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These are the user uploaded subtitles that are being translated: 1 00:00:01,758 --> 00:00:04,655 --captions by vitac-- Www.Vitac.Com 2 00:00:04,758 --> 00:00:07,724 Captions paid for by Discovery communications, inc. 3 00:00:22,551 --> 00:00:25,620 Narrator: Today on "How it's made"... 4 00:00:25,724 --> 00:00:28,206 Chains... 5 00:00:33,413 --> 00:00:35,586 ...Bagels... 6 00:00:39,655 --> 00:00:41,379 ...And vinyl records. 7 00:00:52,413 --> 00:00:54,724 Chains are As indispensable today 8 00:00:54,827 --> 00:00:57,275 As they were Thousands of years ago. 9 00:00:57,379 --> 00:01:00,206 Ancient historians refer To the use of metal chains 10 00:01:00,310 --> 00:01:03,931 For jewelry, shackles, And construction. 11 00:01:04,034 --> 00:01:07,586 Today, chains are used For those very same purposes 12 00:01:07,689 --> 00:01:10,000 And many more. 13 00:01:16,137 --> 00:01:18,310 Chains are used To tie things down, 14 00:01:18,413 --> 00:01:21,000 Hold things together, And pull things along, 15 00:01:21,103 --> 00:01:24,482 And their many sizes Reflect the varied uses. 16 00:01:24,586 --> 00:01:28,448 To make a chain, a turning drum Uncoils this wire rod 17 00:01:28,551 --> 00:01:32,137 And pulls it through a steel Guide ring to a steel draw box. 18 00:01:32,241 --> 00:01:35,724 Grease inside the box Lubricates the wire. 19 00:01:37,517 --> 00:01:40,379 On its way out of the box, The wire goes through a die, 20 00:01:40,482 --> 00:01:43,551 Such as the one Being demonstrated here. 21 00:01:43,655 --> 00:01:46,379 The die has a smaller diameter Than the wire, 22 00:01:46,482 --> 00:01:48,551 And as the turning drum Pulls it through, 23 00:01:48,655 --> 00:01:52,034 The wire narrows, hardens, And becomes stronger. 24 00:01:54,310 --> 00:01:58,068 Now electrically driven tools Move in from all sides. 25 00:01:58,172 --> 00:01:59,758 This is a forming machine. 26 00:01:59,862 --> 00:02:02,724 A tool called a jaw Propels the wire forward, 27 00:02:02,827 --> 00:02:05,172 While another jaw Pushes on the wire, 28 00:02:05,275 --> 00:02:07,310 Bending it around a steel pin. 29 00:02:07,413 --> 00:02:09,000 It forms a "C" shape. 30 00:02:09,103 --> 00:02:11,931 Another forming tool Closes the "C," 31 00:02:12,034 --> 00:02:14,689 Completing one link In the chain, 32 00:02:14,793 --> 00:02:17,689 And then another jaw Makes the next link. 33 00:02:20,551 --> 00:02:22,965 This machine Is making jack chain, 34 00:02:23,068 --> 00:02:26,379 Which is usually used To hang lights. 35 00:02:26,482 --> 00:02:28,517 Another forming machine Makes a chain 36 00:02:28,620 --> 00:02:30,931 That can haul a heavier load. 37 00:02:33,620 --> 00:02:37,344 A grip pulls the wire onto Rollers that straighten it out. 38 00:02:41,241 --> 00:02:46,034 Steel cutters now make notches On both sides of the wire. 39 00:02:46,137 --> 00:02:48,034 These notches mark the place Where the wire 40 00:02:48,137 --> 00:02:50,896 Is to be sliced Into link-sized pieces. 41 00:02:53,344 --> 00:02:58,482 A mechanized knife makes The final cut at the notches. 42 00:02:58,586 --> 00:03:01,655 Next, roller arms loop A cut piece of wire 43 00:03:01,758 --> 00:03:03,172 Around a steel finger. 