Unwrapped 2.0 (2015) s03e05 Episode Script
Inside Job
On this episode of "Unwrapped 2.
0," we'll reveal that the secret to these colorful treats lies inside.
From a chewy taffy that's bursting with fruity flavors to frozen stuffed pockets of pasta filled with cheesy chicken to a spicy cheddar that'll fire up a fiesta in your mouth to a chocolate confection packed with nutty crunch, it's time to check out some truly tasty inside jobs.
My mom always taught me that it's what's on the inside that counts.
Well, lovely candy company Superfruit Chews has a little inside secret that makes them very special.
We are the only candy company that offers real fruit bits in our Superfruit Chews.
That may explain the fruit part, but what about the chew part? Well, that starts here when sugar, brown-rice syrup, palm oil, fruit inclusions, and other natural flavors are poured into a massive It's heated to a boiling 300 degrees while a giant blade stirs the candy for 40 minutes until it becomes a gooey, sticky taffy.
After it's cooked to the correct temperature, we pump it out of that last kettle and into another wheel.
It's like a Ferris wheel for candy.
But it's doing more than giving it a ride.
The wheel is chilled to 40 degrees so it cools the molten candy as it takes a carnival ride around the drum.
It's just meant to give it an extra little time to cool down to a lower temperature.
The candy thickens as it cools, and wave after wave after wave of sweet, sticky taffy pour into these trays.
It takes 45 pounds of taffy to fill up each tray.
Once it's full, a worker separates the candy from the cooling wheel and carries it over to an 800-pound mixer.
Once the mixer starts working the taffy, citric acid goes in for an extra punch of tartness.
And now it's time for this candy's fruity inside job.
The super great thing about the chews is the dried fruit, which really brings out the fruit flavors.
And its vibrant colors.
Real dried fruit in a candy? Of course.
Gigantic mixing blades rotate the candy until everything's blended.
Then the still-soft candy is poured into trays where it will cure for 24 hours.
Once the candy is cured to the point where it's firmer, but not so firm that it will chip in the wrapper, workers give the slab a little massage.
And it's off to the batch roller, which is where the taffy slabs are squeezed down to size.
Spinning rollers compress the candy from 12 inches all the way down to 1-inch thick.
By the time it slithers through the batch roller, the taffy becomes one long snake-like rope.
The batch roller was pretty cool, but it's got nothing on this next machine the high-speed former.
In the blink of an eye, the former takes the rope candy and cuts it into bite-sized pieces.
Those rectangles of fruit-filled taffy move straight to a machine that covers them in the lovely candy wrappers.
Every hour, this machine pops out 25,000 fruity pieces.
Think about that This thing deserves a raise.
At that point, we go ahead and mix the three flavors together.
Blueberry, raspberry, and cranberry chews are weighed out before being deposited in Lovely Candy Company's iconic bags.
Our Lovely packaging speaks to the heart.
It draws you in I think it tells you that it's a fabulous product inside.
of Superfruit Chews makes their way out of the factory and into the mouths of candy fans each year.
If you want to see a kid smile, give him a Superfruit Chew.
Coming up, discover how a patty of peanut butter is the secret to this chocolaty inside job.
And later, learn how this pasta gets its puffed-up shape.
Hey In my opinion, there are two things that go great with chocolate.
The first is my mouth.
The second is peanut butter, and I'm not the only one who thinks so.
MacKensie Colt thinks so, too.
So she created Nashville's iconic Colts Bolts.
Why bolts? It's so good.
It hits you like a lightning bolt, so I called it Colts Bolts.
MacKensie's love for baking didn't stop when she stepped out of the kitchen.
I always loved to cook, and so I would take a cookbook to bed and read that instead of a novel.
Inspired by her bedtime reading, she would often get up the next day and experiment with recipes.
And one fateful morning, she came up with the candy recipe that Colts Bolts still uses today.
