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These are the user uploaded subtitles that are being translated: 1 00:00:07,793 --> 00:00:09,965 [upbeat music] 2 00:00:10,034 --> 00:00:10,965 - [Adam] This sweet treat 3 00:00:11,034 --> 00:00:13,551 is universally loved the world over, 4 00:00:13,655 --> 00:00:15,655 comes in every flavor imaginable, 5 00:00:15,724 --> 00:00:19,620 contains every toping and every item imaginable. 6 00:00:19,689 --> 00:00:20,275 It can be crunchy, 7 00:00:20,344 --> 00:00:22,103 creamy, 8 00:00:22,172 --> 00:00:24,310 chewy, gooey, 9 00:00:24,379 --> 00:00:25,793 even spicy. 10 00:00:25,862 --> 00:00:28,000 You can spoon it, you can drink it, 11 00:00:28,068 --> 00:00:31,827 you can put it in a dish with all your favorite toppings. 12 00:00:31,896 --> 00:00:34,482 I have to tell you guys, this is one of those days 13 00:00:34,551 --> 00:00:36,482 where I can't believe I get paid to do this 14 00:00:36,551 --> 00:00:39,275 because today we're going to an ice cream factory. 15 00:00:39,344 --> 00:00:43,655 [upbeat music] 16 00:00:43,724 --> 00:00:48,448 98% of all US households have ice cream at home 17 00:00:48,517 --> 00:00:49,724 at this very moment. 18 00:00:49,827 --> 00:00:54,620 And in fact, the average American eats about 23 pounds 19 00:00:54,689 --> 00:00:57,482 of ice cream per year each. 20 00:00:57,551 --> 00:01:01,551 The US produces 1.5 billion pounds a year, 21 00:01:01,620 --> 00:01:06,517 and ice cream is an $11 billion a year industry. 22 00:01:07,586 --> 00:01:10,034 But ice cream is more than big business, 23 00:01:10,103 --> 00:01:11,827 Baskin Robbins, 24 00:01:11,896 --> 00:01:12,206 Dreyers, 25 00:01:12,275 --> 00:01:13,206 Carvel, 26 00:01:13,275 --> 00:01:15,344 Dairy Queen, 27 00:01:15,413 --> 00:01:16,379 Turkey Hill, 28 00:01:16,448 --> 00:01:17,896 they're famous brands, 29 00:01:17,965 --> 00:01:20,931 but they're also part of treasured memories. 30 00:01:21,034 --> 00:01:22,551 - [Tom Carvel÷ And year your Carvel dealer 31 00:01:22,620 --> 00:01:24,896 makes him loaded with fudge and nuts, 32 00:01:24,965 --> 00:01:28,758 and you can get fudgie with an ocean to serve 20 people. 33 00:01:28,862 --> 00:01:29,758 [upbeat music] 34 00:01:29,896 --> 00:01:31,896 - [Adam] And today we will answer some 35 00:01:31,965 --> 00:01:36,379 of your most burning ice-cream questions like, 36 00:01:36,448 --> 00:01:39,034 where exactly did the ice cream cone come from? 37 00:01:39,103 --> 00:01:41,034 How are new ice cream flavors created, 38 00:01:41,103 --> 00:01:43,896 and how can I get that job? 39 00:01:43,965 --> 00:01:48,689 Where, and when can you taste ice cream at its very best? 40 00:01:48,758 --> 00:01:49,793 And most importantly, 41 00:01:49,896 --> 00:01:52,724 that delicious carton of cookie dough ice cream 42 00:01:52,793 --> 00:01:55,034 sitting in your freezer right now, 43 00:01:55,103 --> 00:01:59,172 we'll discover how it's made from start to finish. 44 00:01:59,448 --> 00:02:01,275 I scream for it, you scream for it, 45 00:02:01,344 --> 00:02:04,689 but today we get the inside scoop 46 00:02:04,793 --> 00:02:08,586 because this is Modern Marvels' Ice cream. 47 00:02:08,655 --> 00:02:10,241 [upbeat music] 48 00:02:18,931 --> 00:02:20,965 [upbeat music] 49 00:02:21,034 --> 00:02:23,724 - [Adam] Today, I'm gonna start at the Turkey Hill Dairy. 50 00:02:23,793 --> 00:02:25,620 It overlooks the Susquehanna River, 51 00:02:25,689 --> 00:02:27,620 right here in Conestoga, Pennsylvania. 52 00:02:27,689 --> 00:02:31,517 The dairy is a massive operation that sits on 72 acres 53 00:02:31,620 --> 00:02:35,586 and they produce over 70 different ice cream varieties. 54 00:02:36,827 --> 00:02:39,931 Started as a humble dairy in 1931, 55 00:02:40,000 --> 00:02:44,586 it has now grown so big that they produce 25 million gallons 56 00:02:44,655 --> 00:02:46,413 of ice cream per year. 57 00:02:46,482 --> 00:02:48,586 And today I am lucky enough to have a tour 58 00:02:48,655 --> 00:02:49,724 with this fine fellow, 59 00:02:51,344 --> 00:02:54,275 who is also the great grandson 60 00:02:54,344 --> 00:02:56,172 of the founder of Turkey Hill. 61 00:02:56,275 --> 00:02:57,275 - That's correct. 62 00:02:57,344 --> 00:02:59,517 [upbeat music] 63 00:02:59,620 --> 00:03:04,068 - [Adam] Turkey Hill started making ice cream in 1954, 64 00:03:04,172 --> 00:03:07,482 using Derek's own great- grandmother's home recipes. 65 00:03:07,551 --> 00:03:08,862 And guess what? 66 00:03:08,931 --> 00:03:12,000 They still use some of his great-grandmother's recipes 67 00:03:12,068 --> 00:03:14,344 for Turkey Hill's premium label ice cream today. 68 00:03:14,413 --> 00:03:19,517 So your great grandmother made it by hand in 1954, 69 00:03:19,586 --> 00:03:21,551 but how are you making it in the 21st century? 70 00:03:21,655 --> 00:03:22,517 Will you show me? 71 00:03:22,586 --> 00:03:23,620 - Absolutely, let's go check it out. 72 00:03:23,689 --> 00:03:25,000 - Let's do it, all right. 73 00:03:25,068 --> 00:03:27,689 - [Adam] Let's go make some ice cream. 74 00:03:27,758 --> 00:03:29,517 Today, Turkey Hill is whipping up a batch 75 00:03:29,586 --> 00:03:33,034 of chocolate chip cookie dough, 76 00:03:33,103 --> 00:03:36,655 the number five most popular ice cream flavor in America. 77 00:03:37,896 --> 00:03:39,000 Before we get started, 78 00:03:39,068 --> 00:03:41,655 I need to get kitted out in some special gear, 79 00:03:41,724 --> 00:03:43,137 both to protect me, 80 00:03:43,206 --> 00:03:44,310 and to make sure the only thing I'm adding 81 00:03:44,379 --> 00:03:48,310 to the production process are my brilliant insights. 82 00:03:50,758 --> 00:03:51,586 - [Derek] So this is the receiving bay. 83 00:03:51,689 --> 00:03:53,310 So before we can make any ice cream, 84 00:03:53,379 --> 00:03:55,310 we've gotta bring in some raw milk. 85 00:03:55,379 --> 00:03:59,000 [upbeat music] 86 00:04:03,965 --> 00:04:07,413 - [Adam] Whoa, look how massive this thing is. 87 00:04:07,482 --> 00:04:10,206 I mean, how much milk does this hold? 88 00:04:10,275 --> 00:04:13,068 - This tanker holds about 6,000 gallons. 89 00:04:13,137 --> 00:04:15,724 - How many cows realistically would it take 90 00:04:15,793 --> 00:04:16,724 to fill something like this? 91 00:04:16,793 --> 00:04:17,827 - Hundreds. 92 00:04:17,931 --> 00:04:19,758 Yeah, it takes a lot of cows, several farms. 93 00:04:19,827 --> 00:04:21,206 - How many of these come in every day? 94 00:04:21,275 --> 00:04:23,206 - We're averaging about six trucks a day. 95 00:04:23,275 --> 00:04:24,275 - Wow. 96 00:04:25,482 --> 00:04:27,586 You know one of those big concrete mixer trucks, 97 00:04:27,655 --> 00:04:31,758 holds pretty close to 3000 gallons of concrete. 98 00:04:31,827 --> 00:04:34,896 If you filled it with ice cream from Turkey Hill instead, 99 00:04:34,965 --> 00:04:38,241 you'd need 30 of them a day 100 00:04:38,310 --> 00:04:39,413 to match Turkey Hill's daily output 101 00:04:39,482 --> 00:04:43,620 of 100,000 gallons of ice cream. 102 00:04:44,965 --> 00:04:45,965 The milk is then offloaded 103 00:04:46,068 --> 00:04:49,758 to the plants massive 60,000 gallon silos. 104 00:04:50,586 --> 00:04:54,241 But first let's test this milk, 105 00:04:54,310 --> 00:04:56,379 to see if it meets Turkey Hill's high standards. 