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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Compact discs...
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...Mozzarella cheese...
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...Pantyhose...
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...And fluorescent tubes.
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Today there's virtually no limit
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To the information
We can store on compact discs.
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Millions of bits of data
Representing words, numbers,
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Music, graphics, or even video
Can be stored on the discs.
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Let's take a "Spin"
Through a cd factory.
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Compact discs are copies made
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From an original
Glass master disc.
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A thin plate of glass
Is first placed in this unit,
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Which brushes the surface clean.
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00:01:24,620 --> 00:01:26,965
Cleaning is done
With de-ionized water
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00:01:26,965 --> 00:01:28,655
And a small goat-hair brush.
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00:01:28,655 --> 00:01:30,793
The excess water is eliminated
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By the rapid rotation
Of the disc.
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00:01:33,379 --> 00:01:36,034
The disc then goes into
This surface analyzer,
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00:01:36,034 --> 00:01:39,793
Where a laser beam inspects
The cleanliness of the surface.
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00:01:48,517 --> 00:01:51,896
At this stage,
Two chemicals are applied --
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00:01:51,896 --> 00:01:54,931
A primer
And a photoresistant coating.
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00:01:54,931 --> 00:01:56,482
This operation is done
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00:01:56,482 --> 00:01:59,310
At a temperature
Of 70 degrees fahrenheit
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00:01:59,310 --> 00:02:01,586
And lasts three minutes.
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The disc is carefully retrieved
From the apparatus.
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00:02:08,379 --> 00:02:13,586
Then the photoresistant coating
Dries in an oven for 30 minutes.
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00:02:18,379 --> 00:02:21,137
This developer has two spouts.
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00:02:21,137 --> 00:02:25,206
One applies a de-ionized water,
And the other sprays a solution
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To develop the data
Etched on the glass.
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The information
Is now engraved on the disc.
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00:02:30,655 --> 00:02:34,517
Then the disc is placed
In this metal-coating equipment.
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00:02:34,517 --> 00:02:37,103
The next step consists
Of applying a thin coating
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Of nickel and vanadium.
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00:02:38,862 --> 00:02:41,724
This electroforming process
Results in the master
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00:02:41,724 --> 00:02:43,965
From which discs will be made.
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00:02:43,965 --> 00:02:46,931
The etched glass is immersed
In a chemical solution
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00:02:46,931 --> 00:02:48,482
For 70 minutes.
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00:02:48,482 --> 00:02:52,689
Then the plated piece is
Removed, thus obtaining a die.
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00:02:54,689 --> 00:02:57,379
The die is sent off
For finishing.
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It is stamped out
Into the desired shape.
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The excess material is recycled.
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Next, the compact discs
Will be fabricated
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From this master unit.
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Here we clearly see
The stamping-out technique.
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00:03:17,931 --> 00:03:20,793
The master is taken out.
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00:03:24,931 --> 00:03:26,862
A technician peels off the film
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Which protected the data
Etched onto the die.
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00:03:29,689 --> 00:03:32,172
After a visual inspection,
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The die is sent
To the pressing department.
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The die is delicately installed
In the mold,
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Which will form compact discs.
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Discs are made
From a very special plastic
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Called "Polycarbonate."
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The mold is closed,
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And liquid polycarbonate
Is injected into the die.
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It comes out as a small,
Hard, translucent disc.
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It is now ready
To be metal-coated
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00:04:04,310 --> 00:04:07,000
So it can be read
By a compact-disc reader.
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A robotic arm lifts the disc
From the mold
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00:04:10,482 --> 00:04:13,000
And places it on these supports.
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This metallizing process is
Extremely short and very simple,
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Taking but a second.
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It consists of covering
The plastic disc
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With a very thin coating
Of aluminum.
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Here we see the inside
Of the mold,
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00:04:43,551 --> 00:04:45,689
Where the aluminum coating
Is applied.
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00:04:51,206 --> 00:04:54,896
In this facility,
Almost everything is automated,
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Helping them produce over
100,000 compact discs per day.
