All language subtitles for S29E12 - Technological Corks; Zinc Gutters; Traditional Basque Ham; Chisteras (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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1
00:00:16,241 --> 00:00:19,241
--captions by vitac--
Www.Vitac.Com
2
00:00:19,241 --> 00:00:22,241
Captions paid for by
Discovery communications
3
00:00:53,068 --> 00:00:55,448
Narrator: many wine makers
These days are opting
4
00:00:55,448 --> 00:00:58,620
To seal their bottles
With technological corks.
5
00:00:58,620 --> 00:01:01,068
These are stoppers
Made of molded particles
6
00:01:01,068 --> 00:01:02,310
Of natural cork
7
00:01:02,310 --> 00:01:04,793
Which have undergone
A purification treatment
8
00:01:04,793 --> 00:01:08,206
To remove the t.C.A. Molecule
And other contaminants,
9
00:01:08,206 --> 00:01:10,655
Which can give wine
A musty odor.
10
00:01:13,448 --> 00:01:15,655
Technological corks
Look very much
11
00:01:15,655 --> 00:01:17,068
Like the traditional stoppers
12
00:01:17,068 --> 00:01:20,241
That are cut and shaped
From a solid piece of cork.
13
00:01:20,241 --> 00:01:22,413
These two are made
Of natural cork,
14
00:01:22,413 --> 00:01:25,344
Only very differently.
15
00:01:25,344 --> 00:01:28,344
Cork is the bark
Of the cork oak tree.
16
00:01:28,344 --> 00:01:31,275
Once the tree reaches
The age of 25,
17
00:01:31,275 --> 00:01:35,517
It can be harvested for its bark
Once every decade or so.
18
00:01:35,517 --> 00:01:39,172
A specialized worker makes
Cuts in the bark with an ax
19
00:01:39,172 --> 00:01:41,275
Using a very specific technique
20
00:01:41,275 --> 00:01:43,689
That doesn't harm the tree.
21
00:01:43,689 --> 00:01:48,275
Using the handle of the ax,
He gently pries off the bark.
22
00:01:48,275 --> 00:01:51,724
A cork oak typically lives
For 300 years
23
00:01:51,724 --> 00:01:55,758
And can be harvested
Up to 15 times.
24
00:01:55,758 --> 00:01:59,310
Upon receiving planks of cork
From the supplier,
25
00:01:59,310 --> 00:02:03,448
The technological cork factory
Breaks them into small pieces...
26
00:02:05,482 --> 00:02:08,068
...Then grinds those pieces
Into granules,
27
00:02:08,068 --> 00:02:10,827
And then stores them
In huge bags.
28
00:02:14,448 --> 00:02:17,689
The first step is to empty
The bags into silos
29
00:02:17,689 --> 00:02:22,206
That feed
The purification equipment.
30
00:02:22,206 --> 00:02:24,793
The machines, which purify
The cork granules,
31
00:02:24,793 --> 00:02:27,827
Are giant autoclaves.
32
00:02:27,827 --> 00:02:31,965
Workers fill each one
With a ton of granules.
33
00:02:31,965 --> 00:02:33,586
Then they start up a compressor,
34
00:02:33,586 --> 00:02:37,965
Which simultaneously heats
And pressurizes carbon dioxide
35
00:02:37,965 --> 00:02:41,275
That then transforms into
A semiliquid gas
36
00:02:41,275 --> 00:02:43,896
Called supercritical co2,
37
00:02:43,896 --> 00:02:47,034
Which is an environmentally
Friendly solvent.
38
00:02:47,034 --> 00:02:50,827
They inject the supercritical
Co2 into the autoclave
39
00:02:50,827 --> 00:02:53,862
And wash the granules in it
For 3 hours.
40
00:02:56,344 --> 00:02:59,275
The factory's in-house
Laboratory then analyzes
41
00:02:59,275 --> 00:03:02,655
And compares pre-
And postpurification samples
42
00:03:02,655 --> 00:03:04,620
Drawn from each batch
43
00:03:04,620 --> 00:03:07,206
To ensure there are
No offending molecules
44
00:03:07,206 --> 00:03:09,586
Remaining after treatment.