106 00:04:56,448 --> 00:04:59,379 - Top of the world mom. 107 00:05:00,413 --> 00:05:01,172 - [Mikey] Well, this is where it's all.... 108 00:05:01,310 --> 00:05:02,275 - [Adam] Where does it hook to? 109 00:05:02,344 --> 00:05:04,137 - [Adam] For this, I get to work with Mikey, 110 00:05:04,206 --> 00:05:06,137 the processing receiving tech. 111 00:05:06,206 --> 00:05:07,000 - Oh, y'all hooked up. 112 00:05:09,379 --> 00:05:10,758 - Make sure you don't jump down. 113 00:05:10,827 --> 00:05:11,620 - No, no, no. 114 00:05:11,689 --> 00:05:13,793 The wedgie is so real right now. 115 00:05:13,862 --> 00:05:15,137 [Mikey laughs] 116 00:05:15,206 --> 00:05:17,965 - So the first thing we do is we check the temperature. 117 00:05:18,034 --> 00:05:21,758 So the range for milk is from 32 to 40 degrees. 118 00:05:21,827 --> 00:05:22,689 - Okay 119 00:05:24,862 --> 00:05:25,620 - There's the milk. 120 00:05:29,206 --> 00:05:31,482 So we got about 35, that's perfect. 121 00:05:31,551 --> 00:05:34,689 - [Adam] It's under 40, nice. 122 00:05:34,793 --> 00:05:35,793 - Now we're gonna get the sample. 123 00:05:35,862 --> 00:05:37,103 - Okay, let's do it. 124 00:05:38,137 --> 00:05:42,103 Check out the master at work, what a boss! 125 00:05:42,172 --> 00:05:43,827 This is awesome. 126 00:05:43,896 --> 00:05:47,103 But they need two samples, so now it's my turn. 127 00:05:48,344 --> 00:05:49,137 - Good luck. 128 00:05:49,448 --> 00:05:52,965 [calm music] 129 00:05:54,344 --> 00:05:56,655 - Oh I suck, I'm sorry. 130 00:05:56,724 --> 00:05:58,862 - [Mikey] We want the sample inside the bag. 131 00:05:58,965 --> 00:06:00,275 - [Adam] Yeah, yeah, yeah. 132 00:06:00,344 --> 00:06:01,551 [both laughing] 133 00:06:01,620 --> 00:06:04,206 All right so now we're gonna take this to lab, 134 00:06:04,275 --> 00:06:06,724 and look under a microscope for bacteria. 135 00:06:06,793 --> 00:06:09,206 - [Mikey] Bacteria and antibiotics. 136 00:06:09,275 --> 00:06:11,551 [upbeat music] 137 00:06:11,620 --> 00:06:15,206 - [Adam] Antibiotics are sometimes used 138 00:06:15,275 --> 00:06:17,034 to treat sick livestock, 139 00:06:17,103 --> 00:06:20,034 but no antibiotics should ever make it into the milk 140 00:06:20,103 --> 00:06:21,689 or ice cream you buy. 141 00:06:21,758 --> 00:06:24,206 It's the law people. 142 00:06:24,275 --> 00:06:24,931 - [Mikey] So no antibiotics. 143 00:06:27,896 --> 00:06:31,034 Bacteria in milk can make you very sick. 144 00:06:31,103 --> 00:06:32,862 They don't help the flavor either. 145 00:06:32,931 --> 00:06:36,724 This is the new CSI, it's cream science investigating. 146 00:06:36,793 --> 00:06:39,724 - All right, so I'm looking for the colonies, 147 00:06:39,793 --> 00:06:43,344 right now I don't see any, I think it's looking good. 148 00:06:43,413 --> 00:06:44,724 - [Adam] Wow. 149 00:06:44,793 --> 00:06:48,724 All right, so the next step is taking it out of that truck? 150 00:06:48,793 --> 00:06:51,862 - [Mikey] Yep we go hook up the hose and start it up. 151 00:06:51,931 --> 00:06:53,724 [calm music] 152 00:06:53,793 --> 00:06:58,034 - 6,000 gallons of milk will flow from our tanker truck 153 00:06:58,103 --> 00:07:00,896 to the massive storage silos outside, 154 00:07:00,965 --> 00:07:02,896 ready for us to turn it 155 00:07:02,965 --> 00:07:05,586 into delicious Turkey Hill chocolate chip, 156 00:07:05,655 --> 00:07:08,758 cookie dough, ice cream. 157 00:07:11,000 --> 00:07:11,620 - Come on, let's go. 158 00:07:13,344 --> 00:07:14,448 - [Derek] This room right here, 159 00:07:14,517 --> 00:07:17,275 this is really where we start to make ice cream. 160 00:07:17,344 --> 00:07:21,275 But before we start that, I want you to try these flavors 161 00:07:21,344 --> 00:07:23,275 of ice cream that we've got sitting right here. 162 00:07:23,344 --> 00:07:24,620 They look like vastly different flavors. 163 00:07:24,689 --> 00:07:26,758 But they do have one thing in common, 164 00:07:26,827 --> 00:07:29,241 and I'd like you to figure out what it is. 165 00:07:29,310 --> 00:07:32,620 - So party cake, I'm gonna take a spoon, 166 00:07:32,689 --> 00:07:34,586 really dig in there and get the good stuff. 167 00:07:39,517 --> 00:07:42,931 It tastes like the essence of an awesome ice cream cake. 168 00:07:43,000 --> 00:07:44,137 Black raspberry. 169 00:07:45,655 --> 00:07:49,103 Wow, okay. 170 00:07:49,172 --> 00:07:49,931 OG vanilla, 171 00:07:54,344 --> 00:07:56,103 oh my God, awesome. 172 00:07:56,172 --> 00:07:57,620 Let's take ice cream parlor vanilla. 173 00:07:57,689 --> 00:08:01,310 Okay so for my fellow mint chocolate chip lovers, 174 00:08:02,551 --> 00:08:04,000 Oh man. 175 00:08:05,241 --> 00:08:07,827 [upbeat music] 176 00:08:10,517 --> 00:08:13,000 Oh man, come on. 177 00:08:13,068 --> 00:08:14,000 All right. 178 00:08:15,931 --> 00:08:20,000 So you asked me to discern what the mint chocolate chip, 179 00:08:20,068 --> 00:08:22,172 the vanilla, the black raspberry, and the party cake 180 00:08:22,241 --> 00:08:22,724 have in common. 181 00:08:22,827 --> 00:08:25,344 Here it is ready? 182 00:08:25,413 --> 00:08:26,620 - Lay it on me man. 183 00:08:31,344 --> 00:08:33,344 the dairy milk isn't lost. 184 00:08:33,413 --> 00:08:35,517 Feel like there's milk in my ice cream, 185 00:08:35,586 --> 00:08:36,344 that's the best way I can describe it. 186 00:08:36,413 --> 00:08:37,827 - [Derek] Yeah, absolutely. 187 00:08:37,896 --> 00:08:38,379 - That's what I'm getting. 188 00:08:38,482 --> 00:08:39,896 How far off am I? 189 00:08:40,000 --> 00:08:41,172 - I think you're like right there, 190 00:08:41,241 --> 00:08:44,896 and really the thing that ties all these flavors together 191 00:08:45,000 --> 00:08:48,482 is they use the same base ice cream mix. 192 00:08:48,551 --> 00:08:51,137 - Oh wait. 193 00:08:51,206 --> 00:08:54,517 Even, I mean, 194 00:08:54,586 --> 00:08:56,000 could you think of, I mean, you guys at home, 195 00:08:56,068 --> 00:08:57,827 could you think of two flavors, 196 00:08:57,896 --> 00:08:59,655 more different than these two? 197 00:08:59,724 --> 00:09:03,034 Mint chip and black raspberry. 198 00:09:03,103 --> 00:09:03,724 And they start with the exact same base? 199 00:09:03,793 --> 00:09:04,793 - Exact same base. 200 00:09:08,310 --> 00:09:09,724 - [Derek] Let's do it. - [Adam] Let's do it. 201 00:09:12,827 --> 00:09:15,137 - [Derek] Okay Adam, I'll let you select the recipe here. 202 00:09:15,241 --> 00:09:16,724 - Okay. 203 00:09:16,793 --> 00:09:19,931 - We'd like to do premium white. 204 00:09:20,068 --> 00:09:21,965 - And how many gallons should I enter? 205 00:09:22,068 --> 00:09:23,586 - 3000. 206 00:09:23,655 --> 00:09:26,206 - We're gonna make 3000 gallons of ice cream! 207 00:09:27,137 --> 00:09:28,689 - 3000 gallons of ice cream mix. 208 00:09:28,758 --> 00:09:30,758 That's 3000 gallons silo, 209 00:09:30,827 --> 00:09:32,896 is actually gonna yield about 6,000 gallons 210 00:09:32,965 --> 00:09:33,965 of finished product, 211 00:09:34,068 --> 00:09:37,793 because of the fact that we add air to ice cream, 212 00:09:37,931 --> 00:09:41,241 as well as other ingredients such as cookie dough 213 00:09:41,310 --> 00:09:42,793 and chocolate chips. 214 00:09:43,965 --> 00:09:46,655 - [Adam] Time to fire this batch up. 215 00:09:46,758 --> 00:09:49,413 And sorry to disappoint all you home confectioners, 216 00:09:49,482 --> 00:09:52,931 but Turkey Hill keeps all their ice cream recipes, 217 00:09:53,068 --> 00:09:54,758 top secret. 