Would you like to inspect the original subtitles? These are the user uploaded subtitles that are being translated:
1
00:00:02,206 --> 00:00:05,206
--captions by vitac--
Www.Vitac.Com
2
00:00:05,206 --> 00:00:08,172
Captions paid for by
Discovery communications, inc.
3
00:00:22,517 --> 00:00:25,517
Narrator:
Today on "How it's made"...
4
00:00:26,862 --> 00:00:28,931
Yogurt...
5
00:00:32,137 --> 00:00:33,931
Candles...
6
00:00:37,620 --> 00:00:39,448
Neon signs...
7
00:00:43,482 --> 00:00:45,137
And book bindings.
8
00:00:53,689 --> 00:00:56,758
Your mother probably told you
Not to put anything with germs
9
00:00:56,758 --> 00:00:58,275
In your mouth.
10
00:00:58,275 --> 00:01:00,482
Well, it turns out
She was wrong.
11
00:01:00,482 --> 00:01:03,827
Yogurt is one of the healthiest
Foods you can eat,
12
00:01:03,827 --> 00:01:07,413
Yet it's chock-full of germs --
Bacteria, to be precise,
13
00:01:07,413 --> 00:01:11,172
Bacteria that are actually good
For your digestive system.
14
00:01:16,620 --> 00:01:19,482
The first step in making
Fruit-flavored yogurt
15
00:01:19,482 --> 00:01:22,137
Is to inspect the fruit.
16
00:01:22,137 --> 00:01:25,172
Workers discard any skin or pits
That slip through
17
00:01:25,172 --> 00:01:29,344
And any pieces that are
Discolored or bruised.
18
00:01:29,344 --> 00:01:32,413
The fruit doesn't go
Into the yogurt as is.
19
00:01:32,413 --> 00:01:35,344
First, they turn it into jam.
20
00:01:35,344 --> 00:01:38,275
To give the jam just the right
Texture and taste,
21
00:01:38,275 --> 00:01:41,172
They have to weigh all
The ingredients carefully
22
00:01:41,172 --> 00:01:43,275
Before pouring them
In the mixer.
23
00:01:47,793 --> 00:01:50,068
The first ingredient is water,
24
00:01:50,068 --> 00:01:52,862
Followed by artificial
And natural flavoring,
25
00:01:52,862 --> 00:01:57,896
And stabilizers to give the jam
An even consistency.
26
00:01:57,896 --> 00:02:01,310
Certain types of fruit aren't
Colorful enough on their own,
27
00:02:01,310 --> 00:02:03,965
So the factory adds
Artificial coloring.
28
00:02:05,655 --> 00:02:10,241
Next comes two types of sugar --
Fructose and sucrose.
29
00:02:10,241 --> 00:02:14,103
The mixer heats everything
To 140 degrees fahrenheit
30
00:02:14,103 --> 00:02:16,413
To help dissolve
The dry ingredients.
31
00:02:16,413 --> 00:02:19,448
The machine pumps out
And refeeds the mixture
32
00:02:19,448 --> 00:02:21,517
So that it blends evenly.
33
00:02:23,310 --> 00:02:26,310
Then more coloring,
Followed by the fruit,
34
00:02:26,310 --> 00:02:30,000
Followed by another hour or so
Of heating and mixing.
35
00:02:30,000 --> 00:02:32,551
Then they heat the jam
To a minimum
36
00:02:32,551 --> 00:02:35,551
Of 176 degrees fahrenheit
For another hour
37
00:02:35,551 --> 00:02:38,655
To kill off any harmful
Bacteria.
38
00:02:38,655 --> 00:02:40,551
To prepare the yogurt,
39
00:02:40,551 --> 00:02:44,862
They mix different powdered milk
Products with milk and cream.
40
00:02:44,862 --> 00:02:47,793
For low-fat yogurts,
They use fat-free milk
41
00:02:47,793 --> 00:02:49,310
And skip the cream.
