Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:01,734 --> 00:00:04,736
-- Captions by VITAC --
www.vitac.com
2
00:00:04,737 --> 00:00:07,774
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
3
00:00:52,518 --> 00:00:55,219
Narrator: TO CONTAIN
THE SOUNDS OF TRAFFIC,
4
00:00:55,220 --> 00:00:58,690
IT'S OFTEN NECESSARY
TO PUT UP A WALL OF SILENCE.
5
00:00:58,691 --> 00:01:01,992
NOISE-BARRIER WALLS
BOTH ABSORB TRAFFIC NOISE
6
00:01:01,993 --> 00:01:04,529
AND SHIELD NEIGHBORHOODS
FROM IT.
7
00:01:04,530 --> 00:01:07,831
WITH STONE OR BRICK-LIKE
TEXTURES ON BOTH SIDES,
8
00:01:07,832 --> 00:01:10,436
THEY EVEN LOOK GOOD
ON THE STREET.
9
00:01:14,173 --> 00:01:16,173
IN THE 1970s,
10
00:01:16,174 --> 00:01:19,744
NOISE-BARRIER WALLS
WERE MAINLY DRAB CONCRETE.
11
00:01:19,745 --> 00:01:21,545
FAST FORWARD TO TODAY,
12
00:01:21,546 --> 00:01:24,583
AND THE WALLS COME IN A RANGE
OF TEXTURES AND DESIGNS
13
00:01:24,584 --> 00:01:26,717
FOR CURB APPEAL.
14
00:01:26,718 --> 00:01:29,286
BUT OF COURSE, IT'S
THEIR NOISE-ABSORBING QUALITIES
15
00:01:29,287 --> 00:01:32,357
THAT REALLY IMPROVE
THE NEIGHBORHOOD.
16
00:01:32,358 --> 00:01:33,724
THEY'RE MADE FROM A WOOD SHAVING
17
00:01:33,725 --> 00:01:36,093
AND CEMENT MATERIAL
THAT'S VERY POROUS,
18
00:01:36,094 --> 00:01:39,730
WHICH ALLOWS THE WALLS
TO ABSORB SOUND AND ENTRAP IT.
19
00:01:39,731 --> 00:01:42,467
PRODUCTION STARTS
WITH THE RAW SHAVINGS.
20
00:01:42,468 --> 00:01:46,470
A CONVEYOR DELIVERS THEM
TO A HAMMER MILL.
21
00:01:46,471 --> 00:01:49,607
INSIDE, ROTATING HAMMERS
FORCE THE WOOD SHAVINGS
22
00:01:49,608 --> 00:01:51,811
THROUGH A CUTTING SCREEN.
23
00:01:57,248 --> 00:01:59,551
THIS CARVES THEM
INTO SMALLER PARTICLES
24
00:01:59,552 --> 00:02:02,319
OF VARIOUS SIZES.
25
00:02:02,320 --> 00:02:03,988
IT'S THIS COMBINATION OF SIZES
26
00:02:03,989 --> 00:02:06,692
THAT WILL CREATE
THE NOISE-ABSORBING PORES
27
00:02:06,693 --> 00:02:08,427
IN THE COMPLETED WALL.
28
00:02:11,396 --> 00:02:14,098
THEY TEST
A PROPRIETARY CHEMICAL SOLUTION,
29
00:02:14,099 --> 00:02:16,435
THAT WILL BE USED
TO TREAT THE WOOD PARTICLES,
30
00:02:16,436 --> 00:02:19,971
AND CONFIRM
IT'S THE RIGHT CONCENTRATION.
31
00:02:19,972 --> 00:02:22,975
AN AUGER THEN MIXES IT
INTO THE WOOD PARTICLES
32
00:02:22,976 --> 00:02:25,911
UNTIL THEY'RE DAMP
AND THOROUGHLY COATED.
33
00:02:25,912 --> 00:02:27,279
WITHOUT THIS TREATMENT,
34
00:02:27,280 --> 00:02:30,514
THE WOOD PARTICLES
WOULDN'T BIND WITH CEMENT.
35
00:02:30,515 --> 00:02:33,418
IT WILL ALSO PROTECT THE WOOD
FROM DECAY.
36
00:02:35,487 --> 00:02:38,857
IN ANOTHER MIXER, THEY ADD WATER
AND A SECOND CHEMICAL SOLUTION
37
00:02:38,858 --> 00:02:42,328
TO FURTHER ENHANCE
THE BINDING PROCESS.
38
00:02:47,500 --> 00:02:50,768
THE WOOD PARTICLES ARE NOW
PRIMED AND READY TO BE MIXED
39
00:02:50,769 --> 00:02:56,406
WITH A POWDERED MIX OF LIMESTONE
CLAY CALLED PORTLAND CEMENT.
40
00:02:56,407 --> 00:02:58,143
THE MACHINE
WORKS THE INGREDIENTS
41
00:02:58,144 --> 00:03:00,444
UNTIL THEY FORM
A COHESIVE MATERIAL
42
00:03:00,445 --> 00:03:02,115
THAT CAN BE SHAPED.
43
00:03:08,721 --> 00:03:10,755
THE NEXT WORKER
SPRAYS A RELEASE AGENT
44
00:03:10,756 --> 00:03:12,891
ONTO THE STONE-PATTERN LINER.
45
00:03:15,360 --> 00:03:19,496
EACH MOLD WILL FORM
ONE NOISE BARRIER PANEL.
46
00:03:19,497 --> 00:03:22,099
THE TEAM TRANSFERS
THE WOOD-AND-CEMENT BLEND
47
00:03:22,100 --> 00:03:23,700
INTO THE MOLD.
48
00:03:23,701 --> 00:03:25,136
THEY WORK AT A STEADY PACE
49
00:03:25,137 --> 00:03:28,207
TO FILL IT BEFORE THE MIXTURE
BEGINS TO DRY.