218 00:09:54,827 --> 00:09:57,793 Okay, you can't see this, this is censored. 219 00:09:57,896 --> 00:09:59,413 Let's light this candle. - Woo hoo! 220 00:09:59,482 --> 00:10:01,586 [machine whirring] 221 00:10:01,724 --> 00:10:02,551 - [Adam] Please, after you sir. 222 00:10:02,620 --> 00:10:03,551 - [Derek] Oh, all right. 223 00:10:03,620 --> 00:10:05,724 - No harness, yay! 224 00:10:07,482 --> 00:10:09,551 Hey, are you looking at my bootie? 225 00:10:09,620 --> 00:10:11,896 You know, not my tush, but my bootie, see. 226 00:10:13,137 --> 00:10:14,965 - [Derek] All right. 227 00:10:15,068 --> 00:10:15,965 - [Adam] Wow! 228 00:10:16,068 --> 00:10:18,965 [machine whirring] 229 00:10:20,758 --> 00:10:22,413 - [Derek] At this point, it's just milk and sugar. 230 00:10:22,482 --> 00:10:24,068 So sugars are coming in up here. 231 00:10:24,137 --> 00:10:25,724 - [Adam] Oh, that is liquified sugar. 232 00:10:27,103 --> 00:10:28,620 This is the coolest thing ever. 233 00:10:28,758 --> 00:10:30,965 There's like basically like a waterfall 234 00:10:31,068 --> 00:10:34,034 of sugar coming into this, it's amazing. 235 00:10:35,413 --> 00:10:37,586 Ice cream production today looks very different 236 00:10:37,655 --> 00:10:40,000 than it did prior to the 20th century 237 00:10:40,103 --> 00:10:43,620 when making ice cream took some serious muscle power. 238 00:10:45,103 --> 00:10:49,620 Back then ice cream makers used hand cranked freezer buckets 239 00:10:49,758 --> 00:10:53,275 simultaneously freezing their mixed with ice and rock salt 240 00:10:53,413 --> 00:10:55,896 while churning it to keep it air rated. 241 00:10:57,413 --> 00:11:01,379 Early American ice cream fans included our founding fathers. 242 00:11:01,482 --> 00:11:05,689 George Washington reportedly spent $200 on ice cream 243 00:11:05,793 --> 00:11:08,275 during the summer of 1790. 244 00:11:08,344 --> 00:11:13,000 That's about $5,600 today. 245 00:11:13,068 --> 00:11:15,448 And you know that Thomas Jefferson wrote the declaration 246 00:11:15,517 --> 00:11:17,137 of independence, but did you know, 247 00:11:17,206 --> 00:11:20,620 he also wrote one of America's earliest recipes 248 00:11:20,689 --> 00:11:22,275 for vanilla ice cream? 249 00:11:23,379 --> 00:11:26,724 How we serve ice cream has evolved too. 250 00:11:26,827 --> 00:11:29,310 A key turning point in that story happened 251 00:11:29,379 --> 00:11:32,965 at the 1904 World's Fair in St. Louis. 252 00:11:34,482 --> 00:11:37,827 - Ernest A Hamwi, was a Syrian vendor who was making zalabia 253 00:11:37,896 --> 00:11:40,344 which are crispy waffle like pastries. 254 00:11:40,482 --> 00:11:42,689 And right next door, there was an ice cream vendor. 255 00:11:42,827 --> 00:11:44,896 And people were buying his waffles, 256 00:11:45,000 --> 00:11:48,137 and then quickly going over to the ice cream stall 257 00:11:48,206 --> 00:11:50,448 and getting their ice cream. 258 00:11:51,517 --> 00:11:53,862 - That gave Hamwi an idea, 259 00:11:53,965 --> 00:11:56,655 an idea we should still be thanking him for. 260 00:11:56,724 --> 00:12:00,103 He took one of his waffles, rolled it into a funnel shape 261 00:12:00,172 --> 00:12:04,379 and Presto, the ice cream cone was born. 262 00:12:04,448 --> 00:12:07,862 - There are many different stories about the origin 263 00:12:07,931 --> 00:12:09,862 of the ice cream cone, 264 00:12:09,931 --> 00:12:11,620 but it's the 1904 World's Fair 265 00:12:11,724 --> 00:12:14,275 that really solidifies it as a popular item 266 00:12:14,379 --> 00:12:17,275 and a vehicle for ice cream here in America. 267 00:12:17,379 --> 00:12:18,965 [upbeat music] 268 00:12:19,068 --> 00:12:21,413 - [Adam] Today, the biggest ice cream cone company 269 00:12:21,551 --> 00:12:25,206 in the world is Joy Cone. 270 00:12:25,275 --> 00:12:27,275 At their factory in Pennsylvania, 271 00:12:27,379 --> 00:12:32,551 they produce an astounding 10 million cones a day. 272 00:12:32,620 --> 00:12:36,793 - I'm David George, I'm the president and CEO of Joy Cone. 273 00:12:36,896 --> 00:12:41,724 So Joy was started in 1918 by my grandfather, Albert George. 274 00:12:41,862 --> 00:12:43,862 Albert was a Lebanese immigrant. 275 00:12:44,931 --> 00:12:46,724 The very first oven was hand operated, 276 00:12:46,862 --> 00:12:49,448 so it was really slow. 277 00:12:49,551 --> 00:12:51,551 My dad took over in 1964, 278 00:12:51,620 --> 00:12:54,724 he came up with the Joy name for the brand, 279 00:12:54,793 --> 00:12:57,689 and that's when we really started to see some nice growth. 280 00:12:59,896 --> 00:13:03,586 Today we make almost 3 billion cones a year. 281 00:13:04,689 --> 00:13:06,758 - [Adam] Plant manager, Tyler Tupper 282 00:13:06,827 --> 00:13:09,862 is a 17 year Joy Cone veteran. 283 00:13:09,965 --> 00:13:13,758 - We make sugar cones, waffle cones, cade cups, 284 00:13:13,827 --> 00:13:15,586 in many different varieties. 285 00:13:17,000 --> 00:13:21,413 - [Adam] Their 550,000 square foot facility is big, 286 00:13:21,482 --> 00:13:22,275 very big. 287 00:13:23,655 --> 00:13:26,448 Imagine almost 10 football fields, 288 00:13:26,517 --> 00:13:29,275 cranking out ice cream cones, 24 hours a day, 289 00:13:29,344 --> 00:13:30,586 seven days a week. 290 00:13:32,965 --> 00:13:33,931 [diesel engine revving] 291 00:13:34,000 --> 00:13:37,620 It all starts with a daily delivery of flour. 292 00:13:37,689 --> 00:13:41,551 Anywhere from eight to 26 truckloads 293 00:13:41,620 --> 00:13:44,344 arrive every single week. 294 00:13:44,448 --> 00:13:48,103 - Each of the silos holds about 150,000 pounds of flour. 295 00:13:48,172 --> 00:13:50,586 In total will go through about 50 million pounds 296 00:13:50,655 --> 00:13:52,241 of flour each year. 297 00:13:52,310 --> 00:13:55,103 [upbeat music] 298 00:13:55,172 --> 00:13:57,448 - [Adam] From here, the flour flows 299 00:13:57,517 --> 00:13:59,034 into the batter room. 300 00:13:59,827 --> 00:14:00,862 - [Tyler] So the first ingredient 301 00:14:01,000 --> 00:14:02,689 to be added is the brown sugar. 302 00:14:02,758 --> 00:14:05,931 We use brown sugar because it makes a much stronger cone, 303 00:14:06,034 --> 00:14:09,034 it's better flavor, and it gives it it's brown color. 304 00:14:10,206 --> 00:14:12,000 In all we go through about 7 million pounds 305 00:14:12,068 --> 00:14:14,551 of sugar annually here in this location. 306 00:14:15,517 --> 00:14:16,862 The water is then added 307 00:14:16,931 --> 00:14:20,965 and then the whole mixture starts to get mixed together. 308 00:14:21,034 --> 00:14:23,482 - [Adam] Once the batter is mixed, 309 00:14:23,551 --> 00:14:28,482 it can be pumped out to any of 71 ovens in the plant. 310 00:14:29,689 --> 00:14:31,034 - The patties go through the oven. 311 00:14:31,172 --> 00:14:34,379 It's about 350 degrees in about 90 seconds, 312 00:14:34,517 --> 00:14:37,068 and we make about 6,000 an hour. 313 00:14:37,172 --> 00:14:39,344 At this point, when the patties come out, 314 00:14:39,413 --> 00:14:41,827 they're very soft and pliable. 315 00:14:41,896 --> 00:14:44,758 The patties are then fed into a spinner 316 00:14:44,862 --> 00:14:47,137 which wraps the cone and gives it its form. 317 00:14:48,586 --> 00:14:51,241 - [Adam] At this point, the cone is at its best, 318 00:14:51,344 --> 00:14:53,034 fresh and warm. 319 00:14:54,172 --> 00:14:56,068 Now it's time to pack these babies up 320 00:14:56,172 --> 00:14:59,482 and get them headed towards your scoop of ice cream. 