So, I went out to buy chocolate bars and all they had on the shelves were chocolate bars with almonds in them.
And so I tried that, and it made a huge difference.
Chocolate, peanut butter, and almonds? Talk about an inside job.
And every single Bolt starts with the same key ingredient rich chocolate.
We have a 750-pound chocolate tank that is full of chocolate.
We start by tempering it, because that's a process that takes about two hours.
Tempering the chocolate gives it a smooth, glossy texture and snap when you bite into it.
Most people don't know, but when chocolate melts, the fatty acids tend to separate.
The objective in tempering is to get these fatty acids back together again in a stable form.
We can't have unstable chocolate, can we? We go through about 100,000 pounds of chocolate a year.
That's funny.
That's the same amount I go through, too.
All that smooth, velvety, liquid chocolate goes from a massive melting tank into a muffin tin, just like you have in your kitchen.
A layer of chocolate is pumped into the tin creating the bottom layer of the candy.
As the chocolate-filled muffin tins cool, it's time for the next ingredient almonds.
The team preps the almonds for the oven, where they'll roast the whole almonds at 300 degrees for 22 minutes.
Mmm! What I wouldn't give for Smell-O-Vision right now.
Once they're roasted to perfection, the almonds are set aside to cool.
And then we mix the peanut-butter centers.
First in the mixer is the powdered sugar, then the peanut butter, butter, and some more powdered sugar for good measure.
All of these ingredients come together to form the sweet, salty, peanut buttery center Colts Bolts are known for.
Once the peanut-butter center is mixed to perfection, it's ready for the food former.
You'll never guess how this machine got its start.
Its first job was a hamburger-patty press.
They modified it, so now it cranks out perfectly shaped discs of peanut butter.
Talk about thinking outside the box.
When the peanut-butter centers are formed, we take that first layer of chocolate, then we put peanut butter, and then we put the whole roasted almonds on top, at least four or five.
If you thought the recycled hamburger-patty press was cool, then you'll love this.
Once the bottom chocolate layer, the peanut-butter center, and the whole roasted almonds are in the tin, an 80-year-old hand-operated pie press is used to gently smoosh the almonds into the peanut-butter layer.
Some things just never go out of style.
But they're not done yet.
Oh, no.
These delectable candies need a chocolate top.
When the chocolate goes on the last layer, it goes on smooth and the finish is beautiful.
When the muffin tins are complete, they're loaded on to a rack and sent off to the freezer for some alone time.
So, you put them in the freezer for a couple of hours, and when they've solidified and hardened enough to pop out of the muffin tins, we bring them up to this very special little wrapper.
Not to be outdone by the old, manually operated pie press or the customized food former, the antique bun-wrapper machine is as unique as Colts Bolts themselves.
And it's such a special process, because they just don't make wrapping machines like this anymore.
It's not high-speed, so it'll wrap as fast as you can load it on to the belt.
And it wraps them first in glassine paper, and then we take all of those and run it through the machine again and wrap it in foil.
As the candy flies off the wrapping machine, workers are standing by to put on the finishing touch a Colt Bolt sticker.
Then it's off to packaging, where 24 Colts Bolts at a time are boxed up.
And then this scrumptious chocolate-stuffed treat is shipped out all across the country.
When you open the wrapping and you bite into it, it's amazing.
So good.
Anyone have a glass of milk? Coming up, learn what hidden, savory flavors fill up this pasta pocket.
And later, find out how these peppers give this cheddar its fiery name.
Hey I don't like to go to the trouble of making a meal to go with my pasta.
I like it better when the meal comes on the inside.
When it comes to filling those pillowy pockets of pasta, the Parla Company has it down pat with its line of frozen raviolis.
My wife and I received a wedding gift, and it was a pasta machine.
And we hand-made pasta.
It was a hobby that turned into a business.
What started as a small mom-and-pop business now churns out an entire line of frozen pastas.
