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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Brushes and push brooms...
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...Blackboards...
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...Smoked salmon...
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...And zippers.
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Nothing scrubs or sweeps quite
Like a good, sturdy brush.
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Cleaning brushes
In north america
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Date back to about the 1830s.
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Their bristles were usually made
Of wire twisted into wood.
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Today we have many different
Bristle materials,
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Both natural and synthetic.
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The first factory manufactures
The brush block --
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The hardwood base
That holds the bristles.
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It's usually made of maple,
But sometimes oak or beech.
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After cutting the planks
To the required width,
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They use a special wax crayon
To mark lines
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On both sides of any cracks
Or knots in the wood.
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A laser then reads the marks,
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Guiding a saw
To cut out the faults.
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At the same time,
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The saw chops the planks
Into block-size lengths.
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The next step
Is called "Molding."
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A series of saws
Trims the blocks
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To the required thickness.
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Now they contour the pieces,
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Using a machine appropriately
Called a shaper.
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The machine revolves,
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Running the block's outside edge
Against a cutting head.
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This profiles half the block.
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00:02:12,068 --> 00:02:13,793
Workers then turn it around
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And line it up
For a second pass
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00:02:15,931 --> 00:02:18,172
To profile the other half.
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00:02:18,172 --> 00:02:22,689
There's a different shaper
Machine for each model.
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This type is known
As a dauber --
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00:02:24,965 --> 00:02:27,551
A brush for waxing shoes.
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For the cuts to be accurate
And smooth,
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It's essential that
The machine's cutting heads
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Remain sharp
Despite repeated use.
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That's why they're made
Of carbide,
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A material stronger than steel.
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Workers run certain models
Against an extra cutting head
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To carve a groove
In the block's edges.
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The groove gives your hand
A better grip on the brush.
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These 2 1/2x24" blocks
Will become push brooms --
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Those wide, rectangular brooms
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Janitors use to sweep floors.
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The blocks go
To an automated machine
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00:03:20,551 --> 00:03:22,827
That drills a hole
Through the middle
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And carves two grooves
In the underside.
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These are for the steel adapter
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00:03:27,586 --> 00:03:30,000
That will hold the broom's
Wooden handle.
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Rounded push brooms
Sweep more easily in corners.
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To produce those,
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Workers take the rectangular
Push broom blocks
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And round the corners
Against a cutting head.
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At another factory,
The blocks go onto a machine
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That pierces holes
For the bristles,
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Using a computer-guided drill.
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This particular model
Of push broom needs 240 holes.
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It takes barely a minute
To drill them all.
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00:04:13,517 --> 00:04:17,689
Next, the blocks go to the
Bristle-installation machine.
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00:04:20,413 --> 00:04:23,586
Bristles can be made
Of horsehair, vinyl,
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Plants or tree leaves,
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Or synthetics
Such as polypropylene.
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The bristle-installation machine
Is fully automated,
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As we see here in slow motion.
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It takes about 40 strands
At a time, folds them in half,
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Then inserts and staples them
Into a hole.
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Here's what that
Bristling action looks like
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At actual speed.
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The machine fills four holes
Per second.
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The factory uses
This same process
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Regardless of the style of brush
Block or type of bristle.
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Computer software
Guides the machinery
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To follow the correct pattern,
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Making possible a sweeping array
Of brushes and brooms.
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Narrator: chalk one up
For the blackboard.
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This trusted teaching tool
Goes back centuries,
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Yet still remains the focal
Point of the classroom.
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Today's blackboard --
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Or chalkboard,
As it's also called --
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00:06:02,965 --> 00:06:05,689
Hasn't changed that much
In appearance,
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00:06:05,689 --> 00:06:08,793
But the materials
Used to make it have changed.
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Our lesson begins
At the blackboard factory,
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With thin sheets
Of galvanized steel.
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These will eventually form
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The front and back surfaces
Of the blackboard.