321 00:15:00,862 --> 00:15:01,862 - [Tyler] And the cones are automatically packaged 322 00:15:01,931 --> 00:15:02,793 into a carton. 323 00:15:03,965 --> 00:15:06,551 And then it goes into an automated case packer. 324 00:15:09,758 --> 00:15:12,310 It'll remain in the warehouse until we need it for shipment, 325 00:15:12,413 --> 00:15:14,137 at which point it will be loaded onto a truck 326 00:15:14,241 --> 00:15:16,206 and could really be shipped anywhere in the world. 327 00:15:16,275 --> 00:15:17,310 [upbeat music] 328 00:15:17,413 --> 00:15:19,482 - [Adam] Including an ice cream parlor near you. 329 00:15:19,586 --> 00:15:21,793 If you love your ice cream on a cone, 330 00:15:21,896 --> 00:15:24,620 chances are you've had a Joy Cone. 331 00:15:26,137 --> 00:15:29,827 Back at Turkey Hill, it's time to drop some science 332 00:15:29,931 --> 00:15:32,206 on that ice cream mix that we just made. 333 00:15:33,758 --> 00:15:35,379 - This baby right here, this is the pasteurization unit. 334 00:15:35,448 --> 00:15:37,586 We heat the mix up to 180. 335 00:15:37,655 --> 00:15:39,827 We run it through these holding tubes. 336 00:15:39,931 --> 00:15:41,551 - [Adam] So it holds it at that temperature. 337 00:15:41,620 --> 00:15:44,413 - Holds it, and it's timed out to last 30 seconds. 338 00:15:44,482 --> 00:15:47,620 From there we're gonna send it over to the homogenizer. 339 00:15:47,724 --> 00:15:48,413 - [Adam] Gotcha. 340 00:15:48,482 --> 00:15:49,758 And those are those pistons. 341 00:15:49,827 --> 00:15:52,241 They're actually gonna make sure that all the particles, 342 00:15:52,310 --> 00:15:54,551 the fat, the actual milk particles, 343 00:15:54,620 --> 00:15:58,137 the flavoring elements, everything is the same size. 344 00:15:58,241 --> 00:15:59,758 And that kind of evenness 345 00:15:59,827 --> 00:16:02,517 is what makes that creamy feeling in your mouth. 346 00:16:02,620 --> 00:16:04,034 And then where does it go? 347 00:16:04,137 --> 00:16:05,862 - So we're gonna drop it down to 34 degrees, 348 00:16:05,965 --> 00:16:07,689 before we put it into a holding tank, 349 00:16:07,827 --> 00:16:09,655 and take it down to ice cream production. 350 00:16:09,724 --> 00:16:10,379 - And the holding tanks are just over here. 351 00:16:10,482 --> 00:16:11,448 - Right out here, follow me. 352 00:16:11,517 --> 00:16:12,482 - [Adam] Lead on. 353 00:16:15,000 --> 00:16:16,620 Well, they say money can't buy you love, 354 00:16:16,689 --> 00:16:17,275 but it can buy your ice cream. 355 00:16:20,206 --> 00:16:25,862 In fact, the world spends about $175 million on ice cream 356 00:16:25,965 --> 00:16:27,448 every single day. 357 00:16:27,517 --> 00:16:28,827 Here at Turkey Hill, 358 00:16:28,896 --> 00:16:31,137 we've got our premium white mix churning 359 00:16:31,206 --> 00:16:32,965 in these massive vats. 360 00:16:33,034 --> 00:16:35,965 Now it's time to see how it transforms 361 00:16:36,034 --> 00:16:38,931 into chocolate chip cookie dough ice cream. 362 00:16:39,000 --> 00:16:40,137 [upbeat music] 363 00:16:40,206 --> 00:16:42,793 - [Derek] This room can hold about 100,000 gallons. 364 00:16:42,862 --> 00:16:44,137 - So can this room. 365 00:16:44,206 --> 00:16:45,310 [laughs] 366 00:16:45,379 --> 00:16:46,931 - [Adam] Okay so we're actually gonna get a chance 367 00:16:47,000 --> 00:16:47,620 to try a sample from these massive tanks. 368 00:16:47,689 --> 00:16:49,793 - [Derek] Sure are. 369 00:16:49,862 --> 00:16:51,965 - [Adam] So this isn't ice cream yet, 370 00:16:52,034 --> 00:16:54,965 this is just the base. 371 00:16:55,034 --> 00:16:56,827 It hasn't gone through freezing, 372 00:16:56,896 --> 00:17:01,206 and it has no added flavorings or cookie dough. 373 00:17:01,275 --> 00:17:03,896 I'm very curious to see how it tastes. 374 00:17:03,965 --> 00:17:05,586 - We're going to take one of our syringes, 375 00:17:05,689 --> 00:17:07,034 put it in the sample port, 376 00:17:07,103 --> 00:17:08,344 slowly draw out the ice cream mix. 377 00:17:08,413 --> 00:17:10,034 - [Adam]. Okay. 378 00:17:10,103 --> 00:17:10,862 - [Derek] Oh, look at that. 379 00:17:10,931 --> 00:17:13,551 - [Adam] Oh, wow, look at that. 380 00:17:13,620 --> 00:17:15,862 Okay we carefully withdraw this. 381 00:17:15,931 --> 00:17:16,862 - [Derek] Excellent. 382 00:17:16,931 --> 00:17:18,034 - Okay. 383 00:17:18,103 --> 00:17:21,689 Wow flavored coffee creamer, eat your heart out. 384 00:17:23,689 --> 00:17:25,689 This is a prodo ice cream. 385 00:17:25,758 --> 00:17:27,689 - It's a special sauce right there. 386 00:17:27,758 --> 00:17:30,241 [calm music] 387 00:17:32,068 --> 00:17:34,000 - Oh, come on. 388 00:17:35,793 --> 00:17:38,448 It's like the smell old fashioned vanilla 389 00:17:38,551 --> 00:17:42,689 is the first three words that came to mind. 390 00:17:42,758 --> 00:17:43,689 It's just amazing. 391 00:17:46,586 --> 00:17:48,103 you will ever have ever. 392 00:17:48,206 --> 00:17:49,413 [upbeat music] 393 00:17:49,551 --> 00:17:52,206 Part of what makes ice cream mix at this stage so delicious 394 00:17:52,275 --> 00:17:54,172 is how creamy it is, 395 00:17:54,241 --> 00:17:55,344 which reminds me of another frozen treat 396 00:17:55,413 --> 00:17:58,551 that we all know and love. 397 00:17:58,620 --> 00:18:01,655 We can talk about ice cream without talking about, 398 00:18:02,482 --> 00:18:04,344 soft serve. 399 00:18:04,448 --> 00:18:09,103 Soft serve has less milk fat and more air 400 00:18:09,172 --> 00:18:10,931 than hard ice cream. 401 00:18:11,000 --> 00:18:12,793 You can't buy it at a supermarket 402 00:18:12,862 --> 00:18:16,275 because it takes a special machine to keep soft serve 403 00:18:16,344 --> 00:18:19,413 at a low but not completely frozen temperature. 404 00:18:20,689 --> 00:18:23,965 Soft serve wasn't invented until the 1930s. 405 00:18:24,034 --> 00:18:27,413 And as soon as it was, America fell in love with it, fast. 406 00:18:30,275 --> 00:18:34,275 By the 1950s, soft serve was outselling hard ice cream 407 00:18:34,344 --> 00:18:36,931 and estimated 150 million gallons of it 408 00:18:37,000 --> 00:18:40,103 was consumed in 1957 alone. 409 00:18:40,172 --> 00:18:43,103 But here is where it gets even more interesting. 410 00:18:43,172 --> 00:18:46,275 The origins of soft serve are hotly debated 411 00:18:46,344 --> 00:18:48,448 and this ice cream battle royale involves two names 412 00:18:48,517 --> 00:18:53,758 you just may have heard of, Dairy Queen and Carvel. 413 00:18:53,827 --> 00:18:55,931 Dairy Queen founder, J.F. McCullough, 414 00:18:56,000 --> 00:18:59,724 first sold ice cream in its softer pre hardened state 415 00:18:59,793 --> 00:19:00,793 in 1938. 416 00:19:00,862 --> 00:19:05,344 He's sold 1600 servings of his new product 417 00:19:05,413 --> 00:19:07,551 in less than two hours the first day he offered it. 418 00:19:08,551 --> 00:19:11,344 But it took several years 419 00:19:11,413 --> 00:19:13,827 before McCullough perfected a freezer 420 00:19:13,896 --> 00:19:15,689 that reliably dispense soft serve. 421 00:19:15,758 --> 00:19:20,310 It was actually based off a machine used for frozen custard, 422 00:19:20,379 --> 00:19:23,689 which is neither ice cream nor soft serve. 