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Narrator:
Today on "How it's made"...
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Levels...
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...Hot dogs...
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...Abrasive grain...
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...And sandpaper.
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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, llc
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The level was invented
In the 17th century
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00:00:56,206 --> 00:00:58,862
To keep structures
Plumb and true.
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00:00:58,862 --> 00:01:00,931
Without it,
Buildings would lean,
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00:01:00,931 --> 00:01:02,448
Floors would be crooked,
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00:01:02,448 --> 00:01:05,862
And maps would have inaccurate
Elevation information.
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00:01:05,862 --> 00:01:07,482
No matter what you're making,
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00:01:07,482 --> 00:01:10,620
This critical tool
Always gives it to you straight.
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It's a centuries-old concept,
But still measures up.
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Center the little bubble,
And you're perfectly straight.
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00:01:26,413 --> 00:01:29,758
Production begins with a length
Of laminated birchwood.
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00:01:29,758 --> 00:01:33,793
An automated router
Carves out several holes,
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00:01:33,793 --> 00:01:37,413
Three of which
Will enclose the vials.
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The other two
Will serve as handgrips.
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00:01:46,551 --> 00:01:50,068
Next, it's time
To tackle the wood's perimeter.
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00:01:53,448 --> 00:01:55,896
Grooves are cut
Along the length of the wood
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For the level's brass binding.
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00:02:00,517 --> 00:02:04,413
Strips of brass are unwound
Into a forming machine.
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00:02:05,448 --> 00:02:09,137
Rollers iron out the curl
From the coiling.
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00:02:09,137 --> 00:02:12,724
Other rollers
Then crimp the brass.
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00:02:12,724 --> 00:02:14,793
This process will allow
The strip
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00:02:14,793 --> 00:02:17,068
To fit into those grooves
In the wood.
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00:02:26,000 --> 00:02:27,551
Lengths of brass binding
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Are loaded into a machine
That slides them into place.
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00:02:30,862 --> 00:02:33,482
This reinforces
The edges of the wood.
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Over at another station,
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A machine melts and molds
The plastic for the vials.
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Each one
Is slightly curved inside
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00:02:44,827 --> 00:02:48,758
So the bubble
Has a place to sit.
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00:02:48,758 --> 00:02:52,241
The vials wind their way
Through a vibratory feeder.
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00:02:55,551 --> 00:02:57,241
It takes them to a gripper
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00:02:57,241 --> 00:03:00,586
That rotates each one
So the open end faces up.
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00:03:02,827 --> 00:03:05,413
In goes a squirt
Of yellow mineral spirits,
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Leaving just enough room
For a bubble to form.
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00:03:12,000 --> 00:03:15,620
A robotic arm plugs the vials
With plastic caps.
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00:03:18,000 --> 00:03:21,827
Then this sonic welder
Melts the caps onto the vials
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00:03:21,827 --> 00:03:24,448
Using high-frequency
Sound waves.
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00:03:24,448 --> 00:03:27,517
Now it's time for inspection.
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00:03:27,517 --> 00:03:29,655
A tiny camera
Photographs the bubble
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00:03:29,655 --> 00:03:31,586
And sends the picture
To a computer
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00:03:31,586 --> 00:03:34,758
That makes sure the bubbles
Are the right size.
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00:03:34,758 --> 00:03:36,448
For this production run,
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00:03:36,448 --> 00:03:39,379
The bubble should be
About half an inch wide.
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If it's on the mark,
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The computer
Allows the vial to move on.
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A printer then hot-stamps
Centering marks onto the vial.
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But this spirit vial
Isn't quite ready for business.
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First it needs to bake
For 24 hours.
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The heat exposes any flaws,
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And the defective vials
Are rejected.
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The vial is illuminated
With a bright red light
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00:04:17,137 --> 00:04:19,931
As it slowly spins
Between rollers.
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00:04:19,931 --> 00:04:22,413
A camera photographs the bubble,
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00:04:22,413 --> 00:04:25,965
And a computer scans the image
To check for shifting.
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00:04:25,965 --> 00:04:30,413
Too much shifting could
Compromise the level's accuracy.
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The vials that pass the test
Then go on to a molding system.
