Unwrapped 2.0 (2015) s02e09 Episode Script

Play with Your Food

On this episode of "Unwrapped 2.
0," we hit one of America's favorite destinations the snack bar.
From little mints with a huge chocolate taste to crunchy favorites where you can pile on the flavor to some of the country's most mouth-watering desserts, these grab-and-go snack foods will have you going back for more.
Snacks can be sweet, salty or even savory.
But when I'm craving a dose of sugar with just a tiny bit of tart, there's only one thing that satisfies my snack fix.
And that's Tastykake's individual cherry pie.
Yep.
A single-serving pastry you can take anywhere.
A pie is not something that someone is gonna make every day, so it's a way to have that special treat anytime you want it.
The folks at Philadelphia's Tastykake have been making packaged cakes and pies since the early 20th century.
And while it may be made in a modern-day factory, it tastes like it's homemade.
It's sweet and a little tart, and just kind of makes you think of your mom or your grandma.
The crust is soft and buttery and flaky and really reminiscent of what you would have at home.
Their oh-so-flaky crust starts with shortening, flour, sugar, water, and some leavening.
That all goes into a really big mixing bowl, 500 pounds' worth.
We use a large-scale dough mixer with two hooks that combine all the ingredients together.
The dough gets mixed for about 15 minutes.
And then it's left in the bowl for another 45 minutes or so to temper.
It just allows all of the ingredients to get together and form a very strong dough.
Each vat of rested dough gets hoisted up and dumped into a gigantic hopper.
In fact, there are two hoppers, one for each layer of crust.
Now the dough is ready to be rolled out.
Except, with a 500-pound batch, they need something a little larger than grandma's rolling pin.
On this scale, they're called sheeters.
While the sheeters are flattening the dough out, another machine is depositing pre-formed tins into holders on a conveyor belt.
Once in place, the tins move along to the first sheeter, which lays out the bottom sheet of dough.
A plunger then presses the dough down into the tin.
And now each pie is ready for the succulent cherry filling.
We use whole tart cherries.
And it is the perfect combination of tart and sweet.
But it's not just cherries.
The tartness of the fruit is balanced with a good dose of sugar plus a few secret ingredients.
The combination must be working because Tastykake goes through 600,000 pounds of that tart and sweet filling every year.
And it's here, at the depositor, that the tins are filled, eight pies at a time.
Looking good and fruity.
But these guys still need a good topcoat.
And they get it here, where it's laid on in one big, solid sheet.
But they're not quite ready for baking yet.
If you bake them now, the steam would build up, causing the pies to explode in the oven.
First, they pass through a machine that pokes 10 tiny holes at a time in that top layer.
That is to allow the steam to vent when the pies are being baked.
Now that all that delicious cherry filling is safe, the pie tins move along to the crimper, which presses firmly down on the edges of each tin.
It forms the pie by crimping the ends.
And it gets rid of the excess dough.
Then the pies are popped up from below and pushed onto a conveyor by these rotating spindles.
But there's still one last thing before the oven.
Each gets a spritz of what Tastykake calls pie spray a simple sugar and water solution.
That allows the golden color to develop on the pie.
Before these pies get baked, they have to get separated.
Don't want to crowd the oven.
So they hit this sideways sliding conveyor.
Now the lines of pies enter the oven, which reaches temperatures between 450 and 500 degrees.
At that high temperature, they don't take long to bake, just 9 minutes.
When they come out, they snake through the factory on a conveyor in the open air for another 17 minutes.
That just gives the pies enough time to cool down a little bit before they enter the cooling spiral.
That's what they call this enclosed cooling space, which is chilled down to 40 degrees.
And the pies spend quite a while spiraling around in there It allows the pies to come down to a temperature of a little under 100 degrees.
And that's just cool enough for the packing machines.
One machine organizes the pies in a straight line, while another forms the boxes.
A pie drops in, and each box is closed, sealed, and shipped to a snack bar near you.
You pick it up in your hands, and you can just, like, bite in.
It is a perfect snack and the perfect size.
Coming up, we explore a classic salty snack you'll want to snap right up.
Oh! And later, even carrots become craveable with this sweet addition.
Hey! Crispy and salty with the perfect snap.
When I want a snack, I'm usually reaching for this twisted treat, no matter what shape it's in.
Snacks can't get more classic than pretzels.
In fact, legend has it these tasty twists of dough go all the way back to Italian monks in the 7th century A.
D.
