How It’s Made: Camel Cigarettes, Bourbon Whiskey, Streaky Bacon

Added: 2026-05-04

[00:00:13]You're looking at what created a legend that's lasted over 100 years. This is not 100% Virginia tobacco.

[00:00:20]This is the very first blended recipe in American history. the soul of Camel.

[00:00:27]A line that every serious smoker of the 20th century knew by heart.

[00:00:33]But few people know this. Even children back then were drawn to Camel just as much as they were to Mickey Mouse.

[00:00:41]In this video, I'll break down the formula behind this American tobacco legend.

[00:00:53]The story of Camel begins in 1913 when RJ Reynolds introduced a cigarette that would change the American market forever.

[00:01:03]It was the first prepackaged brand sold nationwide, a completely new idea at the time.

[00:01:10]Throughout the 1910s and 1920s, Camel launched one of the most famous slogans in advertising history. I'd walk a mile for a camel.

[00:01:21]That line stuck in people's heads for decades, becoming part of everyday conversation.

[00:01:27]During World War II, in the 1940s, Camel cigarettes were included in American soldiers rations.

[00:01:34]This move spread the brand globally as troops carried them across Europe and the Pacific.

[00:01:41]Then came the controversial Joe Camel campaign from 1987 to 1997.

[00:01:48]The cartoon character made smoking look fun and cool, and children back then were drawn to Camel just as much as they loved Mickey Mouse. Critics argued it was targeting kids too directly, and the comparison to Disney was not an exaggeration.

[00:02:05]By 1997, R.J. Reynolds was forced to drop Joe Camel after facing multiple lawsuits.

[00:02:13]That marked the end of an era for one of America's most legendary tobacco brands.

[00:02:21]It all starts in North Carolina, where the spring conditions make this region perfect for growing tobacco.

[00:02:29]An automatic seating machine then spreads the tobacco seeds evenly across each tray.

[00:02:37]These trays stay in a greenhouse for about 7 weeks until the seedlings are ready.

[00:02:47]After 7 weeks, the young plants move to the open field.

[00:02:55]A transplanting machine places them into the ground automatically, giving each plant room to grow.

[00:03:07]By July, the plants start flowering and reach a height similar to a five or six-year-old child.

[00:03:19]Farmers use a machine to cut off the top flowers, forcing nutrients into the leaves instead.

[00:03:27]They also spray growth inhibitors at this stage, helping the plant focus even more energy on the leaves.

[00:03:35]About 1 month later, the leaves turn yellow, a natural signal that harvest time is near.

[00:03:43]A special machine digs deep under the soil to lift the entire tobacco plant.

[00:03:55]The plants move into containers on a truck, ready for transport to the drying barn.

[00:04:03]This year's harvest has good weather and strong yields, though the process itself never changes.

[00:04:15]Once inside the barn, workers dump the leaves onto a conveyor belt.

[00:04:23]The leaves fall into large drying chambers where wood fires burn beneath the floor.

[00:04:31]This method creates steady heat that removes moisture over 5 to 8 weeks.

[00:04:43]After drying, machines press the leaves into tight square bales. These bales then sit in storage for 1 to 3 years, allowing natural fermentation to improve the tobacco's character.

[00:04:58]Workers first sort the dried leaves by size, type, and quality before any real processing begins.

[00:05:06]Leaves that became too dry receive a light misting of water to make them flexible.

[00:05:14]A special machine removes the thick stem from each leaf, keeping only the valuable part.

[00:05:22]The remaining leaf material then goes through a cutter to create fine tobacco strands.

[00:05:30]These strands get dried again and sprayed with a casing solution for flavor.

[00:05:38]Here is a fun fact. During the 1940s, Camel actually ran ads featuring real doctors recommending their cigarettes.

[00:05:58]Camel uses what the industry calls an American blend, a mix of several tobacco types.

[00:06:06]Virginia, Burley, Turkish, reconstituted, and expanded tobacco all go into the same recipe.

[00:06:22]But the additives list is what makes this blend truly unique.

[00:06:30]sugar, cocoa, licorice, honey, glycerol, propyline glycol, ammonia compounds, and various flavor oils are all part of the formula.

[00:06:44]Can you guess why they add ammonia compounds to the blend? It helps release more nicotine into the smoke, making each puff feel stronger.

[00:06:56]After mixing, the tobacco rests for a period so the flavors can stabilize.

[00:07:12]The prepared tobacco strands feed into a high-speed machine that never stops moving.

