All language subtitles for S03E07 - Prepared Mustard; Violins; Nuts and Bolts; Toilet Paper (576p AMZN WEB-DL x265 Garshasp)_track4_[eng]

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>> narrator: today, on

"How it's made"...

Prepared mustard...

Violins...

Nuts and bolts...

And toilet paper.

We eat it on hot dogs and

Hamburgers, on sausages and

Sandwiches.

No condiment cuts the mustard

Quite like mustard.

The ancient romans took the

Mustard seed to what is now

France, and by the 9th century,

Big-time mustard production was

Under way.

Yellow mustard and dijon mustard

Have a few ingredients in

Common, but that's where the

Similarity ends.

Not only are they prepared quite

Differently -- they're derived

From different varieties of

Mustard seed.

Yellow mustard is made from the

Seeds of the white mustard

Plant.

Turmeric and paprika provide the

Yellow color and sharp flavor.

The other ingredients are salt,

Water, and white vinegar.

The powdered ingredients go down

A shaft to a mixing tank

Containing the water and

Vinegar.

Yellow mustard's proportions are

Roughly 60% water, 20% vinegar,

15% seeds, and 5% salt and

Spices.

The last ingredient to go in is

The mustard seed -- hull, bran,

And all.

The tank's rotating mixers

Blends the ingredients for about

An hour at seed-crushing speeds

Reaching 165 miles per hour.

The tank's contents empty into

Several stainless-steel mills.

Inside each one, a pair of

Synthetic stones grinds the

Seeds, a process known as stone

Milling.

That grinding action heats the

Mixture to about 140 degrees

Fahrenheit.

The liquid thickens into creamy,

Bright yellow mustard.

Before bottling, they perform

What is called a finesse test.

This ensures the mustard is

Smooth enough.

If its particles are larger than

9/1000 of an inch, the factory

Adjusts the milling stones

Closer together to produce a

Finer grind.

They make dijon mustard from

Brown mustard seeds, sometimes

Mixed with other varieties, and

They usually use two types of

Vinegar -- cider and white.

The ingredients ferment in a

Tank for 12 hours before mixing.

That's what gives dijon mustard

Its strong flavor.

After mixing, it's the same

Stone-milling process we saw

Before.

Here's what the inside of those

Mills look like -- a rotating

Stone rubbing seeds against a

Stationary stone -- the same

Principle as an old-fashioned

Mortar and pestle.

Dijon is made with twice as many

Seeds as yellow mustard and 20%

Less water, which is why it

Comes out thicker and denser and

Needs the occasional stir.

Filters screen out any particles

Larger than 9/100 of an inch.

The factory saves these coarse

Pieces to put into specialty

Mustards.

Now the creamy, smooth dijon

Mustard goes into a

Stainless-steel tank.

A slow-speed revolving mixer

Removes the air, which would

Otherwise turn it brown and dull

Its flavor.

The yellow mustard tanks also

Have mixers to remove air and to

Keep the condiment well-blended.

Both dijon and yellow mustard

Have to cool overnight before

Bottling.

From start to finish, it takes

About 20 hours to produce yellow

Mustard, and about 32 hours for

Dijon because of its

Fermentation period.

Yellow mustard has a 15-month

Shelf life, while dijon stays

Fresh for a year.

Both should be refrigerated

After opening to preserve their

Flavor.

Mustard is a condiment that even

Health-conscious eaters can

Enjoy.

It packs a lot of flavor in just

A few calories.

Mustard contains a small amount

Of fat, somewhat more if the

Manufacturer uses oil in the

Recipe, but it's still a

Cholesterol-free food.

>> narrator: the violin was

Developed in the 1500s, evolving

From a series of guitar-like

Instruments that musicians

Played with a bow.

While the violin is best known

For classical and gypsy music,

Today you hear it in pop,

Country, bluegrass, even jazz.

First they cut a piece of maple,

Then split it in half to expose

The grain in mirror image.

They melt down glue flakes made

From animal hide, then bond the

Pieces together.

Violin makers only use glue,

Never nails or screws.

These pieces of wood will form

The back of the violin.

After four hours, the glue

Is dry, and they can remove the

Clamps.

Using a small plane, they even

Out the surface.

Then they trace the violin's

Shape and cut it out.

They shave the surface sculpting

A downward slope from the middle

Using an even smaller plane.

Then they carve a groove along

The circumference.

