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--captions by vitac--
Www.Vitac.Com
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00:00:05,310 --> 00:00:08,310
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 --> 00:00:28,413
Gummies,
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00:00:28,413 --> 00:00:30,241
Aluminum cans,
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00:00:30,241 --> 00:00:34,000
Fish farming,
And bronze sculptures.
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00:00:37,586 --> 00:00:39,931
There's nothing kids love more
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00:00:39,931 --> 00:00:42,827
Than candies they can
Pull and stretch,
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00:00:42,827 --> 00:00:45,793
Which probably explains
Why gummy candies and licorice
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00:00:45,793 --> 00:00:48,586
Have always been
Stick-to-your-teeth favorites,
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00:00:48,586 --> 00:00:52,241
Except with parents who don't
Have a family dental plan.
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00:00:57,482 --> 00:01:00,413
Everyone calls this
Red licorice,
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00:01:00,413 --> 00:01:02,482
But there's actually
No licorice root in it.
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00:01:02,482 --> 00:01:05,482
The ingredients are wheat,
Sugar, and corn syrup,
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With red food dye
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00:01:07,137 --> 00:01:10,137
And both artificial and
Natural strawberry flavoring.
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00:01:10,137 --> 00:01:15,068
They cook the mixture
For 2 hours at 216 degrees.
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00:01:15,068 --> 00:01:17,413
This slowly forms a thick paste.
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00:01:21,034 --> 00:01:23,896
They cool it down,
Then put it through extruders.
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00:01:23,896 --> 00:01:26,896
The extruders
Work like icing nozzles,
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Shaping the paste into a design
Such as the twirls we see here.
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00:01:34,275 --> 00:01:37,551
A water-lubricated knife
Slices the continuous strips
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Into 7- and 8-inch lengths.
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The water also rinses off any
Licorice buildup on the blade.
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00:01:58,241 --> 00:02:01,241
The cut licorice
Goes on aluminum trays.
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00:02:01,241 --> 00:02:03,448
The stacks of trays
Then go into an oven
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00:02:03,448 --> 00:02:07,344
To dry for 8 hours
At 140 degrees.
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00:02:07,344 --> 00:02:09,758
As the excess moisture
Evaporates,
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00:02:09,758 --> 00:02:11,448
The licorice shrivels.
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00:02:19,413 --> 00:02:22,793
Workers weigh the correct amount
Of licorice for each package.
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00:02:36,517 --> 00:02:38,517
To make gummy candies,
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00:02:38,517 --> 00:02:40,827
They use what are called
Printing boards --
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00:02:40,827 --> 00:02:43,275
Large sheets with raised shapes.
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00:02:46,413 --> 00:02:48,413
To make gummy worms,
For example,
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00:02:48,413 --> 00:02:52,103
They mount the gummy-worm board
On a stamping machine.
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00:02:52,103 --> 00:02:54,448
The machine then stamps
The worm shapes
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Onto trays of cornstarch.
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00:02:57,172 --> 00:02:59,793
This creates a series
Of cornstarch molds
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00:02:59,793 --> 00:03:01,862
For the gummy worms.
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00:03:14,827 --> 00:03:16,724
While that's going on,
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00:03:16,724 --> 00:03:20,000
Another machine mixes gelatin,
Sugar, corn syrup,
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Color, and flavoring and cooks
The mixture at 240 degrees.
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A machine called the depositor
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Pours the mixture
Into the cornstarch worm molds.
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00:03:38,827 --> 00:03:42,103
The molds then go
Into a refrigerated room.
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00:03:42,103 --> 00:03:45,965
In 12 to 15 hours,
The candies cool and solidify.
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00:03:58,827 --> 00:04:03,344
A machine then flips the candies
Out of the trays.
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00:04:03,344 --> 00:04:06,172
The cornstarch molds
Disintegrate.
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00:04:06,172 --> 00:04:09,655
As they fall downward,
The machine sifts out the lumps,
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00:04:09,655 --> 00:04:12,379
Then recycles
The used cornstarch
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00:04:12,379 --> 00:04:14,862
Into new cornstarch trays
For the next batch.
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00:04:20,620 --> 00:04:22,931
The candies
Go through a cleaner.
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00:04:22,931 --> 00:04:26,758
As they spin, air nozzles
Blast off the cornstarch.
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The next drum coats the candies
With mineral oil
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00:04:39,448 --> 00:04:41,206
To make them shiny.
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00:04:54,344 --> 00:04:56,344
Children love gummy worms
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Because they're gooey
And slippery and wiggly,
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00:05:00,172 --> 00:05:03,000
But it's not just kids
Who are hooked on them.