44 00:03:03,275 --> 00:03:05,551 The roller arms Make it look easy, 45 00:03:05,655 --> 00:03:08,000 But they're actually exerting Tons of pressure 46 00:03:08,103 --> 00:03:09,931 In order to shape this wire. 47 00:03:10,034 --> 00:03:12,068 After the rollers form the link, 48 00:03:12,172 --> 00:03:15,000 A pliers-like tool grabs it And turns it around. 49 00:03:15,103 --> 00:03:17,172 This positions The completed link 50 00:03:17,275 --> 00:03:20,068 So that it can connect with The next link as it's shaped. 51 00:03:23,172 --> 00:03:25,034 As each link is added, 52 00:03:25,137 --> 00:03:29,206 The chain drops into A pile below the machine. 53 00:03:29,310 --> 00:03:31,689 There are dozens Of forming machines 54 00:03:31,793 --> 00:03:33,413 In most chain factories. 55 00:03:33,517 --> 00:03:36,551 Each machine makes 50 to 60 links per minute. 56 00:03:36,655 --> 00:03:40,241 That's about 250 feet of chain Per machine hour. 57 00:03:40,344 --> 00:03:43,827 To put that into perspective, One machine could make a chain 58 00:03:43,931 --> 00:03:46,551 As long as the empire state Building is high 59 00:03:46,655 --> 00:03:49,310 In just under six hours. 60 00:04:01,344 --> 00:04:05,241 After the chain is formed, It will need to be strengthened. 61 00:04:05,344 --> 00:04:08,344 So it's on To the welding machine. 62 00:04:11,517 --> 00:04:14,068 Hammers to the left and right Push the link in, 63 00:04:14,172 --> 00:04:16,586 Then two copper blocks move in From the sides. 64 00:04:16,689 --> 00:04:19,310 They act as electrodes And zap both sides of the link 65 00:04:19,413 --> 00:04:21,724 With an electrical current. 66 00:04:21,827 --> 00:04:24,310 The current ripples Through the gap in the link, 67 00:04:24,413 --> 00:04:26,586 While the hammers push it in. 68 00:04:26,689 --> 00:04:31,827 The link reaches a scorching 1,700 degrees fahrenheit. 69 00:04:31,931 --> 00:04:35,137 The wire melts And the link fuses together. 70 00:04:40,689 --> 00:04:43,517 Now a pulley system drops The freshly welded chain 71 00:04:43,620 --> 00:04:45,034 Into a heat-treating coil. 72 00:04:45,137 --> 00:04:48,000 An electrical current runs Through the copper coil, 73 00:04:48,103 --> 00:04:50,862 Heating the chain inside Until it's orange-hot -- 74 00:04:50,965 --> 00:04:53,793 1,724 degrees fahrenheit. 75 00:04:53,896 --> 00:04:56,862 The pulleys lower the chain Into a tub of water to cool. 76 00:04:56,965 --> 00:04:58,551 The extreme temperature change 77 00:04:58,655 --> 00:05:01,482 Alters the molecular structure Of the steel, 78 00:05:01,586 --> 00:05:03,103 Making it much harder. 79 00:05:03,206 --> 00:05:06,137 But the experience leaves The chain a bit brittle. 80 00:05:06,241 --> 00:05:08,344 So it goes into A second heat coil 81 00:05:08,448 --> 00:05:10,275 That's not as hot As the first one 82 00:05:10,379 --> 00:05:12,517 And then into another cool bath. 83 00:05:12,620 --> 00:05:14,689 This takes away the brittleness 84 00:05:14,793 --> 00:05:17,206 And gives the steel A bit of stretch. 85 00:05:19,448 --> 00:05:21,724 Now the ultimate Strength test -- 86 00:05:21,827 --> 00:05:23,620 This is the chain calibrator. 87 00:05:23,724 --> 00:05:25,620 Pulleys run the chain Into a groove 88 00:05:25,724 --> 00:05:28,827 That's been cut into A block of steel. 89 00:05:30,068 --> 00:05:31,965 A clamp on the left Holds it in place, 90 00:05:32,068 --> 00:05:34,172 While the hydraulically powered Block of steel 91 00:05:34,275 --> 00:05:35,655 Pulls the chain to the right. 