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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator:
It used to be that you stuffed
And mounted that big catch.
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Nowadays, catch-and-release
Is the norm,
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So the trend
Is to display replicas
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Of the prize fish you caught,
Photographed, then set free.
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It's more humane,
And you get to brag
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About the one that didn't
Get away until you let it.
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Sports fishermen aren't the
Only buyers of fish replicas.
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Marinas, seaquariums,
And seafood restaurants
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Also acquire them for display.
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While a replica
Is a humane alternative
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To mounting the real thing,
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One real fish does have to
Sacrifice his life for the cause
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In order to make the mold from
Which the replicas are cast.
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The first step
Is to surround the dead fish
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In a mix of soil and dirt.
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To construct
The first half of the mold,
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The artist builds the mix-up
To the halfway point,
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Then rinses the surface clean.
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Next, using molding plaster,
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He forms a ledge all around
The fish and under the fins.
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He positions six to eight tabs
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That will help
Align the two mold halves.
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Once the plaster hardens,
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He pins the fins steady
And pours on gelcoat resin.
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This material
Picks up the scales
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And other intricate details.
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Once the gelcoat cures,
He removes the pins,
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Then covers the surface
In fiberglass resin
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And over that,
Shredded fiberglass cloth.
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Then he applies another coat
Of fiberglass resin,
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Ensuring the cloth
Is thoroughly saturated.
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Once the resin hardens,
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He flips the fish
To the other side...
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...Breaks off the plaster,
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And repeats
All the previous steps
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To construct
The second half of the mold.
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After about four hours of labor,
The mold is finally finished.
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The mold maker removes the fish
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And washes
The now vacant cavity.
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Now the team
Can begin casting the replicas.
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They wax the cavity
To prevent sticking.
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00:03:11,620 --> 00:03:14,482
Then they apply
White gelcoat resin,
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Which picks up
All the fine details.
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With a handheld chopping gun,
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They lay down a layer
Of shredded fiberglass cloth.
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They apply resin putty along
The perimeter of the cavity
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On each mold half.
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Using the alignment tabs,
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They close and clamp
The mold halves together.
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Once the putty sets,
They remove the clamps,
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Open the mold, and extract
The fiberglass replica.
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Using a jigsaw,
They cut out the fish's mouth.
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Then via the mouth,
They fill the hollow interior
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With expanding
Polyurethane foam.
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The hard foam
Provides a solid base
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Against which
To sculpt the fish's mouth
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And set its eyes, fins,
And gill.
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With a jigsaw again, they remove
All the excess foam...
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...Then, with a disk sander,
Sand the rough edges smooth.
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Next, they glue a glass eye
On each side of the head
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And, using resin putty,
Set the side and bottom fins,
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Which they had removed at
One point and molded separately.
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They epoxy teeth into the mouth.
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The mold maker
Used the real fish teeth
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To make a rubber mold.
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Then, using that mold,
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He cast this replica set
Of teeth in plastic.
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Now they'll bring
The fish to life with color.
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First, using a paint gun,
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They apply
A coat of gray primer.
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Once that dries,
They apply a white base coat,
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Followed by a coat of silver.
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With an airbrush,
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An artist paints
The subtle shades and markings
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That make this fake fish
Look so incredibly real.
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The finishing touch --
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They paint
A piece of cardboard red,
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Cut it into the shape of a gill,
Then glue it in place.
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After 45 hours
Of casting and painting,
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This prized catch
Is ready for display.
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Narrator:
Siren systems were first
Widely used during world war ii
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To warn of possible air attacks.
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Early on, that wailing effect
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Was generated by forcing air
Against a perforated disk.
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Today's siren sounds
Emanate from higher-tech systems
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And still mean
Trouble is on its way.
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[ siren wailing ]
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From atop towers and buildings,
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Siren systems
Warn surrounding communities
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Of impending tornadoes, floods,
Or any calamity.
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Today's sirens
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Can broadcast both warning tones
And live voice messages.
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They can also be activated
By remote control
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From anywhere in the world.
