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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Plastic bottles and jars...
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...Mail...
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...Eggs...
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...And handcrafted wooden pens.
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Whether you're buying
Apple juice or peanut butter,
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You've probably noticed
That fewer products
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Come in glass containers
These days.
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Plastic packaging
Is becoming more common.
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Plastic bottles and jars
Are lighter to carry
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00:01:07,655 --> 00:01:10,137
And leave no shards of glass
To clean up
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If you drop your grocery bag.
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Many transparent bottles
And jars
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Are made from a type of plastic
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Called polyethylene
Terephthalate,
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Or p.E.T.
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An automated mixer combines
P.E.T. Pellets
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With flakes of recycled p.E.T.
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Reprocessed plastic loses
Some of its physical properties,
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So the recycled content
Can't exceed 10%.
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The p.E.T. Drops from the mixer
Into a plastic injection machine
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That heats it to a piping
600 degrees fahrenheit.
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The dry raw material melts into
Thick and gooey liquid plastic.
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The machine then shoots it
At high pressure into a mold.
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This plastic injection molding
Process
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Casts pieces of plastic
Called preforms,
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Starter shapes
That subsequent machines
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Will transform
Into bottles or jars.
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The molded preforms harden
Almost instantly,
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Thanks to a built-in
Cooling system.
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These preforms
Are now on their way
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To becoming single-serving
Juice bottles.
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This is another plastic
Injection molding machine.
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It uses the same method
To make preforms
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For a different model --
1 1/2- to 2-liter bottles.
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The preform's next stop
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Is a machine called
A reheat stretch-blow molder.
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In a matter of seconds,
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It heats each preform
Just enough
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To make the plastic malleable,
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Then inserts a rod to stretch
The preform lengthwise
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While at the same time
Blowing in air
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At extremely high pressure.
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This forces the preform
Into a bottle-shaped mold.
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Cold water circulates
Within the mold
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To cool and set the plastic
Almost instantly.
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This lightning-fast machine
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Churns out 10,600 bottles
Per hour.
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No wonder we've had to show it
To you in slow motion.
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A conveyor belt transports
The finished bottles
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To the packaging area.
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Before blow molding,
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The preforms for certain models
First pass through an oven.
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A technician sets the heat level
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00:04:05,931 --> 00:04:08,896
Of each infrared oven lamp
Individually,
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Applying more or less heat
At various points
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To influence the thickness
And shaping of the plastic.
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From the oven,
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The preforms go into another
Reheat stretch-blow molder
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That transforms them
Into peanut jars.
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It's the same process
For this peanut butter jar.
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After molding, the machine
Instantly cools the plastic,
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Locking in the shape.
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The factory pulls samples off
The line at regular intervals
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For quality-control testing.
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Technicians measure
The thickness of the plastic
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And perform a compression test
To gauge its strength.
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They verify the sample's
Dimensions and capacity.
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They also evaluate resistance
To vacuum pressure
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Because containers are often
Vacuum sealed after filling.
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Some models
Must also be strong enough
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To resist the pressure
Of their contents --
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Carbonated soft drinks,
For instance.
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The recycled material used in
Making these bottles and jars
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Doesn't come
From used plastic containers.
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For hygienic reasons,
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The factory recycles
Only new plastic
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Left over
From its manufacturing process.
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The finished containers,
Of course, are fully recyclable.
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They're typically reprocessed
Into other plastic products
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Or into products
That contain some plastic.
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Narrator: what do the letters
"F," "D," "I," "O," and "U"
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Have in common?
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They're all part of postal codes
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Used in abbreviations
For state names.
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These letters and numbers
Are read by high-tech machines
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That sort our mail.
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The trucks unload the containers
Picked up from postal outlets...
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And bags of mail that were
Collected from public mailboxes.
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The containers go straight
To automated sorting.
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Their contents have already
Been classified by size.
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Not so for the bags.
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Postal workers empty them
And put standard-size envelopes
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On a conveyor belt leading
To one sorting machine...
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...And large envelopes
Into a bin destined for another.
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The standard-sized letters
Travel to a high-speed,
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High-tech machine
That checks for postage.
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Stamps contain an invisible
Fluorescent material
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That illuminates
Under ultraviolet light.
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The machine's u.V. Sensor scans
Both sides of every envelope.
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No glow, no go.
