Unwrapped 2.0 (2015) s03e06 Episode Script
It's a Rainbow
On this episode of "Unwrapped 2.
0," we'll venture into a world of rainbow flavors.
omtiuit chews surprising, to a salty corn chip whose color comes from an unexpected source, to a curry dish brimming with vibrant veggies, and, finally, a cake jam-packed with fruity flavors, these scrumptious snacks taste just as colorful as they look.
I've always loved chicken, and I've always loved beef.
But lately, my tastes have gotten a lot more exotic.
Now my favorite thing is lemurs, or maybe even frogs well, especially the red frogs.
I'm of course talking about Jelly Belly Organic Fruit Snacks.
Jelly Belly has been making its famous jelly beans for 40 years, but in 2015, they decided to liven up their product line with these rain-forest-themed treats.
And every bag is filled with a rainbow of flavors and colors.
We offer six different flavors cherry, lemon, strawberry, berry, orange, and apple.
These exotic animal treats get their start, like most candy, from lots and lots of sugar.
Proprietary amounts of sugar and tapioca syrup are blended inside a hopper.
After a quick two minutes, the mix is pumped into a second kettle, where they start to bring the rainbow to these chewy treats.
On the menu today cherry red.
After mixing at 200 degrees, the sugary slurry is poured into a hopper.
It's pretty easy to see how it got that name.
But this is just one machine in a series that spans across the entire factory floor.
Look at the size of this thing.
My favorite machine in the factory is the starch-molding machine, which, in the industry, is called a mogul.
It all starts with empty starch-molding trays that are lifted by a mechanical elevator one by one, filled to the brim with corn starch.
We have 200,000 pounds of molding starch.
The smooth, leveled-out trays slide underneath this behemoth a massive molding press which squeezes down on top of the trays, leaving hundreds of little, animal-shaped impressions.
Now it's time for the good stuff.
As the trays exit the press, they head straight for the deposit.
The hopper filled with cherry-slurry mix feeds into dozens of nozzles and fills the molds to the brim with gooey liquid.
These bits are saying goodbye to the mogul for now, but this isn't the last time we'll see this workhorse machine.
The fruit flavor-filled trays are off to the curing room to curl up for the evening.
The next morning, it's straight back to the mogul machine, where it's got one last trick up its sleeve.
It actually will flip the tray over and separate the fruit snack from the starch.
The mogul's getting in a full-body workout.
every minute.
We're producing nearly It's a stampede! The galloping herd of animal candies already taste delicious, but they're still a bit dusty.
At that point, the fruit snacks will go through a tumbler, and a little bit of oil will be added to give it a shine.
The oil helps clean off any remaining corn starch, and keeps the fruit chews separated as they head toward packaging.
The bright and shiny animal chews exit the tumbler and are emptied onto trays that can hold 25 pounds of candy.
As the trays fill, workers stack them on pallets, roll them down the row to the final stop the stoker belt.
So, what's a stoker, anyway? Well, it's pretty simple, actually.
It's a belt that vibrates to move the gummies along while also mixing the flavors together.
I'll take my gummies shaken, not stirred.
That belt will go into a bucket elevator and through the bucket elevator up into our scales.
The scales weigh the candy, and gravity drops them into individual bags.
We will pack up That's over 86,000 packages of fruit chews, ready to crate and ship, every single day.
If it tastes good, they'll come back and buy it again.
And that's something we've attempted in every candy we've ever made.
Coming up, discover which musical tool helps compose these crunchy chips.
And later, learn all the colors of the rainbow from this one cake.
Hey When I was a kid, chips pretty much came in one color chip color.
But not anymore.
It's a chip rainbow out there.
And no one produces a poppable-colored chip quite like RW Garcia's.
Somebody once said a tortilla chip is an edible spoon.
I like it that way.
I like it just eating it by itself.
Back in the early 1980s, when Robert and Margaret Garcia started their business, they saw an untapped market.
My father decided there was space for a natural tortilla chip that people would feel good about snacking on.
RW Garcia makes just about every color corn chip you can think of blue, yellow, red, white.
But it's their MixtBag of yellow and red that stands out as a fan favorite.
All good corn chips start with fresh dough.
Nothing screams "fresh dough" like 800,000 pounds of corn stuffed inside these silos.
are pumped into one of seven cookers.
