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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator: today on
"How it's made"...
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Pasta dies.
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Blueberries.
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Composting toilets.
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And surge arresters.
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Industrial pasta machines
Produce noodles
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By extruding dough
Through a die.
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The die has holes in it,
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Which are shaped to produce
A specific type of pasta.
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As the dough comes
Through the holes
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00:01:05,758 --> 00:01:07,517
In a continuous stream,
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A knife cuts the pasta
To the correct length.
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This industrial pasta die
Produces fusilli,
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Up to one and a half
Tons of it per hour.
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And this is just a midsize die.
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The largest ones can produce
Four tons of pasta per hour.
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The die block is made
Of a bronze-aluminum alloy.
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A computer-guided machine
Drills holes for inserts
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Through which the pasta dough
Will be extruded.
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The front of the block
Is then chrome plated
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To protect
Against the sharp knife
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That cuts the extruded
Pasta off the die.
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The next step is to make inserts
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That go in the holes
In the block.
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An insert is comprised
Of male and female parts
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And a nonstick plastic lining.
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A computer-guided mill
Cuts the linings
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From a plate
Of nonstick plastic.
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Another computer-guided mill
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Machines
The female part of the inserts
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In a more than quarter
Of an inch-thick brass plate.
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00:02:13,517 --> 00:02:17,379
Then a worker places a lining
In each female part.
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He taps it into position
With a mallet and punch.
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The plate then
Goes back on the mill,
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Which cuts an extrusion
Slot in the lining.
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The slot shape determines
The pasta shape.
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A mill machines
The male part of the inserts
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In another brass plate.
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A worker detaches
The male parts from the plate
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With a punch and mallet.
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He detaches the lined female
Parts the same way.
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Then he assembles the male
And female parts
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By forcing one onto the other
With the help of a steel punch.
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He finishes the die insert
By cutting off the protruding
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Excess plastic with a blade
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So that the lining
Is flush with the top.
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The factory makes die inserts
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In thousands of
Different shapes --
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Some standard,
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Others in the client's
Custom-made pasta shape.
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This computer-guided lathe makes
Brass locking rings
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Which will secure
The inserts in the block.
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Now, final assembly begins.
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A worker places
The block face-down,
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And from the back drops
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An insert top-first
Into each hole.
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00:04:06,827 --> 00:04:10,206
Next, he places a locking
Ring in each hole.
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00:04:18,137 --> 00:04:20,551
Then, with a hydraulic
Press and punch,
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He forces down each locking ring
To within approximately
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00:04:23,724 --> 00:04:26,586
1 millimeter
Of the insert underneath.
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In this position, the ring holds
The insert in the hole
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But doesn't prevent it
From spinning within the hole.
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The next step
Is to adjust the inserts
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To make their
Orientation uniform.
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He inserts a pin
Into each insert slot.
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Then he rotates the pin
To rotate the insert.
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Once the insert orientation
Is correct,
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He forces the locking ring
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Down all the way
To immobilize the insert.
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Once he has all the inserts
Oriented the same way,
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He sands the chrome-plated
Front of the die,
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00:05:08,000 --> 00:05:11,206
First with a medium-grit disk,
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Then with a fine-grit sandpaper.
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The die surface must be smooth
As silk for the knife
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To slice off
The extruded pasta cleanly.
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He verifies the width of every
Extrusion slot with a gauge.
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This ensures
Every piece of pasta
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Will be the correct thickness.
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Then on the back
Of the finished die,
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He stamps
The manufacturer's name.
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The die is ready to be mounted
On an industrial machine
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That extrudes dough
Into perfectly shaped,
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00:05:45,689 --> 00:05:47,965
Ready-to-boil pasta.
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Narrator: blueberries are one of
Nature's healthiest foods.
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They're low in calories,
Packed with vitamin c,
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And full of antioxidants.
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And freezing blueberries
Doesn't compromise
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Any of that nutritional value.
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North and south america
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Grow most of
The world's blueberries.
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The length of the harvest
Varies by climate.
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In the south,
It spans april to september.
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Further north,
Mid-june to mid-august.
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At this state-of-the-art
Blueberry farm,
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A mechanical harvester
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Straddles the row
Of blueberry plants
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And shakes the leaves
With vibrating fingers.
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The berries fall
To a sloped floor below
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And roll down into
Side conveyor belts.