But these delicious frozen foods start with fresh ingredients.
Today, they're mixing up a batch of chicken and spinach ravioli.
First, fresh farm spinach is gently washed and run through a centrifuge.
That's like a salad spinner on steroids.
For three minutes, the spinach spins inside this machine to remove any excess moisture.
What we're left with after that is a much drier spinach.
We run it through a grinding machine that takes that spinach and chops it down to a very consistent, smooth texture.
But spinach isn't the only ingredient inside the ravioli.
It's time for a little protein fresh, whole chicken breast.
The chicken makes its way through a special dicing machine that cuts the breasts into uniform 3/4-inch pieces.
Those bite-sized pieces are carried into a braising pan that cooks up to 80 pounds of chicken for 20 minutes.
Throughout that process, the operator is going over and inspecting the chicken and stirring it and making sure we get a very consistent, even cook.
When time is up, they open a valve on the side of the cooker to release any excess moisture.
This is very important to our process, because our fillings are very firm.
Out of the cooker and into buckets, the chicken is wheeled into a freezer room where it'll cool down for a few hours until it reaches 55 degrees.
We've got spinach.
We've got chicken.
How about a little cheese? A whopping 3,000 pounds of ricotta, Parmesan, and Romano cheeses are poured together in a giant blender.
But Parla doesn't stop there They add 3,000 pounds of chopped spinach.
And how about a mix of sautéed garlic and butter? Oh, and a sprinkle of salt, a dash of pepper, and a heaping of rosemary? Don't mind if I do.
All those ingredients churn together before adding the tender, juicy chicken pieces.
And after a few minutes of mixing, the filling is ready to go.
We're still missing something though, maybe the most important part of all pasta.
Each batch begins with 100 pounds of extra fancy durum wheat flour.
It's dumped into a mixer along with eggs and beta-carotene for color and strength.
It basically just adds some gluten to the pasta, which actually makes it stronger.
And that's what gives it stretchiness.
It may be strong, but it's not quite ready to take on the ravioli shape just yet.
First it needs to run through a sheeter.
Workers place the dough inside a hopper at the top, and as it travels through the sheeter, it's squeezed by a series of rollers from a giant dough ball into a long, 3/8ths of an inch sheet.
And this is what comes out at the end.
A giant rolling pin spins round and round, collecting the dough until it weighs around 50 pounds.
Then a worker hand-carries the batch of ravioli.
Two rolls on the machine, and they're feeding dough from the back of the machine and the front of the machine and you have two rolls that are coming together.
The two sheets of dough unravel, meeting each other at the forming duct, which shapes them into ravioli squares.
At that exact same time, you have pistons that are moving up and down and in and out of that pocket of the die introducing the filling.
One ounce of filling goes into every 21/2-inch pocket of dough.
Now, that's what I call an inside job.
I love to see the ravioli being formed.
The pillow is perfectly plumped up.
Every minute, 216 pieces fall off the machine.
But they don't go too far.
It's straight into a scorching-hot 205-degree cooker for two minutes.
As they exit the cooker, the partially cooked puffed-up pasta goes through a quick cool rinse to remove any extra starch.
Now these little beauties need to dry off.
And believe me, they take air-drying to a whole, new level.
A canopy of high-powered fans bring the temperature of the ravioli down in preparation for freezing.
And this freezer isn't like any you've ever seen before.
The blast freezer has close to 100 feet of belts in it, and the product will cascade through it.
The minus 25 degree freezer brings the temperature of the ravioli down to negative 10 degrees and freezes the pasta solid over the course of 20 minutes.
Frozen to the core, the ravioli heads to packaging, where they are placed into 20-ounce containers and vacuum-sealed for freshness.
Every day, Parla produces over 100,000 cheesy, plump, delicious ravioli.
All those pasta-filled pockets make their way into cartons and eventually into kitchens around the country, ready to become someone's delicious dinner.