[00:07:18]A long strip of cigarette paper wraps around the tobacco, forming a continuous tube.

[00:07:26]At the same time, the machine attaches a filter made from cellulose acetate.

[00:07:34]This filter material looks like cotton, but is actually a type of plastic.

[00:07:42]The continuous tube then gets sliced into individual cigarettes at incredible speed.

[00:07:50]The pack itself features an Egyptian pyramid, a design choice that gives Camel its distinctive look.

[00:07:58]Machines wrap each pack in plastic film and group them into cartons.

[00:08:06]One modern machine produces between 8,000 and 20,000 cigarettes per minute.

[00:08:14]A single factory can easily make billions of cigarettes every single year.

[00:08:22]That single factory produces billions of cigarettes every year. Each one following the exact same recipe that started in North Carolina over a century ago.

[00:08:38]But tobacco is just one story from the American South.

[00:08:46]And now we are stepping into a very different kind of factory. One where corn, rye, and barley turn into something people have been enjoying for generations.

[00:09:05]You have probably seen the amber liquid in a glass, maybe at a friend's wedding or your grandfather's dining table.

[00:09:17]But here is something you might not know.

[00:09:21]That smooth drink starts as nothing more than corn, water, and a whole lot of waiting.

[00:09:30]No shortcuts, no quick tricks, just time and charred oak.

[00:09:38]So, how does a simple grain become something people collect for decades?

[00:09:46]Let us walk through the real process.

[00:09:52]Bourbon's story begins in the late 1700s when Scottish and Irish settlers moved into Kentucky. They brought their whiskey making knowledge, but they had to adapt to what grew in American soil.

[00:10:07]Corn was everywhere in this new land, much cheaper and easier to grow than barley.

[00:10:19]These farmers started using corn as the main ingredient and a distinctly American spirit was born.

[00:10:31]The name bourbon actually comes from Bourbon County, a region in Kentucky that shipped whiskey down the Ohio River.

[00:10:43]Barrels marked Bourbon County became known for their quality and the name stuck to the drink itself.

[00:10:55]In 1964, the US Congress made things official by declaring bourbon a distinctive product of the United States. That law means anything labeled bourbon must be made in America with at least 51% corn and aged in new charred oak barrels. No other country can make it, no matter how hard they try.

[00:11:16]Every bourbon starts with a mash bill, which is simply the recipe of grains used for that batch.

[00:11:24]The law requires at least 51% corn, but most premium brands use much more than that.

[00:11:32]Rye or wheat makes up the second largest portion, adding spice or softness to the final flavor.

[00:11:40]A small amount of maltted barley goes in as well because it contains natural enzymes for fermentation.

[00:11:48]Workers load these grains into a large cooking vessel called a mash ton.

[00:11:56]Hot water mixes with the grains, activating those enzymes and turning starches into simple sugars.

[00:12:04]The mixture cooks for about 30 to 45 minutes at specific temperatures. Corn needs the most heat to break down while barley gets added later at cooler temperatures.

[00:12:16]This careful heating schedule ensures each grain releases its maximum sugar content.

[00:12:24]The result is a sweet liquid called wart, ready for the next stage.

[00:12:32]The wart moves into large wooden or stainless steel tanks known as fermenttors. Distillers add a specific strain of yeast to start the fermentation process.

[00:12:44]Yeast consumes the sugars from the grains and produces two main byproducts, alcohol and carbon dioxide. This process typically takes 3 to 5 days to complete.

[00:12:59]During fermentation, the mixture bubbles and releases a sour smell that fills the entire distillery. Many distilleries use a technique called sour mash, adding some old ferment from a previous batch.

[00:13:15]This sour mash method keeps the pH stable and creates a consistent flavor batch after batch. Think of it like a sourdough starter passed down through generations.

[00:13:27]After fermentation finishes, the liquid now looks like a murky beer with about 8 to 10% alcohol. Distillers call this mixture the distiller's beer or simply the wash.

[00:13:43]The wash goes into a copper still where heat separates alcohol from water and solids. Copper is the metal of choice because it removes unwanted sulfur compounds naturally.

[00:13:59]Most bourbon producers use a continuous column still for the first run. This tall tower allows steam to rise through the wash, collecting alcohol vapors at the top.

[00:14:11]The vapors condense back into liquid, creating a low wine at about 25% alcohol. A second distillation in a smaller pot still concentrates the alcohol even further.

