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These are the user uploaded subtitles that are being translated: 1 00:00:02,003 --> 00:00:05,069 -- Captions by VITAC -- www.vitac.com 2 00:00:05,072 --> 00:00:08,039 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:23,490 --> 00:00:26,224 Narrator: TODAY ON "HOW IT'S MADE"... 4 00:00:26,227 --> 00:00:28,026 ALUMINUM FOIL... 5 00:00:31,965 --> 00:00:33,398 ...SNOWBOARDS... 6 00:00:37,505 --> 00:00:39,170 ...CONTACT LENSES... 7 00:00:43,243 --> 00:00:44,876 ...AND BREAD. 8 00:00:55,189 --> 00:00:57,989 ALUMINUM FOIL HAS A MULTITUDE OF USES, 9 00:00:57,992 --> 00:00:59,790 FROM HEATING SOMETHING UP IN THE OVEN 10 00:00:59,793 --> 00:01:03,461 TO KEEPING SOMETHING COLD IN THE FRIDGE. 11 00:01:03,464 --> 00:01:07,131 BUT HAVE YOU EVER WONDERED HOW A HUGE BLOCK OF SOLID ALUMINUM 12 00:01:07,134 --> 00:01:10,435 GETS TRANSFORMED INTO A PAPER-THIN SHEET OF FOIL? 13 00:01:14,942 --> 00:01:16,941 THE MANUFACTURE OF ALUMINUM FOIL 14 00:01:16,944 --> 00:01:19,076 REQUIRES THE REPEATED THINNING OUT 15 00:01:19,079 --> 00:01:20,811 OF A LARGE BLOCK OF ALUMINUM. 16 00:01:20,814 --> 00:01:23,948 WE BEGIN BY MELTING INGOTS OF 100%-PURE ALUMINUM 17 00:01:23,951 --> 00:01:25,816 IN A NATURAL-GAS FURNACE. 18 00:01:25,819 --> 00:01:27,885 THESE INGOTS, CALLED "PIGS," 19 00:01:27,888 --> 00:01:31,555 ARE ESSENTIAL IN ALLOYS WITH ZINC, TITANIUM, AND SILICA. 20 00:01:31,558 --> 00:01:35,159 IT TAKES 3 TO 8 HOURS TO MELT 30 TONS OF ALUMINUM 21 00:01:35,162 --> 00:01:37,027 IN THIS REMELTING FURNACE, 22 00:01:37,030 --> 00:01:42,099 WHICH OPERATES AT 1,380 DEGREES FAHRENHEIT. 23 00:01:42,102 --> 00:01:44,368 THE FUSION TEMPERATURE OF ALUMINUM 24 00:01:44,371 --> 00:01:47,505 IS 1,220 DEGREES FAHRENHEIT. 25 00:01:47,508 --> 00:01:50,240 A PORTION OF ALUMINUM IS POURED INTO THIS SMALL MOLD 26 00:01:50,243 --> 00:01:51,175 TO MAKE A SAMPLE. 27 00:01:51,178 --> 00:01:53,043 SOLIDIFYING IN JUST SECONDS, 28 00:01:53,046 --> 00:01:55,780 THE SAMPLE ALLOWS FOR TESTING TO VERIFY THE CONTENTS 29 00:01:55,783 --> 00:01:58,049 OF THE PREPARED ALLOY. 30 00:01:58,052 --> 00:02:00,985 MOLTEN ALUMINUM RUNS IN A MOVABLE TROUGH 31 00:02:00,988 --> 00:02:04,722 LOCATED ABOVE THE TAPPING WELL. 32 00:02:04,725 --> 00:02:06,924 AT THIS STAGE, IMPURITIES ARE FILTERED OUT 33 00:02:06,927 --> 00:02:09,160 IN SPECIAL RECEPTACLES. 34 00:02:11,866 --> 00:02:13,731 THE MOLDS ARE COOLED WITH WATER 35 00:02:13,734 --> 00:02:16,801 TO ACCELERATE THE SOLIDIFICATION OF THE MOLTEN ALUMINUM. 36 00:02:16,804 --> 00:02:21,005 INGOTS ARE UNMOLDED AND ARE READY FOR MILLING. 37 00:02:21,008 --> 00:02:24,274 EACH INGOT IS MASSIVE, MEASURING 14 FEET IN LENGTH, 38 00:02:24,277 --> 00:02:28,345 5 FEET IN WIDTH, AND 18 INCHES THICK. 39 00:02:28,348 --> 00:02:30,815 IT WEIGHS A WHOPPING 8 TONS, 40 00:02:30,818 --> 00:02:33,217 SO IT HAS TO BE HANDLED BY OVERHEAD CRANES 41 00:02:33,220 --> 00:02:37,087 AND PLACED ON SPECIAL PLATES. 