Snyder's of Hanover hasn't been making pretzels quite that long, just for more than a century, since 1909, when Harry Warehime unveiled his first pretzel at his Pennsylvania company.
These days, Snyder's of Hanover makes all kinds of pretzels, including these.
They're called Snyder Snaps.
And they came into being for one very important reason.
If you look at the standard pretzel, it doesn't always lend itself to dipping.
To fix that, they designed these bite-size pretzels in a lattice grid, perfect for dipping.
And how do they make these perfect pretzel snacks? As those monks knew, pretzels are basically, well, bread.
So they start with a dough whose main ingredient is a specially-enriched wheat flour.
The flour gets measured out from big silos into the mixer, with about 150 pounds of water.
The remaining ingredients, yeast, malt and canola oil, are individually weighed and added to the mixer by hand.
Then, the ingredients blend for about 71/2 minutes.
But you can't just rely on time when you want the ultimate crunch.
When the operator gets it out, they're experienced enough to know, by feel, the elasticity of the dough, and whether it's gonna be right or not for that batch.
When it's ready, the dough is pushed out into a machine they call the doughbot that divides the dough into six different batches.
Each of those then goes up a conveyor belt to the dough shuttle.
This savvy shuttle knows its stuff.
It can determine which of the six extruders is low on dough and fill it up.
Speaking of extruders, these high-tech Play-Doh Fun Factories squeeze the dough through snap-shaped molds and cut them off with a super sharp blade.
And it happens fast.
After it leaves the extruder, we want it 11/2 times its size before it hits the cooker.
Fans on either side of the 150-foot-long proofing belt bathe the snaps in warm air, which helps to speed up the rising process.
After a 9-minute trip on the belt, the are puffed up and ready to take a dip.
The pretzels go for an 8-second dunk in hot oil, and then into the salt.
Puffed, fried and salty, they head right into the oven.
This oven uses two different kinds of heat, first direct heat, then convection, in a total of five different temperature zones.
When you have two different type heats, you have better control of what you're doing.
And it's just to get the pretzel to develop properly.
The snaps take 9 minutes to make the 150-foot trip through the top part of the oven, which increases in temperature along the way from 350 to 425 degrees.
The very first part of the oven is a direct heat.
The second stage of the oven is a convection heat.
When they reach the end, the snaps drop down into the bottom part of the oven, known as the kiln, where they're slow-dried for 11 minutes.
Now the pretzel snaps are all baked and ready for packaging.
They emerge from the kiln onto another belt, which takes them up a long incline to a set of vibrating conveyors that shake them into the final packaging machine that weighs and distributes the snaps before the machine forms a bag around the precise amount of pretzels.
And, snap, just like that, off they go to snack-lovers everywhere, no matter how you may prefer to eat them.
Oh! Coming up, what snack bar staple shines brightest at the movies? Hey! What creamy chocolate snack is junior in size but packs a jumbo punch of mint? Need another hint? It's been one of the most popular candies sold at snack bars since the 1950s.
You guessed it the Junior Mint.
A Junior Mint is a combination of chocolate and cream and just the right amount of mint that kind of explodes in your mouth and just lingers and makes you feel refreshed.
Originally invented in Cambridge, Massachusetts by chocolatier James O.
Welch back in 1949, the bite-size candy was named after a popular play at the time called "Junior Miss.
" Didn't sound quite right.
So he changed it from Junior Miss to Junior Mints.
The name may have changed, but what hasn't changed is the recipe.
Today, the mint is made by Tootsie Industries.
But they still use the same simple ingredients today that they've used for decades mainly sugar, chocolate, and mint, and a lot of it.
The liquid sugar tanks hold about 100,000 pounds.
And we have two of those.
You heard that right Sweet.
The process gins as all that liquid sweetness gets pumped into cooking vats and is heated to over 200 degrees.
That sugar solution is then poured onto a cooling wheel.
Jets, filled with 50-degree water, spray the inside of the wheel, maintaining a consistent temperature.
As the sugar mixture makes its way around the wheel, it cools and starts to firm up.
It then flows into a fondant beater.
And the beating action of this mixer turns the sugar crystals into a creamy white fondant.
Fondant is simply a fancy name for a thick and creamy sugar paste.
And in the case of the Junior Mints, it's the base for the sweet cream centers.
Next, the white fondant gets pumped into a nearby beater, where the addition of natural peppermint oil and a creaming agent complete the ingredients for the Junior Mint centers.
The cream is then pumped over to a depositor.
The depositor then measures out the exact portion that is required for a Junior Mint center.
