Unwrapped 2.0 (2015) s02e03 Episode Script

Everyone loves a barbecue.
But what's a barbecue without without great sides? From melt-in-your-mouth sweet little cakes to perfectly salted chips, to a scoop of cold, creamy goodness, you can't have a barbecue without some delicious barbecue sides, on this episode of "Unwrapped 2.
0".
A backyard barbecue wouldn't be the same without something sweet for dessert and this classic cupcake will never disappoint.
Mrs.
Freshley's Creme Filled Orange Cupcakes have been a bestseller for this Crossville, Tennessee, company for over 20 years.
The recipe for these Creme Filled Orange Cupcakes is not too different from how you make cupcakes at home.
They just make them a whole lot faster.
In fact, this factory bakes up to 42,000 cupcakes an hour.
It all starts in a mixer a big one with flour and sugar.
Every week, we use a little over 400,000 pounds of flour and a little over 500,000 pounds of granulated sugar.
Next, they add salt, and then, a mix of milk, eggs, and a natural orange flavoring.
It gives you the opportunity to have a little fruit in your cupcake, with a natural flavor that just has a great citrus taste.
Once all the ingredients are in, the batter mixes up for 2 minutes, until it's perfectly blended.
Then, the rich batter gets piped over to a special holding tank.
Here, it drains through a mesh that aerates the batter and will eventually give the cakes a nice, light texture when it's time for baking.
From there, it's pumped to the depositor, which will squirt it into the cupcake pans.
First, though, those pans are sprayed with a release agent, just like you'd grease a pan at home.
Now, they're ready.
The depositor drops in precisely 1.
4 ounces of batter per cupcake, The cups may look only half-full, but just wait, because, once they're loaded, each panful rolls right into the oven.
But this oven is not at all like the oven in your kitchen.
It has four separate zones, each set to a different temperature, so they can keep precise control over the moisture content of the cupcakes as they bake.
The temperatures start, in the first zone, at 375 degrees and will end in the fourth zone, at 550 degrees.
It takes 18 minutes for each pan to make it all the way through, and when they come out, it's time for them to cool.
And this cooling step is mission-critical to my favorite part of these cupcakes: the cream filling.
If the cake is too hot, the cream filling will turn to liquid.
If the cake is too cold, it'll break apart.
So they need to get the cakes down to 98 degrees and that happens here in these big coolers.
After 25 minutes, they're cool enough for you know what the cream filling, which is basically powdered sugar whipped up in this special aerator mixer.
It whips air into it to give it a light and fluffy texture.
Well, what I wanna know is: how do they get all that cream into these little cupcakes? With this super-cool injector, that's how.
It shoots the cream directly into the middle of all 50 cakes in the pan at once.
Once they've gotten their shot of delicious sweet cream, they're ready to come out of the pans and a flip and a little blast of air is all it takes.
But wait.
Now, they're upside down.
Not for long.
This ingenious two-layer conveyor flips them right-side-up, just like that.
All that's left to do now is ice, ice these babies.
And the first step is this waterfall of orange icing.
And this next step is really cool: white icing is squirted onto the top with these swirling applicators.
The applicators are programmed to put precisely seven squiggles on each cupcake.
I always wondered how they did that.
Then, it's on to another cooling panel, so that the icing can set.
This one's 180 feet long and the cupcakes take Once they're fully cooled, they head to the wrappers, two to each package.
The cupcakes are placed into plastic packaging cells and then are wrapped and sealed.
Swirled and sealed, these sweet little guys hit the cupcake expressway at full speed, ready to get delivered right to your mouth.
I love eating our Mrs.
Freshley's cupcake.
First, you smell the orange, and then, you take a bite and it just creates this wonderful taste in your mouth.
Coming up How do you peel And, later discover the secret to making a delicious dessert inside a dessert.
Hey! Did you know we gobble down over 1 billion pounds of potato chips a year? True story.
And I know I do my part.
For me, it's that satisfying crunch and that hint of salt that makes them go with just about everything.
Ethel and Eugene Fisher began making their iconic chips at their home in 1932.
They were originally called Fisher's Potato Chips, but, when Eugene left Ethel during the Depression, she changed it to Mrs.
Fisher's and Ethel's potato chips are still going strong today.
- The thing that makes Mrs.
Fisher's Potato Chips stand out is the fact that they're a little thicker-cut.
They're a heartier potato chip.
These hearty chips start with special potatoes called chipping potatoes, which have a lower sugar content, so that they don't get too dark in the fryer.