45
00:03:09,586 --> 00:03:13,310
A technician uses the technique
Of gas chromatography
46
00:03:13,310 --> 00:03:16,862
To separate molecules
By their size and structure,
47
00:03:16,862 --> 00:03:19,551
Then the technique
Of mass spectrometry
48
00:03:19,551 --> 00:03:23,724
To measure the electrical signal
That each molecule emits.
49
00:03:23,724 --> 00:03:27,413
The type of signal
Identifies the type of molecule.
50
00:03:27,413 --> 00:03:30,482
The signal strength
Indicates its quantity.
51
00:03:30,482 --> 00:03:33,241
Once the batch gets
The green light from the lab,
52
00:03:33,241 --> 00:03:36,724
The manufacturer mixes it
With a food-safe binding agent
53
00:03:36,724 --> 00:03:39,344
And transfers the batch
To the molding line.
54
00:03:39,344 --> 00:03:41,862
The molding machine is
Computer-controlled
55
00:03:41,862 --> 00:03:43,827
To automatically adjust
The molds
56
00:03:43,827 --> 00:03:47,000
To the dimensions of
The stopper being produced.
57
00:03:47,000 --> 00:03:50,103
The machine pours the cork mix
Into the molds,
58
00:03:50,103 --> 00:03:53,206
Which then go into an oven
For a few minutes.
59
00:03:53,206 --> 00:03:55,931
The ingredients bake into
A solid stopper
60
00:03:55,931 --> 00:03:59,206
With just the right degree
Of elasticity.
61
00:03:59,206 --> 00:04:02,724
Every stopper made in the same
Mold shape is identical,
62
00:04:02,724 --> 00:04:05,931
But no two stoppers cut
From the whole pieces of cork
63
00:04:05,931 --> 00:04:11,448
Are ever the same because cork
Has natural variations.
64
00:04:11,448 --> 00:04:14,620
This is merely the cork's
Preliminary shape.
65
00:04:17,275 --> 00:04:19,965
A computer-guided
Machining center refines them
66
00:04:19,965 --> 00:04:22,896
To exactly the shape ordered.
67
00:04:22,896 --> 00:04:25,068
After finalizing the dimensions,
68
00:04:25,068 --> 00:04:27,896
The machine chamfers
One or both ends.
69
00:04:27,896 --> 00:04:30,310
A chamfer is a beveled edge
That makes it easier
70
00:04:30,310 --> 00:04:33,275
To insert the cork
Into the bottle.
71
00:04:33,275 --> 00:04:36,068
Every cork then passes
In front of a camera,
72
00:04:36,068 --> 00:04:39,482
Which detects any defects.
73
00:04:39,482 --> 00:04:42,000
This machine conducts
A permeability test
74
00:04:42,000 --> 00:04:44,379
On a few samples from each batch
75
00:04:44,379 --> 00:04:47,517
To measure how much oxygen
Flows past the cork
76
00:04:47,517 --> 00:04:50,586
When it's in position
In the bottle.
77
00:04:50,586 --> 00:04:52,482
The corks are usually
Custom-marked
78
00:04:52,482 --> 00:04:55,758
For a specific winery.
79
00:04:55,758 --> 00:04:58,275
Some wineries order a model
That looks more like
80
00:04:58,275 --> 00:05:02,275
A traditional stopper
Cut from a solid piece of cork.
81
00:05:02,275 --> 00:05:06,586
That type requires a couple of
Extra production steps.
82
00:05:06,586 --> 00:05:09,758
A branding stamp
Burns lines on the top.
83
00:05:09,758 --> 00:05:12,551
Then a computer-guided laser
Burns a pattern
84
00:05:12,551 --> 00:05:14,413
Around the side of the stopper
85
00:05:14,413 --> 00:05:17,034
To mimic the texture
Of natural cork.