42
00:02:51,517 --> 00:02:53,689
Once they've blended
The ingredients,
43
00:02:53,689 --> 00:02:57,241
They heat them to 176 degrees
Fahrenheit or higher
44
00:02:57,241 --> 00:02:58,689
For just 30 seconds.
45
00:02:58,689 --> 00:03:00,448
That's all the time
That's needed
46
00:03:00,448 --> 00:03:02,655
To pasteurize the mixture.
47
00:03:02,655 --> 00:03:06,137
While it's now bacteria-free,
There's another problem.
48
00:03:06,137 --> 00:03:08,310
Milk and cream
Naturally separate
49
00:03:08,310 --> 00:03:12,448
Because cream is lighter
Due to its fat content.
50
00:03:12,448 --> 00:03:15,724
So on to the next step,
Homogenization --
51
00:03:15,724 --> 00:03:18,931
Blending the milk and cream
Together.
52
00:03:18,931 --> 00:03:22,137
The homogenizer's pistons
Crush the fat globules.
53
00:03:22,137 --> 00:03:27,172
This enables the two liquids
To merge.
54
00:03:27,172 --> 00:03:30,620
The mixture then goes
Into fermentation tanks
55
00:03:30,620 --> 00:03:33,655
Heated to 113 degrees
Fahrenheit.
56
00:03:33,655 --> 00:03:37,137
Workers pour in a packet
Of live bacteria
57
00:03:37,137 --> 00:03:39,931
Bought from a factory
That breeds bacterial cultures
58
00:03:39,931 --> 00:03:42,482
For the dairy industry.
59
00:03:42,482 --> 00:03:44,517
Fermentation takes 6 to 20 hours
60
00:03:44,517 --> 00:03:47,379
Depending on the style
Of yogurt.
61
00:03:49,724 --> 00:03:52,689
The factory manufactures
The yogurt containers
62
00:03:52,689 --> 00:03:54,724
Right on the packaging line
63
00:03:54,724 --> 00:03:57,965
Using plastic sheets
And paper labels.
64
00:04:10,103 --> 00:04:15,310
The machine heats the plastic
And molds it into containers.
65
00:04:15,310 --> 00:04:17,172
A split second later,
66
00:04:17,172 --> 00:04:20,137
It wraps the containers
In paper labels.
67
00:04:20,137 --> 00:04:22,827
You can view that
Dual operation best
68
00:04:22,827 --> 00:04:25,241
From underneath the machinery.
69
00:04:25,241 --> 00:04:27,586
Now they fill the containers
70
00:04:27,586 --> 00:04:31,310
With the combination of yogurt
And fruit jam.
71
00:04:31,310 --> 00:04:33,827
To protect the yogurt
From contamination,
72
00:04:33,827 --> 00:04:36,000
The air in this part
Of the machine
73
00:04:36,000 --> 00:04:39,206
Is strictly controlled
And filtered.
74
00:04:39,206 --> 00:04:44,000
The bacteria in the yogurt is
What's known as good bacteria,
75
00:04:44,000 --> 00:04:47,241
The type naturally present
In our intestines.
76
00:04:47,241 --> 00:04:50,275
They produce a compound
Called acetaldehyde.
77
00:04:50,275 --> 00:04:53,965
That's what gives yogurt
Its distinctive flavor.
78
00:04:56,103 --> 00:04:58,758
The red dots
Are electronic sensors
79
00:04:58,758 --> 00:05:00,896
That verify the fill level.
80
00:05:04,586 --> 00:05:08,862
The container covers are made
Of thin but strong aluminum.
81
00:05:08,862 --> 00:05:12,103
First, the sheet of covers
Passes upside down
82
00:05:12,103 --> 00:05:16,655
Over a printer which stamps on
The expiration date.
83
00:05:16,655 --> 00:05:21,241
Unopened, this yogurt will stay
Fresh for more than 40 days.