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00:05:04,068 --> 00:05:07,586
Protecting the surface
Of the disc is essential,
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So a coat of varnish is applied.
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00:05:10,137 --> 00:05:13,310
This also helps silk screening
Stick to the surface.
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00:05:16,275 --> 00:05:20,103
Ultraviolet lamps
Quickly dry the varnish.
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00:05:26,827 --> 00:05:30,068
And here in the pressing room,
They apply the label.
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This step is also very fast
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Since the machine prints
70 discs in 60 seconds.
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Once the silk-screening
Is completed,
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The finished discs leave
For packaging.
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Narrator: in a sandwich,
As a topping, or all by itself,
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Cheese has always been
A popular food.
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This dairy product goes back
Thousands of years,
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And it's always started
With three basic ingredients --
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Milk, curds, and whey.
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Just ask little miss muffet.
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Like all cheeses,
Mozzarella starts from milk.
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To assure good milk quality,
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The interior and exterior
Of milk-transport trucks
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Must be washed
After being emptied.
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A tank such as this one
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Can carry an average
Of 8,000 gallons of raw milk
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00:06:29,310 --> 00:06:33,827
At temperatures between
37 and 39 degrees fahrenheit.
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Raw milk destined
For cheesemaking
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Contains 3.8% fats
And 3.3% proteins.
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They store the milk and whey,
A milk by-product,
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In these immense silos,
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Each with a capacity
Of 59,000 gallons.
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This milk separator
Extracts surplus cream
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00:06:52,827 --> 00:06:54,586
To adjust the percentage of fat
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According to
The type of cheese to be made.
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Fabrication begins
With this tank,
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Which feeds the pasteurizer.
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Pasteurization
Sterilizes beverages
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00:07:03,827 --> 00:07:05,724
Which can easily ferment.
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00:07:05,724 --> 00:07:07,689
Milk samples are drawn off
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00:07:07,689 --> 00:07:11,000
To accurately determine their
Milk-fat and protein content.
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00:07:11,000 --> 00:07:13,827
Tests are carried out
In this laboratory,
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00:07:13,827 --> 00:07:15,724
Where they impose controls.
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00:07:15,724 --> 00:07:18,344
These test tubes
Contain milk samples
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Which will undergo
Microbiological analysis.
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Milk quality must be impeccable.
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00:07:27,827 --> 00:07:32,620
This is a curdler with
A capacity of 6,600 gallons.
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Here milk and other essential
Ingredients are introduced,
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Such as the enzyme, rennet,
That curdles the milk.
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This mix must be well-stirred
And cooked.
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The agitators are used to
Cut the whey into little lumps.
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This step takes
About 30 minutes.
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00:07:50,620 --> 00:07:51,965
The temperature of the tanks
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00:07:51,965 --> 00:07:55,000
Depends on the type of cheese
They're making.
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Agitators
Continue stirring the milk.
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00:07:59,310 --> 00:08:00,689
Once cooking is done,
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00:08:00,689 --> 00:08:03,620
The whey is pumped
Onto tables to be drained.
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00:08:03,620 --> 00:08:07,655
It stays there
For about 25 minutes.
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00:08:07,655 --> 00:08:12,896
The solid and the liquid
Are now well-separated.
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00:08:21,310 --> 00:08:25,034
The liquid we see draining
Is called the "Lactoserum."
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00:08:25,034 --> 00:08:28,034
The lactoserum
Will be concentrated
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00:08:28,034 --> 00:08:31,206
And transformed
Into milk by-products.
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00:08:35,896 --> 00:08:38,827
The water has been
Almost entirely extracted,
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00:08:38,827 --> 00:08:42,655
And the cheese particles
Are now sufficiently dry.
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00:08:48,724 --> 00:08:50,482
This large automated blade
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00:08:50,482 --> 00:08:53,931
Then moves cheese particles
Towards the next step --
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The molder.
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In the molder,
The cheese is cut up
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00:09:06,034 --> 00:09:08,586
Before being carried
To the cooker --
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The final processing step.
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It appears that this mozzarella
Has just the right texture.
