All language subtitles for S04E11 - Countertop Laminate; Frozen Treats; Childrens Building Blocks; Detergents (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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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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Laminate...
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...Frozen treats...
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...Children's building blocks...
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...And detergents.
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Narrator: laminate is
A thin, decorative surface layer
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That's usually glued
Onto a particleboard base
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To create a countertop.
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Laminate is, by far, the most
Affordable countertop material
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On the market.
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It comes in an endless choice
Of colors and patterns,
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From solids
To simulated wood or granite.
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They also use laminate
For kitchen cabinets, furniture,
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And laboratory surfaces.
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And they manufacture
Fast-food restaurant seating,
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Among other things,
Out of a thicker, solid form
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Of the material
Called compact laminate.
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The back of a laminate sheet
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Is made of a type of kraft paper
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That can be saturated without
Becoming soggy and tearing.
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A treater drenches it
With resin containing phenol,
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A compound derived from benzene.
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The resin
Doesn't just coat the paper.
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It absorbs right through.
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The paper
Then enters a drying oven.
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The hot air cures the resin
In a matter of seconds.
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Now they can wind the paper
Into a roll.
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The top of the laminate
Is called the decorative layer.
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It's a sheet of paper
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In either a printed design
Or a solid color.
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Solid-color papers
Go through a treater
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That impregnates them with
The more durable melamine resin.
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Durability is essential
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Because the decorative layer
Must withstand wear and tear.
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Two big rollers
Ring out the excess resin.
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Then the saturated paper
Goes through a drying oven.
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With the resin now cured,
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A cutter slices the paper
Into sheets.
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Before resin treatment,
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The paper
Was flexible and easy to tear.
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Now it's stiff and brittle.
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Bend it, and it snaps
Like a potato chip.
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While the rolls of saturated
Kraft paper get cut into sheets,
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Workers prepare the other style
Of decorative layers --
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Those with printed design,
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Such as simulated wood grains
And granite.
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The treatment process
For these papers
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Is quite different than that
For the solid-color papers.
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Workers start
By cutting them into sheets
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The same length
As the kraft-paper sheets.
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These papers
Don't go into a treater
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To be saturated with resin.
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Instead workers stack them,
Placing an overlay on each one.
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An overlay is
A transparent sheet of paper
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That's saturated
With melanin resin.
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Workers stack the solid-color
Sheets in the same pile,
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But those don't need overlays
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Because they've already been
Resin-saturated.
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Now the stack
Goes to the press room.
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There, workers
Put saturated kraft paper
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Under each decorative layer.
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On top of each decorative layer,
They lay a textured plate.
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This will prevent the finished
Laminate from sticking together.
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Everything
Now goes into a press.
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The intense heat and pressure
Compress the layers.
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The overlays
Bond to the printed papers,
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And the saturated kraft paper
Bonds to each decorative layer,
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Creating laminate sheets.
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The textured plates
Between each set
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Imprint their pattern
Onto the heat-softened resin,
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Texturing the laminate surface.
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The laminates come out
Of the press fully cured.
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On the finishing line,
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Machines trim off
Any excess paper on the edges
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And sand the back of the sheets.
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This helps the laminate
Adhere better
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When glued to particleboard
Or another type of substrate.
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To produce compact laminates,
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Workers compile a thick stack
Of black saturated kraft papers
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And sandwich it
Between two decorative layers.
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The press melts and bonds all
The sheets into a solid unit.
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Alternating colors
Produce a striped edge.
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Compact laminates are so thick,
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They're entirely
Self-supporting.
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Unlike laminate sheets,
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They don't need
To be applied to a substrate.
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Narrator:
On a sweltering summer day,
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A frozen treat
Sure hits the spot.
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Eating a fruit bar, fudge bar,
Or ice-cream bar, though,
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Requires a certain strategy.
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You have to hold the treat
By the stick,
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Lean slightly forward
To dodge the drips,
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Then lick like crazy before
It melts and lands at your feet.
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The outer shell
Of these cream pops
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Starts with a transparent base
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Made of water, liquid sugar,
Corn syrup, citric acid,
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And a stabilizer.
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It travels to
Three separate compartment vats,
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Each of which mixes in
A different coloring
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And flavoring.
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This company produces
Three flavors of cream pops --
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Strawberry, orange,
And blue raspberry.
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Each compartment vat
Pumps its flavor
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To a machine
Called the filling hopper.