84
00:05:24,000 --> 00:05:27,344
Then the sheet of covers
Turns right side up
85
00:05:27,344 --> 00:05:29,620
To be heat sealed
Onto the containers.
86
00:05:32,862 --> 00:05:35,482
Finally, the machine
Automatically divides
87
00:05:35,482 --> 00:05:38,448
The containers according
To whatever pack format
88
00:05:38,448 --> 00:05:41,068
The factory is producing.
89
00:05:50,275 --> 00:05:52,517
Narrator: the invention
Of the candle
90
00:05:52,517 --> 00:05:55,137
Can possibly be credited
To ancient egyptians,
91
00:05:55,137 --> 00:05:57,724
Who dipped reeds into animal fat
And lit them.
92
00:05:57,724 --> 00:06:00,862
Today's wax candles provide
A romantic atmosphere,
93
00:06:00,862 --> 00:06:04,275
Light when there's power
Failure, and, when blown out,
94
00:06:04,275 --> 00:06:06,689
A grand finale
To a rousing rendition
95
00:06:06,689 --> 00:06:08,620
Of "Happy birthday."
96
00:06:10,862 --> 00:06:13,103
At the heart of every candle
Is a wick
97
00:06:13,103 --> 00:06:16,448
Made from woven or twisted
Cotton cord.
98
00:06:16,448 --> 00:06:18,206
To stiffen up that limp cord,
99
00:06:18,206 --> 00:06:21,000
They run it through a tank
Of liquid paraffin,
100
00:06:21,000 --> 00:06:24,000
A wax derived from petroleum.
101
00:06:24,000 --> 00:06:26,793
The cord then passes over
A cooling drum
102
00:06:26,793 --> 00:06:30,310
Whose cold surface instantly
Hardens the wax coating.
103
00:06:30,310 --> 00:06:33,551
The now rigid cord
Winds onto a spool,
104
00:06:33,551 --> 00:06:35,758
Ready to be cut into wicks.
105
00:06:35,758 --> 00:06:38,379
There are several
Candle-making methods,
106
00:06:38,379 --> 00:06:41,068
All of which work
On the simple principle
107
00:06:41,068 --> 00:06:43,379
That hot wax turns hard
And white
108
00:06:43,379 --> 00:06:48,000
When it comes into contact with
Cold air or a cold surface.
109
00:06:48,000 --> 00:06:51,068
This process is called
Candle pressing.
110
00:06:51,068 --> 00:06:53,689
The hot paraffin travels
From the holding tank
111
00:06:53,689 --> 00:06:55,172
To a set of sprinklers
112
00:06:55,172 --> 00:06:59,137
Inside a 20-foot-high
Refrigerated chamber.
113
00:06:59,137 --> 00:07:03,137
The sprinklers shoot the wax
Upwards into the cold air.
114
00:07:03,137 --> 00:07:07,758
Like falling precipitation
Transforming into snowflakes,
115
00:07:07,758 --> 00:07:11,137
The wax droplets transform
Into wax flakes.
116
00:07:11,137 --> 00:07:14,034
They land at the base
Of the chamber,
117
00:07:14,034 --> 00:07:16,448
Then travel
To a hydraulic press.
118
00:07:16,448 --> 00:07:18,965
The press forms them
Into candles,
119
00:07:18,965 --> 00:07:20,931
Using pressure but no heat,
120
00:07:20,931 --> 00:07:24,517
And pierces a hole through
The middle for the wick.
121
00:07:27,241 --> 00:07:29,586
The air in this part
Of the plant
122
00:07:29,586 --> 00:07:32,448
Has to be less
Than 77 degrees fahrenheit,
123
00:07:32,448 --> 00:07:35,620
Or else the flakes will melt
And stick together,
124
00:07:35,620 --> 00:07:37,344
Jamming the machine.
125
00:07:40,931 --> 00:07:44,448
Now the candles travel
To the wicking machine,
126
00:07:44,448 --> 00:07:47,586
Which cuts and inserts a wick
Into each candle.