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The belts dump the berries
Into onboard bins
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Which trucks transport
From the field
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To the on-site packing plant.
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The plant has two
Separate production lines --
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One for berries to be
Shipped out fresh,
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00:07:04,310 --> 00:07:08,275
And this one for berries
To be shipped out frozen.
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00:07:08,275 --> 00:07:10,655
Workers empty the bins
Into a hopper,
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00:07:10,655 --> 00:07:13,448
Which feeds the berries
Onto a conveyor belt.
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A vibrating conveyor belt
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00:07:17,965 --> 00:07:20,034
Then ferries the berries
Under a blower
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00:07:20,034 --> 00:07:24,206
That suctions up loose
Leaves and twigs.
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Then the blueberries tumble
Down a waterfall.
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Stones and debris settle
In the ledges.
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The berries land in a wash tank.
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Most of the ripe ones
Sink to the bottom
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While most of the unripe
Ones float on top
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Where workers can easily
Scoop them out.
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00:07:42,793 --> 00:07:44,931
The berries exit
The wash tank
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With fewer
Unripe ones among them.
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The mesh belt vibrates
To gently shake off water.
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Then it runs the berries
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00:07:53,241 --> 00:07:56,689
Through the first
Of two color sorters.
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00:07:56,689 --> 00:08:00,413
The machine's camera is preset
To ignore the color blue
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00:08:00,413 --> 00:08:04,241
And detect only green and red.
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00:08:04,241 --> 00:08:06,310
Whenever a green
Or red berry passes,
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00:08:06,310 --> 00:08:09,344
The camera sends a signal
To the computer
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00:08:09,344 --> 00:08:11,689
Identifying its exact location
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00:08:11,689 --> 00:08:14,206
So that one of the 136 air jets
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00:08:14,206 --> 00:08:19,172
Blows it off the belt
To a collection trough below.
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00:08:19,172 --> 00:08:20,482
The ripe blueberries fly
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Over the top
Onto a conveyor belt
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That takes them
To the freezer tunnel.
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00:08:26,551 --> 00:08:31,413
The temperature inside
Is minus 29 degrees fahrenheit.
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00:08:31,413 --> 00:08:33,103
Five to 7 minutes later,
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The berries exit
The tunnel frozen solid.
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Workers perform a final
Visual inspection.
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00:08:41,655 --> 00:08:43,655
After passing through
A metal detector,
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The berries drop into
A preprogrammed scale
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00:08:46,517 --> 00:08:50,000
That weighs out the specific
Quantity being packaged.
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00:08:52,137 --> 00:08:55,827
Meanwhile, in an on-site lab,
Government-trained inspectors
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00:08:55,827 --> 00:08:59,310
Pull samples off the line
Every 20 minutes for grading,
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00:08:59,310 --> 00:09:01,379
Which they determine
By assessing factors
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00:09:01,379 --> 00:09:05,827
Such as color,
Aroma, and defects.
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00:09:05,827 --> 00:09:08,206
The frozen berries
Go into a freezer
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00:09:08,206 --> 00:09:12,448
Until shipped out
By freezer truck.
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00:09:12,448 --> 00:09:13,896
The fresh berry production line
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00:09:13,896 --> 00:09:15,827
Is similar to the frozen line,
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00:09:15,827 --> 00:09:17,275
Minus the wash tank
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00:09:17,275 --> 00:09:20,103
And, of course,
The freeze tunnel.
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00:09:20,103 --> 00:09:22,310
However, the color sorters
On this line
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Are even more high-tech.
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00:09:24,965 --> 00:09:26,793
Not only are they set
To detect red
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And green berries,
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00:09:28,103 --> 00:09:30,586
But they also have
A firmness detector,
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00:09:30,586 --> 00:09:31,931
Which by bouncing each berry
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00:09:31,931 --> 00:09:35,413
On a pad can identify
Blue ones too soft
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00:09:35,413 --> 00:09:38,551
To have at least a 12-day
Refrigerated shelf life.
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00:09:40,551 --> 00:09:43,689
Air jets blow those
Soft berries off the conveyor
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So they can be transferred
To the frozen-berry line.
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The rest continue to
A final visual inspection.
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The fresh berries
Are ready for packaging.
