Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:03,070 --> 00:00:05,738
Narrator: A gadget that's been
in everyone's pocket
2
00:00:05,740 --> 00:00:09,775
Since the turn of the century
is getting an upgrade.
3
00:00:13,147 --> 00:00:17,683
The journey to deep space
is under way.
4
00:00:20,388 --> 00:00:23,455
The world's most successful
chocolate bar
5
00:00:23,457 --> 00:00:25,524
Is breaking with tradition.
6
00:00:28,396 --> 00:00:31,897
And one of the fastest
production lines in the world
7
00:00:31,899 --> 00:00:35,534
Is cooking up
an unlikely product.
8
00:00:35,536 --> 00:00:38,937
These groundbreaking innovations
are all taking place
9
00:00:38,939 --> 00:00:42,441
Inside some of the most
incredible factories
10
00:00:42,443 --> 00:00:43,709
On the planet.
11
00:00:43,711 --> 00:00:46,712
-- Captions by vitac --
www.Vitac.Com
12
00:00:46,714 --> 00:00:49,748
Captions paid for by
discovery communications
13
00:00:59,727 --> 00:01:02,961
Nestled in the slopes
of the swiss alps,
14
00:01:02,963 --> 00:01:08,434
A company is making one of the
world's most iconic products.
15
00:01:08,436 --> 00:01:12,838
Victorinox is the leading
manufacturer of pocketknives,
16
00:01:12,840 --> 00:01:17,843
Including the one
and only swiss army knife.
17
00:01:17,845 --> 00:01:20,746
In their sustainable
super factory,
18
00:01:20,748 --> 00:01:23,749
Victorinox makes these
pocket-sized toolkits
19
00:01:23,751 --> 00:01:28,887
By the million
and sells them to 120 countries.
20
00:01:28,889 --> 00:01:31,890
Think of a rolex watch
that is extremely expensive
21
00:01:31,892 --> 00:01:36,095
And has that miniaturization
and key specialist engineering.
22
00:01:36,097 --> 00:01:37,196
Another example
23
00:01:37,198 --> 00:01:38,964
Is a top-of-the-range
swiss army knife,
24
00:01:38,966 --> 00:01:42,501
A hugely premium product
that can set you back $500.
25
00:01:43,671 --> 00:01:47,673
Narrator: Victorinox got their
start in the late 19th century.
26
00:01:49,977 --> 00:01:54,880
It all began in 1884 when
karl elsener and his mother
27
00:01:54,882 --> 00:01:58,484
Opened a cutlery workshop,
where they made knives.
28
00:01:58,486 --> 00:02:01,453
In 1891, the swiss army
commissioned
29
00:02:01,455 --> 00:02:03,789
A purpose-built knife.
30
00:02:03,791 --> 00:02:07,793
It had specific requirements,
such as allowing the soldier
31
00:02:07,795 --> 00:02:12,064
To dismantle their rifle,
to open cans,
32
00:02:12,066 --> 00:02:15,367
And, of course,
to fight in battle.
33
00:02:15,369 --> 00:02:17,569
Elsener won the contract
34
00:02:17,571 --> 00:02:20,806
And designed the officers'
and the sports knife.
35
00:02:22,543 --> 00:02:26,078
Narrator: Fourth-generation
family member carl elsener
36
00:02:26,080 --> 00:02:27,646
Now runs the company.
37
00:02:48,435 --> 00:02:53,172
Today, 850 people work
at the victorinox factory,
38
00:02:53,174 --> 00:02:55,541
Manufacturing swiss army knives
39
00:02:55,543 --> 00:02:59,178
Using methods that date back
100 years.
40
00:02:59,180 --> 00:03:04,183
And an incredible 50%
of the process is done by hand.
41
00:03:05,286 --> 00:03:07,352
It all begins with a coil
42
00:03:07,354 --> 00:03:10,622
Of 3-millimeter-thick
stainless steel.
43
00:03:10,624 --> 00:03:16,161
Wyss: We use 2,500 tons
of steel in the production.
44
00:03:16,163 --> 00:03:18,430
Narrator: Each roll
contains enough steel
45
00:03:18,432 --> 00:03:20,832
To make 16,000 blades.
46
00:03:20,834 --> 00:03:24,303
It will become a little bit
noisier inside here.
47
00:03:26,540 --> 00:03:28,240
Narrator: This is the heart
48
00:03:28,242 --> 00:03:30,442
Of the swiss army knife
assembly.
49
00:03:30,444 --> 00:03:34,012
Here, rolls of steel
are fed into metal presses
50
00:03:34,014 --> 00:03:36,815
To create the knife's
individual components.
51
00:03:38,085 --> 00:03:42,254
Here in this area, these are
all different stamping machines
52
00:03:42,256 --> 00:03:45,290
Where we produce all parts,
53
00:03:45,292 --> 00:03:50,028
Which will be one day
in a swiss army knife.
54
00:03:50,030 --> 00:03:54,833
So blade, can openers, scissors,
on and on.
55
00:03:57,805 --> 00:03:58,937
Narrator: The raw steel
56
00:03:58,939 --> 00:04:00,973
Is pulled through
a stamping machine,
57
00:04:00,975 --> 00:04:04,509
Which uses 154 tons of pressure
58
00:04:04,511 --> 00:04:07,813
To punch out
thousands of individual pieces.
59
00:04:07,815 --> 00:04:12,751
♪♪
60
00:04:12,753 --> 00:04:17,222
This is a little bit of special
stamping machine.
61
00:04:17,224 --> 00:04:22,261
It stamps out our famous emblem,
the cross and shield,
62
00:04:22,263 --> 00:04:25,597
Which comes
to every swiss army knife.
63
00:04:27,268 --> 00:04:30,435
One stamping machine
can produce
64
00:04:30,437 --> 00:04:33,438
Up to 60,000 blades a day.
65
00:04:42,283 --> 00:04:46,051
Narrator: At every stage,
sustainability is key
66
00:04:46,053 --> 00:04:48,186
And minimizing waste
67
00:04:48,188 --> 00:04:50,922
Is a high priority
for victorinox.
68
00:04:52,493 --> 00:04:55,060
Wyss: The waste we collect
in these boxes,
69
00:04:55,062 --> 00:04:59,031
We give back to the suppliers
for recycling.
70
00:04:59,033 --> 00:05:03,435
Narrator: More than half
of the 2,756 tons of steel
71
00:05:03,437 --> 00:05:06,171
Used each year is recycled.
72
00:05:10,477 --> 00:05:13,712
Around 600 tons of grinding
sludge is produced
73
00:05:13,714 --> 00:05:17,582
As a by-product
in the processing of this steel.
74
00:05:17,584 --> 00:05:21,019
The water contained
in the sludge is absorbed
75
00:05:21,021 --> 00:05:24,089
And the steel particles
are pressed into briquettes,
76
00:05:24,091 --> 00:05:27,726
Allowing them
to be properly recycled.
