Unwrapped 2.0 (2015) s03e12 Episode Script
Quick Fix
On this episode of "Unwrapped 2.
0," if you're hungry, we've got you covered with these quick fixes.
From a decadent CupCake with a creamy surprise to a chewy granola bar with a chocolate crunch to a tender, juicy dinner that's prepared in a flash and a cup of joe that tastes like a fresh pot every time, these tasty treats are quick fixes for any time of day.
I love cake, but when I buy a whole one, it can be a bit much for just me.
That's why this little treat has always had a soft spot in my heart.
Hostess Chocolate CupCakes.
It's a dessert that redefined how to eat cake.
Before the Hostess CupCake was born in 1919, people had to buy a whole cake or a single slice at their local bakery.
Snack cakes are delicious, but they're also packaged for convenience for on the go consumption.
and that was a new idea way back, but it's really made the snack cake kind of a permanent mainstay in the snacking world.
Today, Hostess CupCakes come in a variety of flavors, but it's their Chocolate CupCake that sets the standard.
That chocolate dream begins here in the Hostess bakery.
Inside a massive mixing bowl, they combine butter, cake flour, water, cocoa, and a proprietary sugar mix to create a giant batch of cake batter weighing in at 2,000 pounds.
After 90 seconds, the sugary batter is pumped into a continuous mixer.
The continuous mixer acts much like the whipping bowl that your mom would use at home.
It just adds air to the batter to give cake its fluffy texture.
After 11/2 minutes of mixing, the ooey gooey chocolate batter is about to take shape, thanks to these CupCake pans.
Each tray has 85 CupCake molds, and they all get a quick spray of oil before heading underneath the nozzles of the depositor.
with 1 ounce of cake batter every second.
This thing fills CupCake pans even faster than I can empty them.
So now that the pans are filled with CupCake batter, they move on into the oven.
And this is no ordinary oven.
It's a monster four-zone temperature serpentine mega oven.
Look at the size of this thing! The first zone is a lower temperature which gives the cake its volume, and the later temperatures that are higher give the cake its final color.
I want to eat one now, but I need to pace myself, because these freshly baked goodies are too hot to touch and too hot to inject with the special cream filling.
If the cake is too warm when it's filled with cream, the cream can melt.
So, while the cakes cool down, the delicious cream filling is getting ready.
We can't tell you much about the super-secret ingredients that compose this classic filling, but believe me, the combination is just right for sweet and sugary goodness.
The mixing process has big paddles that spin round and round in the mixer that not only disperse all of the ingredients but also add a little bit of heat to give the cream mixture just the right temperature.
We got our creamy filling and we've got our cooled-down Chocolate CupCakes, so it's time for them to come together.
It's hard to see, but as the CupCakes pass under the depositor, a nozzle injects the middle of every cup cake.
The cream injection nozzles go into the top of the CupCake, which you never see because then they're later covered with icing and our original Squiggle.
Packed with creamy filling that will make your tongue tingle, it's time for the CupCakes to jump out of the pans.
A quick puff of air releases them from the molds, and then the trays are flipped upside down as the CupCakes fall onto a conveyor belt.
If you took a bite right now, they'd be pretty delicious, but it's just not a CupCake without my favorite part the icing.
Just look at all those little CupCakes that are about to pass under a waterfall of chocolate.
As the conveyor belt comes to an end, the cream-filled cakes flip right side up.
And get this because of the sloped top, the icing covers just the tops of the CupCakes.
No mess here.
Watching the CupCakes go through the chocolate waterfall is my favorite part because it just makes me want to pick one up off the line and eat one.
Um, me too, but I'll wait, because they still have to get the signature Hostess Squiggle.
Just like its cream filling, the classic Hostess icing also comes from a closely guarded recipe, but you don't have to know the ingredients to be mesmerized by how they create that iconic Squiggle.
Hostess created the iconic Squiggle.
It's what makes a CupCake a Hostess CupCake.
add Squiggles to each CupCake.
Before this army of CupCakes make their way to grocery store shelves, the CupCakes first have to march into a cooler to cool off.
A 6-minute trip through a 120-foot cooling tunnel brings the temperature of the CupCakes down to 65 degrees as the icing sets.
As the CupCakes come out of the cooling tunnel, the icing is firm and the CupCake is ready to be wrapped.