The soupy slurry of corn is cooked at 145 degrees for 20 minutes before dropping into a quench tank, which is exactly what it sounds like a cool dunk that stops the cooking process.
Even corn needs a quick, refreshing bath on a hot day.
But this cooldown doesn't last for long.
These kernels are destined for the steeping kettle.
Steeping allows the moisture to penetrate all the way through the kernel of corn.
For 12 hours, water seeps into the center of the corn kernels and softens the skin.
The corn eventually turns to a gelatin before being pumped into a rotating tunnel, which gently removes the outer skins using a fine-mesh base and water-spray nozzles.
Even after all this moving, the corn kernels retain their shape, but not for much longer, thanks to this guy.
These twirling blades start cutting the skinned corn kernels, and gravity takes over.
The corn falls into a grinding stone that finely shreds it.
It's flaking down as it does that, and bunches it together and becomes what we refer to as "masa.
" The masa, or dough, is the building block for any tortilla chip.
Now that we've got our base for the chips, it's time to add a little color.
And you'll never guess what they use.
We add dehydrated beet to the corn masa.
Dehydrated beets? Who would've thunk it? It has a beautiful, beautiful, rich, red color and a delicious taste.
The red and yellow masas stay separated, but both are headed to the same place the sheeter.
The sheeter are two very large rollers.
It's kind of like you would roll out your pizza dough.
It squeezes and makes the precise thickness of the chip.
The sheeter squeezes both sets of dough down to about 1/8 inch thick before sending it to the rolling cutter.
Triangle-shaped dies cut the sheets of dough into tortilla chips, kind of like a giant, rotating cookie cutter.
It's churning out enough chips to fill 2,500 bags a minute.
Their creativity didn't stop with dehydrated beets for the red color.
They decided the best way to scrape off all these chips from the wheel was to use a musical tool.
It's a number 6 piano wire.
It cuts the masa off of the sheeters.
Now, that's thinking outside the box.
After the piano wire does its job, waves of corn chips fly into a super-heated oven.
I'm talking 750-degree heat.
It's really hot in there so that you get a good toast point on the chips.
After exactly 28 seconds, the chips fall onto a second conveyor that takes them for a quick ride toward the equilibrator.
The outside of the chips dried out in the oven, but there's still moisture on the inside.
To even the moisture levels, thousands of chips ride the equilibrator for 15 minutes before heading off to the fryer.
The fryer is 350 degrees, and it's a river of oil.
The colorful chips spend just under a minute in the bath of boiling oil.
Can we all agree that everything is better fried? They've got their crunch, but still need some seasoning.
That's where the spinning drum comes in.
As the chips tumble, they're sprayed with sea salt until every chip has just enough flavor.
From there, the sea of red and yellow chips travel up an incline belt toward the packaging room.
The chips drop into one of 14 scales that weighs and deposits them into bags.
We produce over 10 billion chips a year.
That's enough to wrap around the entire Earth 14 times over.
Coming up, learn how a little elementary science helped create the colors for this creamy cake.
Hey I love cake pretty much any cake yellow cake, chocolate cake, red velvet cake.
In fact, whatever color cake you make, I'll eat it.
And that goes for frosting and fillings, too.
So, when I found out about Caroline's Cakes in Spartanburg, South Carolina, you won't be surprised to find out that I was excited.
We were working on different fruit fillings, and I realized, "Well, why can't I make the colors of the rainbow out of the natural fruit flavors?" But just how do you bake a cake filled with rainbow colors? What makes the flavors just pop are all of our different curds and coulis.
Blackberry, blueberry, lime, lemon, orange, and raspberry? Whew! That's a mouthful of flavors.
And each one starts just like it would in your kitchen.
Each curd made on the stovetop, it's a very difficult process.
Curds are so delicate, they cannot take direct heat, so they are crafted here using double boilers, which allow the water in the bottom to steam and create the needed heat for the fruit mix in the top.
Butter and sugar are melted down before a combination of fruit juices and zests are added.
And the tricky part comes with the additions of the eggs.
If they're not tempered properly, the eggs will scramble and the whole recipe is ruined.
They slowly increase the temperature of the eggs until they have the right consistency.
But this is just one part of the rainbow.
For the next vibrant colors on our list, bring on the berries raspberry, blueberry, and blackberry.
The fresh fruit is placed in a large copper pot to be cooked.
We let that cook evenly, and just really kind of low and slow.