92 00:05:37,551 --> 00:05:39,586 Will it break or will it hold? 93 00:05:39,689 --> 00:05:42,172 And can it handle the load? 94 00:05:42,275 --> 00:05:46,724 After all, the chain is only As strong as the weakest link. 95 00:06:00,758 --> 00:06:03,103 Narrator: the first bagels Were created in eastern europe 96 00:06:03,206 --> 00:06:04,689 During the 1600s. 97 00:06:04,793 --> 00:06:07,413 Exactly why is debatable, But one account 98 00:06:07,517 --> 00:06:10,103 Is that they were a tribute To the king of poland. 99 00:06:10,206 --> 00:06:12,827 The king was a military hero And a great horseman, 100 00:06:12,931 --> 00:06:15,517 So a baker shaped the dough To resemble a stirrup. 101 00:06:15,620 --> 00:06:18,793 The austrian word for "Stirrup" Sounds like "Bagel." 102 00:06:23,896 --> 00:06:26,517 You used to get bagels In just two varieties -- 103 00:06:26,620 --> 00:06:28,344 Sesame seed or poppy seed. 104 00:06:28,448 --> 00:06:30,517 Today they come in a rainbow Of flavors, 105 00:06:30,620 --> 00:06:33,965 From nine-grain to blueberry To cinnamon-raisin 106 00:06:34,068 --> 00:06:36,172 To whole-wheat sesame. 107 00:06:36,275 --> 00:06:38,689 Commercial bakeries Make them like this. 108 00:06:38,793 --> 00:06:42,344 The first step is to blend all The ingredients in a huge mixer. 109 00:06:42,448 --> 00:06:45,758 These include molasses, Salt, yeast, flour, 110 00:06:45,862 --> 00:06:49,827 Sugar, malt flour, Ascorbic acid, and enzymes. 111 00:06:49,931 --> 00:06:52,655 If needed, workers also add The special flavorings. 112 00:06:52,758 --> 00:06:55,793 Raisins or blueberries go in When the mixing's nearly done 113 00:06:55,896 --> 00:06:58,275 To avoid pulverizing them. 114 00:06:58,379 --> 00:07:01,103 One batch of dough Weighs 750 pounds 115 00:07:01,206 --> 00:07:04,862 And makes about 3,200 bagels. 116 00:07:04,965 --> 00:07:08,206 They slowly add About 26 gallons of water 117 00:07:08,310 --> 00:07:10,517 As the ingredients blend For 10 minutes. 118 00:07:10,620 --> 00:07:12,965 They monitor the water And air temperatures 119 00:07:13,068 --> 00:07:16,000 So that the dough reaches 78 degrees fahrenheit. 120 00:07:16,103 --> 00:07:17,793 That's when yeast activates, 121 00:07:17,896 --> 00:07:21,724 Enabling the dough To rise later on. 122 00:07:21,827 --> 00:07:24,620 Worker uses a thermometer To take the dough's temperature. 123 00:07:24,724 --> 00:07:26,931 Too warm, The dough will rise too quickly. 124 00:07:27,034 --> 00:07:30,379 Too cold and the dough Won't rise enough. 125 00:07:30,482 --> 00:07:34,931 Here, workers cut large chunks Of dough for raisin bagels 126 00:07:35,034 --> 00:07:36,655 Into smaller blocks. 127 00:07:36,758 --> 00:07:39,931 They'll put these blocks Into a machine called a divider. 128 00:07:40,034 --> 00:07:43,413 The machine squeezes the dough Through small openings 129 00:07:43,517 --> 00:07:46,241 To create doughballs That weigh 3.7 ounces, 130 00:07:46,344 --> 00:07:48,551 Which will each become One bagel. 131 00:07:48,655 --> 00:07:51,068 The divider also distributes The balls 132 00:07:51,172 --> 00:07:54,482 Into four single files As they emerge from the machine 133 00:07:54,586 --> 00:07:57,034 And move along plastic Conveyor belts. 134 00:07:57,137 --> 00:08:01,068 They're plastic so workers Can clean them easily and often. 