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The hopper injects the liquid
Into row upon row
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Of half-ounce pop-shaped molds.
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This production line has
340 molds in continuous motion.
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The molds descend
Into a tank of brine,
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Water chilled to negative
30 degrees fahrenheit
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Mixed with calcium.
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Calcium works like antifreeze,
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Keeping the water liquid despite
The below-freezing temperature.
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As the molds travel
Through the ice-cold brine,
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The liquid freezes
From the outside inward,
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Creating a shell
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That will encase
The pops' ice-cream filling.
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Once the shell
Is 1/10 of an inch thick,
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A machine
Called a suction evacuator
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Removes the unfrozen liquid
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And feeds it back
To the filling hopper,
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To be re-injected
At the start of the line.
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The shells are empty now
And ready for filling.
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The ice-cream filling is made
Of various milk products
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Blended with liquid cane sugar,
Corn syrup, stabilizers,
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And emulsifiers
To puff up the consistency.
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The factory
Pasteurizes the mixture,
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Heating it for 35 seconds
At 180 degrees fahrenheit,
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Then freezing it.
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It homogenizes the filling,
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Skimming off the milk fat
That rises to the surface.
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The shells
Are still floating in brine
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As they reach
The filling station.
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The machine shoots
In the ice cream,
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Overfilling the shell a bit
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To create a cap
4/10 of an inch wide.
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The ice cream begins
To harden in the cold brine.
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Once it reaches
A semi-frozen state,
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A machine appropriately
Called the stick inserter
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Pops a wooden stick
In each mold.
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Now the molds leave the brine
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And enter a tank of warm
Water -- 75 degrees fahrenheit,
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Hot enough to detach
The cream pops from the mold
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Without melting them
In the process.
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From initial injection
To final extraction,
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It's been seven minutes.
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The machine dips
The cream pops in cold water
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To produce
A protective coating of ice.
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This will keep the surface
From sticking to the wrapper.
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It will also lengthen
The product's shelf life.
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The machine
Deposits the cream pops
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Into a continuous stream
Of paper wrapping.
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Heating elements seal the
Wrapper on top and between pops,
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Then a slicer cuts them apart.
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The empty molds go through an
Automatic wash-and-rinse cycle
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On their way back
To the start of the line.
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These molds are for making
Chocolate-fudge bars.
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The production process
Is the same,
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Except that the shell
Is fudge-flavored,
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Made from milk solids
And chocolate powder.
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And instead
Of ice cream in the center,
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There's chewy chocolate syrup.
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The factory stamps the packaging
For all its frozen treats
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With the production date
And other information.
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These frozen treats
Have a one-year shelf life
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In the freezer,
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Provided you maintain
The temperature
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At an ideal
Negative 13 degrees fahrenheit.
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Narrator:
Few toys are as timeless
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As interlocking building blocks.
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Children can stick them
Together, pull them apart,
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And rearrange them endlessly.
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From large-sized blocks
For babies
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To intricate kits
For older kids,
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Building blocks
Stimulate creativity
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And improve manual dexterity.
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This company makes
Plastic building blocks.
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Depending on the type of block,
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It uses either polypropylene,
High-density polyethylene,
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Or high-impact polystyrene.
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These plastics arrive
At the factory in pellets.
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Because they're
Naturally transparent,
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The first step is to color them.
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The pellets go into a mixer
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Along with pigment beads
Made of powdered pigment
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00:11:37,034 --> 00:11:40,551
And a type of plastic that's
Compatible with the pellets.
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The pigment beads make up
Just 2% of the weight,
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00:11:46,034 --> 00:11:48,965
But that's enough to color
The plastic a deep hue.
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The mixer feeds
A plastic injection machine.
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It heats the pellets
To 400 degrees fahrenheit,
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00:11:57,275 --> 00:12:00,172
Melting them
In a matter of seconds.
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00:12:00,275 --> 00:12:03,931
The machine then injects
The molten plastic into molds.
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00:12:04,034 --> 00:12:07,655
A system of hoses cools
The molds with cold water,
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00:12:07,758 --> 00:12:11,034
Instantly hardening the plastic.
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00:12:11,137 --> 00:12:12,413
When the machine opens,
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Ejectors thrust the blocks
To a conveyor belt below.
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00:12:16,172 --> 00:12:19,586
For these blocks, the entire
Cycle, from start to finish,
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00:12:19,689 --> 00:12:22,689
Takes just 14 seconds.