Those warm centers now take a 20-minute ride on a 200-foot cooling belt before heading along another conveyor to the panning room.
Once it enters the pan room, it's fed into revolving pans.
And the white centers start to receive a spray of warm chocolate.
Creamy center check.
Dark chocolate shell check.
But there's still one more step.
The final step of making a Junior Mint is adding a confectioner's glaze to make it shiny.
Once those miraculous mints have their shine on, they are scooped out into white buckets that travel down a conveyor into the sorting room.
Now, occasionally some of those mints stick together.
This vibrating screen keeps then from going any further.
We want to make sure the best quality mints are reaching our customers.
Inspectors make one final pass.
And then they are weighed, toted, and sent off to get a little rest after all that hard work.
They have to cure for 1 hour, so the shell can dry, before they can be packaged.
Once dry, a bucket elevator carries the mass of mints to another scale that sorts and delivers them into their boxes, a whole lot of boxes.
We make over 3 billion Junior Mints every year.
It's a good thing, too.
I don't know about you, but once I start eating a box of Junior Mints, I can't stop.
Take one small Junior Mint, and then another and another.
It just melts in your mouth.
When we return, one of my favorite ways to get my daily vegetable.
Hey! Who doesn't love carrot cake? Mmm! That cream cheese frosting makes my mouth water just thinking about it.
I happen to think about carrot cake a lot actually.
And thank goodness I don't have to bake a whole cake every time I get a craving.
San Diego-based Ne-Mo's Bakery has been making a snack-size version for nearly 4 decades.
It all started when Ned and Mona Smith, otherwise known as Ne-Mo, began a storefront bake shop in 1976.
And just around the corner from that shop was a convenience store whose owner really liked their carrot cake.
So he came in and asked us if we would cut the product into squares and wrap it for him to sell by his coffee pots.
The mini cakes were such a hit that soon Ne-Mo's was selling their cakes at snack bars nationwide.
And what makes Ne-Mo's carrot cake so popular? Well, first and foremost, the carrots.
The carrots are fresh.
They're put into the mixer, then ground up.
are mixed with as well as sugar, flour, and some secret ingredients, including cinnamon.
All the ingredients mix for about 4 minutes, until it's the right consistency for a light and fluffy cake.
Meanwhile, a line of 12x18 pans make their way down the conveyor, where they get a quick spritz of nonstick spray before heading under the depositor.
Each pan is then filled with nearly 6 pounds of batter before bakers slide them into racks and roll them to the oven.
The oven counts out two rows of five pans, then places them onto one of the five decks before going back for another set of 10 pans to place on the next deck.
The oven is set to 355 degrees.
And each pan spends 60 minutes traveling across the 60-foot deck.
Then an elevator retrieves the pans and transfers them to a take-away conveyor.
From there, workers transfer the pans onto cooling racks, where they hang out for about 1/2 hours.
Now that the cakes have reached the ideal temperature, they're ready to eat.
But not so fast.
We're missing the best part.
Cream cheese, margarine, and powdered sugar go into a gigantic mixer that holds each 400-pound batch.
After a 41/2 minute mix, the smooth and creamy icing is then gravity fed into a large vat below.
At this point, the icing looks so delicious, you may be tempted to steal a taste.
But it's still not ready to spread on the carrot cake.
It has to cool to between 40 and 50 degrees for at least 2 hours so it won't melt when applied.
Once cooled, the worker rolls it to the icing line, where a pump sucks it out of the giant vat and into a hopper.
Now each of these lucky cakes take a ride under the depositor, where it gets a 22-ounce slathering of rich and creamy icing.
You may be tempted to take a whole cake.
But these are going to get sliced into more snackable-size pieces.
The cakes are cut by hand.
But these aren't your average kitchen knives.
Each three-prong knife quickly cuts the cakes into 24 equal 3x3-inch pieces.
Then it's off to the refrigerator for another swift That helps the icing set before it's ready for packaging.
Once cool, the cakes are ready for packaging.
But these workers need a little stretch before the join one of the seven lines that hand-wrap nearly 250 pieces a minute.
Each individually wrapped piece gets a label before being placed in a carton, frozen for freshness and shipped off to snack bars nationwide.
Once you take a bite of our carrot cake, you can't stop eating it.
It's so delicious.
Who doesn't love carrot cake? What're ya, blind? Right there! I go.
You know, it just doesn't happen.
And we're not ready.
When I crave a truck to drive by and ruin our take Oh, you mean the second truck.
We'll wait for that truck.

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