86
00:05:19,241 --> 00:05:22,413
The last step is to brand
The winery-specific words
87
00:05:22,413 --> 00:05:24,931
And images.
88
00:05:27,137 --> 00:05:30,862
The cork goes from ground
Cork bark to a finished stopper
89
00:05:30,862 --> 00:05:33,206
And then to a final
Visual inspection
90
00:05:33,206 --> 00:05:36,241
Before being shipped out
To the winery.
91
00:05:36,241 --> 00:05:39,620
The cork granules are stabilized
By a binding agent
92
00:05:39,620 --> 00:05:43,931
And molded to a custom shape
To block more or less oxygen
93
00:05:43,931 --> 00:05:47,758
According to the winemaker's
Specifications.
94
00:05:47,758 --> 00:05:51,586
Some wines require
A completely airtight seal
95
00:05:51,586 --> 00:05:54,931
While others require a certain
Degree of air penetration
96
00:05:54,931 --> 00:05:57,620
To mature further
After bottling.
97
00:06:08,068 --> 00:06:09,931
Narrator:
Zinc gutters drain rainwater
98
00:06:09,931 --> 00:06:11,137
And, in the process,
99
00:06:11,137 --> 00:06:14,724
Develop a natural resistance
To corrosion.
100
00:06:14,724 --> 00:06:17,655
When zinc is exposed
To wet and dry cycles,
101
00:06:17,655 --> 00:06:19,862
A chemical reaction occurs,
102
00:06:19,862 --> 00:06:23,275
Forming a protective patina
On its surface,
103
00:06:23,275 --> 00:06:25,827
No paint
Or special treatment needed.
104
00:06:29,241 --> 00:06:31,172
You can't stop the rain,
105
00:06:31,172 --> 00:06:33,275
But you can stop it
From damaging buildings
106
00:06:33,275 --> 00:06:35,137
And their foundations.
107
00:06:35,137 --> 00:06:37,758
These u-shaped zinc gutters
Funnel water
108
00:06:37,758 --> 00:06:41,000
Away from the structures
To keep them dry.
109
00:06:41,000 --> 00:06:43,482
The process starts
With the production
110
00:06:43,482 --> 00:06:47,206
Of these 46-ton coils of zinc.
111
00:06:47,206 --> 00:06:51,586
The zinc arrives at the factory
In the form of thick plates.
112
00:06:51,586 --> 00:06:54,758
These plates are almost
100% zinc.
113
00:06:57,103 --> 00:06:59,379
The plates drop into a furnace.
114
00:06:59,379 --> 00:07:03,413
Inside, the temperature reaches
750 degrees fahrenheit.
115
00:07:03,413 --> 00:07:05,862
Workers add a bit
Of copper and titanium
116
00:07:05,862 --> 00:07:07,689
To reinforce the zinc,
117
00:07:07,689 --> 00:07:10,275
And it melts into
A homogeneous liquid.
118
00:07:12,620 --> 00:07:18,241
The molten zinc then flows into
A trough-style conveyor system.
119
00:07:18,241 --> 00:07:21,931
Residues, like ashes, float
To the top of the metal soup,
120
00:07:21,931 --> 00:07:24,034
And a worker skims them off.
121
00:07:26,517 --> 00:07:28,034
A floating puck monitors
122
00:07:28,034 --> 00:07:30,275
The speed and depth
Of the zinc blend
123
00:07:30,275 --> 00:07:32,448
To prevent overflow.
124
00:07:34,172 --> 00:07:38,275
The molten zinc now arrives
At the casting machine.
125
00:07:38,275 --> 00:07:41,137
Here,
3-foot-wide steel unwinds,
126
00:07:41,137 --> 00:07:44,965
And once linear,
The zinc flows onto it.
127
00:07:44,965 --> 00:07:47,344
The steel acts as a mold
To form the zinc
128
00:07:47,344 --> 00:07:49,379
Into a long rigid sheet.
129
00:07:52,000 --> 00:07:54,931
Water flows onto the zinc
To accelerate cooling
130
00:07:54,931 --> 00:07:57,344
And solidification.
