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Narrator:
Today on "How it's made"...
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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:
When it comes to iconic hats,
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Nothing says french
More than the beret,
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Specifically
The basque-style beret,
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As people wear different
Styles in other countries.
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The basque beret was
Traditionally worn by shepherds
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Tending their flocks along
The pyrenees mountain range
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That divides southern
France from spain.
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The basque beret dates back
To the 1600s in southern france.
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Made of black merino wool,
It has a little cabillou on top.
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The factory making these berets
Has been doing so since 1840.
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An automated machine knits
Undyed wood yarn into a galette,
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The french word for pancake.
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The galette is flat
And round with loose
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Knit stitches making it
Soft and floppy.
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A worker then pulls
The galette's central thread,
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Closing it into a circular shape
Resembling a shower cap.
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In an industrial size
Washing machine,
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A worker washes this rudimentary
Beret in lukewarm water
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From the local river
And soap for about 8 hours.
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The type of soap
Is a trade secret.
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The wool shrinks,
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Causing the loose knit stitches
To tighten.
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The wool fibers also soften,
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Transforming into
The smooth and soft wool
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And fabric we call felt.
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After felting the beret,
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The manufacturers begin
The dyeing process.
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The worker loads it into
Another washing machine,
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Only this time
With powdered dye.
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This factory has always
Produced its own dyes
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In a wide range of colors,
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Again using water
From the local river.
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However, the temperature
To which this company heats
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It is a closely guarded secret.
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When the dye cycle finishes,
Another worker checks
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The beret against a color sample
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Because the wool composition
And the river water quality
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Are variable factors
That can affect dye absorption.
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The next step is to form
The beret to the final shape.
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Traditionally, beret factories
Did this using wooden forms,
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But today, they use metal ones.
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The beret remains on the form
Long enough
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To lock in the shape.
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This process, too, depends on
The wool composition
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As well as on how humid
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It is in the factory
On that particular day.
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Each beret goes for a spin
On the scratching machine,
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A rotating wheel surfaced
With wire brushes.
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The bristles lift the wood
Fibers, thickening the felt.
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After inserting a cardboard
Template to maintain the shape,
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A worker uses a manual
Shearing tool
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To carefully scratch the area
Around the cabillou.
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She removes any clinging plant
Debris left by the river water
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Used in the wash and dye cycles.
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Then she inspects for any holes
Or stretched fibers.
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The beret now goes
To the seamstress.
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First, she heats a black cotton
Lining on a mold to shape it
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To fit perfectly
Inside the beret.
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The lining has
The manufacturer's label
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In the center,
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Which features the company crest
And the model name, vrai basque,
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Confirming that this is indeed
An authentic basque-style beret.
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She turns the beret inside out
To sew in the lining.
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Then she turns the beret
Right side out again
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And puts it on
A stretching machine.
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She sets the machine
To the desired hat size,
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And it automatically stretches
The beret to that size.
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00:05:04,724 --> 00:05:08,241
Now, she sews a black
Leather band to the edge.
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The hat size is printed on it.
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Some models feature
A color trim on the band.
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The finishing touch is
The company's metal hallmark.
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She rivets it to the underside
Of the beret on one side...
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...And that caps off production.
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Narrator: pastis is
An anise-flavored liqueur
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Popular in france,
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Particularly in the southern
City of marseilles
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Where it originated.
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You don't drink
It straight, though.
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The proper technique is
To dilute it with water,
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Typically 5 to 7 parts
Water to one part pastis.
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Then add ice.
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The maker of this pastis
Combines star anise
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With licorice extract
And herbs and spices
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From the provence
Region of france.
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Star anise is an asian spice.
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The starting ingredient
For this pastis is
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A pale yellow star anise
Essential oil
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Purchased
From a chinese supplier.
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The first step at this french
Distillery is to distill
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That essential oil.
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As the oil is heated,
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It evaporates and rises up
The column still,
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Passing through a series
Of stacking cooling trays.
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Each tray condenses,
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Then removes one of the oil's
Various components.