The CupCakes are wrapped in easy-to-grab single or double packs that makes them the perfect snack when you're on the go, or any time, really.
Biting into a Hostess CupCake is like a chocolate dream.
Mmm.
Delicious.
Coming up, find out what sugary-sweet condiment keeps these oats packed together.
And later, discover how you can get this delicious restaurant-fresh taste in the comfort of your own home.
Crunchy, chewy granola.
I love pouring myself a big bowl and diving spoon-first into those sweet nutty bits, but there isn't always time for that.
Luckily, there's a quick fix Quaker Chewy Granola Bars.
Quaker created the classic Chewy Bar in the 1980s, and it's become the ultimate quick fix for families around the country.
It was a great way to bring the goodness of whole grains and oats into a convenient snack bar that can be eaten anywhere.
Today, Quaker Chewy Granola Bars come in 13 varieties, including one of their best-sellers, Chocolate Chip.
Of course, the most important ingredient in their Chewy Bar is what put Quaker on the map in 1877.
It all starts with the oats.
Without the oats, we wouldn't be able to make the delicious Chewy Bars.
Those famous oats arrive four times a day and are unloaded into these gigantic When they're ready to start a batch, the oats are mixed with flaked wheat and crisped rice to create the dry base of the granola bars.
While the dry ingredients are mixing, Quaker is cooking up the perfect sweet glue that will bind the batch together.
Their proprietary syrup is held inside a 3,000-pound holding tank next to the enrober.
When they're ready, the oats and flakes meet the sticky-sweet syrup in the enrobing machine.
As the dry granola ingredients enter the machine, they're quickly doused with a mist of sticky syrup that starts to bind them together.
Without it, we would not have the clusters of granola that we need to make that perfect Chewy Bar.
Who doesn't want a little sugary-sweet syrup with every meal? Once the dry base and the syrup are mixed, the batch is deposited onto a 60-foot conveyor belt.
As the granola bar clusters travel down the conveyor, they pass through a series of paddle spreaders.
The paddles take the mounds of granola bar dough and level it off until it becomes a 11/2-inch-thick layer.
Then it's time for a 20-minute trip through this massive where the temperatures reach 300 degrees.
As the golden-brown granola base exits the conveyor, it falls into a series of lump breakers that work the large granola pieces into the more manageable size we know and love.
If the lumps are too big, they'll actually go back through another lump breaker to break those down into a smaller size.
With the lumps and bumps out of the way, the granola travels on a series of vibrating conveyors that shake it into smaller and smaller bits until it's just the right size to add the next ingredient.
That's right, chocolate.
How they add these little bits of chocolate chips to the granola is a secret, but the amount isn't.
They go through of chocolate chips a year, and apparently, that's the perfect amount.
If there's too many chocolate chips, it'll actually break apart.
I've never heard of too much chocolate, but I'll take his word for it.
With the chocolate in place, the granola goodies move along a conveyor belt towards three compression rollers.
These massive rollers take the uneven granola base and squeeze it down to create a level surface.
These compression rollers are very important to make sure our Chewy Bars get to the perfect height, which is about half an inch for a Chewy Bar.
Once the granola makes it through the third roller, it continues into a 100-foot cooling tunnel that brings the temperature down to 70 degrees.
It's almost ready to eat, but this 150-foot-long flow of granola needs to become snack-sized bars.
First, it passes through a series of spinning blades that cuts it into pieces of granola.
Once the massive bar is cut into strips, angled guides pull the strips apart before they head into Duh duh dun the guillotine.
With each stroke, the guillotine cuts the granola into 31/2-inch bars.
Sliced and diced to the perfect bar shape, the bars enter a second that brings their temperature down to a chilly 55 degrees.
After the second cooling tunnel, the bars will go around a 180-degree belt to be sent into the wrappers.
The machines wrap the granola bars at a rate of 550 bars per minute, which creates 5 million Chewy Granola Bars every day, and that's a good thing, because these bars are so tasty, they're just flying right off the shelf.
My favorite part about the Chewy Bar is it's a perfect balance of chewy, crunchy, and sweet.
Coming up, learn how this quick-fix dinner gets just the perfect amount of sauce in each bag.
And later, discover the secret to getting a freshly brewed taste in every cup of coffee.
As a kid in New York City, I always loved take-out Chinese, especially some steamy rich and savory beef and broccoli.
But sometimes, even take-out isn't quick enough.
