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00:30 GMT, Saturday, 7 June 2008 01:30 UK

Inside the chocolate factory

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The Bournville factory first opened in 1878 with about 200 people working there. By the early 1900s the workforce had grown to about 5,000.

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When the cocoa arrives at the Bournville factory, it is already in the form of a dried crumb, which is then ground and mixed with coca butter and flavourings.

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The semi-liquid mixture is then mixed to develop the required flavour, removing unwanted flavours and reducing the viscosity of the chocolate.

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The liquid chocolate is then "tempered", which means mixing and cooling it under controlled temperatures. This ensures the fat in the chocolate crystallises in the most stable form.

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Tempered liquid chocolate is poured into bar-shaped moulds, shaken and cooled before continuing to the high speed wrapping plant.

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Before packing, the moulded chocolate bars are checked for appearance, shape and weight.

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The familiar purple and gold colours were introduced to the Dairy Milk packaging in 1920.

Chocolate

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Enough Cadbury Dairy Milk is sold each year to cover every Premiership and Nationwide football league pitch five times over.

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