We start our process off with a truckload of potatoes that comes in once a week, about 50,000 pounds.
Did he just say Whoa.
The first thing they do with all those potatoes is sort them into these 1,500-pound totes, which are dumped by forklift into a massive hopper.
The potatoes then will take their first of two baths, soaking and getting any excess mud off of the potato.
Once they've had a good soak, the potatoes are then divided into even smaller batches, of 150 pounds each, and dropped into this high-speed peeler.
They'll peel for 15 to 30 seconds, depending on the size and the weight of the potato, and the peels will spurt out to the back.
The amazing part is that they do it without a single blade.
The skins are stripped off thanks to centrifugal force and water.
I could use one of those in my kitchen.
But, unlike a typical potato peeler, this one leaves some of the skin on, and that's on purpose.
We feel that it gives it a stronger, crisper, more rustic look to it.
Although Mrs.
Fisher's likes plenty of peel, they want to ensure that each chip has a nice, clean surface, so, after peeling and another quick bath, the potatoes are scooped out onto bucket elevators.
Destination? The slicer.
This high-tech slicer has a revolving wheel with eight super-sharp blades.
for ripple chips, like these, they use a wavy blade, instead of a straight one.
Each one is able to slice multiple potatoes at once and our slicer itself is able to slice over 1,000 pounds of potatoes an hour.
Whoa! That's a lot of potato slices.
But it's only after cutting that things really start to heat up.
Before the chips get cooked, they get another bath, and this one's in soybean oil.
It gives our chips the consistency that it has, which is a dry chip, not a wet chip.
It also helps them retain more of their potato taste, by locking in the starch.
The potato slices stay in this superhot, 340-degree soybean oil just long enough to sear the outside without cooking the inside.
This keeps them from clumping or sticking to the other chips.
The chips then roll down the conveyor to the fryer, where the soybean oil is heated to a sizzling 325 degrees.
But they don't stay here for long: about 7 minutes from slice to cook.
To make sure the chips cook evenly, a rake system bobs them up and down in the oil, very gently.
And, to keep them moving, a circulating pump forces them out to the end of the fryer.
These golden chips may look ready to crunch, but they still need a key ingredient: salt.
We use what's called a Shur Fine Flo Salt.
It's supersmall in particle size and, if you were to scoop it up, it would fall straight through your hands.
As these tiny grains of salt rain down on the chips, they don't get completely covered.
One interesting thing with our chips, compared to other companies: We only salt one side of the potato chip.
And that, too, allows more of the potato flavor to come through.
As they come out of that salty avalanche, they run down a long conveyor, so they can cool off a bit and give the salt a chance to adhere.
From that point on, the potato chips ride up into another conveyor belt and will be put into a 2-story hopper bin where they can properly cool overnight.
That gives the chips plenty of time to cool down and dry out before they head to packaging.
The next morning, the chips roll up an inclined conveyor, where a weighing machine measures them before they put them into three types of bags or my personal favorite, the party size.
And, apparently, I'm not the only one.
When I bite into one of our Mrs.
Fisher's Potato Chips, it just makes me feel like it's time to party.
Coming up You may be surprised to learn where they cook this classic barbecue side dish.
Hey! You can dress 'em up or dress 'em down, but nothing says "barbecue" like baked beans.
Sweet and savory baked beans are a perfect complement to almost any meal, and Tennessee's Bush Brothers have been selling their beans since 1934.
They even shipped them to American troops during World War II and, today, they still ship them all over the country.
We make enough cans of beans in a day to stretch from here in Chestnut Hill, Tennessee, all the way to Chattanooga and back, which is approximately Bush Brothers makes over 40 kinds of beans, but their original baked beans are still their most popular and every single can they make starts with, well, beans.
Roll that beautiful bean footage.
We use navy beans primarily because they're able to carry the great flavors of our sauces that we've created.
Navy beans got their name because they were a staple of the Navy diet in the 1800s, and that's because they maintain their full nutritional value when canned.
Every day, fresh navy beans are brought in on trucks.
They travel by conveyor up into these silos, where they hang out 'til it's time to be processed.
When they're unloaded from the silos, we use a vibratory conveyor to gently handle the bean and transport it.
These vibrating conveyors help to reduce friction and keep the skins of the beans intact as they head off for rehydration.
In other words, they go for a swim.
Soaking the beans in these giant vats not only rehydrates the bean, it releases some of their natural starch, which is that foam you see floating on top.
That will eventually allow the beans to absorb the sauce.