[00:14:27]This second run separates the liquid into three parts: heads, hearts, and tails. The hearts contain the cleanest, best tasting alcohol at around 65 to 70%. Here is a question for you. Have you ever noticed that bourbon has a sweet vanilla note even though no vanilla is added?

[00:14:51]That flavor comes entirely from the barrel, not the liquid itself.

[00:14:59]The distiller discards the heads and tails, recycling them into the next batch for more processing.

[00:15:06]The clear new make whiskey goes into a new charred oak barrel never used before. This is not a suggestion. It is the law for anything labeled bourbon.

[00:15:18]The barrel maker burns the inside of each barrel until a thick layer of charcoal forms. This charred layer filters the whiskey and breaks down wood sugars as it ages.

[00:15:34]Kucky's climate plays a huge role in how the whiskey matures inside those barrels. Hot summers push the liquid into the wood while cold winters pull it back out.

[00:15:48]This natural pumping action extracts vanilla, caramel, and tannin compounds from the oak. Each year of aging changes the color from clear to amber to deep brown.

[00:16:04]The law does not require a minimum aging period for straight bourbon, but 2 years is typical. Some premium bottles sit for 10, 15, or even 23 years before bottling.

[00:16:20]When the master distiller decides the whiskey has aged enough, workers roll the barrels to the dumping station.

[00:16:26]Machines puncture each barrel and drain the liquid into holding tanks.

[00:16:36]Filtered water gets added to reduce the alcohol from barrel strength to a consistent proof.

[00:16:44]Most bourbon is bottled at 40 to 50% alcohol by volume or 80 to 100 proof.

[00:16:52]No chill filtration is common for premium brands, keeping more oils and flavor compounds intact.

[00:17:00]This can make the whiskey look cloudy when cold, but drinkers often prefer the richer taste.

[00:17:07]The bottling line fills each bottle, adds the label, and seals the cap at high speed. One line can fill hundreds of bottles per minute, each one exactly the same.

[00:17:19]From cornfield to glass bottle, the entire process takes years from start to finish. And that amber liquid you see on storeshelves represents nothing but time, grain, and charred oak.

[00:17:35]From cornfields and charred oak barrels, we now move to something completely different. Streaky bacon.

[00:17:48]That sizzling sound on a Sunday morning is practically a memory machine for most of us.

[00:18:08]It takes you back to your grandmother's kitchen or maybe that diner your family visited after church.

[00:18:28]But streaky bacon, the one with those beautiful alternating lines of fat and meat, does not just happen by accident.

[00:18:53]There is a whole industrial process behind those crispy strips from the moment the pig leaves the farm to the vacuum-sealed pack in your hand.

[00:19:21]Let me show you how streaky bacon is really made.

[00:19:31]The word bacon actually comes from an old German term bako which referred to the back of a pig.

[00:19:39]Early European settlers brought their curing methods to America, but they had to adapt to what worked in the new world.

[00:19:51]Streaky bacon, also called side bacon or belly bacon, comes from the pork belly rather than the back. This cut has those famous parallel lines of fat running through the meat, creating a stripe pattern.

[00:20:08]American bacon became different from its European cousins because of changing tastes and farming practices.

[00:20:25]British bacon typically comes from the loin, giving it more meat and less fat than the streaky version.

[00:20:35]By the early 1900s, streaky bacon had become a breakfast staple across the United States. World War II rationing actually increased its popularity as bacon fat was saved for cooking other foods.

[00:20:51]Today, over half of American households eat bacon at home, and most of it is the streaky variety. That crispy, salty strip has gone from a simple preservation method to a cultural icon.

[00:21:11]The journey of streaky bacon begins with the pork belly, a rectangular cut from the underside of the pig. This particular section contains alternating layers of muscle and fat, which create that signature stripe pattern when sliced.

[00:21:30]Workers inspect each belly carefully, checking for the right fat to meat ratio before it moves forward. Most American bacon comes from pigs raised in Iowa, North Carolina, or Minnesota, the top pork producing states.

[00:21:52]The bellies arrive at the processing plant chilled to around 34 to 38° F.

[00:21:58]This cold temperature keeps the meat fresh and makes the initial trimming steps much easier.

[00:22:08]Workers remove the skin from each belly using a special machine called a rind puller. The skin gets sold separately for pork rind or other products so nothing goes to waste.

[00:22:24]The trimmed bellies then move along a conveyor belt for the next stage. Each piece is weighed and sorted by thickness and size before curing begins.