50
00:03:33,277 --> 00:03:35,079
ONCE THEY'VE FILLED IT PARTWAY,
51
00:03:35,080 --> 00:03:37,449
THEY LEVEL
THE WOOD-CEMENT MATERIAL...
52
00:03:39,551 --> 00:03:42,055
...THEN COMPACT IT
WITH A TAMPING TOOL.
53
00:03:43,855 --> 00:03:46,490
NEXT, THEY ADD A STEEL MESH.
54
00:03:46,491 --> 00:03:48,626
THIS MESH WILL SERVE
AS A SKELETON,
55
00:03:48,627 --> 00:03:51,962
ALLOWING THE WALL
TO STAND STRONG.
56
00:03:51,963 --> 00:03:55,566
THEY POUR FRESHLY MIXED CONCRETE
ONTO THE STEEL MESH.
57
00:03:55,567 --> 00:03:57,102
IT FLOWS THROUGH THE MESH
58
00:03:57,103 --> 00:03:59,871
AND ONTO THE SOUND-ABSORBING
MIXTURE BELOW,
59
00:03:59,872 --> 00:04:02,507
BINDING THE TWO LAYERS TOGETHER.
60
00:04:02,508 --> 00:04:05,677
THE WORKER SPREADS THE CONCRETE
THROUGHOUT THE MOLD.
61
00:04:07,346 --> 00:04:10,948
HE PIERCES THE SURFACE
WITH A VIBRATING TOOL.
62
00:04:10,949 --> 00:04:13,550
THE VIBRATIONS
CONSOLIDATE THE CONCRETE
63
00:04:13,551 --> 00:04:15,721
AND ELIMINATE AIR POCKETS.
64
00:04:17,456 --> 00:04:19,090
THE TWO-PERSON TEAM LEVELS
65
00:04:19,091 --> 00:04:22,161
THE CONCRETE LAYER
USING A WOOD SCREED.
66
00:04:30,670 --> 00:04:35,239
THEY APPLY A SECOND LAYER
OF THE NOISE-ABSORBING MATERIAL
67
00:04:35,240 --> 00:04:37,110
AND LEVEL IT.
68
00:04:46,351 --> 00:04:48,619
THEY LOWER
THE STONE-PATTERN PRESS LID,
69
00:04:48,620 --> 00:04:51,990
WHICH WILL MOLD THE PATTERN
ONTO THE TOP SIDE OF THE PANEL.
70
00:04:54,526 --> 00:04:57,496
THEY SET A 10-TON CONCRETE BLOCK
ON THE MOLD,
71
00:04:57,497 --> 00:04:59,463
AND PRESSURE FORCES
THE MOLD PATTERNS
72
00:04:59,464 --> 00:05:01,667
ONTO BOTH SIDES OF THE CASTING.
73
00:05:05,204 --> 00:05:06,804
AFTER A FEW MINUTES,
74
00:05:06,805 --> 00:05:11,441
THEY REMOVE THE LID,
AND THE IMPRINT IS REVEALED.
75
00:05:11,442 --> 00:05:14,611
THEY QUICKLY COVER THE PANEL
SURFACE WITH A PLASTIC SHEET
76
00:05:14,612 --> 00:05:17,047
TO PREVENT ANY EVAPORATION
OF MOISTURE
77
00:05:17,048 --> 00:05:19,249
AS THE CURE CONTINUES.
78
00:05:19,250 --> 00:05:21,219
IF THE BLEND CURES TOO QUICKLY,
79
00:05:21,220 --> 00:05:23,455
IT COULD CRACK.
80
00:05:23,456 --> 00:05:25,890
AFTER ANOTHER DAY,
THEY REMOVE THE TARP
81
00:05:25,891 --> 00:05:28,995
AND THEY'RE READY TO EXTRACT
THE PANEL FROM THE MOLD.
82
00:05:30,528 --> 00:05:32,129
A CRANE LIFTS THE PANEL
83
00:05:32,130 --> 00:05:35,167
AND SETS IT ASIDE
TO CURE FOR ABOUT A MONTH.
84
00:05:39,571 --> 00:05:41,205
BUILT PANEL BY PANEL,
85
00:05:41,206 --> 00:05:45,143
THESE NOISE-BARRIER WALLS CAN
BECOME A SUBSTANTIAL FORTRESS,
86
00:05:45,144 --> 00:05:48,747
PROVIDING A SOLID DEFENSE
AGAINST NOISE POLLUTION.
87
00:05:58,500 --> 00:05:59,868
Narrator:
FRONT-LOADING WASHING MACHINES
88
00:05:59,869 --> 00:06:02,705
USE FAR LESS WATER
THAN STANDARD WASHERS.
89
00:06:02,706 --> 00:06:05,539
THEY'RE GENTLER ON CLOTHES
BECAUSE THERE'S NO AGITATOR
90
00:06:05,540 --> 00:06:07,775
IN THE MIDDLE OF THE DRUM.
91
00:06:07,776 --> 00:06:09,277
THE SPIN SPEED IS USUALLY
92
00:06:09,278 --> 00:06:12,780
ABOUT 20 PERCENT FASTER THAN
THE STANDARD TOP-LOAD MACHINE,
93
00:06:12,781 --> 00:06:15,584
SO THE CLOTHES
COME OUT OF THE WASH DRIER.
94
00:06:19,120 --> 00:06:22,756
WITH GRAVITY HELPING TUMBLE
THE LAUNDRY, A FRONT-LOAD WASHER
95
00:06:22,757 --> 00:06:26,693
IS GENTLER ON THE CLOTHES
WHILE USING LESS WATER.