On the menu for today, some delicious beef and broccoli from P.
F.
Chang's.
We strictly follow the recipe to make sure that each experience is the same no matter where you live, and you're going to have that in-restaurant experience at home.
And this rich, delicious dish starts with their delicious Asian brown sauce.
The key ingredients? Lots of garlic and ginger.
We freshly grind our ginger and our garlic because it enhances the flavor of our dinner.
After the garlic and ginger are ground down, they're moved into gigantic Once inside, they're sautéed in canola oil until lightly brown.
Oh, man.
I can practically smell those rich spices all the way from the other side of the TV! A smattering of chicken broth, oyster sauce, and a proprietary mix of additional secret herbs and spices are added to the sauce.
Once all those ingredients are added, we heat the cook kettle up to 205 degrees where over 100 pounds of water are cooked off.
When the sauce has reduced, they add a starch slurry, which consists of one part starch and three parts water to help thicken the batch.
Out of the mixer, the batch is pumped through a series of pipes called a heat exchange, which cools the sauce down to 50 degrees.
It is then pumped over into our stem process.
Trust me, you've never seen anything quite like this behemoth.
The stem process starts with a nozzle which they call a doser.
The doser slides across a 6-foot conveyor belt, continuously depositing a steady stream of Asian sauce.
Then, a series of massive rollers spread out the sauce evenly until it's a half inch thick.
Finally, it's into a chilly that dips the temperature of the sauce down to a super-cold 5 degrees.
The reason we shoot for that temperature is any warmer, it becomes somewhat mushy, and too cold, it'll become brittle and fracture during the cutting process.
As the long, frozen sheet of sauce exits the contact freezer, it moves under a cutting machine that slices it into Sliced and diced, the sauce then travels through a second freezer, and this time, the temperature plummets down even further, all the way to negative 25 degrees.
This is why I live in Southern California.
Yikes! That's cold! The frozen sauce pellets are then put into totes and brought to the production line, where the rest of the scrumptious ingredients are ready and waiting.
And those ingredients are, you guessed it, vibrant green broccoli that's been pre-cut and flash-frozen and tender, juicy beef.
In a standard we'll use about in making these dinners.
The beef, broccoli, and frozen sauce pellets are dumped into separate hoppers that vibrate the ingredients from conveyors and into a high-tech scaling room.
Huh.
This room looks like it could be a set for a science fiction movie.
Each component has their own scale whose primary job is to ensure that the weights for each component matches the recipe.
A mass conveyor system of buckets rides underneath the scales, and one at a time, a perfectly portioned amount of beef, broccoli, and frozen sauce pellets are loaded into the buckets.
Then it's on to bagging, where the ingredients are dropped into the P.
F.
Chang's bags.
Sealed and ready, the frozen dinner bags travel down a conveyor to the boxing area.
If a bag is too heavy or light, a plunger pushes it off the conveyor before it can reach the end of the line.
Nothing less than beef and broccoli perfection will do.
Now that all that goodness is in the bag, it's packed and frozen fresh so all you have to do is heat and eat.
I think people enjoy the P.
F.
Chang meals due to the sensory experience they get from all the rich flavors that come out when you eat it.
Which begs the question, why take the time to order Chinese when there's a quick-fix right in your freezer? Coming up, learn how many coffee beans it takes to create this quick coffee fix.
There is nothing worse than getting the last cup of joe from the bottom of a coffee pot.
But thanks to this quick-fix, I can now get a fresh cup of coffee anytime I want.
Since 1998, the K-Cup Pod has been revolutionizing the way people brew coffee, giving them a quick-fix alternative to their daily routine, and it all started with Vermont-based Green Mountain Coffee.
We're the very first roaster to actually manufacture coffee in K-Cup Pods.
And it all starts with, what else? Coffee beans.
Green Mountain Coffee uses 200 million pounds of coffee beans each year.
When the sacks arrive, a worker slits open the bag to release the beans into a sorting pit that's essentially a large funnel.
At the bottom of the funnel, we have a conveyance system that then picks up those beans and brings them on to the next unit operation.
All those little beans need to go through a bean cleaner, which is a series of conveyor belts that shakes any broken beans or unwanted debris through a mesh liner.
We want to make sure that we're only introducing into our subsequent processes whole green coffee beans.
Once the beans are cleaned, they are stored in these gigantic silos for four to eight hours before heading to the roaster.