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Melted plastic is injected
Into the crevices
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To make a cradle for each vial.
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Next, a technician
Glues the cradled vials
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In the openings
In the wooden framework.
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This is precision work.
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Each vial has to sit
Perfectly level,
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00:05:03,206 --> 00:05:06,103
So technicians rely
On a magnified image
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To check their progress.
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Some vials are installed
Vertically
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To gauge if the walls are plumb,
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00:05:15,137 --> 00:05:18,137
While the horizontal ones let
You know if the floor is level.
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00:05:22,620 --> 00:05:25,206
Acrylic-rimmed windows
Are fitted over the vials
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To protect them.
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Rubber caps are screwed
On to both ends of the level.
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And finally,
The trademark stamp goes on.
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These levels are now ready
To straighten up any jobsite.
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When we return, the real skinny
On an all-american favorite.
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Narrator: hot dogs are
An all-american fare.
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But most likely
It was german sausage makers
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Who first came up with the idea.
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In fact, there are reports
Of german immigrants
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Selling them from pushcarts
In new york's bowery
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As far back as the 1860s.
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A century and a half later,
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Hot dogs are still the
Number-one treat on the street.
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Traditional hot dogs
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Are made from a mix
Of pork, beef, and chicken.
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The cuts they start with
Are called trimmings --
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Pieces of meat left over from
Cutting steaks or pork chops.
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The trimmings are ground
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The same way butchers
Chop up hamburger meat --
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By pushing the cuts
Through grated metal plates.
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Processed chicken trimmings
Are added to the ground meat,
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Followed by food starch, salt,
And other flavorings.
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These flavorings vary
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Depending on where
The hot dogs are to be sold
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Because people in different
Regions have different tastes.
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Water is sprayed into the mix,
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And everything is blended
Together in a big vat.
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Corn syrup
Adds a dash of sweetness.
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The addition of even more water
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Helps to disperse
The ingredients
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And make the hot dogs juicier.
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Another machine
Then purees the meat batter
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Into a fine emulsion
And vacuums out any air.
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Long rolls of cellulose tubing
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Are loaded
Into the stuffing machine.
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It pumps the meat puree
Into these casings,
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Twisting it
Every 5 1/4 inches --
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The length of one hot dog.
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It takes just 35 seconds
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To make a chain of hot dogs that
Would span a soccer field twice.
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Then three
Of those hot-dog chains
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Are linked together
To make an even longer string,
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And they're loaded several
At a time into another machine,
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Which drapes the hot dogs
Onto moving racks.
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The process is carefully timed
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00:08:45,655 --> 00:08:48,310
So that a twist
Always lands on the bar.
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The racks shunt the hot dogs
Through a liquid smoke shower,
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Then into an oven
With several cooking zones.
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The liquid smoke
Seeps through the casing
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00:09:01,000 --> 00:09:03,517
And adds flavor to the dogs
As they bake.
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Hot out of the oven,
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These franks are drenched
In cold, salty water
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To chill them in preparation
For packaging.
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00:09:20,413 --> 00:09:23,448
The hot dogs then file down
To an unloading zone.
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00:09:25,068 --> 00:09:29,034
Here, a machine pulls them
Off the bars onto a conveyor.
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00:09:32,655 --> 00:09:36,758
Then the hot dogs slide off the
Conveyor into metal containers.
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If you've been wondering
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About those black stripes
On the casings,
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All is about to be revealed.
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The stripe is a marker
Attached to the casing.
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The absence of a black stripe
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Means the hot dog is cooked
And ready for packaging.
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Inside the peeler machine,
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A tiny knife slits
Each casing along the top.
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00:10:04,931 --> 00:10:08,103
Then steamy air blows
The casings right off the dogs.
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This machine peels
700 hot dogs a minute.
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An inspector makes sure
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The casing
Has been completely removed
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And that there are no defects
In the dogs.
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Then it's into a device
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00:10:26,793 --> 00:10:29,241
That looks like
A plastic bicycle chain.
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00:10:29,241 --> 00:10:32,586
The sprockets position
The hot dogs for packaging.
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This factory manufactures
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00:10:37,931 --> 00:10:41,620
An incredible 300,000 hot dogs
An hour.