96
00:06:26,694 --> 00:06:30,498
ITS DESIGN CAN ALSO ACCOMMODATE
A LARGER-CAPACITY DRUM,
97
00:06:30,499 --> 00:06:32,767
SO YOU CAN DO BIGGER LOADS.
98
00:06:32,768 --> 00:06:35,303
THE WASHER'S CABINET
IS MADE OF STEEL.
99
00:06:35,304 --> 00:06:38,674
A WASHING MACHINE IS ROUTINELY
EXPOSED TO MOISTURE,
100
00:06:38,675 --> 00:06:43,044
SO THEY USE GALVANIZED STEEL,
WHICH DOESN'T RUST.
101
00:06:43,045 --> 00:06:46,246
THE CABINET BASE IS COMPRISED
OF FOUR PIECES,
102
00:06:46,247 --> 00:06:49,017
WHICH, TOGETHER,
PROVIDE MORE STRUCTURAL STRENGTH
103
00:06:49,018 --> 00:06:50,652
THAN A SINGLE PIECE WOULD.
104
00:06:50,653 --> 00:06:54,323
AT THE CORNERS, WORKERS INSTALL
FOUR SCREW-IN RUBBER FEET
105
00:06:54,324 --> 00:06:55,924
WHICH ARE HEIGHT-ADJUSTABLE.
106
00:06:55,925 --> 00:06:59,361
THIS ALLOWS THE WASHER
TO LEVEL ON AN UNEVEN FLOOR.
107
00:06:59,362 --> 00:07:01,530
NEXT ARE THE TWO SIDE PANELS.
108
00:07:01,531 --> 00:07:04,799
THEY ARE ALREADY STAMPED
TO THE REQUIRED SHAPE IN A PRESS
109
00:07:04,800 --> 00:07:07,034
AND COATED WITH BAKED-ON PAINT.
110
00:07:07,035 --> 00:07:10,571
THIS AUTOMATED MACHINE INSTALLS
BRACKETS ON THE INNER SIDE
111
00:07:10,572 --> 00:07:11,640
FOR MOUNTING COMPONENTS
112
00:07:11,641 --> 00:07:13,073
LATER ON.
113
00:07:13,074 --> 00:07:15,842
THE NEXT AUTOMATED MACHINE
ATTACHES THE SIDE PANELS
114
00:07:15,843 --> 00:07:17,479
TO THE CABINET.
115
00:07:17,480 --> 00:07:19,246
RATHER THAN WELDING THE EDGES,
116
00:07:19,247 --> 00:07:21,114
WHICH WOULD RUIN
THE PAINT FINISH,
117
00:07:21,115 --> 00:07:22,450
THE MACHINE'S PUNCH TOOLS
118
00:07:22,451 --> 00:07:25,285
MECHANICALLY
LOCK THEM TO THE BASE.
119
00:07:25,286 --> 00:07:29,725
A ROBOT THEN TRANSFERS THE
CABINET TO THE ASSEMBLY LINE.
120
00:07:30,893 --> 00:07:32,895
HERE, WORKERS
CONNECT THE SIDE PANELS
121
00:07:32,896 --> 00:07:35,729
WITH A STRUCTURAL SUPPORT
BRACKET AND POWER CORD,
122
00:07:35,730 --> 00:07:37,599
ALREADY INSTALLED ON IT.
123
00:07:37,600 --> 00:07:39,267
WORKERS PREPARE THE REAR PORTION
124
00:07:39,268 --> 00:07:41,904
OF THE MACHINE'S
TWO-PIECE PLASTIC TUB.
125
00:07:41,905 --> 00:07:45,873
FIRST, A ROBOT MOUNTS
A STEEL BEARING ON A PRESS.
126
00:07:45,874 --> 00:07:47,575
THE PRESS THEN
FORCES THE BEARING
127
00:07:47,576 --> 00:07:51,114
INTO A HOLE AT THE BOTTOM
OF THE INSIDE OF THE TUB.
128
00:07:51,115 --> 00:07:55,316
THEN THE PROCESS IS REPEATED
BUT ON THE OUTSIDE OF THE TUB.
129
00:07:55,317 --> 00:07:58,385
THIS PAIR OF BEARINGS
SEALS THE HOLE TO PREVENT LEAKS,
130
00:07:58,386 --> 00:08:02,057
AND ENABLES THE STAINLESS-STEEL
WASH DRUM TO SPIN.
131
00:08:04,059 --> 00:08:06,361
TO COUNTERBALANCE
THE SPINNING LOAD,
132
00:08:06,362 --> 00:08:09,198
THEY WEIGHT THE FRONT
OF THE DRUM WITH A PLASTIC RING,
133
00:08:09,199 --> 00:08:13,534
CONTAINING HEAVY STEEL BALLS
SUSPENDED IN FLUID.
134
00:08:13,535 --> 00:08:16,070
THEN, THEY INSERT THE SHAFT
AT THE BASE OF THE DRUM
135
00:08:16,071 --> 00:08:17,838
INTO THE TUB'S BEARINGS
136
00:08:17,839 --> 00:08:20,308
AND COVER THE TOP OF THE DRUM
WITH THE FRONT SECTION
137
00:08:20,309 --> 00:08:21,609
OF THE TUB.
138
00:08:21,610 --> 00:08:24,412
IT HAS A RUBBER GASKET
CALLED A BELLOW.
139
00:08:24,413 --> 00:08:28,583
THE BELLOW FORMS A LEAK-PROOF
SEAL AROUND THE DRUM.
140
00:08:28,584 --> 00:08:30,919
AFTER WELDING THE TUB SECTIONS
TOGETHER,
141
00:08:30,920 --> 00:08:33,688
THEY MOUNT THE WASHER'S MOTOR
TO THE REAR.