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00:05:03,000 --> 00:05:06,206
Many fishermen
Actually use them for bait.
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00:05:10,965 --> 00:05:13,275
Before packaging the candies,
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The workers weed out
Any that are stretched out
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Or stuck together.
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Wonder if they get to eat
The rejects?
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Narrator: a prion is what causes
Killer neurological diseases
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Such as mad cow in animals
And creutzfeldt-jakob in humans.
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00:05:38,482 --> 00:05:42,000
It's a protein normally found
In the membranes of cells.
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00:05:42,000 --> 00:05:43,965
Scientists
Are trying to determine
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00:05:43,965 --> 00:05:46,793
What changes that protein
To an abnormal form
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To cause
These fatal brain diseases.
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00:05:55,241 --> 00:05:59,517
The next time you buy a canned
Soft drink, consider this --
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00:05:59,517 --> 00:06:03,206
That aluminum can
Will always be recyclable.
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00:06:03,206 --> 00:06:06,586
Unlike plastic,
Aluminum never deteriorates,
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00:06:06,586 --> 00:06:10,241
No matter how often
It's melted down and used again.
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00:06:14,655 --> 00:06:18,241
Aluminum cans are so lightweight
That it's hard to believe
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They're made from
A huge roll of aluminum sheeting
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That weighs almost 10 tons.
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The sheet
Is about 5 feet wide
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And as thin
As construction paper.
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A roll like this is long enough
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To make three-quarters
Of a million drink cans.
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The sheet feeds into a press
That punches out round pieces
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That will be formed into cans.
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The punch press actually
Performs two operations.
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It punches out a disc
5 1/2 inches in diameter,
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Then bends it into a cup.
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What's left of the sheet
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Gets compacted and sent back
To the aluminum factory,
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Where it's recycled
Into new rolls.
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00:07:08,344 --> 00:07:11,241
The cup goes into a machine
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Called the draw-and-iron
Body maker.
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A tool draws out the aluminum,
Forming the body of the can.
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The tool is lubricated
So it won't tear the aluminum
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While stretching it.
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00:07:22,793 --> 00:07:25,241
The lubricant
Also acts as a coolant
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Because the aluminum heats up
As it's being worked.
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Once the body is formed,
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00:07:34,551 --> 00:07:37,275
A trimmer cleans
And straightens the edge.
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Now the cans move along
Upside down on the conveyer belt
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Over to the washer.
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The washer performs
A 6-stage cleaning.
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00:08:07,482 --> 00:08:11,172
The first two washes
Are in hydrofluoric acid
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At 140 degrees.
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The last four washes
Are in deionized water,
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Neutral water with no ph,
Also at 140 degrees.
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00:08:22,448 --> 00:08:24,793
The cans come out of the washer
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And go under a hot-air dryer.
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They're now shiny because
The hydrofluoric-acid wash
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00:08:31,034 --> 00:08:34,724
Removed a thin surface layer
Of aluminum.
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Next, a roller
Passes over the cans,
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Coating the bottom rims
With varnish.
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This varnish coating
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Allows the cans to slide easily
On the conveyer belts
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00:08:44,724 --> 00:08:46,862
And into vending machines.
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It shows up as a blue ring
Under an ultraviolet light.
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The cans are now
Ready to be printed.
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This rotation printing system
Can apply up to five colors,
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One at a time.
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00:09:04,344 --> 00:09:08,620
The machine then applies a layer
Of varnish to protect the ink.
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00:09:13,931 --> 00:09:16,413
This is what
The print and varnish process
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00:09:16,413 --> 00:09:18,551
Looks like in slow motion,
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00:09:18,551 --> 00:09:23,103
And here's the actual speed --
1,800 cans per minute.
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Next, the cans
Fly through an oven
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That instantly hardens the ink
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00:09:30,379 --> 00:09:32,310
And dries
The protective varnish.
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The next machine
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Sprays a water-based varnish
On the inside of the cans.
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00:09:36,965 --> 00:09:40,000
This creates a barrier between
The drink and the aluminum,
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00:09:40,000 --> 00:09:42,793
So the drink won't end up
Tasting like metal.
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00:09:42,793 --> 00:09:44,586
It also prevents the aluminum
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00:09:44,586 --> 00:09:46,862
From being eaten away
From the inside
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By the acid
In carbonated drinks.
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00:09:49,689 --> 00:09:53,000
Next, the cans go through
A machine called the necker
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Which forms a 2-inch neck
On the can.