You really don't have to do much else except boil water.
Coming up, discover how this spicy cheddar gets its farm-fresh taste.
Hey I love cheese and I love spicy, so what's inside this fiery fiesta cheddar cheese is right up my alley.
And nobody packs flavor into a wedge like Sweetwater Valley Farms.
It's a work of love and art, because these guys take it all the way from udder to table.
The whole farmstead concept has kind of developed in recent years.
It gives us some control, and it gives us the ability to tweak that finished product.
Yes.
Here on the farm in Sweetwater, Tennessee, they make everything from start to finish, not only raising their own cows but even growing the grain that feeds them.
Before biting down into that fiery cheddar cheese, we need milk and lots of it.
We have a total of about 2,400 cows.
Whoa! So, how do they milk that many cows? Well, it turns out they've gone high-tech to milk this herd.
A worker cleans the udders and attaches hoses to the cow to begin milking, kind of like a robotic milk maid.
Each cow will produce anywhere from 9 to 12 gallons in a day.
When the cows are finished, the hoses automatically release.
After our cows are milked, it's gonna travel through pipes into these big holding tanks where it's held and cooled down to about 37 degrees.
The chilled milk is pumped into a massive for the quarter-mile trip up the road to its dairy destination.
When it arrives, the milk is heat pasteurized to remove any unwanted bacteria before it flows into this massive Now, this is where we do a 180.
The milk is pasteurized to remove bad bacteria.
But after the vat is filled, they actually add in a different bacteria.
We're putting bacteria in to consume the lactose and produce acid.
It's called fermentation, and it's what gives the cheese its tang.
It's basically turning this milk into yogurt.
The fermentation process takes eight hours.
During that time, the vat is heated to 88 degrees, and the milk is constantly stirred to ensure even distribution.
Something's missing here.
No way I'm putting that on my burger.
So, it's time for a little chemistry experiment.
Enzymes called rennet are added to the fermented milk to start the curdling process.
After about 30 minutes, the liquid mix begins to turn into a large jell-o-y mass of curds and whey.
Curds are the solid protein particles in the vat, and whey is the liquid.
Together, they are known as cottage cheese.
But we know that this beautiful batch is destined for cheddar greatness.
So this vat of whey needs to move on to the drain table.
They start out really, really fragile, and then by the time they're ready to go to the drain table, they're pretty rugged.
It takes about an hour for the full vat to be pumped out and over to the drain table.
Here, the perforated bottom of the table helps to drain away the liquid whey, leaving behind the precious curds.
For two hours, mechanical paddles spin and workers with shovels constantly stir the batch.
If you just let them sit, they'll just mat back together and become a solid mass.
So we're just keeping them broken up.
You can eat these delicious curds at this point, but I'm holding out for their last ingredient.
Bring on the heat.
Our Fiery Fiesta Cheese has a lot of jalapeños in it, so it's got that really fiery kick to it when you bite into it.
To ensure a powerful, spicy punch, and green peppers are added to the curds.
This pepper mix is so intense that workers must be careful to always use scoops and never let the peppers or the brine touch their skin.
After the flavor's mixed in, we're gonna take those cheese particles and put them out into our molds.
Each block mold holds that is pressed overnight to release any remaining whey.
And then the big, baby blocks are placed here in the aging room for a minimum of four months to allow the cheese to mature.
All you want to do is give it enough time where it's one, nice smooth block of cheese.
They grow up so fast, don't they? When this batch of Fiery Fiesta Cheddar is officially ready for sale, the large blocks will be cut down to market sizes.
And whether you're looking for a block, a wedge, or even some cheese curds, they're all shrink-wrapped and labeled to be shipped to supermarkets across the country.
It's just a cheese has a good mouth appeal, great texture, and then that real kick from peppers.
If I talk like this, I could always make it work.
But when I have to talk like this That's the problem, see? Was that "in" enough for you? I'm making it work! What? I'm getting better at it.