131
00:07:57,344 --> 00:08:00,068
Since water and liquid zinc
Don't mix,
132
00:08:00,068 --> 00:08:02,793
The water simply
Runs off the surface.
133
00:08:04,896 --> 00:08:09,551
Now solid, the zinc plate
Is almost 1/3 of an inch thick,
134
00:08:09,551 --> 00:08:13,000
Far too thick for making
Lightweight rain gutters.
135
00:08:13,000 --> 00:08:16,689
The next operation will thin
The plate down dramatically.
136
00:08:18,206 --> 00:08:20,724
This is a powerful rolling mill.
137
00:08:20,724 --> 00:08:23,172
The pressure on its rollers
Is so great
138
00:08:23,172 --> 00:08:27,137
That they often must
Be replaced.
139
00:08:27,137 --> 00:08:29,172
Once the new rollers
Have been loaded,
140
00:08:29,172 --> 00:08:32,034
The mill heats them up.
141
00:08:32,034 --> 00:08:35,275
The operator
Activates the rollers.
142
00:08:35,275 --> 00:08:40,448
As they revolve, the hot rollers
Exert 770 tons of pressure
143
00:08:40,448 --> 00:08:44,103
To iron the zinc much thinner.
144
00:08:44,103 --> 00:08:45,965
Meanwhile, just ahead,
145
00:08:45,965 --> 00:08:50,206
A steel belt tensioning system
Swings into action.
146
00:08:50,206 --> 00:08:53,137
This system prevents slackening
In the zinc sheet
147
00:08:53,137 --> 00:08:57,137
As it exits the rolling mill
And moves forward.
148
00:08:57,137 --> 00:08:59,655
You can see the difference
The rolling has made.
149
00:08:59,655 --> 00:09:02,275
It has reduced the thickness
Of the zinc sheet
150
00:09:02,275 --> 00:09:06,241
To about 3/4 of a millimeter.
151
00:09:06,241 --> 00:09:10,137
The steel-belt system maintains
The tension in the zinc sheet
152
00:09:10,137 --> 00:09:12,896
As it's wound around a core.
153
00:09:12,896 --> 00:09:16,827
This produces
The 46-ton coil of zinc.
154
00:09:16,827 --> 00:09:19,068
It's known as the mother coil.
155
00:09:19,068 --> 00:09:21,551
Approximately 25 miles
Of rain gutters
156
00:09:21,551 --> 00:09:25,103
Can be made from this coil.
157
00:09:25,103 --> 00:09:27,758
Workers slit the mother coil
Into three.
158
00:09:27,758 --> 00:09:31,137
Each coil is a foot wide.
159
00:09:31,137 --> 00:09:34,931
It is now the correct width
To be formed into rain gutters.
160
00:09:37,068 --> 00:09:39,413
A crane lifts one of
The narrower coils
161
00:09:39,413 --> 00:09:41,344
Over the factory floor.
162
00:09:41,344 --> 00:09:44,310
Its journey is guided
By the operator below.
163
00:09:46,379 --> 00:09:50,275
This puts it in position to be
Mounted to the next machine,
164
00:09:50,275 --> 00:09:54,517
One that will cut it into
Uniform 13-foot-long strips.
165
00:09:54,517 --> 00:09:58,137
That's the standard length
For the rain gutters.
166
00:09:58,137 --> 00:10:01,103
As the zinc uncoils,
An overhead mirror
167
00:10:01,103 --> 00:10:03,724
Provides a top view
For the operator.
168
00:10:06,137 --> 00:10:09,620
In quick swoops, the blade
Slices the zinc sheeting
169
00:10:09,620 --> 00:10:13,379
To the correct length.
170
00:10:13,379 --> 00:10:15,172
The zinc strips
Then travel through
171
00:10:15,172 --> 00:10:17,379
A progressively narrow channel
172
00:10:17,379 --> 00:10:19,241
And over a cylinder.
173
00:10:19,241 --> 00:10:23,068
This rounds the profile.