135 00:08:01,172 --> 00:08:03,655 Next, a machine called A bagel former 136 00:08:03,758 --> 00:08:05,724 Flattens the balls into strips. 137 00:08:05,827 --> 00:08:09,137 This way, the strips can be Curved into rings. 138 00:08:09,241 --> 00:08:12,275 The curved conveyor belt Guides the dough 139 00:08:12,379 --> 00:08:14,241 Through a tight circular opening 140 00:08:14,344 --> 00:08:16,896 With a stainless-steel rod At its center. 141 00:08:17,000 --> 00:08:20,758 The rod forces the two ends of The strip to join in a circle. 142 00:08:20,862 --> 00:08:23,827 This process happens In less than two seconds, 143 00:08:23,931 --> 00:08:25,862 Before the dough has a chance To dry out. 144 00:08:25,965 --> 00:08:27,310 It's the moisture in the dough 145 00:08:27,413 --> 00:08:31,482 That enables the ends Of the strips to stick together. 146 00:08:31,586 --> 00:08:34,620 The bagel rings emerge From the bagel former 147 00:08:34,724 --> 00:08:35,896 Onto another conveyor. 148 00:08:36,000 --> 00:08:38,172 Workers then visually inspect The rings 149 00:08:38,275 --> 00:08:42,275 To ensure they came out right. 150 00:08:42,379 --> 00:08:44,862 After placing the bagels Onto ungreased trays, 151 00:08:44,965 --> 00:08:47,551 Workers put them in a large room Called a proofer 152 00:08:47,655 --> 00:08:49,689 For 90 minutes to rise. 153 00:08:49,793 --> 00:08:52,758 The proofer is kept At 109 degrees fahrenheit 154 00:08:52,862 --> 00:08:55,068 With 80% humidity. 155 00:08:56,793 --> 00:09:00,793 Next a worker places the trays Onto a metal conveyor belt. 156 00:09:00,896 --> 00:09:03,620 This conveyor moves the bagels Into a huge steam oven 157 00:09:03,724 --> 00:09:05,862 About the size of a school bus. 158 00:09:05,965 --> 00:09:08,000 Steam makes the bagels Chewy and shiny. 159 00:09:08,103 --> 00:09:10,103 To ensure the dough Develops properly, 160 00:09:10,206 --> 00:09:12,413 They maintain air temperature In the bakery 161 00:09:12,517 --> 00:09:14,827 At a constant 68 degrees fahrenheit. 162 00:09:14,931 --> 00:09:16,862 And there's no air-conditioning 163 00:09:16,965 --> 00:09:19,620 To ensure the right Humidity level. 164 00:09:23,310 --> 00:09:25,724 After baking for exactly 13 minutes 165 00:09:25,827 --> 00:09:28,517 At precisely 450 degrees fahrenheit, 166 00:09:28,620 --> 00:09:31,758 The bagels come out Of the steam oven. 167 00:09:31,862 --> 00:09:34,482 They lost moisture During the baking process, 168 00:09:34,586 --> 00:09:38,137 So they now weigh around A half-ounce less than before. 169 00:09:38,241 --> 00:09:42,000 To cool down, the bagels move Along a winding conveyor belt 170 00:09:42,103 --> 00:09:45,862 That snakes through 6 floors Of this 1.5-square-mile bakery. 171 00:09:48,172 --> 00:09:50,689 Bagel-making ranges From large commercial operations 172 00:09:50,793 --> 00:09:51,931 Like this one 173 00:09:52,034 --> 00:09:53,448 To small neighborhood bakeries 174 00:09:53,551 --> 00:09:55,793 That still make them The old-fashioned way -- 175 00:09:55,896 --> 00:09:57,724 Rolling and shaping the dough By hand 176 00:09:57,827 --> 00:09:59,931 And baking them in a brick oven. 177 00:10:00,034 --> 00:10:02,482 During the 50-minute journey, 178 00:10:02,586 --> 00:10:05,862 Their temperatures drop To about 98 degrees fahrenheit, 179 00:10:05,965 --> 00:10:09,758 Cool enough to package In plastic bags later on. 180 00:10:09,862 --> 00:10:13,931 Here, a worker inspects The bagels for shape, color, 181 00:10:14,034 --> 00:10:16,310 Height, and shine. 