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Narrator:
Today on "How it's made"...
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Toothpicks...
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...Acrylic bathtubs...
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...Helicopters...
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And beer.
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Some people use them to hold
Hors d'oeuvres together.
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Kids make scale models
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Of famous buildings
And bridges out of them.
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And some people
Actually use them
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For their primary purpose --
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To remove food
Caught between their teeth.
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What are we talking about?
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Why, the humble toothpick,
Of course.
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Logs -- lots of birch logs
Are delivered to this factory.
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They're the raw material from
Which toothpicks will be made.
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The heavy logs
Are lifted by grippers
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And placed into a debarker.
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Bark isn't part of the
Toothpick-fabrication process
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And is recovered
By this machine.
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But the bark isn't thrown away.
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It's sold
To a neighboring factory
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Where it will be used as fuel.
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The debarker works in two steps.
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With two passes,
It produces a log roll
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That's perfectly cylindrical
And easier to mill.
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This log is being transported
To the next processing stage.
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This unraveling machine
Unravels the log
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As if it were a roll of paper,
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Cutting it with 12 fine blades
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Each .04 of an inch thick
And 2 1/2 inches wide.
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These same blades will be
Used later to cut toothpicks.
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Then these 12 blades,
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Positioned side by side
On the unraveling machine,
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Will form rolls of strips
Called "Billets."
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These tiny cutters are used to
Trim the ends of the toothpicks.
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Knives placed here and there
On the machine
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Thin the ends of the toothpicks.
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The roller rolls up the cut
Strips, forming a billet.
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Completed strips, or billets,
Are taken out manually.
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Each billet weighs 4 pounds.
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The billets are carried
To the puncher,
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The flat-toothpick puncher
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Cuts the billet strips
Into small, equal-sized pieces.
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The cut pieces come out
At this end of the machine.
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The punch works very rapidly.
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Knives come down
2,000 times per minute
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To cut a total of 8,000
Toothpicks in just 60 seconds.
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Cut toothpicks fall into this
Chute, then into a container.
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At this stage, they're soft.
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They have to be hardened
In a dryer for four hours
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At 250 degrees fahrenheit.
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Then the toothpicks are
Transferred to the polisher.
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Talcum powder and friction
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Help make the toothpicks
Perfectly smooth.
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This operation takes four hours.
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Toothpicks exit the polisher
And pass through this sifter,
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Which filters out broken ones.
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Those in good condition continue
On to an air-blower system.
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Damaged ones are rejected.
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Perfect toothpicks are placed
Onto two conveyers
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By an air-blowing system.
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Drums at the end
Of the conveyors
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Assure quantity distribution,
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Then they're carried to
The automatic packagers.
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This machine counts
The toothpicks.
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Boxes are made up,
Ready for filling.
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The number of toothpicks
Included in each box matters.
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The packager is calibrated
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To place 650 toothpicks
In each container,
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And it produces
About 1,150 boxes an hour.
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It handles
747,500 toothpicks an hour.
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Some toothpicks
Are individually wrapped
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For distribution
To restaurants and airlines.
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This machine wraps 1,200
Toothpicks per minute.
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It automatically wraps, glues,
And cuts the paper.
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This facility can manufacture
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More than 20 million toothpicks
Every day.
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And it all started
From several birch logs.
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Narrator: bathing daily is
A relatively new phenomenon,
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Historically speaking.
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People used to take baths
Only when necessary.
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Today whiling away the afternoon
In the tub
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Is more than a way
To wash our bodies.
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With bubbles and bath oils, it
Can be an experience in luxury.
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Modern bathtubs look nothing
Like tubs of the middle ages
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Or those wooden tubs
We see in western films.
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To achieve supreme comfort,
The designer explores new shapes
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Via computer
And design software,
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Tools which make for a speedy
Review of various shapes.
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Then a model is produced.
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This one, produced on a
1/6 scale, is made of cardboard.
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But other models can be
Made of clay, polystyrene,
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Or by stereolithography.
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Manufacturing begins
With an acrylic sheet.
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It is heated to
About 390 degrees fahrenheit
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With ceramic elements.
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The sheet becomes soft
And malleable.
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So that it takes
The form of the mold,
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Thousands of tiny holes
In the shell
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Suction the sheet by vacuum.
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The mold must cool
Before it can be opened.
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Powerful ventilators blow air
Directly onto the mold,
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Lowering the temperature to
170 degrees in 4 to 6 minutes.
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The ventilators
Are then withdrawn.
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Then the shell
Is easily removed from the mold.
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It weighs a mere 35 pounds.
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To make a tub in another shape,
They change the mold.
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They put in
Another acrylic sheet.