While the berries are being reduced, sugar and vanilla are heated to a boil and mixed with butter to make buttercream.
Once the berries are thickened and pureed, they are added to Caroline's white buttercream frosting.
Whether it's the red of the raspberry or the yellow of the lemon curd or the green of the lime curd or the blueberry or the blackberry, it's a really, really cool process.
Once all six flavors are ready, they will go in the cooler to firm up while the baking staff begins making those seven heavenly layers of cake.
And that starts here in the bake room, using these 80-quart mixers where butter and sugar are creamed together.
Once the sugar is fully incorporated and the butter is super creamy, and a hint of vanilla are added.
Then we add the flour, the baking soda, the baking powder, along with the buttermilk.
The final ingredients for the lemon cake is going to be our lemon.
Caroline's uses over 200 lemons in just one run.
That's almost 40 pounds of lemon zest and juice.
It's making my mouth pucker just thinking about it.
These gigantic mixers will continue stirring things up for about 20 minutes before the batter is complete.
The 90-pound batch of batter is poured into the hopper on top of the deposit.
Each turn of the valve releases a precise 5.
5 ounces of batter into a pan.
But before they are ready for the racks, they get a little love tap to ensure the batter is distributed evenly.
We don't want a layer that is thicker on one side and thinner on the other.
The cakes are now ready for baking, but this is no ordinary oven.
Think of it more like an extra-large rotisserie.
Caroline's mega roaster actually lifts the racks off the floor of the oven and rotates them around to ensure even heat as they bake.
Caroline's is capable of baking 360 layers of cake every 20 minutes.
After the rack is cooled, they take out the cakes out of the pans and stack them up seven high, and then it goes to the icing room, where it is staged for the next step, which is mid-filling the cake.
Mid-filling refers to frosting the inside layers of cake.
For those of you that remember the acronym "ROYGBIV," this is where that elementary-science trivia comes in handy.
Because Caroline's cake isn't just rainbow-inspired, they use the rainbow color spectrum as an actual blueprint.
So, it starts at the very bottom level, which is the violet, which, our fruit filling for violet is a blackberry.
Then the next fruit filling is the blueberry.
The decorators have assigned color stations, and each is responsible for adding their specific color.
Once they scoop, spread, and stack, they pass a layer to the right, and the next color is added until assembly is complete.
And at the end of the line, the cake is sent to be iced.
And believe me, you've never seen a machine like this before.
A light lemon-buttercream frosting is loaded in the top of this hopper.
A seven-layered cake is loaded onto a turntable, and when the pedal on the floor is activated, an automated arm moves over the top of the cake to dispense the icing, covering the cake.
Using a spatula, workers evenly spread the icing from top to bottom.
Then the cakes are placed back on the rack and wheeled into a large freezer.
We always freeze the cakes first before we wrap them to keep the icing intact.
Once the cakes are wrapped, they're placed in a tin for shipping.
It brings the child out in people of all ages.
It is just a really fun, delightful cake to eat and enjoy.
Coming up, find out what makes this curry so colorful.
Hey The sprinkling of spices, the heavenly aroma, and lots of color.
You know what time it is? Time for some Thai food.
And thanks to Amy's Kitchen's tasty frozen Thai Red Curry bowl, I can eat a rainbow of bright-red chilies, deep-green broccoli, and eye-popping orange carrots anytime I want.
The colors, the vegetables It all presents itself in such a beautiful way.
Started in 1987 with a family recipe for pot pie, Amy's owners, Andy and Rachel Berliner, grew the little company named after their daughter into one of the most popular brands in the frozen-food section.
You can just pull out this frozen meal, and it tastes fresh, it tastes homemade.
Today, Amy's Kitchen makes over 250 products, but a real favorite is their Thai Red Curry.
To create that exotic red-Thai-curry taste, the folks at Amy's start with what else? red curry paste.
The red curry paste is poured in a gigantic along with some tamari, sugar, and coconut milk.
The ingredients are mixed together, then boiled at over 200 degrees for about an hour, until it reduces into a rich, flavorful sauce.
As the curry sauce cools, it's time to get to work on another vital ingredient the tofu.
Amy's makes 10,000 pounds of their proprietary organic tofu from scratch every single day.
The tofu is sliced into 6-by-10-inch blocks.
A marinade of soy sauce, tamari, spices, and olive oil coat the tofu before being trayed and stacked on the baking cart.