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They arrive at the factory
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Already precut
To standard sizes --
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6, 8, 10, or 12 feet.
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First stop is a machine that
Blasts the sheets with acid.
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This removes any dirt
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That would prevent paint
From adhering to the surface.
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As the sheets exit the cleaner,
Powerful fans dry them off.
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The paint is a type
Of acrylic enamel
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Designed especially
For blackboards.
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The factory adds
A powdered mineral formulation
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To make it dry
To a rougher texture.
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This helps chalk adhere better.
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00:07:01,689 --> 00:07:05,034
Traditional slate blackboards
Were naturally black.
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Today's steel-surface boards
Come in several colors.
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The most popular, though,
Are black and green.
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00:07:12,655 --> 00:07:17,000
Some companies use colored
Porcelain instead of paint.
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Here, spray guns apply
Three coats of paint,
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One after another,
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With no drying time in between.
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For the paint to harden
Properly, it has to be heat-set,
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So the sheets go into an oven
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At 420 degrees fahrenheit
For 10 minutes.
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A strong fan cools them off
As they exit the oven.
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Next, a worker
Sprays contact cement
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On the backs
Of two painted sheets.
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One sheet will form
The front of the board,
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The other, the back.
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Sandwiched in between
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Will be what's known
As the blackboard's core.
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It can be made of materials
Such as particleboard
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00:08:03,103 --> 00:08:06,931
Or, as we see here,
1/2-inch-thick fiberboard.
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00:08:10,275 --> 00:08:12,896
Workers feed
The three assembled layers
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00:08:12,896 --> 00:08:16,068
Through a high-pressure roller.
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00:08:16,068 --> 00:08:21,758
It forces out any trapped air
And bonds the layers tightly.
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00:08:21,758 --> 00:08:23,724
They make the blackboard's frame
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00:08:23,724 --> 00:08:26,103
Out of one long strip
Of aluminum molding.
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It has a stainproof
Satin finish.
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They make a series
Of 45-degree-angle cuts.
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This enables them
To bend the strip
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00:08:39,344 --> 00:08:40,931
Around the board's perimeter,
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00:08:40,931 --> 00:08:42,758
Creating neat corner seams.
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Workers file down and polish
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Any sharp edges
Left by the cutting.
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00:08:50,862 --> 00:08:54,000
After verifying that
It's perfectly square,
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They fasten the frame,
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00:08:55,655 --> 00:09:00,034
Using either rivets or screws,
Depending on the model.
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00:09:00,034 --> 00:09:03,379
Then, they attach an aluminum
Rail along the bottom
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00:09:03,379 --> 00:09:05,827
To hold the chalk and erasers.
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This model happens to be
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00:09:09,655 --> 00:09:11,965
A reversible
Mobile blackboard --
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00:09:11,965 --> 00:09:14,758
The type typically rolled
Into conference rooms.
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It has a few extra components --
A pivot mechanism,
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Enabling the board to be flipped
To the other side...
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And a latch system
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00:09:23,793 --> 00:09:26,724
For tilting the board
To different angles.
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00:09:29,551 --> 00:09:33,896
The blackboard stand is made
Of painted steel tubing.
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00:09:33,896 --> 00:09:39,068
It rolls on rubber-
And chrome-plated steel castors.
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00:09:39,068 --> 00:09:42,586
The factory takes samples
From the production line
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00:09:42,586 --> 00:09:45,724
And subjects them to rigorous
Quality-control testing.
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00:09:45,724 --> 00:09:47,379
These tests ensure
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00:09:47,379 --> 00:09:50,724
That the painted surface
Is glare-free
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00:09:50,724 --> 00:09:53,241
And can withstand everything
From chemical solvents
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And extreme humidity
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To heavy impact
And hard scratches.
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The company has even designed
This special machine
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00:10:01,793 --> 00:10:05,689
To conduct a killer
Durability test.