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That's close
To 2 1/2 million per shift.
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They really do
Churn them out like sausages.
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Fire up the grill,
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And a mouthwatering meal
Is just minutes away.
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Up next, the hot scoop
On abrasive grains.
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00:11:09,724 --> 00:11:11,724
Narrator: it takes true grit
To make sandpaper,
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00:11:11,724 --> 00:11:13,413
As in abrasive grains.
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People have been using
Abrasive minerals
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To sand and polish things
For centuries.
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Today, these minerals
Undergo heavy processing
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To make the grade,
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From very superfine
To very coarse.
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Whether you're working
On metal or wood,
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The right grade of abrasive grit
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Is essential
For finishing the job.
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The factory starts with bauxite,
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A naturally occurring mineral
That resembles clay.
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They add alumina,
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A white powdery material that's
Actually derived from bauxite.
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00:11:57,862 --> 00:12:00,965
The bauxite and alumina are
Blended with other minerals,
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00:12:00,965 --> 00:12:03,413
Then released
Into an electric arc furnace.
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00:12:06,310 --> 00:12:10,034
Here, three large electrodes
Use intense electrical current
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00:12:10,034 --> 00:12:13,206
To heat the mix to
Over 3,600 degrees fahrenheit.
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That's hotter
Than an active volcano.
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00:12:16,103 --> 00:12:19,413
In fact, the mixture
Looks a lot like lava
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As the minerals melt
And blend together.
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Standing well back
And using a long ladle,
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A technician takes a sample
For chemical analysis.
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00:12:34,172 --> 00:12:36,413
If the mix is right,
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00:12:36,413 --> 00:12:39,586
The molten minerals are emptied
Into a big steel pot.
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00:12:50,379 --> 00:12:53,137
The searing liquid
Weighs several tons,
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00:12:53,137 --> 00:12:56,344
So a crane is needed to
Transport it to a cooling area.
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24 hours later,
With the material hardened,
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It's time to bring in
The wrecking ball.
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It cracks open
The hardened concoction,
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00:13:15,172 --> 00:13:18,724
Which is still quite hot
At the core.
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00:13:24,827 --> 00:13:27,137
The wrecking ball
Is dropped repeatedly
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00:13:27,137 --> 00:13:29,206
To break up
The hardened minerals.
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00:13:35,206 --> 00:13:38,655
Next, the lumps
Of abrasive material
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00:13:38,655 --> 00:13:42,137
Are transferred
To a conveyor system.
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Metal-plated crushers break them
Up into fist-sized chunks.
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00:13:54,482 --> 00:13:58,034
A magnet picks up
Any excess iron.
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00:13:59,103 --> 00:14:01,379
And then
It's into the roll crusher,
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00:14:01,379 --> 00:14:04,482
Where iron cylinders
Grind the chunks to bits.
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00:14:09,103 --> 00:14:12,137
Workers assemble screens
In decreasing mesh sizes
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00:14:12,137 --> 00:14:14,103
To make a kind of shaking sieve.
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00:14:14,103 --> 00:14:15,827
It sifts the mineral particles
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00:14:15,827 --> 00:14:18,344
Through the screen
With largest mesh first,
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00:14:18,344 --> 00:14:22,896
Then continues to sort the grits
In progressively smaller sizes.
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00:14:22,896 --> 00:14:24,517
For some perspective,
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00:14:24,517 --> 00:14:28,137
We placed a quarter
Against the various mesh sizes.
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00:14:28,137 --> 00:14:29,655
As you can see,
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00:14:29,655 --> 00:14:33,620
Only the finest particles could
Pass through tightest weave.
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00:14:39,655 --> 00:14:42,827
The bits of grit
Bounce across the screens
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00:14:42,827 --> 00:14:46,310
And fall into hoppers --
A different one for each size.
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00:14:47,551 --> 00:14:51,137
The coarsest grains will be used
For rough-sanding jobs.
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00:14:51,137 --> 00:14:54,448
The smaller the grain,
The finer the finish.
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00:14:57,724 --> 00:15:01,275
The finest grits
Are virtually microscopic.
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00:15:07,655 --> 00:15:10,965
The next step is to inspect
The grain's shape.
