Gregg Wallace reconnects with the McVitie’s factory in Harlesden, north west London, which he visited back in 2017. The coronavirus crisis caused a huge spike in the nation's desire for sweet treats, and sales of the firm’s chocolate digestives rose by 71 per cent, meaning in just two months, they sold an astonishing 12.5 million packets.
Gregg looks back at his original visit to the factory, following the production of chocolate digestives from the arrival of 28 tonnes of flour right through to dispatch. Along the way, he discovers that the chocolate is added to the bottom not the top of the biscuits - so they are all being eaten the wrong way up!
Cherry Healey is on the trail of the chocolate, the most expensive ingredient at around £2,000 per tonne, and historian Ruth Goodman investigates the link between biscuits and digestion.
Gregg speaks to manager Nina Sparks via video call. Nina reassures him that all the ingredients for the biscuits are still getting through, including the flour which has been missing from many of our supermarket shelves due to a packaging shortage.
Gregg also catches up with manufacturing manager Fraser Jones to find out what challenges he has been facing at this normally straightforward, final stage. Gregg learns that there have been problems with the supply of cardboard for the boxes, which are vital to protect the fragile biscuits during delivery.
Gregg catches up with Nina one last time to learn of yet another challenge for her team, this time at dispatch. The whole supply chain works on a tight timetable with lorries leaving with full loads and empty ones returning from the supermarkets to collect more biscuits. This was put into flux as trucks were held at huge queues at the supermarkets, and the factory’s dispatch yard was rammed with others awaiting their new load. Thanks to the dedicated work of the truck drivers and the organisational skills of Nina and her team, the lorries and therefore the biscuit supply chain has kept moving.
Finally, Gregg says a last goodbye to Nina, thanking her on behalf of 'all the biscuit nibblers of this nation'! Show less