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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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ALUMINUM FOIL...
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...SNOWBOARDS...
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...CONTACT LENSES...
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...AND BREAD.
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ALUMINUM FOIL
HAS A MULTITUDE OF USES,
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00:00:57,992 --> 00:00:59,790
FROM HEATING SOMETHING UP
IN THE OVEN
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00:00:59,793 --> 00:01:03,461
TO KEEPING SOMETHING COLD
IN THE FRIDGE.
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00:01:03,464 --> 00:01:07,131
BUT HAVE YOU EVER WONDERED HOW
A HUGE BLOCK OF SOLID ALUMINUM
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00:01:07,134 --> 00:01:10,435
GETS TRANSFORMED INTO
A PAPER-THIN SHEET OF FOIL?
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00:01:14,942 --> 00:01:16,941
THE MANUFACTURE OF ALUMINUM FOIL
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REQUIRES
THE REPEATED THINNING OUT
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OF A LARGE BLOCK OF ALUMINUM.
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WE BEGIN BY MELTING INGOTS
OF 100%-PURE ALUMINUM
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IN A NATURAL-GAS FURNACE.
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THESE INGOTS, CALLED "PIGS,"
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ARE ESSENTIAL IN ALLOYS
WITH ZINC, TITANIUM, AND SILICA.
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IT TAKES 3 TO 8 HOURS TO MELT
30 TONS OF ALUMINUM
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00:01:35,162 --> 00:01:37,027
IN THIS REMELTING FURNACE,
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WHICH OPERATES
AT 1,380 DEGREES FAHRENHEIT.
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00:01:42,102 --> 00:01:44,368
THE FUSION TEMPERATURE
OF ALUMINUM
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00:01:44,371 --> 00:01:47,505
IS 1,220 DEGREES FAHRENHEIT.
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A PORTION OF ALUMINUM
IS POURED INTO THIS SMALL MOLD
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00:01:50,243 --> 00:01:51,175
TO MAKE A SAMPLE.
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SOLIDIFYING IN JUST SECONDS,
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THE SAMPLE ALLOWS FOR TESTING
TO VERIFY THE CONTENTS
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OF THE PREPARED ALLOY.
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MOLTEN ALUMINUM
RUNS IN A MOVABLE TROUGH
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00:02:00,988 --> 00:02:04,722
LOCATED ABOVE THE TAPPING WELL.
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00:02:04,725 --> 00:02:06,924
AT THIS STAGE,
IMPURITIES ARE FILTERED OUT
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IN SPECIAL RECEPTACLES.
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THE MOLDS ARE COOLED WITH WATER
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TO ACCELERATE THE SOLIDIFICATION
OF THE MOLTEN ALUMINUM.
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INGOTS ARE UNMOLDED
AND ARE READY FOR MILLING.
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EACH INGOT IS MASSIVE,
MEASURING 14 FEET IN LENGTH,
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5 FEET IN WIDTH,
AND 18 INCHES THICK.
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IT WEIGHS A WHOPPING 8 TONS,
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SO IT HAS TO BE HANDLED
BY OVERHEAD CRANES
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AND PLACED ON SPECIAL PLATES.
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THIS CRUST-REMOVING MACHINE
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REMOVES 1/10 OF AN INCH
OF THE INGOT'S THICKNESS.
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IMPURITIES ARE ELIMINATED
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TO ACHIEVE A PERFECTLY
SMOOTH FINISH.
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ALL TRACES OF THE LIQUID USED
TO COOL THE DECRUSTING KNIVES
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HAVE TO BE ELIMINATED.
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THE MANY STEPS IN THE THINNING
OF THE INGOT BEGIN.
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FIRST,
THE ALUMINUM BLOCK IS CRUSHED
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BY THE HOT MILL ROLLERS.
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TEMPERATURES IN THE ROLLERS
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ARE BETWEEN 850
AND 1,000 DEGREES FAHRENHEIT.
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PRESSURE ON THE INGOT
IS CONTINUALLY VERIFIED
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BY A TECHNICIAN.
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IF THE PRESSURE IS TOO GREAT,
THE TECHNICIAN WILL LOWER IT.
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THE HEAT IS SO HIGH
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THAT THE INGOT RISKS STICKING
TO THE MILL'S ROLLER.
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TO PREVENT THIS, EVERYTHING
IS COOLED WITH A LIQUID
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THAT'S 95% WATER AND 5% OIL.