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00:12:22,793 --> 00:12:26,206
The length of the cycle varies
With the size of the block.
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00:12:26,310 --> 00:12:30,586
This large school bus, for
Example, requires more plastic,
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00:12:30,689 --> 00:12:33,655
So injection molding
Takes 22 seconds.
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00:12:36,000 --> 00:12:39,482
The wheels for the bus
Take 20 seconds.
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00:12:59,931 --> 00:13:01,655
At packaging time,
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Each type of block is loaded
Into a separate vibrating bowl.
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00:13:05,724 --> 00:13:07,965
The shaking
Separates the pieces,
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00:13:08,068 --> 00:13:12,034
Enabling them to pass by
An optical counter one by one.
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00:13:12,137 --> 00:13:14,379
This automated
Counting equipment
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Can tally up to 16 different
Types of blocks at a time.
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00:13:17,965 --> 00:13:20,896
It can be programmed
To assemble a kit
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00:13:21,000 --> 00:13:24,379
Consisting of specific
Quantities of certain blocks.
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00:13:41,551 --> 00:13:44,689
Once each kit is counted,
It drops into a bucket.
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00:13:50,206 --> 00:13:52,413
The factory
Also makes the buckets
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By plastic injection molding.
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00:13:55,034 --> 00:13:57,000
And it even incorporates
The labeling
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Right into that process.
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00:13:58,758 --> 00:14:01,137
Here's how it all works.
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00:14:01,241 --> 00:14:03,241
A robot takes two labels,
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00:14:03,344 --> 00:14:06,000
One for the front of the bucket
And one for the back.
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00:14:07,413 --> 00:14:09,172
It passes a static generator
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00:14:09,275 --> 00:14:11,931
That charges them
With static electricity.
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00:14:15,206 --> 00:14:17,965
Then it loads the two labels
Into the mold.
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00:14:18,068 --> 00:14:21,103
The static cling holds them
In a flat position
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00:14:21,206 --> 00:14:23,000
While the machine
Injects the plastic
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00:14:23,103 --> 00:14:25,000
And molds the bucket.
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00:14:55,103 --> 00:14:58,172
The hot plastic
Melts the labels on contact,
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00:14:58,275 --> 00:15:01,620
Bonding them
Into the finished bucket.
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00:15:01,724 --> 00:15:05,172
The result -- labels
That can't be peeled off.
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00:15:11,448 --> 00:15:14,862
The factory produces large
Blocks from polypropylene
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00:15:14,965 --> 00:15:19,103
Or high-density polyethylene,
Which are flexible plastics.
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00:15:19,206 --> 00:15:22,862
This makes the blocks easier
For young children to use.
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00:15:22,965 --> 00:15:26,413
Small blocks are made
Of high-impact polystyrene,
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00:15:26,517 --> 00:15:29,068
A plastic that can be molded
With great precision
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00:15:29,172 --> 00:15:32,620
Into tight-fitting blocks
Designed for older children.
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00:15:44,896 --> 00:15:47,896
Narrator: just walk down the
Aisle of your local supermarket,
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00:15:48,000 --> 00:15:52,000
And you'll see shelf upon
Shelves of soaps and detergents.
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00:15:52,103 --> 00:15:55,551
With so many versions
Of each product to choose from,
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00:15:55,655 --> 00:15:57,689
From extra-strength
To antibacterial
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00:15:57,793 --> 00:15:59,137
To lemon-fresh scent,
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00:15:59,241 --> 00:16:02,551
Consumers aren't
The only ones cleaning up.
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00:16:10,586 --> 00:16:15,000
The craft of soapmaking began
In europe around 700 a.D.,
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00:16:15,103 --> 00:16:18,517
But soap remained a luxury item
For another thousand years.
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00:16:18,620 --> 00:16:20,241
That's when a french scientist
244
00:16:20,344 --> 00:16:22,758
Discovered
How to make inexpensive lye
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00:16:22,862 --> 00:16:24,758
Using table salt.
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00:16:24,862 --> 00:16:27,137
People also made soap at home,
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By boiling wood ashes
With animal fats.
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By the 1900s,
The growing soap industry
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Found ways to make mild
And fragranced products.
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And in 1916, a german scientist
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Invented the first
Synthetic detergent.
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This company produces mostly
Industrial-use detergents,
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Liquid and powdered.