But let's not get ahead of ourselves.
Once they're fully soaked, the water, and then the beans, are drained from the vat.
You've heard of Moon River.
Well, this is Bean River and it carries the beans through the factory.
The beans are buoyant enough to float through that river.
At the end of that river is the blancher, which stops the process of releasing starch by rapidly heating the beans.
We use the blanching process to really kind of shock the bean because it's critically important to kind of maintain the right level of starch that the beans give off.
Wow! Who knew all this went into making a can of beans? And we've still got a ways to go.
After they leave the blancher, the beans then travel up a flue, where they meet up with an avalanche of water that directs them toward their next adventure.
This place is kind of like a bean water park.
While the beans are zipping around on this water slide, the sauce is being made upstairs.
First, sugar, mustard, molasses, and brown sugar are mixed up in these giant vats.
Then, some very secret sweet and savory spices are added in by hand.
The finished sauce is stirred with paddles until it's ready to be married with the beans which, believe it or not, happens right in the can.
But, first, a very special ingredient.
As the cans make their way down the conveyor, a piece of bacon gets added into the bottom, for a darn good reason.
Because that's what our grandmothers would do.
Bacon makes everything good.
Yeah, it does.
That pretty much goes without saying.
Next, they fill the cans with beans on this giant circular conveyor.
And, finally, the sauce.
From there, the cans head off on a long series of conveyors where they're capped and then flipped.
Once we flip the can, we allow the sauce, then, to drain back down through the can, to kind of shake it, if you will, to disperse the sauce evenly across the beans in the can.
But wait a minute.
These are baked beans.
How do they bake them, if they're already in the can? The answer is this massive, they're cooked right in the can.
Bet ya didn't see that coming.
After the cooking process is complete, another conveyor takes the cans of beans to be loaded onto pallets where they sit for 5 days, to let the sauce soak into the beans.
Once they're sufficiently sauced, they're labeled, packed to ship, and ready to eat.
My favorite way to eat 'em is right out of the can.
Ho! Coming up this may look like ordinary ice cream, but it's hiding a delicious secret.
Hey! Remember, as a kid, how the sound of an ice cream truck made you drop whatever you were doing and run as fast as you could to be first in line? Well, I don't remember anything like this when I was a kid.
It's Mayfield Dairy's Banana Split ice cream.
I mean, it's such a delicate, perfect banana flavor.
It just delivers the whole banana split experience.
Like all ice cream, this banana split experience starts with milk and the Mayfield family knows a thing or two about that.
TB Mayfield started the business in 1910 with a few Jersey cows and a horse-drawn carriage to deliver their milk.
In 1923, he bought a 10-gallon batch freezer and started making ice cream packed in a 5-gallon metal can.
Today, they churn out over 1 billion gallons of milk and ice cream a year.
The horse-drawn carriage has been replaced by these enormous They pump the milk into holding tanks before it gets transferred to a separator that, well, separates the cream from the milk.
The cream is pumped into another set of tanks, where it's pasteurized; but, more importantly, brought to just the right butterfat level to become sweet, creamy ice cream.
And this is where things really start to get, um, cool.
This may look like a bunch of pipes, but it's actually a superfast, supercold freezer.
The faster we freeze the ice cream, the smaller the ice crystals and the smoother the texture.
Basically, it gives ice cream its creaminess.
And, now, it's time to give this banana split ice cream its banananess; in this case, a naturally flavored banana purée.
We'll add about 500 pounds of the banana-split flavor to 1,000 gallons of the cream base.
They're combined here in this freezer when the unflavored ice cream is pumped in through these chilled pipes.
These high-tech refrigerated pipes keep the ice cream at a constant 22 degrees.
But this isn't just banana ice cream; this is banana-split ice cream and what would a banana split be without delicious toppings? So, in goes pecans, cherries, and pineapple.
chocolate.
And, then, it's loaded into Mayfield's iconic yellow oval cartons on this huge packing line.
This thing is mesmerizing.
And check this out: every other carton is punched by this plunger, to flip it over, so the cartons can be more efficiently packed.
Then, it's on to the -35-degree blast freezer which keeps the ice cream supercold 'til it reaches the store shelves.
Banana split, anyone? Every bite's different because you get banana in every bite, but this bite, you might get more chocolate or, in the next bite, some cherry, so every bite is like eating a banana split.
Everybody needs a little baked beans I need another rib, y'all Why I only got four? If you're gonna have a rib, y'all you gotta, gotta have five, y'all All right, I'm ready.