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00:03:33,947 --> 00:03:36,747
STARTING FROM A THICKNESS
OF 18 INCHES,
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00:03:36,750 --> 00:03:40,083
THE INGOT BECOMES INCREASINGLY
THINNER WITH EACH PASS-THROUGH.
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00:03:40,086 --> 00:03:41,752
DEPENDING ON REQUIREMENTS,
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THE INGOT WILL GO THROUGH THE
MACHINE BETWEEN 12 AND 16 TIMES.
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00:03:46,293 --> 00:03:49,459
THE INGOT NOW MEASURES
ABOUT 3 INCHES IN THICKNESS.
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00:03:49,462 --> 00:03:53,231
IT HAS TO GET DOWN
TO JUST 2/10 OF AN INCH.
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00:03:57,837 --> 00:04:01,172
AT THIS STAGE, THE INGOT
IS ABOUT 2 INCHES THICK
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00:04:01,175 --> 00:04:03,907
AND MEASURES
ALMOST 30 FEET IN LENGTH.
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00:04:03,910 --> 00:04:08,379
THIS CONVEYOR TRANSPORTS THE
PLATE DURING ITS MILLING STAGES.
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00:04:16,523 --> 00:04:20,257
THE INGOT HAS BECOME A SHEET
2/10 OF AN INCH THICK.
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00:04:20,260 --> 00:04:23,127
IT IS SUFFICIENTLY THIN
TO PROCEED TO SPOOLING,
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00:04:23,130 --> 00:04:24,795
WHERE IT SPOOLS ONTO ITSELF
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BEFORE BEING SENT
TO THE COLD ROLLING MILL.
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00:04:27,200 --> 00:04:30,334
THERE, ITS THICKNESS WILL BE
REDUCED STILL FURTHER.
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00:04:33,474 --> 00:04:36,874
THE ALUMINUM SHEET
HAS BECOME VERY THIN NOW
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AND RISKS BEING BROKEN
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00:04:38,412 --> 00:04:40,745
BY THE TENSION NEEDED
FOR COLD ROLLING.
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SO THE SHEET IS DOUBLED
TO AVOID THIS BREAKAGE.
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00:04:43,751 --> 00:04:46,717
ONE FINAL REDUCTION IN THE MILL,
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00:04:46,720 --> 00:04:48,685
AND THE SHEET
WILL HAVE THE THICKNESS
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00:04:48,688 --> 00:04:50,287
REQUIRED BY THE CUSTOMER.
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A LIQUID COOLANT IS USED
TO PREVENT THE FOIL
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FROM STICKING TO THE ROLLERS.
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00:04:55,229 --> 00:04:57,762
SINCE THE EDGES
OF THE FOIL SHEET
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00:04:57,765 --> 00:05:00,364
ARE LIGHTLY DAMAGED
AND CRINKLED,
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00:05:00,367 --> 00:05:04,201
A KNIFE REMOVES A STRIP
4/10 OF AN INCH WIDE.
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00:05:07,841 --> 00:05:10,908
FINALLY, THE ROLL
IS CUT TO THE DESIRED WIDTH,
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00:05:10,911 --> 00:05:15,379
AND ONE HUGE INGOT HAS PRODUCED
NEARLY 8 MILES OF FOIL.
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Narrator: IF YOU'VE EVER
TRIED SNOWBOARDING,
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YOU'VE PROBABLY DISCOVERED
THAT THOSE COOL MOVES
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00:05:32,465 --> 00:05:36,667
AREN'T QUITE AS EASY
AS THE PROS MAKE IT LOOK.
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00:05:36,670 --> 00:05:40,204
LEARNING TO MANEUVER A SNOWBOARD
IS A LONG AND INVOLVED PROCESS,
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00:05:40,207 --> 00:05:41,938
AND IT'S MUCH THE SAME
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00:05:41,941 --> 00:05:45,676
WHEN IT COMES TO MANUFACTURING
THESE SURFBOARDS FOR SNOW.
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00:05:51,084 --> 00:05:55,019
THE SNOWBOARD IS THE DELIGHT
OF WINTER-SPORTS ENTHUSIASTS.
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ITS CORE IS MADE
OF A THIN SHEET OF WOOD.
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VARIOUS KINDS OF WOODS ARE USED,
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DEPENDING ON THE TYPE
OF BOARD BEING MADE.
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00:06:05,966 --> 00:06:08,966
BINDINGS HAVE TO BE FIRMLY
ATTACHED TO THE BOARD.