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Pastis requires just one of
The extracted components --
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Anethole, which is an organic
Compound responsible
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For the anise flavor and smell.
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This pastis recipe also contains
60 different herbs and spices,
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Each of which is separately
Distilled into alcohol.
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One of these herbs
Is artemisia vulgaris,
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Commonly known as mugwort.
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A worker loads mugwort
Leaves into a tank
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Filled with a mixture
Of water and alcohol.
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As the leaves soak,
The alcohol acts as a solvent,
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Extracting
The aromatic molecules.
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This process
Is called maceration.
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After a few days, workers
Drain the alcoholic liquid,
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Now infused with
Aromatic molecules.
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It's so alcoholic that
It emits volatile fumes,
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So workers wear an alarm
That goes off
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When the surrounding air
Reaches an explosive level.
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The liquid is stored in a vat
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Until it's time
To mix the pastis.
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Then, a worker removes
The alcohol-soaked mugwort
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Leaves from the tank
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And transfer them
To a distillation device
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Called an alembic.
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The alembic heats the mash
Of fermented leaves with steam
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Produced by a wood-fired boiler.
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Once the mash heats to
A temperature of
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172 degrees fahrenheit,
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The alcohol in it
Begins to evaporate and rise.
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The alcoholic vapor eventually
Reaches the neck of the alembic,
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Where cooling coils
Condense it into liquid,
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Which then flows out of
The alembic and through a filter
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That also removes
Plant particles.
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An alcoholometer measures
The percentage of alcohol,
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Which starts off very high,
Then tapers off.
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The pastis maker uses
Only the middle of the flow,
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00:09:02,034 --> 00:09:05,620
When the reading is between
70 and 50%,
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What's known as the heart
Of the distillation.
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To make the pastis, workers
Combine all the ingredients.
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The anethole, distilled from
The anise essential oil,
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The 60 different maceration
Liquids and distillates of
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Herbs and spices
And licorice extract.
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Workers also add water to dilute
The final product's
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Alcohol level to 45%.
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A last filtration
Removes any particles
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That would diminish
The clarity of the pastis.
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A machine bottles the pastis
In dark glass
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To protect the contents
From light,
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Which, by oxidation,
Would damage the liqueur.
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The second station on
The filling line
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Seals each bottle with a t-cork,
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A type of stopper
Designed for bottles
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Which are opened
And sealed repeatedly.
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The next station applies
A sheath of heat shrink plastic
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Over the t-cork.
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The bottle then travels
Through a heating tunnel,
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Which shrinks
The plastic tightly
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Over the neck of the bottle.
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The final station applies
The adhesive-backed label.
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Pastis is always poured
Into the glass first,
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Followed by water.
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This makes the liqueur cloudy
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Because the anethole
Doesn't dissolve in water.
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If you want to add ice, you can
Do so only after the water,
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Otherwise, the anethole
Crystallizes.
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So just remember that
Chemistry lesson and enjoy.
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Narrator:
The first stationary bike
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Was developed by
A london physician
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In the late 18th century
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To exercise the joints of
Patients suffering from gout,
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Rheumatic disorders,
Or other afflictions.
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00:11:15,931 --> 00:11:18,758
The modern stationary bike
Is all about helping people
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Stay fit to prevent illnesses.
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On this stationary bike,
Magnets linked to the flywheel
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Create tension that causes
The cyclist to push harder,
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Making the workout
Truly an uphill battle.
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Production starts with
Steel tubing for the base.
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A probe locates the center
Of the tubing.
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This reference point allows
A computerized laser cutter
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To find the exact spots
To cut assembly holes.
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With the assembly holes cut,
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The laser slices the tubing
To the correct length.
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00:11:57,620 --> 00:12:00,034
An automated system
Retrieves the part
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And transfers it
To a holding area.
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A worker inserts screws
In the base part,
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Which will attach it
To the main frame.
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He pipes sealant
Around the screws.
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00:12:15,379 --> 00:12:18,758
Another worker now arranges
The three tubular base parts
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In a welding fixture
And clamps them in place.