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00:15:10,965 --> 00:15:13,275
A sample is funneled into a cup.
209
00:15:13,275 --> 00:15:16,034
Then it's weighed.
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00:15:16,034 --> 00:15:18,896
A higher weight means the bits
Are densely stacked
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00:15:18,896 --> 00:15:21,344
And therefore blockish in shape
With blunt edges.
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00:15:21,344 --> 00:15:24,379
A lower weight
Means they're flat and sharp.
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00:15:26,206 --> 00:15:30,344
A different test is used
For the most minuscule grits.
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00:15:30,344 --> 00:15:34,344
The particles are suspended
In an an electrolyte solution.
215
00:15:34,344 --> 00:15:36,482
Then an electrical charge
Is applied.
216
00:15:36,482 --> 00:15:39,517
This allows inspectors
To count and evaluate the grits
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00:15:39,517 --> 00:15:41,000
Via computer.
218
00:15:42,931 --> 00:15:45,482
Now these abrasive grits
Are ready to be packaged
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00:15:45,482 --> 00:15:46,655
And shipped out.
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00:15:55,103 --> 00:15:57,896
Coming up, we'll go
To the sandpaper factory,
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00:15:57,896 --> 00:16:01,068
Where the abrasive grits meet
Their ultimate destiny.
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00:16:04,724 --> 00:16:07,896
We'll have the nitty-gritty
On that process next.
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00:16:17,448 --> 00:16:20,241
Narrator: to make sandpaper,
You need a lot of grit.
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00:16:20,241 --> 00:16:23,068
There are thousands
Of tiny abrasive grains
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00:16:23,068 --> 00:16:24,620
On a single sheet.
226
00:16:24,620 --> 00:16:26,931
The whole idea
Is to create friction.
227
00:16:26,931 --> 00:16:29,758
By rubbing the sandpaper
Against wood or metal,
228
00:16:29,758 --> 00:16:34,413
You can remove defects
And create a uniform surface.
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00:16:41,965 --> 00:16:44,241
It's ironic that something
So abrasive
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00:16:44,241 --> 00:16:46,862
Can make things look so smooth
And polished.
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00:16:48,724 --> 00:16:51,827
Sandpaper often isn't made
From paper at all,
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00:16:51,827 --> 00:16:54,379
But fabric like poly cotton.
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00:16:54,379 --> 00:16:57,965
The cloth is unwound into
A machine with a printing press.
234
00:16:57,965 --> 00:17:00,172
Rollers lined
With rubber printers
235
00:17:00,172 --> 00:17:02,793
Stamp product information
Onto the cloth.
236
00:17:07,068 --> 00:17:09,620
The cloth then travels
Underneath the printing press,
237
00:17:09,620 --> 00:17:12,448
Where more rollers apply
A heat-setting adhesive
238
00:17:12,448 --> 00:17:13,965
To the unprinted side.
239
00:17:25,275 --> 00:17:28,793
A computerized system measures
The density of the coating
240
00:17:28,793 --> 00:17:31,551
To ensure that it's been applied
Correctly.
241
00:17:39,620 --> 00:17:42,241
Then the cloth
Is pulled one floor down
242
00:17:42,241 --> 00:17:44,379
To the electrostatic pit.
243
00:17:44,379 --> 00:17:48,000
Here, the environment is kept
Hot and humid --
244
00:17:48,000 --> 00:17:50,344
Perfect for applying
Abrasive grains
245
00:17:50,344 --> 00:17:52,724
To the cloth
Electrostatically.
246
00:17:52,724 --> 00:17:56,103
The grains are poured
Onto a conveyor belt in the pit.
247
00:17:56,103 --> 00:17:58,896
The conveyor moves the grains
Under the rolling cloth
248
00:17:58,896 --> 00:18:02,586
And between electrodes
And ground plates.
249
00:18:02,586 --> 00:18:05,448
The system generates
An electrical field
250
00:18:05,448 --> 00:18:07,931
That triggers a mini sandstorm.
251
00:18:10,758 --> 00:18:12,862
Once airborne,
252
00:18:12,862 --> 00:18:15,689
The abrasive grains stick
To the adhesive-coated cloth
253
00:18:15,689 --> 00:18:18,103
And become embedded in it.