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00:06:08,969 --> 00:06:10,701
HOLES ARE DRILLED FOR INSERTS,
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TO WHICH BINDINGS
WILL BE SECURED.
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00:06:12,773 --> 00:06:17,575
A TEMPLATE ALLOWS THE HOLES
TO BE PRECISELY DRILLED.
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00:06:17,578 --> 00:06:21,378
PLANING REDUCES THE BOARD
TO THE REQUIRED THICKNESS.
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A THICK BOARD IS OBVIOUSLY
MORE RIGID THAN A THIN ONE.
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A SHAPING PROCEDURE
REFINES THE BOARD'S CONTOURS.
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00:06:34,328 --> 00:06:37,861
AT THIS POINT, THE BOARD
IS STILL PERFECTLY FLAT
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WITH NO CURVATURE.
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THE BOARDS ARE THEN STORED
UPRIGHT TO AWAIT THE NEXT STEP.
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NOW THEY MUST SECURE
THE ALUMINUM INSERTS,
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WHICH WILL BE EMBEDDED
IN THE WOOD.
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00:07:00,954 --> 00:07:02,819
THIS THIN SHEET OF FIBERGLASS
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00:07:02,822 --> 00:07:05,489
WILL CREATE BETTER SUPPORT
FOR THE INSERTS.
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00:07:05,492 --> 00:07:07,892
THEREFORE,
THEY WILL BE MORE SOLID.
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00:07:13,366 --> 00:07:15,632
TO MAKE WORKING ON IT EASIER,
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THE BOARD IS SECURELY
HELD IN PLACE BY CLAMPS.
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00:07:19,105 --> 00:07:22,105
EPOXY,
AN EXTREMELY STRONG ADHESIVE
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00:07:22,108 --> 00:07:24,508
OFTEN USED
WITH COMPOSITE MATERIALS,
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00:07:24,511 --> 00:07:27,444
IS APPLIED TO THE FIBERGLASS
AT ROOM TEMPERATURE.
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00:07:27,447 --> 00:07:30,581
IT IS ESSENTIAL
TO REMOVE ANY EXCESS EPOXY,
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00:07:30,584 --> 00:07:32,382
AS WELL AS ELIMINATE
ALL AIR BUBBLES
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00:07:32,385 --> 00:07:34,885
SO THERE WILL BE
A GOOD ADHERENCE.
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00:07:38,725 --> 00:07:40,925
AS FOR THE TOP PART
OF THE BOARD,
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00:07:40,928 --> 00:07:46,063
IT'S MADE OF A RESISTANT PLASTIC
APPLIED BY SILK-SCREENING.
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00:07:46,066 --> 00:07:50,668
IN SILK-SCREENING, INK IS SPREAD
BY THIS LITTLE SQUEEGEE.
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00:07:50,671 --> 00:07:53,003
THIS APPLICATION
IS CALLED A PASS.
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00:07:53,006 --> 00:07:55,606
COLORS HAVE TO BE APPLIED
ONE AT A TIME.
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00:07:55,609 --> 00:07:59,210
THE INKS MUST DRY FOR SEVERAL
HOURS BETWEEN EACH COAT.
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00:08:01,948 --> 00:08:04,281
NOW THE BOARD MUST BE CURVED.
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00:08:04,284 --> 00:08:06,150
A COVER IS PLACED ON THE MOLD.
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00:08:06,153 --> 00:08:07,751
WHEN THE MOLD IS CLOSED,
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00:08:07,754 --> 00:08:10,154
THE BOARD IS GIVEN
THE DESIRED CURVE.
131
00:08:10,157 --> 00:08:14,458
HEAT TRAPPED IN THE MOLD
MAKES THE EPOXY SET AND HARDEN.
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00:08:16,964 --> 00:08:18,896
THE BOARD COMES OUT OF THE MOLD,
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00:08:18,899 --> 00:08:23,100
AND ANY EXCESS EPOXY AND WOOD
ARE REMOVED BY A BAND SAW.
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00:08:23,103 --> 00:08:25,035
TO ACHIEVE A PERFECT CUT,
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00:08:25,038 --> 00:08:27,838
THE SAW BLADE IS CHANGED
EVERY 50 BOARDS.
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00:08:27,841 --> 00:08:31,475
IT'S HIGHLY PRECISE WORK
AND TOTALLY MANUAL.
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00:08:45,459 --> 00:08:48,859
THEY APPLY, AGAIN BY
SILK-SCREENING, ANOTHER COAT,
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00:08:48,862 --> 00:08:50,461
THEN ANOTHER COLOR.
