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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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Narrator:
Today on "How it's made"...
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Hydroponic lettuce,
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Construction wood,
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Recycling,
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And fishing flies.
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Bet you thought
The only way to grow lettuce
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Was in a garden.
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Well, vegetables
Don't necessarily need soil.
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They can also grow in water,
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Provided it contains the proper
Nutrients and fertilizers.
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That's called hydroponics.
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This method of growing
Hydroponic lettuce
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Is called "Deep pool
Floating raft technology."
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It sounds pretty complicated,
But it's really quite simple,
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And it all starts
In the germination area
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With lettuce seeds.
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To plant them,
Workers use a steel tray
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Connected to a vacuum hose.
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The tray has 276 holes,
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And a vacuum sucks a seed
Into each one.
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Next they take a foam block
With corresponding holes
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Called an oasis
And position it into the tray.
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A quick flip deposits a seed
Into each hole of the oasis.
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The seeds are coated in clay.
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Clay holds in moisture
To nourish the seed
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But also breaks apart easily
To let the seed sprout.
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On the way to the greenhouse,
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The seeds get
Their first watering.
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Then workers set them afloat.
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The pool of water
Is about 12 inches deep.
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Technicians continuously monitor
And manipulate
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Its levels of oxygen
And fertilizer.
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That's the key
To hydroponic growing.
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The water is never discarded,
Just topped off
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To replace what the plants drink
And what evaporates.
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On the first day,
They water the seeds frequently.
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Within a couple of days,
The seedlings start to appear.
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They water and fertilize them.
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By about the fourth day,
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There's some significant
Sprouting action.
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Again, they water
And fertilize the plants.
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The first leaves emerge on about
The seventh day in the summer,
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On about the 11th day
In the winter.
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The winter growth rate is slower
Because there's less sun.
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At this point,
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It's time for the first
In a series of transplants.
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Workers transfer the lettuces
From the 276-plant oasis
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To a styrofoam board
That holds more plants -- 288.
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They set the boards afloat
In the nursery zone.
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At about the 13-day mark
In the summer --
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The 20-day mark in the winter --
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Transplant number 2
Takes place, this time
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To a less crowded
Styrofoam board
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That holds just 72 plants.
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This gives the plants more light
And more room to grow.
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Workers use a hook
To avoid damaging the roots.
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A plant needs healthy roots
To absorb water and nutrients.
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The last transplant happens
On about the 26th day
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In the summer,
The 45th day in the winter.
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Now the lettuces go from
The 72-plant board
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To a board that holds just 18.
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By now the plants
Have long roots,
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So they're harder to manipulate.
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The lettuces
Go into the production zone,
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The last move before harvesting.
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These pools are bigger,
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So automatic machines
Move the boards around.
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This hydroponic system
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Produces 500 plants
Per square yard,
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Almost five times the yield
Of field-grown lettuce,
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And it's safer, too.
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There's no need here
For pesticides or fungicides,
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And because it's all indoors,
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Fertilizer can't
Contaminate the environment.
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By about the 45th day
In the summer,
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The 75th day in the winter,
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The lettuces are finally
Ready for harvesting.
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Workers cut off
The yellowed leaves at the base,
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Then either cut off the roots
Or wrap them around the stem,
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Depending on
How this crop will be sold.
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Then they vacuum-cool each
Lettuce for longer shelf life.
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Narrator:
An american engineer
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Has invented
A self-mending plastic
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To use for components
That vibrate and weaken.
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When the plastic tears, tiny
Capsules inside it also tear,
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Releasing a liquid,
Like blood from a cut.
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Then a catalyzing agent
Also in the plastic
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Seals the tear like a scar.
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There was a time
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When if you wanted to
Build something out of wood,
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You had to pick up an ax
And go chop down a tree.
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Thankfully for city dwellers,
All it takes today
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Is a trip to your
Local home-improvement center
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To buy 2x4's, 2x10's --
You name it.
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They start with logs
Cut from spruce or fir trees.
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Turning them into construction
Wood isn't that complicated.
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First they soak the logs
For about 20 minutes.
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This removes the mud
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And softens the bark
To make it easier to remove.
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Next the logs
Go through the debarker,
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A machine with a rotor
That shaves off the bark.
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The rotor has six sharp blades
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That take just 10 seconds
To shave a log bare.
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00:07:07,068 --> 00:07:08,586
In the filing room,
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They regularly sharpen
And inspect the saw blades
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They'll use
To cut the shaved logs,
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Straightening them
Back into shape when necessary.
