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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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Pre-inked stamps...
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...Cranberries...
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...Cotton yarn...
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...And road signs.
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"Paid," "Rush," "Approved"
Are some of the terms
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Routinely stamped
Onto documents.
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Professionals,
Such as engineers,
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Have their official stamps, too.
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00:01:02,965 --> 00:01:06,103
For years, you had to
Dab the stamp on an ink pad
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00:01:06,206 --> 00:01:07,517
For each impression.
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00:01:07,620 --> 00:01:11,724
Nowadays you can get stamps
With the ink built right in.
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00:01:15,724 --> 00:01:17,965
The process begins with a design
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That either the stamp company
Or its customer creates
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00:01:20,827 --> 00:01:23,379
With standard graphics software.
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00:01:23,482 --> 00:01:25,965
They print the stamp design
Onto paper
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00:01:26,068 --> 00:01:29,103
Using a high-quality
Laser printer,
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00:01:29,206 --> 00:01:32,551
Then place the printout
Under an imaging camera.
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They feed in a blank sheet
Of negative film...
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...Then photograph the printout.
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30 seconds later,
Out comes the negative.
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The design is light,
The background dark.
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Now they can begin
Making the mold for the stamp.
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00:02:01,724 --> 00:02:03,068
They apply the negative
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00:02:03,172 --> 00:02:05,344
To a plate
Of light-sensitive polymer --
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00:02:05,448 --> 00:02:07,379
A plastic-like material.
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00:02:07,482 --> 00:02:11,517
Then they vacuum out the air
To prevent defects in the mold.
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00:02:15,517 --> 00:02:18,620
Then they expose the polymer
Plate to ultraviolet light
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For approximately three minutes.
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The u.V. Penetrates through the
Light part of the negative --
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The stamp design --
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And hardens
The polymer underneath.
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00:02:29,034 --> 00:02:30,827
The rest of the polymer
Is shielded
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By the dark portions
Of the negative,
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So it doesn't change.
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A wash cycle then scrubs away
This unhardened polymer,
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Leaving behind a perfect mold
In the shape of the stamp.
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Now they cover the mold
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With a sheet of synthetic resin
Called bakelite
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And put it into a machine
Called a vulcanizer.
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The machine heats the bakelite
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To just over
309 degrees fahrenheit,
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Then forces it into the mold
Using 2 to 3 tons of pressure.
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After four minutes,
The bakelite stamp is ready.
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To be more productive,
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The factory actually molds
Several stamps at a time.
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Next comes the built-in ink.
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They screw the bakelite stamp
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Into what's called
The pre-ink mold,
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Then pour in a mixture
Of ink and gel.
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They cover the mold
And vacuum out the air,
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A process that takes 12 minutes.
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The mold then goes into
A heat press for 17 minutes.
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The press applies 2 tons
Of pressure to expel excess ink
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And heats the ink gel
To about 260 degrees fahrenheit,
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00:03:58,034 --> 00:04:02,241
Transforming it to roughly the
Consistency of a marshmallow.
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So it won't overcook,
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The mold goes onto a special
Cooling table for 12 minutes.
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Next, it's set out to cool
For another 45 minutes,
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This time on newspapers,
Which soak up more excess ink.
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Finally, they wrap the mold
In paper towels and newspapers
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And vacuum out
The last drops of excess ink.
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Then they quickly seal the back
Of the stamp to lock the ink in.
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Now they can cut apart
The individual stamps.
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They glue the stamps by hand
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Onto the base
Of the stamp handles.
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Before they're shipped out
To the customer,
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All stamps undergo
A quality-control check
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To make sure they'll leave
A lasting impression.
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Narrator: cranberries are one
Of just a handful of fruits
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That are native
To north america.
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Before the europeans arrived,
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The indians used them
For food and medicine.
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The cranberry vine
Is well-suited
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To a harsher climate.
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It thrives in low temperatures
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And loves acidic soil
That's scarce in nutrients.
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Cranberries are ripe for
The picking in late september.
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At harvesttime,
Farmers flood their fields
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To make the cranberries
Float to the surface.
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Then they use a machine
Called a beater.
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It generates
Underwater turbulence,
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Pulling the berries
Off the vines.
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The beater is suspended
From a mobile bridge
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That's computer-guided
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To systematically work its way
Through the entire field.
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The beater cuts a swath about
23 feet wide with each sweep.
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Workers move
The floating cranberries
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To one corner of the field...
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...Where a pump transfers them
To a waiting truck.
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Along the way, the berries get
A preliminary rinsing
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To remove branches and leaves.