127
00:07:50,689 --> 00:07:55,137
Another candle-making method
Is the dipping process.
128
00:07:55,137 --> 00:07:58,137
They install 96 wicks
On each frame
129
00:07:58,137 --> 00:08:01,310
Of an automated
Dipping machine.
130
00:08:01,310 --> 00:08:02,689
One after another,
131
00:08:02,689 --> 00:08:06,448
The frames dip the wicks
Into a tank of clear paraffin.
132
00:08:06,448 --> 00:08:09,379
As the frames
Rise from the tank,
133
00:08:09,379 --> 00:08:11,931
Gravity pulls the wax downward,
134
00:08:11,931 --> 00:08:14,827
Creating a conically
Shaped coat of wax.
135
00:08:14,827 --> 00:08:17,965
By the time a frame
Has made the circuit
136
00:08:17,965 --> 00:08:22,137
And returned to the tank,
The wax coat is hard and white.
137
00:08:22,137 --> 00:08:24,482
The wicks go
For a second dipping,
138
00:08:24,482 --> 00:08:26,241
Followed by another go-round.
139
00:08:26,241 --> 00:08:29,724
This continues
Until 25 dips later.
140
00:08:29,724 --> 00:08:34,310
The tapered candles
Are .8 of an inch in diameter.
141
00:08:34,310 --> 00:08:37,689
To turn these white candles
Into colored candles,
142
00:08:37,689 --> 00:08:41,068
They dip them into a vat
Of dyed paraffin...
143
00:08:41,068 --> 00:08:43,965
Then immediately after
Into cold water
144
00:08:43,965 --> 00:08:47,206
To harden the color coat.
145
00:08:47,206 --> 00:08:49,758
To produce votive candles,
146
00:08:49,758 --> 00:08:53,413
The factory uses an automated
Molding process.
147
00:08:53,413 --> 00:08:57,137
They heat each molding table,
Flood it with paraffin,
148
00:08:57,137 --> 00:08:59,275
Then cool the table.
149
00:09:02,482 --> 00:09:06,413
The wax overflow compensates
For the shrinking that occurs
150
00:09:06,413 --> 00:09:08,655
During the 20-minute
Hardening phase.
151
00:09:17,551 --> 00:09:19,931
Once the wax hardens,
152
00:09:19,931 --> 00:09:22,586
They scrape off the excess
And remelt it
153
00:09:22,586 --> 00:09:24,551
To use for the next batch.
154
00:09:34,034 --> 00:09:38,448
A pin inside each mold created
A channel for the wick.
155
00:09:38,448 --> 00:09:42,275
Now another type of automated
Wicking machine inserts a wick
156
00:09:42,275 --> 00:09:45,172
And secures it in place
With the metal clip
157
00:09:45,172 --> 00:09:47,586
At the base of the candle.
158
00:09:52,275 --> 00:09:54,793
They make certain
Specialty candles
159
00:09:54,793 --> 00:09:56,793
On a manually operated dipper
160
00:09:56,793 --> 00:09:59,206
Rather than by automated
Machine.
161
00:09:59,206 --> 00:10:03,103
These altar candles
Are made of paraffin
162
00:10:03,103 --> 00:10:06,068
And 66% pure beeswax,
163
00:10:06,068 --> 00:10:08,275
As required by vatican law.
164
00:10:08,275 --> 00:10:10,862
To create their
Cylindrical shape,
165
00:10:10,862 --> 00:10:14,275
The worker has to flip
The frames after every dip
166
00:10:14,275 --> 00:10:16,482
To equalize the wax.
167
00:10:16,482 --> 00:10:21,448
It takes 90 dips to build
A 3-inch diameter.
168
00:10:21,448 --> 00:10:24,448
The candles still come out
Slightly tapered,
169
00:10:24,448 --> 00:10:28,103
So they go through a heated die
To adjust their shape.