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In this sawmill,
There are two production lines.
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The wider logs
Go through this saw.
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The worker at the controls
Uses a laser
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To help him position
And reposition each log
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As he runs it through the saw
Several times
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To cut it into as many
4x10-inch pieces as possible.
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An average log usually yields
About seven or eight pieces.
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The narrower logs
Go through a different saw.
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This saw first cuts a board
Off each side,
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00:08:26,896 --> 00:08:30,034
Then sends what's left
Of the log on to another saw.
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00:08:36,965 --> 00:08:39,517
The 4x10's on
The first production line
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Go for a second cut
Called the resaw.
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They're cut in half into 2x10's.
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The logs on the second
Production line end up here
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In what's called
The canter-bull machine.
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It has eight
Adjustable circular saws
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That can cut the log
Into various sizes of wood
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Anywhere from 2x3's to 2x8's,
Depending on the log's diameter.
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Both production lines feed to
Machines that smooth the edges
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And trim off any defects
That can effect the strength
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Or resistance of the wood.
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Then an automated sorter
Drops the wood into bins
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According to their size.
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Each bin then feeds
The stacking machine.
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00:10:15,586 --> 00:10:18,689
From here they'll put the wood
Into a kiln to be dried
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00:10:18,689 --> 00:10:21,379
To about 15% humidity.
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Then they'll grade the pieces
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And ship them to a lumberyard
Or home-improvement store.
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00:10:48,137 --> 00:10:50,827
Narrator: if you care about
Our environment,
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00:10:50,827 --> 00:10:53,586
Chances are you separate
Your recyclable waste
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00:10:53,586 --> 00:10:55,103
From your other garbage
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And either take it
To a recycling center
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Or put it out at the curb
For pickup.
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But have you ever wondered
Where it goes from there?
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00:11:11,137 --> 00:11:12,724
When the truck arrives,
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00:11:12,724 --> 00:11:15,551
Your recyclables go through
Their first sorting.
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00:11:18,689 --> 00:11:23,344
The worker puts paper and boxes
In one receptacle,
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00:11:23,344 --> 00:11:26,379
Glass, plastics, and metals
In another.
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00:11:28,931 --> 00:11:30,689
At the sorting plant
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The truck dumps each receptacle
Into a separate area.
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00:11:35,034 --> 00:11:38,620
Then it's on to separate
Conveyor belts for more sorting.
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00:11:38,620 --> 00:11:40,413
On the paper-and-boxes line,
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Workers first remove
Any plastic, metal, or glass
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That got there by mistake.
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00:11:45,000 --> 00:11:48,689
Then they sort what's left
Into three categories --
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First, corrugated cardboard --
What brown boxes are made of --
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Second, newsprint,
And third, mixed-fiber paper
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Such as cereal boxes, envelopes,
And greeting cards.
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00:12:00,310 --> 00:12:03,655
On the glass, metal,
And plastics conveyor belt,
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Workers first remove
The big bulky items
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Such as gallon-sized containers.
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A jumbo magnet
Picks up everything metal
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Except for aluminum,
Which isn't magnetic.
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Workers then sort milk
And juice cartons to one area,
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00:12:17,793 --> 00:12:19,206
Aluminum to another.
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00:12:19,206 --> 00:12:22,241
They separate plastics
Into three categories,
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Glass into two --
Clear and colored.
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00:12:24,620 --> 00:12:26,586
Once everything's
Been separated,
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Each category goes into a baler,
Which compacts it...
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00:12:34,000 --> 00:12:38,620
...Then binds it with wire
Like a giant bale of hay.
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00:12:38,620 --> 00:12:40,586
Then it's off to the warehouse
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00:12:40,586 --> 00:12:42,965
Until they're sold
To a recycler.
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At the recycling plant, they
Cut open a bale of plastics,
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Then load everything
Onto the conveyor belt.
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00:12:57,137 --> 00:12:59,344
The plastics
Pass through magnets
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To remove any metal
That might have slipped through.
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Then it's into the shredder.
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00:13:05,620 --> 00:13:08,551
It takes the shredder
Just an hour
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00:13:08,551 --> 00:13:10,896
To shred two tons of plastic.
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All those containers
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Are now tiny,
Little plastic flakes.
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Next, cleaning by friction
And water.
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Any remaining glass
Or other contaminants
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Now sink to the bottom
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While the lighter plastic flakes
Float to the top.
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The dirty water
Will be chemically filtered
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And used again.