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The fixture revolves and meets
Up with a robotic welder.
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The robot welds
The three parts together.
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This completes the base
Of the stationary bike.
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00:12:36,689 --> 00:12:39,620
The bike's main frame has been
Configured on the other side
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Of the welding fixture.
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The robot welds
These parts together.
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The fixture rotates to serve up
Another base assembly
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To the robot,
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And the worker collects
The welded main frame
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From the reverse side.
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He grinds the welded seam smooth
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00:12:56,620 --> 00:13:00,448
And gets rid of burrs
On the steel.
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00:13:00,448 --> 00:13:05,827
Workers sandblast the metal,
Wash it, and apply primer.
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00:13:05,827 --> 00:13:09,034
After grounding the main frame,
Another worker sprays
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00:13:09,034 --> 00:13:12,655
Electrostatically charged
Resin and pigment onto it.
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00:13:12,655 --> 00:13:15,620
Once it's baked on,
This powder coat will provide
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00:13:15,620 --> 00:13:18,103
A protective finish.
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00:13:18,103 --> 00:13:22,517
At another station, a 55-ton
Press punches holes into posts
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00:13:22,517 --> 00:13:25,448
For the bike's
Handlebar and seat.
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00:13:25,448 --> 00:13:31,241
The holes are for adjusting
The height of these parts.
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00:13:31,241 --> 00:13:33,310
Next up is the casting
For mounting
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00:13:33,310 --> 00:13:35,965
The handlebar to the post.
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00:13:35,965 --> 00:13:37,413
Using another press,
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00:13:37,413 --> 00:13:42,206
The worker entrenches the top
Of the post in the casting.
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00:13:42,206 --> 00:13:44,586
He taps the casting
With a rubber mallet
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00:13:44,586 --> 00:13:50,275
To tweak the installation
And sets the assembly aside.
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00:13:50,275 --> 00:13:53,724
At another station, a worker
Arranges numerous seat posts
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00:13:53,724 --> 00:13:56,206
In tight alignment.
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00:13:56,206 --> 00:13:58,172
He drapes a stencil
Of sequential
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00:13:58,172 --> 00:14:01,965
Lettering on top of the posts.
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00:14:01,965 --> 00:14:04,793
He dips an etching wand
In a chemical solution
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00:14:04,793 --> 00:14:08,758
And then moves it over
The letters five times.
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00:14:08,758 --> 00:14:11,000
This burns the letters
Into the steel,
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00:14:11,000 --> 00:14:15,448
Providing markers
For height adjustment.
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00:14:15,448 --> 00:14:17,724
An assembler drives the wedge
Into one of the bike's
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00:14:17,724 --> 00:14:23,206
Two crank arms to create a hole
That the axle will fit into.
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00:14:23,206 --> 00:14:26,517
He checks the depth of the hole
With a gauge.
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00:14:26,517 --> 00:14:29,413
He inserts the end
Of the axle in the hole
225
00:14:29,413 --> 00:14:34,689
And using a press,
Pushes it into place.
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00:14:34,689 --> 00:14:37,689
He measures the hole from
The other side of the crank arm
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00:14:37,689 --> 00:14:40,689
And confirms that the axle has
Been set to the correct depth.
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00:14:44,620 --> 00:14:49,758
He then bolts the assembly
To a precise torque.
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00:14:49,758 --> 00:14:53,689
He locks the crank arm
Assembly in a lathe.
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00:14:53,689 --> 00:14:56,827
He slips a foam sleeve
Over the axle to protect it
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00:14:56,827 --> 00:14:59,724
From shards of flying metal
As a tool machines
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00:14:59,724 --> 00:15:01,241
The part of the crank arm
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00:15:01,241 --> 00:15:03,551
That will ultimately
Hold the bike's pulley.
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00:15:08,931 --> 00:15:11,344
Another member of the team
Now assembles bearings
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00:15:11,344 --> 00:15:13,379
To a wheel hub.
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00:15:13,379 --> 00:15:16,172
He slides two bearings
With a spacer in a press.