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The messages and warning tones
From a typical system
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Can be heard
From almost half a mile away.
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[ siren wailing ]
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Production begins with the
Transformers for the amplifiers.
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A worker winds
Thick, insulated copper wires
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Around a plastic bobbin
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To produce
The transformer's primary coil.
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She compresses the wires
To eliminate gaps.
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A tight winding is critical
For generating a magnetic field
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And transferring it
To a secondary coil.
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She wraps insulating tape
Around the primary coil.
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She winds thin wire over it
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To produce
The narrower secondary coil,
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And she encases that
In more insulating tape.
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Next, with swift dexterity,
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An employee
Stacks e-shaped iron insulators
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In the center of the bobbin
To build a core.
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She inserts
Smaller iron insulators
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Between the e-shaped ones,
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And this tightens up the pack.
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She taps them into place
And now has a dense iron core
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That will aid the flow of energy
Between the transformer coils.
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With an enamel coating baked on
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And the assembly
Wired for sound,
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This siren transformer
Is now complete.
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A computer-operated machine
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Now punch-cuts assembly holes
In an aluminum panel
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That will be used for
A section of the siren cabinet.
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A robot transfers the panel to
A computerized bending machine.
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Another robot feeds the panel
To a clamping bar
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And, using hydraulic might,
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Bends it against the clamp
In strategic locations.
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This transforms it
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Into a section of
The siren's back and sidewalls.
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It also folds the edges,
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Creating flanges
For the cabinet-door assembly.
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This computerized system
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Takes less than a minute
To complete all these folds.
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The robot then
Transfers the siren-cabinet part
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To a conveyor,
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And it's on to the next station
For assembly.
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Ahead, some cabinet brackets
Are in the wash zone.
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As the parts travel through,
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They get a soapy spray
And then a rinse.
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After drying, the parts
Head into a powder-paint booth.
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Sprayers apply dry powder paint
To the surface of the parts.
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It takes eight automated guns
And two manually operated ones
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To evenly coat these brackets.
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The paint is electrostatically
Charged to cling to the metal,
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But at this point
Can be rubbed off like dust.
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Baking it causes the particles
To melt and bond to the surface
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For a smooth
And very tough paint job.
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This worker now installs the
Siren system's control board.
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It regulates
The siren's six tones,
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16 prerecorded messages,
And the public-address function.
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He bolts it to the inside
Of the cabinet door.
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Next up is an amplifier
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Equipped with the transformer
We saw assembled earlier
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And the amplifier board.
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He installs the completed
Amplifier in the cabinet
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And connects it
To the control board.
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There are five amplifiers
In this siren system --
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One for each speaker
On the tower.
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He equips it with a control pad
For on-site activation.
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Then a 1,650-ton press
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Injects hot liquid plastic
Into molds.
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In seconds, the plastic cools,
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And the press retracts
To reveal the new speaker parts.
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They bolt
The speaker halves together,
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Install the screen through
Which the siren sound emanates,
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And top it off
With a plastic cap.
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They install a 400-watt driver
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In each section
Of the siren's speakers.
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The more speakers there are
Atop the siren tower,
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The greater the reach.
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The most powerful
Can be heard many miles away.
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Emergency vehicles
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Are equipped with smaller
Versions of these systems
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To warn motorists
Of their speedy approach,
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And the concept
Is basically the same --
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To get your instant attention.
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[ siren wailing ]
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Narrator: in today's
Hustle-and-bustle world,
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It's not uncommon
To forgo brown-bagging it
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And instead
To grab a meal on the go.
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It's not surprising
To see that food retailers,
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From mega supermarkets
To tiny convenience stores,
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Carry prepackaged sandwiches for
The hungry-in-a-hurry customer.
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Ham and cheese,
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Cheese and tomato,
Chicken salad --
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Just a few
Of the many sandwich varieties
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You can buy ready-made.
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Retail customers specify
Which ingredients they want
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In their sandwich order,
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And the factory sets up
The assembly lines accordingly.
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The first step is to load fresh
Bread into an automated machine.