Each cart holds about 250 pounds of tofu.
The racks are wheeled into the oven and baked at 500 degrees for 16 minutes.
Baking tofu when it's marinated really gives it a nice outer crust and a little salty flavor and caramelization and crunch.
Once the tofu is removed, testers take a bite from one of the 250-pound racks to make sure each cube of tofu in the curry bowl lives up to the Amy's standard.
The main thing they're looking for is that little bit of browning, little bit of saltiness, a nice chew.
Once it passes the test, the tofu goes into a slicer that dices it into 3/8-inch cubes.
By this time, the meal is starting to take shape, but you can't have a Thai curry bowl without the biggest staple in Thailand rice.
Jasmine rice is boiled in gigantic kettles for 8 to 9 minutes while workers continuously stir it with large paddles.
The paddles are used to keep the rice moving inside the kettle so that there's not clumps of rice.
When time's up, cold water and ice are added to the vat to stop the cooking.
Curry check.
Tofu check.
Rice check.
But where are the veggies? Turns out all those colorful, crunchy vegetables arrive pre-cut and are waiting at the assembly line.
All the different veggies that we add are all brought to the production line to begin making the meal.
Each bowl gets a scoop of rice and tofu, then comes the vegetables, including broccoli, sautéed onions, butternut squash, and carrots, which all get added in by hand.
Who needs a real rainbow when you got so many colors right here in one bowl? We buy about 130 million pounds of organic vegetables every year, which is about 20,000 acres.
Our sauce is applied with a depositor to control the weight and accurately place the sauce in the right place.
The curry then travels onto a scale, where workers make sure each bowl has the perfect before making the 45-minute journey through a -20-degree spiral freezer.
Someone's gonna need a serious parka to go in there.
Once they come out of the freezer, they get a quick shrink wrap that seals in the freshness before being hand-placed into the iconic Amy's carton.
Then it's off to the freezer section of your local grocery.
But I'm guessing it won't stay frozen long.
Our Thai Red Curry is a perfect meal.
It's so flavorful and very satisfying.
The sprinkling of spices, the sounds of trucks, the movement of buses.
I think it's time for some Thai food.
I-I just want to know.
Heh, heh, heh.
0," we'll venture into a world of rainbow flavors.
omtiuit chews surprising, to a salty corn chip whose color comes from an unexpected source, to a curry dish brimming with vibrant veggies, and, finally, a cake jam-packed with fruity flavors, these scrumptious snacks taste just as colorful as they look.
I've always loved chicken, and I've always loved beef.
But lately, my tastes have gotten a lot more exotic.
Now my favorite thing is lemurs, or maybe even frogs well, especially the red frogs.
I'm of course talking about Jelly Belly Organic Fruit Snacks.
Jelly Belly has been making its famous jelly beans for 40 years, but in 2015, they decided to liven up their product line with these rain-forest-themed treats.
And every bag is filled with a rainbow of flavors and colors.
We offer six different flavors cherry, lemon, strawberry, berry, orange, and apple.
These exotic animal treats get their start, like most candy, from lots and lots of sugar.
Proprietary amounts of sugar and tapioca syrup are blended inside a hopper.
After a quick two minutes, the mix is pumped into a second kettle, where they start to bring the rainbow to these chewy treats.
On the menu today cherry red.
After mixing at 200 degrees, the sugary slurry is poured into a hopper.
It's pretty easy to see how it got that name.
But this is just one machine in a series that spans across the entire factory floor.
Look at the size of this thing.
My favorite machine in the factory is the starch-molding machine, which, in the industry, is called a mogul.
It all starts with empty starch-molding trays that are lifted by a mechanical elevator one by one, filled to the brim with corn starch.
We have 200,000 pounds of molding starch.
The smooth, leveled-out trays slide underneath this behemoth a massive molding press which squeezes down on top of the trays, leaving hundreds of little, animal-shaped impressions.
Now it's time for the good stuff.
As the trays exit the press, they head straight for the deposit.
The hopper filled with cherry-slurry mix feeds into dozens of nozzles and fills the molds to the brim with gooey liquid.
These bits are saying goodbye to the mogul for now, but this isn't the last time we'll see this workhorse machine.
The fruit flavor-filled trays are off to the curing room to curl up for the evening.