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This electronic fill machine
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00:09:57,206 --> 00:10:00,034
Is preset to weigh out
The specific quantity
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00:10:00,034 --> 00:10:01,310
They're packaging,
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00:10:01,310 --> 00:10:04,172
In this case,
Nearly 2-pound containers.
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00:10:06,482 --> 00:10:08,448
It drops that quantity
Of berries
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00:10:08,448 --> 00:10:10,965
Into an awaiting
Plastic container.
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00:10:15,275 --> 00:10:17,034
The final stop on
The packaging line
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00:10:17,034 --> 00:10:20,896
Is the flat-seal machine.
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00:10:20,896 --> 00:10:22,758
It applies
A printed plastic film
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00:10:22,758 --> 00:10:24,206
To the top of the container,
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00:10:24,206 --> 00:10:26,482
Melting and bonding it
To the perimeter
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Without a touch of heat.
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00:10:31,068 --> 00:10:33,344
The film has ventilation holes
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00:10:33,344 --> 00:10:36,931
Because fresh berries
Require air.
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00:10:36,931 --> 00:10:38,344
From here, the containers
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00:10:38,344 --> 00:10:40,620
Go off to
A refrigerated warehouse
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To await shipping to the store
By refrigerated truck.
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00:10:45,034 --> 00:10:47,137
And provided they remain
Refrigerated,
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00:10:47,137 --> 00:10:49,448
The blueberries remain
Fresh and juicy
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For 10 to 12 days.
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Narrator:
There's a new john in town.
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Composting toilets are
The greatest thing
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Since indoor plumbing.
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00:11:08,413 --> 00:11:10,793
In fact, they don't need
Any plumbing at all.
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00:11:10,793 --> 00:11:13,551
So they can go where
Traditional toilets do not.
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00:11:13,551 --> 00:11:15,758
They are little waste
Treatment machines.
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00:11:15,758 --> 00:11:17,310
They turn
The unpleasant business
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00:11:17,310 --> 00:11:19,896
Of sewage into something
More agreeable --
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00:11:19,896 --> 00:11:21,689
Garden fertilizer.
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00:11:24,655 --> 00:11:26,551
This composting toilet works
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00:11:26,551 --> 00:11:29,034
A bit of magic with sewage.
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00:11:29,034 --> 00:11:31,758
It transforms the solids
Into compost
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00:11:31,758 --> 00:11:34,827
And makes the liquids disappear.
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00:11:34,827 --> 00:11:38,379
Making these toilets starts
With a composting tank.
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00:11:38,379 --> 00:11:42,655
A worker sprays fiberglass
Into a mold of the tank.
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00:11:42,655 --> 00:11:45,689
Then he and another member
Of the team press out air
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00:11:45,689 --> 00:11:49,758
Trapped between the fiberglass
And mold surface.
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00:11:49,758 --> 00:11:51,517
Once the part cures,
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00:11:51,517 --> 00:11:54,586
A blast of compressed
Air loosens it from the mold.
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00:11:54,586 --> 00:11:57,689
And he lifts it out.
203
00:11:57,689 --> 00:11:59,620
It's a bit ragged
Around the rim.
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00:11:59,620 --> 00:12:01,758
So they do a basic trim.
205
00:12:04,931 --> 00:12:08,655
He drills holes in the tank
For installing fittings.
206
00:12:10,931 --> 00:12:13,206
Using a pneumatic
Circular blade,
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00:12:13,206 --> 00:12:16,827
He slices a hole
For the compost drawer.
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00:12:16,827 --> 00:12:20,068
And he grinds the rim
To precise measurements.
209
00:12:23,827 --> 00:12:25,620
He screws two overflow fittings
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00:12:25,620 --> 00:12:28,482
Into a threaded hole
On the back of the tank.
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00:12:30,758 --> 00:12:32,586
He seals the fittings with epoxy
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00:12:32,586 --> 00:12:35,310
From the other side
Of the tank wall.
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00:12:35,310 --> 00:12:38,448
This epoxy seal will
Prevent leaks.
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00:12:41,758 --> 00:12:43,310
Moving down the line,
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00:12:43,310 --> 00:12:45,275
Another worker sprays adhesive
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00:12:45,275 --> 00:12:48,931
On the bottom
Of the composting tank.
217
00:12:48,931 --> 00:12:51,758
He presses
An aluminum panel to it.