237
00:15:19,655 --> 00:15:24,413
He heats the hub in an oven,
Causing the metal to expand.
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00:15:24,413 --> 00:15:27,724
The machine presses
The hub sandwich together.
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00:15:27,724 --> 00:15:32,655
As the hub cools, it shrinks
For a tight fit to the bearings.
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00:15:32,655 --> 00:15:34,655
He installs a retaining clip
In the hub
241
00:15:34,655 --> 00:15:37,896
To also keep it together.
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00:15:37,896 --> 00:15:40,000
Next up are the holders
For the magnets
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00:15:40,000 --> 00:15:42,896
That create resistance
On the flywheel.
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A worker places each one
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00:15:44,413 --> 00:15:47,896
In a fixture
To inspect the dimensions.
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00:15:47,896 --> 00:15:52,931
He then checks the strength
Of the magnets in a tester,
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And satisfied,
He inserts two in each holder.
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This metal cage, pulled into
Position by the magnets,
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Completes the magnetic field.
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00:16:04,965 --> 00:16:06,413
Stay tuned for more
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On the making of
This stationary bike.
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Narrator:
Stationary bikes are equipped
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With resistance mechanisms.
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00:16:21,206 --> 00:16:25,344
They can be simple tension belts
Or more complex systems in which
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00:16:25,344 --> 00:16:29,413
Magnets produce an electrical
Current in the flywheel.
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00:16:29,413 --> 00:16:32,413
The indoor cyclist simply
Dials up the resistance,
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00:16:32,413 --> 00:16:34,586
And he or she will
Soon feel the burn.
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00:16:39,000 --> 00:16:42,275
The assembler installs
The magnetic resistance unit
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00:16:42,275 --> 00:16:45,586
So that it swings from
A bracket on the main frame.
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00:16:45,586 --> 00:16:49,965
This bracket also holds
The computer board.
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00:16:49,965 --> 00:16:52,655
He mounts the aluminum
Flywheel to the axle,
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00:16:52,655 --> 00:16:56,275
Sliding it between the magnets
And the tension device.
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00:16:56,275 --> 00:17:00,103
He caps the flywheel hub
And secures the cap with screws.
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00:17:02,827 --> 00:17:04,310
The torsion spring-equipped
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00:17:04,310 --> 00:17:07,379
Cover completes the stationary
Bike's tension system.
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00:17:10,758 --> 00:17:13,965
He assembles the crank arm
And axle to the bike
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00:17:13,965 --> 00:17:15,931
And installs a bearing.
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00:17:15,931 --> 00:17:19,655
Then the bike moves on
To the next station.
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00:17:19,655 --> 00:17:21,482
Another worker places
An alignment tool
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00:17:21,482 --> 00:17:24,172
On the back axle.
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00:17:24,172 --> 00:17:27,551
He loops an elastic belt with
Grooves around the small pulley
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On the flywheel
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00:17:29,000 --> 00:17:32,827
And around the larger crank
Arm pulley, linking the two.
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00:17:32,827 --> 00:17:36,137
He inserts another tool into
The crank arm and turns it
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00:17:36,137 --> 00:17:41,068
To better wrap the belt
Around the large crank pulley.
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00:17:41,068 --> 00:17:43,310
He then removes both
Installation tools.
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00:17:47,068 --> 00:17:50,965
He installs four flat bushings
In the handlebar post.
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00:17:50,965 --> 00:17:53,344
These bushings make it possible
For the handlebar
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To be raised and lowered.
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00:17:56,310 --> 00:18:00,206
He applies a decal
With the height indicators.
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00:18:00,206 --> 00:18:02,482
Made of a rugged
Synthetic material,
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00:18:02,482 --> 00:18:06,241
The decal encases three
Sides of the metal post,
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00:18:06,241 --> 00:18:08,448
And this protects it
From abrasion.
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00:18:12,862 --> 00:18:16,241
He bolts the second crank arm
To the axle
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00:18:16,241 --> 00:18:18,517
And torques it
To the specified tension.
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00:18:22,862 --> 00:18:25,689
Next up is the seat assembly.