174
00:10:23,068 --> 00:10:25,862
More rollers improve
On the u-shape
175
00:10:25,862 --> 00:10:29,379
And also curl the edges of
The gutters to reinforce them.
176
00:10:32,172 --> 00:10:35,689
This gives the zinc rain gutters
Their final shape.
177
00:10:37,137 --> 00:10:40,620
The automated profiler ejects
The 13-foot-long gutters
178
00:10:40,620 --> 00:10:42,689
Onto a rounded rack.
179
00:10:42,689 --> 00:10:44,827
Then it tips
To stack the gutters
180
00:10:44,827 --> 00:10:48,241
Neatly on top of each other.
181
00:10:48,241 --> 00:10:51,241
These zinc rain gutters
Are ready to hang.
182
00:10:51,241 --> 00:10:53,551
On site, they'll
Be welded together
183
00:10:53,551 --> 00:10:57,931
And attached to the roof
With special hooks.
184
00:10:57,931 --> 00:11:00,724
They should come in handy
On a rainy day.
185
00:11:15,896 --> 00:11:17,413
Narrator:
The french basque country
186
00:11:17,413 --> 00:11:20,862
Is, culturally, quite distinct
From the rest of france.
187
00:11:20,862 --> 00:11:23,793
Located in the southwest,
Bordering spain,
188
00:11:23,793 --> 00:11:27,275
The region is known,
Among other things, for its ham,
189
00:11:27,275 --> 00:11:30,689
Which is salted and air-cured
In an old tradition,
190
00:11:30,689 --> 00:11:35,931
Passed down through generations
Of basque farmers.
191
00:11:35,931 --> 00:11:39,137
There are several types
Of traditional basque ham.
192
00:11:39,137 --> 00:11:42,482
This one, called kintoa,
Is marbled with fat
193
00:11:42,482 --> 00:11:45,586
And has a deep,
Strong, fruity flavor.
194
00:11:45,586 --> 00:11:48,034
Its distinct taste
And composition
195
00:11:48,034 --> 00:11:50,758
Begin with
A specific breed of pig,
196
00:11:50,758 --> 00:11:56,241
The basque country piebald,
Referring to the animal's skin.
197
00:11:56,241 --> 00:11:59,103
This pig breed is native
To the basque region
198
00:11:59,103 --> 00:12:02,103
Where livestock are raised
On small farms
199
00:12:02,103 --> 00:12:05,793
In the valleys
Of the pyrenees mountains.
200
00:12:05,793 --> 00:12:08,172
Unlike
Commercially farmed animals,
201
00:12:08,172 --> 00:12:12,517
The female pigs have small
Litters of six to nine piglets,
202
00:12:12,517 --> 00:12:14,482
Which grow up roaming
And grazing
203
00:12:14,482 --> 00:12:16,724
Along the vast mountainsides
204
00:12:16,724 --> 00:12:20,689
On an average of 2 acres of land
Per 30 piglets.
205
00:12:20,689 --> 00:12:23,551
As a result of
This free-range rearing,
206
00:12:23,551 --> 00:12:25,000
The pigs grow more slowly
207
00:12:25,000 --> 00:12:28,172
And become heavier
Than commercially farmed pigs.
208
00:12:30,206 --> 00:12:34,068
Once the animals reach a weight
Of about 330 pounds,
209
00:12:34,068 --> 00:12:37,172
Which usually takes a year
To 15 months,
210
00:12:37,172 --> 00:12:40,137
They go to the slaughterhouse.
211
00:12:40,137 --> 00:12:44,344
Each carcass is stamped
With an identification number.
212
00:12:44,344 --> 00:12:48,620
Traditional ham is made
From the hind legs.
213
00:12:48,620 --> 00:12:52,448
After tagging the leg,
A worker places it in a machine,
214
00:12:52,448 --> 00:12:55,551
Which brands the kintoa symbol
Into the flesh.
215
00:12:59,586 --> 00:13:04,310
Then another worker spreads
Dry salt on the exposed portion.
