CONDENSED MILK

Dorothy Kumar

5/27/2025

HOW CONDENSED MILK IS MADE

Transcript

00:00Every year, thousands of tons of Doritos are consumed worldwide.

00:04To meet this enormous demand, giant harvesters are used to harvest tons of corn.

00:10But how are 70,000 bags of Doritos produced every day?

00:13We visited the Frito-Lay factory to discover how one of the world's most popular snacks

00:17is made.

00:18Doritos were created by Arch West, a Frito-Lay marketing executive in the 1960s.

00:24He discovered crispy tortillas in a local restaurant in San Diego, California.

00:28Taking advantage of leftover corn tortillas that would not be used due to being broken

00:32or not meeting sales standards, he came up with the idea to cut them into triangles, fry

00:37them and season them, thus creating the first Doritos.

00:41The term Dorito is derived from the Spanish word dorado, which translates to small pieces

00:47of gold.

00:48By 1988, Doritos had become the best-selling chips globally, a trend that continues today

00:54with a diverse range of 10 different flavors.

00:57Unlike ordinary chips made from potatoes, Doritos have corn flour as a basic ingredient.

01:03Corn are carefully cut from the plants, ensuring not to damage the grains.

01:07The harvesting capacity reaches 140 tons per day, ensuring a steady supply to the plant.

01:14The corn are cut just above the ground and are then removed and transported to the factory.

01:18The supplier takes care to clean and dry the grains.

01:21This is accomplished using vibrating machines that effectively eliminate dust, stones, sand

01:26and other residues, while ensuring an increase in the moisture content to 14%, a crucial factor

01:32for the production process.

01:35Next, the prepared corn is sent to the Nacho factory.

01:38The factory receives a daily shipment of 45,000 kilograms of corn.

01:43The dry corn is moved from extensive storage bins to vessels, where it undergoes cooking

01:48in water.

01:49This results in a yearly production exceeding 6,500,000 kilograms of finished product.

01:56Frito-Lay's factory stands as one of the world's largest chip factories, capable of producing

02:01over 100,000 packs of nachos daily, which are then distributed to the market.

02:07The factory is organized into four main areas.

02:10The corn area is dedicated to the production of tortilla-type products like Doritos.

02:15In the center, there is a distribution center spanning 65,000 square meters.

02:20The factory has the capacity to produce 70,000 to 100,000 bags of Doritos daily, which is

02:26approximately 18 million bags per year.

02:29The first notable feature upon arrival is the presence of two enormous silos, each capable of

02:35storing 120 tons of corn grains.

02:38With the contents of these silos, the factory can produce 20,000 kilograms of Doritos.

02:44This marks the initial phase in creating a Dorito.

02:46The corn must undergo cooking before entering the soaking tank.

02:50Initially, the corn is boiled in kettles close to boiling point.

02:53Later, it is transferred to open tanks, where it soaks for approximately half a day.

02:58Each cooking pot accommodates around 300 kilograms of corn and 90 liters of water.

03:04The corn is cooked at 93 degrees Celsius for about four minutes before being left to soak

03:09for 12 hours.

03:11After the initial cooking, the corn is moved to large tanks for an overnight soaking, facilitating

03:16the softening of the grains.

03:18This soaking process enables the corn to absorb moisture, aiding in the removal of the corn husk.

03:24The outer husk of the grain is filtered out, leaving behind only soft and hydrated corn.

03:29When the moisture content reaches 45%, the husks become soft and can be easily removed.

03:35Following the soaking process, a pumping system transports the corn to the washer, where the

03:39removed husks are separated.

03:41The corn then moves on a conveyor belt from the drum to the mill.

03:45Following the cleaning process, it proceeds to a grinding machine equipped with rotating

03:48millstones that grind the corn into a dough.

03:51This process involves pulverizing the corn grains between the two stones, resulting in the production

03:56of a soft corn dough.

03:58As the grinding process continues, water is added into the flour to achieve the desired

04:03consistency of the corn dough.

04:05The resulting dough undergoes inspection for three crucial factors – moisture content, temperature,

04:11and the texture of the grind.

04:13The dough comes out of the mill through a narrow nozzle that shapes it into a thin sheet.

04:18This sheet is then passed between two metal rollers that shape it into a ribbon.

04:22The third roller is equipped with triangular dies, cutting individual triangular nachos.

04:28The dough moves between these rollers and through the cutter, creating the distinctive Doritos

04:32shape.