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00:08:50,464 --> 00:08:52,396
THIS TIME, RED.
140
00:09:07,814 --> 00:09:10,413
THE SNOWBOARD MUST NOW
BE PROTECTED.
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00:09:10,416 --> 00:09:13,484
A PROTECTING VARNISH FLOWS
AS A THIN CURTAIN.
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00:09:13,487 --> 00:09:15,753
THE BOARD PASSES
BENEATH THIS CURTAIN
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00:09:15,756 --> 00:09:19,189
AND THEN MOVES INTO A DRYER
FOR A SIX-HOUR STAY.
144
00:09:25,498 --> 00:09:29,232
SANDING REMOVES SURPLUS VARNISH
FROM THE EDGES OF THE BOARD.
145
00:09:29,235 --> 00:09:31,702
NEW HOLES ARE PIERCED
INTO THE BOARD
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00:09:31,705 --> 00:09:35,539
TO LOCATE THE INSERTS INSTALLED
AT THE BEGINNING OF PRODUCTION.
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00:09:37,978 --> 00:09:40,443
THIS SANDER REMOVES
IMPERFECTIONS
148
00:09:40,446 --> 00:09:42,045
IN THE HARDENED VARNISH
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00:09:42,048 --> 00:09:45,248
AND PREPARES THE BOARD
FOR ITS SECOND VARNISH COATING.
150
00:09:45,251 --> 00:09:49,519
THEN THE PLASTIC BASE IS SANDED
TO OBTAIN THE DESIRED FINISH.
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00:09:49,522 --> 00:09:53,256
THE BOARD IS CHECKED TO SEE
THAT IT'S PERFECTLY FLAT.
152
00:09:53,259 --> 00:09:55,525
A RAZOR BLADE VERIFIES
THAT THE DIFFERENT COATS
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00:09:55,528 --> 00:09:58,262
ARE WELL-ADHERED TO ONE ANOTHER.
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00:09:58,265 --> 00:10:01,665
CERTAIN BOARDS GET AN ENGRAVED
ALUMINUM INSERT --
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A LUXURY TOUCH.
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00:10:04,204 --> 00:10:07,137
THE BOARD IS NOW READY
FOR ACTION.
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00:10:07,140 --> 00:10:10,874
THIS FACILITY TURNS OUT OVER
500 SNOWBOARDS PER DAY
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00:10:10,877 --> 00:10:12,977
IN 30 DIFFERENT MODELS.
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00:10:21,221 --> 00:10:23,887
Narrator: PEOPLE WHO HAVE
DEFECTIVE VISION
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00:10:23,890 --> 00:10:25,422
CAN ALWAYS WEAR GLASSES,
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00:10:25,425 --> 00:10:29,226
BUT IN MANY CASES, THERE'S
A LESS-NOTICEABLE ALTERNATIVE.
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00:10:29,229 --> 00:10:31,961
CONTACT LENSES
CORRECT FAULTY VISION
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00:10:31,964 --> 00:10:35,098
WITHOUT ANYONE KNOWING
THE WEARER EVEN HAS THEM ON.
164
00:10:35,101 --> 00:10:38,368
WHAT GOES INTO MAKING
THESE TINY OPTICAL AIDS
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00:10:38,371 --> 00:10:40,638
IS REALLY EYE-CATCHING.
166
00:10:45,512 --> 00:10:49,979
CONTACT LENSES HAVE BEEN
IN EXISTENCE FOR OVER A CENTURY.
167
00:10:49,982 --> 00:10:51,782
AT FIRST COMPLETELY RIGID,
168
00:10:51,785 --> 00:10:55,786
THEY HAVE BECOME GAS-PERMEABLE
AND AS FLEXIBLE AS GELATIN.
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00:10:55,789 --> 00:10:58,122
THESE SMALL polyHEMA DISKS
ARE USED
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00:10:58,125 --> 00:11:01,792
TO MAKE SOFT POLYMER CONTACT
LENSES IN A VARIETY OF COLORS.
171
00:11:01,795 --> 00:11:04,261
WE SEE HERE
A PATIENT'S PRESCRIPTION,
172
00:11:04,264 --> 00:11:07,064
ESSENTIAL TO THE FABRICATION
OF LENSES.
173
00:11:07,067 --> 00:11:08,465
THE PROCESS BEGINS
174
00:11:08,468 --> 00:11:10,534
WITH DATA PROCESSING CONTROL
OF THE SHAPING.