216
00:13:04,310 --> 00:13:07,000
The salt comes from
Salies-de-béarn,
217
00:13:07,000 --> 00:13:08,689
A saltwater spring in a basin
218
00:13:08,689 --> 00:13:10,862
Bordered by
The pyrenees mountains,
219
00:13:10,862 --> 00:13:13,689
The adour river,
And the atlantic ocean.
220
00:13:16,620 --> 00:13:19,586
Workers leave the salted ham
In a cold, damp room
221
00:13:19,586 --> 00:13:22,551
For 1 day per every 2 pounds,
222
00:13:22,551 --> 00:13:25,724
Typically about 15 days per ham.
223
00:13:25,724 --> 00:13:28,103
The salt preserves the meat.
224
00:13:28,103 --> 00:13:32,620
Next, the ham undergoes
A first dry curing.
225
00:13:32,620 --> 00:13:34,620
It hangs on
A stainless-steel rack
226
00:13:34,620 --> 00:13:38,379
In a temperature and humidity
Controlled room for 7 months.
227
00:13:41,551 --> 00:13:43,379
When the ham comes
Out of the room,
228
00:13:43,379 --> 00:13:46,689
It has lost about 20% of
Its original weight
229
00:13:46,689 --> 00:13:49,448
Because most of the moisture
Has evaporated.
230
00:13:51,620 --> 00:13:53,724
A worker brushes off
The surface...
231
00:13:58,000 --> 00:14:01,551
...And coats the exposed part
Of the ham with a special grease
232
00:14:01,551 --> 00:14:05,827
That's made out of pig's
Kidneys, rice flour, and water.
233
00:14:09,965 --> 00:14:12,862
This grease prevents the surface
From drying out
234
00:14:12,862 --> 00:14:15,482
And crusting during
The second dry curing.
235
00:14:17,655 --> 00:14:20,896
The ham now goes into
A second drying room,
236
00:14:20,896 --> 00:14:23,482
Which dries the ham
In the open air,
237
00:14:23,482 --> 00:14:27,931
Taking advantage of this
Particular geographic location.
238
00:14:27,931 --> 00:14:30,344
A warm southern wind from spain
239
00:14:30,344 --> 00:14:33,448
And humid air from
The atlantic ocean to the west
240
00:14:33,448 --> 00:14:36,413
Blow into the room
Through windows.
241
00:14:36,413 --> 00:14:38,655
Nature does all the work.
242
00:14:38,655 --> 00:14:41,758
Humans merely regulate
The airflow and humidity
243
00:14:41,758 --> 00:14:45,793
By lifting
Or lowering the blinds.
244
00:14:45,793 --> 00:14:47,586
In this room, the ham hangs
245
00:14:47,586 --> 00:14:50,724
From a wooden rather than
Stainless-steel rack.
246
00:14:50,724 --> 00:14:53,655
That's because the wood
Absorbs excess humidity
247
00:14:53,655 --> 00:14:55,931
And transfers moisture
To the meat
248
00:14:55,931 --> 00:14:57,482
If the air gets too dry.
249
00:15:00,068 --> 00:15:03,586
As the ham dries,
Its flavor concentrates.
250
00:15:03,586 --> 00:15:06,655
The charcutier,
An artisanal pork butcher,
251
00:15:06,655 --> 00:15:09,034
Inspects every ham carefully.
252
00:15:13,620 --> 00:15:16,034
The wind that dries the ham
Carries pollen
253
00:15:16,034 --> 00:15:18,482
And other natural particles,
254
00:15:18,482 --> 00:15:23,620
Which give this ham
A distinct flavor and fragrance.
255
00:15:23,620 --> 00:15:26,241
The secret is slow curing
256
00:15:26,241 --> 00:15:29,172
Until the ham reaches
Optimal maturity.
257
00:15:29,172 --> 00:15:32,724
That takes approximately
1 month per 2 pounds,
258
00:15:32,724 --> 00:15:35,034
So the ham remains
In the second drying room
259
00:15:35,034 --> 00:15:37,620
For more than a year.