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It uses salt as filler
In the powdered ones.
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Fillers add volume, making
A product less concentrated.
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This will be
A powdered detergent
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For cleaning
And degreasing cement floors.
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They add colorant,
Then surfactant,
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A substance that creates foam,
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The vehicle
For lifting away dirt.
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Now they pour in pine oil,
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A disinfecting agent
That also adds fragrance.
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Now the cleaning agent --
Sodium tripolyphosphate.
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It's essential to mix
All the ingredients thoroughly.
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This ensures the chemicals
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Are evenly distributed
Throughout the cleaner.
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The last ingredient
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Is a chemical called
Sodium metasilicate.
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It boosts
The mixture's alkaline level.
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This particular cleaner
Needs high alkalinity
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To be effective.
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The factory packages
Its powdered cleaners,
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Such as this laundry soap,
In large plastic buckets.
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Automated equipment weighs, then
Pours in the appropriate amount,
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Capping the container
Tightly to prevent leaks.
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The filler in liquid
Cleaning products is water.
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To produce liquid hand soap,
They first add citric acid.
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This creates the mild acidity
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Needed to get the most
Out of the surfactants.
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This soap contains three
Different types of surfactants.
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00:18:21,758 --> 00:18:25,241
It's a specific formulation
Designed by the company chemist
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00:18:25,344 --> 00:18:28,068
To optimize the soap's
Cleaning power.
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To give the soap a pearl luster,
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The company uses
This secret recipe of chemicals.
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The factory makes
Most of its liquid soap
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From this same base mixture.
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The colors and fragrances vary.
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For coloring,
It uses powdered pigments.
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00:18:51,344 --> 00:18:54,551
It dissolves them in hot water,
Then pours them in.
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00:18:55,724 --> 00:18:58,482
This batch of soap will be pink.
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00:19:01,103 --> 00:19:03,551
They pour
In a rose-scented fragrance...
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...Then add a preservative
To prevent the proliferation
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00:19:08,931 --> 00:19:11,551
Of bacteria
Should the soap be exposed
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00:19:11,655 --> 00:19:13,241
To a substandard environment.
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00:19:15,379 --> 00:19:17,827
Finally,
They adjust the viscosity
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00:19:17,931 --> 00:19:20,172
By adding a powdered thickener.
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00:19:20,275 --> 00:19:23,620
If liquid soap is runny,
It'll leak out of the dispenser.
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00:19:23,724 --> 00:19:28,172
After 15 minutes of mixing,
The soap is ready.
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00:19:28,275 --> 00:19:30,206
And the lab analyzes a sample,
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00:19:30,310 --> 00:19:35,103
Assessing its physical
And chemical properties.
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When the batch gets the "Okay,"
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It proceeds
To the packaging machine.
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This soap is going
Into dispenser bags
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Made of plastic film.
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00:19:43,448 --> 00:19:46,000
The machine
First inserts a valve.
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00:19:52,724 --> 00:19:56,172
It heat-seals the film, forming
The bottom of the bag.
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00:19:56,275 --> 00:19:59,551
Then it injects
27 ounces of soap.
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00:19:59,655 --> 00:20:03,586
Next, it simultaneously
Heat-seals the top of the bag
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And the bottom of the next one.
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It cuts them apart,
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Releasing the finished bag
To a conveyor belt below.
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After checking for leaks,
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00:20:15,172 --> 00:20:19,103
Workers insert a spout that
Controls output from the valve.
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00:20:19,206 --> 00:20:21,068
This ensures the dispenser
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00:20:21,172 --> 00:20:24,172
Will release a measured amount
Of soap per push.
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00:20:26,137 --> 00:20:28,827
Elsewhere in the factory,
An automated machine
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Called the pressure filler
Pumps dishwashing liquid
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Into plastic bottles.
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00:20:33,896 --> 00:20:35,896
An overflow
And weight-control device
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Ensures the right fill level.
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00:20:48,172 --> 00:20:51,965
The next machine applies
A twist cap with pull-out spout.
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Then it's off to labeling.
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Those bags of liquid hand soap
Went into special boxes
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That are designed to slip right
Into the soap dispenser.
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If you have any comments
About the show,
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00:21:24,482 --> 00:21:27,034
Or if you'd like to suggest
Topics for future shows,
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00:21:27,137 --> 00:21:29,310
Drop us a line at...
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