182 00:10:16,413 --> 00:10:18,206 To help the consumer, 183 00:10:18,310 --> 00:10:21,448 A machine preslices the bagels Almost in half. 184 00:10:21,551 --> 00:10:22,931 It leaves a portion uncut 185 00:10:23,034 --> 00:10:27,896 So the bagel sections Stick together and stay fresh. 186 00:10:28,000 --> 00:10:30,827 Next, workers separate The bagels into groups of six, 187 00:10:30,931 --> 00:10:32,931 Placing them along Another conveyor 188 00:10:33,034 --> 00:10:35,172 Lined with tiny brushes. 189 00:10:35,275 --> 00:10:37,241 These brushes Keep the bagels upright 190 00:10:37,344 --> 00:10:42,000 As they head off for packaging. 191 00:10:42,103 --> 00:10:44,758 A mechanical arm scoops The bagels along, 192 00:10:44,862 --> 00:10:48,379 And another blows open the bags And inserts the bagels. 193 00:10:48,482 --> 00:10:51,379 This bakery prepares up To 3,000 half-dozen packages 194 00:10:51,482 --> 00:10:52,655 An hour for shipping, 195 00:10:52,758 --> 00:10:55,000 Fast enough to have A fresh bagel 196 00:10:55,103 --> 00:10:58,965 Land on your breakfast plate As soon as 12 hours later. 197 00:11:08,068 --> 00:11:10,862 Narrator: vinyl records have An ever-increasing following 198 00:11:10,965 --> 00:11:14,068 Among audiophiles, collectors, And deejays. 199 00:11:14,172 --> 00:11:18,172 Some say they sound better Than digital cds and mp3s. 200 00:11:18,275 --> 00:11:19,517 To cater to this market, 201 00:11:19,620 --> 00:11:22,689 Some record companies are Releasing more music on vinyl, 202 00:11:22,793 --> 00:11:26,965 A manufacturing process that's Interesting and fun to watch. 203 00:11:29,862 --> 00:11:34,172 The first step is to cut A master record. 204 00:11:34,275 --> 00:11:36,206 This flat disk Is made of aluminum, 205 00:11:36,310 --> 00:11:39,655 And it will be the core Of the master. 206 00:11:39,758 --> 00:11:42,068 The surface has a gritty texture Early on, 207 00:11:42,172 --> 00:11:45,000 But they sand it down And polish it smooth. 208 00:11:49,206 --> 00:11:52,137 They place the aluminum disks On a conveyor belt, 209 00:11:52,241 --> 00:11:54,310 And they ride towards A device that will coat them 210 00:11:54,413 --> 00:11:56,448 With a veneer of lacquer. 211 00:11:59,241 --> 00:12:02,689 The disk enters The curtain coater. 212 00:12:02,793 --> 00:12:04,448 Nitrocellulose lacquer -- 213 00:12:04,551 --> 00:12:07,034 A similar substance To nail polish -- 214 00:12:07,137 --> 00:12:08,965 Oozes out of a long, Thin opening, 215 00:12:09,068 --> 00:12:12,689 Forming a veil, or curtain. 216 00:12:12,793 --> 00:12:14,896 As the disk passes Through the curtain, 217 00:12:15,000 --> 00:12:17,241 It's slathered with the lacquer. 218 00:12:19,827 --> 00:12:22,482 Rollers with scrapers Catch the runoff. 219 00:12:22,586 --> 00:12:26,344 The excess lacquer they collect Is reused. 220 00:12:28,172 --> 00:12:30,448 The lacquer starts to dry Immediately. 221 00:12:30,551 --> 00:12:32,379 The solvents evaporate, 222 00:12:32,482 --> 00:12:35,793 And the veneer hardens Into a nail-polish-like finish. 223 00:12:38,068 --> 00:12:43,448 But like any manicure job, There are often flaws. 