260
00:15:37,620 --> 00:15:39,517
When the cured ham is ready,
261
00:15:39,517 --> 00:15:42,379
Workers sprinkle it
With espelette pepper,
262
00:15:42,379 --> 00:15:46,517
A mildly hot pepper from
The northern basque country.
263
00:15:46,517 --> 00:15:49,793
This gives the ham a fragrance
That's as appetizing
264
00:15:49,793 --> 00:15:53,413
As its taste.
265
00:16:02,172 --> 00:16:05,793
Narrator:
The ancient basque sport
Of pelota, or jai alai,
266
00:16:05,793 --> 00:16:09,448
Can be played with a paddle,
A racket, just your hands,
267
00:16:09,448 --> 00:16:11,241
Or with a specially
Made wicker scoop
268
00:16:11,241 --> 00:16:12,620
Called a chistera,
269
00:16:12,620 --> 00:16:15,551
Which helps propel a ball
At lightning speeds,
270
00:16:15,551 --> 00:16:16,793
Making the sport
271
00:16:16,793 --> 00:16:19,241
One of the fastest ball games
In the world.
272
00:16:22,344 --> 00:16:26,586
The chistera was an innovation
Of the mid-19th century.
273
00:16:26,586 --> 00:16:29,862
Ever since then, making
Chisteras has been the domain
274
00:16:29,862 --> 00:16:34,172
Of a few specialized artisans.
275
00:16:34,172 --> 00:16:37,448
The family-owned workshop
And all the tools it contains
276
00:16:37,448 --> 00:16:39,310
For making chisteras
277
00:16:39,310 --> 00:16:43,862
Has been passed on
From father to son since 1887.
278
00:16:46,275 --> 00:16:51,344
In use for more than 100 years,
These tools still work.
279
00:16:51,344 --> 00:16:54,103
The great grandson
Of the workshop's founder
280
00:16:54,103 --> 00:16:55,655
Uses an old plane
281
00:16:55,655 --> 00:16:59,793
And clamping bench to shape
A curved piece of chestnut.
282
00:17:03,413 --> 00:17:07,241
He clamps one end in a vice
And uses a modern drill
283
00:17:07,241 --> 00:17:10,344
To round the tip
Before rubbing on a little wax
284
00:17:10,344 --> 00:17:12,241
To help fit a crosspiece.
285
00:17:17,275 --> 00:17:20,551
To prepare for the next phase,
He smoothes the surfaces
286
00:17:20,551 --> 00:17:24,206
With some fine-grit sandpaper.
287
00:17:24,206 --> 00:17:26,620
It's now time for him
To create the substructure
288
00:17:26,620 --> 00:17:29,137
Of the chistera.
289
00:17:29,137 --> 00:17:32,103
He starts by clamping
The frame onto a mold.
290
00:17:35,103 --> 00:17:37,586
He gauges the curve
Of the side ribs
291
00:17:37,586 --> 00:17:41,137
And uses steam to adjust them.
292
00:17:41,137 --> 00:17:43,172
He's used plaster to
Patch the mold
293
00:17:43,172 --> 00:17:44,586
Where it's been worn down
294
00:17:44,586 --> 00:17:47,724
By more than 100 years
Of constant use.
295
00:17:52,172 --> 00:17:54,482
Then he moves on
To the bottom ribs,
296
00:17:54,482 --> 00:17:58,137
Which he carefully shapes
And trims to length.
297
00:17:58,137 --> 00:18:01,275
Each chistera is completely
Bespoke -- that is,
298
00:18:01,275 --> 00:18:04,758
Made to order for
The individual pelota players.
299
00:18:07,172 --> 00:18:09,827
This means each chistera
Will differ slightly
300
00:18:09,827 --> 00:18:12,862
To meet the needs of its owner.
301
00:18:12,862 --> 00:18:14,862
That's why the artisan
Must take care
302
00:18:14,862 --> 00:18:17,689
To ensure all the dimensions
Are correct.