42 00:02:37,090 --> 00:02:39,489 THIS CRUST-REMOVING MACHINE 43 00:02:39,492 --> 00:02:42,226 REMOVES 1/10 OF AN INCH OF THE INGOT'S THICKNESS. 44 00:02:42,229 --> 00:02:43,895 IMPURITIES ARE ELIMINATED 45 00:02:43,898 --> 00:02:46,297 TO ACHIEVE A PERFECTLY SMOOTH FINISH. 46 00:02:46,300 --> 00:02:49,500 ALL TRACES OF THE LIQUID USED TO COOL THE DECRUSTING KNIVES 47 00:02:49,503 --> 00:02:51,769 HAVE TO BE ELIMINATED. 48 00:02:51,772 --> 00:02:54,571 THE MANY STEPS IN THE THINNING OF THE INGOT BEGIN. 49 00:02:54,574 --> 00:02:56,974 FIRST, THE ALUMINUM BLOCK IS CRUSHED 50 00:02:56,977 --> 00:02:58,843 BY THE HOT MILL ROLLERS. 51 00:03:02,516 --> 00:03:04,715 TEMPERATURES IN THE ROLLERS 52 00:03:04,718 --> 00:03:08,419 ARE BETWEEN 850 AND 1,000 DEGREES FAHRENHEIT. 53 00:03:08,422 --> 00:03:11,055 PRESSURE ON THE INGOT IS CONTINUALLY VERIFIED 54 00:03:11,058 --> 00:03:12,556 BY A TECHNICIAN. 55 00:03:12,559 --> 00:03:16,194 IF THE PRESSURE IS TOO GREAT, THE TECHNICIAN WILL LOWER IT. 56 00:03:16,197 --> 00:03:17,861 THE HEAT IS SO HIGH 57 00:03:17,864 --> 00:03:20,931 THAT THE INGOT RISKS STICKING TO THE MILL'S ROLLER. 58 00:03:20,934 --> 00:03:23,601 TO PREVENT THIS, EVERYTHING IS COOLED WITH A LIQUID 59 00:03:23,604 --> 00:03:27,004 THAT'S 95% WATER AND 5% OIL. 60 00:03:33,947 --> 00:03:36,747 STARTING FROM A THICKNESS OF 18 INCHES, 61 00:03:36,750 --> 00:03:40,083 THE INGOT BECOMES INCREASINGLY THINNER WITH EACH PASS-THROUGH. 62 00:03:40,086 --> 00:03:41,752 DEPENDING ON REQUIREMENTS, 63 00:03:41,755 --> 00:03:46,290 THE INGOT WILL GO THROUGH THE MACHINE BETWEEN 12 AND 16 TIMES. 64 00:03:46,293 --> 00:03:49,459 THE INGOT NOW MEASURES ABOUT 3 INCHES IN THICKNESS. 65 00:03:49,462 --> 00:03:53,231 IT HAS TO GET DOWN TO JUST 2/10 OF AN INCH. 66 00:03:57,837 --> 00:04:01,172 AT THIS STAGE, THE INGOT IS ABOUT 2 INCHES THICK 67 00:04:01,175 --> 00:04:03,907 AND MEASURES ALMOST 30 FEET IN LENGTH. 68 00:04:03,910 --> 00:04:08,379 THIS CONVEYOR TRANSPORTS THE PLATE DURING ITS MILLING STAGES. 69 00:04:16,523 --> 00:04:20,257 THE INGOT HAS BECOME A SHEET 2/10 OF AN INCH THICK. 70 00:04:20,260 --> 00:04:23,127 IT IS SUFFICIENTLY THIN TO PROCEED TO SPOOLING, 71 00:04:23,130 --> 00:04:24,795 WHERE IT SPOOLS ONTO ITSELF 72 00:04:24,798 --> 00:04:27,197 BEFORE BEING SENT TO THE COLD ROLLING MILL. 73 00:04:27,200 --> 00:04:30,334 THERE, ITS THICKNESS WILL BE REDUCED STILL FURTHER. 74 00:04:33,474 --> 00:04:36,874 THE ALUMINUM SHEET HAS BECOME VERY THIN NOW 75 00:04:36,877 --> 00:04:38,409 AND RISKS BEING BROKEN 76 00:04:38,412 --> 00:04:40,745 BY THE TENSION NEEDED FOR COLD ROLLING. 77 00:04:40,748 --> 00:04:43,748 SO THE SHEET IS DOUBLED TO AVOID THIS BREAKAGE. 78 00:04:43,751 --> 00:04:46,717 ONE FINAL REDUCTION IN THE MILL, 79 00:04:46,720 --> 00:04:48,685 AND THE SHEET WILL HAVE THE THICKNESS 80 00:04:48,688 --> 00:04:50,287 REQUIRED BY THE CUSTOMER. 