224 00:12:43,551 --> 00:12:45,000 At this inspection station, 225 00:12:45,103 --> 00:12:47,344 Workers scrutinize Each lacquered disk 226 00:12:47,448 --> 00:12:50,379 For pits, bumps, or dirt. 227 00:12:50,482 --> 00:12:53,206 Even a minor imperfection Won't be tolerated, 228 00:12:53,310 --> 00:12:57,689 So the rejection rate is high -- About 50%. 229 00:12:57,793 --> 00:13:00,482 They recycle the rejects. 230 00:13:03,482 --> 00:13:05,551 They rim the good masters With plastic edging. 231 00:13:05,655 --> 00:13:08,275 It will stop the disks from Rubbing together during stacking 232 00:13:08,379 --> 00:13:10,965 And damaging the finish. 233 00:13:14,517 --> 00:13:17,758 Next, a worker holds the disk Under a hydraulic puncher 234 00:13:17,862 --> 00:13:20,275 That cuts a hole in the center. 235 00:13:20,379 --> 00:13:24,103 Then, handling it carefully so He doesn't disturb the finish, 236 00:13:24,206 --> 00:13:26,862 He places it on a spindle. 237 00:13:29,103 --> 00:13:32,172 A robotic arm slides A plastic ring down the spindle, 238 00:13:32,275 --> 00:13:35,206 Depositing it around The center hole of the disk. 239 00:13:35,310 --> 00:13:36,758 Like the plastic edging, 240 00:13:36,862 --> 00:13:40,758 The ring will also space The disks apart. 241 00:13:40,862 --> 00:13:45,206 Now the master disks are ready To take a trip to the studio. 242 00:13:49,344 --> 00:13:52,655 The lacquer disk Is about to be cut. 243 00:13:52,758 --> 00:13:55,551 The engineer places it on The recording machine 244 00:13:55,655 --> 00:13:58,379 Called a lathe. 245 00:13:58,482 --> 00:14:03,103 He peels the protective ribbing Away from the rim. 246 00:14:03,206 --> 00:14:06,827 He places a vacuum line At the center, 247 00:14:06,931 --> 00:14:08,724 Which suctions To the underside of the disk 248 00:14:08,827 --> 00:14:11,206 And holds it in place. 249 00:14:11,310 --> 00:14:14,482 The engineer now moves The cutter and a microscope 250 00:14:14,586 --> 00:14:17,862 Above the disk. 251 00:14:17,965 --> 00:14:20,620 He lowers the cutter Onto the outer edge of the disk 252 00:14:20,724 --> 00:14:22,931 And it does a test cut. 253 00:14:24,793 --> 00:14:28,000 He positions a microscope Just above the test groove 254 00:14:28,103 --> 00:14:32,551 And then peers into it To get a good look at the cut. 255 00:14:32,655 --> 00:14:37,689 He makes adjustments to the cut, And then he's ready to record. 256 00:14:37,793 --> 00:14:40,827 The lathe cuts the lead-in Groove and the music begins. 257 00:14:40,931 --> 00:14:43,137 The sapphire-tipped cutter 258 00:14:43,241 --> 00:14:45,827 Etches the sound Into the surface of the disk. 259 00:14:45,931 --> 00:14:47,620 From start to finish, 260 00:14:47,724 --> 00:14:51,344 The recording will be one Continuous groove in the record. 261 00:15:02,586 --> 00:15:04,482 A computer monitors the cutting 262 00:15:04,586 --> 00:15:07,241 And adjusts the spacing between The grooves where needed. 263 00:15:07,344 --> 00:15:13,655 A little vacuum draws up scrap, As the cutter carves the groove. 264 00:15:13,758 --> 00:15:15,965 Some believe this sound Is warmer 265 00:15:16,068 --> 00:15:18,310 And has more depth Than digital recordings. 266 00:15:18,413 --> 00:15:22,000 But making music fit On an analog disk 267 00:15:22,103 --> 00:15:24,448 Is sometimes challenging. 