142
00:08:33,689 --> 00:08:37,293
IN THIS STATOR-ROTOR MOTOR,
THE ELECTRIC CURRENT TRAVELS
143
00:08:37,294 --> 00:08:40,227
THROUGH THE COILED COPPER WIRES
OF THE MOTOR'S STATOR,
144
00:08:40,228 --> 00:08:43,363
GENERATING PULSES
OF ELECTRICITY.
145
00:08:43,364 --> 00:08:46,901
THOSE PULSES PUSH ON MAGNETS
LINING THE MOTOR'S ROTOR,
146
00:08:46,902 --> 00:08:49,069
POSITIONED ON TOP.
147
00:08:49,070 --> 00:08:51,038
THE MAGNETS REPEL THE PULSES,
148
00:08:51,039 --> 00:08:52,841
AND THIS REPEATED
PULSE REPELLING
149
00:08:52,842 --> 00:08:57,344
DRIVES THE DRUM IN THE DIRECTION
AND SPEED REQUIRED.
150
00:08:57,345 --> 00:09:01,616
NEXT, THEY INSTALL A DRAIN HOSE
ON THE SIDE OF THE TUB
151
00:09:01,617 --> 00:09:03,920
AND ATTACH IT
WITH A RETAINER CLIP.
152
00:09:05,987 --> 00:09:09,491
THEY BOLT A PIECE OF CONCRETE TO
EITHER SIDE OF THE DRUM OPENING
153
00:09:09,492 --> 00:09:12,894
TO COUNTERBALANCE THE WEIGHT
OF THE MOTOR ON THE BACK.
154
00:09:12,895 --> 00:09:16,432
THEN, THEY TURN THE NOW-COMPLETE
WASH UNIT ON ITS SIDE
155
00:09:16,433 --> 00:09:18,634
AND INSTALL IT IN THE CABINET.
156
00:09:21,936 --> 00:09:25,640
NEXT, THEY MOUNT THE DRAIN PUMP
IN THE CABINET BASE
157
00:09:25,641 --> 00:09:27,541
AND CONNECT ITS WIRING.
158
00:09:27,542 --> 00:09:31,813
THE PUMP'S JOB IS TO REMOVE
DIRTY WATER FROM THE TUB.
159
00:09:33,681 --> 00:09:35,784
FOUR SHOCK ABSORBERS
ARE INSTALLED
160
00:09:35,785 --> 00:09:39,520
BETWEEN THE BOTTOM
OF THE WASH UNIT AND THE BASE.
161
00:09:39,521 --> 00:09:42,424
THESE LARGE PISTONS DAMPEN
MUCH OF THE VIBRATION
162
00:09:42,425 --> 00:09:44,861
DURING THE WASH AND SPIN CYCLES.
163
00:09:46,261 --> 00:09:47,929
NEXT, THE FRONT PANEL.
164
00:09:47,930 --> 00:09:50,398
LIKE THE SIDES,
IT'S MADE OF A STAMPED SHEET
165
00:09:50,399 --> 00:09:53,770
OF GALVANIZED STEEL
WITH A BAKED-ON PAINT FINISH.
166
00:09:55,304 --> 00:09:57,172
THEY INSTALL AND CONNECT
THE CONSOLE,
167
00:09:57,173 --> 00:10:00,209
WHICH HOUSES THE MACHINE'S
CENTRAL CONTROL MODULE.
168
00:10:03,145 --> 00:10:06,414
THEY PULL THE BELLOW ON THE DRUM
ALL AROUND THE FRONT OPENING
169
00:10:06,415 --> 00:10:08,251
TO SEAL THE PERIMETER.
170
00:10:12,220 --> 00:10:16,058
THEY SECURE IT IN PLACE
WITH A WIRE RETAINER CLIP.
171
00:10:21,030 --> 00:10:24,299
THE HINGED DOOR HAS
A SEE-THROUGH PLASTIC WINDOW.
172
00:10:24,300 --> 00:10:26,735
LIKE THE REST
OF THE MACHINE'S METAL PARTS,
173
00:10:26,736 --> 00:10:29,404
THE DOOR PANEL
AND HARDWARE ATTACHING IT
174
00:10:29,405 --> 00:10:33,107
ARE ALSO MADE
OF GALVANIZED STEEL.
175
00:10:33,108 --> 00:10:35,544
THE BACK PANEL
IS LEFT UNPAINTED.
176
00:10:35,545 --> 00:10:38,111
AFTER FEEDING THE POWER CORD
THROUGH ITS HOLE,
177
00:10:38,112 --> 00:10:42,116
WORKERS SCREW THE PANEL
TO THE REST OF THE CABINET.
178
00:10:42,117 --> 00:10:44,819
THEN, THEY COMPLETE THE CABINET
WITH THE TOP PANEL,
179
00:10:44,820 --> 00:10:47,290
WHICH HAS THE BAKED-ON PAINT
FINISH.
180
00:10:49,090 --> 00:10:50,625
THE FRONT-LOAD WASHING MACHINE
181
00:10:50,626 --> 00:10:54,731
IS NOW ALL SET
AND READY FOR ITS FIRST LOAD.
182
00:11:03,500 --> 00:11:05,500
Narrator: BOURBON WHISKEY
IS UNIQUELY AMERICAN.
183
00:11:05,501 --> 00:11:08,138
THE U.S. CONGRESS
OFFICIALLY RECOGNIZED IT
184
00:11:08,139 --> 00:11:10,239
AS A PRODUCT
DISTINCT TO THE NATION.
185
00:11:10,240 --> 00:11:12,675
THIS AMBER-HUED BREW
WAS FIRST COOKED UP
186
00:11:12,676 --> 00:11:17,245
BY SCOTTISH AND IRISH SETTLERS
IN LATE 18th CENTURY KENTUCKY.
