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00:00:01,793 --> 00:00:04,689
--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
3
00:00:52,517 --> 00:00:55,103
Narrator: TO CONTAIN
THE SOUNDS OF TRAFFIC,
4
00:00:55,206 --> 00:00:58,586
IT'S OFTEN NECESSARY
TO PUT UP A WALL OF SILENCE.
5
00:00:58,689 --> 00:01:01,931
NOISE-BARRIER WALLS
BOTH ABSORB TRAFFIC NOISE
6
00:01:02,034 --> 00:01:04,482
AND SHIELD NEIGHBORHOODS
FROM IT.
7
00:01:04,586 --> 00:01:07,758
WITH STONE OR BRICK-LIKE
TEXTURES ON BOTH SIDES,
8
00:01:07,862 --> 00:01:10,448
THEY EVEN LOOK GOOD
ON THE STREET.
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00:01:14,206 --> 00:01:16,103
IN THE 1970s,
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00:01:16,206 --> 00:01:19,655
NOISE-BARRIER WALLS
WERE MAINLY DRAB CONCRETE.
11
00:01:19,758 --> 00:01:21,482
FAST FORWARD TO TODAY,
12
00:01:21,586 --> 00:01:24,482
AND THE WALLS COME IN A RANGE
OF TEXTURES AND DESIGNS
13
00:01:24,586 --> 00:01:26,655
FOR CURB APPEAL.
14
00:01:26,758 --> 00:01:29,206
BUT OF COURSE, IT'S
THEIR NOISE-ABSORBING QUALITIES
15
00:01:29,310 --> 00:01:32,275
THAT REALLY IMPROVE
THE NEIGHBORHOOD.
16
00:01:32,379 --> 00:01:33,655
THEY'RE MADE FROM A WOOD SHAVING
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00:01:33,758 --> 00:01:36,034
AND CEMENT MATERIAL
THAT'S VERY POROUS,
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00:01:36,137 --> 00:01:39,655
WHICH ALLOWS THE WALLS
TO ABSORB SOUND AND ENTRAP IT.
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00:01:39,758 --> 00:01:42,379
PRODUCTION STARTS
WITH THE RAW SHAVINGS.
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00:01:42,482 --> 00:01:46,379
A CONVEYOR DELIVERS THEM
TO A HAMMER MILL.
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00:01:46,482 --> 00:01:49,517
INSIDE, ROTATING HAMMERS
FORCE THE WOOD SHAVINGS
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00:01:49,620 --> 00:01:51,793
THROUGH A CUTTING SCREEN.
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00:01:57,241 --> 00:01:59,413
THIS CARVES THEM
INTO SMALLER PARTICLES
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00:01:59,517 --> 00:02:02,275
OF VARIOUS SIZES.
25
00:02:02,379 --> 00:02:03,931
IT'S THIS COMBINATION OF SIZES
26
00:02:04,034 --> 00:02:06,620
THAT WILL CREATE
THE NOISE-ABSORBING PORES
27
00:02:06,724 --> 00:02:08,448
IN THE COMPLETED WALL.
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00:02:11,448 --> 00:02:14,034
THEY TEST
A PROPRIETARY CHEMICAL SOLUTION,
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00:02:14,137 --> 00:02:16,379
THAT WILL BE USED
TO TREAT THE WOOD PARTICLES,
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00:02:16,482 --> 00:02:19,931
AND CONFIRM
IT'S THE RIGHT CONCENTRATION.
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00:02:20,034 --> 00:02:22,896
AN AUGER THEN MIXES IT
INTO THE WOOD PARTICLES
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00:02:23,000 --> 00:02:25,827
UNTIL THEY'RE DAMP
AND THOROUGHLY COATED.
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00:02:25,931 --> 00:02:27,206
WITHOUT THIS TREATMENT,
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00:02:27,310 --> 00:02:30,448
THE WOOD PARTICLES
WOULDN'T BIND WITH CEMENT.
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00:02:30,551 --> 00:02:33,413
IT WILL ALSO PROTECT THE WOOD
FROM DECAY.
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00:02:35,517 --> 00:02:38,793
IN ANOTHER MIXER, THEY ADD WATER
AND A SECOND CHEMICAL SOLUTION
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00:02:38,896 --> 00:02:42,310
TO FURTHER ENHANCE
THE BINDING PROCESS.
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THE WOOD PARTICLES ARE NOW
PRIMED AND READY TO BE MIXED
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00:02:50,793 --> 00:02:56,310
WITH A POWDERED MIX OF LIMESTONE
CLAY CALLED PORTLAND CEMENT.
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00:02:56,413 --> 00:02:58,034
THE MACHINE
WORKS THE INGREDIENTS
41
00:02:58,137 --> 00:03:00,344
UNTIL THEY FORM
A COHESIVE MATERIAL
42
00:03:00,448 --> 00:03:02,137
THAT CAN BE SHAPED.
43
00:03:08,793 --> 00:03:10,689
THE NEXT WORKER
SPRAYS A RELEASE AGENT
44
00:03:10,793 --> 00:03:12,931
ONTO THE STONE-PATTERN LINER.
45
00:03:15,413 --> 00:03:19,448
EACH MOLD WILL FORM
ONE NOISE BARRIER PANEL.
46
00:03:19,551 --> 00:03:22,034
THE TEAM TRANSFERS
THE WOOD-AND-CEMENT BLEND
47
00:03:22,137 --> 00:03:23,620
INTO THE MOLD.
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00:03:23,724 --> 00:03:25,068
THEY WORK AT A STEADY PACE
49
00:03:25,172 --> 00:03:28,206
TO FILL IT BEFORE THE MIXTURE
BEGINS TO DRY.