423 00:19:23,758 --> 00:19:25,689 - Frozen custard by legal definition 424 00:19:25,758 --> 00:19:28,482 has to have 1.4% or more egg yolk. 425 00:19:28,551 --> 00:19:31,310 People love custard, 426 00:19:31,379 --> 00:19:33,517 because the egg yolk gives it a more robust texture. 427 00:19:33,586 --> 00:19:37,344 - [Adam] Meanwhile, Carvel founder, Tom Carvel, 428 00:19:37,413 --> 00:19:39,310 hit upon the idea for soft serve 429 00:19:39,379 --> 00:19:43,137 when his freezer truck broke down in 1934. 430 00:19:43,206 --> 00:19:46,241 Realizing his product would soon literally melt away, 431 00:19:46,344 --> 00:19:48,413 Tom quickly started selling it to anyone and everyone 432 00:19:48,517 --> 00:19:50,482 who stopped by, and was surprised 433 00:19:50,551 --> 00:19:55,551 to find people loved the melty softer version of his ice cream. 434 00:19:57,172 --> 00:19:57,862 [upbeat music] 435 00:19:58,000 --> 00:20:01,724 The rest is soft serve history. 436 00:20:01,827 --> 00:20:04,862 [upbeat music] 437 00:20:04,931 --> 00:20:07,310 Today, we're going behind the curtain at Carvel 438 00:20:07,379 --> 00:20:09,344 in Hackensack, New Jersey. 439 00:20:09,413 --> 00:20:11,551 Since 1974, this location has been run 440 00:20:11,655 --> 00:20:13,517 by a husband and wife team 441 00:20:13,586 --> 00:20:16,517 who trained under Tom Carvel himself. 442 00:20:16,586 --> 00:20:19,172 - Hi what can I get for you. 443 00:20:19,241 --> 00:20:21,344 - That customer walks in the door, 444 00:20:21,413 --> 00:20:23,827 they have a hundred percent of your attention. 445 00:20:23,896 --> 00:20:25,068 [calm music] 446 00:20:25,172 --> 00:20:28,172 - [Adam] While Tom Sasso was training under Tom Carvel, 447 00:20:28,241 --> 00:20:30,068 the company's founder and namesake 448 00:20:30,172 --> 00:20:32,344 was working on a new idea. 449 00:20:32,413 --> 00:20:34,344 Ice cream cakes had existed in America 450 00:20:34,413 --> 00:20:36,827 since at least the 19th century. 451 00:20:36,896 --> 00:20:39,344 Tom Carvel's revolutionary concept 452 00:20:39,413 --> 00:20:42,172 was to create themed ice cream cakes, 453 00:20:42,241 --> 00:20:43,896 using signature ingredients 454 00:20:44,000 --> 00:20:47,689 and then tie them to particular holidays. 455 00:20:47,758 --> 00:20:51,000 Carvel's most iconic cake was launched in 1977 456 00:20:51,068 --> 00:20:54,310 to celebrate a whale of a dad on father's day, 457 00:20:54,379 --> 00:20:55,655 Fudgie the Whale. 458 00:20:55,724 --> 00:20:59,827 His homemade commercials for, it quickly became a sensation. 459 00:20:59,896 --> 00:21:01,103 - It was Tom's voice. 460 00:21:06,068 --> 00:21:06,965 [upbeat music] 461 00:21:07,068 --> 00:21:09,413 - [Tom Carvel] Fudgie the Whale is back. 462 00:21:09,482 --> 00:21:12,034 That's a whale of a cake for a whale of a dad, 463 00:21:12,103 --> 00:21:14,896 at your participating Carvel ice cream store yup, 464 00:21:14,965 --> 00:21:17,241 and this year your Carvel dealer makes them loaded 465 00:21:17,310 --> 00:21:19,241 with fudge and nuts. 466 00:21:19,310 --> 00:21:23,344 - We had a line out the door waiting two hours 467 00:21:23,413 --> 00:21:24,206 for that cake. 468 00:21:25,241 --> 00:21:26,275 [upbeat music] 469 00:21:26,413 --> 00:21:28,724 - [Adam] Today, Anthony Simione will provide us 470 00:21:28,793 --> 00:21:30,413 with a behind the scenes look 471 00:21:30,482 --> 00:21:32,586 at how the famous Fudgie the whale cake gets made. 472 00:21:32,655 --> 00:21:37,241 - The crunchies are basically the offline sauces crackers 473 00:21:37,310 --> 00:21:39,241 broken up in a specific size, 474 00:21:39,310 --> 00:21:42,241 so like this we're able to spread them 475 00:21:42,310 --> 00:21:44,758 in a layer of our cakes. 476 00:21:44,827 --> 00:21:47,241 - [Adam] Carvel introduced their flying saucer 477 00:21:47,310 --> 00:21:51,034 ice cream sandwiches way back in 1951. 478 00:21:51,103 --> 00:21:54,413 They're made with rich chocolate cookies. 479 00:21:54,482 --> 00:21:57,724 - [Anthony] Brown Bonnet is a chocolate shell that we use. 480 00:21:57,793 --> 00:22:01,793 What this does is it coats the crunchies, 481 00:22:01,862 --> 00:22:05,103 it enables the cake to stay together. 482 00:22:06,034 --> 00:22:08,275 Carvel cakes, Carvel crunchies. 483 00:22:08,344 --> 00:22:10,137 - [Adam] You can't make an ice cream cake 484 00:22:10,206 --> 00:22:11,241 without ice cream. 485 00:22:14,862 --> 00:22:15,620 to the soft serve machine. 486 00:22:15,689 --> 00:22:19,172 And the secret ingredient is... 487 00:22:20,379 --> 00:22:22,413 ...still a secret. 488 00:22:22,482 --> 00:22:23,379 [upbeat music] 489 00:22:23,482 --> 00:22:24,172 - [Anthony] It's a special formula 490 00:22:24,310 --> 00:22:26,827 that only a few people know. 491 00:22:26,896 --> 00:22:31,310 So once we take a cold mold out of the freezer, 492 00:22:31,379 --> 00:22:33,965 what we're gonna do is we're gonna apply a layer 493 00:22:34,034 --> 00:22:35,620 of vanilla ice cream into the mold. 494 00:22:38,206 --> 00:22:40,965 We're gonna put a layer of crunchies in it, 495 00:22:41,034 --> 00:22:44,793 next we're going to put a layer of chocolate. 496 00:22:47,551 --> 00:22:48,827 - [Adam] After five hours in the freezer, 497 00:22:48,896 --> 00:22:53,137 Anthony's Fudgie the Whale cake is ready to be decorated. 498 00:22:53,206 --> 00:22:54,965 - [Anthony] Once we've added the fudge, 499 00:22:56,172 --> 00:22:59,344 we add that layer of delicious crunchies. 500 00:22:59,448 --> 00:23:01,551 [upbeat music] 501 00:23:01,620 --> 00:23:05,551 We hear many stories from customers, why they buy fudgie. 502 00:23:05,620 --> 00:23:08,034 It reminds them of happy times. 503 00:23:08,103 --> 00:23:11,517 They wanna share fudgie with friends and family, 504 00:23:13,379 --> 00:23:15,344 and there you have it, Fudgie the Whale. 505 00:23:17,103 --> 00:23:20,172 - Ice cream is almost, Tom, I think thought of it as a gift. 506 00:23:21,448 --> 00:23:22,689 Even today, our customers come in, 507 00:23:22,758 --> 00:23:24,689 they're coming in to get happy. 508 00:23:24,758 --> 00:23:26,689 You know, they are escaping back 509 00:23:26,758 --> 00:23:29,448 to when they were 12 years old, 510 00:23:29,551 --> 00:23:32,241 had no problems and a cone in their hand. 511 00:23:35,620 --> 00:23:38,034 - [Adam] You know you want it, you know you love it, 512 00:23:38,103 --> 00:23:40,862 you know you can never get enough. 513 00:23:40,931 --> 00:23:42,724 Ice cream, baby! 514 00:23:42,862 --> 00:23:43,724 So fasten your seat belts, 515 00:23:43,793 --> 00:23:46,689 because we're now at my favorite stage 516 00:23:46,758 --> 00:23:49,034 of the ice cream making process, 517 00:23:49,103 --> 00:23:52,379 adding the flavors and inclusions! 518 00:23:52,448 --> 00:23:53,586 Inclusions are like toppings, 519 00:23:53,724 --> 00:23:57,862 but swirled right into the ice cream itself. 520 00:23:59,241 --> 00:24:02,275 And Turkey Hill Manufacturing Manager Michelle Finch 521 00:24:02,344 --> 00:24:05,068 wants to put my taste buds to the test 522 00:24:05,137 --> 00:24:07,482 with some secret samples. 523 00:24:07,620 --> 00:24:09,379 - Let's try the blue one. [laughs] 524 00:24:09,448 --> 00:24:11,103 - Oh my gosh. 525 00:24:11,172 --> 00:24:12,931 It's like Smurf DNA, right here. 526 00:24:14,344 --> 00:24:18,931 [intriguing music] 527 00:24:19,000 --> 00:24:21,931 It tastes like the icing on a birthday cake. 528 00:24:22,000 --> 00:24:23,275 - Absolutely correct. 