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00:12:51,758 --> 00:12:53,413
This panel will radiate heat
219
00:12:53,413 --> 00:12:57,034
From a heating element
He installs over it.
220
00:12:57,034 --> 00:12:58,896
It will heat
The evaporation chamber
221
00:12:58,896 --> 00:13:02,000
In the tank
To dissipate liquids.
222
00:13:02,000 --> 00:13:04,689
He places fiberglass insulation
Over the heater
223
00:13:04,689 --> 00:13:09,344
And encases it with
A molded fiberglass cover.
224
00:13:09,344 --> 00:13:12,000
He wires the heater
And installs a thermostat
225
00:13:12,000 --> 00:13:13,620
That will regulate the heat
226
00:13:13,620 --> 00:13:15,310
And also shut off the system
227
00:13:15,310 --> 00:13:19,068
If the temperature drops below
Or exceeds the threshold.
228
00:13:23,034 --> 00:13:25,827
He turns the composting
Toilet tank right-side-up
229
00:13:25,827 --> 00:13:27,724
To await further assembly.
230
00:13:30,034 --> 00:13:32,620
Meanwhile, another worker
Assembles the fan
231
00:13:32,620 --> 00:13:36,103
For exhausting the evaporated
Fluids and any odors.
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00:13:38,413 --> 00:13:41,448
He inserts the motor shaft
In a hole in the fan door
233
00:13:41,448 --> 00:13:43,931
So that it protrudes inside.
234
00:13:43,931 --> 00:13:49,034
He then screws the motor
To the outside of the door.
235
00:13:49,034 --> 00:13:51,551
Next, he assembles
The centrifugal blower
236
00:13:51,551 --> 00:13:53,655
To the motor shaft.
237
00:13:55,724 --> 00:13:58,793
He installs
A plastic shroud.
238
00:13:58,793 --> 00:14:00,068
It surrounds the fan,
239
00:14:00,068 --> 00:14:03,000
Protecting the blades'
Interacting airflow.
240
00:14:10,206 --> 00:14:11,482
At the next station,
241
00:14:11,482 --> 00:14:13,137
A worker prepares the drum
242
00:14:13,137 --> 00:14:16,034
In which solid waste
Will be converted to compost
243
00:14:16,034 --> 00:14:19,965
By aerobic decomposition.
244
00:14:19,965 --> 00:14:21,862
He fastens a stainless
Steel screen
245
00:14:21,862 --> 00:14:23,965
To an opening in the drum.
246
00:14:26,827 --> 00:14:29,103
Liquid waste will drain
Through this screen
247
00:14:29,103 --> 00:14:33,241
And into
The evaporation chamber.
248
00:14:33,241 --> 00:14:35,827
Once evaporated,
The fan will expel it
249
00:14:35,827 --> 00:14:38,310
Through the vent stack.
250
00:14:41,862 --> 00:14:46,034
He now places the drum
In the tank, bearings elevated,
251
00:14:46,034 --> 00:14:50,862
So it sits just above
The evaporation chamber.
252
00:14:50,862 --> 00:14:53,551
He fits a plastic top
To the tank
253
00:14:53,551 --> 00:14:56,034
And screws the two
Components together.
254
00:14:59,931 --> 00:15:02,068
He inserts a metal
Shaft with gears,
255
00:15:02,068 --> 00:15:05,448
Engaging them with grooves
On the outside of the drum.
256
00:15:07,931 --> 00:15:09,758
He inserts the fan
Into an opening
257
00:15:09,758 --> 00:15:12,620
At the back and secures it.
258
00:15:12,620 --> 00:15:16,793
He wires the fan
To the power source.
259
00:15:16,793 --> 00:15:19,482
He installs a cover
To protect the wiring.
260
00:15:19,482 --> 00:15:23,068
And he connects the shaft
To a handle at the front.
261
00:15:23,068 --> 00:15:25,724
It rotates the drum
To mix the contents
262
00:15:25,724 --> 00:15:27,034
And introduce air
263
00:15:27,034 --> 00:15:30,448
So that the aerobic
Microorganisms will thrive.
264
00:15:32,448 --> 00:15:34,551
After electrical
And other tests,
265
00:15:34,551 --> 00:15:38,413
A worker installs the drawer
For the finished compost.