77
00:05:27,728 --> 00:05:31,830
There are also nearly 14,000
square feet of solar panels
78
00:05:31,832 --> 00:05:35,567
On the factory's roof that
help reduce energy consumption.
79
00:05:39,573 --> 00:05:41,540
It's not just green.
80
00:05:41,542 --> 00:05:44,209
It's also steeped in history.
81
00:05:44,211 --> 00:05:48,179
Traditional production methods
haven't changed for generations.
82
00:05:48,181 --> 00:05:52,117
Some of the machines
are over 50 years old.
83
00:05:52,119 --> 00:05:54,720
After the blades
and accessories are cut,
84
00:05:54,722 --> 00:05:58,023
The edges still remain rough,
so they're processed
85
00:05:58,025 --> 00:06:01,593
Through a mix
of vibrating stones and water.
86
00:06:01,595 --> 00:06:05,130
The friction produced
cleans and polishes the steel.
87
00:06:07,201 --> 00:06:10,469
After five hours in the mix,
a powerful magnet
88
00:06:10,471 --> 00:06:12,637
Pulls the parts out of the bowl.
89
00:06:12,639 --> 00:06:19,077
♪♪
90
00:06:25,953 --> 00:06:27,853
They may be polished,
91
00:06:27,855 --> 00:06:30,856
But the parts are not yet
strong enough to use.
92
00:06:32,860 --> 00:06:34,593
So they're sent
93
00:06:34,595 --> 00:06:39,464
To a 1,922-degree-fahrenheit
furnace to harden.
94
00:06:39,466 --> 00:06:44,202
This crucial step ensures
the knives will last a lifetime.
95
00:06:45,906 --> 00:06:47,105
At this temperature,
96
00:06:47,107 --> 00:06:49,474
The molecular structure
of steel changes,
97
00:06:49,476 --> 00:06:51,009
Making it stronger.
98
00:06:51,011 --> 00:06:54,913
Only steel that's high in carbon
can be hardened and tempered.
99
00:06:54,915 --> 00:06:57,849
If it doesn't contain the
necessary quantity of carbon,
100
00:06:57,851 --> 00:07:00,185
Then its crystalline structure
can't be broken.
101
00:07:00,187 --> 00:07:03,789
Therefore, its physical makeup
can't be altered.
102
00:07:03,791 --> 00:07:06,224
Narrator: Each blade has
a different function.
103
00:07:06,226 --> 00:07:09,528
So every one of them requires
a different hardness.
104
00:07:34,788 --> 00:07:40,025
There are 400 different knife
models in production today.
105
00:07:40,027 --> 00:07:43,895
Over the last few decades,
extra gadgets have been added,
106
00:07:43,897 --> 00:07:47,232
Including cigar cutters,
nail files,
107
00:07:47,234 --> 00:07:49,534
And a usb memory stick.
108
00:07:51,238 --> 00:07:55,340
Nasa even equips its astronauts
with swiss army knives.
109
00:08:10,591 --> 00:08:16,061
The steel is now hardened,
but it's still only roughly cut,
110
00:08:16,063 --> 00:08:18,964
So it's placed on a turntable
and rotated
111
00:08:18,966 --> 00:08:22,434
Under a grinding stone
until it's the right size.
112
00:08:24,238 --> 00:08:26,872
Then it drops through
to the collection bowl.
113
00:08:58,105 --> 00:09:00,171
If the proportions of each part
114
00:09:00,173 --> 00:09:03,708
Deviate more than
0.02 millimeters,
115
00:09:03,710 --> 00:09:06,645
They will not fit together
in the handle.
116
00:09:06,647 --> 00:09:12,050
After the blades are sharpened,
every part must pass inspection.
117
00:09:12,052 --> 00:09:16,555
Only then is the company name
stamped on the base.
118
00:09:18,959 --> 00:09:21,226
The knife is ready
to be assembled,
119
00:09:21,228 --> 00:09:23,895
And despite
today's age of robotics,
120
00:09:23,897 --> 00:09:27,832
This process is
mostly done by hand.
121
00:09:27,834 --> 00:09:30,669
People are better than robots
at complex tasks
122
00:09:30,671 --> 00:09:32,871
That require manipulation
123
00:09:32,873 --> 00:09:35,473
And also hand-making
or handcrafting something
124
00:09:35,475 --> 00:09:37,509
Carries a premium.
125
00:09:37,511 --> 00:09:40,679
People aspire to having
a handmade item
126
00:09:40,681 --> 00:09:43,815
Which carries
some kind of cachet.
127
00:09:43,817 --> 00:09:46,618
Narrator: The different tools
are added one by one,
128
00:09:46,620 --> 00:09:50,288
Along with springs
that allow them to come forward.
129
00:09:50,290 --> 00:09:52,324
Can opener...
130
00:09:52,326 --> 00:09:54,426
Screwdriver...
131
00:09:54,428 --> 00:09:56,962
Multi-purpose hook...
132
00:09:56,964 --> 00:09:58,763
Scissors...
133
00:09:58,765 --> 00:10:00,532
Wood saw...
134
00:10:00,534 --> 00:10:02,033
And corkscrew.
135
00:10:02,035 --> 00:10:04,436
All these essential tools
136
00:10:04,438 --> 00:10:07,138
Are micro-engineered
into the knife.
137
00:10:09,910 --> 00:10:13,144
And it wouldn't be an authentic
swiss army knife
138
00:10:13,146 --> 00:10:16,548
Without the famous red handle.
139
00:10:16,550 --> 00:10:18,650
The tool bundle
is placed on a machine
140
00:10:18,652 --> 00:10:22,621
That sandwiches it between
the two iconic red handles.
141
00:10:22,623 --> 00:10:25,757
Incredibly, for this knife,
all nine tools
142
00:10:25,759 --> 00:10:30,128
Are packed into
the 2.5-centimeter-thick handle.
143
00:10:41,775 --> 00:10:45,510
Victorinox sells each knife
with a lifetime guarantee.
144
00:10:49,650 --> 00:10:53,918
So all tools are checked
by hand before being shipped.
145
00:10:57,658 --> 00:11:00,625
This sustainable super factory
is leading the way
146
00:11:00,627 --> 00:11:02,961
In greener metal manufacturing.
147
00:11:04,598 --> 00:11:07,032
Their meticulous attention
to detail
148
00:11:07,034 --> 00:11:09,067
And traditional craftsmanship
149
00:11:09,069 --> 00:11:11,536
Mean victorinox will keep
this small town
150
00:11:11,538 --> 00:11:15,907
In central switzerland
bustling for years to come.
151
00:11:18,912 --> 00:11:23,314
Coming up, scientists
in one futuristic factory
152
00:11:23,316 --> 00:11:26,317
Are shooting for the moon
and beyond
153
00:11:26,319 --> 00:11:29,754
As they build the world's
most advanced rocket.
154
00:11:29,756 --> 00:11:35,093
And later, a famous chocolate
bar is breaking with tradition.