50
00:03:33,310 --> 00:03:35,000
ONCE THEY'VE FILLED IT PARTWAY,
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00:03:35,103 --> 00:03:37,448
THEY LEVEL
THE WOOD-CEMENT MATERIAL...
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00:03:39,586 --> 00:03:42,034
...THEN COMPACT IT
WITH A TAMPING TOOL.
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00:03:43,862 --> 00:03:46,413
NEXT, THEY ADD A STEEL MESH.
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00:03:46,517 --> 00:03:48,551
THIS MESH WILL SERVE
AS A SKELETON,
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00:03:48,655 --> 00:03:51,896
ALLOWING THE WALL
TO STAND STRONG.
56
00:03:52,000 --> 00:03:55,482
THEY POUR FRESHLY MIXED CONCRETE
ONTO THE STEEL MESH.
57
00:03:55,586 --> 00:03:57,000
IT FLOWS THROUGH THE MESH
58
00:03:57,103 --> 00:03:59,758
AND ONTO THE SOUND-ABSORBING
MIXTURE BELOW,
59
00:03:59,862 --> 00:04:02,482
BINDING THE TWO LAYERS TOGETHER.
60
00:04:02,586 --> 00:04:05,724
THE WORKER SPREADS THE CONCRETE
THROUGHOUT THE MOLD.
61
00:04:07,413 --> 00:04:10,896
HE PIERCES THE SURFACE
WITH A VIBRATING TOOL.
62
00:04:11,000 --> 00:04:13,517
THE VIBRATIONS
CONSOLIDATE THE CONCRETE
63
00:04:13,620 --> 00:04:15,758
AND ELIMINATE AIR POCKETS.
64
00:04:17,517 --> 00:04:19,034
THE TWO-PERSON TEAM LEVELS
65
00:04:19,137 --> 00:04:22,172
THE CONCRETE LAYER
USING A WOOD SCREED.
66
00:04:30,724 --> 00:04:35,172
THEY APPLY A SECOND LAYER
OF THE NOISE-ABSORBING MATERIAL
67
00:04:35,275 --> 00:04:37,103
AND LEVEL IT.
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00:04:46,379 --> 00:04:48,551
THEY LOWER
THE STONE-PATTERN PRESS LID,
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00:04:48,655 --> 00:04:52,000
WHICH WILL MOLD THE PATTERN
ONTO THE TOP SIDE OF THE PANEL.
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00:04:54,551 --> 00:04:57,413
THEY SET A 10-TON CONCRETE BLOCK
ON THE MOLD,
71
00:04:57,517 --> 00:04:59,379
AND PRESSURE FORCES
THE MOLD PATTERNS
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00:04:59,482 --> 00:05:01,724
ONTO BOTH SIDES OF THE CASTING.
73
00:05:05,275 --> 00:05:06,793
AFTER A FEW MINUTES,
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00:05:06,896 --> 00:05:11,413
THEY REMOVE THE LID,
AND THE IMPRINT IS REVEALED.
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00:05:11,517 --> 00:05:14,586
THEY QUICKLY COVER THE PANEL
SURFACE WITH A PLASTIC SHEET
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00:05:14,689 --> 00:05:17,000
TO PREVENT ANY EVAPORATION
OF MOISTURE
77
00:05:17,103 --> 00:05:19,206
AS THE CURE CONTINUES.
78
00:05:19,310 --> 00:05:21,172
IF THE BLEND CURES TOO QUICKLY,
79
00:05:21,275 --> 00:05:23,413
IT COULD CRACK.
80
00:05:23,517 --> 00:05:25,862
AFTER ANOTHER DAY,
THEY REMOVE THE TARP
81
00:05:25,965 --> 00:05:29,000
AND THEY'RE READY TO EXTRACT
THE PANEL FROM THE MOLD.
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00:05:30,586 --> 00:05:32,068
A CRANE LIFTS THE PANEL
83
00:05:32,172 --> 00:05:35,172
AND SETS IT ASIDE
TO CURE FOR ABOUT A MONTH.
84
00:05:39,586 --> 00:05:41,172
BUILT PANEL BY PANEL,
85
00:05:41,275 --> 00:05:45,068
THESE NOISE-BARRIER WALLS CAN
BECOME A SUBSTANTIAL FORTRESS,
86
00:05:45,172 --> 00:05:48,758
PROVIDING A SOLID DEFENSE
AGAINST NOISE POLLUTION.
87
00:06:02,896 --> 00:06:04,137
Narrator:
FRONT-LOADING WASHING MACHINES
88
00:06:04,241 --> 00:06:07,000
USE FAR LESS WATER
THAN STANDARD WASHERS.
89
00:06:07,103 --> 00:06:09,793
THEY'RE GENTLER ON CLOTHES
BECAUSE THERE'S NO AGITATOR
90
00:06:09,896 --> 00:06:12,034
IN THE MIDDLE OF THE DRUM.
91
00:06:12,137 --> 00:06:13,551
THE SPIN SPEED IS USUALLY
92
00:06:13,655 --> 00:06:17,034
ABOUT 20 PERCENT FASTER THAN
THE STANDARD TOP-LOAD MACHINE,
93
00:06:17,137 --> 00:06:19,931
SO THE CLOTHES
COME OUT OF THE WASH DRIER.
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00:06:23,482 --> 00:06:27,000
WITH GRAVITY HELPING TUMBLE
THE LAUNDRY, A FRONT-LOAD WASHER
95
00:06:27,103 --> 00:06:30,965
IS GENTLER ON THE CLOTHES
WHILE USING LESS WATER.
96
00:06:31,068 --> 00:06:34,724
ITS DESIGN CAN ALSO ACCOMMODATE
A LARGER-CAPACITY DRUM,
97
00:06:34,827 --> 00:06:37,000
SO YOU CAN DO BIGGER LOADS.