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At the factory,
The truck unloads its cargo.
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The cranberries travel
Along the water canal
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And onto a conveyor belt,
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Then through a cleaning station,
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Where workers use brushes
And water jets
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To get rid of any remaining
Leaves and branches.
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Then they dump the cranberries
Into large bins
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To be frozen
For up to several months.
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To produce cranberry juice,
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They defrost the frozen berries
In hot water,
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Then mash them --
Skins, seeds, and all --
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Into a puree.
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00:08:18,482 --> 00:08:22,068
They add special enzymes to
Break up the pectin molecules,
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00:08:22,172 --> 00:08:26,827
Making the puree less viscous
And therefore easier to press.
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00:08:26,931 --> 00:08:31,206
The press processes almost
9 tons of puree at a time.
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That's the weight
Of 1 1/2 elephants.
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It takes three to four pressing
Cycles to extract all the juice.
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The juice then goes through a
Sophisticated filtration system.
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The 216 filters
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Remove any plant particles or
Bacteria larger than one micron.
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A micron is about 25,000 times
Smaller than an inch.
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Then they evaporate the water
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Until the juice
Is 10 times more concentrated.
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Cranberries not destined
For juice
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Go through a grading process.
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Undersized berries drop down
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Through the holes
Of a giant sifter.
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00:09:12,724 --> 00:09:15,551
The bigger cranberries move on
To the grading table,
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00:09:15,655 --> 00:09:18,689
Where workers remove any
That are substandard.
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An electronic sorter
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00:09:28,862 --> 00:09:31,896
Then scans the remaining
Cranberries for color,
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Signaling an air gun
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To blow any reject berries
Off the production line.
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The rest move on
To the packaging department
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00:09:40,103 --> 00:09:43,241
Or continue down the line
To be dried.
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Cranberries destined for drying
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Are automatically seeded,
Cut in half, and pressed,
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Then soaked in a sugar-and-water
Solution to make them sweeter.
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The side-to-side motion
Of the conveyor belt
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Spreads the berries thinly
So that they'll dry evenly.
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00:10:02,310 --> 00:10:05,137
The hot-air dryer subjects them
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To temperatures varying from
86 to 176 degrees fahrenheit.
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After about three hours,
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The cranberries come out
Looking like this.
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00:10:23,448 --> 00:10:27,172
As you sip your cranberry tea,
Ponder this --
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00:10:27,275 --> 00:10:29,827
Cranberries are a source
Of potassium
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And vitamins "A" and "C,"
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00:10:31,620 --> 00:10:33,103
And drinking cranberry juice
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Can prevent and treat
Urinary tract infections.
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Narrator: twisting plant
Or animal fibers into yarn
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00:10:50,068 --> 00:10:52,068
Dates back to ancient times,
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00:10:52,172 --> 00:10:55,758
When people fashioned primitive
Spindles out of sticks.
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00:10:55,862 --> 00:10:57,310
Around 500 b.C.,
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00:10:57,413 --> 00:10:59,758
The spinning wheel was born
In india.
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00:10:59,862 --> 00:11:02,793
Today's factories have fully
Automated spinning machines
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00:11:02,896 --> 00:11:06,689
That work on the same principle
As the spinning wheel.
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This is a 2-ply commercial yarn,
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00:11:11,620 --> 00:11:14,103
The kind factories use
To weave fabric
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For making jeans and tops.
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00:11:16,620 --> 00:11:20,724
It's made from large bales
Of raw cotton.
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00:11:20,827 --> 00:11:22,689
Cotton comes from a plant,
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00:11:22,793 --> 00:11:24,724
So, naturally,
Some leaves and stems
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00:11:24,827 --> 00:11:28,034
Are mixed in
With the cotton fibers.
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00:11:28,137 --> 00:11:31,793
To remove them, the first
Machine passes over the bales
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00:11:31,896 --> 00:11:35,758
And removes a layer of cotton
.2 of an inch wide...
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00:11:38,689 --> 00:11:40,724
...Then sends it
Through a duct system
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00:11:40,827 --> 00:11:42,896
To the blending
And cleaning machine.
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00:11:44,655 --> 00:11:49,034
The machine processes
Half a ton of cotton per hour.
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00:11:49,137 --> 00:11:52,379
The cotton comes out
Evenly blended and cleaner,
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00:11:52,482 --> 00:11:54,448
But still not clean enough,
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00:11:54,551 --> 00:11:57,068
So it goes into
A second cleaning machine,
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00:11:57,172 --> 00:11:59,827
Which finishes the job.