170
00:10:28,103 --> 00:10:32,241
No longer just a staple of
Religion, ritual, or romance,
171
00:10:32,241 --> 00:10:36,103
Today's candles are a hot
Decorative item.
172
00:10:47,758 --> 00:10:50,965
Narrator: neon signs
Are made of glass tubes
173
00:10:50,965 --> 00:10:54,724
Bent into letters or shapes
And filled with inert gas.
174
00:10:54,724 --> 00:10:57,931
When the electric current hits
The electrodes in the tubes,
175
00:10:57,931 --> 00:11:02,241
Electrons flow through the gas,
Making its atoms glow.
176
00:11:02,241 --> 00:11:04,241
The type of gas and glass
177
00:11:04,241 --> 00:11:06,379
Determine the color
Of the light.
178
00:11:10,758 --> 00:11:12,689
In a clear glass tube,
179
00:11:12,689 --> 00:11:15,206
Argon gas gives off blue light
180
00:11:15,206 --> 00:11:18,275
While neon gas
Produces red light.
181
00:11:18,275 --> 00:11:20,172
To create vivid designs,
182
00:11:20,172 --> 00:11:22,482
They can parlay
Those two base colors
183
00:11:22,482 --> 00:11:24,724
Into more than 80
Additional colors
184
00:11:24,724 --> 00:11:27,000
By using glass tubes
That are colored
185
00:11:27,000 --> 00:11:29,586
With fluorescent powders.
186
00:11:29,586 --> 00:11:33,586
For instance, blue glowing
Argon gas in a yellow tube
187
00:11:33,586 --> 00:11:35,137
Creates a green light.
188
00:11:37,827 --> 00:11:41,172
To shape the tube, they use
A glass-blowing technique.
189
00:11:41,172 --> 00:11:44,965
Following a pattern drawn
On a fire-resistant sheet,
190
00:11:44,965 --> 00:11:47,241
They mark where they have
To bend the tube.
191
00:11:50,000 --> 00:11:54,275
Then they heat each spot on a
Device called a ribbon burner,
192
00:11:54,275 --> 00:11:59,655
Whose propane flame is a blazing
1,200 degrees fahrenheit.
193
00:11:59,655 --> 00:12:01,655
Within half a minute,
194
00:12:01,655 --> 00:12:03,862
The glass softens enough
To be pliable.
195
00:12:03,862 --> 00:12:05,482
They gently bend the tube,
196
00:12:05,482 --> 00:12:07,586
Then blow into the uncorked end
197
00:12:07,586 --> 00:12:10,379
To restore the tube's
Original diameter.
198
00:12:10,379 --> 00:12:14,758
With each bend, they check
The shape against the pattern,
199
00:12:14,758 --> 00:12:18,413
Every so often pressing
A wooden block along the tube
200
00:12:18,413 --> 00:12:21,034
To equalize the width.
201
00:12:21,034 --> 00:12:24,413
Argon gas emits
Steel-blue light,
202
00:12:24,413 --> 00:12:28,827
But this blue-colored tube
Will change that to dark blue.
203
00:12:28,827 --> 00:12:31,965
After shaping,
They cut off the excess
204
00:12:31,965 --> 00:12:34,689
And rub the coloring
Powder off the ends.
205
00:12:34,689 --> 00:12:37,275
Now they can attach
These glass casings,
206
00:12:37,275 --> 00:12:39,620
Which contain electrodes.
207
00:12:39,620 --> 00:12:42,931
They fuse an electrode
To each end of the tube
208
00:12:42,931 --> 00:12:44,413
Using a propane hand torch
209
00:12:44,413 --> 00:12:48,172
And a flexible
Latex blowing tube.
210
00:12:50,793 --> 00:12:53,793
They seal the glass
Around one electrode
211
00:12:53,793 --> 00:12:55,724
But leave the other one open.