I've been working really hard.
0," we'll reveal that the secret to these colorful treats lies inside.
From a chewy taffy that's bursting with fruity flavors to frozen stuffed pockets of pasta filled with cheesy chicken to a spicy cheddar that'll fire up a fiesta in your mouth to a chocolate confection packed with nutty crunch, it's time to check out some truly tasty inside jobs.
My mom always taught me that it's what's on the inside that counts.
Well, lovely candy company Superfruit Chews has a little inside secret that makes them very special.
We are the only candy company that offers real fruit bits in our Superfruit Chews.
That may explain the fruit part, but what about the chew part? Well, that starts here when sugar, brown-rice syrup, palm oil, fruit inclusions, and other natural flavors are poured into a massive It's heated to a boiling 300 degrees while a giant blade stirs the candy for 40 minutes until it becomes a gooey, sticky taffy.
After it's cooked to the correct temperature, we pump it out of that last kettle and into another wheel.
It's like a Ferris wheel for candy.
But it's doing more than giving it a ride.
The wheel is chilled to 40 degrees so it cools the molten candy as it takes a carnival ride around the drum.
It's just meant to give it an extra little time to cool down to a lower temperature.
The candy thickens as it cools, and wave after wave after wave of sweet, sticky taffy pour into these trays.
It takes 45 pounds of taffy to fill up each tray.
Once it's full, a worker separates the candy from the cooling wheel and carries it over to an 800-pound mixer.
Once the mixer starts working the taffy, citric acid goes in for an extra punch of tartness.
And now it's time for this candy's fruity inside job.
The super great thing about the chews is the dried fruit, which really brings out the fruit flavors.
And its vibrant colors.
Real dried fruit in a candy? Of course.
Gigantic mixing blades rotate the candy until everything's blended.
Then the still-soft candy is poured into trays where it will cure for 24 hours.
Once the candy is cured to the point where it's firmer, but not so firm that it will chip in the wrapper, workers give the slab a little massage.
And it's off to the batch roller, which is where the taffy slabs are squeezed down to size.
Spinning rollers compress the candy from 12 inches all the way down to 1-inch thick.
By the time it slithers through the batch roller, the taffy becomes one long snake-like rope.
The batch roller was pretty cool, but it's got nothing on this next machine the high-speed former.
In the blink of an eye, the former takes the rope candy and cuts it into bite-sized pieces.
Those rectangles of fruit-filled taffy move straight to a machine that covers them in the lovely candy wrappers.
Every hour, this machine pops out 25,000 fruity pieces.
Think about that This thing deserves a raise.
At that point, we go ahead and mix the three flavors together.
Blueberry, raspberry, and cranberry chews are weighed out before being deposited in Lovely Candy Company's iconic bags.
Our Lovely packaging speaks to the heart.
It draws you in I think it tells you that it's a fabulous product inside.
of Superfruit Chews makes their way out of the factory and into the mouths of candy fans each year.
If you want to see a kid smile, give him a Superfruit Chew.
Coming up, discover how a patty of peanut butter is the secret to this chocolaty inside job.
And later, learn how this pasta gets its puffed-up shape.
Hey In my opinion, there are two things that go great with chocolate.
The first is my mouth.
The second is peanut butter, and I'm not the only one who thinks so.
MacKensie Colt thinks so, too.
So she created Nashville's iconic Colts Bolts.
Why bolts? It's so good.
It hits you like a lightning bolt, so I called it Colts Bolts.
MacKensie's love for baking didn't stop when she stepped out of the kitchen.
I always loved to cook, and so I would take a cookbook to bed and read that instead of a novel.
Inspired by her bedtime reading, she would often get up the next day and experiment with recipes.
And one fateful morning, she came up with the candy recipe that Colts Bolts still uses today.
So, I went out to buy chocolate bars and all they had on the shelves were chocolate bars with almonds in them.