175
00:11:10,537 --> 00:11:14,137
DATA IS SUPPLIED BY COMPUTER,
WHICH CONTROLS A DIGITAL LATHE.
176
00:11:14,140 --> 00:11:17,741
THEY BEGIN BY SHAPING
THE INNER CURVATURE OF THE LENS.
177
00:11:17,744 --> 00:11:21,478
THIS DIGITAL LATHE, ROTATING
AT 6,000 REVOLUTIONS PER MINUTE,
178
00:11:21,481 --> 00:11:24,014
IS EQUIPPED WITH
AN INDUSTRIAL DIAMOND.
179
00:11:24,017 --> 00:11:25,682
IT SHAPES THE INNER SURFACE --
180
00:11:25,685 --> 00:11:27,818
THE PART
THAT TOUCHES THE CORNEA.
181
00:11:27,821 --> 00:11:30,888
IT MUST BE FREE FROM ANY
ABRASIONS AND IMPERFECTIONS
182
00:11:30,891 --> 00:11:33,957
AND IS POLISHED WITH
A SUPER-FINE ABRASIVE PASTE.
183
00:11:33,960 --> 00:11:35,959
POLISHING IS A CRUCIAL STEP
184
00:11:35,962 --> 00:11:40,631
BECAUSE IT ASSURES EXCELLENT
COMFORT AND PERFECT VISION.
185
00:11:40,634 --> 00:11:43,300
A TECHNICIAN MEASURES
LENS THICKNESS
186
00:11:43,303 --> 00:11:46,570
WITH AN EXTREMELY PRECISE GAUGE.
187
00:11:46,573 --> 00:11:48,839
THEY NOW SHAPE
THE OUTER SURFACE,
188
00:11:48,842 --> 00:11:51,175
THE PART THAT TOUCHES
THE EYELID.
189
00:11:51,178 --> 00:11:53,443
THE LENS IS GLUED
WITH A SPECIAL WARM WAX,
190
00:11:53,446 --> 00:11:55,045
WHEN THE LENS IS COMPLETED,
191
00:11:55,048 --> 00:11:59,783
AN ULTRASOUND DEVICE
WILL REMOVE THE WAX.
192
00:11:59,786 --> 00:12:04,054
THE WAX TAKES ON THE DESIRED
SHAPE IN JUST SECONDS.
193
00:12:15,135 --> 00:12:18,401
THE COMFORT OF A LENS IS ALSO
DETERMINED BY ITS THICKNESS.
194
00:12:18,404 --> 00:12:20,204
IT MUST BE AS THIN AS POSSIBLE
195
00:12:20,207 --> 00:12:22,606
WHILE RETAINING
SUFFICIENT SOLIDITY.
196
00:12:22,609 --> 00:12:25,342
THEY BEGIN BY SHAPING
THE OUTER DIAMETER OF THE LENS,
197
00:12:25,345 --> 00:12:28,011
WHICH TAKES ONLY A FEW SECONDS.
198
00:12:37,357 --> 00:12:40,357
THEY NOW POLISH THE OUTER
SURFACE OF THE LENS.
199
00:12:40,360 --> 00:12:42,692
THIS POLISHING,
DONE AT HIGH SPEED,
200
00:12:42,695 --> 00:12:45,495
CALLS FOR AN ABRASIVE PASTE,
SOME OIL,
201
00:12:45,498 --> 00:12:49,566
AND A SMALL POLYESTER
COTTON BALL.
202
00:12:49,569 --> 00:12:53,837
THIS APPARATUS POLISHES SEVERAL
LENSES AT THE SAME TIME --
203
00:12:53,840 --> 00:12:56,573
A STEP THAT TAKES
ONLY 60 SECONDS.
204
00:12:56,576 --> 00:13:00,410
WITH EVERYTHING COMPUTERIZED,
QUALITY IS INCOMPARABLE.
205
00:13:04,050 --> 00:13:08,085
A TECHNICIAN THEN POLISHES
THE RIMS OF THE LENS.
206
00:13:13,059 --> 00:13:16,059
THE POLYMER IS HYDRATED
TO MAKE IT FLEXIBLE.
207
00:13:16,062 --> 00:13:17,661
LENSES REMAIN IMMERSED
208
00:13:17,664 --> 00:13:21,531
IN A BALANCED pH SALINE SOLUTION
FOR 24 HOURS.