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It applies 100,000
Chalk and brush strokes,
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00:10:08,931 --> 00:10:13,137
Using the typical amount
Of pressure a person would use.
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00:10:13,137 --> 00:10:16,172
For the production batch
To make it to market,
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00:10:16,172 --> 00:10:18,068
Surface wear on the sample
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Has to amount to less than
1/100 of a millimeter.
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And that's not all.
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The paint finish
Must still be matte.
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A writing test
Has to produce chalk lines
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That are clear and dark enough,
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And the writing has to erase
Cleanly and easily.
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Narrator:
For thousands of years,
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Smoked fish was a survival food.
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People would cure their catches
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By salting them
And hanging them to dry
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Or by smoking them
Over an open fire.
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This enabled people
In cold climates
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To stockpile nutrient-rich fish
For those long winter months.
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Today we smoke fish primarily
To enhance its flavor.
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This is wild sockeye salmon
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That was gutted and frozen
On board the fishing trawler
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To preserve maximum freshness.
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The smokehouse defrosts the fish
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For over 15 hours
In running water
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That's just 2 degrees
Above freezing.
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00:11:31,965 --> 00:11:34,448
This slow, cold water thaw
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Helps prevent bacteria
From forming.
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Next step, filleting.
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First, they slice off
What's known as the collar --
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The fish version of a neck.
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Then, they cut each fish in half
Lengthwise,
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Separating two fillets
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From what's called
The control bone --
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The fish equivalent
Of a spinal column.
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The tail is attached to it.
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They feed the control bones
Into a machine
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That strips off any
Remaining scraps of flesh.
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00:12:08,068 --> 00:12:11,310
The machine grinds these bits
Into minced salmon,
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00:12:11,310 --> 00:12:14,827
Which is used to make
Salmon pie.
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00:12:14,827 --> 00:12:18,448
They trim the fillets
Using a razor-sharp knife,
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Slicing off the fins,
Any excess fat,
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00:12:22,034 --> 00:12:25,482
And any control-bone fragments
Left behind.
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00:12:25,482 --> 00:12:28,655
After this, the fish will be
Ready for curing --
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A preservation process
That also enhances taste.
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Workers coat the fillets in
A mixture of salt and 26 spices,
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00:12:38,241 --> 00:12:41,655
Then let them sit for roughly
An hour and a half.
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00:12:41,655 --> 00:12:43,965
This short cure time
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00:12:43,965 --> 00:12:48,655
Will limit the salmon's
Salt content to less than 1%.
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00:12:48,655 --> 00:12:50,551
To stop the curing process,
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00:12:50,551 --> 00:12:53,655
They rinse off the coating
With cold water,
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00:12:53,655 --> 00:12:56,517
Then glaze the fillets
With maple syrup
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00:12:56,517 --> 00:12:59,655
To neutralize
Any remaining salt residue.
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00:12:59,655 --> 00:13:01,862
Some companies
Use a less costly mix
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00:13:01,862 --> 00:13:05,206
Of boiled water and brown sugar.
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00:13:07,655 --> 00:13:10,965
The fillets go into
A huge smoke oven.
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00:13:10,965 --> 00:13:14,620
Workers load its combustion
Chamber with sawdust --
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00:13:14,620 --> 00:13:18,793
Maple-tree sawdust for
The first 8 hours of smoking,
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00:13:18,793 --> 00:13:21,517
Cherry-tree sawdust
For the next 8 hours,
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00:13:21,517 --> 00:13:24,965
And apple-tree sawdust
For the last 8 hours.
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00:13:24,965 --> 00:13:26,827
This particular sequence
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00:13:26,827 --> 00:13:30,551
Is a major factor
In flavoring the fish.
216
00:13:30,551 --> 00:13:34,931
They douse the fire with water
To generate smoke.
217
00:13:34,931 --> 00:13:37,517
This process
Is called "Cold smoking,"
218
00:13:37,517 --> 00:13:41,103
Because the oven temperature
Is 50 degrees fahrenheit --
219
00:13:41,103 --> 00:13:46,310
Significantly lower than
The industry norm of 77 degrees.
