Whether you prefer chicken salad or egg mayonnaise, a sandwich is undeniably a convenient lunch choice. Yet, many are just now uncovering the production process behind their pre-packaged meals, leading some to swear off them indefinitely.
The discussion was ignited by a YouTube video from How It’s Made, revealing the comprehensive behind-the-scenes operations of an American factory, from ingredient assembly to shelf-ready packaging.
The video begins by elucidating that retailers “specify the ingredients they desire for their sandwich orders, and the factory arranges the assembly lines accordingly.”
Depending on the customer’s preferences, pre-packaged sandwiches are made using two primary methods.
Method 1: Combination of Manual and Machine
The initial approach involves a blend of manual labor and automated processes. In the first step, a worker places fresh bread into an automated machine, simultaneously inspecting the slices visually and discarding any with imperfections.
Subsequently, the machine takes control, separating the slices within the loaf and applying melted butter using an internal roller. The buttered slices are then conveyed face up on a belt along the production line, where an automated depositor dispenses mayonnaise onto them.
An automated depositor precisely dispenses the requested quantity and type of mayonnaise as specified by the customer.
Following this step, workers manually add the more specific ingredients, such as cold cuts or grated cheddar cheese.
Viewers were taken aback to discover that the workers in the video were not wearing gloves while handling the sandwiches.
Following this, the process returns to the workers who manually add the more specific ingredients, such as cold cuts or grated cheddar cheese.
Viewers were surprised to observe that the workers in the video were not wearing gloves while handling the sandwiches.
The video further explains that “in the prep area, workers load logs of ham into a slicer. The retail customer specifies the size and weight of the slices it wants in the sandwich, and the slicer is programmed accordingly.”
The sliced ham then proceeds to the assembly line where workers incorporate them into the sandwiches, once again, without gloves in this particular video.
Finally, the sandwiches are sealed and stacked in pairs. The belt then transports the sandwiches to a mechanized cutter, where the stacked halves on each side are packaged together as one sandwich.
The video further details that in the preparation area, workers load logs of ham into a slicer. Customers specify the desired size and weight of the slices for the sandwich, and the slicer is programmed accordingly.
Method two: Fully Automated Assembly Line
Another approach involves producing products on a fully automated assembly line, eliminating the need for manual labor, which is ideal for high-volume requirements.
A robot utilizes suction to pick up bread slices and positions them on a conveyor belt.
Adjustable plates descend to ensure the slices are perfectly centered under the nozzles that dispense the sandwich ingredients.
In the video, egg salad sandwiches serve as an example. A nozzle precisely deposits a set quantity of chopped egg with mayonnaise onto every alternate slice.
The alternative method is frequently employed for sandwich varieties manufactured in the largest quantities.
In the video, egg salad sandwiches are showcased as an example, where a nozzle dispenses a specific amount of chopped egg with mayonnaise onto every alternate slice.
A robotic arm picks up bread slices using suction and positions them onto a conveyor belt.
At the subsequent station, robotic arms equipped with suction cups grasp the following slices and flip them over onto the filled slices.
Then, an ultrasonic knife slices the sandwiches in half, utilizing vibrations generated by high-frequency sound waves.
Robotic arms then pick up each half of the sandwich, rotate it, and stack it onto the other half.
A robot handles four completed sandwiches simultaneously, placing them into triangular plastic trays, which are then directed to the sealing and labeling stations.
On the semi-automated assembly line, workers manually stack the sandwiches and insert them into individual plastic-lined cardboard packages.
A conveyor belt transports them to a machine that presses down the top flap and heat seals it securely shut.
The video elaborates that “the sandwiches hit store shelves within 12 hours of production and remain fresh for an additional three days, after which the sandwich company removes any unsold ones while making its daily delivery of new ones.”
Returning to the semi-automated assembly line, workers complete the process by manually stacking the sandwiches and inserting them into individual cardboard packages lined with plastic.
The explanatory video has garnered nearly 8,000 views and received over 1,200 comments.
The explanatory video has garnered nearly 8,000 views and received over 1,200 comments. However, not all comments were positive.
Many viewers expressed horror after watching, with one person remarking, “As someone who works in a school kitchen, it’s blowing my mind to see these workers handling food that will go out to millions without any form of glove.”
Another commenter humorously noted the absence of gloves, stating, “I love how her wedding band touches every sandwich she makes.”
Even individuals working in the same industry were taken aback by what they witnessed.
Over three hundred others also expressed agreement by liking the comment, with someone humorously replying, “Felt a tiny pang of betrayal when I saw that.”
A former employee at a sandwich factory described the experience as “absolutely horrible,” citing not only the chaos but also the unfair pay. They emphasized the concern of sandwiches being handled by numerous individuals before consumption, highlighting potential hygiene issues.
Another worker shared their experience, stating, “As someone who worked at a small convenience store/gas station, they DO use food safety gloves and change them frequently. I don’t know why the company in this video doesn’t; that’s a super huge health hazard that you literally learn about on the first day of food handling and prep.”
Several viewers claimed the video has discouraged them from purchasing pre-packaged sandwiches in the future. One wrote, “It’s been years since I’ve bought a premade sandwich, and after seeing this, I can confidently say it will be many more years before I buy another.”
Another added, “Thank you for this video. No more eating packaged sandwiches!”
However, the absence of gloves wasn’t the only surprising revelation. Another viewer commented, “My biggest takeaway is that the two halves in the pack aren’t from the same sandwich” with a mind-blown emoji. Over three hundred others also liked the comment, with someone humorously replying, “Felt a tiny pang of betrayal when I saw that.”
