HOW ICE CREAM CONES ARE MADE! #Let'sSee

Extra coverage for one more real Today we've come all the way to Ourinhos in the interior of São Paulo to show you how ice cream cones are made Let's take a look The industry we're visiting is Marvi which is none other than the largest manufacturer of ice cream ingredients in Latin America They produce 8 million cones daily plus 600 other different products including coatings essences emulsifiers and toppings Everything for ice cream and many other foods Even if you don't recall buying one of their products at the supermarket I'm certain you've already eaten something that came out of this factory here Just to give you an idea Marvi produces eight out of every ten ice cream cones consumed in Brazil cluding those from major ice cream brands and restaurant chains As with any recipe video we always start with the ingredients Here everything goes through a rigorous inspection Only after the quality department inspects the supplier sides The test confirms that tank trucks are authorized to unload into the silos Sugar and cassava starch come in these large bags They are lifted and placed into a hopper which is like a giant funnel She has magnets and a sieve to ensure nothing unusual gets through From this hopper the ingredients go through a pneumatic system with compressed air for each individual silo The process also involves soy lecithin palm fat salt and flavors And some ingredients used in smaller quantities which go straight into the mini silos According to what I've been told he's a German chef in charge of the recipes He doesn’t seem like much of a talker but they let meet him Let’s go Well the boss is a computer—actually a supercomputer The supervisor He came straight from Germany and keeps all the factory 's recipes on file knowing precisely how much of each ingredient to use When someone selects a recipe on the computer the ingredients automatically arrive here through these air-powered tubes Here we'll have multiple scales that weigh the ingredients and automatically dump them down into a giant blender What I like about this place is that it's a continuous process—it never stops So as soon as the blender finishes mixing the batter and sends it to the factory a new recipe arrives and it all starts over again There are basically three recipes but further down the line these will evolve into many different products Here at the factory the dough will be stored in this tank which they call the lung Each line has a different lung and it's all automated As the lung level drops the machine already signals the kitchen to send more dough Make more over there German Here at the plant there are five automated production sectors each with multiple lines We have supplies for cones large cones molded cups jewelry and small baskets Now comes the fun part Look here there's a metering nozzle that feeds the dough into the oven entrance You can tell from the pattern there which will become visible later on the shell Here a round pancake-like item is made which they call a biscuit She'll be traveling through a fairly long oven here at around 140 to 150 degrees Celsius Even after going through the oven it still doesn't become firm it needs to remain soft in order to be shaped We'll try catching a little shell here so you can see how it remains pliable As it cools it hardens I'll just hold this cone in my hand—it's a bit warm but I think it'll work I mean I made the cone backwards As you can see the texture turned out inward but I think it should still be delicious It's still warm The cone I just formed in my hand is obviously made here by a machine that works very quickly So we'll try to show this in slow motion That sort of pancake-shaped object entering a forming cone The shape is now exactly right for the cone and then it immediately goes to harden Watching the machine work so quickly it's hard to grasp how a circle turns into a cone But holding it in my hand you realize it's rather obvious That's why the heel has one side that's just a bit higher than the other When you place a heavy scoop of ice cream up here its weight gets distributed down to the base And this reduces the risk of cracking Also this cone shape is extremely easy to store You can nest one inside the other There are other cones made from semicircles And there they'll have a straight edge just like this one you're seeing here That rough texture on the outside—when I was a kid I thought it was there so you wouldn't slip out of your hand Yeah that could be it too But the main thing is that she's a rib She provides strength to the shell So much so that practically everything produced here has that texture on the outside And you'll find this quality in many other things in life For instance a car is never completely rounded it will always have ridges in the bodywork You take a drum or a can it's never completely smooth—there are ridges along the sides that reinforce the structure This is where the biju is made The process is the same The dough is baked inside Only it comes out in the form of a ribbon And it keeps being wrapped around a cylinder The process is continuous So out comes a giant bangle And here at the front it's being cut We just let go of one end of the ribbon from the decoration I'm trying to create a giant version of it It ended up looking kind of like a rose But I’ll tell you it’s damn good If I were Marvy I'd already be launching a new product here The Biju Rose by Manual do Mundo There's another way to make a cone that's quite different—and it doesn't use sugar In this machine the dough is injected directly into a mold—a kind of cup-shaped form Something goes into the oven and then gets another glass piece inside it It's roughly how glass is made In this case the cracker we saw on the other machines isn't formed Instead the dough is baked directly inside the mold itself And here it's particularly interesting to consider sugar's role in the recipe It's not just about adding flavor It significantly affects the dough's texture Sugar is pliable while it's hot As it cools it hardens significantly That's why you can make those cookies with it Enroll the cone in the way we saw it Without sugar we'll need an entirely different production method Most of the items here are packaged in sachets before they've even cooled down with just a few shells inside The purpose of this is to protect against moisture This preserves crunchiness and also improves hygiene for the consumer Remember when I said you've definitely already eaten something made by them That's because here they supply McDonald's Chicken Unilever How great Nestlé Burger King Bob's Starbucks Bate de Latte Fini Giraffas Outback With a partner like this you can surely appreciate the importance of quality control Quality checks are carried out continuously to ensure products meet the required standards But it also includes products that can be customized with laser engraving Check out this crazy one from Manual do Mundo And I haven't mentioned these little coffee cups yet—they'll get a chocolate lining on the inside But we'll show you that on another setup here nearby The idea of this chocolate-coated coffee cup is fantastic It's taking the concept of ice cream You can eat the container along with the product and bring it to coffee It needs to go through a crystallization tunnel The idea is to create an inner shell that seals the cup while adding flavor Can you drink the chocolate from the chocolate cup The best part is that nothing is left behind at the end This machine also offers the option to laser-customize the cups Isn't that cool The boxes are palletized and sent to stock where they remain on dynamic pallet racks Marvin has its own logistics They handle everything—from sorting the cargo and shipping it to the docks to loading it onto trucks The company bears the family name And the grandfather who founded the brand has a truly fascinating story Martini Renzo Giovanni left Italy and came to Brazil where he began working in the food industry in a very unique way He sold soda flavoring The kind known as tubaína Each city had its own distinct version And so traveling through the interior of São Paulo He fell in love got married Ended up combining Martini with Viana And that's where the name comes from Marvin After that he settled in Ourinhos Today the company is 70 years old And it's already in its third generation Over here are the flavor powder production lines Emulsifiers fillings and coatings That's another one of their flagship products But what I found most amusing was how they do all this— they actually need ice cream to test some of their products There's a little ice cream factory right here inside Naturally I'm going to try making my own ice cream Let's agree that today was practically the day of fulfilling a childhood dream—ones like visiting a fantastic factory I even put my mouth right under the ice cream machine I did it In a Brazilian factory It is one of the five largest in its field worldwide The good news is if this video has sparked a desire in you It’s easy to fix Because Marvi products are present in nearly every Brazilian state Latin America United States and Europe But you can also find them in bulk at markets and supermarkets And if you're not planning to take one home with you It's practically everywhere in any restaurant and ice cream brand