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Letters with postage
Are canceled with a postmark
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So the stamps can't be reused.
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The postal mark
Contains the date, the state,
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And the sorting plant's
Postal code.
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Next stop, a machine
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Called the multiline optical
Character reader...
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An impressive piece of equipment
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That processes
Up to 30,000 letters per hour.
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It reads
And digitally photographs
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Each destination address,
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Matching it to the computer's
Address database.
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Then it prints the postal code
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In barcode format
On the front of the envelope.
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A scanner now reads the barcodes
And does a preliminary sorting.
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Local and regional mail
Stays here
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And moves on
To the next sorting machine
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For a more detailed breakdown.
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Letters addressed
To other regions
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Go to the postal plants there,
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Where a thorough sorting
Will take place.
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But what happens when all this
Sophisticated technology
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Just can't make out the address
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Due to, say, sloppy handwriting
Or smudged ink?
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The optical character reader
Machine puts the letter on hold
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00:08:29,206 --> 00:08:33,137
And sends the address photo
To the video encoding system.
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A postal worker
Deciphers the writing
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And types in the postal code,
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Sending the letter back
Into the sorting system.
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Now the local and regional mail
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Goes through what's called
The bcs -- the barcode sorter.
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00:08:48,931 --> 00:08:53,241
This performs a more detailed
Sorting by postal route.
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The machine scans the barcodes
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At a rate of 30,000 letters
Per hour, sending the mail
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To the corresponding
Letter carrier's bin.
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00:09:03,137 --> 00:09:05,103
A worker preps the mail
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00:09:05,103 --> 00:09:08,413
For each route, grouping
And labeling it by sector.
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00:09:11,068 --> 00:09:13,413
Meanwhile, the large envelopes
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00:09:13,413 --> 00:09:15,896
Go through what's called
The flat sorting machine.
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It does what three machines did
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For the standard-sized
Letters --
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Postmarks the stamp,
Reads the address,
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Applies a barcode sticker,
Reads the barcode,
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Sorts the mail, and drops it
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00:09:28,931 --> 00:09:32,586
Into the corresponding
Letter carrier's bin.
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If the machine can't make out
An address,
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The envelope goes
For manual sorting.
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In manual sorting,
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Postal workers handle more
Than just illegible addresses.
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They also hand sort mail
Going out of country
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And envelopes
That are too thick or bulky
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To go through
The automated machines.
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At all stages
Of mail processing and delivery,
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Workers are on the lookout
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For envelopes bearing
Insufficient postage.
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00:10:00,965 --> 00:10:04,000
Those letters
Are returned to sender.
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00:10:06,620 --> 00:10:09,172
Letter carriers sort the mail
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For the routes by street
And house number.
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If they have a walking route,
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They load up their first bagful
And head off.
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A truck delivers the rest
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To a locked box along the route
Called a relay box.
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Carriers pick up the rest of
Their mail when they pass by it.
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00:10:26,689 --> 00:10:30,448
Some letter carriers have
What's called a motorized route.
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They deliver all their
Customers' mail by truck,
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Which sure beats walking
Door-to-door in a blizzard.
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Narrator: hens don't have to
Mate to lay eggs,
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And as long as there's no
Rooster in the vicinity,
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The eggs will remain
Unfertilized and edible.
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The color of the shell is
Determined by the breed of hen,
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But there's no pecking order
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When it comes
To shell color.
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White or brown,
All eggs are the same inside.
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The action begins
In the hen house,
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Where female chickens
Start laying eggs
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When they're 19 weeks old.
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The building is well-ventilated,
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00:11:19,241 --> 00:11:23,034
And the temperature and humidity
Are strictly controlled.
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To stimulate laying,
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Fluorescent lighting
Simulates 15 hours of daylight.
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00:11:30,724 --> 00:11:34,724
The hens eat a measured amount
Of food three times a day.
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Their feed is made up
Of various grains
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Mixed with soybeans for protein.
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It's fortified with vitamins
And minerals
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And contain calcium
To strengthen the eggshells.
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The hens drink water
From nipple-ended tubes
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Attached to their cages.
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All these
Carefully monitored conditions
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Are designed
To maximize the yield.
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The average hen
Lays about 300 eggs a year.
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The cage floor is sloped
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So the eggs automatically roll
Onto a conveyor belt.