98
00:06:37,103 --> 00:06:39,551
THE WASHER'S CABINET
IS MADE OF STEEL.
99
00:06:39,655 --> 00:06:42,931
A WASHING MACHINE IS ROUTINELY
EXPOSED TO MOISTURE,
100
00:06:43,034 --> 00:06:47,275
SO THEY USE GALVANIZED STEEL,
WHICH DOESN'T RUST.
101
00:06:47,379 --> 00:06:50,482
THE CABINET BASE IS COMPRISED
OF FOUR PIECES,
102
00:06:50,586 --> 00:06:53,241
WHICH, TOGETHER,
PROVIDE MORE STRUCTURAL STRENGTH
103
00:06:53,344 --> 00:06:54,896
THAN A SINGLE PIECE WOULD.
104
00:06:55,000 --> 00:06:58,551
AT THE CORNERS, WORKERS INSTALL
FOUR SCREW-IN RUBBER FEET
105
00:06:58,655 --> 00:07:00,137
WHICH ARE HEIGHT-ADJUSTABLE.
106
00:07:00,241 --> 00:07:03,620
THIS ALLOWS THE WASHER
TO LEVEL ON AN UNEVEN FLOOR.
107
00:07:03,724 --> 00:07:05,827
NEXT ARE THE TWO SIDE PANELS.
108
00:07:05,931 --> 00:07:09,068
THEY ARE ALREADY STAMPED
TO THE REQUIRED SHAPE IN A PRESS
109
00:07:09,172 --> 00:07:11,310
AND COATED WITH BAKED-ON PAINT.
110
00:07:11,413 --> 00:07:14,827
THIS AUTOMATED MACHINE INSTALLS
BRACKETS ON THE INNER SIDE
111
00:07:14,931 --> 00:07:15,896
FOR MOUNTING COMPONENTS
112
00:07:16,000 --> 00:07:17,344
LATER ON.
113
00:07:17,448 --> 00:07:20,103
THE NEXT AUTOMATED MACHINE
ATTACHES THE SIDE PANELS
114
00:07:20,206 --> 00:07:21,724
TO THE CABINET.
115
00:07:21,827 --> 00:07:23,517
RATHER THAN WELDING THE EDGES,
116
00:07:23,620 --> 00:07:25,379
WHICH WOULD RUIN
THE PAINT FINISH,
117
00:07:25,482 --> 00:07:26,724
THE MACHINE'S PUNCH TOOLS
118
00:07:26,827 --> 00:07:29,551
MECHANICALLY
LOCK THEM TO THE BASE.
119
00:07:29,655 --> 00:07:34,034
A ROBOT THEN TRANSFERS THE
CABINET TO THE ASSEMBLY LINE.
120
00:07:35,241 --> 00:07:37,137
HERE, WORKERS
CONNECT THE SIDE PANELS
121
00:07:37,241 --> 00:07:39,965
WITH A STRUCTURAL SUPPORT
BRACKET AND POWER CORD,
122
00:07:40,068 --> 00:07:41,827
ALREADY INSTALLED ON IT.
123
00:07:41,931 --> 00:07:43,517
WORKERS PREPARE THE REAR PORTION
124
00:07:43,620 --> 00:07:46,137
OF THE MACHINE'S
TWO-PIECE PLASTIC TUB.
125
00:07:46,241 --> 00:07:50,103
FIRST, A ROBOT MOUNTS
A STEEL BEARING ON A PRESS.
126
00:07:50,206 --> 00:07:51,827
THE PRESS THEN
FORCES THE BEARING
127
00:07:51,931 --> 00:07:55,344
INTO A HOLE AT THE BOTTOM
OF THE INSIDE OF THE TUB.
128
00:07:55,448 --> 00:07:59,551
THEN THE PROCESS IS REPEATED
BUT ON THE OUTSIDE OF THE TUB.
129
00:07:59,655 --> 00:08:02,689
THIS PAIR OF BEARINGS
SEALS THE HOLE TO PREVENT LEAKS,
130
00:08:02,793 --> 00:08:06,413
AND ENABLES THE STAINLESS-STEEL
WASH DRUM TO SPIN.
131
00:08:08,448 --> 00:08:10,655
TO COUNTERBALANCE
THE SPINNING LOAD,
132
00:08:10,758 --> 00:08:13,482
THEY WEIGHT THE FRONT
OF THE DRUM WITH A PLASTIC RING,
133
00:08:13,586 --> 00:08:17,827
CONTAINING HEAVY STEEL BALLS
SUSPENDED IN FLUID.
134
00:08:17,931 --> 00:08:20,344
THEN, THEY INSERT THE SHAFT
AT THE BASE OF THE DRUM
135
00:08:20,448 --> 00:08:22,103
INTO THE TUB'S BEARINGS
136
00:08:22,206 --> 00:08:24,551
AND COVER THE TOP OF THE DRUM
WITH THE FRONT SECTION
137
00:08:24,655 --> 00:08:25,862
OF THE TUB.
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00:08:25,965 --> 00:08:28,689
IT HAS A RUBBER GASKET
CALLED A BELLOW.
139
00:08:28,793 --> 00:08:32,827
THE BELLOW FORMS A LEAK-PROOF
SEAL AROUND THE DRUM.
140
00:08:32,931 --> 00:08:35,172
AFTER WELDING THE TUB SECTIONS
TOGETHER,
141
00:08:35,275 --> 00:08:37,965
THEY MOUNT THE WASHER'S MOTOR
TO THE REAR.