The next morning, it's straight back to the mogul machine, where it's got one last trick up its sleeve.
It actually will flip the tray over and separate the fruit snack from the starch.
The mogul's getting in a full-body workout.
every minute.
We're producing nearly It's a stampede! The galloping herd of animal candies already taste delicious, but they're still a bit dusty.
At that point, the fruit snacks will go through a tumbler, and a little bit of oil will be added to give it a shine.
The oil helps clean off any remaining corn starch, and keeps the fruit chews separated as they head toward packaging.
The bright and shiny animal chews exit the tumbler and are emptied onto trays that can hold 25 pounds of candy.
As the trays fill, workers stack them on pallets, roll them down the row to the final stop the stoker belt.
So, what's a stoker, anyway? Well, it's pretty simple, actually.
It's a belt that vibrates to move the gummies along while also mixing the flavors together.
I'll take my gummies shaken, not stirred.
That belt will go into a bucket elevator and through the bucket elevator up into our scales.
The scales weigh the candy, and gravity drops them into individual bags.
We will pack up That's over 86,000 packages of fruit chews, ready to crate and ship, every single day.
If it tastes good, they'll come back and buy it again.
And that's something we've attempted in every candy we've ever made.
Coming up, discover which musical tool helps compose these crunchy chips.
And later, learn all the colors of the rainbow from this one cake.
Hey When I was a kid, chips pretty much came in one color chip color.
But not anymore.
It's a chip rainbow out there.
And no one produces a poppable-colored chip quite like RW Garcia's.
Somebody once said a tortilla chip is an edible spoon.
I like it that way.
I like it just eating it by itself.
Back in the early 1980s, when Robert and Margaret Garcia started their business, they saw an untapped market.
My father decided there was space for a natural tortilla chip that people would feel good about snacking on.
RW Garcia makes just about every color corn chip you can think of blue, yellow, red, white.
But it's their MixtBag of yellow and red that stands out as a fan favorite.
All good corn chips start with fresh dough.
Nothing screams "fresh dough" like 800,000 pounds of corn stuffed inside these silos.
are pumped into one of seven cookers.
The soupy slurry of corn is cooked at 145 degrees for 20 minutes before dropping into a quench tank, which is exactly what it sounds like a cool dunk that stops the cooking process.
Even corn needs a quick, refreshing bath on a hot day.
But this cooldown doesn't last for long.
These kernels are destined for the steeping kettle.
Steeping allows the moisture to penetrate all the way through the kernel of corn.
For 12 hours, water seeps into the center of the corn kernels and softens the skin.
The corn eventually turns to a gelatin before being pumped into a rotating tunnel, which gently removes the outer skins using a fine-mesh base and water-spray nozzles.
Even after all this moving, the corn kernels retain their shape, but not for much longer, thanks to this guy.
These twirling blades start cutting the skinned corn kernels, and gravity takes over.
The corn falls into a grinding stone that finely shreds it.
It's flaking down as it does that, and bunches it together and becomes what we refer to as "masa.
" The masa, or dough, is the building block for any tortilla chip.
Now that we've got our base for the chips, it's time to add a little color.
And you'll never guess what they use.
We add dehydrated beet to the corn masa.
Dehydrated beets? Who would've thunk it? It has a beautiful, beautiful, rich, red color and a delicious taste.
The red and yellow masas stay separated, but both are headed to the same place the sheeter.
The sheeter are two very large rollers.
It's kind of like you would roll out your pizza dough.
It squeezes and makes the precise thickness of the chip.
The sheeter squeezes both sets of dough down to about 1/8 inch thick before sending it to the rolling cutter.
Triangle-shaped dies cut the sheets of dough into tortilla chips, kind of like a giant, rotating cookie cutter.
It's churning out enough chips to fill 2,500 bags a minute.
Their creativity didn't stop with dehydrated beets for the red color.
They decided the best way to scrape off all these chips from the wheel was to use a musical tool.
It's a number 6 piano wire.
It cuts the masa off of the sheeters.
Now, that's thinking outside the box.
After the piano wire does its job, waves of corn chips fly into a super-heated oven.
I'm talking 750-degree heat.
It's really hot in there so that you get a good toast point on the chips.
After exactly 28 seconds, the chips fall onto a second conveyor that takes them for a quick ride toward the equilibrator.
The outside of the chips dried out in the oven, but there's still moisture on the inside.
