Swallow This: Serving Up the Food Industry’s Darkest Secrets. Joanna Blythman

why clog up your cold storage area with vats of real cream when you can use a ‘powdery, homogeneous and free flowing cream to yellow powder with a cream taste and smell’ that doesn’t need to be chilled, and takes up a fraction of the factory space?

      To a manufacturer whose constant concern is reducing or at least containing costs in the face of regular price rises in raw materials, it seems quite logical to use, say, a powder made from freeze-dried apricots, blended with some type of starch, that smells just enough like the fresh fruit to pass muster in your Danish pastries or yogurt, rather than much more expensive fresh apricots, or frozen apricot pulp.

      From water-injected poultry and powdered coagulated egg, to ultra-adhesive batters and pre-mixed marinades, the raw materials in industrial food manufacturing are rarely as simple as most of us would like to think. In fact, they commonly share quite complicated back-stories of processing and intervention that their labels don’t reveal. Indeed, they are predicated on ingredients that are processed, comprised versions of the real thing, far removed from their original forms.

      The undisclosed hidden history of their ingredients helps explain why ready meals manufactured in factories cannot hold a candle to the competently homemade equivalent, prepared in a domestic or restaurant kitchen. It also sheds light on why supposedly different ready meals from different retailers taste so similar. The big supermarket chains that sell us these products share the same manufacturers. These manufacturers, in turn, share the same pool of ingredient suppliers. The specifications our multiple retailers give to manufacturers may vary marginally – one might prefer a runnier stew, the other a stickier one – but the industrial systems they are locked into leave little leeway for genuine variety. One conveyor belt, on a given day of the week, is dedicated to meals for Asda or Tesco, while another does pretty much the same thing for M&S and Sainsbury’s. One chain might specify a certain ingredient, say free-range pasteurised egg rather than the caged-hen equivalent, but no manufacturer can afford to alter their production system on request, especially when they very rarely have the security of proper contracts from retailers, only short-term agreements. So like a subscription to over-hyped satellite TV channels, the selection of ready meals on supermarket shelves, despite the apparent diversity, is surprisingly homogenous in terms of its contents.

      And if the larder used by manufacturers is, shall we say, samey, what of the production method? In the context of food processing, the word cooking merits permanent parenthesis because the techniques used are so radically different from the time-honoured equivalent as understood by cooks down the ages. Any good domestic cook making the meat ragù for a pasta dish, for instance, would begin by browning onions and mince before adding the liquid ingredients, in order to deepen the flavour. In food mass production, you can forget pre-browning. All the ingredients will be measured into one gigantic, temperature-controlled industrial vat and bubbled up for a specified time until they form a stew-like mass. Add a dash of extract of this, and powder of that, and hey presto, you have the recipe for a meat layer. A dose of caramel will compensate for the missing taste, colour and aroma that natural browning would have given the dish. A little added thickener, in one form or another, usually from cheap sweet starches and sticky gums, will give the illusion of the natural viscosity found in the patiently made traditional article. All that remains is to have the mixture spewed into plastic cartons, along with the other manufactured white sauce and pasta components, and passed through blisteringly hot, cavernous steam-injected ovens to ensure that your lasagne or pasta bake remains soft for reheating. A rapid cooling in a spiral chiller, a mechanical conveyor system that moves food through a continuous chilling process, and the job is done.

      What you have here is a streamlined production system of assembly, amalgamation, fusion, combination and transformation by heat that very efficiently flattens out any slight lingering personality in already anonymous, much compromised ingredients. No wonder ready meals taste so spookily similar. If the beauty industry is in the business of selling hope in a jar, the factory food industry is in the business of selling hope in a plastic carton, under a cardboard sleeve. It promises us something near-instant and edible that tastes more or less like real, home-cooked food – a promise that it is structurally unable to deliver.

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       On the factory floor

      I now realise that I was naïve, but there was a time when I expected food processing companies to joyously announce their existence. I suppose that I had imagined factories with household names above the door, and proud signage explaining what they do. ‘Smith & Sons: delicious meals in minutes’, that sort of thing. I can’t think why I clung to this idea, because come to think of it, I had never stumbled upon any that fitted that bill.

      It was only when I started searching out the companies that process our food that I understood why: they prefer to keep a low profile, on industrial estates in amongst other anonymous, big box industrial units. Such locations give them the space and freedom to operate day and night. There are no immediate neighbours to complain about noise or smells. Heavy lorries can come and go, without drawing the ire of the local community.

      Considering the volume of products they manufacture, there are surprisingly few of these factories in the UK: think in tens and hundreds, not thousands. On the chilled food front, for instance, in 2013, just 25 major chilled food companies operated from 100 highly streamlined production sites, employing around 60,000 people.

      These factories supply supermarket chains that do not want the hassle of dealing with a plurality of small or medium-sized companies. With the exception of Morrisons, which is unusual in that it owns its own dedicated meat processing facilities, UK chains prefer not to get hands-on with the products they sell. Although 95% of the chilled prepared food Britain eats is sold under a retailer’s brand, supermarket chains do not own the factories churning out the food and drink that bears their names. Instead, they devolve that expense, responsibility and potential risk to third-party suppliers who work at arm’s length, according to the chain’s specification.

      In order to squeeze economies of scale from their investment, food manufacturers need to be turning out products on a fairly constant basis to make good on their outlay and investment. Time is money. Stop-start processing plants without a full production schedule don’t make commercial sense, so these enterprises commonly supply not one, but several supermarket chains, to attain that critical volume. One shift, it will be Sainsbury’s ready-to-grill kebabs gliding along the assembly line, the next, meatballs for Tesco, or chicken pies for Asda. Even those processed foods that are sold as familiar household brands – as opposed to supermarket own-label – are commonly manufactured by a company other than the one with its well-recognised name on the box.

      This is why third-party factories have innocuous, neutral names that give little or no clue as to the nature of the enterprise. If you drive past them, they look anonymous and blank, like vast storage units. Unlike the characterful brick and stone factories that still remain from Victorian times, they have no windows.

      Inside, their employees work long, demanding shifts: 12 hours isn’t unusual, sometimes night shifts. They tend to be young, and driven by a very strong work ethos, the kind of people who are prepared to take any job that’s going, seeing it as a stepping stone on the road to eventual financial betterment. Typically, some 90 per cent of the staff come from Eastern Europe and the Baltic States. In one workplace canteen I visited, the cook was Polish, making a daily bigos, Poland’s favourite cabbage and sausage stew.

      Except for the odd tantalising glimpse of the external world from the canteen windows, these people work in artificial light, in a factory world. And outsiders most certainly cannot see in, a necessary measure to guard secret recipes and commercial confidentiality, we’re told.

      So although these factories provide households up and down the land with billions of portions of processed food – half a million kebabs on just one day would not be unusual for a busy meat processing site – most of us haven’t a clue what these mammoth population-feeding units look like inside. They don’t run Doors Open Days, and any visitor, pre-arranged or otherwise, will be greeted by a uniformed guard, and a security barrier. Their unwritten