155
00:11:52,612 --> 00:11:55,580
Narrator: In new orleans
lies a super factory
156
00:11:55,582 --> 00:11:58,683
On a truly gigantic scale.
157
00:11:58,685 --> 00:12:03,688
The innovative product created
here takes years to assemble,
158
00:12:03,690 --> 00:12:05,957
Costs billions of dollars,
159
00:12:05,959 --> 00:12:10,095
And then self-destructs
in just eight minutes.
160
00:12:14,901 --> 00:12:18,403
Since 2011,
nasa has been hard at work
161
00:12:18,405 --> 00:12:21,206
On the space launch system,
or sls.
162
00:12:21,208 --> 00:12:24,609
This advanced
space launch vehicle
163
00:12:24,611 --> 00:12:26,344
Will be able to send astronauts
164
00:12:26,346 --> 00:12:30,715
And cargo to the moon
on a single mission.
165
00:12:30,717 --> 00:12:34,185
But it will also have the power
to go beyond the moon,
166
00:12:34,187 --> 00:12:37,822
To explore destinations
far into the solar system
167
00:12:37,824 --> 00:12:41,659
And even land a crew on mars.
168
00:12:41,661 --> 00:12:45,964
Rockets are the most
complex machines
169
00:12:45,966 --> 00:12:49,267
Ever devised by human beings.
170
00:12:49,269 --> 00:12:52,570
Narrator: The key part to
getting the sls into space
171
00:12:52,572 --> 00:12:54,339
Is under construction here
172
00:12:54,341 --> 00:12:59,043
At nasa's michoud
assembly facility.
173
00:12:59,045 --> 00:13:00,512
Michoud has been
building rockets
174
00:13:00,514 --> 00:13:05,817
Since the dawn of the space age
in the 1950s.
175
00:13:05,819 --> 00:13:08,720
And their futuristic
super factory
176
00:13:08,722 --> 00:13:13,525
Now covers almost
183,000 square feet,
177
00:13:13,527 --> 00:13:17,529
More than 31 football fields
combined.
178
00:13:17,531 --> 00:13:21,132
Over 1,000 manufacturers
from all over the u.S.
179
00:13:21,134 --> 00:13:24,102
Are getting the various
sls parts ready
180
00:13:24,104 --> 00:13:26,137
Before it is eventually
assembled
181
00:13:26,139 --> 00:13:28,640
At kennedy space center
in florida.
182
00:13:28,642 --> 00:13:31,543
Here at michoud, they're making
the largest section
183
00:13:31,545 --> 00:13:34,379
Of the rocket -- the core.
184
00:13:34,381 --> 00:13:37,382
It will hold the liquid hydrogen
and oxygen
185
00:13:37,384 --> 00:13:40,952
That feed the four engines
powering the rocket.
186
00:13:40,954 --> 00:13:44,389
The core stage is comprised
of five major segments.
187
00:13:44,391 --> 00:13:45,790
That's the engine section.
188
00:13:45,792 --> 00:13:48,927
The liquid hydrogen tank,
the intertank,
189
00:13:48,929 --> 00:13:51,296
The liquid oxygen tank,
and the forward skirt.
190
00:13:51,298 --> 00:13:53,731
Now, that's not
the completed rocket in itself,
191
00:13:53,733 --> 00:13:55,867
But it is if you want to imagine
the muscle
192
00:13:55,869 --> 00:13:59,304
Behind what gets us
to the moon and beyond.
193
00:13:59,306 --> 00:14:02,473
Narrator: This complex
of over 200-foot-high tanks
194
00:14:02,475 --> 00:14:05,343
That fuel
four liquid propellant engines
195
00:14:05,345 --> 00:14:08,479
Will be capable of blasting
the rocket into orbit
196
00:14:08,481 --> 00:14:13,451
With over 1,984,000
pounds of thrust,
197
00:14:13,453 --> 00:14:18,323
Allowing it to reach speeds
of over 24,000 miles per hour.
198
00:14:18,325 --> 00:14:23,394
♪♪
199
00:14:23,396 --> 00:14:26,698
The effects of this massive
surge of power
200
00:14:26,700 --> 00:14:29,868
Are being observed
on the michoud engine test bay.
201
00:14:29,870 --> 00:14:33,304
And the test confirms just
how challenging this project
202
00:14:33,306 --> 00:14:37,008
Will be for the michoud
rocket scientists.
203
00:14:37,010 --> 00:14:39,210
The fuel tanks need to be
as light as possible,
204
00:14:39,212 --> 00:14:41,279
But still be able to resist
incredible heat
205
00:14:41,281 --> 00:14:43,248
Generated during liftoff.
206
00:14:43,250 --> 00:14:45,250
What they need to get right
are the domes.
207
00:14:45,252 --> 00:14:48,019
These are the sections
which seal the fuel tanks
208
00:14:48,021 --> 00:14:50,288
At the top and the bottom.
209
00:14:50,290 --> 00:14:53,725
Narrator: Some extra-strength
machinery is on site to help
210
00:14:53,727 --> 00:14:56,261
With the heavy lifting.
211
00:14:56,263 --> 00:14:59,631
As we're nearing the completion
of the forward dome
212
00:14:59,633 --> 00:15:02,433
For the liquid hydrogen tank,
some of our mechanics here
213
00:15:02,435 --> 00:15:05,003
Are using
this overhead lifting tool.
214
00:15:05,005 --> 00:15:07,505
And once we've completed
with the weld series,
215
00:15:07,507 --> 00:15:10,074
We will remove this dome
from the tool,
216
00:15:10,076 --> 00:15:12,377
Take it to the far end
of our factory.
217
00:15:12,379 --> 00:15:13,945
And yet another larger
welding tool
218
00:15:13,947 --> 00:15:16,948
Where we will fully assemble
a completed fuel tank.
219
00:15:18,618 --> 00:15:23,054
Narrator: This is the biggest
welding machine in the world.
220
00:15:23,056 --> 00:15:25,590
All of the domes,
rings and barrels
221
00:15:25,592 --> 00:15:31,429
That make up the 171-foot-tall
and 79-foot-wide rocket core
222
00:15:31,431 --> 00:15:34,532
Are welded together
section by section
223
00:15:34,534 --> 00:15:37,502
On this colossal vertical
assembly rig.
224
00:15:40,240 --> 00:15:42,206
Once it's blasted off
from earth,
225
00:15:42,208 --> 00:15:44,409
The core has a life span
of about eight minutes.
226
00:15:44,411 --> 00:15:46,945
After that, it's jettisoned
from the rest of the rocket
227
00:15:46,947 --> 00:15:50,114
And falls back down to earth,
where it lands in the ocean.
228
00:15:50,116 --> 00:15:52,850
Narrator:
The rocket scientists at michoud
229
00:15:52,852 --> 00:15:54,819
Are no strangers to spaceflight.
230
00:15:54,821 --> 00:15:58,790
12, 11, 10, 9...
231
00:15:58,792 --> 00:16:00,858
This super factory
has been central
232
00:16:00,860 --> 00:16:05,063
To america's space program
for more than 50 years.