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While doing so,
They visually inspect the slices
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00:11:36,965 --> 00:11:40,241
And remove any
With holes or other flaws.
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The machine separates the slices
In the loaf.
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Then, because
This sandwich requires it,
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An internal roller
Spreads melted butter.
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The machine then
Drops the buttered slices faceup
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Onto the belt that moves
Through the production line,
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Where first,
An automated depositor
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Squirts on the quantity
And type of mayonnaise
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The customer requested.
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Workers manually lay on
The more specific ingredients,
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Such as cold cuts
Or grated cheddar cheese.
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In the prep area,
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Workers
Load logs of ham into a slicer.
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The customer has specified
The size and weight
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Of the slices
It wants in the sandwich,
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And the factory
Programs the slicer accordingly.
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The slices go off
To the assembly line,
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Where workers
Add them to the sandwiches.
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Next,
They close up the sandwiches.
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They stack the sandwiches
In piles of two.
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The belt
Then brings the sandwiches
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To a mechanized cutter.
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The cutter
Works like a reciprocating saw,
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The vertical blade
Oscillating at high speed
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As the sandwich
Travels through it.
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00:13:16,137 --> 00:13:18,034
The stacked halves on each side
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00:13:18,034 --> 00:13:20,517
Will be packaged together
As one sandwich.
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Some of the sandwich varieties
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Produced
In the largest quantities
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Are made on a fully automated
Assembly line.
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A robot suctions up bread slices
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00:13:33,862 --> 00:13:37,137
And places them
On a moving belt.
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Positioning plates
Descend and adjust the slices
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So that they'll be perfectly
Centered under the nozzles,
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00:13:50,137 --> 00:13:53,310
Which dispense
The sandwich ingredients.
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In production here,
Egg-salad sandwiches.
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A nozzle deposits a set quantity
Of chopped egg with mayonnaise
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On every second slice.
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At the next station,
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00:14:16,758 --> 00:14:19,068
Robotic arms
Lined with suction cups
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Grab the empty slices
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00:14:20,724 --> 00:14:23,827
And flip them over
Onto the filled slices.
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00:14:25,137 --> 00:14:28,241
Next stop, an ultrasonic knife.
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It slices the sandwiches in two
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00:14:31,103 --> 00:14:35,275
Using vibrations produced
By high-frequency sound waves.
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00:14:35,275 --> 00:14:38,310
This cutting method
Gives a cleaner edge.
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00:14:38,310 --> 00:14:42,103
Next, robotic arms
Pick up half of each sandwich,
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00:14:42,103 --> 00:14:45,896
Spin it around, and stack it
Onto the other half.
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00:14:47,310 --> 00:14:50,310
A robot grabs four
Finished sandwiches at a time
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And puts them
In triangular, plastic trays,
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00:14:53,103 --> 00:14:56,689
Which then move on to the
Sealing and labeling stations.
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00:15:05,241 --> 00:15:07,931
Back on the
Semi-automated assembly line,
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00:15:07,931 --> 00:15:10,379
Workers
Stack the sandwiches manually
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And place them
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00:15:11,689 --> 00:15:15,482
In individual plastic-lined
Cardboard packages.
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00:15:18,586 --> 00:15:21,310
A conveyor belt
Brings them to a machine,
250
00:15:21,310 --> 00:15:24,655
Which pushes down the top flap
And heat-seals it shut.
251
00:15:25,896 --> 00:15:30,310
The sandwiches hit store shelves
Within 12 hours of production.
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00:15:30,310 --> 00:15:33,620
They stay fresh
For an additional three days,
253
00:15:33,620 --> 00:15:37,517
After which the sandwich company
Removes the unsold ones
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00:15:37,517 --> 00:15:41,034
While making its daily delivery
Of new ones.
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00:15:50,655 --> 00:15:53,517
Narrator: before the invention
Of electrical lighting,
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00:15:53,517 --> 00:15:55,724
Candlesticks
Were household essentials.
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00:15:55,724 --> 00:16:00,000
They often had shiny flanges to
Reflect the light of the flame
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00:16:00,000 --> 00:16:01,896
And throw the glow farther.