This is where the magic happens.
The roaster is where individual types of beans become a specific type of coffee.
Green Mountain offers 50 varieties, but today, we're making their Founder's Blend.
To do that, they need to turn those green coffee beans a dark, smoky brown, and that happens in the roaster.
And this roaster can get hot.
Temperatures can reach The beans are roasted with a very specific time and temperature curve.
The higher the temperature and the longer the beans roast, the darker the blend.
Mmm.
I can smell my morning cup of coffee already.
The beans stay inside of the roaster up until about 425 degrees, and then they'll drop into the cooling tray, where they're cooled down to about 200 degrees.
The coffee beans are constantly stirred within the roaster as they cool off before starting the next step.
It's called a de-stoning operation where we will float the beans up overhead using high-velocity air.
It's kind of a high-powered wind tunnel for coffee beans.
As the beans float away, it's onto a three-part grinding system coarse, medium, and fine.
We are producing a very specific particle size distribution which is important inside of our K-Cup Pods.
Now for a little science.
As the beans grind down to size, carbon dioxide is created, so the ground beans are stored in 800-pound super-sacks for 24 hours so it can dissipate.
Otherwise it would happen inside of our pod.
That would make the top pop.
Once the carbon dioxide has dissipated, the sacks are hoisted up and dumped into the filler where the ground coffee meets up with the K-Cup Pods.
The cups enter the machine, and each pod is filled with coffee grinds.
We have a gravity feed system.
The coffee will flow from the super-sack down into the dosing unit that's part of the filler machine.
Each little K-Cup Pod is made from 75 beans.
This site produces That'll help a lot of people wake up in the morning.
Next, the lids slide on and are heat-sealed before the K-Cup Pods are ejected from the filler and onto a conveyor belt that will take them to packaging.
The pods then are nested and put into packaging.
The box is marked and labeled and then brought over to our palletizing robot that then puts them into a master case distribution.
Their next stop, grocery store shelves, giving customers around the world a quick fix whenever they need a cup of joe.
People love K-Cup Pods because every cup has first-cup freshness to it.
Crunchy, chewy granola.
Oh, sugar.
What was that? Hmm, all right, let's get serious.
Mmm, mmm.
Always time for that, with those nutty bits.
It's what we do, yo.
0," if you're hungry, we've got you covered with these quick fixes.
From a decadent CupCake with a creamy surprise to a chewy granola bar with a chocolate crunch to a tender, juicy dinner that's prepared in a flash and a cup of joe that tastes like a fresh pot every time, these tasty treats are quick fixes for any time of day.
I love cake, but when I buy a whole one, it can be a bit much for just me.
That's why this little treat has always had a soft spot in my heart.
Hostess Chocolate CupCakes.
It's a dessert that redefined how to eat cake.
Before the Hostess CupCake was born in 1919, people had to buy a whole cake or a single slice at their local bakery.
Snack cakes are delicious, but they're also packaged for convenience for on the go consumption.
and that was a new idea way back, but it's really made the snack cake kind of a permanent mainstay in the snacking world.
Today, Hostess CupCakes come in a variety of flavors, but it's their Chocolate CupCake that sets the standard.
That chocolate dream begins here in the Hostess bakery.
Inside a massive mixing bowl, they combine butter, cake flour, water, cocoa, and a proprietary sugar mix to create a giant batch of cake batter weighing in at 2,000 pounds.
After 90 seconds, the sugary batter is pumped into a continuous mixer.
The continuous mixer acts much like the whipping bowl that your mom would use at home.
It just adds air to the batter to give cake its fluffy texture.
After 11/2 minutes of mixing, the ooey gooey chocolate batter is about to take shape, thanks to these CupCake pans.
Each tray has 85 CupCake molds, and they all get a quick spray of oil before heading underneath the nozzles of the depositor.
with 1 ounce of cake batter every second.
This thing fills CupCake pans even faster than I can empty them.
So now that the pans are filled with CupCake batter, they move on into the oven.
And this is no ordinary oven.
It's a monster four-zone temperature serpentine mega oven.
Look at the size of this thing! The first zone is a lower temperature which gives the cake its volume, and the later temperatures that are higher give the cake its final color.
I want to eat one now, but I need to pace myself, because these freshly baked goodies are too hot to touch and too hot to inject with the special cream filling.
If the cake is too warm when it's filled with cream, the cream can melt.