187
00:11:17,246 --> 00:11:19,514
TODAY,
PRODUCTION CONTINUES THERE
188
00:11:19,515 --> 00:11:21,651
WITH THE APPROVAL OF CONGRESS.
189
00:11:23,787 --> 00:11:27,089
THE AMERICAN GOVERNMENT
REGULATES THE MAKING OF BOURBON
190
00:11:27,090 --> 00:11:30,725
TO KEEP THIS NATIVE SPIRIT
TRUE TO TRADITION.
191
00:11:30,726 --> 00:11:32,528
BY LAW, IT MUST BE MADE
192
00:11:32,529 --> 00:11:36,566
FROM A GRAIN MIX
THAT'S AT LEAST 51% CORN.
193
00:11:36,567 --> 00:11:40,536
DISTILLERS
OFTEN USE MORE FOR FLAVOR.
194
00:11:40,537 --> 00:11:43,940
SHAKERS SIFT OUT COBS
OR OTHER FOREIGN MATERIAL,
195
00:11:43,941 --> 00:11:47,241
AND THE KERNELS
HEAD INTO A GRINDER.
196
00:11:47,242 --> 00:11:49,811
INSIDE,
ROLLERS CRUSH THE KERNELS
197
00:11:49,812 --> 00:11:52,447
TO RELEASE
THE FLAVOR OF THE STARCH.
198
00:11:52,448 --> 00:11:56,552
THE PROCESS LEAVES LARGER CHUNKS
OF THE CORN GERM AND HUSKS.
199
00:11:56,553 --> 00:11:59,756
ONCE DISTILLED,
THESE BITS WILL SETTLE OUT.
200
00:12:01,692 --> 00:12:03,725
IN SEPARATE BATCHES, THE MACHINE
201
00:12:03,726 --> 00:12:08,466
ALSO GRINDS MALTED BARLEY
AND SOFT RED WINTER WHEAT.
202
00:12:09,865 --> 00:12:11,533
THEY COOK THE CORN AND BLEND IT
203
00:12:11,534 --> 00:12:15,604
WITH LIMESTONE-RICH,
IRON-FREE KENTUCKY WATER.
204
00:12:15,605 --> 00:12:17,807
THEY ADD THE BARLEY,
WINTER WHEAT,
205
00:12:17,808 --> 00:12:20,744
AND A BIT OF MASH
FROM A PREVIOUS BATCH.
206
00:12:22,779 --> 00:12:26,081
ALONG WITH A SPECIAL YEAST
FORMULATION, THE GRAIN MASH
207
00:12:26,082 --> 00:12:29,320
FLOWS INTO FERMENTATION TANKS
MADE OF CYPRESS WOOD.
208
00:12:31,788 --> 00:12:35,390
AFTER 8 TO 10 HOURS,
THE YEAST WORKS ITS MAGIC
209
00:12:35,391 --> 00:12:38,695
AND THE MASH
BECOMES A BUBBLING BREW.
210
00:12:40,929 --> 00:12:42,197
THE BUBBLING IS CAUSED
211
00:12:42,198 --> 00:12:44,801
BY THE RELEASE
OF CARBON-DIOXIDE GAS
212
00:12:44,802 --> 00:12:48,803
AS THE GRAIN SUGARS FERMENT
AND BECOME ALCOHOL.
213
00:12:48,804 --> 00:12:50,138
AFTER THREE DAYS,
214
00:12:50,139 --> 00:12:52,008
IT HAS FERMENTED
INTO A THICK LIQUID
215
00:12:52,009 --> 00:12:54,144
THEY CALL 'DISTILLER'S BEER."
216
00:12:55,812 --> 00:12:59,983
THEY PUMP IT INTO A COLUMN STILL
WHICH BOILS OFF THE ALCOHOL,
217
00:12:59,984 --> 00:13:03,118
LEAVING WATER
AND OTHER SUBSTANCES BEHIND.
218
00:13:03,119 --> 00:13:06,656
THE ALCOHOLIC VAPOR RISES UP
TO BE CONDENSED INTO LIQUID.
219
00:13:06,657 --> 00:13:09,691
AFTER DISTILLING IT
A SECOND TIME,
220
00:13:09,692 --> 00:13:14,431
THE ALCOHOL CONCENTRATION
RISES TO A STRONG 130 PROOF.
221
00:13:17,833 --> 00:13:20,869
IT'S CLEAR,
WITH NO NOTICEABLE COLOR.
222
00:13:20,870 --> 00:13:23,374
AT THIS STAGE,
THEY CALL IT "WHITE DOG."
223
00:13:24,573 --> 00:13:26,975
ONCE WATER HAS BEEN ADDED
TO DILUTE THE WHISKEY
224
00:13:26,976 --> 00:13:28,911
TO 110 PROOF,
225
00:13:28,912 --> 00:13:33,648
AN EMPLOYEE TAKES A SAMPLE
AND SENDS IT TO THE LAB.
226
00:13:33,649 --> 00:13:37,085
THERE, A TECHNICIAN PLACES
A TEST TUBE OF THE ALCOHOL
227
00:13:37,086 --> 00:13:39,990
INTO A GAS CHROMATOGRAPH TESTER.
228
00:13:42,625 --> 00:13:44,560
IT VAPORIZES THE ALCOHOL
229
00:13:44,561 --> 00:13:48,632
AND THEN ANALYZES THE FLAVOR
COMPOUNDS AND ALCOHOL STRENGTH.
230
00:13:50,534 --> 00:13:52,500
WITH APPROVAL FROM THE LAB,
231
00:13:52,501 --> 00:13:55,772
THEY'RE READY
TO BARREL THE BATCH.
232
00:13:55,773 --> 00:13:58,807
THEY PUMP IT OUT OF STORAGE
TANKS AND INTO NEW OAK BARRELS
233
00:13:58,808 --> 00:14:03,211
THAT HAVE BEEN PURPOSELY CHARRED
ON THE INSIDE.
