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--captions by vitac--
Www.Vitac.Com
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00:00:05,206 --> 00:00:08,172
Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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00:00:26,379 --> 00:00:28,172
Aluminum screw caps --
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We'll pop the top
Off this manufacturing secret.
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Chocolate --
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There's nothing like
The taste of sweet success.
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Pills --
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Watch as directed.
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And pasta --
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We'll visit a factory that
Churns out oodles of noodles.
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00:00:52,896 --> 00:00:55,517
Twisting off
An aluminum screw cap
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00:00:55,517 --> 00:00:58,344
May lack the style
And sophistication
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00:00:58,344 --> 00:01:01,379
Of uncorking
A fine bottle of wine.
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00:01:01,379 --> 00:01:02,862
But as devices go,
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These caps are one
Of the easiest ways
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To put an airtight seal
On a bottle or jar,
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00:01:08,344 --> 00:01:13,137
And the added bonus is that
They're entirely recyclable.
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00:01:16,620 --> 00:01:20,000
There are hundreds of everyday
Objects that are capped.
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This plant makes 250 million
Metal screw caps yearly
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In 12 different sizes.
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The caps are made
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From these 11-square-foot sheets
Of aluminum
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Weighing one pound.
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Some 3,500 thin aluminum sheets
Pass through this feeder.
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00:01:34,965 --> 00:01:37,827
They begin by coloring
The aluminum sheet
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With a colored varnish --
A lacquer and an ink.
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00:01:41,793 --> 00:01:44,827
Then 12 minutes of drying
Is needed.
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The colored sheets set off
On a conveyor for drying.
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00:01:52,551 --> 00:01:54,724
Then designs are produced.
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00:01:54,724 --> 00:01:57,413
The coloring is applied
By this varnisher.
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00:02:01,137 --> 00:02:05,724
The aluminum sheets pass through
The varnisher one at a time.
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00:02:11,827 --> 00:02:14,379
Here we see the sheet printed.
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Above are the colors used.
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They are highly colored inks
That adhere well to metal.
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Suction cups grab the sheets
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00:02:28,724 --> 00:02:31,689
And send them toward
The transport system
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Of the punch press.
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This press will give the caps
The required shape.
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But the caps have to be machined
In successive steps by molds,
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Such as this one.
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The punches first cut the caps.
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Over 500 caps a minute
Can be produced.
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The blades of the punches
Are made of carbide,
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A very hard metal that can cut
Tens of millions of caps.
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At the exit point
Of the punch press,
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The caps are formed, but don't
Yet have the right dimension.
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00:03:06,965 --> 00:03:11,275
This stretching press performs
The last two cold-forming steps
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00:03:11,275 --> 00:03:14,275
So that the tube will have
The required length.
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00:03:15,655 --> 00:03:18,034
Now for the second stretching.
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00:03:18,034 --> 00:03:21,275
This achieves
The desired diameter.
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00:03:21,275 --> 00:03:23,827
When the cap exits the press,
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00:03:23,827 --> 00:03:27,413
It will finally have
The desired dimensions.
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At this point, the cap now has
The required shape.
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The caps now have to be
Decorated
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To the client's requirements.
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The lateral imprint is made with
This silk-screen-type decorator
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00:03:41,413 --> 00:03:45,896
Which colors some 100 caps
In 60 seconds.
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00:03:49,724 --> 00:03:51,482
The decorator uses an ink
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00:03:51,482 --> 00:03:54,655
Specially formulated to adhere
To metal.
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00:04:00,344 --> 00:04:04,482
The caps will then dry
In a warm-air oven.
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The dried caps are ejected
And fall into a container.
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00:04:14,620 --> 00:04:17,551
This other flexographic type
Of decorator
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Prints 155 caps a minute.
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We can clearly see
The ink roller,
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Which imprints the side
Of the caps
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As they rotate against it
In a steady stream.
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All that's required now is to
Form the cap and make the cut.
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00:04:39,482 --> 00:04:42,206
The profiling and jointing
Machine
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Makes the cuts and reliefs
On 200 caps per minute.
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00:04:48,862 --> 00:04:52,586
Machining the cap takes
But a fraction of a second.
