How KitKat Are Made In a Factory | See How They Make 8 Million Bars Every Day!

Summary

This video takes viewers on a fascinating journey behind the scenes of Kit Kat's production process, from the cocoa farms in West Africa to the state-of-the-art chocolate factories. It reveals the meticulous steps of transforming cocoa beans and wheat flour into the signature crispy, chocolate-covered wafer bars. The video highlights the delicate roasting, grinding, and tempering of ingredients, as well as the careful crafting of the wafer layers and chocolate coating. The journey concludes with the packaging and distribution of over 8 million Kit Kat bars daily, showcasing the precision and care that make each bite irresistible.

Takeaways

• 😀 Kit Kat bars are produced in one of the world's largest chocolate factories, crafting over 8 million bars daily.
• 🌱 Cocoa beans, essential for Kit Kat's chocolate flavor, are sourced from West Africa, where they are carefully harvested and dried.
• 🧐 The cocoa beans undergo rigorous quality checks at the factory, including moisture checks, size assessment, and scent testing.
• 🔥 The roasted cocoa beans are ground into a smooth cocoa paste, which is then pressed to extract cocoa butter, forming pure cocoa cakes.
• 🍫 Kit Kat's signature chocolate flavor is created by blending cocoa powder, sugar, milk powder, cocoa butter, and secret ingredients.
• 🔬 Conching, a refining process, grinds chocolate particles to a microscopic size, making the chocolate melt instantly on the tongue.
• 🌡️ Tempering is crucial to ensure smooth, glossy chocolate by cycling its temperature to prevent the formation of unsightly crystals.
• 🍪 The wafer layers are crafted from wheat flour, water, sugar, vegetable fats, and salt, with a leavening agent to create a crispy texture.
• 🍫 The chocolate filling between Kit Kat's wafer layers includes crushed Kit Kat pieces, creating a unique and smoother consistency.
• 💨 The final chocolate coating process includes three precise layers applied to the wafers, ensuring a glossy, irresistible finish.
• 🚛 Once the Kit Kat bars pass strict quality checks, they are wrapped, packaged, and shipped to warehouses for global distribution.

Q & A

Where does the journey of creating Kit Kat begin?

The journey of creating Kit Kat begins in the distant lands of West Africa, where cocoa is harvested from the fertile, tropical cocoa fields.

How are the cocoa beans harvested?

Cocoa beans are harvested by hand, with farmers carefully selecting the ripe cocoa pods to ensure the beans inside remain unharmed.

What happens to the cocoa beans after they are harvested?

After being harvested, the cocoa beans are cracked open, arranged on drying mats, and left to dry under the tropical sun for about 8 days.

How are cocoa beans checked for quality before production?

Cocoa beans undergo a rigorous quality inspection that includes a moisture check, size and texture assessment, and a scent test to ensure they meet exacting standards.

What is the process of transforming the cocoa beans into chocolate?

The cocoa beans are cleaned, roasted, ground into a paste, and then pressed to extract cocoa butter. This is followed by grinding into cocoa powder, which is mixed with other ingredients to form the signature chocolate.

What role does conching play in chocolate production?

Conching is a refining process that grinds the chocolate particles to microscopic sizes, ensuring the chocolate melts smoothly on the tongue and develops a creamy texture.

How does Kit Kat achieve its signature crunchy texture?

The crunchy texture of Kit Kat comes from its wafer layers, which are made from a mixture of wheat flour, water, sugar, vegetable fats, and a leavening agent that gives the wafers their lightness.

What is the purpose of the chocolate filling inside Kit Kat bars?

The chocolate filling inside the wafer layers is slightly thinner in consistency compared to the outer chocolate coating. It helps bind the layers together without making them crumble.

How are Kit Kat bars coated with chocolate?

The wafer layers pass through a chocolate waterfall, where a precise amount of liquid chocolate is applied in three layers to create a glossy and even coating.

What happens to flawed Kit Kat bars during production?

Flawed Kit Kat bars, such as those with air bubbles or cracks, are rejected and crushed to be used as part of the chocolate filling for other bars.

What is the significance of the 'Have a break, Have a Kit Kat' slogan?

The slogan, which debuted in 1958, has become iconic and connects the idea of taking a break with enjoying a Kit Kat, creating a memorable and deeply resonant message in consumer psychology.