Unwrapped 2.0 (2015) s03e07 Episode Script

On this episode of "Unwrapped 2.
0," we'll leave you feeling a sweet sensation.
From a chocolatey square that oozes a sticky, smooth treat to a chewy cube that packs a surprisingly sour taste; to a new twist on the classic Swiss roll; to a lollipop that says it all in its name; these sugary sweets are a sensation waiting to happen.
You can't talk sweet sensations without bringing up the ultimate sweet treat: velvety, decadent, tantalizing chocolate.
No one does chocolate quite like Ghirardelli.
The San Francisco-based chocolatier has been perfecting the cocoa-based confection for over 150 years.
Domingo Ghirardelli founded this company in 1852.
He actually had learned the chocolate-making craft way back in Italy, where he grew up.
This San Francisco landmark has plenty of products to satisfy your sweet tooth.
On tap today, their famous milk chocolate caramel squares.
Just like all Ghirardelli products, these mouth-watering squares start withhe cocoa bean.
To make caramel squares, we start with tempering.
We pump chocolate over from the mass tank farm and then we run it through a tempering column.
The chocolate is heated to over 90 degrees, using a series of pipes filled with warm and cool water.
Tempering ensures that the chocolate is nice and glossy when the product's finished.
Once it's tempered, the chocolate is piped over to the molding room.
This is where the confection gets its square shape.
Before the liquid chocolate is deposited, the molding trays are warmed up to 90 degrees inside a temperature- controlled area.
This way, the trays won't disturb the already-tempered chocolate.
With the molds warm and toasty, the nozzles fill each of the 120 impressions with a half-ounce of decadent, creamy, milk chocolate.
I wonder if I can eat these, as fast as they can fill them.
From there, the mold travels into a section where we vibrate the mold and shake out all the air bubbles.
It also ensures that a smooth chocolate layer fills every corner of the mold, and that's key, because we're not making solid milk-chocolate squares.
We still need to make room for the caramel.
We actually flip the mold back over, and we allow the center part of the chocolate to drain out.
Some of the milk chocolate drains down on the con.
But once the molding trays flip right-side-up, there is still a thin layer of milk chocolate, known as the shell.
The reason why we do this is because we need the chocolate to form all the way up the sides of the mold.
With the shell complete, the molds travel into a room-temperature cooler for about 8 to 10 minutes, to harden the chocolate.
When it emerges from its chilly trip, it's time to add the luscious caramel filling.
The recipe for their caramel filling is a closely guarded secret, but, that indulgent and creamy taste is undeniable.
The caramel makes its way down to the depositor to meet the hardened chocolate shells.
As the shell-filled molds pass underneath the depositor, all 102 squares are filled with 5 grams of caramel.
Then, the squares go through the same path the chocolate shell traveled down, vibrated once again to knock out the air bubbles and evenly spread the caramel.
There's a quick, 8-minute trip through another cooler to set the caramel before traveling under infrared lights.
Hold on a second.
If we just cooled the squares down, why do we have to heat them up again? We're trying to liquify the little layer of chocolate shell that's still on top of the mold.
When we add the bottom, we want the shell and the bottom to seal very tightly together.
So, right after a little warming under the infrared light, the mold trays filled already with caramel and liquid chocolate shell get one last layer of chocolate.
Now that all the flavors are loaded in the trays to create perfect squares, they need to trim off any excess liquid chocolate.
A 1-foot-long knife scrapes along the tops of the trays, leaving behind milk chocolate caramel squares.
Once the bottom is complete, they go into another cooler, for about 25 minutes, to ensure that the final product is fully cooled.
Now, it's time for the iconic Ghirardelli wrappers.
The squares are deposited onto a conveyor belt that sends each one through a flow wrapper.
We fold and we form a roll of film around the squares.
We seal it on the bottom and then we also seal the ends while we cut the individual squares of hard elements down.
The flow wrappers cut That's 10 million squares each day.
And that's a good thing, because consumers can't seem to get enough of them.
You know, the caramel square has a perfect ratio of chocolate to filling.
What I like about it is the little bit of caramel that comes out.
Always kind of have to lick that a bit and then go back in for another bite.
Coming up discover how this sour chewy cube leaves a sweet-lasting impression.
And, later, learn how a nutty spread put a brand-new spin on this classic roll.
Hey! I've got a sweet tooth.
Actually, a lot of sweet teeth.
That's why I love this little treat, because its sour flavor turns into a sweet surprise.
I'm talking about Warheads Sour Chewy Cubes, the perfect mix of sour and sweet.
These fruity little candies are filled with flavors that will twist your tongue.
I love the kick of sour you get when you start eating it and then you finish with a sweet, chewy center.
Warheads Chewy Cubes first appeared in grocery stores in 2009 and they've been flying off the shelves ever since.
We developed Warheads Chewy Cubes to fill a demand and deliver an extra-sour, chewy experience.
To create that extreme sour outside and sugary-sweet inside, the cubes start in the candy kitchen.
Inside a giant, they pump in a mix of corn syrup and water before adding sugar.