233
00:16:05,065 --> 00:16:08,333
We have a liftoff.
Liftoff on apollo 11.
234
00:16:08,335 --> 00:16:10,635
Whipps:
We made both gemini spacecraft,
235
00:16:10,637 --> 00:16:13,972
Particularly the first-stage
rockets and the early apollo.
236
00:16:13,974 --> 00:16:16,407
And finally, all the apollo
first-stage rockets
237
00:16:16,409 --> 00:16:18,943
Called the massive saturn 1-c
238
00:16:18,945 --> 00:16:21,212
That took our astronauts
to the moon.
239
00:16:21,214 --> 00:16:24,749
Armstrong:
That's one small step for man.
240
00:16:24,751 --> 00:16:27,452
One giant leap for mankind.
241
00:16:29,022 --> 00:16:31,189
Narrator:
After the final apollo mission,
242
00:16:31,191 --> 00:16:33,424
The factory refocused
its efforts
243
00:16:33,426 --> 00:16:35,126
Towards the space shuttle.
244
00:16:37,163 --> 00:16:40,264
Whipps: From the middle '70s
through 2011,
245
00:16:40,266 --> 00:16:42,900
A total of 138 external tanks
246
00:16:42,902 --> 00:16:46,504
For the space shuttle
were all fabricated here
247
00:16:46,506 --> 00:16:48,840
At the michoud assembly
facility.
248
00:16:48,842 --> 00:16:52,443
Man: Confirm good, solid
rocket-booster separation.
249
00:16:52,445 --> 00:16:54,579
Narrator: But compared
to the space shuttle
250
00:16:54,581 --> 00:16:57,982
Or even the mighty
apollo saturn v,
251
00:16:57,984 --> 00:17:01,152
Building the sls
is a massive task
252
00:17:01,154 --> 00:17:03,988
Because this multi-billion
dollar craft
253
00:17:03,990 --> 00:17:06,557
Is going into deep space.
254
00:17:06,559 --> 00:17:09,627
The space shuttle was just
designed to get to earth orbit
255
00:17:09,629 --> 00:17:11,095
And no further.
256
00:17:11,097 --> 00:17:14,332
So if we're looking at the next
generation of space travel,
257
00:17:14,334 --> 00:17:17,068
Of going to the moon
and even beyond to mars
258
00:17:17,070 --> 00:17:18,469
Or the outer solar system,
259
00:17:18,471 --> 00:17:23,074
We need much more powerful
rockets than we have today.
260
00:17:23,076 --> 00:17:25,576
Narrator: Making the sls
is the biggest challenge
261
00:17:25,578 --> 00:17:28,546
This team here at michoud
has ever faced.
262
00:17:28,548 --> 00:17:31,315
This mission has to go faster
and farther
263
00:17:31,317 --> 00:17:34,385
Than any previous mission
rockets.
264
00:17:34,387 --> 00:17:37,722
And they're making it
with far fewer people.
265
00:17:37,724 --> 00:17:40,058
We are doing something
that's never been done before
266
00:17:40,060 --> 00:17:43,027
On a rocket
that has this kind of power.
267
00:17:49,102 --> 00:17:50,334
Narrator: Construction
268
00:17:50,336 --> 00:17:52,570
Of the space launch system's
rocket core
269
00:17:52,572 --> 00:17:55,673
Is under way at nasa's
michoud assembly facility
270
00:17:55,675 --> 00:17:56,974
In new orleans.
271
00:17:59,546 --> 00:18:01,679
Once complete, the sls
272
00:18:01,681 --> 00:18:04,515
Will be the most powerful rocket
ever built,
273
00:18:04,517 --> 00:18:07,118
Capable of carrying humans
beyond the grasp
274
00:18:07,120 --> 00:18:11,122
Of earth's gravity
and into deep space.
275
00:18:11,124 --> 00:18:13,124
It's a major undertaking,
276
00:18:13,126 --> 00:18:15,726
But this super factory
is fully equipped
277
00:18:15,728 --> 00:18:19,097
With the very latest
in rocket technology.
278
00:18:19,099 --> 00:18:20,565
Whipps:
State-of-the-art tooling,
279
00:18:20,567 --> 00:18:22,967
State-of-the-art
manufacturing techniques
280
00:18:22,969 --> 00:18:26,270
And significant
multidisciplinary people.
281
00:18:26,272 --> 00:18:28,106
We can make a rocket akin
282
00:18:28,108 --> 00:18:31,342
And more powerful
than the apollo-era rockets
283
00:18:31,344 --> 00:18:34,879
With a workforce of somewhere
around 1,500 people,
284
00:18:34,881 --> 00:18:38,883
Compared to nearly twice that
for even the last generation.
285
00:18:40,220 --> 00:18:42,620
Narrator: Technology
has made massive strides
286
00:18:42,622 --> 00:18:44,689
Since the early days of nasa,
287
00:18:44,691 --> 00:18:47,125
But building
this new super rocket
288
00:18:47,127 --> 00:18:51,062
Has tested even
the most experienced engineers.
289
00:18:51,064 --> 00:18:53,431
We are doing something
that's never been done before
290
00:18:53,433 --> 00:18:56,501
On a rocket
that has this kind of power,
291
00:18:56,503 --> 00:18:58,603
That is able to do the payload
292
00:18:58,605 --> 00:19:00,771
And the astronauts
into deep space.
293
00:19:00,773 --> 00:19:03,274
We are going to go further
than we've ever gone before.
294
00:19:03,276 --> 00:19:06,244
So it is extremely complex.
295
00:19:06,246 --> 00:19:09,780
Narrator: Work has already
started on sls 2
296
00:19:09,782 --> 00:19:12,183
And crucial lessons
have been learned.
297
00:19:12,185 --> 00:19:14,886
We've already started building
for stage 2,
298
00:19:14,888 --> 00:19:18,523
And we are seeing dramatic
improvements in productivity
299
00:19:18,525 --> 00:19:21,025
Just from learning
from the very first one.
300
00:19:23,897 --> 00:19:26,898
Narrator: The first sls
is almost complete.
301
00:19:26,900 --> 00:19:31,536
But the team at michoud faces
one more massive challenge --
302
00:19:31,538 --> 00:19:34,338
Moving the rocket core
to the final assembly
303
00:19:34,340 --> 00:19:37,074
And launch site in florida.
304
00:19:37,076 --> 00:19:41,512
But this super factory's
location gives it an advantage.
305
00:19:41,514 --> 00:19:43,848
Dutriex: As you would
understand, you can't ship those
306
00:19:43,850 --> 00:19:46,617
Over the roadways
because they're too large.
307
00:19:46,619 --> 00:19:49,854
What's so unique to michoud is,
is we have a deep-water port
308
00:19:49,856 --> 00:19:51,789
So we can ship
the components out,
309
00:19:51,791 --> 00:19:54,659
The full-sized components
on barges.
