New Channel 4 collection Snackmasters is offering Michelin-starred cooks the an obstacle to recreate some UK snack staples. Because that the first episode, organize Fred Sirieix (First Dates) will job chefs come replicate one of Britain"s many popular coco bars. So how are Kit Kats made, and also will the chefs operation into any kind of difficulties once trying to do it from scratch?

The first port of speak to for the cooks would be come look in ~ the ingredient list, yet that"ll only gain them therefore far. A lot goes into making this heavenly treats, and there"s a particular means to placed all those ingredients together to develop that top Kit Kat crunch. In the UK, the bars are developed at the Nestlé factory in York, where a staggering 5 million bars room made every day, follow to the Yorkshire Post.

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Although, that"s nothing compared to Japan"s love because that the coco bar. Follow to the new York times Magazine, the nation has developed practically 400 various flavours that Kit Kat since they were presented in 1973, which room "produced in 2 Nestlé-owned factory in Himeji and also Kasumigaura."

It appears that the UK has taken some motivation from Japan"s love of flavours, together Nestlé newly announced that they room launching "made-to-order" bars, as the Guardian reports. Just in time for Christmas, this business will offer customers the an option of 1,500 different flavour combine "for up to £14 a bar". The service is currently easily accessible in 30 man Lewis & Partner"s stores, follow to a Nestlé push statement, for this reason you better get your orders in quick.

Anyway, back to how the bar is made. Japan"s Kasumigara factory was featured in a short video produced through CNN Business, demonstrating just how Kit Kats room made ~ above an industrial scale. Tech website Cheddar Gadgets also uploaded a comparable video, however it"s no clear which of the two factories is featured. Regardless, the Kit Kat making procedure is actually rather simple. First, the cacao is melted if sheets of wafer biscuit space baked and then cooled ~ above a conveyer belt. The New York times Magazine reckons the the lightweight wafers most most likely consist the "air and also gelatinised wheat flour."

As Cheddar gadgets shows, these wafers space then coated v a sandwiching cream, "which provides Kit Kats your flavour." It additionally seems that offcuts the Kit Kats space mixed into this cream, according to BBC Two"s Inside the factory (via the Daily Mail). 3 layers the wafers are then stacked on optimal of each other and also cooled, and cut into various sizes.


The above moulds climate come into play, which gives the bars their distinct shape. These room filled v the previously melted chocolate, and also then the wafers are placed on top. After ~ being covered in even an ext chocolate, the process is perfect by removing overabundance chocolate and also pressing the wafers flat, cooling the bars, and also taking them out of the mould.

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Voilá! You"ve got yourself a Kit Kat. The balance the ingredients and also flavourings are what do that familiar taste shine. However overall, the significance of a Kit Kat is every in the layering the wafers and using a large amount that chocolate. Yum.