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00:12:12,068 --> 00:12:15,758
Now the cotton goes through
What's called a carding machine.
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00:12:15,862 --> 00:12:19,137
It has huge rollers
With wire teeth.
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00:12:19,241 --> 00:12:20,689
They comb out the tangled fibers
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00:12:20,793 --> 00:12:24,517
And line them up
In parallel rows.
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00:12:24,620 --> 00:12:26,689
The machine also discards
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00:12:26,793 --> 00:12:29,689
Any fibers that are too short
To process.
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00:12:32,862 --> 00:12:34,862
Next stop -- the coiler.
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00:12:34,965 --> 00:12:37,379
This device
Takes the rows of fibers
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00:12:37,482 --> 00:12:40,758
And forms them into a thick
And loose first-stage yarn
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Called sliver.
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00:12:50,000 --> 00:12:52,724
The slivers move on
To the drawing machine.
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00:12:52,827 --> 00:12:56,068
It lines them up six at a time
And draws them out,
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00:12:56,172 --> 00:12:59,862
Stretching them to form
A second-stage yarn.
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00:13:04,172 --> 00:13:06,275
Then a machine
Called a roving frame
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00:13:06,379 --> 00:13:09,000
Stretches
This second-stage yarn,
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Strengthening it
By thinning it out...
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...Until it looks like this.
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00:13:18,551 --> 00:13:21,517
This third-stage yarn
Is called roving.
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00:13:21,620 --> 00:13:24,034
Depending on the type of yarn
They're making,
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00:13:24,137 --> 00:13:28,689
It's anywhere from 3 1/2
To 16 times thinner than sliver.
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00:13:31,172 --> 00:13:34,758
They now stretch the roving
Up to 30 times thinner,
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00:13:34,862 --> 00:13:37,137
Which strengthens it even more.
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00:13:37,241 --> 00:13:40,206
The yarn is finally finished.
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00:13:42,689 --> 00:13:46,068
Now they have to transfer the
Yarn from all these small spools
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00:13:46,172 --> 00:13:51,931
Onto huge, industrial-size
Cones -- 20 spools to a cone.
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00:13:52,034 --> 00:13:55,862
One transfer method
Uses the winding machine.
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00:13:55,965 --> 00:14:00,482
It winds the yarn from
The first spool onto the cone.
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00:14:00,586 --> 00:14:04,517
Then it automatically takes
The back end of that yarn
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00:14:04,620 --> 00:14:05,896
And attaches it with a knot
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00:14:06,000 --> 00:14:09,000
To the front end of the yarn
From the next spool.
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00:14:09,103 --> 00:14:12,724
It winds it onto the cone,
Then attaches the back end
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00:14:12,827 --> 00:14:15,551
To the front end
From the next spool and so on.
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00:14:15,655 --> 00:14:17,655
As each spool empties,
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00:14:17,758 --> 00:14:20,413
The machine automatically
Discards it.
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00:14:26,448 --> 00:14:28,379
And while all that winding
Is going on,
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00:14:28,482 --> 00:14:30,448
The machine's optical sensor --
203
00:14:30,551 --> 00:14:33,482
That white object you see
Crossing the screen --
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00:14:33,586 --> 00:14:35,655
Does a quality-control check.
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00:14:35,758 --> 00:14:38,758
If a portion of yarn
Doesn't meet specifications,
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00:14:38,862 --> 00:14:42,724
The winding stops, the machine
Cuts off the offending portion,
207
00:14:42,827 --> 00:14:46,034
Then reconnects the ends
And resumes winding.
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00:14:49,068 --> 00:14:50,655
This is air-jet spinning,
209
00:14:50,758 --> 00:14:53,517
Another method
Of making yarn from slivers
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00:14:53,620 --> 00:14:57,482
And winding it onto giant spools
Known as tubes.
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00:15:05,310 --> 00:15:08,517
A suction tube
Grabs the front end of one spool
212
00:15:08,620 --> 00:15:11,379
And connects it to the back end
Of the previous one,
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00:15:11,482 --> 00:15:13,482
Again with a tiny knot.
214
00:15:15,517 --> 00:15:17,896
Before fully automated machines
Like this
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00:15:18,000 --> 00:15:19,620
Were invented 50 years ago,
216
00:15:19,724 --> 00:15:22,827
All that knotting
Had to be done by hand.
217
00:15:22,931 --> 00:15:24,517
The thin, finished yarn
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00:15:24,620 --> 00:15:27,551
Is 200 times lighter
Than the thick, first-stage yarn
219
00:15:27,655 --> 00:15:30,413
That came out
Of the carding machine.