529 00:24:23,344 --> 00:24:25,551 That's the icing that goes in our party cake ice cream. 530 00:24:25,620 --> 00:24:28,275 - That is crazy! 531 00:24:28,344 --> 00:24:29,275 - Now let's blow your mind. 532 00:24:29,344 --> 00:24:31,413 Let's put one of those on your spoon. 533 00:24:36,931 --> 00:24:39,586 [Michelle laughs] 534 00:24:42,172 --> 00:24:44,103 - It doesn't make any sense. 535 00:24:44,172 --> 00:24:46,931 It tastes like a cake and icing. 536 00:24:47,000 --> 00:24:48,275 How did you do that? 537 00:24:48,344 --> 00:24:50,758 How did you squeeze a whole cake into a pebble? 538 00:24:50,827 --> 00:24:52,068 - [Michelle] It's magic. 539 00:24:52,137 --> 00:24:55,448 That's what makes our party cake ice cream the best. 540 00:24:55,517 --> 00:24:57,000 - Do you ever just mess around with these things 541 00:24:57,137 --> 00:24:59,793 and just make really delicious little things to eat? 542 00:24:59,862 --> 00:25:01,344 - [Michelle] Not typically, but we can. 543 00:25:01,413 --> 00:25:02,655 - All right, so, I'm gonna see. 544 00:25:02,724 --> 00:25:05,000 I'm gonna start off with some of these. 545 00:25:05,068 --> 00:25:07,689 They look like roasted salted almonds, 546 00:25:07,758 --> 00:25:10,344 so they'll have a little bit of a saltiness, 547 00:25:10,482 --> 00:25:11,551 a little bit of 548 00:25:11,689 --> 00:25:13,344 a kinda charred smokiness. - Do you know what would 549 00:25:13,413 --> 00:25:15,517 be really good on there? 550 00:25:15,586 --> 00:25:16,517 - Let's say it on three. Ready? 551 00:25:16,655 --> 00:25:18,172 One, two, three. 552 00:25:18,241 --> 00:25:19,310 - [Adam & Michelle] Caramel. 553 00:25:20,413 --> 00:25:21,517 - [Adam] Great minds think alike. 554 00:25:21,586 --> 00:25:23,344 All right, let's get it going. 555 00:25:23,413 --> 00:25:25,344 [anticipatory orchestral music] 556 00:25:25,482 --> 00:25:26,034 [laughing] Okay. 557 00:25:29,896 --> 00:25:33,827 We've done it, here. 558 00:25:33,896 --> 00:25:35,034 We've done it here. 559 00:25:35,172 --> 00:25:37,000 R&D, call me! 560 00:25:37,068 --> 00:25:38,827 Okay. Well, thank you for letting me do this. 561 00:25:38,896 --> 00:25:40,172 What do we do next? 562 00:25:40,241 --> 00:25:40,862 - [Michelle] We're gonna go into the production area, 563 00:25:42,724 --> 00:25:46,172 and make cookie dough ice cream. 564 00:25:46,241 --> 00:25:47,482 - Lead on, my lady! 565 00:25:48,517 --> 00:25:51,827 [playful curious music] 566 00:25:52,724 --> 00:25:55,517 - This is exactly where 567 00:25:55,586 --> 00:25:57,655 the mix will come into the flavor batch! 568 00:25:57,724 --> 00:25:59,862 - [Adam] What's that? 569 00:25:59,931 --> 00:26:01,724 - I'm gonna have you add the cookie dough flavor! 570 00:26:04,068 --> 00:26:06,034 - Thank you, thank you. 571 00:26:09,793 --> 00:26:11,758 [Michelle laughs] 572 00:26:11,827 --> 00:26:15,551 - [Adam] Our premium white mix still tastes like vanilla 573 00:26:15,620 --> 00:26:18,275 until we add this. 574 00:26:18,413 --> 00:26:22,241 - [Michelle] That's the cookie dough ice cream flavor! 575 00:26:22,310 --> 00:26:23,586 - [Adam] That is so awesome. 576 00:26:23,655 --> 00:26:27,413 - And you just made your first cookie dough ice cream mix. 577 00:26:27,482 --> 00:26:29,586 - I love it, and the smell is amazing. 578 00:26:29,655 --> 00:26:31,758 Cookie dough is one of the country's favorite flavors. 579 00:26:31,827 --> 00:26:36,241 In fact, it's hard to find anyone who doesn't like it! 580 00:26:36,310 --> 00:26:37,724 And you could say the same for my favorite flavor, 581 00:26:37,793 --> 00:26:40,103 mint chocolate chip, 582 00:26:40,241 --> 00:26:43,241 which, legend has it, was conceived in 1973 583 00:26:43,310 --> 00:26:44,896 by a British culinary student 584 00:26:44,965 --> 00:26:47,241 who won a contest to provide ice cream 585 00:26:47,310 --> 00:26:49,275 for Princess Anne's wedding, 586 00:26:49,413 --> 00:26:52,379 or Neapolitan ice cream, which was brought to America 587 00:26:52,448 --> 00:26:53,931 by immigrants from Naples 588 00:26:54,068 --> 00:26:56,103 in the late 19th century. 589 00:26:57,758 --> 00:27:01,000 But other cultures have even more variety than we do, 590 00:27:03,034 --> 00:27:04,793 like squid, 591 00:27:04,862 --> 00:27:07,448 cow tongue, 592 00:27:09,034 --> 00:27:10,965 and raw horse flesh. 593 00:27:11,034 --> 00:27:13,793 To be clear, not just horse flesh, 594 00:27:13,862 --> 00:27:16,793 but raw horse flesh. 595 00:27:18,379 --> 00:27:20,137 You can chase all these flavors 596 00:27:20,206 --> 00:27:22,275 the next time you visit Tokyo. 597 00:27:23,206 --> 00:27:25,000 Not wetting your appetite? 598 00:27:25,068 --> 00:27:28,000 The fact is that coming up with new ice cream flavors 599 00:27:28,137 --> 00:27:30,620 that appeal to large swaths of the public 600 00:27:30,689 --> 00:27:32,689 is an art in and of itself. 601 00:27:34,551 --> 00:27:36,655 Welcome to an ice cream shrine 602 00:27:36,724 --> 00:27:39,620 very few have been blessed to enter. 603 00:27:39,689 --> 00:27:42,655 The Dreyer's Grand Ice Cream test kitchen, 604 00:27:42,724 --> 00:27:45,103 where new ice cream flavors are born! 605 00:27:45,827 --> 00:27:48,620 One of the greatest ice cream flavors of all time, 606 00:27:48,689 --> 00:27:53,137 Rocky Road, was invented by founders William Dreyer 607 00:27:53,206 --> 00:27:55,103 and Joseph Edy. 608 00:27:55,172 --> 00:27:56,965 Dryer's Grand Ice Cream 609 00:27:57,034 --> 00:28:00,137 has been the company name since 1948, 610 00:28:00,206 --> 00:28:01,241 but in the eighties, 611 00:28:01,379 --> 00:28:04,034 Dryer's was expanding east of the Rockies 612 00:28:04,103 --> 00:28:06,379 into markets that were already selling 613 00:28:06,448 --> 00:28:08,862 Breyers brand ice cream. 614 00:28:10,103 --> 00:28:11,931 They decided to use the Edy's label in those areas, 615 00:28:12,068 --> 00:28:15,862 so their product wouldn't be confused with Breyers. 616 00:28:15,931 --> 00:28:18,862 Today, we get a secret glimpse of the development team 617 00:28:18,931 --> 00:28:22,413 as they test out a new flavor, 618 00:28:22,551 --> 00:28:25,827 one that looks back to Rocky Road for inspiration. 619 00:28:26,379 --> 00:28:30,206 Dryer and Edy added marshmallows and chopped walnuts 620 00:28:30,275 --> 00:28:31,862 to chocolate ice cream in 1929, 621 00:28:31,931 --> 00:28:35,379 and called their new flavor Rocky Road 622 00:28:35,448 --> 00:28:38,206 because America had just fallen into the great depression, 623 00:28:38,275 --> 00:28:40,241 and had a rocky road ahead of it. 624 00:28:41,620 --> 00:28:43,862 A big reason for Rocky Road's enduring popularity 625 00:28:43,931 --> 00:28:45,896 has to do with its texture. 626 00:28:45,965 --> 00:28:50,551 The gooeyness of marshmallows is a perfect counterpoint 627 00:28:50,689 --> 00:28:52,551 to the crunch of the nuts, 628 00:28:52,620 --> 00:28:54,379 so, taking that as inspiration, 629 00:28:54,448 --> 00:28:57,206 the team uses brownies to get the gooey texture 630 00:28:57,275 --> 00:28:58,724 similar to marshmallows. 631 00:28:58,862 --> 00:29:00,379 But what about the crunch? 632 00:29:00,448 --> 00:29:03,793 First, they try chocolate rice. 633 00:29:03,862 --> 00:29:05,103 - [Tester] I would like the crunch a lot. 634 00:29:05,172 --> 00:29:07,482 I'm not personally sold yet 635 00:29:07,620 --> 00:29:10,586 that a rice crunch goes well with brownie. 