142
00:08:38,068 --> 00:08:41,551
IN THIS STATOR-ROTOR MOTOR,
THE ELECTRIC CURRENT TRAVELS
143
00:08:41,655 --> 00:08:44,482
THROUGH THE COILED COPPER WIRES
OF THE MOTOR'S STATOR,
144
00:08:44,586 --> 00:08:47,620
GENERATING PULSES
OF ELECTRICITY.
145
00:08:47,724 --> 00:08:51,137
THOSE PULSES PUSH ON MAGNETS
LINING THE MOTOR'S ROTOR,
146
00:08:51,241 --> 00:08:53,310
POSITIONED ON TOP.
147
00:08:53,413 --> 00:08:55,275
THE MAGNETS REPEL THE PULSES,
148
00:08:55,379 --> 00:08:57,068
AND THIS REPEATED
PULSE REPELLING
149
00:08:57,172 --> 00:09:01,655
DRIVES THE DRUM IN THE DIRECTION
AND SPEED REQUIRED.
150
00:09:01,758 --> 00:09:05,896
NEXT, THEY INSTALL A DRAIN HOSE
ON THE SIDE OF THE TUB
151
00:09:06,000 --> 00:09:08,275
AND ATTACH IT
WITH A RETAINER CLIP.
152
00:09:10,379 --> 00:09:13,793
THEY BOLT A PIECE OF CONCRETE TO
EITHER SIDE OF THE DRUM OPENING
153
00:09:13,896 --> 00:09:17,172
TO COUNTERBALANCE THE WEIGHT
OF THE MOTOR ON THE BACK.
154
00:09:17,275 --> 00:09:20,689
THEN, THEY TURN THE NOW-COMPLETE
WASH UNIT ON ITS SIDE
155
00:09:20,793 --> 00:09:23,000
AND INSTALL IT IN THE CABINET.
156
00:09:26,310 --> 00:09:29,896
NEXT, THEY MOUNT THE DRAIN PUMP
IN THE CABINET BASE
157
00:09:30,000 --> 00:09:31,827
AND CONNECT ITS WIRING.
158
00:09:31,931 --> 00:09:36,137
THE PUMP'S JOB IS TO REMOVE
DIRTY WATER FROM THE TUB.
159
00:09:38,034 --> 00:09:40,034
FOUR SHOCK ABSORBERS
ARE INSTALLED
160
00:09:40,137 --> 00:09:43,793
BETWEEN THE BOTTOM
OF THE WASH UNIT AND THE BASE.
161
00:09:43,896 --> 00:09:46,655
THESE LARGE PISTONS DAMPEN
MUCH OF THE VIBRATION
162
00:09:46,758 --> 00:09:49,172
DURING THE WASH AND SPIN CYCLES.
163
00:09:50,586 --> 00:09:52,172
NEXT, THE FRONT PANEL.
164
00:09:52,275 --> 00:09:54,655
LIKE THE SIDES,
IT'S MADE OF A STAMPED SHEET
165
00:09:54,758 --> 00:09:58,068
OF GALVANIZED STEEL
WITH A BAKED-ON PAINT FINISH.
166
00:09:59,655 --> 00:10:01,413
THEY INSTALL AND CONNECT
THE CONSOLE,
167
00:10:01,517 --> 00:10:04,517
WHICH HOUSES THE MACHINE'S
CENTRAL CONTROL MODULE.
168
00:10:07,482 --> 00:10:10,620
THEY PULL THE BELLOW ON THE DRUM
ALL AROUND THE FRONT OPENING
169
00:10:10,724 --> 00:10:12,551
TO SEAL THE PERIMETER.
170
00:10:16,551 --> 00:10:20,344
THEY SECURE IT IN PLACE
WITH A WIRE RETAINER CLIP.
171
00:10:25,344 --> 00:10:28,517
THE HINGED DOOR HAS
A SEE-THROUGH PLASTIC WINDOW.
172
00:10:28,620 --> 00:10:30,931
LIKE THE REST
OF THE MACHINE'S METAL PARTS,
173
00:10:31,034 --> 00:10:33,620
THE DOOR PANEL
AND HARDWARE ATTACHING IT
174
00:10:33,724 --> 00:10:37,310
ARE ALSO MADE
OF GALVANIZED STEEL.
175
00:10:37,413 --> 00:10:39,758
THE BACK PANEL
IS LEFT UNPAINTED.
176
00:10:39,862 --> 00:10:42,310
AFTER FEEDING THE POWER CORD
THROUGH ITS HOLE,
177
00:10:42,413 --> 00:10:46,310
WORKERS SCREW THE PANEL
TO THE REST OF THE CABINET.
178
00:10:46,413 --> 00:10:49,000
THEN, THEY COMPLETE THE CABINET
WITH THE TOP PANEL,
179
00:10:49,103 --> 00:10:51,551
WHICH HAS THE BAKED-ON PAINT
FINISH.
180
00:10:53,379 --> 00:10:54,827
THE FRONT-LOAD WASHING MACHINE
181
00:10:54,931 --> 00:10:59,000
IS NOW ALL SET
AND READY FOR ITS FIRST LOAD.
182
00:11:08,793 --> 00:11:10,689
Narrator: BOURBON WHISKEY
IS UNIQUELY AMERICAN.
183
00:11:10,793 --> 00:11:13,310
THE U.S. CONGRESS
OFFICIALLY RECOGNIZED IT
184
00:11:13,413 --> 00:11:15,413
AS A PRODUCT
DISTINCT TO THE NATION.
185
00:11:15,517 --> 00:11:17,862
THIS AMBER-HUED BREW
WAS FIRST COOKED UP
186
00:11:17,965 --> 00:11:22,413
BY SCOTTISH AND IRISH SETTLERS
IN LATE 18th CENTURY KENTUCKY.