310
00:19:55,929 --> 00:19:58,796
Narrator:
Nasa's giant barge, pegasus,
311
00:19:58,798 --> 00:20:02,366
Will make the nearly
932-mile-long journey
312
00:20:02,368 --> 00:20:04,368
To the kennedy space center.
313
00:20:04,370 --> 00:20:08,839
The sls core stage is more
than 49 feet longer
314
00:20:08,841 --> 00:20:13,477
And over 500,000 pounds heavier
than its last cargo --
315
00:20:13,479 --> 00:20:15,880
The space shuttle external tank.
316
00:20:15,882 --> 00:20:18,983
So pegasus had to be lengthened
and refurbished
317
00:20:18,985 --> 00:20:20,384
For this new mission.
318
00:20:20,386 --> 00:20:23,321
By the time the sls blasts off,
319
00:20:23,323 --> 00:20:26,791
Space will be a much more
crowded place.
320
00:20:26,793 --> 00:20:29,126
A growing number
of private companies
321
00:20:29,128 --> 00:20:32,897
Such as spacex,
virgin galactic and boeing,
322
00:20:32,899 --> 00:20:36,334
Are now speeding
toward space exploration.
323
00:20:36,336 --> 00:20:37,768
There are a lot
of private companies
324
00:20:37,770 --> 00:20:39,036
With their own rockets,
325
00:20:39,038 --> 00:20:41,172
Their own missions,
their own goals.
326
00:20:41,174 --> 00:20:44,141
But still,
nasa is a major player.
327
00:20:44,143 --> 00:20:47,545
And the administration
has recently announced plans
328
00:20:47,547 --> 00:20:49,614
To return to the moon.
329
00:20:49,616 --> 00:20:51,882
And if that plan goes through,
330
00:20:51,884 --> 00:20:53,851
Those astronauts to land
on the moon
331
00:20:53,853 --> 00:20:58,356
Will do so on rockets
built at the michoud facility.
332
00:20:58,358 --> 00:21:02,593
Its history in the making,
and this factory is energized
333
00:21:02,595 --> 00:21:04,962
To support the mission
and support the challenge.
334
00:21:04,964 --> 00:21:07,832
To the efforts of the core-stage
production team here at michoud,
335
00:21:07,834 --> 00:21:11,535
We will support yet again a man
and a woman stepping foot
336
00:21:11,537 --> 00:21:13,938
On the surface of the moon.
337
00:21:13,940 --> 00:21:16,540
Narrator:
The moon is just the first stop
338
00:21:16,542 --> 00:21:18,042
For the sls.
339
00:21:18,044 --> 00:21:21,078
Future models
will have 25% more thrust
340
00:21:21,080 --> 00:21:23,214
And be able to reach mars
341
00:21:23,216 --> 00:21:25,816
And other deep-space
destinations.
342
00:21:25,818 --> 00:21:30,421
And that's what makes michoud
a super factory.
343
00:21:30,423 --> 00:21:33,824
How many factories on earth
are making super-giant rockets
344
00:21:33,826 --> 00:21:36,294
To launch us to the edge
of the solar system?
345
00:21:36,296 --> 00:21:38,763
Michoud is.
346
00:21:41,601 --> 00:21:43,401
Narrator: Nasa michoud
was established
347
00:21:43,403 --> 00:21:45,636
At the dawn of the space age
348
00:21:45,638 --> 00:21:49,340
And still has plenty
of busy years ahead.
349
00:21:49,342 --> 00:21:52,576
This rocket super factory
remains at the cutting edge
350
00:21:52,578 --> 00:21:57,181
Of mankind's quest
to explore the universe.
351
00:22:00,086 --> 00:22:03,220
Coming up,
a british chocolate bar
352
00:22:03,222 --> 00:22:05,456
Is bringing good luck to japan.
353
00:22:07,527 --> 00:22:11,062
And later, one of the world's
fastest production lines
354
00:22:11,064 --> 00:22:14,432
Is cooking up an unlikely
new product.
355
00:22:29,982 --> 00:22:32,616
Narrator:
This sprawling giant factory
356
00:22:32,618 --> 00:22:36,420
May look like hundreds of other
industrial plants near tokyo.
357
00:22:38,558 --> 00:22:44,095
But it's actually the epicenter
of japan's chocolate industry.
358
00:22:44,097 --> 00:22:47,298
And inside
the ultra-clean facility,
359
00:22:47,300 --> 00:22:50,301
Workers are gearing up
to put their own spin
360
00:22:50,303 --> 00:22:53,204
On what "time" magazine
has designated
361
00:22:53,206 --> 00:22:57,641
The most influential candy bar
of all time --
362
00:22:57,643 --> 00:22:59,510
The kit kat.
363
00:22:59,512 --> 00:23:02,580
Russell: Kit kats are a big deal
in japan.
364
00:23:02,582 --> 00:23:04,315
They were originally imported
365
00:23:04,317 --> 00:23:08,219
As a traditional, english
chocolate-wafer snack.
366
00:23:08,221 --> 00:23:11,889
But when nestlé decided
to open a factory in japan,
367
00:23:11,891 --> 00:23:15,559
They decided to put
their very own local spin on it.
368
00:23:15,561 --> 00:23:17,094
To appeal to the japanese,
369
00:23:17,096 --> 00:23:20,564
They started producing kit kats
with flavors like soy sauce,
370
00:23:20,566 --> 00:23:23,033
Wasabi and purple potato.
371
00:23:23,035 --> 00:23:25,336
And this policy really paid off
372
00:23:25,338 --> 00:23:28,272
Because the japanese eat
an amazing 4 million
373
00:23:28,274 --> 00:23:30,007
Kit kat every day,
374
00:23:30,009 --> 00:23:33,778
Making kit kat the number-one
japanese chocolate brand.
375
00:23:35,915 --> 00:23:39,216
Narrator: Many unique flavors
of the candy bar are made here
376
00:23:39,218 --> 00:23:42,987
At japan's kit kat
super factory in kasumigaura.
377
00:23:46,292 --> 00:23:48,893
Here,
the basic kit kat ingredients
378
00:23:48,895 --> 00:23:51,962
Are the same
as in the rest of the world --
379
00:23:51,964 --> 00:23:53,998
Wafers smothered in chocolate.
380
00:23:55,935 --> 00:23:58,369
In this highly
automated factory,
381
00:23:58,371 --> 00:24:02,306
The two are brought together
without a human in sight.
382
00:24:04,076 --> 00:24:07,812
First chocolate is heated
and melted,
383
00:24:07,814 --> 00:24:11,949
Then pumped through
to the production line.
384
00:24:11,951 --> 00:24:16,687
The wafers, made mostly
of wheat flour, cocoa and sugar,
385
00:24:16,689 --> 00:24:20,691
Are baked and then slowly moved
along the line to cool.
386
00:24:23,729 --> 00:24:26,664
The first wafer layer
is covered with chocolate.
387
00:24:29,235 --> 00:24:34,104
A second chocolate-coated layer
is placed under the first
388
00:24:34,106 --> 00:24:37,475
And then another
389
00:24:37,477 --> 00:24:42,313
To create the classic
three-wafer kit kat.