And so I tried that, and it made a huge difference.
Chocolate, peanut butter, and almonds? Talk about an inside job.
And every single Bolt starts with the same key ingredient rich chocolate.
We have a 750-pound chocolate tank that is full of chocolate.
We start by tempering it, because that's a process that takes about two hours.
Tempering the chocolate gives it a smooth, glossy texture and snap when you bite into it.
Most people don't know, but when chocolate melts, the fatty acids tend to separate.
The objective in tempering is to get these fatty acids back together again in a stable form.
We can't have unstable chocolate, can we? We go through about 100,000 pounds of chocolate a year.
That's funny.
That's the same amount I go through, too.
All that smooth, velvety, liquid chocolate goes from a massive melting tank into a muffin tin, just like you have in your kitchen.
A layer of chocolate is pumped into the tin creating the bottom layer of the candy.
As the chocolate-filled muffin tins cool, it's time for the next ingredient almonds.
The team preps the almonds for the oven, where they'll roast the whole almonds at 300 degrees for 22 minutes.
Mmm! What I wouldn't give for Smell-O-Vision right now.
Once they're roasted to perfection, the almonds are set aside to cool.
And then we mix the peanut-butter centers.
First in the mixer is the powdered sugar, then the peanut butter, butter, and some more powdered sugar for good measure.
All of these ingredients come together to form the sweet, salty, peanut buttery center Colts Bolts are known for.
Once the peanut-butter center is mixed to perfection, it's ready for the food former.
You'll never guess how this machine got its start.
Its first job was a hamburger-patty press.
They modified it, so now it cranks out perfectly shaped discs of peanut butter.
Talk about thinking outside the box.
When the peanut-butter centers are formed, we take that first layer of chocolate, then we put peanut butter, and then we put the whole roasted almonds on top, at least four or five.
If you thought the recycled hamburger-patty press was cool, then you'll love this.
Once the bottom chocolate layer, the peanut-butter center, and the whole roasted almonds are in the tin, an 80-year-old hand-operated pie press is used to gently smoosh the almonds into the peanut-butter layer.
Some things just never go out of style.
But they're not done yet.
Oh, no.
These delectable candies need a chocolate top.
When the chocolate goes on the last layer, it goes on smooth and the finish is beautiful.
When the muffin tins are complete, they're loaded on to a rack and sent off to the freezer for some alone time.
So, you put them in the freezer for a couple of hours, and when they've solidified and hardened enough to pop out of the muffin tins, we bring them up to this very special little wrapper.
Not to be outdone by the old, manually operated pie press or the customized food former, the antique bun-wrapper machine is as unique as Colts Bolts themselves.
And it's such a special process, because they just don't make wrapping machines like this anymore.
It's not high-speed, so it'll wrap as fast as you can load it on to the belt.
And it wraps them first in glassine paper, and then we take all of those and run it through the machine again and wrap it in foil.
As the candy flies off the wrapping machine, workers are standing by to put on the finishing touch a Colt Bolt sticker.
Then it's off to packaging, where 24 Colts Bolts at a time are boxed up.
And then this scrumptious chocolate-stuffed treat is shipped out all across the country.
When you open the wrapping and you bite into it, it's amazing.
So good.
Anyone have a glass of milk? Coming up, learn what hidden, savory flavors fill up this pasta pocket.
And later, find out how these peppers give this cheddar its fiery name.
Hey I don't like to go to the trouble of making a meal to go with my pasta.
I like it better when the meal comes on the inside.
When it comes to filling those pillowy pockets of pasta, the Parla Company has it down pat with its line of frozen raviolis.
My wife and I received a wedding gift, and it was a pasta machine.
And we hand-made pasta.
It was a hobby that turned into a business.
What started as a small mom-and-pop business now churns out an entire line of frozen pastas.
But these delicious frozen foods start with fresh ingredients.