04:33Similar to a cookie cutter, the sharp edges of the roller pierce the dough, producing perfect

04:38triangular pieces.

04:40This machine has a capacity to cut 6000 individual chips per minute, amounting to over 8 million chips

04:46every 24 hours.

04:49The freshly cut Doritos move along a conveyor belt to the next stage, which involves baking

04:53in the oven.

04:55Despite the seemingly organized process, any leftover dough is not wasted.

04:59Instead, it is recycled and sent back to the dough vats to be reused.

05:04Now it's time to toast those tortillas.

05:07The triangular nachos enter an extraordinary oven operating at 340 degrees Celsius with three

05:13levels and high temperatures.

05:15The nachos spend just a few seconds in this specialized oven, achieving the desired texture, preventing

05:20them from drying out and preserving moisture.

05:23This process also contributes to the formation of the characteristic bubbles found in Doritos.

05:29The industrial oven effectively seals the outer surface, preserving moisture and creating

05:34bubbles in the dough.

05:35This process is crucial for giving Doritos their distinctive crunch.

05:39Despite spending only 16 seconds inside, it is sufficient to dry the dough to a point where

05:44it remains intact when handled.

05:46The heat entrapment results in tiny moisture pockets within the dough.

05:50This gives Doritos their characteristic irregular texture.

05:53Later, the team allows the tortillas to cool on a series of conveyor belts before proceeding

05:58to the fryer.

05:59This short break also provides inspectors with an opportunity to ensure that none of the triangles

06:04have burned during their time in the oven.

06:06Next, a mesh conveyor belt takes the triangles to the fryer, where the oil is maintained at

06:11a temperature of 182 degrees Celsius, and nachos require only 55 seconds to fry.

06:18At this stage, the nachos attain the perfect color and crispy texture.

06:22The bubbles present in a completed Dorito are essentially air pockets trapped in the chip

06:26during the frying process.

06:28After this step, a mesh conveyor belt removes the nachos and the excess oil returns to the

06:33fryer.

06:34Using vibrating conveyors, the Doritos are now transported to a special drum, where they

06:39are mixed with the appropriate spices and ingredients.

06:42At the following station, a screw auger dispenses nacho seasoning into the drum.

06:47Large bags of the blend, containing a secret combination of cheddar cheese, parmesan cheese,

06:51and spices are added to the machine's top, funneling the mix into the drum.

06:56The primary ingredients include various cheeses, spices, flavor enhancers like monosodium glutamate,

07:02and preservatives to prolong the product's shelf life.

07:05Nozzles spray the nachos with canola oil, enhancing the surface's adhesiveness and ensuring

07:10the seasoning sticks.

07:13This massive drum effectively and evenly distributes the seasoning.

07:17As the delicate chips move through the drum, they serve as buffers, preventing breakage against

07:21each other.

07:22The seasoned Doritos embark on a lengthy journey along a 30-meter conveyor belt to ensure thorough

07:27cooling before undergoing packaging.

07:30With an annual value of $4 billion, this high-demand product undergoes careful handling.

07:35Once out of the seasoning drum, the nachos are directed to various packaging machines by

07:39hoppers.

07:40The packaging device represents a technical choreography at its finest, with each machine equipped

07:45with 14 cube-shaped scales.

07:48Nachos are carefully positioned and drop through the measuring machine, where a series of spoons

07:52precisely weigh a bag of Doritos.

07:55When there's enough for a package, a trap door opens, the nachos fall, and simultaneously,

08:00a machine shapes an aluminum and plastic strip into a bag.

08:04The nachos drop into the bag, which is promptly closed and cut by heat sealing, simultaneously sealing

08:10the bottom of the next bag.

08:11The bagging machine introduces nitrogen and packs it with an airtight seal.

08:16This process removes oxygen to prevent spoilage, ensuring that Doritos stay fresh for an extended

08:20period.

08:21Additionally, it creates an air cushion inside the bag, preventing the chips from breaking.

08:26Each large bag of Doritos contains approximately 100 chips.

08:30A worker verifies that there are 8 bags in each box.

08:33This plant has the capacity to manufacture and package 70,000 bags of Doritos every day, totalling

08:39over 18 million bags per year.

08:42Next, they are distributed to the retailers and made available for consumers to enjoy.

08:46If you want to know how chocolate is made, watch the video on your screen and please like

08:51the video if you enjoyed it and share it with someone who might be interested.

08:56Also, subscribe to this channel by activating the notifications to continue learning.

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