390
00:24:42,315 --> 00:24:45,349
With two layers of chocolate
sandwiched in the middle,
391
00:24:45,351 --> 00:24:48,319
The covering
will be added later.
392
00:24:48,321 --> 00:24:51,455
The oversized wafers
continue to cool
393
00:24:51,457 --> 00:24:54,124
As they travel
to the wafer-stacking area.
394
00:24:57,096 --> 00:24:59,797
After the supersized wafers
are stacked,
395
00:24:59,799 --> 00:25:01,699
They're cut down to size.
396
00:25:04,170 --> 00:25:07,071
Then a robotic arm stacks them.
397
00:25:07,073 --> 00:25:10,174
Now they're ready
for the next step --
398
00:25:10,176 --> 00:25:12,076
A thick covering of chocolate.
399
00:25:12,078 --> 00:25:15,045
Chocolate is
an extraordinary material.
400
00:25:15,047 --> 00:25:19,183
It is one of the few stuffs
designed for our pleasure.
401
00:25:19,185 --> 00:25:21,552
It is a material
that is engineered
402
00:25:21,554 --> 00:25:24,455
To make you go, "yum!"
and have another bit.
403
00:25:24,457 --> 00:25:25,890
When we eat chocolate,
404
00:25:25,892 --> 00:25:27,958
All sorts of chemicals
are whizzing 'round our brain.
405
00:25:27,960 --> 00:25:30,861
But basically it produces
neurotransmitters,
406
00:25:30,863 --> 00:25:33,864
Mainly dopamine,
which make us want another bit
407
00:25:33,866 --> 00:25:36,567
And give us huge sensations
of pleasure.
408
00:25:36,569 --> 00:25:42,706
♪♪
409
00:25:42,708 --> 00:25:46,810
Narrator: In japan, kit kats
are a luxury brand.
410
00:25:46,812 --> 00:25:49,246
The options found
in its downtown boutique
411
00:25:49,248 --> 00:25:51,882
Are staggering.
412
00:25:51,884 --> 00:25:53,751
The company has grabbed
the top spot
413
00:25:53,753 --> 00:25:59,790
In the japanese chocolate market
by offering over 350 varieties.
414
00:26:01,561 --> 00:26:04,762
This commercial savvy has its
roots in a business model
415
00:26:04,764 --> 00:26:08,465
Which demands stores
put new products on the shelves
416
00:26:08,467 --> 00:26:10,301
Every two to three weeks.
417
00:26:10,303 --> 00:26:14,705
This means that new flavors
can appear really quickly.
418
00:26:16,108 --> 00:26:19,577
Narrator: Coming up with new
flavors is highly lucrative,
419
00:26:19,579 --> 00:26:22,212
So here in the kit kat
tasting lab,
420
00:26:22,214 --> 00:26:26,884
A team of chefs concocts
all sorts of different recipes.
421
00:26:26,886 --> 00:26:30,854
The experimental flavors
are ground into a powder.
422
00:26:30,856 --> 00:26:34,658
Today, the head of flavor
developments, mr. Nato,
423
00:26:34,660 --> 00:26:37,161
Is trying out sweet potato,
424
00:26:37,163 --> 00:26:40,331
Yuzu, a citrus fruit similar
to lemon,
425
00:26:40,333 --> 00:26:43,100
And a variation
of one of japan's
426
00:26:43,102 --> 00:26:46,036
Favorite kit kat flavors --
matcha.
427
00:26:46,038 --> 00:26:50,574
This mix has % more
tea leaves for an extra kick.
428
00:26:52,678 --> 00:26:54,712
The wafers are cut to size
429
00:26:54,714 --> 00:26:57,348
And then the new flavors
are blended with chocolate
430
00:26:57,350 --> 00:27:00,484
And poured into molds.
431
00:27:00,486 --> 00:27:03,454
The mini wafers are added
to create a perfect
432
00:27:03,456 --> 00:27:06,056
Bite-sized kit kat.
433
00:27:06,058 --> 00:27:08,192
After cooling,
434
00:27:08,194 --> 00:27:11,228
The factory's professional
tasters are called in.
435
00:27:14,400 --> 00:27:18,102
First up, it's the matcha
with extra tea leaves.
436
00:27:21,340 --> 00:27:22,840
[ woman speaking japanese ]
437
00:27:34,420 --> 00:27:37,087
Next up, sweet potato.
438
00:27:40,726 --> 00:27:43,327
And finally, yuzu.
439
00:27:57,810 --> 00:27:59,610
It won't be long
before the results
440
00:27:59,612 --> 00:28:04,081
Of this tasting session arrive
on japan's retail shelves.
441
00:28:05,651 --> 00:28:12,222
But the standard kit kat bar is
also big in flavor-crazy japan.
442
00:28:12,224 --> 00:28:15,759
That's what's on
the production line today.
443
00:28:15,761 --> 00:28:18,062
In the highly automated factory,
444
00:28:18,064 --> 00:28:21,899
A robotic arm
swings into action,
445
00:28:21,901 --> 00:28:25,502
Ready to insert the wafer
sandwiches into the molds.
446
00:28:28,074 --> 00:28:31,542
The wafers are pressed
into the molds
447
00:28:31,544 --> 00:28:33,644
And covered with more chocolate.
448
00:28:35,915 --> 00:28:38,182
Excess chocolate is removed
449
00:28:38,184 --> 00:28:40,751
By pressing them
under a flat surface.
450
00:28:43,322 --> 00:28:47,157
Now the bars are cooled
to harden the chocolate
451
00:28:47,159 --> 00:28:51,528
Until they're ready
to be removed from the molds.
452
00:28:51,530 --> 00:28:54,598
Nobody wants a kit kat
that's already broken.
453
00:28:54,600 --> 00:28:56,900
So they're x-rayed
and photographed
454
00:28:56,902 --> 00:28:59,937
To ensure the consistency
of every single bar
455
00:28:59,939 --> 00:29:02,005
Coming off the production line.
456
00:29:05,811 --> 00:29:12,182
This factory turns out 4 million
of these bars every day.
457
00:29:12,184 --> 00:29:15,452
At the end of the line, they're
measured out for packaging
458
00:29:15,454 --> 00:29:19,857
Into japan's hugely
popular family-sized multipacks.
459
00:29:19,859 --> 00:29:21,725
But there's an unlikely reason
460
00:29:21,727 --> 00:29:23,961
The japanese love
their kid kats.
461
00:29:23,963 --> 00:29:26,730
And it has nothing to do
with the flavor.
462
00:29:29,435 --> 00:29:32,102
When the japanese visit
ancient shrines,
463
00:29:32,104 --> 00:29:36,740
It's customary to make wishes
and pray for good luck.
464
00:29:36,742 --> 00:29:38,475
Once the wish is made,
465
00:29:38,477 --> 00:29:41,011
Many people
make a small donation.