303
00:18:19,896 --> 00:18:23,241
He attaches lengths
Of elastic strapping to the mold
304
00:18:23,241 --> 00:18:25,931
To hold the ribs in place
As he works.
305
00:18:30,206 --> 00:18:32,379
Ribs give a chistera its shape,
306
00:18:32,379 --> 00:18:35,206
But they're not strong enough
By themselves.
307
00:18:35,206 --> 00:18:36,724
They need to be woven
308
00:18:36,724 --> 00:18:39,862
With wicker made from
Willow heartwood.
309
00:18:39,862 --> 00:18:42,379
The artisan prepares the wicker
With tools
310
00:18:42,379 --> 00:18:46,206
Designed to shave it down
To the required dimensions.
311
00:18:49,068 --> 00:18:52,000
He then turns the chistera
Over to his uncle,
312
00:18:52,000 --> 00:18:55,206
A specialist in wicker wood.
313
00:18:55,206 --> 00:18:58,413
There are two different sizes
Of chistera.
314
00:18:58,413 --> 00:18:59,689
For a small one,
315
00:18:59,689 --> 00:19:04,068
It takes a specialist
Roughly 9 hours to weave.
316
00:19:04,068 --> 00:19:08,000
For a big one like this,
It takes about 14 hours.
317
00:19:11,241 --> 00:19:13,275
In the game of pelota,
318
00:19:13,275 --> 00:19:17,689
The small hard ball travels
At incredible speeds.
319
00:19:17,689 --> 00:19:20,034
In fact, the guinness book
Of world records
320
00:19:20,034 --> 00:19:24,655
Reports a pelota ball
Clocked at 188 miles per hour.
321
00:19:24,655 --> 00:19:28,689
Speeds like that could cause
Some serious damage.
322
00:19:28,689 --> 00:19:31,655
Here, the artisan rolls
And sews leather padding
323
00:19:31,655 --> 00:19:34,758
Designed to protect
The player's hands from injury.
324
00:19:39,206 --> 00:19:41,724
Once he's made the padding
Components,
325
00:19:41,724 --> 00:19:46,551
He sews them onto the chistera,
Positioning them where needed.
326
00:19:46,551 --> 00:19:52,241
This leatherwork phase alone
Takes about 2 hours to complete.
327
00:19:52,241 --> 00:19:55,241
He now cuts out the shape
Required for the glove portion
328
00:19:55,241 --> 00:19:56,689
Of the chistera,
329
00:19:56,689 --> 00:20:02,137
Then slices the outlines
For the individual fingers.
330
00:20:02,137 --> 00:20:04,379
True to form,
Even the sewing machine
331
00:20:04,379 --> 00:20:07,586
Is an antique original.
332
00:20:07,586 --> 00:20:10,310
It may be old,
But this well-built machine
333
00:20:10,310 --> 00:20:15,310
Can still do the job of sewing
The leather to a layer of cloth,
334
00:20:15,310 --> 00:20:18,413
Which is specially formulated
To wick away sweat.
335
00:20:21,172 --> 00:20:23,620
To attach the glove
To the wicker scoop,
336
00:20:23,620 --> 00:20:26,517
The artisan must set aside
The sewing machine
337
00:20:26,517 --> 00:20:30,413
And complete this step
The old-fashioned way
338
00:20:30,413 --> 00:20:33,965
By carefully sewing
The components together by hand.
339
00:20:37,206 --> 00:20:41,206
He then trims off any excess
Material with a pair of scissors
340
00:20:41,206 --> 00:20:44,275
And inserts his hand
Into the glove.
341
00:20:44,275 --> 00:20:47,206
This makes it easier for him
To complete the final step
342
00:20:47,206 --> 00:20:50,275
Of attaching a handy loop.
343
00:20:50,275 --> 00:20:53,517
Preserving a tradition
Of handcrafted excellence,
344
00:20:53,517 --> 00:20:57,551
The finished chistera
Is a work of artisanal art.
345
00:20:57,551 --> 00:21:01,758
That helps make pelota one of
The fastest games in the world.
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