187
00:11:22,517 --> 00:11:24,655
TODAY,
PRODUCTION CONTINUES THERE
188
00:11:24,758 --> 00:11:26,896
WITH THE APPROVAL OF CONGRESS.
189
00:11:29,068 --> 00:11:32,241
THE AMERICAN GOVERNMENT
REGULATES THE MAKING OF BOURBON
190
00:11:32,344 --> 00:11:35,862
TO KEEP THIS NATIVE SPIRIT
TRUE TO TRADITION.
191
00:11:35,965 --> 00:11:37,689
BY LAW, IT MUST BE MADE
192
00:11:37,793 --> 00:11:41,724
FROM A GRAIN MIX
THAT'S AT LEAST 51% CORN.
193
00:11:41,827 --> 00:11:45,689
DISTILLERS
OFTEN USE MORE FOR FLAVOR.
194
00:11:45,793 --> 00:11:49,068
SHAKERS SIFT OUT COBS
OR OTHER FOREIGN MATERIAL,
195
00:11:49,172 --> 00:11:52,379
AND THE KERNELS
HEAD INTO A GRINDER.
196
00:11:52,482 --> 00:11:54,931
INSIDE,
ROLLERS CRUSH THE KERNELS
197
00:11:55,034 --> 00:11:57,586
TO RELEASE
THE FLAVOR OF THE STARCH.
198
00:11:57,689 --> 00:12:01,758
THE PROCESS LEAVES LARGER CHUNKS
OF THE CORN GERM AND HUSKS.
199
00:12:01,862 --> 00:12:05,000
ONCE DISTILLED,
THESE BITS WILL SETTLE OUT.
200
00:12:06,965 --> 00:12:08,931
IN SEPARATE BATCHES, THE MACHINE
201
00:12:09,034 --> 00:12:13,724
ALSO GRINDS MALTED BARLEY
AND SOFT RED WINTER WHEAT.
202
00:12:15,137 --> 00:12:16,724
THEY COOK THE CORN AND BLEND IT
203
00:12:16,827 --> 00:12:20,758
WITH LIMESTONE-RICH,
IRON-FREE KENTUCKY WATER.
204
00:12:20,862 --> 00:12:22,965
THEY ADD THE BARLEY,
WINTER WHEAT,
205
00:12:23,068 --> 00:12:26,000
AND A BIT OF MASH
FROM A PREVIOUS BATCH.
206
00:12:28,068 --> 00:12:31,241
ALONG WITH A SPECIAL YEAST
FORMULATION, THE GRAIN MASH
207
00:12:31,344 --> 00:12:34,551
FLOWS INTO FERMENTATION TANKS
MADE OF CYPRESS WOOD.
208
00:12:37,034 --> 00:12:40,551
AFTER 8 TO 10 HOURS,
THE YEAST WORKS ITS MAGIC
209
00:12:40,655 --> 00:12:43,931
AND THE MASH
BECOMES A BUBBLING BREW.
210
00:12:46,172 --> 00:12:47,344
THE BUBBLING IS CAUSED
211
00:12:47,448 --> 00:12:49,965
BY THE RELEASE
OF CARBON-DIOXIDE GAS
212
00:12:50,068 --> 00:12:53,931
AS THE GRAIN SUGARS FERMENT
AND BECOME ALCOHOL.
213
00:12:54,034 --> 00:12:55,275
AFTER THREE DAYS,
214
00:12:55,379 --> 00:12:57,137
IT HAS FERMENTED
INTO A THICK LIQUID
215
00:12:57,241 --> 00:12:59,344
THEY CALL 'DISTILLER'S BEER."
216
00:13:01,068 --> 00:13:05,172
THEY PUMP IT INTO A COLUMN STILL
WHICH BOILS OFF THE ALCOHOL,
217
00:13:05,275 --> 00:13:08,310
LEAVING WATER
AND OTHER SUBSTANCES BEHIND.
218
00:13:08,413 --> 00:13:11,827
THE ALCOHOLIC VAPOR RISES UP
TO BE CONDENSED INTO LIQUID.
219
00:13:11,931 --> 00:13:14,896
AFTER DISTILLING IT
A SECOND TIME,
220
00:13:15,000 --> 00:13:19,689
THE ALCOHOL CONCENTRATION
RISES TO A STRONG 130 PROOF.
221
00:13:23,103 --> 00:13:26,034
IT'S CLEAR,
WITH NO NOTICEABLE COLOR.
222
00:13:26,137 --> 00:13:28,620
AT THIS STAGE,
THEY CALL IT "WHITE DOG."
223
00:13:29,862 --> 00:13:32,137
ONCE WATER HAS BEEN ADDED
TO DILUTE THE WHISKEY
224
00:13:32,241 --> 00:13:34,068
TO 110 PROOF,
225
00:13:34,172 --> 00:13:38,827
AN EMPLOYEE TAKES A SAMPLE
AND SENDS IT TO THE LAB.
226
00:13:38,931 --> 00:13:42,241
THERE, A TECHNICIAN PLACES
A TEST TUBE OF THE ALCOHOL
227
00:13:42,344 --> 00:13:45,206
INTO A GAS CHROMATOGRAPH TESTER.
228
00:13:47,862 --> 00:13:49,724
IT VAPORIZES THE ALCOHOL
229
00:13:49,827 --> 00:13:53,862
AND THEN ANALYZES THE FLAVOR
COMPOUNDS AND ALCOHOL STRENGTH.
230
00:13:55,758 --> 00:13:57,655
WITH APPROVAL FROM THE LAB,
231
00:13:57,758 --> 00:14:00,931
THEY'RE READY
TO BARREL THE BATCH.
