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How are Maltesers made?

How are Maltesers made? - Hunter Valley Gourmet Food & Wine Tasting - Two Fat Blokes

I rang up the makers a few years ago (being very bored at work). Apparently, it’s a trade secret. Does that help?
Richard Cutler, Kingston Upon Thames

Maltesers are made in two stages. The inner crunchy part is made by making small pellets of a dough like mixture. This is placed in a low pressure container which forces the bubbles in the mixture to expand, making the pellets larger. The pellets are then coated with chocolate and polished. The details are vague because the company wouldn’t give me exact details!
Simon Mackie, Birmingham

I’m not sure of the exact recipe for the “honeycomb” bit, but I’m reliably informed that it is no coincidence that the Horlicks factory is just up the road from the Mars factory where they make Maltesers. Whatever the ingredients are, once mixed they are made into little pellets. These pellets are then cooked in a vacuum oven which gives them their “honeycomb” texture. Then, they are sent tumbling over lots of chocolate covered rollers to get their coating, chilled and finally bagged and boxed.
Anna, Iver, England

The same way Brits or Yanks are made. A male and female get together and – presto! – nine months later a little Malteser appears.
Norman Ross, Dublin, Ireland

As a student I worked at the Horlicks factory in Slough and (since no-one told me to keep it secret) can reliably inform that the stuff inside Maltesers is ground up to make Horlicks. The recipe included malt extract and milk which were cooked in a partial vacuum, firstly to reduce its water content then, to puff it up. We used to munch big chunks of it fresh out of the oven – delicious.
Martin Stevenson, Acton, MA, USA

Making Maltesers is easy. How do they make “Aero”?
Jim Butcher, London

I saw them made at the factory once. First the honeycomb dough is made and rolled out in a long sheet. This passes between two rollers which have little hemispheres carved out of them to make the bubbles and compress the dough around them. When the dough is baked the little balls pop up and the compressed bits between them are broken off. The little balls are then coated in chocolate and when that’s dry they are rolled along a section of track which is at an angle, probably about 30-40 degrees. Only the maltesers which manage to make it to the end of the track while still rolling on the highest part are packaged, the others are crushed up and used to make more maltesers. This is to weed out the lumpy maltesers; apparently they don’t roll properly and end up at the bottom of the track. But I saw some siamese maltesers get through successfully. I hope I’m not going to go to hell for exposing trade secrets…
Nicky, Melbourne Australia


They’re round, strong and full of chocolate…

It’s ‘Balls of Steel’ our orange coated jaffa milk chocolates that taste so good they are our chocolate of the month from the Two Fat Blokes Deli.

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Our locally made sweets contain only premium ingredients to make sure you get the best tasting experiences. Our delicious balls come in a variety of fun packs that are sure to put a smile on the face of anyone who receives them.

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Group Information

What is the minimum number of people you will pick up?

There is no minimum restriction to book so singles and couples can book tours, but there is a minimum number of people needed to run tours effectively.

We do our best to make sure every tour runs, which sometimes means shuffling minimum numbers together so tours can operate.

We need to group together at least  4 people (minimum number shown on each tour) for it to operate.

Do you take parties like a 40th or 50th?

Yes. A day tour with your friends enjoying drinks and tasty food is one of the most enjoyable but hassle free ways to celebrate a birthday. We take care of the details and let us know if you would like something extra special too!

What size groups can you cater too?

Each tour vehicle contains passengers from multiple bookings until it is filled to the ‘maximum guest limit’ (shown on each tour). This limit keeps our group small so it’s fast and fun with premium access.

A tour will operate when a minimum of four seats are booked. If there are only four seats booked, great you will have the tour all to yourselves in one of our smaller vehicles. The more a tour fills up, the bigger the vehicle we use until our maximum guest limit for that tour is reached.

If you would like a completely private tour for two, or, have a larger group than the ‘maximum guest limit’ please contact us for options.

We can cater to larger groups by combining multiple vehicles for any tour.

Transfer Locations

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Sydney Transfers

  • SYDNEY direct transfers are not available.
  • To arrive from Sydney customers can catch the train between ‘Sydney-Newcastle-Maitland’ and request a Two Fat Blokes pick-up/drop-off at ‘Maitland’.

Transfer Fee Information

  • Flat rate is a single price for pick-up/drop-off at that location whether it’s two people or a full group of people.
  • Minimum 2 person pickup is required to operate the pickup service to fee based locations.
  • Fees are in addition to your tour booking and will be collected by your guide at time of pick-up. Please pay these fees by cash, ATM’s will be available on the tour.
Visit Wineries

Discover up to 3 great wineries handpicked for you.

How do you determine which wineries are best for my group?

Because we know the area so well and try to deliver the best experiences based on:
– Rave reviews from previous tour groups
– Boutique, non-touristy locations
– Excellent wines, moderately priced
– Warm & friendly service
– Perks available (cellar tours, barrel-tasting, wine-maker available, etc.)

Which wineries do we visit?

There is no set schedule of wineries. Our tour guides will take advantage of the best winery experiences available on that day, including special events, to make sure you get the most value from your itinerary, have an enjoyable day and maximise your taste time of the Hunter Valley.