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The sheet is heated on
The ceramic and fiberglass mold,
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The little holes vacuum out air,
And the job is done.
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The molded acrylic sheet
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Is not sturdy enough
To be filled with water,
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So it must be reinforced
With fiberglass.
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This is the fiberglass.
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Mixed with resin, it is blown
Onto the mold by a robotic unit.
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Stored in reservoirs,
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The resin is carried
To the robot by pumps.
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Here it produces
A chemical reaction
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Between the fiberglass
And the resin,
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Which produces
A reinforced shell.
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00:08:56,931 --> 00:09:00,000
Laminating is one of
The most important steps.
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With brush and roller,
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They eliminate all air bubbles
That could weaken the tub.
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This makes the fiberglass resin
Adhere perfectly
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To the acrylic shell.
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The process takes 75 minutes.
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The shell is then transported
To the milling department.
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The shell is dry and hard.
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They can extract it manually,
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But here they use
Digitally controlled machines.
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The operation begins
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With the trimming of the edges
Of the bathtub.
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During this process,
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The robot will pierce openings
For the drains,
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The whirlpool jets,
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And the air jets
For the overflow
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And for ambient light.
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The bathtub, almost completed,
Is now sent to another workshop.
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They can now install the pump,
The piping, and the blower.
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00:10:03,655 --> 00:10:06,206
These last operations
Are done manually.
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The pump is installed
For the whirlpool system,
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As well as the pvc pipes,
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Whose joints have been
Hermetically sealed
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To prevent any leaks.
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Finally, to make sure that
Everything is functioning well,
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Each bathtub
Undergoes a water test.
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The tub is finally ready.
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After 13 steps and anywhere from
Three to five hours of work,
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Depending on the type of tub.
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It almost invites you
To climb in.
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Narrator:
In the world of aeronautics,
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The helicopter is
The ideal go-anywhere machine.
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Unlike airplanes,
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Choppers can move
In almost any direction
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And take off and land
Straight up and down.
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Now that we've "Coptered"
Your attention,
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Let's see what goes into
Building these whirlybirds.
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Man has always wanted to fly.
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And the versatility of
The helicopter has allowed him
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To reach unexpected heights.
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Plans for a helicopter
Are created
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With catia 3-d design-assisting
Computer software.
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It takes 700 hours of work
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00:11:26,620 --> 00:11:30,275
Between the drawing stage
And the assembly of the pattern.
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00:11:30,275 --> 00:11:32,827
The helicopter is made
Of carbon fiber,
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A composite material lighter
And stronger than steel,
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Protected by two layers
Of green plastic.
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00:11:39,000 --> 00:11:42,689
The fiber is cut with a blade
Controlled by ultrasound.
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They lay on
Several thicknesses of fiber
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To make the rear fuselage.
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The green light of a laser
Helps position the parts.
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Then with a heat gun,
They apply a beehive web
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Which increases
The solidity of the structure.
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00:12:01,655 --> 00:12:03,965
But the carbon fiber
Is still soft.
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To harden, it must be baked
Under pressure
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For 10 hours in this autoclave
Oven at 350 degrees fahrenheit.
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The pieces exit the oven
And head for machining.
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The door of the motor housing
Is kept in a cutting jig
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00:12:18,482 --> 00:12:21,241
And is shaped
With a manual shaper.
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00:12:21,241 --> 00:12:23,103
Before installing the parts,
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They strike the carbon fiber
With a resonance hammer
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To detect any faults.
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00:12:27,931 --> 00:12:31,551
The electrical harness
Is mounted on a pattern
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Before being installed
In the aircraft.
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This particular helicopter
Has 2,570 yards of wiring,
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But others can have
Almost 6 miles.
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The wiring will be connected
To the flight-instruments panel,
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The brain of the helicopter.
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00:12:47,620 --> 00:12:54,793
This aircraft has 9,964 rivets
Fastened with a gun and a ram.
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00:12:54,793 --> 00:12:56,517
They also apply a sealant
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To prevent
Corrosion-creating humidity.
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00:13:00,448 --> 00:13:04,655
They now assemble
The helicopter's rear fuselage.
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Piece by piece,
The aircraft takes shape.
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They will install
Mechanical components later.
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00:13:21,482 --> 00:13:23,655
The motor arrives.
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00:13:23,655 --> 00:13:28,413
This one weighs 260 pounds
And has to be carefully handled.
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00:13:30,931 --> 00:13:33,241
Among the other parts
To be installed
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Is the circular plate on which
The blades will be attached.
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00:13:37,620 --> 00:13:39,482
Safety is primary.
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00:13:39,482 --> 00:13:41,551
The screw-nut holes
Are perforated,
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Allowing for the insertion
Of the brake cable.
