Segments in this Video

Baked Beans: Inside the Factory—Introduction (02:05)


People in Britain consume over 2 million cans of baked beans every day. Gregg Wallace and Cherry Healey will tour the largest food factory in Europe and follow the journey of a recycled tin can. Ruth Goodman will investigate the importance of tinned food.

Heinz Factory: Bean Intake (04:26)

The factory employs 1,200 staff and runs 24 hours a day to produce 200 products; baked beans are the best seller. Wallace helps oversee the delivery and unloading of Haricot beans; the factory makes 3 million cans of beans a day.

Blanching Room (03:01)

Time and temperature are vital to the rehydration process; the beans will take in approximately 65% more water. The beans undergo a wash before a laser sorter rejects any discolored beans.

Materials Recovery Facility (03:29)

Healey visits a recycling center in East London that sorts 520 truckloads of materials every week. David Rumbold explains the separation process. Healey's tin can becomes part of a cube created by the baling machine.

Spice Mixing Room (02:17)

Every manufacturer uses Haricot beans but each one makes a particular tomato sauce. Only two people know Heinz's spice recipe that has been unchanged since 1896. Wallace tries to determine what is in the powder mixes.

Tomato Sauce Room (02:28)

Wallace helps Peter Foster prepare the sauce for baked beans; Foster is in charge of eight mixing vats. The tomato puree arrives in one ton bags. The factory can produce up to 4 million baked bean cans a day.

Tata Steel (06:36)

Healey follows her tin can to the largest steelworks in the U.K. Workers turn scrap metal into sheets of steel; scrap metal comprises approximately 25% of the finished steel. Workers will coat the steel sheet with tin to prevent rust and protect the beans.

Can Making Factory (03:40)

The factory receives 168 tons of steel every day. The steel sheets travel through a series of machines to become tin cans for baked beans. In Britain, the average household uses more than 10 cans of food per week.

Food Preservation (04:36)

In the early 19th century; malnutrition killed more than half of British seaman in the Seven Years' War. In 1795, Nicolas Appert invented a way of preserving food with glass bottles. Brian Duncan was the first man to successfully use tin cans for preservation.

Filling Hall (02:51)

Jason Lowe explains the process of filling the cans with the blanched Haricot beans and tomato sauce; approximately 465 beans fill each can. A machine seals the cans and the cans move on to the cooking stage.

Canned Food (03:27)

Cans that are not dented, punctured, swollen, or rusty can be used after their best before date. Carla Philips measures the vitamin C of a can of tomatoes 14 months past its best before date and compares it to fresh tomatoes. Dr. Daniel Amond tests a 45-year-old can of skippers for hidden microbes.

Cooking Room (03:20)

Greg Leach oversees the cooking of 3 million cans of baked beans every day. Steam raises the temperature and pressure inside the cans; the cans pass through five chambers of the cooker.

Passion for Baked Beans (02:52)

During the 19th century, Fortnum and Mason was the leading supplier of tinned goods in Britain; they were the first to sell Heinz baked beans. Polly Russell explains the introduction of baked beans to the mass market; British people consume 2 million cans of baked beans every day.

Quality Control and Labeling (02:38)

Every two hours, experts remove a can of baked beans from the production line for tasting. The factory labels over 3 million cans of baked beans per day. Wallace learns about the labeling process and the final quality check.

Food Experiment (05:49)

Healey and Jack Monroe serve a group of foodies a two course gourmet meal made with canned foods; Monroe hopes to dispel the "snobbery" about canned goods.

Distribution Center (04:09)

The center stores nearly all Heinz products made in U.K. factories. Automated cranes maneuver the canned goods. Wallace reviews the production and distribution of baked beans.

Credits: Baked Beans: Inside the Factory—How Our Food Is Made (Series 2) (00:33)

Credits: Baked Beans: Inside the Factory—How Our Food Is Made (Series 2)

For additional digital leasing and purchase options contact a media consultant at 800-257-5126
(press option 3) or

Baked Beans

Part of the Series : Inside the Factory (Series 2)
DVD (Chaptered) Price: $300.00
DVD + 3-Year Streaming Price: $450.00
3-Year Streaming Price: $300.00



Gregg Wallace helps to unload 27 tons of dried haricot beans from North America and follows them on a one and a half mile journey through the largest baked bean factory in the world, which makes more than three million cans of beans every 24 hours. Meanwhile, Cherry Healey follows the journey of her discarded baked bean can through a recycling center and on to the largest steelworks in the UK. And historian Ruth Goodman reveals that in the early 19th century, malnutrition killed more than half of all British seamen, and how tinned food was invented to improve their nutrition and prevent them developing scurvy on their long voyages at sea.

Length: 59 minutes

Item#: BVL138666

ISBN: 978-1-64198-070-8

Copyright date: ©2016

Closed Captioned

Performance Rights

Prices include public performance rights.

Not available to Home Video and Publisher customers.