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00:04:58,034 --> 00:05:01,034
They sometimes have to assure
The watertightness
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Of a container
Such as a wine bottle.
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00:05:03,517 --> 00:05:06,655
For this, a polypropylene liner
Is inserted,
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00:05:06,655 --> 00:05:09,275
Which hermetically
Seals the container.
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00:05:12,482 --> 00:05:14,896
A check is carried out
Under a light
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To verify whether the cut
Has been properly made
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And the ridges well-formed.
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At last, the final steps --
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This screw-tightening machine
Hermetically seals the caps
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Onto the bottles.
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The 250 million screw caps
Made here each year
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Call for the machining
Of 1,000 tons of aluminum.
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Narrator: working
In a chocolate factory --
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Talk about
A childhood fantasy.
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Well, "How it's made"
Is about to take a bite
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Out of one of the all-time
Great dream jobs.
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Just beware
Of the occupational hazards --
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00:06:04,793 --> 00:06:09,551
Stomachache, weight gain,
And cavities.
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00:06:12,931 --> 00:06:15,344
These delicious chocolate
Confections
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Are made from melted chocolate
Flowing into molds.
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00:06:18,482 --> 00:06:21,206
The master molds
Are first made of wood
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Or plaster of paris.
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They are then reproduced as
Copies in an epoxy material.
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To allow them to become flexible
And give them the desired shape,
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The sheets of epoxy
Are first heated
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To 350 degrees.
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The epoxy sheet is then placed
Onto the original molds.
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The sheet is heated,
Then lifted off.
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Suction from a vacuum system
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Makes it adhere perfectly
To the shapes of the molds.
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Here we see the epoxy adhering
To the master molds.
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Still hot and malleable,
The plastic has to be cooled.
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A jet of compressed air
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00:07:05,206 --> 00:07:07,655
Effectively lowers
Its temperature.
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00:07:09,620 --> 00:07:12,551
The mold undergoes
A visual inspection
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00:07:12,551 --> 00:07:14,931
To make certain of its quality.
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00:07:16,103 --> 00:07:18,862
And now we move on
To the chocolate.
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00:07:23,448 --> 00:07:26,896
This melting unit, whose shell
Is fed by boiling water,
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00:07:26,896 --> 00:07:28,448
Is like a double boiler
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00:07:28,448 --> 00:07:32,655
And melts 1 1/2 tons
Of chocolate in 12 hours
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At about 100 degrees.
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The ready-to-be-filled
Plastic molds
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Are placed onto a conveyor.
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Filling is done automatically.
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Liquid chocolate runs directly
Into the molds.
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This particular machine produces
400 hearts a minute.
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00:07:49,862 --> 00:07:52,931
The hearts are filled
With a concoction of chocolate,
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00:07:52,931 --> 00:07:57,103
Cream, and coffee that has been
Brewed for several minutes.
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00:07:57,103 --> 00:07:59,758
It takes 20 minutes
For the chocolate to set
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00:07:59,758 --> 00:08:04,551
As the molds move along
On this 9-level conveyor.
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00:08:04,551 --> 00:08:08,896
Well-hardened, the hearts arrive
At the unmolding point.
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00:08:08,896 --> 00:08:10,724
The molds are turned over,
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00:08:10,724 --> 00:08:13,310
And a rod lightly taps them
On the bottom
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00:08:13,310 --> 00:08:16,620
To allow the chocolates to fall
Out without being broken.
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00:08:19,103 --> 00:08:23,241
The chocolates fall out
Onto a sheet.
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00:08:24,758 --> 00:08:26,620
As soon as they've been emptied,
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00:08:26,620 --> 00:08:29,517
The molds return to the starting
Point on the line
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00:08:29,517 --> 00:08:31,344
To be newly filled.
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00:08:35,655 --> 00:08:37,517
During their transport
On the line,
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00:08:37,517 --> 00:08:40,379
The chocolates complete
Their cooling and hardening.
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00:08:46,137 --> 00:08:49,344
Now they're going to be prepared
For packaging.
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00:08:50,620 --> 00:08:53,655
Packaging depends
On customers' preferences.