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00:09:30,206 --> 00:09:32,931
The cheese finally arrives
At the molder,
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00:09:32,931 --> 00:09:35,482
Which will give it
The proper shape.
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00:09:35,482 --> 00:09:41,379
Each mold has a 5 1/2-pound
Capacity and is rectangular.
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00:09:41,379 --> 00:09:46,344
Brine, a salt solution, cools
And salts the cheese blocks.
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The blocks are unmolded
And fall into a brine tank.
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The cheese blocks will remain
In another brine solution
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00:09:58,965 --> 00:10:00,413
For a while.
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00:10:00,413 --> 00:10:03,482
Then they're carried by
A conveyor towards another tank,
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00:10:03,482 --> 00:10:06,344
Where they will be immersed
For 4 to 10 hours
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00:10:06,344 --> 00:10:09,758
At a temperature
Of 36 degrees fahrenheit.
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00:10:14,620 --> 00:10:16,931
Sprays of brine remove the foam
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00:10:16,931 --> 00:10:20,413
Which forms
At the surface of the tank.
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00:10:20,413 --> 00:10:22,586
The 8,000 gallons of milk
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We saw coming in by truck
At the beginning
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00:10:25,241 --> 00:10:29,482
Have enabled the factory to
Produce 1,400 blocks of cheese
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00:10:29,482 --> 00:10:32,103
In 8 to 12 hours.
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00:10:32,103 --> 00:10:34,931
Finally, the cheese blocks
Are vacuum-packed
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00:10:34,931 --> 00:10:37,310
And ready for shipment.
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00:10:47,379 --> 00:10:51,137
Narrator: there was a time
When women wore silk stockings.
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00:10:51,137 --> 00:10:53,758
Then came the invention
Of pantyhose,
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A cheaper,
More convenient alternative.
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Pantyhose are knitted
From strands of raw nylon.
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It's no "Stretch"
Of the imagination to say
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That when they go on sale,
There's usually a "Run" on them.
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00:11:12,310 --> 00:11:15,620
Making a nylon stocking
Takes only a few minutes.
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00:11:15,620 --> 00:11:18,413
However,
It's a complex operation
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00:11:18,413 --> 00:11:21,379
That involves the knitting
Of five to eight threads
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As fine as a hair.
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The threads,
Usually nylon and spandex,
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00:11:25,586 --> 00:11:27,689
Are used along with elastic.
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00:11:27,689 --> 00:11:30,482
Sometimes polyester or cotton
Are added.
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00:11:30,482 --> 00:11:33,379
The knitting machine
Goes into action.
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00:11:33,379 --> 00:11:37,344
This one fashions a tube for
Sheer stockings in 90 seconds.
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00:11:37,344 --> 00:11:40,103
In three minutes,
It makes a tube for tights.
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00:11:40,103 --> 00:11:43,965
Its speed is adjusted according
To the product being made,
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00:11:43,965 --> 00:11:48,758
Varying between 750 and 1,200
Revolutions per minute.
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00:11:48,758 --> 00:11:52,620
Once the tube is knitted, it is
Sucked up and lands in a bag,
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Where it will be inspected.
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00:11:54,862 --> 00:11:58,068
More than 500 machines
Share the work,
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00:11:58,068 --> 00:12:00,724
Each making a specific model.
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00:12:04,310 --> 00:12:07,172
The two ends must now be joined.
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00:12:07,172 --> 00:12:10,758
This automated machine assembles
The two tubes together
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00:12:10,758 --> 00:12:12,758
To form the pantyhose.
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Then scissors
Cut the pantyhose,
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00:12:21,551 --> 00:12:24,758
A necessary step
In production of a pair.
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This opening is enlarged
To allow for sewing,
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00:12:31,896 --> 00:12:36,103
Which will join the two tubes
At the top of the leg.
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The label with the size
Or brand name
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00:12:38,655 --> 00:12:42,413
Is sewn in place in 10 seconds
By this robotic machine.
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00:12:42,413 --> 00:12:47,551
At this pace, it sews on
4,800 labels in 8 hours.