232
00:14:01,034 --> 00:14:04,000
THEY PUMP IT OUT OF STORAGE
TANKS AND INTO NEW OAK BARRELS
233
00:14:04,103 --> 00:14:08,413
THAT HAVE BEEN PURPOSELY CHARRED
ON THE INSIDE.
234
00:14:08,517 --> 00:14:11,482
CHARRING CARAMELIZES
NATURALLY OCCURRING WOOD SUGARS
235
00:14:11,586 --> 00:14:15,965
TO ADD SWEETNESS
TO THE ALCOHOL AS IT AGES.
236
00:14:16,068 --> 00:14:19,655
IT WILL ALSO TURN THE CLEAR
ALCOHOL AN AMBER COLOR.
237
00:14:23,275 --> 00:14:25,689
ONCE CORKED
WITH A WALNUT STOPPER,
238
00:14:25,793 --> 00:14:30,862
THE EMPLOYEE ROLLS THE BARREL
INTO A MULTI-TIERED WAREHOUSE.
239
00:14:30,965 --> 00:14:33,758
HERE, THE BOURBON
WILL AGE FOR MANY YEARS.
240
00:14:33,862 --> 00:14:35,172
PARTWAY THROUGH,
241
00:14:35,275 --> 00:14:37,379
THEY'LL MOVE THE BARREL
TO ANOTHER LEVEL OF THE BUILDING
242
00:14:37,482 --> 00:14:39,931
DUE TO TEMPERATURE VARIATIONS.
243
00:14:40,034 --> 00:14:43,655
THIS WILL MAKE THE PRODUCT
MORE CONSISTENT.
244
00:14:43,758 --> 00:14:45,862
AFTER SIX TO SEVEN YEARS,
245
00:14:45,965 --> 00:14:48,931
THEY UNCORK THE STOPPER
AND INSERT STEEL TUBES
246
00:14:49,034 --> 00:14:51,241
TO DRAW IN AMBIENT AIR.
247
00:14:53,000 --> 00:14:55,965
THIS CAUSES THE BOURBON
TO FLOW FREELY WHEN TIPPED,
248
00:14:56,068 --> 00:14:58,931
AND IT GUSHES INTO A TROUGH.
249
00:14:59,034 --> 00:15:03,310
THE ALCOHOL HAS RIPENED
TO A SWEET CARAMEL-COLORED BREW.
250
00:15:06,034 --> 00:15:08,896
AFTER THEY ADD MORE WATER
TO MAKE IT 90 PROOF,
251
00:15:09,000 --> 00:15:11,448
IT'S READY FOR BOTTLING.
252
00:15:11,551 --> 00:15:14,931
NOZZLES FILL THE BOTTLES
WITH BOURBON RIGHT TO THE NECK.
253
00:15:18,034 --> 00:15:22,517
THE BOTTLES THEN CIRCLE
OVER TO THE CAP APPLICATORS.
254
00:15:22,620 --> 00:15:27,172
THE APPLICATORS SPIN METAL CAPS,
SCREWING THEM ONTO THE BOTTLES.
255
00:15:29,103 --> 00:15:30,931
THE BOTTLES THEN RIDE A CAROUSEL
256
00:15:31,034 --> 00:15:34,482
AND A DEVICE
PICKS UP AND APPLIES THE LABELS.
257
00:15:34,586 --> 00:15:37,517
A BRUSH SMOOTHES THEM
TO THE BOTTLES.
258
00:15:39,758 --> 00:15:42,103
DOWN THE LINE, A TWO-PERSON TEAM
259
00:15:42,206 --> 00:15:47,034
RETRIEVES THE BOTTLES
AND DIPS THE CAPS IN HOT WAX.
260
00:15:47,137 --> 00:15:50,172
THE WAX QUICKLY DRIES AND
SOLIDIFIES TO GIVE THE BOURBON
261
00:15:50,275 --> 00:15:52,103
A BETTER SEAL.
262
00:15:54,931 --> 00:15:57,310
AFTER SEVERAL YEARS
IN THE DISTILLERY,
263
00:15:57,413 --> 00:16:00,517
THIS KENTUCKY BOURBON
HAS COME OF AGE,
264
00:16:00,620 --> 00:16:03,137
AND THAT CALLS FOR A TOAST.
265
00:16:16,344 --> 00:16:18,172
Narrator: THE CIRCUIT BOARD
266
00:16:18,275 --> 00:16:20,310
IS WHERE THE ELECTRONIC
COMPONENTS ARE LOCATED,
267
00:16:20,413 --> 00:16:22,275
ALONG WITH THE ELECTRICAL
CONNECTIONS WHICH POWER THEM.
268
00:16:22,379 --> 00:16:24,793
IN A LARGER DEVICE,
SUCH AS A COMPUTER,
269
00:16:24,896 --> 00:16:26,793
THE CIRCUIT BOARD
IS TYPICALLY RIGID.
270
00:16:26,896 --> 00:16:29,448
WHEN THE DEVICE IS COMPACT,
LIKE A SMALL CAMERA,
271
00:16:29,551 --> 00:16:31,758
THE CIRCUIT BOARD
MUST BE FLEXIBLE.
272
00:16:31,862 --> 00:16:34,448
IT NEEDS TO FOLD TO FIT INSIDE.
273
00:16:36,103 --> 00:16:39,034
FLEXIBLE CIRCUIT BOARDS
ARE SO THIN AND PLIABLE,
274
00:16:39,137 --> 00:16:41,482
THEY'RE NICKNAMED
ORIGAMI CIRCUITRY,
275
00:16:41,586 --> 00:16:45,000
AFTER THE JAPANESE ART
OF PAPER FOLDING.
276
00:16:45,103 --> 00:16:48,620
AT THE CORE OF THE BOARDS
IS A HAIR-THIN POLYMER FILM
277
00:16:48,724 --> 00:16:51,172
THAT'S BOTH BENDABLE
AND HEAT RESISTANT.