Today, they're mixing up a batch of chicken and spinach ravioli.
First, fresh farm spinach is gently washed and run through a centrifuge.
That's like a salad spinner on steroids.
For three minutes, the spinach spins inside this machine to remove any excess moisture.
What we're left with after that is a much drier spinach.
We run it through a grinding machine that takes that spinach and chops it down to a very consistent, smooth texture.
But spinach isn't the only ingredient inside the ravioli.
It's time for a little protein fresh, whole chicken breast.
The chicken makes its way through a special dicing machine that cuts the breasts into uniform 3/4-inch pieces.
Those bite-sized pieces are carried into a braising pan that cooks up to 80 pounds of chicken for 20 minutes.
Throughout that process, the operator is going over and inspecting the chicken and stirring it and making sure we get a very consistent, even cook.
When time is up, they open a valve on the side of the cooker to release any excess moisture.
This is very important to our process, because our fillings are very firm.
Out of the cooker and into buckets, the chicken is wheeled into a freezer room where it'll cool down for a few hours until it reaches 55 degrees.
We've got spinach.
We've got chicken.
How about a little cheese? A whopping 3,000 pounds of ricotta, Parmesan, and Romano cheeses are poured together in a giant blender.
But Parla doesn't stop there They add 3,000 pounds of chopped spinach.
And how about a mix of sautéed garlic and butter? Oh, and a sprinkle of salt, a dash of pepper, and a heaping of rosemary? Don't mind if I do.
All those ingredients churn together before adding the tender, juicy chicken pieces.
And after a few minutes of mixing, the filling is ready to go.
We're still missing something though, maybe the most important part of all pasta.
Each batch begins with 100 pounds of extra fancy durum wheat flour.
It's dumped into a mixer along with eggs and beta-carotene for color and strength.
It basically just adds some gluten to the pasta, which actually makes it stronger.
And that's what gives it stretchiness.
It may be strong, but it's not quite ready to take on the ravioli shape just yet.
First it needs to run through a sheeter.
Workers place the dough inside a hopper at the top, and as it travels through the sheeter, it's squeezed by a series of rollers from a giant dough ball into a long, 3/8ths of an inch sheet.
And this is what comes out at the end.
A giant rolling pin spins round and round, collecting the dough until it weighs around 50 pounds.
Then a worker hand-carries the batch of ravioli.
Two rolls on the machine, and they're feeding dough from the back of the machine and the front of the machine and you have two rolls that are coming together.
The two sheets of dough unravel, meeting each other at the forming duct, which shapes them into ravioli squares.
At that exact same time, you have pistons that are moving up and down and in and out of that pocket of the die introducing the filling.
One ounce of filling goes into every 21/2-inch pocket of dough.
Now, that's what I call an inside job.
I love to see the ravioli being formed.
The pillow is perfectly plumped up.
Every minute, 216 pieces fall off the machine.
But they don't go too far.
It's straight into a scorching-hot 205-degree cooker for two minutes.
As they exit the cooker, the partially cooked puffed-up pasta goes through a quick cool rinse to remove any extra starch.
Now these little beauties need to dry off.
And believe me, they take air-drying to a whole, new level.
A canopy of high-powered fans bring the temperature of the ravioli down in preparation for freezing.
And this freezer isn't like any you've ever seen before.
The blast freezer has close to 100 feet of belts in it, and the product will cascade through it.
The minus 25 degree freezer brings the temperature of the ravioli down to negative 10 degrees and freezes the pasta solid over the course of 20 minutes.
Frozen to the core, the ravioli heads to packaging, where they are placed into 20-ounce containers and vacuum-sealed for freshness.
Every day, Parla produces over 100,000 cheesy, plump, delicious ravioli.
All those pasta-filled pockets make their way into cartons and eventually into kitchens around the country, ready to become someone's delicious dinner.
You really don't have to do much else except boil water.
