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DTSTART:20250330T020000Z
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SUMMARY:Inside the Factory 9x3 - Cheese Curls
DTSTAMP:20241231T105506Z
SEQUENCE:0
UID:190279-2-841ebed20eb198c4569419e99b7bf40a@themidnightzone.com
ORGANIZER;CN="Midnight":midnight@themidnightzone.com
DESCRIPTION:In this episode\, Paddy McGuinness explores the secrets of t
	heWalkers factory in Lincoln\, to reveal how it makes 500 millionpacks of 
	Quavers every year.Paddy begins by meeting factorymanager Layla Whiting\, 
	who reveals that\, despite popularbelief\, cheese curls aren't officially 
	classed as crisps! Infact\, while crisps are made from sliced potatoes\, Q
	uavers aremade from the potato starch powder left behind during thecrisp-m
	aking process. Their first stop is a huge mixer wherethe starch powder is 
	added\, along with equally fine rice andsoya flours. Then they add some mi
	ld seasoning of salt\,pepper\, onion powder and yeast - but no cheese flav
	our yet.The whole lot is mixed with water to create a dough.This is ahuge 
	and very hot factory! Comparing it to getting off a planeon holiday\, Padd
	y exclaims\, ‘this is like landing on thesun!' But he soldiers on to the
	 next stage of production. Aftermixing\, the dough is forced under very hi
	gh pressure throughan extruder\, emerging as a continuous one-millimetre-t
	hicksheet. It looks more like a lasagne sheet at this stage and theprocess
	 is nothing like Paddy imagined it would be.To ensureevery one of the snac
	ks ends up with the famous curly shape\,the dough is stretched over roller
	s to add tension. Then ittravels through an 18-metre-long steamer\, increa
	sing themoisture level in the dough to 40%\, making it more pliable andstr
	etchy. After being quickly cooled\, the continuous sheet ofdough is sent r
	ushing through a machine which chops it into 13millimetre by 40 millimetre
	 pellets\, at a rate of 7\,900 aminute. But the pellets contain too much m
	oisture\, so they aresent through a series of dryers\, bringing the moistu
	re contentdown to 11%.Over in the frying area\, Paddy learns how 1.2tonnes
	 of pellets travel through a specialist fryer every hour.Inside the fryer\
	, the pellets are plunged into sunflower oilheated to 200 degrees Celsius.
	 The heat of the oil causes anyremaining water inside to turn to steam\, p
	uffing them andleaving tiny air holes. At the same time\, the tension crea
	tedwhen the dough was stretched now contracts and curls up. Aftertwenty se
	conds in the oil\, 1.8 million perfectly-formed curlscascade out of the fr
	yer every hour. Finally\, Paddy is able tosee the curly snack he knows. Th
	ere is one vital thing missingfrom the snacks though – cheese flavouring
	. To put thatright\, each one of the freshly cooked curls travels through 
	ahuge metal drum where a precise amount of cheese powderflavouring is appl
	ied.After a welcome taste test\, Paddyfollows his snacks\, still warm off 
	the production line\, tothe packing department. First\, a specialist machi
	ne called amulti-head weigher carefully portions out 16 grams of cheesecur
	ls before another machine seals them neatly into aluminiumand plastic pack
	ets. Then\, each packet is sent hurtlingtowards a robot which sorts them i
	nto groups of six\, beforethey are packed into multipack bags.Finally\, th
	e multipacksare put into boxes and placed on pallets before making theirwa
	y to the dispatch area. There\, Paddy learns how 93\,600packets are loaded
	 onto each waiting lorry\, before being sentto shops and supermarkets acro
	ss the country.Earlier in theepisode\, Cherry visits a Walkers crisp facto
	ry to learn howthe starch from potato crisp production is transformed into
	 thepotato starch powder used to make the cheese curls. And shevisits anot
	her factory in Leicester to find out how ten millionbags of Bombay Mix are
	 produced every year.Meanwhile\,historian Ruth Goodman learns how a group 
	of American militaryscientists invented cheese flavouring during the Secon
	d WorldWar.
DTSTART:20250114T200000Z
DTEND:20250114T210000Z
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