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They dry the flakes by hot air,
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00:13:53,379 --> 00:13:56,379
Then put them into silos
To be compacted.
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00:14:00,206 --> 00:14:05,344
Inside the compactor,
It's 320 degrees fahrenheit.
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00:14:05,344 --> 00:14:07,862
The heat partially melts
The plastic,
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Fusing the pieces
As they compact.
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00:14:10,413 --> 00:14:11,689
The flakes
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00:14:11,689 --> 00:14:14,034
Go through the compactor's
Perforated inner drum,
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00:14:14,034 --> 00:14:16,000
Much like a pasta press...
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00:14:18,103 --> 00:14:21,137
...And come out
Looking a bit like macaroni.
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00:14:33,931 --> 00:14:37,655
They're now officially recycled
Plastic
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00:14:37,655 --> 00:14:40,275
In raw-material form.
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00:14:40,275 --> 00:14:43,551
Next they're melted,
Pressed through a screen,
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00:14:43,551 --> 00:14:46,275
Then cut into pellets
1/8 inch long.
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00:14:46,275 --> 00:14:50,379
They drop into water to cool,
Then go into a dryer.
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00:14:53,655 --> 00:14:55,793
Factories buy these pellets
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00:14:55,793 --> 00:14:58,896
And use them
To make plastic products.
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00:15:03,034 --> 00:15:06,689
This recycling plant takes
The plastic flakes it produces
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00:15:06,689 --> 00:15:08,724
To mold warehouse pallets.
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00:15:08,724 --> 00:15:11,896
The mold goes in
At 446 degrees fahrenheit
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00:15:11,896 --> 00:15:15,000
For just about
Seven or eight minutes.
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00:15:15,000 --> 00:15:19,586
It takes just 2 1/2 minutes
To mold a recycling bin...
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00:15:22,724 --> 00:15:25,137
...Something to help ensure
A steady supply
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00:15:25,137 --> 00:15:29,758
Of what the factory needs to
Keep producing recycled plastic.
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00:15:41,000 --> 00:15:44,275
Narrator: still moping
About the one that got away?
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00:15:44,275 --> 00:15:47,275
Well, maybe you just
Didn't use the right fly.
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00:15:47,275 --> 00:15:50,137
Fly-fishing is one of
The most challenging types
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00:15:50,137 --> 00:15:51,344
Of sport fishing,
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00:15:51,344 --> 00:15:53,896
And tying a good fly
To the end of your line
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00:15:53,896 --> 00:15:56,068
Can make all the difference.
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00:16:01,965 --> 00:16:06,655
In about 300 a.D., people began
Decorating their fishing hooks
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00:16:06,655 --> 00:16:09,000
To mimic insects and small fish.
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00:16:10,965 --> 00:16:13,931
The macedonians were known
To use a fishing fly
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00:16:13,931 --> 00:16:16,862
Made of red yarn
And rooster feathers.
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00:16:18,517 --> 00:16:21,793
Today, with so many synthetic
Materials available,
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00:16:21,793 --> 00:16:25,241
The design possibilities
Are endless.
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00:16:25,241 --> 00:16:26,931
But every fishing fly
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00:16:26,931 --> 00:16:29,965
Is still based on that
Centuries-old technique
224
00:16:29,965 --> 00:16:33,931
Of attaching bird feathers
Or animal hairs to a hook.
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00:16:43,965 --> 00:16:46,931
The whole idea
Is to trick the fish.
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00:16:46,931 --> 00:16:50,758
The fly imitates
An aquatic insect or tiny fish,
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00:16:50,758 --> 00:16:53,793
Something the fish you're
Trying to catch likes to eat.
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00:16:53,793 --> 00:16:57,620
The flymaker starts
By placing a hook in a vise.
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00:17:00,000 --> 00:17:03,275
Using a tool
Called a bobbin holder,
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00:17:03,275 --> 00:17:05,724
He winds a waxed nylon thread
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00:17:05,724 --> 00:17:08,620
Carefully and tightly
Around the shank of the hook...
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00:17:08,620 --> 00:17:11,379
Then cuts off the excess.
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00:17:13,448 --> 00:17:16,827
This fly will simulate a
Mothlike insect called a caddis,
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00:17:16,827 --> 00:17:18,724
A primary food for trout --
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00:17:18,724 --> 00:17:21,965
A caddis in the pupal stage
Of its life cycle,
236
00:17:21,965 --> 00:17:25,310
Just before it
Transforms into an adult.