266
00:15:38,413 --> 00:15:40,068
She fastens the seat to the base
267
00:15:40,068 --> 00:15:42,965
With nylon nuts
And bolts with caps.
268
00:15:45,482 --> 00:15:48,000
She inserts a plastic liner
In the bowl.
269
00:15:48,000 --> 00:15:51,517
And this completes
The composting toilet.
270
00:15:51,517 --> 00:15:54,000
By turning human waste
Into compost,
271
00:15:54,000 --> 00:15:57,896
Things will eventually end up
Smelling like roses.
272
00:16:08,965 --> 00:16:11,827
Narrator: electrical systems are
Vulnerable to voltage spikes
273
00:16:11,827 --> 00:16:15,275
From lightning
Or switching surges.
274
00:16:15,275 --> 00:16:16,793
Surge arresters take over
275
00:16:16,793 --> 00:16:19,620
In these high-voltage
Situations.
276
00:16:23,344 --> 00:16:24,758
When lightning strikes,
277
00:16:24,758 --> 00:16:27,517
Surge arresters
Handle the fallout.
278
00:16:27,517 --> 00:16:30,551
They divert the ensuing
Power surges to the earth,
279
00:16:30,551 --> 00:16:33,413
Where they won't cause damage.
280
00:16:33,413 --> 00:16:37,137
At their core are discs
That act as switches.
281
00:16:37,137 --> 00:16:41,275
They turn on and off
To divert voltage spikes.
282
00:16:41,275 --> 00:16:43,379
The discs are known as m.O.V.S,
283
00:16:43,379 --> 00:16:47,827
Which is short
For metal oxide varistors.
284
00:16:47,827 --> 00:16:51,689
A worker loops fiberglass
Strapping onto aluminum endcaps
285
00:16:51,689 --> 00:16:55,103
To prepare the casing
For the m.O.V.S.
286
00:16:55,103 --> 00:16:59,068
He places a spacer on one
End of the end caps.
287
00:16:59,068 --> 00:17:02,034
He then packs numerous
M.O.V.S on top,
288
00:17:02,034 --> 00:17:04,034
Equipping this arrester
To divert
289
00:17:04,034 --> 00:17:08,068
A 60,000-volt power surge.
290
00:17:08,068 --> 00:17:11,068
He adds more spacers
To fill in any gaps
291
00:17:11,068 --> 00:17:12,551
Because the m.O.V. Stack
292
00:17:12,551 --> 00:17:15,000
Has to sit tight
Within the casing.
293
00:17:17,724 --> 00:17:19,310
With the stack complete,
294
00:17:19,310 --> 00:17:21,448
He loops more fiberglass
Strapping around
295
00:17:21,448 --> 00:17:25,344
The m.O.V.S to complete
The casing.
296
00:17:25,344 --> 00:17:28,413
He torques the set screw
To compress the stack.
297
00:17:28,413 --> 00:17:31,965
The set screw also pushes
Back the end caps.
298
00:17:31,965 --> 00:17:36,689
This pulls the fiberglass
Strapping tighter.
299
00:17:36,689 --> 00:17:38,827
He now clamps
The surge arrester
300
00:17:38,827 --> 00:17:41,344
Assembly between two mandrels.
301
00:17:44,965 --> 00:17:47,034
He ties a resin-reinforced
Thread
302
00:17:47,034 --> 00:17:49,482
Around the fiberglass
Loop at one end.
303
00:17:56,103 --> 00:17:59,310
He lowers a guard
As a safety precaution.
304
00:17:59,310 --> 00:18:03,413
The mandrels then spin
The surge arrester module
305
00:18:03,413 --> 00:18:05,655
As a computer-programmed
Dispenser
306
00:18:05,655 --> 00:18:09,620
Winds the thread
Around it to strengthen it.
307
00:18:09,620 --> 00:18:12,448
It creates gaps
Between the windings.
308
00:18:12,448 --> 00:18:14,310
This will allow sparks and fumes
309
00:18:14,310 --> 00:18:18,103
To escape in the event
Of a power overload.
310
00:18:18,103 --> 00:18:19,827
With the winding complete,
311
00:18:19,827 --> 00:18:24,103
He cuts the end and tucks it
Under the last winding.
312
00:18:24,103 --> 00:18:26,310
He hangs the module
On a rack conveyer,
313
00:18:26,310 --> 00:18:28,310
Which takes it into a chamber.