To even the moisture levels, thousands of chips ride the equilibrator for 15 minutes before heading off to the fryer.
The fryer is 350 degrees, and it's a river of oil.
The colorful chips spend just under a minute in the bath of boiling oil.
Can we all agree that everything is better fried? They've got their crunch, but still need some seasoning.
That's where the spinning drum comes in.
As the chips tumble, they're sprayed with sea salt until every chip has just enough flavor.
From there, the sea of red and yellow chips travel up an incline belt toward the packaging room.
The chips drop into one of 14 scales that weighs and deposits them into bags.
We produce over 10 billion chips a year.
That's enough to wrap around the entire Earth 14 times over.
Coming up, learn how a little elementary science helped create the colors for this creamy cake.
Hey I love cake pretty much any cake yellow cake, chocolate cake, red velvet cake.
In fact, whatever color cake you make, I'll eat it.
And that goes for frosting and fillings, too.
So, when I found out about Caroline's Cakes in Spartanburg, South Carolina, you won't be surprised to find out that I was excited.
We were working on different fruit fillings, and I realized, "Well, why can't I make the colors of the rainbow out of the natural fruit flavors?" But just how do you bake a cake filled with rainbow colors? What makes the flavors just pop are all of our different curds and coulis.
Blackberry, blueberry, lime, lemon, orange, and raspberry? Whew! That's a mouthful of flavors.
And each one starts just like it would in your kitchen.
Each curd made on the stovetop, it's a very difficult process.
Curds are so delicate, they cannot take direct heat, so they are crafted here using double boilers, which allow the water in the bottom to steam and create the needed heat for the fruit mix in the top.
Butter and sugar are melted down before a combination of fruit juices and zests are added.
And the tricky part comes with the additions of the eggs.
If they're not tempered properly, the eggs will scramble and the whole recipe is ruined.
They slowly increase the temperature of the eggs until they have the right consistency.
But this is just one part of the rainbow.
For the next vibrant colors on our list, bring on the berries raspberry, blueberry, and blackberry.
The fresh fruit is placed in a large copper pot to be cooked.
We let that cook evenly, and just really kind of low and slow.
While the berries are being reduced, sugar and vanilla are heated to a boil and mixed with butter to make buttercream.
Once the berries are thickened and pureed, they are added to Caroline's white buttercream frosting.
Whether it's the red of the raspberry or the yellow of the lemon curd or the green of the lime curd or the blueberry or the blackberry, it's a really, really cool process.
Once all six flavors are ready, they will go in the cooler to firm up while the baking staff begins making those seven heavenly layers of cake.
And that starts here in the bake room, using these 80-quart mixers where butter and sugar are creamed together.
Once the sugar is fully incorporated and the butter is super creamy, and a hint of vanilla are added.
Then we add the flour, the baking soda, the baking powder, along with the buttermilk.
The final ingredients for the lemon cake is going to be our lemon.
Caroline's uses over 200 lemons in just one run.
That's almost 40 pounds of lemon zest and juice.
It's making my mouth pucker just thinking about it.
These gigantic mixers will continue stirring things up for about 20 minutes before the batter is complete.
The 90-pound batch of batter is poured into the hopper on top of the deposit.
Each turn of the valve releases a precise 5.
5 ounces of batter into a pan.
But before they are ready for the racks, they get a little love tap to ensure the batter is distributed evenly.
We don't want a layer that is thicker on one side and thinner on the other.
The cakes are now ready for baking, but this is no ordinary oven.
Think of it more like an extra-large rotisserie.
Caroline's mega roaster actually lifts the racks off the floor of the oven and rotates them around to ensure even heat as they bake.
Caroline's is capable of baking 360 layers of cake every 20 minutes.
After the rack is cooled, they take out the cakes out of the pans and stack them up seven high, and then it goes to the icing room, where it is staged for the next step, which is mid-filling the cake.
Mid-filling refers to frosting the inside layers of cake.
For those of you that remember the acronym "ROYGBIV," this is where that elementary-science trivia comes in handy.
Because Caroline's cake isn't just rainbow-inspired, they use the rainbow color spectrum as an actual blueprint.
So, it starts at the very bottom level, which is the violet, which, our fruit filling for violet is a blackberry.
Then the next fruit filling is the blueberry.
The decorators have assigned color stations, and each is responsible for adding their specific color.