234
00:14:03,212 --> 00:14:06,282
CHARRING CARAMELIZES
NATURALLY OCCURRING WOOD SUGARS
235
00:14:06,283 --> 00:14:10,752
TO ADD SWEETNESS
TO THE ALCOHOL AS IT AGES.
236
00:14:10,753 --> 00:14:14,391
IT WILL ALSO TURN THE CLEAR
ALCOHOL AN AMBER COLOR.
237
00:14:17,994 --> 00:14:20,495
ONCE CORKED
WITH A WALNUT STOPPER,
238
00:14:20,496 --> 00:14:25,701
THE EMPLOYEE ROLLS THE BARREL
INTO A MULTI-TIERED WAREHOUSE.
239
00:14:25,702 --> 00:14:28,604
HERE, THE BOURBON
WILL AGE FOR MANY YEARS.
240
00:14:28,605 --> 00:14:30,004
PARTWAY THROUGH,
241
00:14:30,005 --> 00:14:32,207
THEY'LL MOVE THE BARREL
TO ANOTHER LEVEL OF THE BUILDING
242
00:14:32,208 --> 00:14:34,777
DUE TO TEMPERATURE VARIATIONS.
243
00:14:34,778 --> 00:14:38,513
THIS WILL MAKE THE PRODUCT
MORE CONSISTENT.
244
00:14:38,514 --> 00:14:40,682
AFTER SIX TO SEVEN YEARS,
245
00:14:40,683 --> 00:14:43,786
THEY UNCORK THE STOPPER
AND INSERT STEEL TUBES
246
00:14:43,787 --> 00:14:46,023
TO DRAW IN AMBIENT AIR.
247
00:14:47,724 --> 00:14:50,828
THIS CAUSES THE BOURBON
TO FLOW FREELY WHEN TIPPED,
248
00:14:50,829 --> 00:14:53,762
AND IT GUSHES INTO A TROUGH.
249
00:14:53,763 --> 00:14:58,035
THE ALCOHOL HAS RIPENED
TO A SWEET CARAMEL-COLORED BREW.
250
00:15:00,737 --> 00:15:03,706
AFTER THEY ADD MORE WATER
TO MAKE IT 90 PROOF,
251
00:15:03,707 --> 00:15:06,240
IT'S READY FOR BOTTLING.
252
00:15:06,241 --> 00:15:09,646
NOZZLES FILL THE BOTTLES
WITH BOURBON RIGHT TO THE NECK.
253
00:15:12,715 --> 00:15:17,318
THE BOTTLES THEN CIRCLE
OVER TO THE CAP APPLICATORS.
254
00:15:17,319 --> 00:15:21,924
THE APPLICATORS SPIN METAL CAPS,
SCREWING THEM ONTO THE BOTTLES.
255
00:15:23,827 --> 00:15:25,760
THE BOTTLES THEN RIDE A CAROUSEL
256
00:15:25,761 --> 00:15:29,297
AND A DEVICE
PICKS UP AND APPLIES THE LABELS.
257
00:15:29,298 --> 00:15:32,269
A BRUSH SMOOTHES THEM
TO THE BOTTLES.
258
00:15:34,505 --> 00:15:36,938
DOWN THE LINE, A TWO-PERSON TEAM
259
00:15:36,939 --> 00:15:41,842
RETRIEVES THE BOTTLES
AND DIPS THE CAPS IN HOT WAX.
260
00:15:41,843 --> 00:15:45,013
THE WAX QUICKLY DRIES AND
SOLIDIFIES TO GIVE THE BOURBON
261
00:15:45,014 --> 00:15:46,884
A BETTER SEAL.
262
00:15:49,686 --> 00:15:52,155
AFTER SEVERAL YEARS
IN THE DISTILLERY,
263
00:15:52,156 --> 00:15:55,358
THIS KENTUCKY BOURBON
HAS COME OF AGE,
264
00:15:55,359 --> 00:15:57,861
AND THAT CALLS FOR A TOAST.
265
00:16:08,639 --> 00:16:10,572
Narrator: THE CIRCUIT BOARD
266
00:16:10,573 --> 00:16:12,707
IS WHERE THE ELECTRONIC
COMPONENTS ARE LOCATED,
267
00:16:12,708 --> 00:16:14,676
ALONG WITH THE ELECTRICAL
CONNECTIONS WHICH POWER THEM.
268
00:16:14,677 --> 00:16:17,180
IN A LARGER DEVICE,
SUCH AS A COMPUTER,
269
00:16:17,181 --> 00:16:19,181
THE CIRCUIT BOARD
IS TYPICALLY RIGID.
270
00:16:19,182 --> 00:16:21,850
WHEN THE DEVICE IS COMPACT,
LIKE A SMALL CAMERA,
271
00:16:21,851 --> 00:16:24,186
THE CIRCUIT BOARD
MUST BE FLEXIBLE.
272
00:16:24,187 --> 00:16:26,789
IT NEEDS TO FOLD TO FIT INSIDE.
273
00:16:28,423 --> 00:16:31,460
FLEXIBLE CIRCUIT BOARDS
ARE SO THIN AND PLIABLE,
274
00:16:31,461 --> 00:16:33,895
THEY'RE NICKNAMED
ORIGAMI CIRCUITRY,
275
00:16:33,896 --> 00:16:37,398
AFTER THE JAPANESE ART
OF PAPER FOLDING.
276
00:16:37,399 --> 00:16:41,036
AT THE CORE OF THE BOARDS
IS A HAIR-THIN POLYMER FILM
277
00:16:41,037 --> 00:16:43,574
THAT'S BOTH BENDABLE
AND HEAT RESISTANT.
