes to crispy chicken. No one cooks it up quite like Kentucky Fried
Chicken. We have wings. We have strips. We have our snack or sandwiches and of
course, our chicken on the bone. Obviously, our original recipe chicken. Believe it or not, this famous face isn't
just an ad campaign. Colonel Harland Sanders was real and you'll
never guess where he got his start. We actually had a Sanders Court cafe down in
Corbin, Kentucky, and basically it was part of a gasoline station. After ten years of experimenting, he created
the most famous fried chicken recipe in America. The colonel took his chicken very personally. He had spent a lot of time not only
developing the flavor, but the color, the texture. And it was his idea. It was his baby, if you will. Then he hit the road to introduce his soon to
be famous chicken to restaurant owners. He put the recipe a couple of pots, a bag of
seasoning in the back of his car and just drove around and talked to restaurant
owners. He was charging a nickel. A chicken was his royalty rate. Today, it does cost more than a nickel, but
the colonel's original recipe is still their number one seller. It's what people crave. And they come to our restaurants. They can only get it at KFC. Get this. The colonel's original handwritten
recipe is so secret, it's actually locked in a vault, along with vials containing samples
of all 11 herbs and spices. But much more than that goes into making
this chicken. They start with flour, dry milk, powdered
eggs and salt. And finally, we're going to add the colonel's
secret 11 herbs and spices to our mix. It's such a big secret that not even the
people making the mix know what's in it. Half of them were made in one place. Half of them were put together in another
place. The two were shipped somewhere in a third
party mix. So you're not going to get that recipe. Next, it's time to get down and dirty, mixing
all the ingredients by hand. This is a process that involves lifting and
folding at 20 times. Then a mechanical mixer takes care of the
rest. This is actually incorporating all the
ingredients together. It also sifts out the clumps of flour. Then the secret blend goes back into the bin. And now we're ready to breed our chicken. This is a standard eight piece cut of
chicken has breast, thighs, wings and legs. It gets a quick dunk in water and a shake. Shake it seven times. After years of trial and error, KFC has
created very specific techniques. And it goes into our flour. It's all about the magic number seven. We'll lift and fold it four, seven times. I'm going to shake off the excess with our
rocker basket. And they shake it. You guessed it seven times. Now our chicken is ready to be placed on our
racks to be fried. Stephen Fry it up the same way the Colonel
did back in 1940. Colonel Sanders perfected the original recipe
chicken by pressure, frying his chicken. So today we still use those same standards. That's right. It's cooked in a pressure
fryer. The pressure seals all the juices inside. And just like the mystery spices, the
temperature and cook time are top secret. Here's our famous colonel's original recipe. Chicken. Today. People all over the world enjoy the
colonel's famous chicken. It's also an 80 countries around the world. So if you're in another country, you'll
still taste that same great flavor that you would at home. The recipe has been the same for over 60
years, and there's no plan to change any time soon. Why mess with perfection? At McDonald's restaurants all across America. And in 117 countries around the world,
servers ask the same question thousands of times a day. We're fast. The answer for most of us with fries. Mcdonald's customers love our fries. In fact, over 50% of our customers order
fries with each of their meals. Sometimes. It starts on the farm. Mcdonald's uses about £3.5 billion of French
fries a year. That's global. This factory alone makes about £1,000,000 of
fries every day. To make all those fries. These trucks each haul 25 tons of spuds from
the field to the factory. Once they're washed, this high pressure
steam machine peels off the skins. That super heats the the water underneath the
skin of the potato. And so when that high pressure is released,
that water then flashes off into steam and it loosens the peel off the outside of that
potato. Workers hand-cut any imperfections off the
naked potatoes, but it takes some serious firepower to give them that signature fry
shape. Basically these long tubes act like potato
canons with a grid of razor sharp knives. Inside. They will shoot forward through a grid of
knives at about 75 miles per hour. And that's how we get that that classic
McDonald's French fry shoestring. The newly minted shoestrings flood out onto
conveyor belts and get this to make sure every single fry is perfect. Mcdonald's employs some seriously high
technology in this next step. We'll send over £70,000 of raw French fry
strips to the optical sorters. And our optical scanners look at each and
every potato strip searching for blemishes. The machine automatically snags any fry with
a fault. There's 132 little air jets at the end of
that belt, and the camera is going to tell which air jet to put a little puff air on
that French fry. Knock it out of its flight pattern where
then later it can get the defect cut out of that French fry strip. But perfectly shoestring potatoes are only
part of the secret to the world's most famous fries. The cooking process does the rest. We call it the art of processing. That's where it starts. These 100 foot long planters soak the potato
strips in steaming hot water for about 15 minutes to give these fries the texture you