Once they scoop, spread, and stack, they pass a layer to the right, and the next color is added until assembly is complete.
And at the end of the line, the cake is sent to be iced.
And believe me, you've never seen a machine like this before.
A light lemon-buttercream frosting is loaded in the top of this hopper.
A seven-layered cake is loaded onto a turntable, and when the pedal on the floor is activated, an automated arm moves over the top of the cake to dispense the icing, covering the cake.
Using a spatula, workers evenly spread the icing from top to bottom.
Then the cakes are placed back on the rack and wheeled into a large freezer.
We always freeze the cakes first before we wrap them to keep the icing intact.
Once the cakes are wrapped, they're placed in a tin for shipping.
It brings the child out in people of all ages.
It is just a really fun, delightful cake to eat and enjoy.
Coming up, find out what makes this curry so colorful.
Hey The sprinkling of spices, the heavenly aroma, and lots of color.
You know what time it is? Time for some Thai food.
And thanks to Amy's Kitchen's tasty frozen Thai Red Curry bowl, I can eat a rainbow of bright-red chilies, deep-green broccoli, and eye-popping orange carrots anytime I want.
The colors, the vegetables It all presents itself in such a beautiful way.
Started in 1987 with a family recipe for pot pie, Amy's owners, Andy and Rachel Berliner, grew the little company named after their daughter into one of the most popular brands in the frozen-food section.
You can just pull out this frozen meal, and it tastes fresh, it tastes homemade.
Today, Amy's Kitchen makes over 250 products, but a real favorite is their Thai Red Curry.
To create that exotic red-Thai-curry taste, the folks at Amy's start with what else? red curry paste.
The red curry paste is poured in a gigantic along with some tamari, sugar, and coconut milk.
The ingredients are mixed together, then boiled at over 200 degrees for about an hour, until it reduces into a rich, flavorful sauce.
As the curry sauce cools, it's time to get to work on another vital ingredient the tofu.
Amy's makes 10,000 pounds of their proprietary organic tofu from scratch every single day.
The tofu is sliced into 6-by-10-inch blocks.
A marinade of soy sauce, tamari, spices, and olive oil coat the tofu before being trayed and stacked on the baking cart.
Each cart holds about 250 pounds of tofu.
The racks are wheeled into the oven and baked at 500 degrees for 16 minutes.
Baking tofu when it's marinated really gives it a nice outer crust and a little salty flavor and caramelization and crunch.
Once the tofu is removed, testers take a bite from one of the 250-pound racks to make sure each cube of tofu in the curry bowl lives up to the Amy's standard.
The main thing they're looking for is that little bit of browning, little bit of saltiness, a nice chew.
Once it passes the test, the tofu goes into a slicer that dices it into 3/8-inch cubes.
By this time, the meal is starting to take shape, but you can't have a Thai curry bowl without the biggest staple in Thailand rice.
Jasmine rice is boiled in gigantic kettles for 8 to 9 minutes while workers continuously stir it with large paddles.
The paddles are used to keep the rice moving inside the kettle so that there's not clumps of rice.
When time's up, cold water and ice are added to the vat to stop the cooking.
Curry check.
Tofu check.
Rice check.
But where are the veggies? Turns out all those colorful, crunchy vegetables arrive pre-cut and are waiting at the assembly line.
All the different veggies that we add are all brought to the production line to begin making the meal.
Each bowl gets a scoop of rice and tofu, then comes the vegetables, including broccoli, sautéed onions, butternut squash, and carrots, which all get added in by hand.
Who needs a real rainbow when you got so many colors right here in one bowl? We buy about 130 million pounds of organic vegetables every year, which is about 20,000 acres.
Our sauce is applied with a depositor to control the weight and accurately place the sauce in the right place.
The curry then travels onto a scale, where workers make sure each bowl has the perfect before making the 45-minute journey through a -20-degree spiral freezer.
Someone's gonna need a serious parka to go in there.
Once they come out of the freezer, they get a quick shrink wrap that seals in the freshness before being hand-placed into the iconic Amy's carton.
Then it's off to the freezer section of your local grocery.
But I'm guessing it won't stay frozen long.
Our Thai Red Curry is a perfect meal.
It's so flavorful and very satisfying.
The sprinkling of spices, the sounds of trucks, the movement of buses.
I think it's time for some Thai food.
I-I just want to know.
Heh, heh, heh.