212
00:12:55,724 --> 00:12:59,034
Then, using what's called
A crossfire burner,
213
00:12:59,034 --> 00:13:00,965
They create a tubulation,
214
00:13:00,965 --> 00:13:02,931
A thin tube with a bubble
215
00:13:02,931 --> 00:13:07,034
That will act as a passage way
Into the open electrode.
216
00:13:08,517 --> 00:13:12,448
They fuse the tubulation
To that electrode...
217
00:13:19,965 --> 00:13:23,034
...Then carefully inject
A drop of mercury
218
00:13:23,034 --> 00:13:26,482
Into the open end
Of the tubulation.
219
00:13:26,482 --> 00:13:29,413
Argon gas needs a touch
Of mercury
220
00:13:29,413 --> 00:13:31,517
To brighten the color it emits.
221
00:13:31,517 --> 00:13:33,517
Neon gas doesn't.
222
00:13:38,206 --> 00:13:40,655
Using what's known
As an end torch,
223
00:13:40,655 --> 00:13:43,379
They fuse the open end
Of the tubulation
224
00:13:43,379 --> 00:13:47,137
To a long glass tube
Leading to a pumping system.
225
00:13:47,137 --> 00:13:50,275
They connect the electrodes
To the system,
226
00:13:50,275 --> 00:13:52,275
Then power it up.
227
00:13:52,275 --> 00:13:56,172
The pump vacuums out the air,
Then injects the gas.
228
00:13:56,172 --> 00:14:00,206
The electrical current makes
The atoms in the gas glow.
229
00:14:05,758 --> 00:14:08,448
To trap the gas inside the tube,
230
00:14:08,448 --> 00:14:11,620
They use the crossfire burner
To remove the tubulation
231
00:14:11,620 --> 00:14:14,655
And seal off the open electrode,
232
00:14:14,655 --> 00:14:19,172
Making sure the drop of mercury
Has descended into it first.
233
00:14:28,620 --> 00:14:32,448
They dip the back of the sign
Into black paint.
234
00:14:32,448 --> 00:14:35,931
This will make the lettering
Or design stand out.
235
00:14:35,931 --> 00:14:38,620
They use a brush
To spread the coat evenly
236
00:14:38,620 --> 00:14:40,551
And remove the excess.
237
00:14:43,310 --> 00:14:47,413
Next, they'll light up the sign
At high voltage for a half hour.
238
00:14:47,413 --> 00:14:50,379
This will dry the paint
And, more importantly,
239
00:14:50,379 --> 00:14:52,758
Transform the liquid mercury
Into vapor
240
00:14:52,758 --> 00:14:55,068
That spreads
Throughout the sign.
241
00:14:57,379 --> 00:14:59,034
Using transparent clips,
242
00:14:59,034 --> 00:15:02,586
They mount the sign onto a black
Plexiglas background
243
00:15:02,586 --> 00:15:05,137
To make it stand out even more.
244
00:15:13,482 --> 00:15:16,724
Finally, they connect
The protruding electrode wires
245
00:15:16,724 --> 00:15:18,586
To a transformer.
246
00:15:18,586 --> 00:15:22,137
This transformer converts
The standard 110-volt current
247
00:15:22,137 --> 00:15:26,413
From our electrical outlets
Into high-voltage current,
248
00:15:26,413 --> 00:15:29,517
Into the 3,000 to 15,000 volts
249
00:15:29,517 --> 00:15:32,137
You need to light up
A neon sign.
250
00:15:44,620 --> 00:15:46,724
Narrator: hardcover books
Have bindings
251
00:15:46,724 --> 00:15:48,448
Made of heavy paperboards
252
00:15:48,448 --> 00:15:51,137
Covered with cloth, leather,
Or plastic.
253
00:15:51,137 --> 00:15:54,655
Soft-cover books have flimsier
Paper bindings.