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00:09:56,413 --> 00:09:58,965
This is done gradually
In 11 steps,
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00:09:58,965 --> 00:10:01,896
So as not to puncture
The paper-thin aluminum.
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00:10:04,103 --> 00:10:06,413
The next machine,
Called the flanger,
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Forms a curved-over edge
At the top of the can,
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00:10:09,206 --> 00:10:12,172
Which will later attach
To the pull-tab cover.
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00:10:15,344 --> 00:10:18,517
The cans pass through
A sophisticated vision system
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That photographs the inside
Of each can.
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00:10:21,103 --> 00:10:23,310
Any can
That doesn't meet standards,
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That has a bump or ink inside,
For example,
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00:10:25,724 --> 00:10:29,827
Is automatically removed
From the production line.
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00:10:29,827 --> 00:10:33,137
They strap the finished cans
Onto a pallet.
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00:10:33,137 --> 00:10:35,551
From here, they're shipped
To the drink company,
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00:10:35,551 --> 00:10:39,206
Which fills them and then
Attaches the pull-tab cover.
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Narrator:
Fish farming generates about 20%
Of the world's fish production.
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00:10:52,896 --> 00:10:55,551
Some fish farms
Are very high tech,
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00:10:55,551 --> 00:10:58,655
While others use
More traditional methods.
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00:10:58,655 --> 00:11:01,793
Fish farming began in 2000 b.C.
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If these rainbow trout
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00:11:08,448 --> 00:11:10,896
Are going to have the energy
To make baby trout,
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00:11:10,896 --> 00:11:13,413
They'll have to be well fed.
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00:11:13,413 --> 00:11:15,827
On today's menu -- brown shrimp.
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00:11:19,103 --> 00:11:22,034
The fish farmer
Gives the mating process a hand.
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He takes the female fish
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And presses on her belly
To squeeze out her eggs.
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A 1-pound fish
Has about 1,000 eggs.
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It takes about a minute
To get them out.
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00:11:59,413 --> 00:12:04,413
Next, he takes the male fish
And squeezes out his sperm.
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00:12:04,413 --> 00:12:06,965
This also takes about a minute.
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The fertilization process
Is pretty low tech --
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No microscopes, no test tubes.
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The farmer mixes
The eggs and sperm by hand.
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00:12:24,827 --> 00:12:27,310
He then rinses the eggs
With clean water.
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00:12:27,310 --> 00:12:30,344
He repeats this step
Seven or eight times
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Until the water runs clear.
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00:12:43,172 --> 00:12:46,103
The eggs that
Stay at the surface are duds,
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So they're discarded.
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00:12:48,862 --> 00:12:51,758
The farmer transfers
The good eggs to bottles,
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Then fills the bottles
To the top with water.
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The eggs incubate
For about a month.
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By the 25-day mark,
If an egg is alive,
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Two little black dots appear --
Fish eyes.
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After the incubation period,
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00:13:12,965 --> 00:13:15,241
The farmer empties the bottles
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00:13:15,241 --> 00:13:18,172
And spreads the eggs
On a surface with slats.
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00:13:18,172 --> 00:13:21,103
The eggs lie here underwater...
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...Until they hatch
10 to 15 days later.
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00:13:33,965 --> 00:13:35,724
The newly hatched trout
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00:13:35,724 --> 00:13:38,965
Swim down through the slats
Into the basin below.
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The baby trout feed off their
Placenta for the first 18 days.
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00:13:55,172 --> 00:13:58,793
After that, they eat special
Trout food made of fish meal.
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00:14:07,103 --> 00:14:09,827
The trout grow to about
8 inches long
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00:14:09,827 --> 00:14:11,896
By the age of 8 months.
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00:14:11,896 --> 00:14:14,827
At that point, the smaller trout
Swimming around them
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00:14:14,827 --> 00:14:17,896
Start looking pretty appetizing.
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00:14:17,896 --> 00:14:21,206
So the farmer has to
Classify the fish by size
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00:14:21,206 --> 00:14:24,586
And move them
Into separate basins.
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00:14:54,310 --> 00:14:58,137
Trout reach adulthood at the age
Of a year and a half.
191
00:14:58,137 --> 00:15:02,000
Now the farmer transfers them
Into his man-made lake.
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00:15:08,448 --> 00:15:11,241
From here,
The fish will go to market.
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00:15:20,344 --> 00:15:23,724
But before they leave,
The farmer mates them,
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00:15:23,724 --> 00:15:26,344
Starting the cycle
All over again.
195
00:15:40,655 --> 00:15:44,241
Narrator: bronze is the oldest
Metal alloy known to man.