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00:18:25,689 --> 00:18:28,275
He slides the seat
Stem into the post
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00:18:28,275 --> 00:18:34,000
And tightens the adjustment
Knob to lock it in place.
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00:18:34,000 --> 00:18:36,931
He inserts the handlebar post
Into the bike frame
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00:18:36,931 --> 00:18:38,551
And fishes the gear cable
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00:18:38,551 --> 00:18:42,517
And communication wires
Through it.
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00:18:42,517 --> 00:18:47,655
He secures the handlebar post
With the adjustment knob.
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00:18:47,655 --> 00:18:49,862
He connects
The communication line
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00:18:49,862 --> 00:18:53,724
To the resistance
System's computer board.
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00:18:53,724 --> 00:18:56,586
He links the gear cable to
The resistance system
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00:18:56,586 --> 00:18:59,724
And tests its functionality.
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00:18:59,724 --> 00:19:04,931
Satisfied, he tightens a nut at
The side to secure the cable.
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00:19:04,931 --> 00:19:06,862
Another worker installs
A plastic cover
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00:19:06,862 --> 00:19:08,965
On the drivetrain.
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00:19:08,965 --> 00:19:12,206
This will protect the cyclist's
Legs from the pulley system
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00:19:12,206 --> 00:19:16,034
And shield the metal
Components from human sweat.
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00:19:16,034 --> 00:19:19,620
For added moisture protection,
She applies sealer around
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00:19:19,620 --> 00:19:23,448
A welded reinforcement
On the bike frame.
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00:19:23,448 --> 00:19:25,068
She then encases
The fork of the bike
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With more molded plastic.
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00:19:30,000 --> 00:19:35,413
Bolts secure the casings
To the bike.
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00:19:35,413 --> 00:19:39,344
She now places a magnetized
Microphone on the axle
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00:19:39,344 --> 00:19:42,931
And spins the flywheel
At a high rpm.
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00:19:42,931 --> 00:19:44,586
This is a test.
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00:19:44,586 --> 00:19:48,931
The bike must operate
Noiselessly.
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00:19:48,931 --> 00:19:53,896
And the decibel meter confirms
The noise level is negligible.
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00:19:53,896 --> 00:19:58,000
She also feels the frame
For unwanted vibrations.
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00:19:58,000 --> 00:19:59,620
She now sets the location of
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00:19:59,620 --> 00:20:01,793
The magnetic resistance
Mechanism
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00:20:01,793 --> 00:20:04,172
Using a special tool.
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00:20:04,172 --> 00:20:06,172
This calibrates the resistance
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00:20:06,172 --> 00:20:08,793
So that they handlebar
Computer can find it
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00:20:08,793 --> 00:20:13,103
And display the resistance
Setting during cycling.
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00:20:13,103 --> 00:20:16,724
Another member of the team then
Applies thread-locking adhesive
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00:20:16,724 --> 00:20:20,482
To the screw holes
In the crank arms.
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00:20:20,482 --> 00:20:23,344
He screws the pedals
Tightly to the crank arms
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00:20:23,344 --> 00:20:25,379
And torques them
To a specific setting.
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00:20:29,448 --> 00:20:32,517
The worker aligns the four
Bolt holes on the frame
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00:20:32,517 --> 00:20:35,793
To the bolts on the base
And secures them with cap nuts.
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00:20:39,482 --> 00:20:43,931
He installs a metal guard that
Encircles most of the flywheel.
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00:20:43,931 --> 00:20:46,344
This prevents contact
With the edge of the wheel
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00:20:46,344 --> 00:20:49,137
When it's spinning.
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00:20:49,137 --> 00:20:52,620
Once the trip computer has been
Mounted to the top of the frame,
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00:20:52,620 --> 00:20:56,448
He slides the handlebar
Into place.
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00:20:56,448 --> 00:20:58,758
It takes about 2 hours
To manufacture
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00:20:58,758 --> 00:21:00,965
This stationary bike.
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00:21:00,965 --> 00:21:04,068
Now that the work is done,
The workout can begin.
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