259
00:16:01,896 --> 00:16:04,758
Necessity may have been
The reason for their invention,
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00:16:04,758 --> 00:16:08,275
But candlesticks soon evolved
Into a thing of beauty.
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00:16:11,034 --> 00:16:12,862
With their elegant curves,
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00:16:12,862 --> 00:16:16,827
These pewter candlesticks add
A touch of class to any decor.
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00:16:16,827 --> 00:16:20,655
Top them off with lit candles,
And the ambiance improves,
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00:16:20,655 --> 00:16:22,827
Which is why
People still use candlesticks
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00:16:22,827 --> 00:16:25,551
To both decorate and illuminate.
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00:16:25,551 --> 00:16:28,620
This candlestick
Starts with a flat pewter disk.
267
00:16:28,620 --> 00:16:31,310
The worker stamps
The company insignia onto it.
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00:16:31,310 --> 00:16:33,379
He loads the stamped disk
Into a lathe
269
00:16:33,379 --> 00:16:36,379
Against a flared form
Known as the chuck --
270
00:16:36,379 --> 00:16:40,206
A kind of template
For the base of the candlestick.
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00:16:40,206 --> 00:16:42,586
He rubs a wax-like lubricant
Onto the pewter
272
00:16:42,586 --> 00:16:44,103
To reduce friction,
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00:16:44,103 --> 00:16:48,448
While he works the metal as it
Spins very fast on the lathe.
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00:16:48,448 --> 00:16:50,793
He exerts
A fair amount of pressure
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00:16:50,793 --> 00:16:52,413
With a finger-shaped tool
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00:16:52,413 --> 00:16:56,275
To make the pewter conform
To the shape of the chuck.
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00:16:56,275 --> 00:16:57,965
This process is called spinning.
278
00:16:57,965 --> 00:17:00,862
It takes a series of passes
With the tool
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00:17:00,862 --> 00:17:02,689
To transform the flat disk
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00:17:02,689 --> 00:17:05,517
Into the basic shape
Of a candlestick base.
281
00:17:05,517 --> 00:17:09,000
He trims the bottom to
Make the part perfectly level.
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00:17:09,000 --> 00:17:11,413
Now, with a wooden dowel,
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00:17:11,413 --> 00:17:13,551
He rolls the bottom
Of the candlestick base
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00:17:13,551 --> 00:17:15,655
To make it more substantial.
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00:17:15,655 --> 00:17:18,448
The base now complete,
He sets it aside.
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00:17:18,448 --> 00:17:22,241
He now works a smaller pewter
Disk against a different chuck
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00:17:22,241 --> 00:17:25,586
To shape the candlestick top,
Which is called the bobeche.
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00:17:25,586 --> 00:17:28,724
He flares the bobeche,
Creating a flange
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00:17:28,724 --> 00:17:32,103
To reflect candlelight
And catch wax drippings.
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00:17:32,103 --> 00:17:34,965
Using the chuck,
Pictured on the left,
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00:17:34,965 --> 00:17:37,896
He's produced
A stylish candlestick top.
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00:17:37,896 --> 00:17:40,137
To make the candlestick post,
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00:17:40,137 --> 00:17:44,000
The next worker melts pewter
And skims off the impurities.
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00:17:44,000 --> 00:17:46,275
He pours the molten pewter
Into a mold,
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00:17:46,275 --> 00:17:48,482
And it solidifies quickly.
296
00:17:48,482 --> 00:17:51,137
He drains
The remaining liquid pewter
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00:17:51,137 --> 00:17:54,344
And opens the mold,
Revealing a hollow post
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00:17:54,344 --> 00:17:57,965
That matches the top and base
Of the candlestick.
299
00:17:59,448 --> 00:18:02,000
Pewter is also
Hardened in the channel
300
00:18:02,000 --> 00:18:03,620
Through which it was poured.
301
00:18:03,620 --> 00:18:08,000
This extra material, called
Sprue, will be removed later.
