How Nutella Is Made In Factory? | Captain Discovery

Summary

Join Captain Discovery on an exciting journey inside one of the largest Nutella factories to uncover the secrets behind its rich, delicious flavor. From the careful harvesting of cocoa and hazelnuts to the precise blending of ingredients like palm oil, milk, and sugar, discover how Nutella's perfect mix of natural ingredients and cutting-edge technology come together. The process includes strict quality checks, roasting, refining, and packaging, ensuring every jar is flawless. Get an exclusive look at the intricate methods that make Nutella a global favorite.

Takeaways

• 😀 Nutella was invented in 1946 by Pietro Ferrero in Italy and initially called 'Ganache.' It was renamed Nutella in 1964.
• 😀 Nutella's success is attributed to its combination of high-quality, natural ingredients and advanced production technology.
• 😀 Nutella's main ingredients include cocoa, hazelnuts, palm oil, milk, and sugar, each sourced from different regions around the world.
• 😀 Cocoa beans used in Nutella are sourced from West African farms and undergo hand harvesting, fermentation, and sun drying.
• 😀 Hazelnuts are harvested from the Longi region of Italy, roasted, and undergo rigorous testing to ensure the perfect flavor.
• 😀 Palm oil is harvested in Malaysia and Indonesia, processed quickly to preserve its quality, and has a neutral taste that doesn't affect Nutella’s flavor.
• 😀 Nutella uses skim milk powder from fresh milk, which undergoes strict quality control before being used in production.
• 😀 Nutella uses a combination of 75% beet sugar and 25% cane sugar, which is processed and refined before it is added to the product.
• 😀 The cocoa processing involves drying, husking, roasting, and grinding beans into cocoa mass, from which cocoa butter and cocoa powder are separated.
• 😀 The Nutella factory emphasizes quality control, with expert testing and refinement at every stage of production to ensure the final product’s consistency and taste.
• 😀 Nutella's packaging is automated, with glass jars being filled, sealed, labeled, and prepared for distribution, while the factory also recycles to minimize environmental impact.

Q & A

What is the origin of Nutella, and how did it evolve over time?

Nutella was invented by Pietro Ferrero in Italy in 1946. Initially, it was called 'Ganet' and made from hazelnuts, sugar, and a small amount of cocoa. In 1964, it was renamed 'Nutella' and began being mass-produced as a spread for bread. It was introduced to the U.S. in the late 1980s, becoming a popular product.

Why is hand harvesting preferred for cocoa beans in West Africa?

Hand harvesting is preferred because it reduces the rate of crushed cocoa beans. This careful method helps preserve the quality of the beans, which is essential for developing Nutella's signature flavor.

How does fermentation affect cocoa beans?

Fermentation helps develop the flavor and reduce the bitterness of the cocoa beans. The beans are placed in large bins and fermented for 2 to 7 days before being dried, which contributes to the complex and enticing taste of Nutella.

What are the key regions where Nutella sources its main ingredients?

Nutella sources its ingredients from various parts of the world: cocoa beans are harvested in West Africa, hazelnuts come from the Longi region in Italy, and palm oil is sourced from Malaysia and Indonesia.

What role does palm oil play in Nutella's production process?

Palm oil is a crucial ingredient in Nutella because it provides a neutral taste and smooth texture. It is sterilized, separated from the fruit, and refined before being used in the production process.

How is sugar processed for Nutella?

The sugar used in Nutella consists of 75% beet sugar and 25% cane sugar. After harvesting, the beets or cane are washed, cut into strips, and processed to extract juice. This juice is then refined to produce the sugar used in Nutella.

What steps are involved in processing cocoa beans at the factory?

Cocoa beans undergo several stages at the factory: preliminary drying, husking (where the husk is separated from the bean), roasting to develop flavor and color, grinding into cocoa mass, and pressing to separate cocoa butter from cocoa cake. The final product is then ground into cocoa powder.

How are hazelnuts processed in the Nutella factory?

Upon arrival at the factory, hazelnuts are tested for quality. They are then roasted in batches, with experts checking the flavor, aroma, and consistency at each stage to ensure the best quality for Nutella.

What happens after the cocoa and hazelnuts are processed?

After processing, the cocoa and hazelnuts are mixed with other ingredients like sugar, palm oil, and milk powder in a large industrial mixer. This forms a homogeneous mixture that is then refined to achieve Nutella's signature smooth and creamy texture.

How does Nutella maintain environmental sustainability in its production process?

Nutella's factory engages in environmental protection by recycling glass jars to reduce waste. This effort helps minimize their environmental footprint while maintaining the quality and efficiency of production.