268 00:15:24,551 --> 00:15:28,137 To reproduce bass, the cutter Has to make big, wide grooves 269 00:15:28,241 --> 00:15:30,413 That take up a lot of space. 270 00:15:30,517 --> 00:15:32,862 And although the grooves Can touch, 271 00:15:32,965 --> 00:15:35,896 They can't cut across One another. 272 00:15:36,000 --> 00:15:38,103 At the end of the recording, 273 00:15:38,206 --> 00:15:42,448 The cutter lifts and the master Disk is ready for inspection. 274 00:15:45,000 --> 00:15:46,482 If it's acceptable, 275 00:15:46,586 --> 00:15:49,068 The engineer places A sliding platform on it 276 00:15:49,172 --> 00:15:52,689 And scribes a unique Serial number into the lacquer. 277 00:15:55,586 --> 00:15:59,965 Soon, this master disk will be Used to make more records. 278 00:16:15,379 --> 00:16:18,551 Narrator: the master disk Has just been cut, 279 00:16:18,655 --> 00:16:21,724 But the lacquer surface Is far too delicate to play. 280 00:16:21,827 --> 00:16:23,896 It's been produced solely To act as a mold. 281 00:16:24,000 --> 00:16:26,000 It will literally be pressed Into service 282 00:16:26,103 --> 00:16:28,758 To make tougher versions Of the recorded grooves. 283 00:16:28,862 --> 00:16:30,931 And this will enable The manufacturers 284 00:16:31,034 --> 00:16:33,793 To make many copies From just one. 285 00:16:38,206 --> 00:16:39,758 In the next step, 286 00:16:39,862 --> 00:16:43,931 They wash the lacquer disk With soap and water. 287 00:16:44,034 --> 00:16:47,206 They spray it with tin chloride And liquid silver. 288 00:16:47,310 --> 00:16:49,275 The tin chloride is a sensitizer 289 00:16:49,379 --> 00:16:52,103 That helps the silver stick To the lacquer. 290 00:16:54,379 --> 00:16:57,103 They wash away little bits Of silver that don't stick. 291 00:16:57,206 --> 00:16:59,137 In seconds, One side of the lacquer 292 00:16:59,241 --> 00:17:02,758 Has become a stunning silver Disk with the grooves intact. 293 00:17:04,862 --> 00:17:08,620 But next, they'll add a duller Metal to the silvered side 294 00:17:08,724 --> 00:17:12,413 In order To really stiffen the disk. 295 00:17:12,517 --> 00:17:15,862 They fasten it to a spindle On the underside of a tank lid. 296 00:17:17,758 --> 00:17:22,000 The disk spins, And they rinse it one more time. 297 00:17:22,103 --> 00:17:25,448 The water in the tank below Is green 298 00:17:25,551 --> 00:17:29,137 Because these nickel nuggets Are dissolving into it. 299 00:17:29,241 --> 00:17:30,724 They lower the lid 300 00:17:30,827 --> 00:17:34,034 And the spinning disk Is immersed in the solution. 301 00:17:34,137 --> 00:17:37,862 An electric charge fuses The nickel to the silver... 302 00:17:39,827 --> 00:17:43,310 ...And the nickel settles Neatly into the grooves. 303 00:17:48,034 --> 00:17:50,034 Now they remove it From the tank 304 00:17:50,137 --> 00:17:51,689 And pry the metal layer away 305 00:17:51,793 --> 00:17:54,068 From the original Lacquer disk. 306 00:17:54,172 --> 00:17:55,724 This metal layer is a stamper 307 00:17:55,827 --> 00:17:58,103 That will be used to press Vinyl records. 308 00:17:58,206 --> 00:18:01,068 And the lacquer disk, Which has served as its mold, 309 00:18:01,172 --> 00:18:03,103 Is discarded. 310 00:18:05,206 --> 00:18:08,482 Now they look for the exact Center of the stamper. 311 00:18:08,586 --> 00:18:11,241 A worker places it Under the microscope, 312 00:18:11,344 --> 00:18:13,758 Which is part Of an optical centering punch. 