After dabbing it with glue, they

Insert what's known as purfling,

A reinforcement made from a thin

Strip of hardwood, usually

Maple.

Finally, they carve the reverse

Side to the right form and

Thickness.

Next they make the sides

Of the violin, known as the

Ribs.

First they soak thin strips

Of maple or sycamore and press

Them against a heated bending

Iron to curve them.

Then they glue the strips around

A form, connecting them at the

Top and bottom, and at the

Corners with small blocks of

Wood.

They clamp everything together

And let the glue dry for four

Hours.

Next they glue thin strips of

Wood called counter-ribs onto

The edge of the ribs.

This enlarges the surface so

That it's easier to glue the

Ribs and the back together.

They make the violin's front, or

Belly, from a solid piece of

Spruce.

To the underside, they glue a

Spruce support bar called the

Base bar.

Sound escapes through the two

Curved slots called f-holes.

They cut out and carve the

Violin's neck and scrolled head

From a piece of maple.

Then they glue it to the body.

They sculpt the fingerboard from

Ebony, a hardwood durable enough

To withstand centuries of

A violinist's fingering.

Using a tool called a peghole

Reamer, they make the holes for

The ebony or rosewood pegs

Around which the strings are

Wound.

They coat the wood with four or

Five coats of varnish, depending

On the color, then polish

It with several coats of oil

Over several days until the

Finish is shiny and

Silky-smooth.

Next they insert the sound post.

This little cylinder conducts

Sounds and supports the belly

Against bowing pressure, so it's

Critical to position it in

Precisely the right spot between

The belly and the back.

It's not glued, but rather

Wedged into place.

The bridge isn't glued either.

It's held in place by the

Pressure of the four strings,

Which they feed through the

Ebony tailpiece and wind onto

The pegs.

The bridge has little notches

In which the strings sit.

The violin is finished.

They make the bow from horsehair

And a high-quality brazilian

Wood called pernambuco.

They bind the hairs at one end

With strong sewing thread, then

Burn them and seal them with wax

To prevent fraying.

This end goes into the frog, the

Wooden box at the bottom, or

Heel, of the bow.

They cover the frog with the

Mother-of-pearl lining, then

Slip on a ring made of nickel,

Silver, or gold to prevent the

Hairs from tangling.

Next comes the screw that

Controls the tension of the

Hairs.

They comb the hairs to make them

Parallel, then insert them into

The tip of the bow, known as the

Head.

They tighten the screw until the

Hairs are taut.

Finally they rub on rosin, a

Sticky pine-tree resin that

Keeps the bow from slipping off

The strings.

>> narrator: at "How it's made,"

We pride ourselves in showing

You the nuts and bolts of how

Everyday items are made, so it's

About time we visited a real

Nuts-and-bolts operation.

We sure couldn't do without

These tiny but essential pieces

Of hardware.

If only they weren't so darn

Easy to lose.

Nuts and bolts are made from

What's called steel wire rod.

After spending up to 30 hours in

A furnace to make it pliable,

The wire rod goes into a bath of

Sulfuric acid to remove any rust

Particles.

It's rinsed in water then

Coated with phosphate, a

Chemical compound.

This prevents the steel from

Rusting before the bolt forming

Begins and lubricates the steel

To make forming easier.

They form the bolts by cold

Forging, shaping the steel at

Room temperature by forcing it

Through various dies at high

Pressure.

The forming machine first

Straightens the wire rod, then

Cuts it into pieces slightly

Longer than the bolt length.

The extra will become the bolt

Head.

Each piece goes through a die

That makes it perfectly round,

Then through a series of dies

That progressively shape the

Head of the bolt on one end.

The machine heads up to 300

Bolts per minute.

Here's what the heading stages

Look like in slow motion.

This die creates a slight

Collar.

The next one turns it into a

Round head.

Then the last one transforms

That into a hexagonal head --

The most common shape.

Next the machine forms the

Opposite end of the bolt.

A tool called the pointer shapes

The bottom of each bolt,

Creating what's called the

Chamfer, the part the nut

Catches on to.

Here's the bullet before and

After the chamfer.

The bolt needs threads to enable

The nut to screw onto it.

Once again, they use the cold

Forging method.

High-pressure rollers press in

The thread pattern...As we see

Here in slow motion.

This is the actual speed, up to

300 bolts per minute.

During each production run, they

Take several samples to verify

Dimensions.

They use various measuring

Devices -- a micrometer to check

The bolt's length, calipers to

Measure the width of the head,

And a ring gauge to check the

Threads.