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Then it's onto
A larger conveyor belt,
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00:12:11,931 --> 00:12:15,413
Which transports the eggs
To the packing room.
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The hens' manure drops through
The bottom of their cages
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Onto a conveyor below.
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Even so, some eggs get dirty.
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They'll be thoroughly cleaned
And disinfected later on.
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Automated equipment transfers
The eggs onto plastic flats.
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00:12:49,965 --> 00:12:52,137
It places them wide-end up
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00:12:52,137 --> 00:12:55,000
To keep the yolks
Properly centered.
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The flats go into a cold room
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00:12:59,586 --> 00:13:03,482
Until a refrigerated truck ships
Them to the grading station,
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Whose job is to classify
The eggs by quality.
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00:13:07,172 --> 00:13:11,241
The best, grade "A,"
End up on supermarket shelves.
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00:13:12,827 --> 00:13:15,344
Lesser grades
Go to processing plants
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To be turned into ingredients
Used in foods, pharmaceuticals,
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00:13:19,310 --> 00:13:21,931
And products such as shampoos.
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00:13:21,931 --> 00:13:26,758
This automated station
Is high-tech and high-speed,
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00:13:26,758 --> 00:13:30,931
Processing 144,000 eggs
Per hour.
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00:13:32,758 --> 00:13:35,931
First, a suction machine lifts
The eggs off the flats
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00:13:35,931 --> 00:13:38,413
And transfers them
Onto a moving track
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Leading to the cleaning station.
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00:13:41,758 --> 00:13:44,379
There, a washer
Gently scrubs the eggs
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00:13:44,379 --> 00:13:46,620
With soap and disinfectant.
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00:13:46,620 --> 00:13:50,620
The water is just over
100 degrees fahrenheit.
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00:13:50,620 --> 00:13:53,620
Anything hotter
Would cook the eggs.
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00:13:53,620 --> 00:13:56,689
Then, it's into a dryer
For five seconds,
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00:13:56,689 --> 00:13:58,448
Where a fan sucks up
The moisture.
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00:14:00,517 --> 00:14:03,793
The eggs then pass over
A bright light,
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00:14:03,793 --> 00:14:06,310
Which highlights
The condition of the shells.
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00:14:06,310 --> 00:14:09,965
Workers do a preliminary
Visual inspection,
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00:14:09,965 --> 00:14:12,310
Removing any that are cracked.
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00:14:14,965 --> 00:14:17,172
A grading camera above
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00:14:17,172 --> 00:14:19,413
Assesses the condition
And quality
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00:14:19,413 --> 00:14:20,931
Of the shell's exterior.
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00:14:25,586 --> 00:14:27,413
Further down the line,
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00:14:27,413 --> 00:14:30,931
Other cameras will inspect
The interior for blood.
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00:14:32,827 --> 00:14:35,137
To check the strength
Of the eggshells,
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00:14:35,137 --> 00:14:38,379
Acoustic sensors
Tap on the eggs.
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00:14:38,379 --> 00:14:42,586
They detect brittle shells by
The different sound of the tap.
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00:14:45,344 --> 00:14:48,758
The inspection machines mark
And reject any egg
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00:14:48,758 --> 00:14:51,724
That doesn't make the grade --
Grade "A," that is.
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00:14:51,724 --> 00:14:55,862
The approved eggs move on
To electronic scales,
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00:14:55,862 --> 00:14:59,862
Which register their weight
Class from peewee to jumbo.
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00:14:59,862 --> 00:15:03,068
Pressure-controlled claws
Then transport them
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00:15:03,068 --> 00:15:05,448
To the corresponding
Packaging line.
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00:15:05,448 --> 00:15:08,965
On the way, every egg gets
Stamped with a lot number
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00:15:08,965 --> 00:15:11,482
For quality-control tracking.
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00:15:11,482 --> 00:15:14,310
The packing machine
Stamps the egg cartons
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00:15:14,310 --> 00:15:15,827
With a "Best before" date.
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00:15:15,827 --> 00:15:18,965
The eggs have a shelf life
Of 35 days.
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00:15:18,965 --> 00:15:20,620
As for the hens,
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00:15:20,620 --> 00:15:24,206
Their expiration date
Comes at 72 weeks,
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00:15:24,206 --> 00:15:27,931
When the eggs they lay are
No longer consumption-quality.