220
00:13:46,310 --> 00:13:48,551
Smoking at this
Lower temperature
221
00:13:48,551 --> 00:13:52,137
Takes at least 24 hours --
3 times longer than the norm --
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00:13:52,137 --> 00:13:55,862
But the company says
It produces a moister product.
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00:13:58,551 --> 00:14:01,310
When the fillets
Come out of the smoke oven,
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00:14:01,310 --> 00:14:02,931
They're thoroughly cooked
225
00:14:02,931 --> 00:14:07,068
But still have the consistency
Of raw fish.
226
00:14:07,068 --> 00:14:11,482
Workers remove the fin bones --
40 fin bones per fillet --
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00:14:11,482 --> 00:14:14,103
Located between
The head and fin.
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00:14:19,241 --> 00:14:22,241
The fillets then go through
A skinning machine,
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00:14:22,241 --> 00:14:27,206
Which neatly slices off the skin
Without removing any flesh.
230
00:14:34,655 --> 00:14:38,448
Then, it's into a freezer
At 27 degrees fahrenheit.
231
00:14:38,448 --> 00:14:42,344
This firms up the fillets,
Making them easier to slice.
232
00:14:46,344 --> 00:14:49,310
The manual slicing machines
Cut them into pieces
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00:14:49,310 --> 00:14:51,068
About 1/10 of an inch thick.
234
00:14:56,517 --> 00:14:59,310
Workers weigh out the amount
They're packaging --
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00:14:59,310 --> 00:15:02,689
In this case, 2 1/2 ounces.
236
00:15:05,758 --> 00:15:08,000
They place each portion
On a tray
237
00:15:08,000 --> 00:15:10,413
Made of aluminum-coated
Cardboard.
238
00:15:10,413 --> 00:15:13,689
Aluminum blocks the fat
From seeping through.
239
00:15:13,689 --> 00:15:16,310
To kill off
Any remaining bacterial,
240
00:15:16,310 --> 00:15:18,344
They vacuum-pack the wrappers,
241
00:15:18,344 --> 00:15:20,689
Then deep-freeze them
For about an hour
242
00:15:20,689 --> 00:15:24,137
At negative-31
Degrees fahrenheit.
243
00:15:24,137 --> 00:15:27,344
They store and ship
At a milder zero degrees --
244
00:15:27,344 --> 00:15:30,137
The temperature
Of your home freezer --
245
00:15:30,137 --> 00:15:32,379
Where this preservative-free
Smoked salmon
246
00:15:32,379 --> 00:15:35,517
Stays fresh for a full year.
247
00:15:44,758 --> 00:15:47,344
Narrator: zippers
Can be found on clothing,
248
00:15:47,344 --> 00:15:50,034
On bags, even on footwear.
249
00:15:50,034 --> 00:15:53,620
The zipper started out as
A closure mechanism for boots
250
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And tobacco pouches.
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00:15:55,068 --> 00:15:58,034
The fashion industry
Didn't put them on clothing
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Until the 1930s --
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Some 80 years
After the invention
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00:16:02,103 --> 00:16:04,000
Of this fabulous fastener.
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00:16:09,689 --> 00:16:13,000
An american, elias howe,
Was the first to patent
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00:16:13,000 --> 00:16:16,172
A zipperlike clothing fastener
In 1851,
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00:16:16,172 --> 00:16:18,862
But he never ended up
Marketing it.
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00:16:18,862 --> 00:16:21,862
It wasn't until 1893
That another american,
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00:16:21,862 --> 00:16:24,827
Whitcomb judson,
Designed a similar device,
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Called a clasp locker.
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00:16:28,551 --> 00:16:32,586
He eventually hired a canadian
Engineer, gideon sundback,
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00:16:32,586 --> 00:16:35,586
To simplify the original
Complex design,
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00:16:35,586 --> 00:16:38,103
Which had never really
Taken off.