So, while the cakes cool down, the delicious cream filling is getting ready.
We can't tell you much about the super-secret ingredients that compose this classic filling, but believe me, the combination is just right for sweet and sugary goodness.
The mixing process has big paddles that spin round and round in the mixer that not only disperse all of the ingredients but also add a little bit of heat to give the cream mixture just the right temperature.
We got our creamy filling and we've got our cooled-down Chocolate CupCakes, so it's time for them to come together.
It's hard to see, but as the CupCakes pass under the depositor, a nozzle injects the middle of every cup cake.
The cream injection nozzles go into the top of the CupCake, which you never see because then they're later covered with icing and our original Squiggle.
Packed with creamy filling that will make your tongue tingle, it's time for the CupCakes to jump out of the pans.
A quick puff of air releases them from the molds, and then the trays are flipped upside down as the CupCakes fall onto a conveyor belt.
If you took a bite right now, they'd be pretty delicious, but it's just not a CupCake without my favorite part the icing.
Just look at all those little CupCakes that are about to pass under a waterfall of chocolate.
As the conveyor belt comes to an end, the cream-filled cakes flip right side up.
And get this because of the sloped top, the icing covers just the tops of the CupCakes.
No mess here.
Watching the CupCakes go through the chocolate waterfall is my favorite part because it just makes me want to pick one up off the line and eat one.
Um, me too, but I'll wait, because they still have to get the signature Hostess Squiggle.
Just like its cream filling, the classic Hostess icing also comes from a closely guarded recipe, but you don't have to know the ingredients to be mesmerized by how they create that iconic Squiggle.
Hostess created the iconic Squiggle.
It's what makes a CupCake a Hostess CupCake.
add Squiggles to each CupCake.
Before this army of CupCakes make their way to grocery store shelves, the CupCakes first have to march into a cooler to cool off.
A 6-minute trip through a 120-foot cooling tunnel brings the temperature of the CupCakes down to 65 degrees as the icing sets.
As the CupCakes come out of the cooling tunnel, the icing is firm and the CupCake is ready to be wrapped.
The CupCakes are wrapped in easy-to-grab single or double packs that makes them the perfect snack when you're on the go, or any time, really.
Biting into a Hostess CupCake is like a chocolate dream.
Mmm.
Delicious.
Coming up, find out what sugary-sweet condiment keeps these oats packed together.
And later, discover how you can get this delicious restaurant-fresh taste in the comfort of your own home.
Crunchy, chewy granola.
I love pouring myself a big bowl and diving spoon-first into those sweet nutty bits, but there isn't always time for that.
Luckily, there's a quick fix Quaker Chewy Granola Bars.
Quaker created the classic Chewy Bar in the 1980s, and it's become the ultimate quick fix for families around the country.
It was a great way to bring the goodness of whole grains and oats into a convenient snack bar that can be eaten anywhere.
Today, Quaker Chewy Granola Bars come in 13 varieties, including one of their best-sellers, Chocolate Chip.
Of course, the most important ingredient in their Chewy Bar is what put Quaker on the map in 1877.
It all starts with the oats.
Without the oats, we wouldn't be able to make the delicious Chewy Bars.
Those famous oats arrive four times a day and are unloaded into these gigantic When they're ready to start a batch, the oats are mixed with flaked wheat and crisped rice to create the dry base of the granola bars.
While the dry ingredients are mixing, Quaker is cooking up the perfect sweet glue that will bind the batch together.
Their proprietary syrup is held inside a 3,000-pound holding tank next to the enrober.
When they're ready, the oats and flakes meet the sticky-sweet syrup in the enrobing machine.
As the dry granola ingredients enter the machine, they're quickly doused with a mist of sticky syrup that starts to bind them together.
Without it, we would not have the clusters of granola that we need to make that perfect Chewy Bar.
Who doesn't want a little sugary-sweet syrup with every meal? Once the dry base and the syrup are mixed, the batch is deposited onto a 60-foot conveyor belt.
As the granola bar clusters travel down the conveyor, they pass through a series of paddle spreaders.
The paddles take the mounds of granola bar dough and level it off until it becomes a 11/2-inch-thick layer.
Then it's time for a 20-minute trip through this massive where the temperatures reach 300 degrees.
As the golden-brown granola base exits the conveyor, it falls into a series of lump breakers that work the large granola pieces into the more manageable size we know and love.