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00:15:27,931 --> 00:15:29,965
For all their hard work,
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00:15:29,965 --> 00:15:33,724
They win an all-expenses-paid
Trip to the slaughterhouse.
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Narrator: a pen set is a classic
Gift for any occasion,
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Be it a birthday, graduation,
Or promotion.
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We're not talking pens
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Of the inexpensive,
Ball-point variety...
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But rather those cadillac models
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In sleek metal
Or sumptuous wood.
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The quill dates back
To about 700 a.D.
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Made from a bird feather,
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It's tip had to be repeatedly
Dipped in ink.
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Messy and inefficient,
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The quill remained the norm
For more than 1,000 years.
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In 1884,
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An american invented
The fountain pen,
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With its built-in
Refillable ink barrel.
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But the true revolution came
With the no-fuss ball-point pen
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Patented by two hungarian
Brothers in 1938.
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Handcrafted wooden pens can be
Made from just one type of wood
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Or from a combination of woods.
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This artisan
Uses some 50 different kinds,
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Ranging from domestic maple
And oak
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To imported rosewood, ebony,
Olive wood, and purpleheart.
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When using just one type
Of wood,
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He runs the block
Through a band saw,
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Cutting a strip
6/10 of an inch wide.
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Then, with a radial saw,
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He cuts that strip
Into two pieces,
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Each about two inches long.
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These will become the pen's top
And bottom casings.
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Using a tool
Called a drill press,
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He bores a hole roughly
3/10 of an inch in diameter
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Right through each piece.
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Making a pen
From a combination of woods
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Takes a little more work.
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Instead of using a block
Of solid wood,
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He constructs a block
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By gluing together thin planks
Of contrasting woods.
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Once the glue dries,
He uses a wood planer
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To remove the excess
And smooth out the sides.
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Then, just as he did
For the single-wood pen,
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He cuts the block into strips
6/10 of an inch wide.
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This time, he slices diagonally
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So that each strip showcases
The multiple woods.
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Again, he cuts pieces
For the top and bottom casings,
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Then drills a hole through them.
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From this point on, whether
He's using one or more woods,
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The process is the same.
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He coats two brass tubes
With glue
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00:18:38,724 --> 00:18:40,551
And inserts one in each casing.
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00:18:40,551 --> 00:18:43,724
A few drops of water are added
To expand the adhesive
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00:18:43,724 --> 00:18:48,068
Into any gaps between the tube
And surrounding wood.
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These brass tubes
Will house the pen's mechanism.
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The glue
Takes about an hour to dry.
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Then he uses what's called
A hand mill
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To square all the angles
And remove the excess glue.
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00:19:12,310 --> 00:19:14,827
Now for the artistic part.
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He turns the casings
On a lathe to shape them.
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First, he rounds them out.
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Then, using a series of tools,
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00:19:23,758 --> 00:19:26,379
He gives each casing
Unique detailing.
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He highlights the grooves
By using the heat
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That friction generates
To burn them dark.
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When the design work's done,
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He runs sanding cord
Inside the grooves.
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00:19:58,896 --> 00:20:02,206
Then he sands the surface
Three times
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00:20:02,206 --> 00:20:04,896
With progressively finer
Sandpaper.
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00:20:07,931 --> 00:20:09,965
To protect the wood,
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00:20:09,965 --> 00:20:11,379
He varnishes the casings
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00:20:11,379 --> 00:20:13,862
With four coats
Of hardwood-floor varnish,
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Sanding between
Each application.
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00:20:18,172 --> 00:20:21,172
When the last coat dries,
He can assemble the pen,
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Starting with the tip.
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00:20:24,793 --> 00:20:26,793
He glues it
To the bottom casing,
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Tapping it with a mallet
To ensure it's fully inserted.
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00:20:34,965 --> 00:20:39,448
The tip is made of titanium,
A very resilient metal.
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Next comes the clip,
Also made of titanium.
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He glues it into the top casing.
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Finally, using a vise,
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00:20:48,275 --> 00:20:51,275
He forces in
The pen's mechanism.
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The mechanism houses
A replaceable ink cartridge.
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A titanium ring
Joins the two casings.
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As an added touch,
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00:21:03,103 --> 00:21:06,586
The pen can be personalized
With an engraved clip.
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And the gift box can bear
The recipient's name
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Or a corporate logo.
26759
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