The sugary mix is heated, first to 180 degrees, over a period of 15 to 20 minutes; then, to 330 degrees, in a separate kettle called a heat picker.
The heat picker instantly raises the temperature of the liquid over 100 degrees by injecting steam into the candy.
Boiling hot, this sugary slurry is fully cooked and ready for some color and flavor.
The color deck is where we add the color and flavor.
Six 100-pound tanks each hold a different juicy flavor of chewy curves.
The cooked slurry is pumped into tanks and mixed with food coloring and flavors for several minutes.
Filled with flavor, it's time for the sugary candy slurry to descend down from the color deck into the mobile machine.
The candy coming out of the color decks is still warm enough.
It's in a liquid state, almost like pumping water.
So, to give this liquid some shape, they need cornstarch molding trays, and lots of them.
As the tray passes under the depositor, nozzles release just enough liquid hot slurry to fill each mold.
It's just a beautiful array of colors, a kaleidoscope of color.
She's not kidding! There's a liquid rainbow of bright colors pouring out of these nozzles.
Each molding tray has a layer of cornstarch with close to 300 cube impressions.
That means, every minute, under the nozzles.
But these candies are still a long ways from your mouth.
It's still very liquid.
It's still very hot.
So we need to cure it to get it to that gummy state.
The candy-filled molds make their way down the line, where they are stacked Those stacks then have to be moved to a dry room, in order to be dried the proper amount of time to get the moisture out of each candy.
The racks of candy stay in heated drying rooms for 24 hours, while the starch slowly absorbs the extra liquid and the heat.
At any given time, there are over 70,000 cubes curing in this room.
It's like the Fort Knox of sour candy cubes.
After their overnight stay, the molds head back to the mogul, which is the same machine where the candy was deposited, but, this time, the mogul isn't filling the molds.
It takes each individual tray, tips them upside down, dumps the candy out.
Now, we have perfectly square chewy cubes.
There's still just one problem: all that starch from the mold is still stuck to the outside.
We have to get that off, so we have a cleaning tunnel that will blow all that starch off.
The brushless polisher uses compressed air to blast off any excess starch on the candy.
Comes out as this beautiful, clean-looking cube.
These candies are definitely sweet enough to eat, but they wouldn't be the same without a touch of sour.
The colorful cubes get a quick spray of steam to make them sticky before jumping into the sanding tumbler.
The tumbler spins round and round, showering the chewy bites with a mix of sugar sweetness and a hint of malic acid to give it a pop of sour.
The chewy bites are almost ready to eat, but in order to avoid the candies clumping together in the package, they need to be cooled down.
To do this, the candy cubes take a 6- minute ride down a 100-foot cooling tunnel that brings the temperature of the Warheads down to 70 degrees.
Finally, all those chewy cubes make their way to packaging, where each of the six colors are mixed together before being weighed and deposited into bags.
Just load all these beauties in my trunk.
We make half a billion that's B with a billion cubes a year.
That's a lot of cubes.
It sure is.
And, with a rainbow of flavors to choose from, you'll always end up with a sweet surprise on your tongue.
When you're eating the candy, you put it in your mouth, you'll get that wild explosion of sour, but it also has that nice sweet aftertaste that we all love in a gummy candy.
I can't choose just one color! Here goes nothing.
Mmm! Coming upfind out how these chocolatey rolls get their sweet center filling.
And, later fi out how this sugary caramel sensation gets cut down to size.
Hey! When I was a kid, my mom always packed a sweet roll in my lunch.
But I never had one like this.
Mrs.
Freshley's peanut-butter Swiss Rolls, so delicious, you can't stop at just one.
Probably why they make so many.
Have a wonderful chocolate cake, we have a great peanut-butter cream, and it just creates a great flavor experience.
Swiss rolls have been around since the 19th century, but the peanut-butter variety didn't hit the shelves until Mrs.
Freshley's in Crossville, Tennessee, started making them in 2014.
The combination of chocolate and peanut butter is such a hot flavor today.
People love that combination.
And that combination of flavor start with the cake.
Cake flour is pumped from 40,000-pound storage tanks through a sifter and into a batter mixer, where it is then mixed with equal amounts of bread flour, water, and sugar.
It takes approximately to produce our peanut-butter Swiss Rolls each day.
A proprietary mix of cocoa, eggs, and vanilla are added to the 1,400-pound batch before mixing for 60 seconds.
After that quick mix, the batter is pumped into a continuous mixer.
The continuous mixer mixes air with the batter to get it to the correct fluffy texture, so that it bakes evenly and has a smooth texture.
After a few minutes, the fluffy batter is on the move again.
The batch is pumped into a depositor.
Two nozzles move back and forth, continuously depositing cake batter across a 4-foot conveyor belt.
I want my next birthday cake to be this big.
As a depositor cycles back and forth, a series of rollers flatten the batter into an even, Then it's onto an oven.
But not like the one in your kitchen.
This fiery furnace stretches Inside these walls, the batter will cook at 400 degrees for 4.
5 minutes.
The cake will double in size through the baking process, from about 2.
5 millimeters to 5 millimeters in thickness.
After the cake exits the oven, it take a 10-minute trip on a cooling belt, where the temperature is brought down to 100 degrees.