expect. When you go to McDonald's and and open up a
French fry and look inside of it. Should have that a nice, fluffy baked potato
type internal texture. And that's what the Blanchard does for us. To get the addictively crispy exterior takes
a two step process. This machine dries the blanched potatoes
before they dive into the fryers and these vats of vegetable oil bubbling in almost 400
degrees Fahrenheit. The fries earn their name. By both doing a quick fry here at the plant
and the fry at the McDonald's restaurant. The combination of those two allows us to
get that nice, crisp exterior shell on that french fry that you expect every time you
bite into one of those McDonald's French fries. It's now out of the frying pan and into the
freeze tunnel. The short trip through drops the temperature
to ten degrees Fahrenheit. It prepares them for packaging that allows
them to be shipped all over the world. This plant alone supplies fries to McDonald's
restaurants in more than 20 countries where they fry them up one more time. If you lined up all the McDonald's French
fries produced worldwide on an annual basis from end to end, they would actually travel
from the earth to the moon and back almost 600 times. In 1930. Candyman Frank C Mars created an
unforgettable, sweet and salty combination the Snickers bar. Mars at the time already had a Three
Musketeers bar, which was based on a milkshake. What better to put on a milkshake
than peanuts and caramel and that rich milk chocolate? As for the history behind the name. It was named after the horse that was owned
by the Mars family. In the early days, Snickers sold for just a
nickel. Seven decades later, the price has gone up. But so have sales. Mars tops $2 billion every year by selling
Snickers on six continents. One thing that hasn't changed is the recipe. At the 600,000 square foot master food plan
in Waco, Texas. Mars is working hard to keep up with the
Snickers demand. Every day we produce enough bars to reach
from Waco to Houston and back. And it all starts with that creamy milk
chocolate. The chocolate is put into a mixer, which we
call a cage. And in there it's mixed and mixed with more
cocoa butter and that creates that creamy milk chocolate. Here's a fun fact for you. It takes nearly 7550 cows. To produce enough milk for the Snickers
caramel and chocolate every day. The other key ingredients into a Snickers bar
are those fresh roasted peanuts. And they really pack them in. Mars uses over 71 acres of peanuts in just
one day of Snickers production. We put approximately 28 peanuts in each and
every Snickers bar, and that creamy caramel mixed with those salty peanuts really gives
Snickers its unique characteristic. The peanuts and caramel combo drops from the
mixer and spreads thin onto a cooling roll. While the creamy Snickers nugget does the
same. The nugget is actually made from milk and
sugar and eggs, and that creates the bottom layer of the Snickers bar. After the caramel and nougat sheets cool
down, it's time for them to meet up. The creamy caramel that's mixed with the
fresh roasted peanuts is rolled on top of the nougat, and that creates a slab that goes
then into our splitter area. The slitter machine slices the candy sandwich
into 38 long strips. The next machine cuts in the opposite
direction, creating the individual Snickers bars. That uncoated bar then goes through a bottom
in Rover where it puts on a bottom layer of that creamy chocolate and then into a full
rubber which coats the entire bar with chocolate. The final touch on this popular candy bar is
its secret signature swirl, a quick cooldown, and the stickers are ready to be packaged. Even though Snickers bars fly off the
shelves, Mars continues to come up with new takes on the old favorite. Besides the different sizes of Snickers, such
as king size, regular singles, fun size and minis, we also have Snickers, almond, and
this year we're introducing Snickers Dark. Would you believe Dairy Queen workers
actually have to go to school to learn how to put that famous twist on top of their frozen
treats? Goodness gracious. All right. Maybe next time. Welcome to DD Q. You were probably make several hundred calls
before they finally get it correct. One might think it's easy to make the perfect
Dairy Queen cone, but it does take a fair amount of training. Missing the curl. First you fill the crevice of the cone,
followed by making two balls. You're dropping as you do this and then a
flick of the wrist and you have the perfect curl. Everybody loves a good treat with the curl on
top. The GQ girl has served in 18 countries around
the world. Vanilla is the number one flavor, and
chocolate is the most popular dipping sauce. But the recipe hasn't changed much since
1938, when a father and his son developed the ice cream. The McCullough's own an ice cream factory in
Green River, Illinois. One of the things that they found was that
ice cream tasted best when it was right out of the freezer before it was frozen. So they devised a way, a machine, if you
will, to dispense fresh ice cream. This is what we call the soft serve. Ice cream machine. And the man behind the
marketing campaign was Shirley Noble. He had about seven or ten Dairy Queen stores. He came up with the idea of all you can eat
ice cream for $0.10. And he started this promotion and literally
hundreds and hundreds. Of people would descend upon his store. For 70 years, Dairy Queen has been king of
the ice cream chain restaurants thanks to their soft serve ice cream. Yummy. The soft serve is made up of sugar
vanilla flavoring stabilizer, which gives the ice cream its texture and lots and lots of