209
00:13:21,534 --> 00:13:24,934
THE LENS BECOMES ENGORGED
WITH LIQUID AND EXPANDS,
210
00:13:24,937 --> 00:13:27,504
REACHING THE DESIRED
PROPORTIONS.
211
00:13:39,152 --> 00:13:42,285
THIS OPTICAL TOPOGRAPHER
IS USED TO VERIFY,
212
00:13:42,288 --> 00:13:44,153
THROUGH COLOR DISTRIBUTION,
213
00:13:44,156 --> 00:13:46,689
WHETHER THE SPREAD
OF OPTICAL POWER IN THE LENS
214
00:13:46,692 --> 00:13:49,860
IS PRECISE ENOUGH
TO ASSURE PERFECT VISION.
215
00:13:53,566 --> 00:13:57,567
AND NOW WE PROCEED WITH ANOTHER
IMPORTANT TESTING PROCEDURE.
216
00:13:57,570 --> 00:14:00,971
THE SOFT, FRAGILE LENSES
ARE ALWAYS HANDLED
217
00:14:00,974 --> 00:14:02,739
WITH THE GREATEST OF CARE.
218
00:14:06,313 --> 00:14:08,445
THIS UNIT,
CALLED A FRONTOFOCOMETER,
219
00:14:08,448 --> 00:14:10,113
IS A METERING DEVICE
220
00:14:10,116 --> 00:14:12,983
WHICH VERIFIES THE OPTICAL
PRECISION OF THE LENS.
221
00:14:18,258 --> 00:14:21,992
THE LENSES ARE NOW COMPLETED
AND ARE CLEANED.
222
00:14:21,995 --> 00:14:25,596
THEY'RE STORED IN CONTAINERS
FILLED WITH A SALT SOLUTION.
223
00:14:29,069 --> 00:14:31,802
THIS LITTLE VIAL THAT
WE MIGHT FIND AT OPTOMETRISTS'
224
00:14:31,805 --> 00:14:35,906
IS SEALED WITH A SILICONE CAP
AND ANOTHER OF ALUMINUM.
225
00:14:38,211 --> 00:14:40,944
THESE VIALS ARE PLACED
IN A STERILIZER
226
00:14:40,947 --> 00:14:43,413
AT TEMPERATURES
OF 250 DEGREES FAHRENHEIT
227
00:14:43,416 --> 00:14:45,349
FOR AN HOUR AND A HALF.
228
00:14:45,352 --> 00:14:47,084
THE CONTENTS WILL REMAIN STERILE
229
00:14:47,087 --> 00:14:50,420
FOR UP TO SEVEN YEARS
IF NOT OPENED.
230
00:14:50,423 --> 00:14:53,690
THE PRODUCTION OF A LENS
INVOLVES 14 STEPS.
231
00:14:53,693 --> 00:14:56,960
IF WE EXCLUDE THE RATHER LENGTHY
HYDRATION PROCESS,
232
00:14:56,963 --> 00:15:00,363
ACTUAL LENS PRODUCTION
REQUIRES ONLY 15 MINUTES.
233
00:15:00,366 --> 00:15:04,167
THEY CAN PRODUCE ALMOST
1,000 CONTACT LENSES PER DAY --
234
00:15:04,170 --> 00:15:07,337
ALL MADE FROM THESE TINY
COLORED DISKS.
235
00:15:17,383 --> 00:15:21,451
Narrator: IT'S A STAPLE
FOR PEOPLE ALL OVER THE WORLD.
236
00:15:21,454 --> 00:15:25,055
SMOTHERED IN BUTTER AND JELLY
OR DIPPED IN GRAVY,
237
00:15:25,058 --> 00:15:28,392
IT'S A DELICIOUS TREAT
THAT'S HARD TO RESIST.
238
00:15:28,395 --> 00:15:31,861
AND WE'RE WILLING TO BET
YOU CAN'T RESIST THE OPPORTUNITY
239
00:15:31,864 --> 00:15:36,500
TO FIND OUT WHAT GOES INTO
THE MAKING OF YOUR DAILY BREAD.