278
00:16:43,575 --> 00:16:47,842
THE MANUFACTURER PRODUCES THIS
MATERIAL FOR SEVERAL INDUSTRIES.
279
00:16:47,843 --> 00:16:49,946
IN THIS CASE,
THEY CUT ROLLS OF IT
280
00:16:49,947 --> 00:16:53,616
TO THE WIDTH REQUIRED FOR MAKING
FLEXIBLE CIRCUIT BOARDS.
281
00:16:55,851 --> 00:16:59,720
WITH A RIGID SHEET OF PAPER
LENDING SUPPORT FROM UNDERNEATH,
282
00:16:59,721 --> 00:17:01,289
THE FILM ENTERS A MACHINE
283
00:17:01,290 --> 00:17:04,626
WHICH SANDWICHES IT BETWEEN
TWO THIN SHEETS OF COPPER.
284
00:17:04,627 --> 00:17:06,494
A CUTTER THEN
SLICES THE SANDWICH
285
00:17:06,495 --> 00:17:08,664
INTO RECTANGULAR SHEETS.
286
00:17:08,665 --> 00:17:11,000
A CUSHION OF AIR
PUMPED THROUGH THE CONVEYOR BELT
287
00:17:11,001 --> 00:17:14,237
LITERALLY FLOATS SHEET
AFTER SHEET OFF THE MACHINE
288
00:17:14,238 --> 00:17:17,439
AND INTO A STACK.
289
00:17:17,440 --> 00:17:20,176
EACH THREE-LAYER SHEET
IS SEPARATED FROM THE NEXT
290
00:17:20,177 --> 00:17:23,911
BY THE SUPPORT PAPER
CALLED A LAMINATE.
291
00:17:23,912 --> 00:17:27,617
THE FILM AT THE CENTER HAS A
HEAT-ACTIVATED ADHESIVE COATING,
292
00:17:27,618 --> 00:17:29,652
WHILE THE ADJOINING
COPPER SURFACES
293
00:17:29,653 --> 00:17:33,254
HAVE BEEN CHEMICALLY ROUGHENED
TO ENHANCE ADHESION.
294
00:17:33,255 --> 00:17:36,559
AFTER DRAWING THE LAYERS
TIGHTLY TOGETHER WITH A VACUUM,
295
00:17:36,560 --> 00:17:38,127
WORKERS PLACE THE LAMINATES
296
00:17:38,128 --> 00:17:40,529
IN A HIGH-TEMPERATURE,
HIGH-PRESSURE CHAMBER
297
00:17:40,530 --> 00:17:42,365
FOR SEVERAL HOURS.
298
00:17:42,366 --> 00:17:46,334
THIS ACTIVATES THE ADHESIVE,
BONDING THE LAYERS.
299
00:17:46,335 --> 00:17:48,137
TO TEST THE BOND STRENGTH,
300
00:17:48,138 --> 00:17:51,441
THEY BURN SOME ADHESIVE OFF
A SAMPLE OF FINISHED LAMINATE
301
00:17:51,442 --> 00:17:54,510
TO PRY APART THE LAYERED EDGE.
302
00:17:54,511 --> 00:17:58,013
THEN, THEY GRAB THE TOP COPPER
LAYER WITH THIS PULLING DEVICE
303
00:17:58,014 --> 00:18:00,015
AND MEASURE THE STRENGTH
REQUIRED TO PEEL
304
00:18:00,016 --> 00:18:02,051
IT OFF THE FILM.
305
00:18:02,052 --> 00:18:05,254
THE LAMINATE'S NOW SHIPPED
TO A CIRCUIT BOARD FACTORY.
306
00:18:05,255 --> 00:18:07,188
HERE, COMPUTER-GUIDED MACHINES
307
00:18:07,189 --> 00:18:09,390
CUT THEM
INTO SPECIFIC-SIZED PANELS
308
00:18:09,391 --> 00:18:11,126
AND DRILL TINY HOLES
FOR MOUNTING
309
00:18:11,127 --> 00:18:13,130
THE ELECTRONIC COMPONENTS.
310
00:18:14,597 --> 00:18:15,798
THEN A COATING MACHINE
311
00:18:15,799 --> 00:18:18,567
USES A COMBINATION
OF HEAT AND PRESSURE
312
00:18:18,568 --> 00:18:22,404
TO APPLY A LIGHT-SENSITIVE FLUID
TO THE PANEL'S SURFACE.
313
00:18:22,405 --> 00:18:25,773
TECHNICIANS LOAD THE PANEL
INTO AN EXPOSURE MACHINE,
314
00:18:25,774 --> 00:18:29,378
IN WHICH A COMPUTER-GUIDED LASER
SCANS THE CIRCUITRY PATTERN
315
00:18:29,379 --> 00:18:31,179
ONTO THE CODED SURFACE.
316
00:18:31,180 --> 00:18:33,681
A LASER IS A BEAM
OF FOCUSED LIGHT,
317
00:18:33,682 --> 00:18:38,052
SO WHEREVER IT HITS,
THE FLUID REACTS AND HARDENS.
318
00:18:38,053 --> 00:18:42,357
THE DARK AREAS
OF UNEXPOSED FLUID REMAIN SOFT.
319
00:18:42,358 --> 00:18:45,895
THE NEXT MACHINE
ACID-WASHES THE SOFT AREAS,
320
00:18:45,896 --> 00:18:47,495
REMOVING BOTH THE FLUID
321
00:18:47,496 --> 00:18:49,430
AND THE COPPER LAYER
UNDERNEATH IT.
322
00:18:49,431 --> 00:18:52,935
NOW THE ONLY COPPER REMAINING
ON TOP OF THE POLYMER FILM
323
00:18:52,936 --> 00:18:55,436
IS IN THE CIRCUITRY PATTERN.