If the lumps are too big, they'll actually go back through another lump breaker to break those down into a smaller size.
With the lumps and bumps out of the way, the granola travels on a series of vibrating conveyors that shake it into smaller and smaller bits until it's just the right size to add the next ingredient.
That's right, chocolate.
How they add these little bits of chocolate chips to the granola is a secret, but the amount isn't.
They go through of chocolate chips a year, and apparently, that's the perfect amount.
If there's too many chocolate chips, it'll actually break apart.
I've never heard of too much chocolate, but I'll take his word for it.
With the chocolate in place, the granola goodies move along a conveyor belt towards three compression rollers.
These massive rollers take the uneven granola base and squeeze it down to create a level surface.
These compression rollers are very important to make sure our Chewy Bars get to the perfect height, which is about half an inch for a Chewy Bar.
Once the granola makes it through the third roller, it continues into a 100-foot cooling tunnel that brings the temperature down to 70 degrees.
It's almost ready to eat, but this 150-foot-long flow of granola needs to become snack-sized bars.
First, it passes through a series of spinning blades that cuts it into pieces of granola.
Once the massive bar is cut into strips, angled guides pull the strips apart before they head into Duh duh dun the guillotine.
With each stroke, the guillotine cuts the granola into 31/2-inch bars.
Sliced and diced to the perfect bar shape, the bars enter a second that brings their temperature down to a chilly 55 degrees.
After the second cooling tunnel, the bars will go around a 180-degree belt to be sent into the wrappers.
The machines wrap the granola bars at a rate of 550 bars per minute, which creates 5 million Chewy Granola Bars every day, and that's a good thing, because these bars are so tasty, they're just flying right off the shelf.
My favorite part about the Chewy Bar is it's a perfect balance of chewy, crunchy, and sweet.
Coming up, learn how this quick-fix dinner gets just the perfect amount of sauce in each bag.
And later, discover the secret to getting a freshly brewed taste in every cup of coffee.
As a kid in New York City, I always loved take-out Chinese, especially some steamy rich and savory beef and broccoli.
But sometimes, even take-out isn't quick enough.
On the menu for today, some delicious beef and broccoli from P.
F.
Chang's.
We strictly follow the recipe to make sure that each experience is the same no matter where you live, and you're going to have that in-restaurant experience at home.
And this rich, delicious dish starts with their delicious Asian brown sauce.
The key ingredients? Lots of garlic and ginger.
We freshly grind our ginger and our garlic because it enhances the flavor of our dinner.
After the garlic and ginger are ground down, they're moved into gigantic Once inside, they're sautéed in canola oil until lightly brown.
Oh, man.
I can practically smell those rich spices all the way from the other side of the TV! A smattering of chicken broth, oyster sauce, and a proprietary mix of additional secret herbs and spices are added to the sauce.
Once all those ingredients are added, we heat the cook kettle up to 205 degrees where over 100 pounds of water are cooked off.
When the sauce has reduced, they add a starch slurry, which consists of one part starch and three parts water to help thicken the batch.
Out of the mixer, the batch is pumped through a series of pipes called a heat exchange, which cools the sauce down to 50 degrees.
It is then pumped over into our stem process.
Trust me, you've never seen anything quite like this behemoth.
The stem process starts with a nozzle which they call a doser.
The doser slides across a 6-foot conveyor belt, continuously depositing a steady stream of Asian sauce.
Then, a series of massive rollers spread out the sauce evenly until it's a half inch thick.
Finally, it's into a chilly that dips the temperature of the sauce down to a super-cold 5 degrees.
The reason we shoot for that temperature is any warmer, it becomes somewhat mushy, and too cold, it'll become brittle and fracture during the cutting process.
As the long, frozen sheet of sauce exits the contact freezer, it moves under a cutting machine that slices it into Sliced and diced, the sauce then travels through a second freezer, and this time, the temperature plummets down even further, all the way to negative 25 degrees.
This is why I live in Southern California.
Yikes! That's cold! The frozen sauce pellets are then put into totes and brought to the production line, where the rest of the scrumptious ingredients are ready and waiting.
And those ingredients are, you guessed it, vibrant green broccoli that's been pre-cut and flash-frozen and tender, juicy beef.
In a standard we'll use about in making these dinners.
The beef, broccoli, and frozen sauce pellets are dumped into separate hoppers that vibrate the ingredients from conveyors and into a high-tech scaling room.