milk. Each year, the milk for more than 80,000 cows
is needed to make the Guinness to milk solids for a four hour soft serve. Sun Whenever we want a treat, we say moo. In fact, everybody does. That's because the greatest genuine milk
treat is Dairy Queen Moo. But not all of their flavour experiments
sound yummy to everyone. We actually played around with something
recently that was a little bit of what we call it hot chocolate, but hot meaning that
it had hot peppers in it. So you've got the chocolate and you got a
little heat at the same time. Hot toppings aside, what is the perfect
temperature to serve ice cream? According to these ice cream experts, it's
23 degrees Fahrenheit. That also happens to be the perfect
temperature to create that famous twist on top. I like it. I like it. I think I can give this
one away. It's one of the food world's most well known
slogans. Melt in your mouth, not in your hands. And it goes along with one of the world's
most craved candies. M&ms are definitely a part of American
culture, and currently they're in everything from the Academy Awards to New Year's Eve
celebrations to NASCAR. Pretty much every big special event you can
think of. You'll find M&Ms. So aside from the snappy slogan, how did
these tiny trees become such a big hit? Well, the story actually starts when candy
maker Forrest Mars visited wartime Spain in the late 1930s. He saw soldiers eating chocolate pellets
covered with sugar and it didn't melt. And he was inspired by that idea. By 1941, Mars was churning out his own
version of candy coated chocolate stateside. And he did initially have a partner, which
is where the name comes from. The M stands for Forrest Mars Senior and
Bernie Murray, his partner. Today, M&M Mars is making around 1 billion
M&Ms every day. To put it in further perspective, if we put
all the M&Ms end to end that we make in the course of the year, it would encircle the
earth 48 times. And at their facility in Hackettstown, New
Jersey, the 12 hour M&M making process starts with the chocolate. A mix made from milk,
sugar and cocoa first rolls through refiners, turning the semi liquid paste into powder. Then powder conveys its way down to the
conch room, where giant containers filled with metal beads grind up the powder with
cocoa butter and chocolate liqueur. The end result a smooth semi-solid
chocolate, ready for depositing into tiny bean shaped sheets. We call it a lentil shape, and we think a
lentil shape is the best shape to ensure that the sugar cell is put on in a consistent and
even fashion. Now, the step of putting on the first coat of
candy is top secret. But once the chocolate centers have their
first sweet coat on, it's time for them to take a tumble. Here, extra layers of color
are shellacked onto the shells. Next, candies get christened with their own
little letters. And then all the different colors blend
together before being bagged. But this is not a random assortment of sweet
colors. A bag of M&Ms contains exactly 25% orange,
25% blue, and 12 and one half percent of brown, red, yellow and green candies. And different colors do come and go as
tastes change over the years. We actually have specialists who are trained
in color, and they keep very close to all the color trends and make sure that all our
colors stay very current and very contemporary. At five guys. Regular cheese, little cheese. Burgers and fries are the specialty of the
house. The Grille proudly sports very few frills
and makes meat patties like you do at home. I love coming to a place that's got real
hamburger meat that's fresh in the morning. If I can find those places, that's where
I'll stop every time. The five guys are actually five brothers who
began grilling up their homemade hamburgers in Virginia in the mid 1980s. Okay. We'll start with the oldest, my oldest
brother, Jim. And that'd be me, Matt. And then we have Chad, and then we have Ben
and Tyler. All brothers. Their love for mouthwatering meat, potatoes
now stretches across America. This five guys restaurant in Colorado
Springs, Colorado, cooks up well over 1000 burgers every day. Getting ready for hungry hamburger fans
starts early in the morning. They slice veggies and form fresh ground
beef into perfect patties all by hand. The freshness is really what we focus on. And keep in mind when we do our prep in the
morning. We prep for. Only one day. Then the number of people who walk in the
door determines how many patties sizzle on the grill. As soon as that customer walks in the door,
you're going to hear somebody up front yell, Two in the door. One in the door, three in
the door. That's the cue to put some patties on the
grill. They watch the outer edges of the patty to
turn a grayish color. Then give them a flip flip that we're going
to give it a good press and a level. The press keeps the burgers juicy, and it's
the juices that signal when it's time for another turn. We can train these guys where
they can look at a burger and say, you know what? That burger is done. I'm going to swing that right over here. But this is only half the meal. Now, you can't have baseball without a bat. You can't have a burger without fries. Sacks of potatoes around customers in the
restaurant. A board shows where the spuds come from each
day. Would you believe five guys fries up £100
million of potatoes each year? The fries start with a slice, then soak in
water. They precooked the potatoes for a couple of
minutes. So that gives us that perfect fry that the
inside of that is like a baked potato. Then when orders come in, a final drop of the
peanut oil crisps, the outside. Pretty much. Goes from the dirt to the bag into the sink,