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00:15:44,241 --> 00:15:48,068
It is ideal for casting works
Of art because, when molten,
197
00:15:48,068 --> 00:15:51,551
It flows into even
The tiniest crevices of a mold.
198
00:15:51,551 --> 00:15:55,310
This allows sculptors to achieve
Incredible detail in their work.
199
00:16:02,655 --> 00:16:07,379
Man first discovered how to
Cast metal around 3500 b.C.,
200
00:16:07,379 --> 00:16:10,482
During the period
Known as the bronze age.
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00:16:13,172 --> 00:16:16,620
Many civilizations
Honored their royalty and gods
202
00:16:16,620 --> 00:16:18,689
With bronze statues.
203
00:16:18,689 --> 00:16:20,724
When it comes to art,
204
00:16:20,724 --> 00:16:24,310
The late 19th-century
French sculptor auguste rodin
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00:16:24,310 --> 00:16:26,206
Was the master.
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00:16:26,206 --> 00:16:28,068
They say his bronzes
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00:16:28,068 --> 00:16:31,241
Were more lifelike
Than the subjects themselves.
208
00:16:31,241 --> 00:16:34,344
Bronze is also a popular medium
For modern art.
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00:16:48,103 --> 00:16:52,344
Sculptors first carve a replica
Of their sculpture from wood
210
00:16:52,344 --> 00:16:57,000
Or shape it out of a plaster
Or clay.
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00:16:57,000 --> 00:16:58,931
They coat it with a lubricant...
212
00:17:01,586 --> 00:17:04,448
Then with silicone rubber.
213
00:17:15,448 --> 00:17:18,965
When the rubber hardens
About six hours later,
214
00:17:18,965 --> 00:17:22,034
The lubricated replica
Slips out easily,
215
00:17:22,034 --> 00:17:24,068
Leaving a detailed rubber mold.
216
00:17:26,068 --> 00:17:29,000
Next, they pour hot wax
Into the mold.
217
00:17:39,000 --> 00:17:41,827
The wax cools
In about 15 minutes,
218
00:17:41,827 --> 00:17:45,000
Leaving an exact wax replica
Of the sculpture.
219
00:17:56,379 --> 00:17:59,379
Next, they attach
What's called a sprew --
220
00:17:59,379 --> 00:18:03,551
A wax channel that will funnel
The molten bronze into the mold.
221
00:18:21,275 --> 00:18:25,206
They dip the wax replica
Into a ceramic material.
222
00:18:31,551 --> 00:18:34,137
Then coat it
With powdered silicone,
223
00:18:34,137 --> 00:18:37,344
A common mineral,
To strengthen the ceramic.
224
00:18:41,655 --> 00:18:44,793
Next stop -- an autoclave.
225
00:18:44,793 --> 00:18:49,103
In about 10 minutes, under the
Machine's hot steam pressure,
226
00:18:49,103 --> 00:18:51,689
The wax inside the ceramic shell
Melts away,
227
00:18:51,689 --> 00:18:55,620
Leaving a hardened
And hollow ceramic mold.
228
00:19:05,413 --> 00:19:10,758
That mold goes into a kiln
At 1,560 degrees.
229
00:19:10,758 --> 00:19:13,448
After two hours, it's fired.
230
00:19:13,448 --> 00:19:18,586
This is the finished mold into
Which the bronze will be cast.
231
00:19:18,586 --> 00:19:23,172
At the foundry, they heat
The bronze to 2,084 degrees...
232
00:19:25,344 --> 00:19:28,965
Then carefully pour it
Into the mold.
233
00:19:28,965 --> 00:19:34,551
The molten metal takes
Just a few minutes to solidify.
234
00:19:34,551 --> 00:19:37,413
Then they chisel off
The ceramic casing
235
00:19:37,413 --> 00:19:40,000
To reveal the bronze statue
Inside.
236
00:19:49,413 --> 00:19:53,517
They sandblast the statue
To remove the ceramic residue.
237
00:20:03,793 --> 00:20:06,344
Then, they saw off the sprew.
238
00:20:11,172 --> 00:20:14,620
They weld shut any holes
Or other imperfections...
239
00:20:17,172 --> 00:20:21,137
Then polish the statue
Using various abrasive heads.
240
00:20:24,034 --> 00:20:28,000
They heat the statue,
Then spray on an acid coating.
241
00:20:30,206 --> 00:20:32,551
This coating, called patina,
242
00:20:32,551 --> 00:20:35,620
Gives the bronze its shimmer
And richness of color.
243
00:20:57,758 --> 00:21:02,034
Finally, a coat of wax
Makes the statue shine.
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