278
00:16:51,275 --> 00:16:55,413
THE MANUFACTURER PRODUCES THIS
MATERIAL FOR SEVERAL INDUSTRIES.
279
00:16:55,517 --> 00:16:57,517
IN THIS CASE,
THEY CUT ROLLS OF IT
280
00:16:57,620 --> 00:17:01,310
TO THE WIDTH REQUIRED FOR MAKING
FLEXIBLE CIRCUIT BOARDS.
281
00:17:03,586 --> 00:17:07,344
WITH A RIGID SHEET OF PAPER
LENDING SUPPORT FROM UNDERNEATH,
282
00:17:07,448 --> 00:17:08,931
THE FILM ENTERS A MACHINE
283
00:17:09,034 --> 00:17:12,241
WHICH SANDWICHES IT BETWEEN
TWO THIN SHEETS OF COPPER.
284
00:17:12,344 --> 00:17:14,103
A CUTTER THEN
SLICES THE SANDWICH
285
00:17:14,206 --> 00:17:16,275
INTO RECTANGULAR SHEETS.
286
00:17:16,379 --> 00:17:18,620
A CUSHION OF AIR
PUMPED THROUGH THE CONVEYOR BELT
287
00:17:18,724 --> 00:17:21,827
LITERALLY FLOATS SHEET
AFTER SHEET OFF THE MACHINE
288
00:17:21,931 --> 00:17:25,034
AND INTO A STACK.
289
00:17:25,137 --> 00:17:27,793
EACH THREE-LAYER SHEET
IS SEPARATED FROM THE NEXT
290
00:17:27,896 --> 00:17:31,517
BY THE SUPPORT PAPER
CALLED A LAMINATE.
291
00:17:31,620 --> 00:17:35,206
THE FILM AT THE CENTER HAS A
HEAT-ACTIVATED ADHESIVE COATING,
292
00:17:35,310 --> 00:17:37,241
WHILE THE ADJOINING
COPPER SURFACES
293
00:17:37,344 --> 00:17:40,862
HAVE BEEN CHEMICALLY ROUGHENED
TO ENHANCE ADHESION.
294
00:17:40,965 --> 00:17:44,137
AFTER DRAWING THE LAYERS
TIGHTLY TOGETHER WITH A VACUUM,
295
00:17:44,241 --> 00:17:45,724
WORKERS PLACE THE LAMINATES
296
00:17:45,827 --> 00:17:48,103
IN A HIGH-TEMPERATURE,
HIGH-PRESSURE CHAMBER
297
00:17:48,206 --> 00:17:49,965
FOR SEVERAL HOURS.
298
00:17:50,068 --> 00:17:53,896
THIS ACTIVATES THE ADHESIVE,
BONDING THE LAYERS.
299
00:17:54,000 --> 00:17:55,724
TO TEST THE BOND STRENGTH,
300
00:17:55,827 --> 00:17:59,000
THEY BURN SOME ADHESIVE OFF
A SAMPLE OF FINISHED LAMINATE
301
00:17:59,103 --> 00:18:02,172
TO PRY APART THE LAYERED EDGE.
302
00:18:02,275 --> 00:18:05,655
THEN, THEY GRAB THE TOP COPPER
LAYER WITH THIS PULLING DEVICE
303
00:18:05,758 --> 00:18:07,620
AND MEASURE THE STRENGTH
REQUIRED TO PEEL
304
00:18:07,724 --> 00:18:09,689
IT OFF THE FILM.
305
00:18:09,793 --> 00:18:12,862
THE LAMINATE'S NOW SHIPPED
TO A CIRCUIT BOARD FACTORY.
306
00:18:12,965 --> 00:18:14,793
HERE, COMPUTER-GUIDED MACHINES
307
00:18:14,896 --> 00:18:17,000
CUT THEM
INTO SPECIFIC-SIZED PANELS
308
00:18:17,103 --> 00:18:18,724
AND DRILL TINY HOLES
FOR MOUNTING
309
00:18:18,827 --> 00:18:20,827
THE ELECTRONIC COMPONENTS.
310
00:18:22,310 --> 00:18:23,413
THEN A COATING MACHINE
311
00:18:23,517 --> 00:18:26,172
USES A COMBINATION
OF HEAT AND PRESSURE
312
00:18:26,275 --> 00:18:30,034
TO APPLY A LIGHT-SENSITIVE FLUID
TO THE PANEL'S SURFACE.
313
00:18:30,137 --> 00:18:33,379
TECHNICIANS LOAD THE PANEL
INTO AN EXPOSURE MACHINE,
314
00:18:33,482 --> 00:18:36,965
IN WHICH A COMPUTER-GUIDED LASER
SCANS THE CIRCUITRY PATTERN
315
00:18:37,068 --> 00:18:38,758
ONTO THE CODED SURFACE.
316
00:18:38,862 --> 00:18:41,275
A LASER IS A BEAM
OF FOCUSED LIGHT,
317
00:18:41,379 --> 00:18:45,655
SO WHEREVER IT HITS,
THE FLUID REACTS AND HARDENS.
318
00:18:45,758 --> 00:18:49,931
THE DARK AREAS
OF UNEXPOSED FLUID REMAIN SOFT.
319
00:18:50,034 --> 00:18:53,482
THE NEXT MACHINE
ACID-WASHES THE SOFT AREAS,
320
00:18:53,586 --> 00:18:55,068
REMOVING BOTH THE FLUID
321
00:18:55,172 --> 00:18:57,034
AND THE COPPER LAYER
UNDERNEATH IT.