636 00:29:10,655 --> 00:29:12,793 - [Adam] Next, they dried toffee. 637 00:29:12,931 --> 00:29:14,448 - [Agata] Toffee is yummy, 638 00:29:14,517 --> 00:29:17,068 but is it taking away from the brownie? 639 00:29:17,137 --> 00:29:18,586 - [Tester] Yeah. 640 00:29:18,655 --> 00:29:19,620 What was that material 641 00:29:19,689 --> 00:29:21,586 we looked at a couple of weeks ago, Agata? 642 00:29:21,655 --> 00:29:22,620 - [Agata] Brownie brittle. 643 00:29:22,689 --> 00:29:23,965 Let me have one of those mixing bowls. 644 00:29:24,034 --> 00:29:25,931 - [Adam] To find the right crunch for their new flavor, 645 00:29:26,000 --> 00:29:29,620 the team turns to brownie brittle! 646 00:29:29,689 --> 00:29:30,931 They mix it in with the gooey regular brownies, 647 00:29:31,000 --> 00:29:34,310 and also brownie batter. 648 00:29:35,172 --> 00:29:36,448 - [Tester 2] Oh my gosh. 649 00:29:36,517 --> 00:29:37,586 - [Tester] I think this is it! - [Tester 3] That's so good! 650 00:29:42,103 --> 00:29:44,931 The next step is to refine the ingredients 651 00:29:45,000 --> 00:29:48,448 and make sure the new flavor works well 652 00:29:48,517 --> 00:29:50,758 when produced on a larger scale. 653 00:29:50,827 --> 00:29:53,103 - Take the brownies up just a smidge more. 654 00:29:53,172 --> 00:29:54,448 - [Adam] The development team 655 00:29:54,517 --> 00:29:58,137 will keep working on the new flavor until it's perfected 656 00:29:58,275 --> 00:30:00,068 and ready for mass production on the factory floor. 657 00:30:04,344 --> 00:30:05,206 Back at Turkey Hill, 658 00:30:08,172 --> 00:30:10,137 to our cookie dough ice cream. 659 00:30:10,275 --> 00:30:11,137 - You're a pro! 660 00:30:11,275 --> 00:30:13,586 - [Adam] These look too good not to try! 661 00:30:14,655 --> 00:30:16,275 - Cheers! - Cheers! 662 00:30:16,344 --> 00:30:18,275 What's different about the cookie dough 663 00:30:18,344 --> 00:30:19,586 in cookie dough ice cream, 664 00:30:19,655 --> 00:30:21,448 and what do we add next? 665 00:30:24,000 --> 00:30:26,103 Here at the Turkey Hill ice cream factory, 666 00:30:26,172 --> 00:30:28,103 we just put the pedal to the metal 667 00:30:28,172 --> 00:30:31,241 and added cookie dough to our cookie dough ice cream. 668 00:30:34,000 --> 00:30:36,103 It's delicious! 669 00:30:36,172 --> 00:30:37,758 And it has, like, the same granularity 670 00:30:37,827 --> 00:30:39,448 of real cookie dough! 671 00:30:39,517 --> 00:30:41,586 That's the thing that I love! 672 00:30:41,655 --> 00:30:43,758 It doesn't taste artificial. 673 00:30:43,827 --> 00:30:45,620 You could keep your tequila 674 00:30:45,689 --> 00:30:47,655 to be a cookie dough shooter. 675 00:30:47,793 --> 00:30:50,620 But I'm learning there is a lot more than just cookie dough 676 00:30:50,689 --> 00:30:52,620 in this cookie dough ice cream. 677 00:30:52,689 --> 00:30:54,448 - [Michelle] So, that's a liquid chip. 678 00:30:54,517 --> 00:30:55,758 - [Adam] Wait, wait. 679 00:30:55,827 --> 00:30:56,827 Liquid chip? 680 00:30:56,965 --> 00:30:59,758 - Liquid chip. - Like, liquid chocolate chip? 681 00:30:59,827 --> 00:31:00,620 - Yeah. 682 00:31:00,689 --> 00:31:02,896 When it goes into the ice cream, 683 00:31:03,034 --> 00:31:06,172 it's like a little sheet going into the ice cream, 684 00:31:06,241 --> 00:31:07,310 and it solidifies. 685 00:31:07,379 --> 00:31:10,482 - Oh, the cold of the ice cream hardens it! 686 00:31:10,551 --> 00:31:10,655 - Yes. 687 00:31:13,586 --> 00:31:15,344 - They extrude liquid warm chocolate 688 00:31:15,413 --> 00:31:17,379 into freezing cold ice cream, 689 00:31:17,517 --> 00:31:22,517 it hardens, and it breaks in the churning process 690 00:31:22,586 --> 00:31:25,827 so you get those awesome, irregular bits 691 00:31:25,896 --> 00:31:27,000 - [Elizabeth] Slivers! 692 00:31:27,068 --> 00:31:29,172 that are rigid, and they're a little chewy. 693 00:31:29,241 --> 00:31:32,000 It's like chocolate chip 2.0. 694 00:31:32,724 --> 00:31:33,827 It's amazing! 695 00:31:33,896 --> 00:31:36,827 Liquid chocolate chips, people. 696 00:31:36,896 --> 00:31:38,517 We are living in the future! 697 00:31:38,586 --> 00:31:40,344 Our ice cream batch is almost ready, 698 00:31:40,413 --> 00:31:44,655 and here is where it gets loaded into cartons. 699 00:31:45,586 --> 00:31:47,689 And if you follow this pipe, 700 00:31:47,758 --> 00:31:50,517 it goes all the way back to right where we were standing, 701 00:31:50,586 --> 00:31:53,000 where you see the cookie dough. 702 00:31:53,068 --> 00:31:54,655 The cookie dough balls go in. 703 00:31:55,724 --> 00:31:57,206 There's the chocolate. 704 00:31:58,413 --> 00:32:01,241 So, you have the liquid chip, the ice cream meet, 705 00:32:01,310 --> 00:32:04,724 that cookie dough meet, it gets mixed together, 706 00:32:04,793 --> 00:32:05,517 the lids go in here, 707 00:32:08,310 --> 00:32:12,241 and right here is literally where the rubber meets the road. 708 00:32:12,310 --> 00:32:14,413 Container goes down, and the ice cream goes right here. 709 00:32:14,482 --> 00:32:17,586 And look how creamy it is! 710 00:32:17,655 --> 00:32:20,241 It's actually closer to soft serve 711 00:32:20,310 --> 00:32:21,724 than hard scoop ice cream. 712 00:32:23,137 --> 00:32:27,068 I love when ice cream is this consistency. 713 00:32:27,137 --> 00:32:28,620 There's nothing like it in the world. 714 00:32:28,758 --> 00:32:30,551 - No, this is the best way you can get it. 715 00:32:30,620 --> 00:32:31,689 - I agree. 716 00:32:36,172 --> 00:32:40,586 and when I die, I want you to bury me in one of these tubs. 717 00:32:40,724 --> 00:32:42,586 [upbeat music] 718 00:32:42,655 --> 00:32:44,413 - [Adam] These cartons are destined for home freezers 719 00:32:44,482 --> 00:32:47,206 all across America, 720 00:32:48,482 --> 00:32:51,241 but before the home freezer became common in the 1940s, 721 00:32:51,310 --> 00:32:53,793 ice cream was a destination, 722 00:32:54,965 --> 00:32:56,896 and the places where we enjoyed ice cream 723 00:32:56,965 --> 00:32:58,896 became cultural touchstones, 724 00:32:58,965 --> 00:33:02,103 starting soon after the revolution in 1776 725 00:33:02,172 --> 00:33:05,482 with the emergence of the ice cream parlor. 726 00:33:05,551 --> 00:33:09,275 - [Michael] Where ice cream was particularly popular 727 00:33:10,724 --> 00:33:13,310 in that sort of early post-revolutionary period 728 00:33:13,379 --> 00:33:16,310 was in these places called pleasure gardens. 729 00:33:16,379 --> 00:33:19,655 They would specialize in things like ice cream and lemonade. 730 00:33:19,724 --> 00:33:22,310 It was a relatively respectable place to go, 731 00:33:22,379 --> 00:33:26,689 versus the bars and the taverns 732 00:33:26,827 --> 00:33:29,827 where no respectable woman would be seen. 733 00:33:29,965 --> 00:33:32,310 - [Adam] But as the 20th century dawned, 734 00:33:32,379 --> 00:33:35,137 ice cream parlors had to compete for customers 735 00:33:35,206 --> 00:33:39,137 with a new ice cream destination, the soda fountain. 736 00:33:39,206 --> 00:33:40,827 The first soda fountains 737 00:33:40,896 --> 00:33:43,827 actually appeared in drug stores and pharmacies. 738 00:33:43,896 --> 00:33:46,827 They marketed their soft drinks as health tonics 739 00:33:46,965 --> 00:33:49,827 with ingredients that truly packed a punch, 740 00:33:49,896 --> 00:33:53,655 like cocaine and the digestive enzyme, pepsin, 741 00:33:53,724 --> 00:33:56,000 before they expanded their offerings. 