81 00:04:50,290 --> 00:04:52,556 A LIQUID COOLANT IS USED TO PREVENT THE FOIL 82 00:04:52,559 --> 00:04:55,226 FROM STICKING TO THE ROLLERS. 83 00:04:55,229 --> 00:04:57,762 SINCE THE EDGES OF THE FOIL SHEET 84 00:04:57,765 --> 00:05:00,364 ARE LIGHTLY DAMAGED AND CRINKLED, 85 00:05:00,367 --> 00:05:04,201 A KNIFE REMOVES A STRIP 4/10 OF AN INCH WIDE. 86 00:05:07,841 --> 00:05:10,908 FINALLY, THE ROLL IS CUT TO THE DESIRED WIDTH, 87 00:05:10,911 --> 00:05:15,379 AND ONE HUGE INGOT HAS PRODUCED NEARLY 8 MILES OF FOIL. 88 00:05:27,194 --> 00:05:29,593 Narrator: IF YOU'VE EVER TRIED SNOWBOARDING, 89 00:05:29,596 --> 00:05:32,462 YOU'VE PROBABLY DISCOVERED THAT THOSE COOL MOVES 90 00:05:32,465 --> 00:05:36,667 AREN'T QUITE AS EASY AS THE PROS MAKE IT LOOK. 91 00:05:36,670 --> 00:05:40,204 LEARNING TO MANEUVER A SNOWBOARD IS A LONG AND INVOLVED PROCESS, 92 00:05:40,207 --> 00:05:41,938 AND IT'S MUCH THE SAME 93 00:05:41,941 --> 00:05:45,676 WHEN IT COMES TO MANUFACTURING THESE SURFBOARDS FOR SNOW. 94 00:05:51,084 --> 00:05:55,019 THE SNOWBOARD IS THE DELIGHT OF WINTER-SPORTS ENTHUSIASTS. 95 00:05:55,022 --> 00:05:57,755 ITS CORE IS MADE OF A THIN SHEET OF WOOD. 96 00:05:57,758 --> 00:05:59,556 VARIOUS KINDS OF WOODS ARE USED, 97 00:05:59,559 --> 00:06:02,193 DEPENDING ON THE TYPE OF BOARD BEING MADE. 98 00:06:05,966 --> 00:06:08,966 BINDINGS HAVE TO BE FIRMLY ATTACHED TO THE BOARD. 99 00:06:08,969 --> 00:06:10,701 HOLES ARE DRILLED FOR INSERTS, 100 00:06:10,704 --> 00:06:12,770 TO WHICH BINDINGS WILL BE SECURED. 101 00:06:12,773 --> 00:06:17,575 A TEMPLATE ALLOWS THE HOLES TO BE PRECISELY DRILLED. 102 00:06:17,578 --> 00:06:21,378 PLANING REDUCES THE BOARD TO THE REQUIRED THICKNESS. 103 00:06:21,381 --> 00:06:24,949 A THICK BOARD IS OBVIOUSLY MORE RIGID THAN A THIN ONE. 104 00:06:30,557 --> 00:06:34,325 A SHAPING PROCEDURE REFINES THE BOARD'S CONTOURS. 105 00:06:34,328 --> 00:06:37,861 AT THIS POINT, THE BOARD IS STILL PERFECTLY FLAT 106 00:06:37,864 --> 00:06:40,030 WITH NO CURVATURE. 107 00:06:44,003 --> 00:06:48,305 THE BOARDS ARE THEN STORED UPRIGHT TO AWAIT THE NEXT STEP. 108 00:06:54,014 --> 00:06:57,281 NOW THEY MUST SECURE THE ALUMINUM INSERTS, 109 00:06:57,284 --> 00:07:00,951 WHICH WILL BE EMBEDDED IN THE WOOD. 110 00:07:00,954 --> 00:07:02,819 THIS THIN SHEET OF FIBERGLASS 111 00:07:02,822 --> 00:07:05,489 WILL CREATE BETTER SUPPORT FOR THE INSERTS. 112 00:07:05,492 --> 00:07:07,892 THEREFORE, THEY WILL BE MORE SOLID. 113 00:07:13,366 --> 00:07:15,632 TO MAKE WORKING ON IT EASIER, 114 00:07:15,635 --> 00:07:19,102 THE BOARD IS SECURELY HELD IN PLACE BY CLAMPS. 115 00:07:19,105 --> 00:07:22,105 EPOXY, AN EXTREMELY STRONG ADHESIVE 116 00:07:22,108 --> 00:07:24,508 OFTEN USED WITH COMPOSITE MATERIALS, 117 00:07:24,511 --> 00:07:27,444 IS APPLIED TO THE FIBERGLASS AT ROOM TEMPERATURE. 