324
00:18:55,437 --> 00:18:56,772
THIS INSPECTION DEVICE
325
00:18:56,773 --> 00:19:00,577
METICULOUSLY CHECKS
EVERY SINGLE COPPER CIRCUIT.
326
00:19:01,910 --> 00:19:05,613
NEXT, THEY REMOVE SURFACE DUST
WITH A STICKY ROLLER.
327
00:19:05,614 --> 00:19:07,181
THE PANEL MUST BE PRISTINE
328
00:19:07,182 --> 00:19:10,052
BEFORE RECEIVING THE SHEET
OF ELECTRICAL INSULATION,
329
00:19:10,053 --> 00:19:14,823
A MERE .25 OF A MILLIMETER
THICK.
330
00:19:14,824 --> 00:19:16,725
TECHNICIANS USE A MAGNIFIER
331
00:19:16,726 --> 00:19:19,395
TO CAREFULLY MATCH UP
ALIGNMENT HOLES ON THE FILM
332
00:19:19,396 --> 00:19:22,432
WITH CORRESPONDING
ALIGNMENT HOLES ON THE PANEL.
333
00:19:22,433 --> 00:19:24,866
BY ACTIVATING
THE FILM'S BUILT-IN ADHESIVE
334
00:19:24,867 --> 00:19:26,435
WITH A SOLDERING IRON,
335
00:19:26,436 --> 00:19:31,039
THEY TACK THE INSULATION
TO THE PANEL AT KEY SPOTS.
336
00:19:31,040 --> 00:19:33,675
THE NEXT STEP IS TO FULLY
LAMINATE THE INSULATION
337
00:19:33,676 --> 00:19:34,975
TO THE PANEL.
338
00:19:34,976 --> 00:19:36,712
TECHNICIANS SANDWICH TWO PANELS
339
00:19:36,713 --> 00:19:40,048
AT A TIME BETWEEN SHEETS
OF PROTECTIVE PLASTIC.
340
00:19:40,049 --> 00:19:42,585
THIS PROTECTS THE SURFACES
FROM THE HEAT AND WEIGHT
341
00:19:42,586 --> 00:19:44,919
OF THE LAMINATION PRESS.
342
00:19:44,920 --> 00:19:48,322
AS IT FORCES THE INSULATION FILM
DEEP DOWN ONTO THE PANEL,
343
00:19:48,323 --> 00:19:51,560
IT ENCAPSULATES THE CIRCUITRY.
344
00:19:51,561 --> 00:19:54,096
THEY LOAD THE PANELS
INTO THE LAMINATION PRESS,
345
00:19:54,097 --> 00:19:57,666
APPLY A VACUUM TO REMOVE
THE AIR BETWEEN THE LAYERS
346
00:19:57,667 --> 00:19:59,735
AND START HER UP.
347
00:19:59,736 --> 00:20:01,771
FOR THE NEXT HOUR AND A HALF,
348
00:20:01,772 --> 00:20:04,941
THE PRESS SIMULTANEOUSLY
APPLIES HIGH PRESSURE
349
00:20:04,942 --> 00:20:09,377
WHILE HEATING THE PANELS
TO 400 DEGREES FAHRENHEIT.
350
00:20:09,378 --> 00:20:12,513
WHEN THE PANELS COOL
AND COME OUT OF THE PRESS,
351
00:20:12,514 --> 00:20:17,752
TECHNICIANS PLACE ONE AT A TIME
ON A CIRCUIT BOARD-SHAPED DYE.
352
00:20:17,753 --> 00:20:19,522
THEN THEY RELEASE A PRESS
353
00:20:19,523 --> 00:20:22,224
WHICH FORCES THE PANEL
ONTO THE SHARP DYE,
354
00:20:22,225 --> 00:20:25,526
SLICING AWAY
THE EXCESS MATERIAL.
355
00:20:25,527 --> 00:20:28,463
THE FLEXIBLE CIRCUIT BOARD
IS NOW READY FOR THE COMPANY
356
00:20:28,464 --> 00:20:31,301
THAT INSTALLS
THE ELECTRONIC COMPONENTS.
357
00:20:34,570 --> 00:20:37,205
THERE ARE TWO WAYS
TO MOUNT COMPONENTS --
358
00:20:37,206 --> 00:20:39,975
SOLDER THEM DIRECTLY
ONTO THE BOARD'S SURFACE
359
00:20:39,976 --> 00:20:41,677
OR SOLDER TINY PRONGS
360
00:20:41,678 --> 00:20:43,846
UNDERNEATH THE COMPONENTS,
KNOWN AS LEADS,
361
00:20:43,847 --> 00:20:46,281
INTO THE BOARD'S MOUNTING HOLES.
362
00:20:46,282 --> 00:20:47,648
A FLEXIBLE CIRCUIT BOARD
363
00:20:47,649 --> 00:20:50,386
CAN HAVE AS FEW
AS A DOZEN COMPONENTS
364
00:20:50,387 --> 00:20:53,154
OR AS MANY AS 500.
365
00:20:53,155 --> 00:20:54,423
TECHNICIANS CAN SOLDER
366
00:20:54,424 --> 00:20:58,126
LARGER ONES
MAGNIFIED UNDER A MICROSCOPE,
367
00:20:58,127 --> 00:21:01,129
BUT ONLY ROBOTS
CAN SOLDER SMALLER ONES
368
00:21:01,130 --> 00:21:02,831
BECAUSE THEY'RE SO TINY
369
00:21:02,832 --> 00:21:05,534
AND BARELY VISIBLE
TO THE HUMAN EYE.
370
00:21:13,275 --> 00:21:15,777
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
371
00:21:15,778 --> 00:21:18,914
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
372
00:21:18,915 --> 00:21:24,321
DROP US A LINE AT
sciencechannel.com/howitsmade.
29991
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.