322
00:18:57,137 --> 00:19:00,517
NOW THE ONLY COPPER REMAINING
ON TOP OF THE POLYMER FILM
323
00:19:00,620 --> 00:19:03,068
IS IN THE CIRCUITRY PATTERN.
324
00:19:03,172 --> 00:19:04,413
THIS INSPECTION DEVICE
325
00:19:04,517 --> 00:19:08,275
METICULOUSLY CHECKS
EVERY SINGLE COPPER CIRCUIT.
326
00:19:09,655 --> 00:19:13,241
NEXT, THEY REMOVE SURFACE DUST
WITH A STICKY ROLLER.
327
00:19:13,344 --> 00:19:14,827
THE PANEL MUST BE PRISTINE
328
00:19:14,931 --> 00:19:17,689
BEFORE RECEIVING THE SHEET
OF ELECTRICAL INSULATION,
329
00:19:17,793 --> 00:19:22,448
A MERE .25 OF A MILLIMETER
THICK.
330
00:19:22,551 --> 00:19:24,344
TECHNICIANS USE A MAGNIFIER
331
00:19:24,448 --> 00:19:27,000
TO CAREFULLY MATCH UP
ALIGNMENT HOLES ON THE FILM
332
00:19:27,103 --> 00:19:30,034
WITH CORRESPONDING
ALIGNMENT HOLES ON THE PANEL.
333
00:19:30,137 --> 00:19:32,482
BY ACTIVATING
THE FILM'S BUILT-IN ADHESIVE
334
00:19:32,586 --> 00:19:34,034
WITH A SOLDERING IRON,
335
00:19:34,137 --> 00:19:38,655
THEY TACK THE INSULATION
TO THE PANEL AT KEY SPOTS.
336
00:19:38,758 --> 00:19:41,275
THE NEXT STEP IS TO FULLY
LAMINATE THE INSULATION
337
00:19:41,379 --> 00:19:42,586
TO THE PANEL.
338
00:19:42,689 --> 00:19:44,310
TECHNICIANS SANDWICH TWO PANELS
339
00:19:44,413 --> 00:19:47,655
AT A TIME BETWEEN SHEETS
OF PROTECTIVE PLASTIC.
340
00:19:47,758 --> 00:19:50,172
THIS PROTECTS THE SURFACES
FROM THE HEAT AND WEIGHT
341
00:19:50,275 --> 00:19:52,517
OF THE LAMINATION PRESS.
342
00:19:52,620 --> 00:19:55,896
AS IT FORCES THE INSULATION FILM
DEEP DOWN ONTO THE PANEL,
343
00:19:56,000 --> 00:19:59,137
IT ENCAPSULATES THE CIRCUITRY.
344
00:19:59,241 --> 00:20:01,689
THEY LOAD THE PANELS
INTO THE LAMINATION PRESS,
345
00:20:01,793 --> 00:20:05,241
APPLY A VACUUM TO REMOVE
THE AIR BETWEEN THE LAYERS
346
00:20:05,344 --> 00:20:07,310
AND START HER UP.
347
00:20:07,413 --> 00:20:09,344
FOR THE NEXT HOUR AND A HALF,
348
00:20:09,448 --> 00:20:12,517
THE PRESS SIMULTANEOUSLY
APPLIES HIGH PRESSURE
349
00:20:12,620 --> 00:20:16,965
WHILE HEATING THE PANELS
TO 400 DEGREES FAHRENHEIT.
350
00:20:17,068 --> 00:20:20,103
WHEN THE PANELS COOL
AND COME OUT OF THE PRESS,
351
00:20:20,206 --> 00:20:25,310
TECHNICIANS PLACE ONE AT A TIME
ON A CIRCUIT BOARD-SHAPED DYE.
352
00:20:25,413 --> 00:20:27,068
THEN THEY RELEASE A PRESS
353
00:20:27,172 --> 00:20:29,758
WHICH FORCES THE PANEL
ONTO THE SHARP DYE,
354
00:20:29,862 --> 00:20:33,103
SLICING AWAY
THE EXCESS MATERIAL.
355
00:20:33,206 --> 00:20:36,000
THE FLEXIBLE CIRCUIT BOARD
IS NOW READY FOR THE COMPANY
356
00:20:36,103 --> 00:20:38,931
THAT INSTALLS
THE ELECTRONIC COMPONENTS.
357
00:20:42,206 --> 00:20:44,758
THERE ARE TWO WAYS
TO MOUNT COMPONENTS --
358
00:20:44,862 --> 00:20:47,482
SOLDER THEM DIRECTLY
ONTO THE BOARD'S SURFACE
359
00:20:47,586 --> 00:20:49,206
OR SOLDER TINY PRONGS
360
00:20:49,310 --> 00:20:51,379
UNDERNEATH THE COMPONENTS,
KNOWN AS LEADS,
361
00:20:51,482 --> 00:20:53,793
INTO THE BOARD'S MOUNTING HOLES.
362
00:20:53,896 --> 00:20:55,172
A FLEXIBLE CIRCUIT BOARD
363
00:20:55,275 --> 00:20:57,896
CAN HAVE AS FEW
AS A DOZEN COMPONENTS
364
00:20:58,000 --> 00:21:00,724
OR AS MANY AS 500.
365
00:21:00,827 --> 00:21:02,000
TECHNICIANS CAN SOLDER
366
00:21:02,103 --> 00:21:05,724
LARGER ONES
MAGNIFIED UNDER A MICROSCOPE,
367
00:21:05,827 --> 00:21:08,689
BUT ONLY ROBOTS
CAN SOLDER SMALLER ONES
368
00:21:08,793 --> 00:21:10,413
BECAUSE THEY'RE SO TINY
369
00:21:10,517 --> 00:21:13,172
AND BARELY VISIBLE
TO THE HUMAN EYE.
29668
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