313 00:18:13,862 --> 00:18:16,000 As the stamper disk spins, 314 00:18:16,103 --> 00:18:19,965 He aligns the grooves With a guide in the viewfinder. 315 00:18:20,068 --> 00:18:23,655 When he finds the center, He punches a hole there. 316 00:18:32,103 --> 00:18:36,620 Next, they clamp the stamper Disk into a trimming machine. 317 00:18:38,793 --> 00:18:42,137 The disk turns and a cutting Wheel trims the edge, 318 00:18:42,241 --> 00:18:47,793 Cutting the stamper disk To a diameter of 12 1/2 inches. 319 00:18:47,896 --> 00:18:51,931 Now the stampers are ready To make their mark. 320 00:18:52,034 --> 00:18:56,655 But first the labels Must be prepared. 321 00:18:56,758 --> 00:19:00,931 A punch bores into the center of A stack of them, making holes. 322 00:19:06,689 --> 00:19:09,379 Then they place the labels On a mini-press. 323 00:19:09,482 --> 00:19:13,344 It rises to another cutter, Which rounds them out. 324 00:19:20,689 --> 00:19:24,103 They pour black polyvinyl Chloride pellets into a hopper. 325 00:19:24,206 --> 00:19:26,862 The pellets fall Into an extruder, 326 00:19:26,965 --> 00:19:30,172 Which turns them into hot Rubbery paddies called biscuits. 327 00:19:30,275 --> 00:19:31,551 Hoists above and below 328 00:19:31,655 --> 00:19:33,551 Push labels to each side Of the biscuit. 329 00:19:33,655 --> 00:19:34,896 Suction cups hold them there 330 00:19:35,000 --> 00:19:37,586 While a carriage moves The biscuit forward 331 00:19:37,689 --> 00:19:40,310 Then drops the biscuit And labels in the press. 332 00:19:40,413 --> 00:19:42,379 Two stampers Mounted in the press 333 00:19:42,482 --> 00:19:44,689 Apply 100 tons of pressure. 334 00:19:44,793 --> 00:19:48,448 The stampers are a searing 380 degrees fahrenheit. 335 00:19:48,551 --> 00:19:50,827 They melt and mold the biscuit Into a record. 336 00:19:50,931 --> 00:19:53,448 A quick cooling cycle hardens it 337 00:19:53,551 --> 00:19:57,344 And bonds the labels To the vinyl. 338 00:19:57,448 --> 00:20:00,517 A carriage then transports it To a trimming table. 339 00:20:00,620 --> 00:20:03,241 The table spins the record Against a knife 340 00:20:03,344 --> 00:20:05,965 As it cuts away The ragged edges. 341 00:20:08,344 --> 00:20:10,758 Then, the table takes The trimmed record 342 00:20:10,862 --> 00:20:13,172 To the finished stack. 343 00:20:13,275 --> 00:20:15,103 And the process begins again. 344 00:20:24,103 --> 00:20:25,241 This is really 345 00:20:25,344 --> 00:20:28,448 A well-choreographed Musical production. 346 00:20:28,551 --> 00:20:31,000 As one record is lifted out Of the press, 347 00:20:31,103 --> 00:20:33,275 The next one goes in. 348 00:20:40,344 --> 00:20:42,413 The pressing and trimming Of a vinyl record 349 00:20:42,517 --> 00:20:46,241 Takes just 28 seconds. 350 00:20:46,344 --> 00:20:49,931 But it's sure to get hours Of play by enthusiasts 351 00:20:50,034 --> 00:20:53,241 Who refuse to buy into The digital revolution 352 00:20:53,344 --> 00:20:56,827 And still believe that vinyl Is a cut above. 353 00:21:18,206 --> 00:21:20,344 If you have any comments About the show, 354 00:21:20,448 --> 00:21:23,034 Or if you'd like to suggest Topics for future shows, 355 00:21:23,137 --> 00:21:25,413 Drop us a line at... 28687

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