into the fryer and into your mouth. And that's it. I mean, there's not there's
very few steps. Their secret for freshness is to stay low
tech. No microwaves, freezers or even timers. Here we want them to leave and go. How do they make that burger so good? This all-American meal takes just 5 to 7
minutes to make. Here you are. Certainly. Have a great day. And for some, it takes even less time to
eat. They are extra crispy and finger looking
good. But we're not talking chicken. We're talking Cheetos. This snappy snack was introduced nationally
in 1948 and soon became the king of the crunch. Now we make about 4 million bags of Cheetos a
day that comes out to over a billion bags of Cheetos a year. Even though so many of us eat them, how many
of us really know what a Cheeto is? It's actually a corn puff. The crunchy variety is fried while the puffs
are baked. At their factory in Frankfort, Indiana. Frito-lay makes so many Cheetos, it stores
the main ingredient cornmeal in silos. The Cheetos get cooking as cornmeal mixes
with water, creating a batter. The batter moves through a tube to a machine
called an extruder. The Cheeto extruder is so top secret, we're
not allowed to show it to you. But it's what gives the Cheeto its unique
shape. As the cornmeal. Is passing through our extruders, it builds
heat as well as pressure. And that's what makes it pop into the shape. A Colette is the technical term for an
uncooked Cheeto. At this point, the Collet is a pale yellow
color like the corn is made from and has the consistency of a rice cake. The Colts ride a conveyor to the fryer where
they are cooked to more than 300 degrees. When we first make the Cheeto coming out of
our extruders, it does not have that crunchy texture that people have come to love. It doesn't take on that crunchy texture
until after it passes through. A frying operation. But wait, what about the cheese? Well, to make Cheetos, we use about £12
million of aged cheddar cheese a year. And that cheese is mixed with oil and some
other seasonings and then applied to the Cheetos. The cheese is what gives Cheetos their
distinctive bright orange color. It's also a shade that tends to stick to
fingers, something Cheeto lovers really don't seem to mind. People actually like to lick that cheese
powder off their fingers. A sea of super cheesy Cheetos then moves
towards bagging along the way. Trapdoors open up on the conveyor, dropping
the Cheetos into weight check machines that measure the perfect amount for each bag. The bags themselves are wound on a spool and
thread through a filling machine. Each bag is sealed at the bottom, filled
from the top and then sealed shut. An astonishing £40,000 of Cheetos are made
every hour. That's enough to keep Chester Cheese
crunchy. I'm just a cool dude and a loose smooth. And here's a fun fact for you. Chester is actually related to another cool
cat. What people might not know is that Chester
was brought to life by the same artist who came up with a Pink Panther. It's not easy being cheesy. Gummy glow worms are one of Ferrero Pan
candies, top selling treats. They make the gummies with lots of gelatin
blended in this machine with corn syrup, sugar and water. Surprisingly, every step is mechanized. The machine does all the measuring. The program will run and it will say how many
pounds of each ingredient. When you hit that amount in the tank, then
the valve will close and the next ingredient will come in. Fully automated. Here they heat the mixture to 240 degrees
Fahrenheit. Then it's put into a vacuum that cools it
and removes much of the moisture. When that step would be to add any of the
color of the flavor, the juice before we deposit it. And that's done in this huge machine they
call a CFA or color flavor additive deck. Now, this is a very critical piece of
equipment because it's measuring out precisely how much color, how much flavor
and is doing it batch after batch after batch, so that every time you buy a gummy
worm, you're getting the same flavor and the same color in that gummy worm. Now the colored flavored mixture is ready to
turn into gummy worms. But most people are shocked to find out how
gummies take their shape. The gummy mixture never touches a mold. Instead, it goes into this white stuff which
has been pressed with a mold into a gummy shape. It's the cornstarch with a small percent of
mineral oil. And if I wanted to make a gummy hand, I'd
flatten it out. Press in. And then just fill that up with
slurry. Cool. The cornstarch is actually a better
mold than a metal pan. Plus, it's easier to get the gummies out
once they're dry. And when you use a piston pump and a nozzle
that lines up directly with the mold and injects the liquid candy into the starch. They can fill 28 of these boards a minute,
which is a total of 6720 worms every 60 seconds or 403,000 an hour and over nine and
one half million a day. Just in case you're counting, these boards
are taken to a drying room for 18 hours, then put back on the machine to be processed. After the product shakes out of the mold, it
goes through a steamer, gets it all sticky, and then it will roll in the sugar acid
blend. The sugar acid gives these Black Forest
gummies their famous sweet and sour taste, especially popular with the under 12 set. After the product goes through the steamer. It's going to roll in this drum where it's
going to get covered with the sugar acid blend that gives us the glow worm and
sourness. From here, we'll convey it up. We'll catch it in bores and send it off to
the packaging room. And then all that's left to do is to put them
in a package and let kids do the rest.