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00:12:47,551 --> 00:12:50,551
Installing a gusset
Requires some preparation.
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00:12:50,551 --> 00:12:53,448
Scissors makes a hole
At the joining point.
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00:12:53,448 --> 00:12:56,655
Then the stocking
Is turned inside out by suction
191
00:12:56,655 --> 00:13:00,034
So certain stitching
Can be done on the inside.
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00:13:00,034 --> 00:13:03,965
Thus, these stitches
Will be less visible.
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00:13:16,586 --> 00:13:19,103
Now the foot must be sewn.
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00:13:19,103 --> 00:13:22,034
This robotic machine
Places the foot in position.
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00:13:22,034 --> 00:13:24,344
Then a sewing machine
Makes stitches
196
00:13:24,344 --> 00:13:28,344
At the same time it cuts away
Excess material.
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00:13:28,344 --> 00:13:32,655
This step takes only 10 seconds.
198
00:13:32,655 --> 00:13:35,413
Then the pantyhose
Is turned right side out,
199
00:13:35,413 --> 00:13:38,000
Again using suction.
200
00:13:45,620 --> 00:13:49,034
Everything is ready
For installation of the gusset.
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00:13:49,034 --> 00:13:53,172
The pantyhose is placed in a tub
And taken to this department.
202
00:13:53,172 --> 00:13:55,310
The stocking is again suctioned
203
00:13:55,310 --> 00:13:58,137
And placed on a gusset machine
By the operator.
204
00:13:58,137 --> 00:14:01,931
This method assures that
The gusset will be well-centered
205
00:14:01,931 --> 00:14:03,551
Without a pleat.
206
00:14:06,034 --> 00:14:09,034
Putting in the gusset is the
Final operation in the process.
207
00:14:09,034 --> 00:14:10,655
A precut piece of cotton
208
00:14:10,655 --> 00:14:13,655
Is slid into the space
Reserved for the gusset
209
00:14:13,655 --> 00:14:16,931
And automatically sewn in.
210
00:14:19,586 --> 00:14:21,586
Only aesthetic touches remain,
211
00:14:21,586 --> 00:14:24,827
Such as adding a little color
To the pantyhose.
212
00:14:24,827 --> 00:14:26,862
They're placed in this machine,
213
00:14:26,862 --> 00:14:29,896
Which has a large drum
With four compartments
214
00:14:29,896 --> 00:14:31,965
And a 99-pound capacity.
215
00:14:31,965 --> 00:14:34,758
The pantyhose are washed
In soapy water,
216
00:14:34,758 --> 00:14:36,310
Then immersed in dye.
217
00:14:36,310 --> 00:14:40,241
Temperature climbs gradually
To 200 degrees fahrenheit.
218
00:14:40,241 --> 00:14:43,862
After a 5-minute rinsing cycle,
A softener is added.
219
00:14:43,862 --> 00:14:48,206
This process takes 2 1/2 hours.
220
00:14:48,206 --> 00:14:51,137
Once dried,
They proceed to inspection.
221
00:14:51,137 --> 00:14:53,827
The pantyhose
Is placed onto a form
222
00:14:53,827 --> 00:14:55,931
Which stretches it
To allow inspection
223
00:14:55,931 --> 00:14:58,310
For any imperfections.
224
00:14:58,310 --> 00:14:59,586
If all is well,
225
00:14:59,586 --> 00:15:02,827
The pantyhose is transferred
Onto another metal form,
226
00:15:02,827 --> 00:15:04,310
Where it will be pressed.
227
00:15:08,068 --> 00:15:12,517
The pantyhose's position
Is guided by a magic eye.
228
00:15:14,655 --> 00:15:18,000
The pantyhose is then
Carried toward a steam room,
229
00:15:18,000 --> 00:15:20,931
Where it will stay
For 2 1/2 seconds
230
00:15:20,931 --> 00:15:25,344
Before being dried in
7 1/2 seconds at 280 degrees.
231
00:15:25,344 --> 00:15:29,758
They fold and pack
420 pantyhose per hour
232
00:15:29,758 --> 00:15:33,793
And make 180,000 pairs per day.