Then the cake goes through a turning wheel that flips it and then cuts it into 11 equal strips, finally ready for its creamy filling.
So where is that peanut-butter goodness hiding? Well, it turns out they make it from scratch along with some liquid shortening and water, are blended inside this kettle for 5 minutes.
Then, it's pumped into a depositor, where it's ready and waiting to join the cake.
As the 11 strips of cake ride a conveyor, they pass underneath a set of nozzles that deposit the sweet, creamy filling on top of the cake in one, continuous stream.
But it wouldn't be a Swiss Roll without the roll, so, the cakes continue on the conveyor to a set of mechanical rollers.
An angled block lifts and folds one side of the cake before rotating They gently wind the peanut butter filling inside the cake, creating the classic Swiss-roll shape.
I'd eat them just like this, but they wouldn't exactly fit nice and neat on a grocery store shelf.
You may think that cutting these cakes down to size takes a lot of knives, but how about just one really big one? Meet the guillotine.
Every minute, this massive, bounces up and down enough times to cut 8003-inch Swiss Rolls.
That's 48,000 every hour.
How many of these sweet little cakes do you think I could fit in my mouth at once? I'm holding myself back, though, because we're not done with these desserts, yet.
The next step is going through the chocolate enrober.
The enrober holds 700 pounds of melted chocolate that gets drizzled onto the Swiss Rolls in a luscious, chocolatey waterfall.
After the rolls exit the enrober, they need to chill out, so it's into a massive, The first part of the cooling tunnel is and this allows the chocolate coating to harden up.
Having the chocolate harden is an important step, because there's one last touch to add to the cakes: the peanut-butter stripes.
Streams of liquid peanut butter float back and forth, creating a sweet drizzly design of icing that tops off every roll.
Oof.
I keep this video on loop at my house all day long.
After the stripes, added on a continuous fashion, it'll enter the second half of the cooling tunnel, which is another 2.
5 minutes, which allows the stripe to be set up.
Once the peanut-butter stripe is hardened onto the chocolate coating, the Swiss Rolls are cool enough to make their way to the packaging department.
They're bunched up into pairs, wrapped in clear bags, and stuffed in boxes for everyone to enjoy.
And I mean everyone.
They can package When you bite into the Swiss Roll, you have the wonderful chocolate cake and the creamy, peanut-butter filling and a great coating.
It just produces a wonderful experience in your mouth.
Coming up discover why this classic sucker changed its name over 80 years ago.
Hey! You know the sweet treat that you can remember pulling off the shelf when you were a kid? Well, this one goes back so far, even your grandfather has the same memory.
That's right, I'm talking about Sugar Daddy.
For nearly 100 years, every caramel-filled lick and milky-sweet bite of Tootsie's Sugar Daddies have been tempting kids and adults alike.
You get that nice feeling of warm caramel on your tongue as you suck it away.
These caramel pops go all the way back to 1925, when Robert Welch named his candy the Papa Sucker.
It maintained that name 'til about 1932, at which time they changed it to Sugar Daddy, which they thought conveyed more of "a wealth of sweetness.
" And that wealth of sweetness starts just the same way it did back in the Roaring Twenties.
We take milk solids and mix them up with water.
Then, we add sugar and corn syrup.
All those ingredients mix together inside a giant kettle to create a 750-pound batch of liquid candy.
But the real action is here, in the caramelizer.
It's a caramel that is a little firmer, therefore, it's gonna last a lot longer.
Once the candymakers get the caramel flavor just right, it's onto a gigantic cooling wheel.
They thinly spread the molting hot liquid caramel By the time it falls off the wheel, onto the conveyor, the caramel is chilled at 70 degrees.
Back and forth, the sweet sheets of caramel form one long rhythm.
I don't care how the caramel falls off the wheel.
I just want to be there when it does.
As it's cooled, it is scraped off and cut into sections of about 25 pounds apiece.
As the workers add rollers squeeze the form of candy from 360 inches all the way down to 3 inches.
When the caramel slithers out of the batch roller, it's turned into one long, neverending, snakelike rope.
So, now, the caramel needs to be cut down to size, and that happens inside this one-of-a-kind cutting machine.
They were built 50 years ago.
They were made just for this process and continue to serve us, making Sugar Daddies.
The caramel rope enters a tunnel and meets a stainless-steel wheel that flattens and cuts the candy into 1.
7-ounce rectangles.
The taffy-sized slabs of caramel slide into a spinning wheel that inserts a stick into every pop.
Finally, these sugary caramel sweets are ready for their iconic yellow-and-red wrappers.
Before they exit, pinchers grab the bottom of the wrapper and seal the lollipop with a twist.
This machine produces about That's over 40 million chewy, gooey, caramel pops every year, enough to give one sweet and creamy sucker to every person in California.
I got a sweet tooth.
Surprise, surprise, surprise.
That's the candy I want! Should I do it like a gangsta? I'm like, "Something changed.
" This is a wrap with a different kind of rap We're steppin' it up, baby.
Not the wrap of a candy Did you like how I escalated it? Bup-bup bup-bup, bup-bup