This Christmas, join Gregg Blickly, Cherry Healey, and Paddy McGuinness as they explore the fascinating world of chocolate creation in a festive edition of Inside the Factory. This special episode ventures into the heart of Guylian’s Belgian chocolate factory, where millions of those iconic seashells are crafted daily.
The programme takes a look at the intricate process behind this Christmas favourite. From the initial roasting of hazelnuts in copper kettles heated to a scorching 140 degrees Celsius to the precise filling of each shell with 6.8 grams of hazelnut praline, the factory’s blend of traditional methods and modern automation is revealed. The production line, a marvel of engineering, uses 2,600 moulds to create the delicate chocolate shells, each receiving a distinctive marbled effect through a splash of both white and milk chocolate.
While Paddy McGuinness immerses himself in the main production process, Cherry Healey explores the creation of white chocolate at another Belgian chocolate factory. Adding to the festive mix, mathematician Bobby Seagull looks into the surprisingly complex mathematics of Christmas tree decorating, while historian Ruth Goodman unearths the rich history of Belgian chocolate and explores the origins of Santa Claus.
With a staggering output of four million individual chocolates per day, and Brits consuming a remarkable 44.7 million Guylian seashells during the festive season alone, this episode offers a unique insight into a Christmas treat enjoyed by millions. The entire process, from hazelnut to finished seashell, takes a swift four hours and twenty-five minutes.
Inside the Factory: Chocolate Seashells airs on BBC Two on Sunday, 22 December at 6:30 pm.