466
00:29:44,083 --> 00:29:48,152
Kit kats play an unusual role
in this tradition.
467
00:29:49,722 --> 00:29:52,222
About 15 years ago,
the boffins at kit kat
468
00:29:52,224 --> 00:29:55,793
Noticed huge sales spikes
in January.
469
00:29:55,795 --> 00:29:57,661
Well, they wondered why.
470
00:29:57,663 --> 00:30:01,165
What they realized
was university entrance exams
471
00:30:01,167 --> 00:30:02,766
Take place in January.
472
00:30:02,768 --> 00:30:06,703
And people were giving students
kit kats as good-luck charms.
473
00:30:29,662 --> 00:30:31,395
Narrator: The fact
that the japanese phrase
474
00:30:31,397 --> 00:30:35,165
"kitto katsu" literally
means "sure to win"
475
00:30:35,167 --> 00:30:38,535
Is the stuff
of a marketing team's dreams.
476
00:30:39,972 --> 00:30:44,007
Today's production of kit kats
are now packed and boxed...
477
00:30:48,113 --> 00:30:51,582
...Ready to satisfy the
voracious japanese demand
478
00:30:51,584 --> 00:30:55,552
For these chocolate
good-luck charms.
479
00:30:55,554 --> 00:30:58,589
All made here at kasumigaura,
480
00:30:58,591 --> 00:31:02,259
Japan's very own
kit kat super factory.
481
00:31:02,261 --> 00:31:07,197
♪♪
482
00:31:07,199 --> 00:31:10,167
Coming up, a lightning-fast
production line
483
00:31:10,169 --> 00:31:13,904
Is cooking up a product
with an important history.
484
00:31:13,906 --> 00:31:15,739
Russell:
For much of the 19th century,
485
00:31:15,741 --> 00:31:18,542
It was used as rations
for the american navy.
486
00:31:35,327 --> 00:31:38,262
Narrator: On the north coast
of England is a factory
487
00:31:38,264 --> 00:31:41,431
That makes an old
but reliable product.
488
00:31:44,737 --> 00:31:47,638
This is heinz, wigan,
489
00:31:47,640 --> 00:31:52,709
Covering a massive 236,806
square feet,
490
00:31:52,711 --> 00:31:54,912
Around 40 football fields.
491
00:31:54,914 --> 00:31:58,348
It's the largest
food-processing plant in europe
492
00:31:58,350 --> 00:32:02,686
And the biggest baked-bean
factory in the world.
493
00:32:02,688 --> 00:32:06,456
850 people
work here day and night,
494
00:32:06,458 --> 00:32:09,493
Producing 4 million cans
of food a day,
495
00:32:09,495 --> 00:32:12,729
Over 1 billion a year.
496
00:32:12,731 --> 00:32:15,899
60% of them are baked beans.
497
00:32:18,604 --> 00:32:22,940
Every week, 661 tons
of steel plate
498
00:32:22,942 --> 00:32:25,309
Arrives at heinz, wigan.
499
00:32:25,311 --> 00:32:28,478
It's sent to one of the most
modern and automated parts
500
00:32:28,480 --> 00:32:30,781
Of the site.
501
00:32:30,783 --> 00:32:33,951
The canning plant here
is one of the most advanced
502
00:32:33,953 --> 00:32:36,553
And fastest in the world.
503
00:32:36,555 --> 00:32:42,125
It can belt out a staggering
4,500 cans every minute.
504
00:32:42,127 --> 00:32:47,731
♪♪
505
00:32:47,733 --> 00:32:50,133
The humble tin can is truly
506
00:32:50,135 --> 00:32:53,537
One of the building blocks
of the modern world.
507
00:32:53,539 --> 00:32:56,707
They were invented
just over 200 years ago.
508
00:32:56,709 --> 00:32:59,643
And the first commercial
canning factory
509
00:32:59,645 --> 00:33:02,946
Was in east london in 1813.
510
00:33:02,948 --> 00:33:06,116
We've gone from the original,
rather crude template canisters
511
00:33:06,118 --> 00:33:08,485
Made by hand
to today's lightweight,
512
00:33:08,487 --> 00:33:10,520
Completely recyclable
containers.
513
00:33:10,522 --> 00:33:13,323
But the design principles
are effectively still the same.
514
00:33:13,325 --> 00:33:16,994
And the can still preserves and
endures like no other packaging.
515
00:33:16,996 --> 00:33:20,063
That's why in the u.S. Alone,
every year,
516
00:33:20,065 --> 00:33:22,132
130 billion of them are made.
517
00:33:22,134 --> 00:33:23,633
That's over 400 per person.
518
00:33:26,605 --> 00:33:30,073
Narrator: The metal is mostly
steel with a thin coating of tin
519
00:33:30,075 --> 00:33:34,277
On the outside
to stop oxidation.
520
00:33:34,279 --> 00:33:37,748
0.3-millimeter-thick sheets
are cut,
521
00:33:37,750 --> 00:33:39,383
Rolled into tubes,
522
00:33:39,385 --> 00:33:42,486
Then electrically
welded and sealed.
523
00:33:42,488 --> 00:33:46,723
Heinz veteran john brockley
oversees this process.
524
00:34:18,023 --> 00:34:21,158
At this stage, the base
of the can remains open
525
00:34:21,160 --> 00:34:25,595
And for one
very important reason.
526
00:34:25,597 --> 00:34:27,597
It's time to fill it
with something.
527
00:34:27,599 --> 00:34:33,770
♪♪
528
00:34:33,772 --> 00:34:37,641
Every week, over 1,200 tons
of haricot beans
529
00:34:37,643 --> 00:34:42,079
Arrive at wigan, shipped in
from north america.
530
00:34:42,081 --> 00:34:45,949
Russell: The haricot bean
is native to south america
531
00:34:45,951 --> 00:34:48,885
And the variety
used in canned baked beans
532
00:34:48,887 --> 00:34:51,855
Is often referred to
as the navy bean,
533
00:34:51,857 --> 00:34:54,157
Because for much
of the 19th century,
534
00:34:54,159 --> 00:34:57,494
It was used as rations
for the american navy.
535
00:34:57,496 --> 00:34:59,963
Narrator: Just two hours
after their arrival,
536
00:34:59,965 --> 00:35:05,402
The beans are in their tins
and stored in a warehouse.
537
00:35:05,404 --> 00:35:10,107
But not all of the dry beans
will complete that trip.
538
00:35:10,109 --> 00:35:12,909
They face a stringent
series of tests
539
00:35:12,911 --> 00:35:15,979
As they travel
across this huge factory.
540
00:35:17,850 --> 00:35:19,883
The beans are covered in dirt,
541
00:35:19,885 --> 00:35:22,419
So they head to the washer
to be cleaned.
542
00:35:34,933 --> 00:35:40,203
The blanching process rehydrates
the beans with steaming water,
543
00:35:40,205 --> 00:35:41,838
Partially cooking them.