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00:13:44,137 --> 00:13:47,448
This tightly braided metal wire
Prevents the nut from loosening,
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Due to strong vibrations.
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00:13:49,586 --> 00:13:52,206
Now they bolt on
The four blades,
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Which makes the helicopter fly.
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00:13:54,448 --> 00:13:56,275
Weighing 90 pounds each,
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00:13:56,275 --> 00:14:00,448
They're made of composite
Materials and an aluminum alloy.
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00:14:00,448 --> 00:14:02,827
They're attached
To the main rotor.
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00:14:06,551 --> 00:14:09,241
The dashboard is installed
In the cockpit,
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00:14:09,241 --> 00:14:11,275
And all the wires are hooked up.
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00:14:11,275 --> 00:14:15,103
Contact is established,
And all is functioning properly.
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00:14:20,655 --> 00:14:24,655
The last step -- finishing
The interior of the craft.
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00:14:24,655 --> 00:14:28,172
They install seats,
Safety belts, the consoles,
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00:14:28,172 --> 00:14:31,827
Bulkheads, windows and doors,
As well as the trimmings.
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00:14:41,655 --> 00:14:44,620
The helicopter
Is almost completed,
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00:14:44,620 --> 00:14:48,137
But it still has to be painted.
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When done,
The helicopter is towed
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Outside the assembly hangar.
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00:14:52,655 --> 00:14:54,172
Flight tests are performed
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00:14:54,172 --> 00:14:57,137
To make sure that mechanical
And electrical components
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Are functioning properly.
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00:15:06,896 --> 00:15:10,000
It requires
An average of 110 days
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00:15:10,000 --> 00:15:13,275
To assemble
The more than 3,000 parts
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00:15:13,275 --> 00:15:15,827
Of a helicopter like this one,
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00:15:15,827 --> 00:15:19,689
And they turn out
Almost 185 units each year.
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00:15:23,931 --> 00:15:29,517
These 3-ton engines are capable
Of reaching speeds of 140 knots
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00:15:29,517 --> 00:15:33,931
And flying at a maximum altitude
Of 20,000 feet.
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00:15:44,827 --> 00:15:46,344
Narrator: beer has been around
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00:15:46,344 --> 00:15:49,551
For as long
As civilization itself.
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00:15:49,551 --> 00:15:52,862
Historical records show
That ancient peoples made beer
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00:15:52,862 --> 00:15:56,275
With barley, hops, water,
And yeast.
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We still use
The same ingredients,
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00:15:58,379 --> 00:15:59,689
But as you'll see,
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00:15:59,689 --> 00:16:04,344
Today's production technology
Is far more complex.
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00:16:10,862 --> 00:16:15,275
Beer has been drunk
Since 4,000 b.C. In mesopotamia.
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00:16:15,275 --> 00:16:17,862
The sikaru made it
As a sacred beverage
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00:16:17,862 --> 00:16:19,931
From grains but without hops.
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00:16:19,931 --> 00:16:21,344
The gauls and the celts
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00:16:21,344 --> 00:16:24,724
Drank a beverage made
With barley, wheat, and rye.
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00:16:24,724 --> 00:16:28,068
During the crusades,
Europeans discovered spices
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00:16:28,068 --> 00:16:31,586
And flavored the beverage
With cinnamon and laurel.
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00:16:31,586 --> 00:16:35,724
In the 15th century, nordic
Peoples used hops as a spice,
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00:16:35,724 --> 00:16:39,413
Giving rise to the beer
We know today.
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00:16:48,068 --> 00:16:51,655
Beer is a fermented beverage
Made with cereals and water.
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00:17:00,000 --> 00:17:03,379
The company has its own
Water-filtration plant.
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00:17:03,379 --> 00:17:05,931
It will be refiltered
Before being used
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00:17:05,931 --> 00:17:07,896
To eliminate chlorine.
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00:17:07,896 --> 00:17:11,827
This materials tanks can hold
21,000 gallons of water.
249
00:17:11,827 --> 00:17:15,517
Between 11 and 16 tons of malt
And another grain are added.
250
00:17:15,517 --> 00:17:16,827
They use dark malt,
251
00:17:16,827 --> 00:17:20,241
Which has been heat-treated
To a high temperature.
252
00:17:23,517 --> 00:17:26,241
The mixture
Will spend two hours here.
253
00:17:26,241 --> 00:17:28,310
An agitator prevents malt husks
254
00:17:28,310 --> 00:17:31,655
From settling
To the bottom of the tank.
255
00:17:31,655 --> 00:17:34,517
Turbulence from the pumps
During the transfer
256
00:17:34,517 --> 00:17:37,241
Causes the formation
Of this protein foam.