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00:08:53,655 --> 00:08:57,379
The chocolates can be sold
In bulk or placed in boxes.
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00:08:57,379 --> 00:09:02,275
Here, 185 hearts
Are put into each box.
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00:09:03,379 --> 00:09:04,896
Like the pure chocolate,
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00:09:04,896 --> 00:09:08,965
White chocolate comes in
As slabs before melting.
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00:09:08,965 --> 00:09:11,344
Milk chocolate
Is often delivered
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In the form
Of one-inch pastilles.
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00:09:14,896 --> 00:09:16,724
Some chocolates are hollow.
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00:09:16,724 --> 00:09:19,137
They have to be molded
In two halves.
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00:09:19,137 --> 00:09:22,034
These chocolate bears
Need special decorations
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00:09:22,034 --> 00:09:25,379
Applied by hand before
The pouring of liquid chocolate.
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00:09:25,379 --> 00:09:27,827
This decoration is made
Of white chocolate
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00:09:27,827 --> 00:09:30,965
With an added colorant.
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00:09:30,965 --> 00:09:35,931
In just one hour,
They will make 1,200 bears.
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00:09:35,931 --> 00:09:39,551
They're made by joining
Two hollow chocolate halves.
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00:09:41,655 --> 00:09:45,965
The assembly is done using
A refrigerated rotating machine.
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00:09:48,034 --> 00:09:53,344
This machine turns the molds
A full 360 degrees on two axes
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00:09:53,344 --> 00:09:55,758
And vibrates the chocolates
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00:09:55,758 --> 00:09:57,931
To prevent the formation
Of air bubbles.
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00:09:57,931 --> 00:10:00,000
The chocolates rotate
For five minutes
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00:10:00,000 --> 00:10:02,310
Before being sent
To the cooling conveyor,
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00:10:02,310 --> 00:10:05,827
Where they will remain
For another 20-minute period.
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00:10:09,275 --> 00:10:10,689
And now they're ready.
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00:10:10,689 --> 00:10:13,137
At this point,
The bears are unmolded,
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00:10:13,137 --> 00:10:15,586
And they head off for packaging.
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00:10:23,275 --> 00:10:24,793
Each year,
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00:10:24,793 --> 00:10:28,931
This company processes 550 tons
Of pure chocolate.
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00:10:28,931 --> 00:10:31,172
Many thousands of products
Are made here
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Using 400 different molds
In a variety of sizes.
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00:10:47,586 --> 00:10:51,103
Narrator: now, here's a topic
That's easy to swallow --
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How drug companies
Make the pills we take.
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00:10:53,896 --> 00:10:56,517
It's a carefully-monitored
Process
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In which quality control
Is paramount.
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00:11:00,103 --> 00:11:01,689
So stand by --
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00:11:01,689 --> 00:11:05,206
We're going to give you a taste
Of your own medicine,
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00:11:05,206 --> 00:11:07,344
Or at least
What goes into making it.
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00:11:11,344 --> 00:11:15,517
Medications are essential
In the treatment of illnesses.
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00:11:15,517 --> 00:11:17,379
It begins by a grinding process
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00:11:17,379 --> 00:11:20,344
Where the active ingredient
In a tablet or pill
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00:11:20,344 --> 00:11:23,172
Is ground and mixed
With a binding agent.
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00:11:23,172 --> 00:11:25,827
The quantity of the ingredient
Needed to be ground
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00:11:25,827 --> 00:11:29,517
Is transported to the dryer
In this container.
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00:11:29,517 --> 00:11:31,172
Like all the other equipment,
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00:11:31,172 --> 00:11:33,724
This container is made
Of stainless steel
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00:11:33,724 --> 00:11:36,517
So as not to contaminate
The product.
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00:11:36,517 --> 00:11:38,034
The temperature of the dryer
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00:11:38,034 --> 00:11:41,896
And the airflow are programmed
With this interface.
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00:11:45,724 --> 00:11:49,724
The granulation has to be dried
At around 100 or 120 degrees
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00:11:49,724 --> 00:11:54,206
Before being shaped
Into the desired tablet form.