220
00:15:30,517 --> 00:15:35,931
From start to finish, spinning
This yarn has taken 48 hours.
221
00:15:43,793 --> 00:15:45,689
Narrator:
You might not have noticed,
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00:15:45,793 --> 00:15:49,827
But road signs have undergone
A subtle change in recent years
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00:15:49,931 --> 00:15:52,896
Thanks to advances
In technology.
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00:15:53,000 --> 00:15:55,586
Today's signs
Are more reflective than ever.
225
00:15:55,689 --> 00:15:58,931
You can actually read them
In the dead of night,
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00:15:59,034 --> 00:16:01,172
Even when the only source
Of illumination
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00:16:01,275 --> 00:16:03,241
Is your car's headlights.
228
00:16:10,034 --> 00:16:12,827
The earliest road signs
Were crude --
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00:16:12,931 --> 00:16:14,448
A stick in the ground
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00:16:14,551 --> 00:16:17,068
Or a heap of stones
To mark a route.
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00:16:17,172 --> 00:16:18,931
In the roman empire,
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00:16:19,034 --> 00:16:22,862
Stone posts were erected along
Roadsides at regular intervals,
233
00:16:22,965 --> 00:16:25,379
Indicating the distance to rome.
234
00:16:25,482 --> 00:16:27,379
Centuries later,
235
00:16:27,482 --> 00:16:30,724
Stone-marker systems gave way
To wooden cross signs
236
00:16:30,827 --> 00:16:33,724
Pointing in several directions
At once.
237
00:16:33,827 --> 00:16:37,379
The international system
Of road signs we know today
238
00:16:37,482 --> 00:16:40,379
Came out of the first
International road congress,
239
00:16:40,482 --> 00:16:42,551
Held in 1908.
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00:16:51,379 --> 00:16:54,275
The process
Of manufacturing a road sign
241
00:16:54,379 --> 00:16:56,000
Starts with a computer.
242
00:16:56,103 --> 00:16:57,862
The government
Strictly regulates
243
00:16:57,965 --> 00:16:59,758
The specifics of the design
244
00:16:59,862 --> 00:17:04,517
And requires a certain degree
Of reflectivity.
245
00:17:04,620 --> 00:17:07,758
The computer's specialized
Software guides a machine
246
00:17:07,862 --> 00:17:10,137
To cut the design
On a sheet of film.
247
00:17:12,206 --> 00:17:14,034
Once the design is cut,
248
00:17:14,137 --> 00:17:17,517
Workers carefully peel off
And discard the pieces.
249
00:17:19,482 --> 00:17:22,241
What's left is a film stencil
Of the sign --
250
00:17:22,344 --> 00:17:25,137
In this case,
A french stop sign.
251
00:17:29,896 --> 00:17:32,068
They inspect it for defects,
252
00:17:32,172 --> 00:17:35,413
Then prepare a screen
Of polyester fabric
253
00:17:35,517 --> 00:17:38,413
That they'll later use
To print the sign.
254
00:17:38,517 --> 00:17:40,068
They start by coating it
255
00:17:40,172 --> 00:17:43,034
With a thin layer
Of light-sensitive emulsion.
256
00:17:43,137 --> 00:17:47,206
Once the emulsion is dry,
They adhere the film stencil
257
00:17:47,310 --> 00:17:49,724
Using vacuum pressure
To flatten it
258
00:17:49,827 --> 00:17:52,896
And get rid of any creases
Or air bubbles.
259
00:17:56,000 --> 00:17:59,793
Then they expose the screen
To an intense, 6,000-watt light
260
00:17:59,896 --> 00:18:02,000
For seven minutes.
261
00:18:02,103 --> 00:18:04,000
This activates the emulsion
262
00:18:04,103 --> 00:18:07,000
On the lettering and area
Outside the octagon --
263
00:18:07,103 --> 00:18:09,655
What's not shielded from
The light by the film stencil.
264
00:18:09,758 --> 00:18:12,448
This exposed emulsion hardens,
265
00:18:12,551 --> 00:18:15,758
Plugging the minute holes
Between the screen's fibers.
266
00:18:15,862 --> 00:18:19,482
After rinsing,
You see the result.
267
00:18:19,586 --> 00:18:22,620
Elsewhere in the factory,
Workers cut the aluminum panels
268
00:18:22,724 --> 00:18:25,310
On which the signs
Will be printed.
269
00:18:25,413 --> 00:18:29,482
Using a punch press,
They round out the edges.
270
00:18:29,586 --> 00:18:32,034
They make holes for the bolts
271
00:18:32,137 --> 00:18:35,172
That will later
Attach the sign to the post.