254
00:15:54,655 --> 00:15:57,379
While bookbinding
On a commercial scale
255
00:15:57,379 --> 00:15:59,000
Is all mechanized today,
256
00:15:59,000 --> 00:16:01,137
You can still find craftspeople
257
00:16:01,137 --> 00:16:04,344
Who skillfully bind books
By hand.
258
00:16:10,068 --> 00:16:13,379
Book bindings date back
To second-century egypt
259
00:16:13,379 --> 00:16:17,000
Where christian monks sewed
Sheets of papyrus together,
260
00:16:17,000 --> 00:16:19,206
Then enclosed them
In leather-covered boards
261
00:16:19,206 --> 00:16:22,310
Connected by strips of hide.
262
00:16:22,310 --> 00:16:24,000
Monks in medieval europe
263
00:16:24,000 --> 00:16:26,862
Stitched together
Handwritten parchments,
264
00:16:26,862 --> 00:16:28,862
Binding them
Between wooden boards
265
00:16:28,862 --> 00:16:31,206
Often covered in leather.
266
00:16:31,206 --> 00:16:36,000
Sometimes they were embellished
With gold leaf and gems.
267
00:16:36,000 --> 00:16:38,448
The 16th century
Saw the arrival
268
00:16:38,448 --> 00:16:42,103
Of cheaper printed books
With simple pasteboard bindings.
269
00:16:55,172 --> 00:16:58,482
Today, commercial bookbinding
Is highly mechanized.
270
00:16:58,482 --> 00:17:01,793
The process starts
With large sheets of paper,
271
00:17:01,793 --> 00:17:05,620
Each containing several
Consecutive pages of the book.
272
00:17:05,620 --> 00:17:09,000
A worker positions a stack
Of each sheet into a machine
273
00:17:09,000 --> 00:17:11,586
Appropriately called
The guillotine.
274
00:17:11,586 --> 00:17:16,482
Its sharp blade drops down
And chops off excess paper.
275
00:17:16,482 --> 00:17:20,310
After trimming, the stack moves
Into a machine called the folder
276
00:17:20,310 --> 00:17:23,068
Which folds each sheet
Into book size
277
00:17:23,068 --> 00:17:26,758
With the pages
In the right order.
278
00:17:26,758 --> 00:17:28,793
As we see here in slow motion,
279
00:17:28,793 --> 00:17:32,551
The machine starts
By perforating the fold line.
280
00:17:32,551 --> 00:17:35,103
Then the sheet moves along
The conveyor belt
281
00:17:35,103 --> 00:17:38,482
Until it hits the stopper
To the far right.
282
00:17:38,482 --> 00:17:41,172
That stop position
Aligns the perforation
283
00:17:41,172 --> 00:17:42,931
Between two rollers.
284
00:17:42,931 --> 00:17:46,758
Watch in slow motion how those
Rollers pull the page down,
285
00:17:46,758 --> 00:17:48,551
Pressing a neat fold.
286
00:17:48,551 --> 00:17:52,620
This process repeats itself
For each fold of the sheet.
287
00:17:55,586 --> 00:17:59,310
The result of all that folding
Is what's called a signature,
288
00:17:59,310 --> 00:18:01,827
A unit of pages
In the correct order
289
00:18:01,827 --> 00:18:04,103
But still attached
To each other.
290
00:18:04,103 --> 00:18:07,413
A book is made up
Of several signatures.
291
00:18:07,413 --> 00:18:10,793
Another machine now assembles
Them in the right sequence,
292
00:18:10,793 --> 00:18:14,000
Along with the cover,
For binding.
293
00:18:14,000 --> 00:18:17,000
There are many different
Binding methods.
294
00:18:17,000 --> 00:18:20,379
This one is called
Wire stitching.
295
00:18:20,379 --> 00:18:22,482
As we see here in slow motion,
296
00:18:22,482 --> 00:18:25,689
The machine drives heavy-duty
Staples right through the spine
297
00:18:25,689 --> 00:18:28,827
Of the signatures and cover.