To make the nuts, they use a

Process called hot forging.

They cut steel bars into small

Pieces known as slugs, then heat

Them to 2,200 degrees fahrenheit

To make them malleable.

As we see here in slow motion,

Hydraulic cameras punch the

Slugs into hexagons, while a

Die pierces the hole.

Then a tool called a tapper

Drives into the hole to cut the

Threads.

That black liquid is a lubricant

Oil to minimize wear and tear on

The tappers.

The nuts and bolts now go into

An oven at 1,600 degrees

Fahrenheit for about an hour.

This gives them the required

Strength.

Then a rapid cooling in oil for

Five minutes to solidify the

Steel's internal structure.

By now the steel is hard, but

Brittle, so they heat the nuts

And bolts for another hour.

This removes their brittleness

Yet maintains their strength.

The quality-control team pulls

Samples off the line, measuring

How much force it takes to break

Them.

If a bolt meets its minimum

Strength requirement, it passes

Inspection, provided the break

Occurred in the threading -- the

Weakest part.

Finally packaging -- labeled,

Among other things, by size and

Grade.

>> narrator: toilet paper is

Probably the most indispensable

Item in your home.

After all, it's not something

You want to run out of at the

Wrong time.

Most of us probably take our

Rolls of toilet paper for

Granted.

So you may be surprised to learn

That bathroom tissue, as it's

Properly called, is a relatively

New invention.

The vikings used wool.

The ancient romans employed

Sponges, and french royalty

Wiped with lace.

Then in 1857, an american

Entrepreneur figured that people

Had had enough of using leaves,

Corncobs, newspapers, and

Mail-order catalogs, so he

Invented therapeutic paper, as

He so tastefully named it.

Toilet paper only came in piles

Of pre-cut sheets until 1890.

That's when one company

Introduced bathroom tissue on a

Roll.

Ever wonder where all that

Recycled paper goes?

Well, look no further than your

Bathroom.

Many brands of toilet paper

Begin as recycled paper.

The bales of paper drop down

Into the pulper, a giant tank

With an agitator, similar to a

Washing machine.

It mixes the paper in lukewarm

Water for about 10 minutes,

Transforming it into what's

Known as pulp and screening out

All the bits of metal and

Plastic.

Now they have to take out the

Ink.

The ink-removal system injects

The pulp with air.

Ink particles attach to the air

Bubbles, which rise to the top.

The system then skims off the

Foam, leaving the pulp ink-free.

Next the pulp passes through a

Series of rollers, which squeeze

Out the water.

This dries out the soggy pulp,

Enabling it to absorb the

Chemicals they'll use to bleach

It.

Revolving knives now chop up the

Pulp to prepare it for the

Bleaching process, the details

Of which are a closely guarded

Trade secret.

The bleach turns the gray pulp a

Pure white.

The company says it does this

Without using chlorine or other

Toxic chemicals.

They spread the wet pulp onto a

Flat screen that runs through a

Hot dryer.

In less than a second, the pulp

Dries into a delicate paper

4/1000 of an inch thick.

Each spool holds close to 47

Miles of paper.

That spool now feeds a machine

With rollers that emboss a

Pattern, in this case a waffle

Print.

The pattern isn't just

Aesthetic.

It also makes the paper thicker

And therefore more absorbent.

Elsewhere in the factory,

Production is rolling, so to

Speak, with two strips of

Cardboard, each 3 inches wide.

The machine coats the underside

Of the top strip with glue, then

Winds the two strips diagonally

To create a continuous cardboard

Tube.

The machine then cuts the tube

In 65-inch lengths.

The tubes ride an elevator to

The toilet paper zone.

There, two giant spools of paper

Feed what's called the winding

Machine.

The two sheets come together to

Form a two-ply toilet paper.

The paper then winds onto a

Cardboard tube, creating a

Super-wide roll of toilet paper.

When the roll is full, a blade

Automatically cuts the paper,

And winding resumes on the next

Tube.

The machine automatically seals

The end of the roll with glue

To prevent unraveling.

A circular saw slices the

Super-wide toilet paper roll

Into 16 standard rolls,

4 inches wide.

The toilet paper is finished and

Ready for packaging.

This batch is for commercial

Use.

Each roll is individually

Wrapped in paper.

Check out this slow-motion

Wrapping action.

Toilet paper destined for

Residential use gets wrapped in

Transparent plastic, 4 to 30

Rolls per package.

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