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00:17:26,551 --> 00:17:29,793
The flymaker first attaches
A special synthetic yarn
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00:17:29,793 --> 00:17:31,344
To create the tail.
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00:17:39,896 --> 00:17:43,068
He secures it along
The middle of the hook.
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00:17:54,034 --> 00:17:57,482
He then takes another synthetic
Material called dubbing
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00:17:57,482 --> 00:18:00,172
To create the body.
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00:18:00,172 --> 00:18:04,172
He spins the dubbing between
His fingers onto the thread.
243
00:18:04,172 --> 00:18:07,000
The wax on the thread
Helps it adhere.
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00:18:11,034 --> 00:18:15,137
He winds the dubbing over the
Base of yarn to form the body.
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00:18:26,172 --> 00:18:29,068
Then he folds some yarn
Over the dubbing
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00:18:29,068 --> 00:18:31,862
And attaches it
With more nylon thread.
247
00:18:36,896 --> 00:18:39,482
Then he cuts off the excess.
248
00:18:43,137 --> 00:18:46,827
Good fishing flies not only
Look like the real thing,
249
00:18:46,827 --> 00:18:51,172
They also act like it, mimicking
The insect's natural movements.
250
00:18:51,172 --> 00:18:55,000
When a caddis pupa is ready
To transform into an adult,
251
00:18:55,000 --> 00:18:59,137
It swims to the surface of the
Water, then deploys its wings.
252
00:18:59,137 --> 00:19:01,448
The shimmering yarn
On this fake caddis
253
00:19:01,448 --> 00:19:03,758
Will give the illusion
Of the air bubbles
254
00:19:03,758 --> 00:19:07,551
This voyage to the surface
Creates.
255
00:19:07,551 --> 00:19:09,034
To simulate the wings,
256
00:19:09,034 --> 00:19:12,551
The flymaker uses dubbing
Made of deer fur.
257
00:19:12,551 --> 00:19:16,310
He cuts off the long, coarse
Hairs known as guard hairs...
258
00:19:22,689 --> 00:19:25,241
...Then places them
Into a device
259
00:19:25,241 --> 00:19:27,724
Called a hair stacker.
260
00:19:27,724 --> 00:19:29,896
He shakes it...
261
00:19:32,931 --> 00:19:35,931
...Turns it to the side...
262
00:19:35,931 --> 00:19:38,068
Then opens it up.
263
00:19:38,068 --> 00:19:41,275
All the hairs
Are now evenly aligned.
264
00:19:48,206 --> 00:19:52,241
He measures the length he needs
To create the fly's wings.
265
00:19:57,655 --> 00:19:59,103
Then he attaches it,
266
00:19:59,103 --> 00:20:01,896
Leaving a portion sticking out
The front
267
00:20:01,896 --> 00:20:04,758
To form the insect's head.
268
00:20:04,758 --> 00:20:08,379
Next he uses a tool
Called a whip finisher
269
00:20:08,379 --> 00:20:12,103
To tie a sturdy knot
Made of several loops.
270
00:20:14,620 --> 00:20:16,827
This caddis fly imposter
271
00:20:16,827 --> 00:20:19,379
Is now ready
To trick some trout.
272
00:20:22,275 --> 00:20:24,862
There are thousands of styles
Of flies.
273
00:20:24,862 --> 00:20:26,413
You choose which to use
274
00:20:26,413 --> 00:20:29,965
According to what fish
Are feeding on at the moment.
275
00:20:33,344 --> 00:20:37,172
Flymakers use many types of
Natural and synthetic dubbings
276
00:20:37,172 --> 00:20:40,241
To form and decorate
Their flies --
277
00:20:40,241 --> 00:20:42,620
Feathers, animal hairs, metals,
278
00:20:42,620 --> 00:20:45,931
And plastics often dyed
Brilliant colors.
279
00:20:56,896 --> 00:21:00,827
Tying a great fly won't always
Snag you the catch of the day,
280
00:21:00,827 --> 00:21:02,620
But if you maneuver the fly
281
00:21:02,620 --> 00:21:05,379
To make realistic movements
In the water,
282
00:21:05,379 --> 00:21:08,620
The fish will buy it --
Hook, line, and sinker.
283
00:21:15,172 --> 00:21:17,586
If you have any comments
About the show
284
00:21:17,586 --> 00:21:20,068
Or if you'd like to suggest
Topics for future shows,
285
00:21:20,068 --> 00:21:22,068
Drop us a line at...
22933
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