254
00:18:18,103 --> 00:18:21,620
This method allows for even
Distribution of the grains
255
00:18:21,620 --> 00:18:23,310
Across the cloth.
256
00:18:31,137 --> 00:18:34,241
The grain-coated cloth
Now rolls out of the pit
257
00:18:34,241 --> 00:18:36,965
And back up to the main level
Of the factory.
258
00:18:42,689 --> 00:18:45,586
A technician cuts a swatch
Of the sandpaper,
259
00:18:45,586 --> 00:18:49,172
Then peels away layers and makes
Three different cutouts --
260
00:18:49,172 --> 00:18:51,275
One of the cloth alone,
261
00:18:51,275 --> 00:18:54,103
Another of the cloth
With the adhesive coating,
262
00:18:54,103 --> 00:18:57,896
And a third, the grain-
And adhesive-coated cloth.
263
00:18:59,000 --> 00:19:00,482
He weighs each cutout
264
00:19:00,482 --> 00:19:03,724
To confirm that the sandpaper
Has been formulated
265
00:19:03,724 --> 00:19:05,379
Precisely to specification.
266
00:19:06,862 --> 00:19:10,241
He also examines the gritty
Surface under a microscope
267
00:19:10,241 --> 00:19:12,965
To make sure the grains
Are standing up evenly.
268
00:19:16,758 --> 00:19:19,310
This production run
Gets the go-ahead,
269
00:19:19,310 --> 00:19:20,862
So workers move the sandpaper
270
00:19:20,862 --> 00:19:22,655
Through
A hundred-yard-long oven.
271
00:19:24,862 --> 00:19:27,241
It has three
Different heating zones,
272
00:19:27,241 --> 00:19:29,482
Each progressively hotter.
273
00:19:29,482 --> 00:19:33,931
The increasing heat bakes
The grains into the adhesive.
274
00:19:37,448 --> 00:19:39,827
The sandpaper
Is now rough enough,
275
00:19:39,827 --> 00:19:42,137
But it's not quite ready
For use.
276
00:19:44,310 --> 00:19:46,068
In the next step,
277
00:19:46,068 --> 00:19:48,620
A coat of resin is rolled
Over the gritty surface,
278
00:19:48,620 --> 00:19:51,103
Binding the grains to the base.
279
00:19:51,103 --> 00:19:54,241
After the resin
Is cured to the surface,
280
00:19:54,241 --> 00:19:57,620
These jumbo rolls of sandpaper
Are stored in a warehouse
281
00:19:57,620 --> 00:20:00,137
Until it's time
To cut them down to size.
282
00:20:07,172 --> 00:20:09,827
Some rolls are sliced
Into big sheets.
283
00:20:09,827 --> 00:20:12,448
These will be made
Into commercial sanding belts --
284
00:20:12,448 --> 00:20:14,275
The kind used
In heavy manufacturing.
285
00:20:22,931 --> 00:20:26,068
Another machine
Punches out sanding discs.
286
00:20:33,517 --> 00:20:36,379
And at this station,
Four rolls of sandpaper
287
00:20:36,379 --> 00:20:40,000
Are simultaneously unwound
Into a machine.
288
00:20:40,000 --> 00:20:42,896
It carves the four layers
Into rectangles.
289
00:20:44,103 --> 00:20:46,827
These rectangles
Won't be used for sanding,
290
00:20:46,827 --> 00:20:49,310
But as grip tape
For skateboards.
291
00:20:51,068 --> 00:20:52,931
From refinishing your furniture
292
00:20:52,931 --> 00:20:55,241
To nose-grinding
At the skate park,
293
00:20:55,241 --> 00:20:57,793
Sandpaper
Will always give you an edge.
294
00:20:57,793 --> 00:21:00,379
And with so many grits
To choose from,
295
00:21:00,379 --> 00:21:03,482
There really is a sandpaper
For every job.
296
00:21:13,344 --> 00:21:15,448
If you have any comments
About the show,
297
00:21:15,448 --> 00:21:18,068
Or if you'd like to suggest
Topics for future shows,
298
00:21:18,068 --> 00:21:20,862
Drop us a line at...
23998
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