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00:16:38,103 --> 00:16:43,172
In 1917, judson and sundback
Patented the modern zipper.
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00:16:52,275 --> 00:16:56,551
Zipper teeth are made of metal,
Plastic, or nylon.
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00:16:56,551 --> 00:16:59,482
The fabric part of the zipper
Is called the tape.
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00:16:59,482 --> 00:17:01,206
It's usually polyester,
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00:17:01,206 --> 00:17:03,931
But sometimes cotton
Or fireproof fabric.
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00:17:03,931 --> 00:17:05,379
To make metal zippers,
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00:17:05,379 --> 00:17:08,655
The factory feeds a long,
Continuous roll of tape
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00:17:08,655 --> 00:17:11,103
Into what's called
The teeth machine,
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00:17:11,103 --> 00:17:13,724
Along with a long roll of metal
Ribbon known as "Flat wire."
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00:17:17,620 --> 00:17:19,620
As we see here in slow motion,
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00:17:19,620 --> 00:17:23,344
The machine cuts off
A tiny piece of flat wire,
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00:17:23,344 --> 00:17:27,586
Forces it through a die
That forms into a tooth shape,
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00:17:27,586 --> 00:17:32,137
Then clamps it onto the edge
Of one side of the tape.
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00:17:32,137 --> 00:17:37,206
The machine does all this at
A rate of 45 teeth per second.
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00:17:38,517 --> 00:17:40,551
These zipper teeth are aluminum.
279
00:17:40,551 --> 00:17:43,448
Sturdier zippers
Are made of stronger metals
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00:17:43,448 --> 00:17:45,206
Like brass and nickel.
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00:17:45,206 --> 00:17:46,931
Depending on the model,
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00:17:46,931 --> 00:17:48,482
Teeth can range in width
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00:17:48,482 --> 00:17:52,068
From about 1/10 of an inch
To 4/10 of an inch.
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00:17:52,068 --> 00:17:54,931
The wider the teeth,
The thicker they have to be.
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00:17:54,931 --> 00:17:57,517
Workers now feed two tapes
With metal teeth
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00:17:57,517 --> 00:17:59,931
Into what's called
The joining machine.
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00:17:59,931 --> 00:18:01,551
The teeth interlock,
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00:18:01,551 --> 00:18:05,241
Meshing the two halves of what's
Now a continuous zipper.
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00:18:05,241 --> 00:18:08,034
From there, it's into
A cleaning machine,
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00:18:08,034 --> 00:18:09,689
Which washes the zipper,
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00:18:09,689 --> 00:18:12,448
Removing any shards of metal
Left behind
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00:18:12,448 --> 00:18:15,448
By the tooth-cutting process.
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00:18:15,448 --> 00:18:17,034
After drying the zipper,
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00:18:17,034 --> 00:18:19,655
The machine applies
A coat of hot wax.
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00:18:19,655 --> 00:18:21,379
This lubricates the teeth
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00:18:21,379 --> 00:18:25,517
So the slider will glide
Over them smoothly.
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00:18:25,517 --> 00:18:27,482
Next stop
Is the gapping machine.
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00:18:27,482 --> 00:18:31,724
It removes a 2-inch-long section
Of teeth at regular intervals.
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00:18:31,724 --> 00:18:34,862
They'll later cut the tape
At these gaps,
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00:18:34,862 --> 00:18:39,034
Dividing the continuous zipper
Into several shorter zippers.
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00:18:41,137 --> 00:18:43,517
There are two main types
Of zippers.
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00:18:43,517 --> 00:18:45,241
Closed-end zippers are the kind
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00:18:45,241 --> 00:18:48,379
Whose two halves don't separate
At the bottom when opened --
304
00:18:48,379 --> 00:18:50,551
Purse zippers, for example.