240
00:15:42,808 --> 00:15:46,677
OVER 3,000 YEARS AGO,
IN THE TIME OF KING TUT,
241
00:15:46,680 --> 00:15:51,348
EGYPTIANS WERE ALREADY BAKING
40 VARIETIES OF LEAVEN BREAD.
242
00:15:51,351 --> 00:15:54,551
THE GREEKS' CONTRIBUTION
TO THIS HISTORY WAS THE OVEN
243
00:15:54,554 --> 00:15:57,487
AND 70 VARIETIES
OF FLAVORED BREADS --
244
00:15:57,490 --> 00:16:01,358
BREADS SO GOOD THAT THE ROMANS
TOOK THE GREEK BAKERS TO ROME
245
00:16:01,361 --> 00:16:03,960
AND THEIR OVENS TO GAUL.
246
00:16:03,963 --> 00:16:05,762
BY THE MIDDLE AGES,
247
00:16:05,765 --> 00:16:09,433
BREAD HAD BECOME THE PRIMARY
FOOD OF WESTERN EUROPE.
248
00:16:20,046 --> 00:16:22,912
MULTIGRAIN BREAD IS MADE
FROM SEVERAL INGREDIENTS
249
00:16:22,915 --> 00:16:26,316
SUCH AS FLAXSEED, BUCKWHEAT,
SOY, AND MILLET.
250
00:16:26,319 --> 00:16:29,052
THIS PROTECTIVE GRILL
PREVENTS FOREIGN MATTER
251
00:16:29,055 --> 00:16:31,588
FROM ACCIDENTALLY FALLING
INTO THE RECIPE MIX --
252
00:16:31,591 --> 00:16:35,258
A RECIPE THAT CALLS
FOR A HALF A TON OF FLOUR.
253
00:16:35,261 --> 00:16:38,094
THE INGREDIENTS,
GROUND IN A MILL,
254
00:16:38,097 --> 00:16:41,598
ARE KEPT IN THESE
36 ENORMOUS CONTAINERS.
255
00:16:46,005 --> 00:16:48,538
WE BEGIN BY MIXING
THE INGREDIENTS TOGETHER.
256
00:16:48,541 --> 00:16:51,675
THESE KNEADING TROUGHS
ARE USED TO FERMENT THE YEAST,
257
00:16:51,678 --> 00:16:54,077
A STEP WHICH TAKES THREE HOURS.
258
00:16:54,080 --> 00:16:57,647
THE FERMENTING YEAST MAKES
THE DOUGH RISE CONSIDERABLY.
259
00:17:05,091 --> 00:17:09,559
THIS HUGE MIXER KNEADS THE DOUGH
FOR ABOUT EIGHT MINUTES.
260
00:17:17,770 --> 00:17:19,769
WHEN THOROUGHLY HOMOGENOUS,
261
00:17:19,772 --> 00:17:22,506
THE CONTENTS ARE EMPTIED
INTO A LARGE TUB.
262
00:17:22,509 --> 00:17:25,542
THE DOUGH WEIGHS
A LITTLE OVER A TON.
263
00:17:29,181 --> 00:17:31,715
THE DOUGH IS LOADED ONTO A SLIDE
264
00:17:31,718 --> 00:17:34,184
SITUATED
ABOVE THE DOUGH DIVIDER.
265
00:17:37,057 --> 00:17:39,255
AT THE BOTTOM OF THE MACHINE,
266
00:17:39,258 --> 00:17:41,858
A SMALL HOLE
ALLOWS THE DOUGH TO ESCAPE.
267
00:17:41,861 --> 00:17:43,793
TWO MECHANICALLY OPERATED ARMS
268
00:17:43,796 --> 00:17:46,463
CUT THE DOUGH PIECES
INTO EQUAL LENGTHS.
269
00:17:46,466 --> 00:17:49,065
IT FORMS 192 OF THESE A MINUTE.
270
00:17:49,068 --> 00:17:51,435
THE DOUGH THEN FALLS
ONTO A CONVEYOR.
271
00:17:56,810 --> 00:17:59,409
HERE DOUGH PIECES
ARE ROLLED INTO BALLS,
272
00:17:59,412 --> 00:18:01,812
WHICH CAN BE MORE EASILY WORKED.
273
00:18:05,885 --> 00:18:07,617
THE DOUGHBALLS ARE FLOURED
274
00:18:07,620 --> 00:18:10,220
TO PREVENT THEM FROM STICKING
DURING THEIR TRANSPORT
275
00:18:10,223 --> 00:18:12,022
AND WHEN THEY'RE MOLDED.
276
00:18:12,025 --> 00:18:14,491
HERE THE BALLS OF DOUGH
LEAVE THE DIVIDER
277
00:18:14,494 --> 00:18:15,959
AND GO TO THE MOLDER.