Coming up, discover how this spicy cheddar gets its farm-fresh taste.
Hey I love cheese and I love spicy, so what's inside this fiery fiesta cheddar cheese is right up my alley.
And nobody packs flavor into a wedge like Sweetwater Valley Farms.
It's a work of love and art, because these guys take it all the way from udder to table.
The whole farmstead concept has kind of developed in recent years.
It gives us some control, and it gives us the ability to tweak that finished product.
Yes.
Here on the farm in Sweetwater, Tennessee, they make everything from start to finish, not only raising their own cows but even growing the grain that feeds them.
Before biting down into that fiery cheddar cheese, we need milk and lots of it.
We have a total of about 2,400 cows.
Whoa! So, how do they milk that many cows? Well, it turns out they've gone high-tech to milk this herd.
A worker cleans the udders and attaches hoses to the cow to begin milking, kind of like a robotic milk maid.
Each cow will produce anywhere from 9 to 12 gallons in a day.
When the cows are finished, the hoses automatically release.
After our cows are milked, it's gonna travel through pipes into these big holding tanks where it's held and cooled down to about 37 degrees.
The chilled milk is pumped into a massive for the quarter-mile trip up the road to its dairy destination.
When it arrives, the milk is heat pasteurized to remove any unwanted bacteria before it flows into this massive Now, this is where we do a 180.
The milk is pasteurized to remove bad bacteria.
But after the vat is filled, they actually add in a different bacteria.
We're putting bacteria in to consume the lactose and produce acid.
It's called fermentation, and it's what gives the cheese its tang.
It's basically turning this milk into yogurt.
The fermentation process takes eight hours.
During that time, the vat is heated to 88 degrees, and the milk is constantly stirred to ensure even distribution.
Something's missing here.
No way I'm putting that on my burger.
So, it's time for a little chemistry experiment.
Enzymes called rennet are added to the fermented milk to start the curdling process.
After about 30 minutes, the liquid mix begins to turn into a large jell-o-y mass of curds and whey.
Curds are the solid protein particles in the vat, and whey is the liquid.
Together, they are known as cottage cheese.
But we know that this beautiful batch is destined for cheddar greatness.
So this vat of whey needs to move on to the drain table.
They start out really, really fragile, and then by the time they're ready to go to the drain table, they're pretty rugged.
It takes about an hour for the full vat to be pumped out and over to the drain table.
Here, the perforated bottom of the table helps to drain away the liquid whey, leaving behind the precious curds.
For two hours, mechanical paddles spin and workers with shovels constantly stir the batch.
If you just let them sit, they'll just mat back together and become a solid mass.
So we're just keeping them broken up.
You can eat these delicious curds at this point, but I'm holding out for their last ingredient.
Bring on the heat.
Our Fiery Fiesta Cheese has a lot of jalapeños in it, so it's got that really fiery kick to it when you bite into it.
To ensure a powerful, spicy punch, and green peppers are added to the curds.
This pepper mix is so intense that workers must be careful to always use scoops and never let the peppers or the brine touch their skin.
After the flavor's mixed in, we're gonna take those cheese particles and put them out into our molds.
Each block mold holds that is pressed overnight to release any remaining whey.
And then the big, baby blocks are placed here in the aging room for a minimum of four months to allow the cheese to mature.
All you want to do is give it enough time where it's one, nice smooth block of cheese.
They grow up so fast, don't they? When this batch of Fiery Fiesta Cheddar is officially ready for sale, the large blocks will be cut down to market sizes.
And whether you're looking for a block, a wedge, or even some cheese curds, they're all shrink-wrapped and labeled to be shipped to supermarkets across the country.
It's just a cheese has a good mouth appeal, great texture, and then that real kick from peppers.
If I talk like this, I could always make it work.
But when I have to talk like this That's the problem, see? Was that "in" enough for you? I'm making it work! What? I'm getting better at it.
I've been working really hard.