305
00:18:50,551 --> 00:18:53,482
These need a part
Called a bottom stop --
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00:18:53,482 --> 00:18:55,206
A thick piece of flat wire
307
00:18:55,206 --> 00:18:57,862
Positioned at the base
Of the zipper.
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00:18:57,862 --> 00:18:59,931
When you unzip,
It stops the slider
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00:18:59,931 --> 00:19:03,793
And prevents the two halves
From separating.
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00:19:03,793 --> 00:19:05,482
Open-end zippers are the kind
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00:19:05,482 --> 00:19:08,655
Whose two halves doseparate
At the bottom when opened --
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00:19:08,655 --> 00:19:10,724
Jacket zippers, for instance.
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00:19:10,724 --> 00:19:12,517
At the bottom of these zippers,
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00:19:12,517 --> 00:19:15,275
A machine applies
A clear reinforcement strip.
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00:19:15,275 --> 00:19:16,827
This stiffens the tape
316
00:19:16,827 --> 00:19:20,862
So that the next machine
Can apply the pin and box.
317
00:19:23,517 --> 00:19:25,931
The pin is that vertical piece
Of metal
318
00:19:25,931 --> 00:19:27,413
On one half of the zipper
319
00:19:27,413 --> 00:19:29,724
That you have to align
In the box on the other half
320
00:19:29,724 --> 00:19:32,655
Before you can pull the slider
To zip up.
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00:19:49,896 --> 00:19:53,000
The next machine
Installs the slider.
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00:20:02,413 --> 00:20:05,344
Watch in slow motion
As it opens each gap
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00:20:05,344 --> 00:20:09,620
And hooks a slider
Onto the track of teeth.
324
00:20:12,482 --> 00:20:16,103
The next machine inserts
What's called the top stop --
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00:20:16,103 --> 00:20:18,379
A thick piece of flat wire
326
00:20:18,379 --> 00:20:20,758
That stops the slider
At the top of the track
327
00:20:20,758 --> 00:20:23,068
When you zip up all the way.
328
00:20:23,068 --> 00:20:26,172
The machine then slices the tape
At each gap,
329
00:20:26,172 --> 00:20:28,724
Separating the finished zippers.
330
00:20:31,206 --> 00:20:34,275
Plastic zippers are made quite
Differently than metal ones.
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00:20:34,275 --> 00:20:36,137
The tape is the same,
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00:20:36,137 --> 00:20:39,034
But the teeth are made
From plastic pellets.
333
00:20:39,034 --> 00:20:40,689
A machine melts them,
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00:20:40,689 --> 00:20:43,275
Then injects the liquid plastic
Into a mold
335
00:20:43,275 --> 00:20:46,620
That's the shape of a strip
Of zipper teeth.
336
00:20:46,620 --> 00:20:51,206
The mold cools almost instantly,
Hardening the plastic.
337
00:20:51,206 --> 00:20:53,655
The machine then stamps
The teeth onto the tape,
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00:20:53,655 --> 00:20:56,379
Automatically gapping
The desired zipper length
339
00:20:56,379 --> 00:20:58,310
At the same time.
340
00:20:58,310 --> 00:21:02,000
The excess plastic in the middle
Is remelted.
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00:21:02,000 --> 00:21:04,551
There's no joining machine
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00:21:04,551 --> 00:21:07,068
To mesh the two halves
Of plastic zippers.
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00:21:07,068 --> 00:21:08,689
Workers do this manually
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00:21:08,689 --> 00:21:11,103
So that they can inspect
The plastic teeth
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00:21:11,103 --> 00:21:13,724
To make sure
They're well formed.
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00:21:13,724 --> 00:21:17,517
Then, automated machines install
The remaining components.
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00:21:22,000 --> 00:21:24,275
If you have any comments
About the show,
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00:21:24,275 --> 00:21:27,103
Or if you'd like to suggest
Topics for future shows,
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00:21:27,103 --> 00:21:29,758
Drop us a line at...
27775
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