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Molding of the pills
Is done by this press,
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00:11:57,413 --> 00:11:59,413
Which crushes the powder.
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00:11:59,413 --> 00:12:01,448
The press exerts a pressure
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00:12:01,448 --> 00:12:04,103
Varying between
Two and five tons.
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00:12:05,310 --> 00:12:07,448
Here's how the molding
Is done --
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00:12:07,448 --> 00:12:10,000
The press magazine distributes
The powder
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00:12:10,000 --> 00:12:11,758
In molds made of steel disks.
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00:12:11,758 --> 00:12:14,344
Two stampers, one above
And the other below,
190
00:12:14,344 --> 00:12:17,379
Crush the powder
And form the pill.
191
00:12:19,034 --> 00:12:22,379
Here the press operates
At full capacity.
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00:12:22,379 --> 00:12:25,827
It can produce 5,000 pills
Per minute.
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00:12:25,827 --> 00:12:31,241
Quality testing is carried out
On 5 pills every 15 minutes.
194
00:12:31,241 --> 00:12:34,275
Their hardness is verified
With this apparatus
195
00:12:34,275 --> 00:12:36,620
In which jaws crush it
With a force
196
00:12:36,620 --> 00:12:41,586
Varying between .3 and 3 psi,
Or pounds per square inch.
197
00:12:41,586 --> 00:12:44,620
The pills must now be coated
So that they won't crumble.
198
00:12:44,620 --> 00:12:49,827
A coating solution made of water
And coloring pigments is used.
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00:12:51,586 --> 00:12:53,931
This is the coating unit.
200
00:12:53,931 --> 00:12:58,379
It can hold 350 pounds of pills.
201
00:12:58,379 --> 00:13:01,689
Three plastic tubes,
Strategically positioned,
202
00:13:01,689 --> 00:13:05,482
Will spray the solution
Onto the pills in motion.
203
00:13:05,482 --> 00:13:09,965
The quantity of dry pills to be
Coated is put into the unit.
204
00:13:20,551 --> 00:13:24,413
Then the door of the coating
Unit is carefully closed.
205
00:13:26,448 --> 00:13:30,931
A drum turns inside the unit,
Tumbling the pills.
206
00:13:32,137 --> 00:13:35,586
Then nozzles spray the solution
In the form of a mist
207
00:13:35,586 --> 00:13:37,103
That quickly dries,
208
00:13:37,103 --> 00:13:39,586
Preventing the pills from
Sticking to one another.
209
00:13:41,000 --> 00:13:45,000
This spraying operation
Lasts 40 minutes.
210
00:13:45,000 --> 00:13:46,931
Here we can compare pills.
211
00:13:46,931 --> 00:13:49,551
On the left are those made
Only of powder,
212
00:13:49,551 --> 00:13:52,482
While on the right
Are the spray-coated ones.
213
00:13:53,931 --> 00:13:57,655
The finished pills move down
A chute to enter a counter
214
00:13:57,655 --> 00:13:59,724
Prior to filling bottles.
215
00:13:59,724 --> 00:14:03,448
They are lined up in grooves
To make filling easier.
216
00:14:07,793 --> 00:14:10,482
The quantity of pills
To be placed into bottles
217
00:14:10,482 --> 00:14:15,068
Is controlled by this automated
Unit connected to the counter.
218
00:14:15,068 --> 00:14:19,241
In this instance, 500 pills
Are poured into each bottle.
219
00:14:19,241 --> 00:14:21,310
This plant also makes capsules
220
00:14:21,310 --> 00:14:23,965
Where the ingredient
Is not crushed,
221
00:14:23,965 --> 00:14:26,724
But encapsulated
In a gelatin casing.
222
00:14:26,724 --> 00:14:30,068
The distributor places the two
Halves of the capsules
223
00:14:30,068 --> 00:14:32,482
In the proper position
For filling,
224
00:14:32,482 --> 00:14:35,413
With the wider half
Situated above.
225
00:14:35,413 --> 00:14:39,241
The top and the bottom portions
Of the capsule are separated.
226
00:14:39,241 --> 00:14:42,000
The lower half is then filled
With powder.