544
00:35:45,744 --> 00:35:48,411
After 20 minutes,
the beans are inspected
545
00:35:48,413 --> 00:35:51,815
By a high-spec laser beam.
546
00:35:51,817 --> 00:35:55,152
The ones that don't
shape up, size or color-wise,
547
00:35:55,154 --> 00:35:57,587
Are discarded.
548
00:36:16,108 --> 00:36:19,075
Russell: Laser sorting has
revolutionized
549
00:36:19,077 --> 00:36:22,412
Counting technology
in the last 20 or 30 years.
550
00:36:22,414 --> 00:36:24,814
Lasers can sort in various ways.
551
00:36:24,816 --> 00:36:27,918
For instance, when the light
from a laser bounces
552
00:36:27,920 --> 00:36:29,719
Off the surface of a bean,
553
00:36:29,721 --> 00:36:33,156
It tells us about its texture
and its structure.
554
00:36:34,593 --> 00:36:38,395
Narrator: They've been sorted,
sifted, washed and blanched
555
00:36:38,397 --> 00:36:40,931
And are on their way
to the canning plant.
556
00:36:44,236 --> 00:36:48,071
But opening up a can of beans
would be a major disappointment
557
00:36:48,073 --> 00:36:50,941
Without one key element
558
00:36:50,943 --> 00:36:54,311
And a few top-secret
ingredients.
559
00:37:07,626 --> 00:37:10,927
Narrator: After they've been
sorted, cleaned and blanched,
560
00:37:10,929 --> 00:37:12,996
It's time to add
the key ingredients
561
00:37:12,998 --> 00:37:17,734
That give heinz beans
their distinct flavor.
562
00:37:17,736 --> 00:37:20,737
Almost half of what goes
into every tin
563
00:37:20,739 --> 00:37:23,773
Is this thick,
bright-red liquid.
564
00:37:23,775 --> 00:37:25,442
It's tomato sauce,
565
00:37:25,444 --> 00:37:28,712
An ingredient
heinz takes seriously,
566
00:37:28,714 --> 00:37:31,181
Very seriously.
567
00:37:31,183 --> 00:37:34,551
The paste arrives from Italy,
Spain, and california,
568
00:37:34,553 --> 00:37:38,388
Prepacked in heavy-duty
bulk bags.
569
00:37:38,390 --> 00:37:42,926
These bags are the end result
of pulping 10,000
570
00:37:42,928 --> 00:37:45,161
Juicy, ripe tomatoes.
571
00:37:48,834 --> 00:37:51,901
Every day they process enough
572
00:37:51,903 --> 00:37:54,904
To fill an olympic-sized
swimming pool.
573
00:37:57,576 --> 00:38:02,145
Narrator: So how do you squeeze
out 4 tons of tomato paste
574
00:38:02,147 --> 00:38:05,682
Without making the plant
resemble a crime scene?
575
00:38:05,684 --> 00:38:07,050
You need one of these --
576
00:38:07,052 --> 00:38:10,687
A tomato pulp extractor.
577
00:38:10,689 --> 00:38:12,122
Once extracted,
578
00:38:12,124 --> 00:38:15,458
The freshly squeezed paste
is diluted with water
579
00:38:15,460 --> 00:38:18,762
And ends up
in one of these massive vats.
580
00:38:38,884 --> 00:38:43,119
Now it's time to add
a very special ingredient.
581
00:38:43,121 --> 00:38:49,092
The secret recipe for heinz
baked beans dates back to 1896
582
00:38:49,094 --> 00:38:52,562
And is closely guarded
in the world of food processing.
583
00:39:01,807 --> 00:39:05,909
The exact amount of the mix
has to be perfect.
584
00:39:17,889 --> 00:39:21,257
Just 27 minutes
into the process,
585
00:39:21,259 --> 00:39:24,060
It's time to combine
the beans and sauce
586
00:39:24,062 --> 00:39:25,862
And add them to the cans.
587
00:39:27,899 --> 00:39:30,333
When you're turning out
around 4 million cans
588
00:39:30,335 --> 00:39:33,603
Of beans a day,
you have to be fast-moving.
589
00:39:33,605 --> 00:39:36,439
And the factory's
very latest production line
590
00:39:36,441 --> 00:39:38,441
Is turbo-charged.
591
00:39:53,992 --> 00:39:56,393
The beans are now sealed
in their cans,
592
00:39:56,395 --> 00:39:58,962
But they're far from baked.
593
00:39:58,964 --> 00:40:01,898
In fact, they're still uncooked.
594
00:40:01,900 --> 00:40:05,001
The next step is
the most surprising part
595
00:40:05,003 --> 00:40:07,704
Of the whole heinz
baked bean process.
596
00:40:20,252 --> 00:40:22,018
The sealed cans of beans
597
00:40:22,020 --> 00:40:25,388
Continually turn
in these giant rotating ovens...
598
00:40:29,094 --> 00:40:31,294
...While getting blasted
with steam.
599
00:40:34,399 --> 00:40:37,734
So baked beans
are not actually baked.
600
00:40:37,736 --> 00:40:40,069
And although they're cooked
by steam,
601
00:40:40,071 --> 00:40:42,572
It is on the outside
of the can.
602
00:40:44,142 --> 00:40:48,111
They effectively cook
in their own sauce.
603
00:40:50,682 --> 00:40:51,915
Once cooked,
604
00:40:51,917 --> 00:40:55,185
One of the 57 famous labels
are attached
605
00:40:55,187 --> 00:40:58,588
At an astonishing rate
of 1,000 per minute.
606
00:40:58,590 --> 00:41:03,927
♪♪
607
00:41:03,929 --> 00:41:07,630
But precooked, preserved food
may never have happened
608
00:41:07,632 --> 00:41:09,999
Without a french discovery.
609
00:41:10,001 --> 00:41:13,102
What made modern canned
food possible
610
00:41:13,104 --> 00:41:17,106
Was a discovery at the very end
of the 18th century
611
00:41:17,108 --> 00:41:20,643
That if you heated food
inside of a sealed jar,
612
00:41:20,645 --> 00:41:22,178
It would last longer.
613
00:41:22,180 --> 00:41:23,980
That observation was made
614
00:41:23,982 --> 00:41:26,816
By a french chef
named nicolas appert,
615
00:41:26,818 --> 00:41:30,153
Who was responding
to napoleon's challenge
616
00:41:30,155 --> 00:41:34,090
To more effectively feed
his troops during a campaign.
617
00:41:36,561 --> 00:41:39,462
Narrator: It takes just two
hours to turn bags
618
00:41:39,464 --> 00:41:44,801
Of dusty navy beans into
a product ready for shipping.
619
00:41:44,803 --> 00:41:48,137
Loaded trucks are ready
to distribute baked beans
620
00:41:48,139 --> 00:41:50,907
To over 60 countries worldwide.
621
00:41:52,978 --> 00:41:57,113
And this process continues
day in and day out
622
00:41:57,115 --> 00:42:02,285
Here at the world's biggest
baked bean super factory.
55710
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.