298
00:18:28,827 --> 00:18:32,103
The staples are cut from
Steel wire that's so strong,
299
00:18:32,103 --> 00:18:36,379
You have to tear the book apart
To remove them.
300
00:18:36,379 --> 00:18:39,931
Here's another slow-motion look
At the stapling action.
301
00:18:49,931 --> 00:18:54,172
This is another binding method
Called perfect binding.
302
00:18:54,172 --> 00:18:57,551
First, a scanner ensures
The pages are in order.
303
00:18:57,551 --> 00:18:59,793
Then the covers go on.
304
00:18:59,793 --> 00:19:01,448
With traditional bookbinding,
305
00:19:01,448 --> 00:19:04,103
They sew these components
Together.
306
00:19:04,103 --> 00:19:07,862
In the perfect bind process,
They glue them together.
307
00:19:07,862 --> 00:19:11,000
To do that, the machine first
Feeds the assembled books,
308
00:19:11,000 --> 00:19:15,103
Spine side down, onto trays.
309
00:19:15,103 --> 00:19:18,965
The trays compress the pages.
310
00:19:18,965 --> 00:19:21,482
Then a saw underneath
Cuts off the folds,
311
00:19:21,482 --> 00:19:25,275
Detaching the pages from
Each other along the spine.
312
00:19:25,275 --> 00:19:27,724
But that cut
Creates a smooth edge
313
00:19:27,724 --> 00:19:31,000
To which glue would have
Difficulty adhering.
314
00:19:31,000 --> 00:19:33,793
So a second saw
Notches the spine,
315
00:19:33,793 --> 00:19:38,724
Creating a rough,
Glue-friendly surface.
316
00:19:38,724 --> 00:19:41,655
The notched spine
Now runs over rollers
317
00:19:41,655 --> 00:19:43,379
That coat it in hot glue.
318
00:19:56,586 --> 00:19:59,655
Finally,
Two conveyor belts merge --
319
00:19:59,655 --> 00:20:01,241
One with the book's pages
320
00:20:01,241 --> 00:20:04,827
Assembled with the notched
And glue-coated spine,
321
00:20:04,827 --> 00:20:07,517
And the other
With the book's cover.
322
00:20:07,517 --> 00:20:10,965
The machine presses the cover
Onto the spine.
323
00:20:27,689 --> 00:20:30,517
The book now travels
Along the conveyor belt
324
00:20:30,517 --> 00:20:32,000
For another 30 seconds,
325
00:20:32,000 --> 00:20:35,000
During which time
The glue air dries.
326
00:20:37,551 --> 00:20:41,068
By this stage of the process,
With either binding method,
327
00:20:41,068 --> 00:20:43,793
Most pages on the unbound sides
Of the book
328
00:20:43,793 --> 00:20:46,862
Are still attached by folds.
329
00:20:46,862 --> 00:20:48,448
To separate the pages,
330
00:20:48,448 --> 00:20:52,482
The books go through a machine
Called a three-knife trimmer.
331
00:20:52,482 --> 00:20:57,103
It cuts the folds off the three
Sides simultaneously.
332
00:20:57,103 --> 00:21:00,137
The book is now finished.
333
00:21:00,137 --> 00:21:03,827
Fine-quality books still have
Some bindings.
334
00:21:03,827 --> 00:21:08,206
But your average book today is
Wire stitched or perfect bound.
335
00:21:08,206 --> 00:21:11,103
Those newer methods
Are far less costly,
336
00:21:11,103 --> 00:21:15,620
Yet still produce books
That are sturdy and durable.
337
00:21:22,689 --> 00:21:24,793
If you have any comments
About the show
338
00:21:24,793 --> 00:21:27,413
Or if you'd like to suggest
Topics for future shows,
339
00:21:27,413 --> 00:21:29,068
Drop us a line at...
27185
Can't find what you're looking for?
Get subtitles in any language from opensubtitles.com, and translate them here.