[00:22:36]Curing is the process that transforms fresh pork into bacon, preserving the meat and adding flavor. Most modern factories use a method called wet curing, injecting a brine solution directly into each belly.

[00:22:56]The brine contains water, salt, sugar, sodium aerorbate, and sodium nitrite or celery powder. Sodium nitrite gives bacon its pink color and prevents the growth of dangerous bacteria like botulism.

[00:23:16]Injection machines use dozens of needles to pump brine evenly throughout the meat. This process takes only a few seconds per belly, much faster than the old dry salt methods.

[00:23:31]After injection, the bellies tumble in a large drum to distribute the brine more evenly. Some premium brands still use dry curing, rubbing salt and sugar onto the meat by hand. The bellies then rest in a temperature controlled room for 12 to 24 hours. This resting period allows the brine to penetrate every part of the meat.

[00:23:55]Now comes the part that gives bacon its unmistakable aroma and flavor. The cured bellies hang from metal racks inside large smoking chambers, each holding thousands of pounds of meat.

[00:24:11]Natural hardwood smoke, usually from hickory or applewood, fills the chamber for several hours. The smoke contains hundreds of chemical compounds that stick to the meat's surface.

[00:24:28]Here is something you might not realize.

[00:24:31]Have you ever wondered why bacon smells so much better than almost any other breakfast food? That is because the fat renders slightly during smoking, carrying those smoky compounds deep into each strip.

[00:24:51]The temperature inside the smoker gradually rises to around 130 to 150° F.

[00:24:58]This slow increase cooks the bacon without drying it out or making it tough.

[00:25:08]Some commercial bacon receives additional liquid smoke for a more consistent flavor across batches. The entire smoking and cooking process takes between 6 and 18 hours depending on the recipe.

[00:25:24]After smoking, the bacon moves through a blast chiller to bring the temperature back down. This rapid cooling makes the bacon firm enough for the slicing machines.

[00:25:40]The chilled bacon slabs go to a high-speed slicing machine that operates with incredible precision. Each blade cuts through the belly at a set thickness, usually between 132nd and 1/16th of an inch.

[00:25:56]Commercial slicers can cut over 1,000 slices per minute, far faster than any human could manage. The machine stacks the slices automatically, creating neat piles ready for packaging.

[00:26:11]Some bacon is shaved so thin that the slices are almost transparent when held up to light. Thicker cuts, often labeled as thick cut bacon, require slower blade speeds and more pressure.

[00:26:27]The machine adjusts for the natural taper of each pork belly. Since no two bellies are exactly alike, this ensures that most slices in a package have roughly the same size and shape.

[00:26:43]Workers monitor the slicer constantly, removing any slices that tear or break during cutting. Those imperfect pieces go into other products like bacon bits or sandwich toppings.

[00:26:59]The stacked bacon slices move directly from the slicer into a packaging machine. Each stack drops into a plastic tray or directly onto a film sheet for vacuum sealing.

[00:27:14]The packaging machine removes almost all oxygen from the bag before sealing it shut. Oxygen is bacon's worst enemy, causing it to spoil faster and turn brown.

[00:27:26]Many packages include a small oxygen absorber packet to keep the bacon fresh longer. The sealed packages then pass through a metal detector to check for any stray metal fragments.

[00:27:42]A labeling machine applies the brand name, weight, cooking instructions, and expiration date. Each package receives a unique code that helps track it back to the original pig.

[00:27:59]The finished bacon packages go into cardboard boxes, stacked on pallets, and moved into a cold warehouse. From there, refrigerated trucks deliver them to grocery stores across the country.

[00:28:16]Within a few days, that bacon will be sitting in your refrigerator waiting for Sunday morning. The entire journey from pig to package takes about 24 to 48 hours of processing time.

[00:28:35]So there you have it. Three very different American classics, each made in a completely unique way. Camel cigarettes with their secret blend of tobacos and controversial history.

[00:28:47]Bourbon whiskey following strict laws about corn, new oak, and patient aging.

[00:28:53]And streaky bacon transforming from simple pork belly into those crispy strips through curing and smoking.

[00:29:11]What strikes me most is how much factory science hides behind everyday items we barely think about. The next time you pour a drink, open a pack, or fry some bacon, you will see the process differently.

[00:29:35]If you enjoyed this behind-the-scenes look, hit that like button and subscribe to Captain Discovery. Tell us in the comments which product surprised you the most. And as always, thanks for watching. See you in the next factory.