278
00:18:15,962 --> 00:18:18,228
DURING TRANSPORT,
THE DOUGH CAN REST,
279
00:18:18,231 --> 00:18:19,996
ALLOWING THE YEAST TO ACT.
280
00:18:23,770 --> 00:18:27,503
THE DOUGH IS THEN FOLDED
AND ROLLED.
281
00:18:27,506 --> 00:18:29,639
THE MACHINE CAN HANDLE
THREE PER SECOND
282
00:18:29,642 --> 00:18:33,243
FOR A TOTAL OF 11,500 AN HOUR.
283
00:18:33,246 --> 00:18:36,379
THE DOUGH IS ROLLED OUT
TO THE EXACT SIZE
284
00:18:36,382 --> 00:18:38,515
AND FALLS INTO BAKING MOLDS.
285
00:18:41,654 --> 00:18:44,854
HERE WE SEE THE MAKING
OF HOT DOG ROLLS.
286
00:18:44,857 --> 00:18:47,790
THESE LITTLE DOUGHBALLS
HAVE TO BE SHAPED LENGTHWISE
287
00:18:47,793 --> 00:18:50,060
AND FERMENTED BEFORE MOLDING.
288
00:19:05,578 --> 00:19:10,613
HERE THE HOG DOG ROLLS
ARE BEING MACHINE-MOLDED.
289
00:19:10,616 --> 00:19:13,016
DOUGH PIECES
MUST NOT TOUCH ONE ANOTHER,
290
00:19:13,019 --> 00:19:16,419
SO THEY'RE SPACED APART
BY A SMALL MECHANICAL ARM.
291
00:19:16,422 --> 00:19:20,090
NOW WE GO BACK
TO MULTIGRAIN BREAD PRODUCTION.
292
00:19:23,496 --> 00:19:26,296
SQUATTED DOWN AT THE BOTTOM
OF THE MOLDS,
293
00:19:26,299 --> 00:19:28,164
THE DOUGH PIECES
GO INTO THE PROOFER,
294
00:19:28,167 --> 00:19:31,501
WHERE THEY RISE FOR AN HOUR
AT 110 DEGREES FAHRENHEIT
295
00:19:31,504 --> 00:19:33,770
AND AT 70% HUMIDITY.
296
00:19:33,773 --> 00:19:38,575
THEN THEY BAKE FOR 20 MINUTES
AT 490 DEGREES.
297
00:19:38,578 --> 00:19:43,146
WHEN FINALLY BAKED, THE LOAVES
END UP WITH A NICE GOLDEN COLOR.
298
00:19:47,653 --> 00:19:51,588
A VACUUM SYSTEM DRAWS
THE LOAVES FROM THEIR MOLDS.
299
00:19:51,591 --> 00:19:54,758
THEY'RE THEN PLACED
ON A CONVEYOR TO COOL.
300
00:20:05,471 --> 00:20:08,671
A GUIDANCE SYSTEM TAKES CARE
OF CARRYING THE BREADS
301
00:20:08,674 --> 00:20:11,407
TO VARIOUS SECTIONS
OF THE BAKERY.
302
00:20:11,410 --> 00:20:14,878
WHEN WELL-COOLED,
BREADS GO TO THE SLICER,
303
00:20:14,881 --> 00:20:17,213
WHICH CUTS 65 LOAVES A MINUTE.
304
00:20:17,216 --> 00:20:19,749
THEY ARE SLICED BY 7-FOOT-WIDE
305
00:20:19,752 --> 00:20:22,152
AND 16-INCH-LONG
STEEL SAW BLADES.
306
00:20:22,155 --> 00:20:25,622
THESE BLADES ARE CHANGED
EVERY TWO WEEKS.
307
00:20:30,096 --> 00:20:34,364
SLICED LOAVES ARE AUTOMATICALLY
PACKED AT 65 PER MINUTE.
308
00:20:34,367 --> 00:20:36,166
THEY'RE NOW READY FOR SHIPPING.
309
00:20:36,169 --> 00:20:39,302
SOME 5 1/2 HOURS HAVE PASSED
310
00:20:39,305 --> 00:20:41,504
BETWEEN PREPARATION
OF THE DRY FLOUR
311
00:20:41,507 --> 00:20:44,641
AND PACKAGING
OF THE BAKED BREAD.
312
00:20:50,583 --> 00:20:52,982
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
313
00:20:52,985 --> 00:20:55,852
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
314
00:20:55,855 --> 00:20:57,454
DROP US A LINE AT...
23829
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