233
00:15:45,103 --> 00:15:47,137
Narrator: throughout the ages,
Artificial light
234
00:15:47,137 --> 00:15:50,413
Has let people extend
The convenience of daylight
235
00:15:50,413 --> 00:15:52,517
Long after the sun goes down.
236
00:15:52,517 --> 00:15:55,413
Fluorescent tubes
Are more energy-efficient
237
00:15:55,413 --> 00:15:56,827
Than light bulbs.
238
00:15:56,827 --> 00:16:00,689
That's probably why they've
Become a "Fixture," so to speak,
239
00:16:00,689 --> 00:16:04,000
In stores, factories,
And offices.
240
00:16:10,275 --> 00:16:14,103
Once, the only source of light
Was the flame of fire
241
00:16:14,103 --> 00:16:17,482
In the forms of torch,
Candle, and oil lamps.
242
00:16:17,482 --> 00:16:20,827
It remained so
Right up until the 19th century,
243
00:16:20,827 --> 00:16:24,413
When gaslight made its first
Appearance around 1840.
244
00:16:24,413 --> 00:16:26,000
Almost 40 years later,
245
00:16:26,000 --> 00:16:30,068
Thomas edison invented his
Famous incandescent light bulb.
246
00:16:30,068 --> 00:16:31,551
In 1909,
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The frenchman georges claude
Developed the fluorescent tube,
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A light that remains unaltered
To this very day.
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Did you know that mercury
Allows us to see in the dark?
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The production of fluorescent
Lamps is highly complex.
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The fabrication process
Starts with glass tubes
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That have been meticulously
Cleaned with warm water
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To remove dirt and impurities.
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Then the tubes have to be
Specifically shaped
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With a folder-shaper.
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They're heated for 30 seconds,
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Then quickly curved
Using a template.
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This automated machine
Can bend 14 tubes a minute.
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The bent tubes go into
The coating chamber,
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Where a thin coat of phosphorus
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Is applied
To their inner surfaces.
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Phosphorus produces light by
Transforming ultraviolet photons
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Generated by the ionization
Of mercury.
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The surplus phosphorus
Is removed
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From the ends of the tube
To facilitate sealing.
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They now move
To the electrical components.
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The cathode mount is made
In this auto mount.
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Here, they make the wire
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That will carry the current
From the mount.
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The wire carrying the current
Is shaped.
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And here, the wire is heated.
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This prepares it
For the next step.
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It's essential to prevent
The cathode coating
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From spreading to the prongs.
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The filaments are inserted
Into their mounts.
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The emissive substance plays
A crucial role.
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When heated, it emits electrons,
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Which participate
In producing light.
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The emissive substance
Is actually this liquid.
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The wiring mount is transferred
From the auto mount
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To the sealing machine.
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At this stage,
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The wiring mount
And the glass tube are joined.
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Sealing is done
At a very high temperature.
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One important step remains.
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This is where the glass tube
Is emptied of air
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And filled with gas.
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00:19:27,344 --> 00:19:29,724
This machine also
Decarbonizes the tube
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And introduces
The drop of mercury
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Essential for producing light.
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Once the very tiny drop
Of mercury
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Is injected into the tube,
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The fluorescent lamp
Is almost completed.
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But one step remains.
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This threader positions
The wires
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For insertion of the tube cap,
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Which establishes
Electrical contact.
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The tube cap is placed
Into position
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In preparation for sealing.
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The cap must be
Securely attached
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And installed
In a watertight manner
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To eliminate
Any risk of leaking.
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The capper permanently seals
The cap onto the tube,
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And it's all finished.
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Each lamp is tested
On a large testing wheel
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To verify its quality
And performance.
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Once the meticulous inspection
Is over,
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The fluorescent lamps
Are carried
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To the packaging department.
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A robotic machine handles
The lamps
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And places them
Into the packages.
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The glass tubes have now
Become fluorescent lamps.
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If you have any comments
About the show,
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Or if you'd like to suggest
Topics for future shows,
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Drop us a line at...
25086
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