Host Gregg Wallace of MasterChef fame will follow the production of freeze-dried instant coffee, from the arrival of 27t of Brazilian green coffee beans through to dispatch.
A clip on the show’s website featured Wallace following coffee syrup as it’s cooled to -46°C, lower than the temperature at the North Pole. The coffee freezes in two minutes and is then fed into a chipper before it’s dried and packaged.
‘Complexities of how it is made’
Commenting on the production of the show, factory project manager Mike Dale said: “Almost all homes have a jar of soluble coffee, but very few know the complexities of how it is made.
“Gregg discovered that it’s a combination of high-quality coffee beans, state-of-the-art manufacturing facilities and people who are passionate about coffee that make the perfect cup of Nescafé Gold Blend.”
Nestlé Tutbury is home to some of the company’s most iconic household brands, such as Nescafé Original and Nescafé Dolce Gusto, producing more than 35,000t of coffee a year with up to 1,000 employees on site.
Kit Kat factory in York
It was the second time that the show has visited a Nestlé factory, having previously pulled back the curtain on production at its Kit Kat factory in York.
Companies previously featured on the series included Pladis, Typhoo and Italian dried pasta manufacturer Barilla.
Business secretary Sajid Javid officially opened the coffee factory in Tutbury in March 2016, praising the £325m investment and the additional 425 jobs created.
Nestlé said the investment had resulted in a major transformation at the plant and added: “For the first time in the UK, all forms of coffee production – including freeze-dried, spray-dried and pod technology – have been brought together on one site, creating a coffee centre of excellence.”