314
00:18:31,379 --> 00:18:32,689
Here, a tank filled
315
00:18:32,689 --> 00:18:35,275
With an adhesive-promoting
Solution rises up
316
00:18:35,275 --> 00:18:37,586
And immerses the module.
317
00:18:37,586 --> 00:18:40,172
This leaves a coating
That will help silicone rubber
318
00:18:40,172 --> 00:18:42,620
Housing bond
To the module later.
319
00:18:44,310 --> 00:18:45,965
He removes the hook used
320
00:18:45,965 --> 00:18:48,068
To hang the module
On the rack conveyer
321
00:18:48,068 --> 00:18:50,931
And installs mandrels
At both ends to be used
322
00:18:50,931 --> 00:18:54,103
At a later stage of processing.
323
00:18:54,103 --> 00:18:55,448
He sets the module between
324
00:18:55,448 --> 00:18:57,896
The rungs of
A chain-driven conveyer.
325
00:19:00,689 --> 00:19:04,931
It takes it through an oven
Set at 302 degrees fahrenheit.
326
00:19:04,931 --> 00:19:07,034
This cures the resin
In the thread,
327
00:19:07,034 --> 00:19:11,206
Causing it to harden
Around the fiberglass strapping.
328
00:19:11,206 --> 00:19:13,931
It also preheats the surge
Arrester module
329
00:19:13,931 --> 00:19:16,724
In preparation
For the next process --
330
00:19:16,724 --> 00:19:20,379
The molding of
The outer housing.
331
00:19:20,379 --> 00:19:21,793
Using the mandrels,
332
00:19:21,793 --> 00:19:25,034
He locks two of the surge
Arrester modules in a platform
333
00:19:25,034 --> 00:19:27,379
And slides it under
A mold press.
334
00:19:29,310 --> 00:19:31,689
A lift takes it to the press.
335
00:19:33,827 --> 00:19:36,310
It injects silicone rubber
Into the mold.
336
00:19:36,310 --> 00:19:38,068
And using pressure and heat,
337
00:19:38,068 --> 00:19:39,724
It forms insulating jackets
338
00:19:39,724 --> 00:19:42,793
Around the arrester modules.
339
00:19:42,793 --> 00:19:45,413
The primer coating
Enhances the adhesion
340
00:19:45,413 --> 00:19:47,517
Of the silicone rubber
To the modules.
341
00:19:47,517 --> 00:19:50,655
He clips off unwanted
Bits of silicone rubber
342
00:19:50,655 --> 00:19:52,068
From the molded housing
343
00:19:52,068 --> 00:19:54,724
And cleans up the ends
With a wire brush.
344
00:19:56,896 --> 00:19:59,586
Surge arresters come
In a range of voltage ratings
345
00:19:59,586 --> 00:20:03,275
For different
Electrical systems.
346
00:20:03,275 --> 00:20:07,862
He now lubricates the threaded
Bolt holes in one end.
347
00:20:07,862 --> 00:20:10,448
He aligns those holes
348
00:20:10,448 --> 00:20:13,724
With the ones
On a terminal connector.
349
00:20:13,724 --> 00:20:16,862
He bolts the connector
To the surge arrester.
350
00:20:22,379 --> 00:20:24,275
He installs a base
On the other end.
351
00:20:24,275 --> 00:20:26,379
This base will allow
The arrester
352
00:20:26,379 --> 00:20:28,241
To be mounted to the ground
353
00:20:28,241 --> 00:20:31,137
To send excess voltages
To the earth.
354
00:20:42,379 --> 00:20:45,758
He now puts the surge
Arrester to the test.
355
00:20:45,758 --> 00:20:48,000
He connects electrodes
To the terminal connector
356
00:20:48,000 --> 00:20:51,103
And to the base.
357
00:20:51,103 --> 00:20:53,275
He runs different voltages
Of electricity
358
00:20:53,275 --> 00:20:55,517
Through the arrester
And confirms
359
00:20:55,517 --> 00:20:59,172
That it adequately
Discharges them.
360
00:20:59,172 --> 00:21:02,896
This surge arrester is now ready
To join others on the grid,
361
00:21:02,896 --> 00:21:05,068
Forming a defense
Against lightning strikes
362
00:21:05,068 --> 00:21:06,724
And power spikes.
28222
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