742 00:33:56,068 --> 00:33:58,482 - [Michael] They came up with various kinds of new ways 743 00:33:58,551 --> 00:34:02,206 of combining soda and ice cream, 744 00:34:02,275 --> 00:34:05,379 so this is where you get that ice cream float 745 00:34:05,448 --> 00:34:08,068 that became popular throughout the 20th century. 746 00:34:09,448 --> 00:34:12,034 - [Adam] And with the rise of prohibition in 1920, 747 00:34:12,103 --> 00:34:15,862 soda fountains' popularity exploded even more! 748 00:34:15,931 --> 00:34:18,344 You could enjoy an ice cold Coca-Cola 749 00:34:18,413 --> 00:34:20,241 or Hires' root beer float 750 00:34:20,379 --> 00:34:24,724 at more than 100,000 soda fountains across the US. 751 00:34:24,793 --> 00:34:26,206 - [Michael] Once they close the bars and the taverns, 752 00:34:26,275 --> 00:34:27,724 where are you gonna socialize? 753 00:34:27,793 --> 00:34:29,551 - [Adam] Prohibition ended in 1933, 754 00:34:29,620 --> 00:34:33,896 and soda fountains have since waned in popularity, 755 00:34:34,034 --> 00:34:37,379 but the ice cream parlor remains a top spot 756 00:34:37,448 --> 00:34:41,344 for both high school dates and family fun two centuries on. 757 00:34:43,896 --> 00:34:46,551 [upbeat music] 758 00:34:46,620 --> 00:34:51,862 We've made or mix, added our inclusions, 759 00:34:51,931 --> 00:34:54,034 and now we're finally loading up 760 00:34:54,103 --> 00:34:56,379 those iconic Turkey Hill cartons 761 00:34:56,448 --> 00:34:59,896 with our own batch of cookie dough ice cream. 762 00:35:01,517 --> 00:35:04,103 All right, so, now, where are they going 763 00:35:04,172 --> 00:35:04,793 once they're filled? 764 00:35:06,344 --> 00:35:07,275 - [Michelle] At this point, 765 00:35:07,344 --> 00:35:09,758 we're gonna take every container over, 766 00:35:09,827 --> 00:35:14,275 and put the code date on the bottom of the container. 767 00:35:14,344 --> 00:35:16,758 - [Adam] The code, so, like, 768 00:35:37,137 --> 00:35:38,793 - [Michelle] Then they go through a metal detector 769 00:35:38,862 --> 00:35:40,068 'cause, of course, we wanna make sure 770 00:35:40,137 --> 00:35:43,103 that there's no foreign objects in our ice cream. 771 00:35:43,172 --> 00:35:44,448 - That's a metal detector? - Yep! 772 00:35:44,517 --> 00:35:48,068 - [Adam] So, we saw quality control, 773 00:35:48,137 --> 00:35:50,482 even coming from the milk. 774 00:35:50,586 --> 00:35:52,448 But, 775 00:35:52,517 --> 00:35:56,586 even on the way out, they're getting a date, 776 00:35:56,655 --> 00:35:59,965 a batch number, the time they were made, 777 00:36:01,241 --> 00:36:03,000 who is the operator, 778 00:36:04,034 --> 00:36:06,827 and then they run through a metal detector 779 00:36:06,896 --> 00:36:10,689 for even extra added level of safety. 780 00:36:10,758 --> 00:36:12,827 - [Michelle] So, this is the best part. 781 00:36:12,896 --> 00:36:14,655 We're gonna taste the ice cream. 782 00:36:14,724 --> 00:36:16,827 - Finally! 783 00:36:16,896 --> 00:36:19,827 Hallelujah! 784 00:36:19,896 --> 00:36:21,344 - So, this is your container. 785 00:36:21,413 --> 00:36:24,137 - [laughing] Oh, my precious. 786 00:36:24,206 --> 00:36:26,827 - So, there's two parts to this, alright? 787 00:36:26,896 --> 00:36:29,000 One is, we're gonna dip through it 788 00:36:29,068 --> 00:36:32,344 to just make sure that we've got cookie dough pieces 789 00:36:32,413 --> 00:36:36,172 and the chocolate chips all throughout it, 790 00:36:36,241 --> 00:36:39,655 and then, whatever's on the lid, you can taste. 791 00:36:39,724 --> 00:36:42,172 Hold it like a spoon. 792 00:36:42,241 --> 00:36:43,172 - Oh, you do it like that? 793 00:36:43,241 --> 00:36:46,620 - And we're gonna dip through that. 794 00:36:46,689 --> 00:36:48,000 - Oh, hell yeah! 795 00:36:52,413 --> 00:36:55,689 - The best scoop of ice cream you've ever had! 796 00:36:55,758 --> 00:36:58,655 - I can eat it like this? Right here? 797 00:36:58,724 --> 00:37:02,206 [playful curious music] 798 00:37:09,620 --> 00:37:13,551 [Michelle laughs] 799 00:37:16,965 --> 00:37:18,068 - Good. 800 00:37:18,137 --> 00:37:18,551 - [laughing] It's really good. 801 00:37:18,620 --> 00:37:20,586 Oh my God. 802 00:37:20,655 --> 00:37:24,896 This is unlike any ice cream you're ever going to have, 803 00:37:24,965 --> 00:37:26,034 'cause you know why? 804 00:37:27,482 --> 00:37:30,413 Before you freeze it, I think you really taste 805 00:37:30,482 --> 00:37:32,586 the characteristic of every ingredient. 806 00:37:32,655 --> 00:37:36,896 You taste the cream, you taste the milk, 807 00:37:36,965 --> 00:37:41,413 you get the little tiny liquid chips, the cookie dough. 808 00:37:41,482 --> 00:37:44,931 It's a different soft than the ice cream. 809 00:37:46,482 --> 00:37:48,689 I'm telling you, if you can go to a creamery, 810 00:37:48,758 --> 00:37:50,758 if you go to Turkey Hill, 811 00:37:50,827 --> 00:37:52,862 it's better than every soft serve, 812 00:37:52,931 --> 00:37:55,068 it's better than every hard pack. 813 00:37:55,137 --> 00:37:58,689 I just oh, I want a spoon and some privacy. That's it. 814 00:37:58,758 --> 00:37:59,724 [Michelle laughs] 815 00:37:59,793 --> 00:38:01,137 - [Adam] Alright. 816 00:38:01,206 --> 00:38:03,137 So, now that goes to the freezer? 817 00:38:03,206 --> 00:38:05,137 - We'll pack six, - By 6? 818 00:38:05,206 --> 00:38:06,931 - in a case. 819 00:38:07,000 --> 00:38:09,689 That six pack will then go into the freezer. 820 00:38:11,862 --> 00:38:14,793 - If you, being nice, patient, informed, 821 00:38:14,862 --> 00:38:17,793 and letting me do fun stuff weren't enough, 822 00:38:17,862 --> 00:38:19,275 you gave me a bite of, arguably, 823 00:38:19,344 --> 00:38:21,793 some of the best ice cream I've ever had 824 00:38:21,862 --> 00:38:23,827 in the coolest way imaginable, 825 00:38:23,896 --> 00:38:26,965 so I'm giving you an air hug and an elbow bump. 826 00:38:27,034 --> 00:38:29,172 You're so cool, Michelle. Thank you so much. 827 00:38:29,241 --> 00:38:32,413 I'm gonna go find a treadmill, and I'ma take some ice cream. 828 00:38:32,482 --> 00:38:35,310 [Michelle laughs] 829 00:38:40,034 --> 00:38:40,965 - [Adam] That's it! 830 00:38:42,724 --> 00:38:45,655 is on its way to a supermarket near you. 831 00:38:49,034 --> 00:38:50,655 In many ways, the story of ice cream in America 832 00:38:50,724 --> 00:38:53,517 is like the story of America itself! 833 00:38:55,034 --> 00:38:57,103 It's been with us from our earliest days, 834 00:38:57,172 --> 00:39:00,482 and has grown and changed just as our country has. 835 00:39:00,551 --> 00:39:02,206 Whether in a cake or a cone 836 00:39:02,275 --> 00:39:04,034 or straight off the factory line, 837 00:39:04,103 --> 00:39:05,655 it was amazing to see how it's made, 838 00:39:05,724 --> 00:39:07,689 Wow! 839 00:39:07,758 --> 00:39:10,551 And meet the wonderful people 840 00:39:10,620 --> 00:39:13,034 whose work brings millions of smiles 841 00:39:13,103 --> 00:39:16,862 to ice cream lovers, like myself, every day. 842 00:39:16,931 --> 00:39:21,000 Now, if I could only decide which flavor I wanna have next. 843 00:39:22,620 --> 00:39:25,034 Where do you guys keep the mint chocolate chip? 63741

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