302
00:18:12,724 --> 00:18:14,379
Over at the next station,
303
00:18:14,379 --> 00:18:16,724
A worker
Removes a seam-like ridge
304
00:18:16,724 --> 00:18:19,931
Created where the parts
Of the mold came together.
305
00:18:19,931 --> 00:18:23,172
He scrapes and files the ridge
To even the surface.
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00:18:25,344 --> 00:18:28,103
On the left,
You can see the candlestick post
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00:18:28,103 --> 00:18:30,068
Before the ridge removal.
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00:18:30,068 --> 00:18:32,310
And this is the part afterward.
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00:18:32,310 --> 00:18:36,586
Another worker now slices off
The sprue ends with a band saw,
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00:18:36,586 --> 00:18:38,931
Leaving the post design intact.
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00:18:41,896 --> 00:18:46,758
The pewter sprues
Will be remelted and reused.
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00:18:50,241 --> 00:18:53,655
Next, the worker
Clamps the post into position,
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00:18:53,655 --> 00:18:57,172
And a paddle drill bores
Into one end and then the other.
314
00:18:57,172 --> 00:18:59,689
It slopes the lip
Of the casting inward,
315
00:18:59,689 --> 00:19:01,551
Creating a chamfered edge
316
00:19:01,551 --> 00:19:04,586
That will connect neatly
To the candlestick top and base.
317
00:19:09,275 --> 00:19:11,379
He slides a rod
Through the casting
318
00:19:11,379 --> 00:19:12,724
To better grip the part
319
00:19:12,724 --> 00:19:16,137
As he presses it
Against a fine-grit sand belt.
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00:19:16,137 --> 00:19:19,862
The sanding process
Removes scuffs and scrapes,
321
00:19:19,862 --> 00:19:22,344
And the result is satiny-smooth.
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00:19:24,206 --> 00:19:26,000
Now it's time
For this pewter candlestick
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00:19:26,000 --> 00:19:27,724
To come together.
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00:19:27,724 --> 00:19:30,655
He places the post
On the candlestick top
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00:19:30,655 --> 00:19:33,068
And solders them together.
326
00:19:33,068 --> 00:19:35,034
The tin-alloy solder wire melts
327
00:19:35,034 --> 00:19:38,241
And acts like hot glue
To bond the two parts.
328
00:19:39,896 --> 00:19:44,103
He moves the candlestick base
Into position.
329
00:19:46,000 --> 00:19:49,793
He dips the open end of the
Cast post into a flux substance
330
00:19:49,793 --> 00:19:53,379
To prepare the surface
And transfers it to the base.
331
00:19:54,724 --> 00:19:58,482
As he solders the two,
He taps the post with the torch
332
00:19:58,482 --> 00:20:01,482
To realign it
When it slips a bit.
333
00:20:01,482 --> 00:20:03,793
Then he continues soldering.
334
00:20:05,517 --> 00:20:09,551
He now dips the completed
Candlestick in soapy water.
335
00:20:09,551 --> 00:20:13,620
This removes flux residue
And hardens the solder bond.
336
00:20:14,827 --> 00:20:16,655
For a highly polished finish,
337
00:20:16,655 --> 00:20:20,275
He presses the candlestick
Against a spinning cotton wheel
338
00:20:20,275 --> 00:20:22,724
That rubs
A special compound onto it.
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00:20:22,724 --> 00:20:26,551
It's a shinier alternative
To the satin-pewter candlestick,
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00:20:26,551 --> 00:20:29,068
And the effect
Is similar to silver.
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00:20:31,517 --> 00:20:35,862
When it comes to candlesticks,
Two are always better than one,
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00:20:35,862 --> 00:20:38,793
So it's time to pair them up.
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00:20:38,793 --> 00:20:41,068
Together, they'll really shine.
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00:20:51,689 --> 00:20:54,034
If you have any comments
About the show,
345
00:20:54,034 --> 00:20:56,896
Or if you'd like to suggest
Topics for future shows
346
00:20:56,896 --> 00:20:59,241
Drop us a line at...
28148
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