Huh.
This room looks like it could be a set for a science fiction movie.
Each component has their own scale whose primary job is to ensure that the weights for each component matches the recipe.
A mass conveyor system of buckets rides underneath the scales, and one at a time, a perfectly portioned amount of beef, broccoli, and frozen sauce pellets are loaded into the buckets.
Then it's on to bagging, where the ingredients are dropped into the P.
F.
Chang's bags.
Sealed and ready, the frozen dinner bags travel down a conveyor to the boxing area.
If a bag is too heavy or light, a plunger pushes it off the conveyor before it can reach the end of the line.
Nothing less than beef and broccoli perfection will do.
Now that all that goodness is in the bag, it's packed and frozen fresh so all you have to do is heat and eat.
I think people enjoy the P.
F.
Chang meals due to the sensory experience they get from all the rich flavors that come out when you eat it.
Which begs the question, why take the time to order Chinese when there's a quick-fix right in your freezer? Coming up, learn how many coffee beans it takes to create this quick coffee fix.
There is nothing worse than getting the last cup of joe from the bottom of a coffee pot.
But thanks to this quick-fix, I can now get a fresh cup of coffee anytime I want.
Since 1998, the K-Cup Pod has been revolutionizing the way people brew coffee, giving them a quick-fix alternative to their daily routine, and it all started with Vermont-based Green Mountain Coffee.
We're the very first roaster to actually manufacture coffee in K-Cup Pods.
And it all starts with, what else? Coffee beans.
Green Mountain Coffee uses 200 million pounds of coffee beans each year.
When the sacks arrive, a worker slits open the bag to release the beans into a sorting pit that's essentially a large funnel.
At the bottom of the funnel, we have a conveyance system that then picks up those beans and brings them on to the next unit operation.
All those little beans need to go through a bean cleaner, which is a series of conveyor belts that shakes any broken beans or unwanted debris through a mesh liner.
We want to make sure that we're only introducing into our subsequent processes whole green coffee beans.
Once the beans are cleaned, they are stored in these gigantic silos for four to eight hours before heading to the roaster.
This is where the magic happens.
The roaster is where individual types of beans become a specific type of coffee.
Green Mountain offers 50 varieties, but today, we're making their Founder's Blend.
To do that, they need to turn those green coffee beans a dark, smoky brown, and that happens in the roaster.
And this roaster can get hot.
Temperatures can reach The beans are roasted with a very specific time and temperature curve.
The higher the temperature and the longer the beans roast, the darker the blend.
Mmm.
I can smell my morning cup of coffee already.
The beans stay inside of the roaster up until about 425 degrees, and then they'll drop into the cooling tray, where they're cooled down to about 200 degrees.
The coffee beans are constantly stirred within the roaster as they cool off before starting the next step.
It's called a de-stoning operation where we will float the beans up overhead using high-velocity air.
It's kind of a high-powered wind tunnel for coffee beans.
As the beans float away, it's onto a three-part grinding system coarse, medium, and fine.
We are producing a very specific particle size distribution which is important inside of our K-Cup Pods.
Now for a little science.
As the beans grind down to size, carbon dioxide is created, so the ground beans are stored in 800-pound super-sacks for 24 hours so it can dissipate.
Otherwise it would happen inside of our pod.
That would make the top pop.
Once the carbon dioxide has dissipated, the sacks are hoisted up and dumped into the filler where the ground coffee meets up with the K-Cup Pods.
The cups enter the machine, and each pod is filled with coffee grinds.
We have a gravity feed system.
The coffee will flow from the super-sack down into the dosing unit that's part of the filler machine.
Each little K-Cup Pod is made from 75 beans.
This site produces That'll help a lot of people wake up in the morning.
Next, the lids slide on and are heat-sealed before the K-Cup Pods are ejected from the filler and onto a conveyor belt that will take them to packaging.
The pods then are nested and put into packaging.
The box is marked and labeled and then brought over to our palletizing robot that then puts them into a master case distribution.
Their next stop, grocery store shelves, giving customers around the world a quick fix whenever they need a cup of joe.
People love K-Cup Pods because every cup has first-cup freshness to it.
Crunchy, chewy granola.
Oh, sugar.
What was that? Hmm, all right, let's get serious.
Mmm, mmm.
Always time for that, with those nutty bits.
It's what we do, yo.