118 00:07:27,447 --> 00:07:30,581 IT IS ESSENTIAL TO REMOVE ANY EXCESS EPOXY, 119 00:07:30,584 --> 00:07:32,382 AS WELL AS ELIMINATE ALL AIR BUBBLES 120 00:07:32,385 --> 00:07:34,885 SO THERE WILL BE A GOOD ADHERENCE. 121 00:07:38,725 --> 00:07:40,925 AS FOR THE TOP PART OF THE BOARD, 122 00:07:40,928 --> 00:07:46,063 IT'S MADE OF A RESISTANT PLASTIC APPLIED BY SILK-SCREENING. 123 00:07:46,066 --> 00:07:50,668 IN SILK-SCREENING, INK IS SPREAD BY THIS LITTLE SQUEEGEE. 124 00:07:50,671 --> 00:07:53,003 THIS APPLICATION IS CALLED A PASS. 125 00:07:53,006 --> 00:07:55,606 COLORS HAVE TO BE APPLIED ONE AT A TIME. 126 00:07:55,609 --> 00:07:59,210 THE INKS MUST DRY FOR SEVERAL HOURS BETWEEN EACH COAT. 127 00:08:01,948 --> 00:08:04,281 NOW THE BOARD MUST BE CURVED. 128 00:08:04,284 --> 00:08:06,150 A COVER IS PLACED ON THE MOLD. 129 00:08:06,153 --> 00:08:07,751 WHEN THE MOLD IS CLOSED, 130 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. 132 00:08:16,964 --> 00:08:18,896 THE BOARD COMES OUT OF THE MOLD, 133 00:08:18,899 --> 00:08:23,100 AND ANY EXCESS EPOXY AND WOOD ARE REMOVED BY A BAND SAW. 134 00:08:23,103 --> 00:08:25,035 TO ACHIEVE A PERFECT CUT, 135 00:08:25,038 --> 00:08:27,838 THE SAW BLADE IS CHANGED EVERY 50 BOARDS. 136 00:08:27,841 --> 00:08:31,475 IT'S HIGHLY PRECISE WORK AND TOTALLY MANUAL. 137 00:08:45,459 --> 00:08:48,859 THEY APPLY, AGAIN BY SILK-SCREENING, ANOTHER COAT, 138 00:08:48,862 --> 00:08:50,461 THEN ANOTHER COLOR. 139 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. 141 00:09:10,416 --> 00:09:13,484 A PROTECTING VARNISH FLOWS AS A THIN CURTAIN. 142 00:09:13,487 --> 00:09:15,753 THE BOARD PASSES BENEATH THIS CURTAIN 143 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 146 00:09:31,705 --> 00:09:35,539 TO LOCATE THE INSERTS INSTALLED AT THE BEGINNING OF PRODUCTION. 147 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 149 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. 151 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 153 00:09:55,528 --> 00:09:58,262 ARE WELL-ADHERED TO ONE ANOTHER. 154 00:09:58,265 --> 00:10:01,665 CERTAIN BOARDS GET AN ENGRAVED ALUMINUM INSERT -- 155 00:10:01,668 --> 00:10:04,201 A LUXURY TOUCH. 156 00:10:04,204 --> 00:10:07,137 THE BOARD IS NOW READY FOR ACTION. 157 00:10:07,140 --> 00:10:10,874 THIS FACILITY TURNS OUT OVER 500 SNOWBOARDS PER DAY 158 00:10:10,877 --> 00:10:12,977 IN 30 DIFFERENT MODELS. 159 00:10:21,221 --> 00:10:23,887 Narrator: PEOPLE WHO HAVE DEFECTIVE VISION 160 00:10:23,890 --> 00:10:25,422 CAN ALWAYS WEAR GLASSES, 161 00:10:25,425 --> 00:10:29,226 BUT IN MANY CASES, THERE'S A LESS-NOTICEABLE ALTERNATIVE. 162 00:10:29,229 --> 00:10:31,961 CONTACT LENSES CORRECT FAULTY VISION 163 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 165 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. 169 00:10:55,789 --> 00:10:58,122 THESE SMALL polyHEMA DISKS ARE USED 170 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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