257
00:17:40,310 --> 00:17:43,137
The wort is in the process
Of being extracted
258
00:17:43,137 --> 00:17:44,551
And will be boiled.
259
00:17:44,551 --> 00:17:48,586
About five hours have passed
Since the brewing process began.
260
00:17:51,793 --> 00:17:53,551
Here they draw off a sample.
261
00:17:53,551 --> 00:17:55,793
They will make
Other control tests
262
00:17:55,793 --> 00:17:57,586
At various stages of brewing.
263
00:18:02,344 --> 00:18:07,172
This is the draff, a solid
Residue extracted from the wort.
264
00:18:07,172 --> 00:18:09,689
It will be used as cattle feed.
265
00:18:11,586 --> 00:18:14,517
Here is a close-up view
Of the draff.
266
00:18:19,275 --> 00:18:21,655
Then the liquid is filtered.
267
00:18:21,655 --> 00:18:23,172
Here's the filtration tank
268
00:18:23,172 --> 00:18:25,896
Where the wort is separated
From the malt husks.
269
00:18:25,896 --> 00:18:28,655
A sample is withdrawn
From the wort heater
270
00:18:28,655 --> 00:18:32,379
To verify the density of sugars
And the quality of the wort.
271
00:18:40,172 --> 00:18:42,689
Now another ingredient --
The hops --
272
00:18:42,689 --> 00:18:44,758
Is added into the wort heater.
273
00:18:44,758 --> 00:18:48,827
The hops impart the bitterness
And aroma particular to beer.
274
00:18:48,827 --> 00:18:51,689
The hops looks like this.
275
00:18:56,275 --> 00:18:58,000
They can now start the brewing.
276
00:18:58,000 --> 00:19:00,310
In the control room,
An operator handles
277
00:19:00,310 --> 00:19:03,862
The data-control system
Of the brewing process.
278
00:19:06,379 --> 00:19:09,965
They add in the yeast, which
Starts off the fermentation.
279
00:19:09,965 --> 00:19:12,862
This process lasts
Between 7 and 10 days.
280
00:19:12,862 --> 00:19:16,172
This foam indicates
That fermentation has begun,
281
00:19:16,172 --> 00:19:19,896
And sugars will now
Transform into alcohol.
282
00:19:19,896 --> 00:19:22,758
Each fermentation tank
Is computer-controlled
283
00:19:22,758 --> 00:19:25,103
To maintain
A specific temperature.
284
00:19:25,103 --> 00:19:26,724
During fermentation,
285
00:19:26,724 --> 00:19:30,379
Chemical reactions create
The scum that we see.
286
00:19:30,379 --> 00:19:35,241
Now aged for three weeks,
The beer is almost finished.
287
00:19:35,241 --> 00:19:38,000
We see here the bottling tanks.
288
00:19:42,896 --> 00:19:45,241
The beer has to be filtered
Once more.
289
00:19:45,241 --> 00:19:47,965
Exiting these filters,
The wort is clarified,
290
00:19:47,965 --> 00:19:49,965
Then rid of the components
291
00:19:49,965 --> 00:19:53,241
Responsible for the cloudiness
Of the beer.
292
00:19:53,241 --> 00:19:56,379
Here's the beer
Filtered a second time...
293
00:19:56,379 --> 00:19:59,551
And finally finished,
As a clear product.
294
00:20:02,413 --> 00:20:04,896
Used bottles are now washed.
295
00:20:04,896 --> 00:20:08,482
After their wash cycle, the
Bottles have become sterilized.
296
00:20:12,034 --> 00:20:15,517
Empty bottles arrive on
This plate, ready to be filled.
297
00:20:17,965 --> 00:20:22,620
About 1,000 bottles a minute
Are filled while on the move.
298
00:20:29,413 --> 00:20:31,448
Then they pass to the capper
299
00:20:31,448 --> 00:20:35,000
Before being sent
To the pasteurizer.
300
00:20:48,172 --> 00:20:49,586
Only two steps remain.
301
00:20:49,586 --> 00:20:51,724
Labels are glued
Onto the bottles,
302
00:20:51,724 --> 00:20:55,275
Then they're sent by conveyor
To be put in cases.
303
00:21:03,689 --> 00:21:06,275
Made from water
And cereal grains,
304
00:21:06,275 --> 00:21:09,931
The beer is now ready
To be consumed and enjoyed.
305
00:21:09,931 --> 00:21:12,931
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306
00:21:12,931 --> 00:21:15,931
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307
00:21:18,275 --> 00:21:20,448
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308
00:21:20,448 --> 00:21:23,172
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309
00:21:23,172 --> 00:21:24,931
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