227
00:14:45,517 --> 00:14:47,275
When well-filled,
228
00:14:47,275 --> 00:14:50,275
The two halves of the capsule
Are joined together.
229
00:14:51,689 --> 00:14:56,379
The completed capsules are then
Ejected from the filling unit.
230
00:14:57,620 --> 00:14:59,310
Then, via centrifugal force,
231
00:14:59,310 --> 00:15:02,172
They are positioned
For the packaging process.
232
00:15:06,068 --> 00:15:10,241
The weight of each capsule
Is verified by this counter.
233
00:15:10,241 --> 00:15:13,586
Each capsule must have
The precise weight.
234
00:15:16,172 --> 00:15:18,241
The final step is packaging.
235
00:15:18,241 --> 00:15:21,586
A sheet of transparent pvc
Is heat-embossed,
236
00:15:21,586 --> 00:15:24,172
Forming an impression
To receive capsules.
237
00:15:24,172 --> 00:15:26,965
Then a preglued
Aluminum foil sheet
238
00:15:26,965 --> 00:15:30,551
Is adhered to the back side,
Sealing everything in.
239
00:15:30,551 --> 00:15:34,655
This plant turns out millions of
Pills and capsules every year.
240
00:15:44,344 --> 00:15:48,655
Narrator:
Ever since marco polo brought
The noodle back from china
241
00:15:48,655 --> 00:15:50,758
Some 700 years ago,
242
00:15:50,758 --> 00:15:55,620
Pasta has earned its place
On tables around the world.
243
00:15:55,620 --> 00:15:59,137
Pasta comes in an array
Of shapes and sizes,
244
00:15:59,137 --> 00:16:01,379
Like the diehard pasta lovers
245
00:16:01,379 --> 00:16:04,137
Who just can't seem
To get enough.
246
00:16:10,344 --> 00:16:13,206
Pasta is actually chinese
In origin.
247
00:16:13,206 --> 00:16:16,517
When marco polo returned
To venice in 1295
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After spending 24 years
In the far east,
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He brought back with him
Chinese pasta noodles.
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00:16:22,344 --> 00:16:26,724
Pasta became popular so quickly
That by the 15th century,
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It occupied a prime position
In italian cooking.
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In this same era, commercial
Production began in naples.
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Italians today favor macaronis
And raviolis
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With garlic and cheese.
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00:16:46,724 --> 00:16:50,344
Pastas are generally made
From semolina and water.
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These silos contain
More than 33 tons of semolina,
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Derived from durum wheat.
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The semolina heads toward
The high-speed premixer,
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Where it will be vigorously
Mixed with water
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For 5 to 10 seconds.
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This machine can treat
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Between one and two tons
Of semolina per hour.
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The dough is extracted
From the premixer
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And falls into a first-blade
Mixer open to the air.
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Then the dough goes
Into this vacuum-blade mixer.
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The mix is now ready to go
Through the brass molds.
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Here's a spaghetti mold
And a mold for mafalda --
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Very narrow lasagna.
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Here are molds used to make
Lined shells...
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And stars for soups...
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As well as cresto di gallo.
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00:17:41,172 --> 00:17:45,379
The dough is injected
Into the mold under pressure.
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00:17:45,379 --> 00:17:50,241
This rotating blade machine cuts
Some 12,000 rotinis per minute.
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00:17:50,241 --> 00:17:52,206
That's 720,000 per hour.
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00:17:52,206 --> 00:17:56,896
With the dough being still quite
Fresh, the rotinis are soft.
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They will dry somewhat
On this plate.
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Now we move to the lasagnas.
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The dough goes
Through this brass mold,
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00:18:07,310 --> 00:18:11,448
And the strips of fresh dough,
42 inches long,
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00:18:11,448 --> 00:18:15,758
Are placed on these sticks
To dry at 150 degrees.
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00:18:15,758 --> 00:18:20,586
They dry vertically so as to
Retain their nice, flat shape.
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00:18:26,413 --> 00:18:28,931
After drying for 15 hours,
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00:18:28,931 --> 00:18:31,275
The strips are then cut
In four --
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00:18:31,275 --> 00:18:36,000
Thus making four strips
Measuring about 10 inches each.