272
00:18:35,275 --> 00:18:38,103
They stamp on the company name
And the year of manufacture
273
00:18:38,206 --> 00:18:40,896
For warranty purposes.
274
00:18:41,000 --> 00:18:43,482
They immerse the panels
In a chemical bath
275
00:18:43,586 --> 00:18:47,000
To remove grease
And other residues.
276
00:18:47,103 --> 00:18:48,758
Then they rinse off the panels
277
00:18:48,862 --> 00:18:51,344
And dip them in an acid solution
That seals the metal
278
00:18:51,448 --> 00:18:54,551
To make it better withstand
Harsh weather.
279
00:18:56,586 --> 00:18:58,172
Next, they laminate
The aluminum panels
280
00:18:58,275 --> 00:19:02,689
With a film containing
Miniscule glass particles.
281
00:19:02,793 --> 00:19:05,310
This film will make the sign
Reflect in the dark
282
00:19:05,413 --> 00:19:06,827
When light hits it.
283
00:19:14,172 --> 00:19:16,931
Then they cut the panel
To the final shape.
284
00:19:26,793 --> 00:19:29,689
Now they can finally
Print the sign.
285
00:19:29,793 --> 00:19:32,413
The process they use
Is called silk-screening,
286
00:19:32,517 --> 00:19:35,482
Although the fabric screen,
As you saw earlier,
287
00:19:35,586 --> 00:19:36,862
Isn't actually silk.
288
00:19:36,965 --> 00:19:39,517
It's polyester.
289
00:19:39,620 --> 00:19:42,586
The machine forces the ink
Down through the screen
290
00:19:42,689 --> 00:19:44,068
Onto the panel.
291
00:19:44,172 --> 00:19:47,655
The ink penetrates through the
Open fiber holes of the octagon,
292
00:19:47,758 --> 00:19:51,034
Printing the red background
On the stop sign.
293
00:19:51,137 --> 00:19:54,068
But it can't penetrate
Through the blocked fiber holes
294
00:19:54,172 --> 00:19:57,310
Of the lettering and the area
Outside the octagon,
295
00:19:57,413 --> 00:20:00,379
So those remain white.
296
00:20:00,482 --> 00:20:03,206
The freshly printed signs
Pass through a dryer
297
00:20:03,310 --> 00:20:07,793
At about 150 degrees fahrenheit
For 5 minutes.
298
00:20:07,896 --> 00:20:09,827
To produce street signs,
299
00:20:09,931 --> 00:20:12,344
Workers first laminate
Aluminum panels
300
00:20:12,448 --> 00:20:15,172
With reflective film
For the background color...
301
00:20:17,620 --> 00:20:19,896
...Then either silk-screen
The street name
302
00:20:20,000 --> 00:20:23,517
Or apply self-adhesive
Reflective lettering.
303
00:20:27,068 --> 00:20:29,689
But it's back to
The silk-screening process
304
00:20:29,793 --> 00:20:32,137
For printing multicolored signs.
305
00:20:32,241 --> 00:20:34,586
Workers print them
One color at a time
306
00:20:34,689 --> 00:20:37,620
With a drying cycle
Between colors.
307
00:20:40,655 --> 00:20:44,689
All the film stencils are
Carefully stored for future use.
308
00:20:44,793 --> 00:20:48,172
The printed signs go into
An oven for a final curing
309
00:20:48,275 --> 00:20:51,034
At 349 degrees fahrenheit --
310
00:20:51,137 --> 00:20:53,862
An hour for a one-color sign,
311
00:20:53,965 --> 00:20:57,724
A half-hour per color
For a multicolored sign.
312
00:20:57,827 --> 00:20:59,448
The ink is transparent enough
313
00:20:59,551 --> 00:21:02,241
Not to block the reflective film
Underneath.
314
00:21:02,344 --> 00:21:05,379
Therefore, the entire sign,
Not just the lettering,
315
00:21:05,482 --> 00:21:08,000
Is highly reflective.
316
00:21:08,103 --> 00:21:10,689
That maximizes
The sign's visibility,
317
00:21:10,793 --> 00:21:14,965
Thereby minimizing the excuses
Drivers can come up with
318
00:21:15,068 --> 00:21:17,137
For not heeding it.
319
00:21:22,448 --> 00:21:24,482
If you have any comments
About the show,
320
00:21:24,586 --> 00:21:27,172
Or if you would like to suggest
Topics for future shows,
321
00:21:27,275 --> 00:21:29,620
Drop us a line at...
25788
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