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00:18:36,000 --> 00:18:39,448
To minimize losses and make
Cutting the dry lasagna easier,
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00:18:39,448 --> 00:18:41,586
Scissors trim the dough pieces
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00:18:41,586 --> 00:18:44,137
Into equal lengths
On the sticks.
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00:18:44,137 --> 00:18:47,724
The long lasagna-drying process
Begins.
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00:18:50,517 --> 00:18:54,172
Once dry, the lengths
Of lasagnas are finally cut.
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00:18:54,172 --> 00:18:56,482
They're now ready for packaging.
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00:18:57,206 --> 00:18:59,137
To make some
Of the other pastas,
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00:18:59,137 --> 00:19:01,172
The mix has to be worked
A bit more
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00:19:01,172 --> 00:19:03,586
In order for it to have
The required shape.
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00:19:03,586 --> 00:19:05,413
The dough goes through
This roller,
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00:19:05,413 --> 00:19:07,931
Which gives it
The desired thickness.
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00:19:09,827 --> 00:19:12,068
And now butterflies are formed.
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00:19:12,068 --> 00:19:15,896
This mold cuts 7,500 of them
A minute
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00:19:15,896 --> 00:19:19,448
For a total of 450,000 an hour.
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00:19:19,448 --> 00:19:22,551
The sheet of dough
Is two feet wide.
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00:19:22,551 --> 00:19:25,068
It is produced
In a steady stream
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00:19:25,068 --> 00:19:27,448
And goes right
To the cutting mold.
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00:19:28,827 --> 00:19:32,620
The butterflies fall onto
This conveyor to dry somewhat.
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00:19:32,620 --> 00:19:35,379
Then they head toward
The next production step.
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00:19:35,379 --> 00:19:36,896
Certain short pastas,
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00:19:36,896 --> 00:19:39,620
Such as these butterflies
And fusillis,
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00:19:39,620 --> 00:19:43,206
Have to be dried, so they're
Then put into this full dryer.
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00:19:45,793 --> 00:19:47,551
Coming out of the dryer,
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00:19:47,551 --> 00:19:50,689
The pastas are hard
And ready for packaging.
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00:19:52,034 --> 00:19:55,551
Here we see the ever-popular
Spaghettis being made.
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00:19:55,551 --> 00:19:59,241
As with lasagnas, spaghettis are
Also dried vertically.
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00:20:02,689 --> 00:20:05,448
Now this automated machine
Places the spaghettis
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00:20:05,448 --> 00:20:09,068
Onto a cutting table and breaks
Them to the proper length.
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00:20:10,620 --> 00:20:14,034
The spaghettis are now ready
For packaging.
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00:20:14,034 --> 00:20:18,103
Exact quantities to be bagged
Are determined by computer.
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00:20:18,103 --> 00:20:22,137
Then the spaghettis go gently
Down the chute.
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00:20:27,517 --> 00:20:30,310
The amount of spaghetti
Going into each bag
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00:20:30,310 --> 00:20:33,689
Is transported and emptied out
By this moving container.
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00:20:35,689 --> 00:20:37,275
To make filling easier,
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00:20:37,275 --> 00:20:40,448
The spaghettis are properly
Positioned by this chute.
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00:20:40,448 --> 00:20:45,344
In just one minute, this machine
Can package 10 8.8-pound bags.
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00:20:45,344 --> 00:20:49,103
Whenever needed, it can handle
Up to 60 bags a minute.
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00:20:51,758 --> 00:20:55,275
Pastas are a favorite meal
The world over.
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This plant makes
Over 100 different products
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00:20:58,068 --> 00:21:02,103
And every day uses between
60 and 360 tons,
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00:21:02,103 --> 00:21:05,620
Or between 2 and 12 truckloads
Of semolina
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Made from hard wheat.
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00:21:16,758 --> 00:21:19,000
If you have any comments
About the show,
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00:21:19,000 --> 00:21:21,551
Or if you'd like to suggest
Topics for future shows,
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00:21:21,551 --> 00:21:23,689
Drop us a line at...
26774
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