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Narrator:
Today on "How it's made"...
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Car radiators...
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00:00:31,965 --> 00:00:33,827
...Hatchery chicks...
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...Phyllo dough...
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00:00:43,724 --> 00:00:45,620
...And cross-country skis.
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When the gasoline
In a car engine burns,
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Up to 70% of the energy
Generated converts into heat.
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00:00:59,448 --> 00:01:03,172
A lot of this heat
Goes out the exhaust system,
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00:01:03,172 --> 00:01:06,034
But much of it stays
Heating up the engine.
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00:01:06,034 --> 00:01:09,172
The car's cooling system
Prevents overheating.
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The system's key component
Is the radiator.
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A water-and-antifreeze mix
Absorbs the heat
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Generated by the engine.
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00:01:20,931 --> 00:01:25,413
The fluid then flows through
The radiator tubes to cool down.
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The tubes are made
From paper-thin brass.
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The 1.5-inch-wide strip
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Is bent by rollers
Into the shape of a flat tube.
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The tubing
Then runs through a vat
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Of bubbling-hot molten lead.
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As the tubing exits the vat,
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It runs through cold water
That hardens the lead coating.
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A cutter then chops the tubing
Into pieces,
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The length of which varies
According to the model
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Of radiator.
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00:02:07,655 --> 00:02:09,655
These are about 30 inches long.
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00:02:11,586 --> 00:02:15,000
Meanwhile, another machine
Shapes a narrow strip
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00:02:15,000 --> 00:02:18,137
Of copper
Just 6/100 of an inch thick
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Into what are called
"Cooling fins."
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00:02:21,724 --> 00:02:23,551
As we'll see in slow motion,
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The machine folds
The copper strip like a fan,
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00:02:26,896 --> 00:02:31,068
Then perforates it,
Creating mini air vents.
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When the hot fluid
Runs through the tubes,
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These fins will transfer
The heat
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To the air flowing
Through the radiator.
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The cooled fluid
Can then go back
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00:02:40,206 --> 00:02:43,724
For another round
Of absorbing engine heat.
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The cooling fins come out
Of the machine cut to size.
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Then workers manually stack
The tubes and fins
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One on top of the other.
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They straighten them out
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00:02:58,965 --> 00:03:01,793
And apply a brass tag indicating
The model number
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And date of production.
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Then they compress and strap
The components together.
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Elsewhere, a computer-guided
Machine punches out a pattern
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On brass sheets.
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These will become
What are called "Headers."
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There's one
On each side of a radiator.
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The punching tool
Then changes to a knife,
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00:03:24,689 --> 00:03:27,344
Which now cuts
Along the perforation lines.
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Using a press,
They bend each header.
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Then punch slots
For the radiator's tubes.
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Now, using a mallet,
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They hammer the headers
Onto the ends of the tubes.
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The banging inadvertently
Closes a few tubes,
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So they use a special roller
To reopen them.
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00:04:05,965 --> 00:04:08,413
After cleaning the surface,
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It's into an oven
At 600 degrees fahrenheit.
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In just two minutes,
The lead melts,
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Fusing the tubes
And cooling fins.
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00:04:19,931 --> 00:04:22,413
After straightening out
Any crooked tubes,
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Workers dip the headers
In a tank of hot-liquid lead
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For 30 seconds.
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This solders them
To the sides of the radiator.
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They apply a few drops
Of lead on the corners
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For reinforcement.
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The headers and tube openings
Are now encased in lead.
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Workers now feed a sheet
Of brass into a press
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To form the tanks
That go onto the headers.
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One contains a brass tube.
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Hot transmission oil enters one
End of it and exits the other,
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Cooling along the way.
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Once workers finish soldering
The tanks to the headers,
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They solder on
What's called the filler net,
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00:05:13,172 --> 00:05:16,482
A spout for pouring antifreeze
Into the tank.
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On the opposite tank, they
Solder on a water-intake pipe.
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This will be the entry point
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For the fluid
Heated by the engine.
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Finally, they coat
The finished radiator
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In an asphalt-based black paint.
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The asphalt content
Makes the paint heat resistant
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And protects the radiator's
Cooling fins.
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Narrator: which came first,
The chicken or the egg?
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It's an age-old question,
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And we can't give you
The definitive answer.
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But we can take you
To a hatchery
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To see how baby chicks are bred.
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It's the first step
In commercial chicken farming,
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Or the second step
If you think the egg came first.
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Chicks come from eggs
Fertilized by mating,
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But a hen can lay eggs
Without mating.
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Those unfertilized eggs
Are the ones we eat.
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The fertilized ones
Go to the hatchery
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Three or four days
After being laid.
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Hatchery workers transfer
The eggs onto special trolleys,
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Then roll them into
The incubator,
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Where the temperature
And humidity level
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Mimic natural conditions.
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The egg yolk, egg white, and
Shell all nourish the embryo.
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Every hour,
The trays shift 45 degrees
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To the opposite side and back,
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Simulating
The way hens turn their eggs
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While waiting
For them to hatch.
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After 18 1/2 days,
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The eggs come out of incubation
And go onto a conveyer belt.
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They pass
Under an infrared sensor
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That checks for eggs
That are too transparent.
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These are unfertilized eggs
That slipped through.
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The sensor triggers
A suction device to remove them.
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They go to a rendering plant
To become animal feed.
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The fertilized eggs continue
Along to the next station
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To be vaccinated against marek,
A poultry disease.
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Automated needles
Pierce a hole in each shell
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And inject a vaccine
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Into the amniotic fluid
Surrounding the chick.
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Now a suction device transfers
The eggs to hatching trays,
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168 eggs per tray.
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About 150 of them
Can be expected to hatch.
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The rest die in incubation
Or have physical defects.
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Day 19 --
The chicks use their beaks
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To crack a hole
Through the shell,
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Then a horizontal line
All around.
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After six to eight hours,
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00:08:06,931 --> 00:08:09,413
The chicks finally emerge
From the shell.
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They're covered in short
Feathers called "Down,"
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And they're able
To walk and see.
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After about four hours,
Their down has dried.
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Now workers roll the chicks to
What's called the separator,
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A machine that separates
The birds from the shell halves.
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The shells are larger
Than the chicks,
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So they stay on top
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While the chicks fall down
To a conveyer belt below.
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The shells,
Which are high in calcium,
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Go to a rendering plant.
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The chicks move on to be
Classified according to gender.
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Workers put the females
Down one chute,
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The males down another.
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They determine the sex by
Checking two rows of feathers.
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If one row's shorter
Than the other,
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The chick's a female.
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If the rows are the same height,
It's a male.
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Each chute feeds
A separate conveyer belt.
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An optical counter tracks
The number of males and females.
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The chicks now fall
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Into specially designed
Transportation boxes,
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102 chicks per box.
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Some clients request
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That their order of chicks be
Vaccinated against bronchitis.
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Those boxes pass
Under an aerosol sprayer
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That sprinkles them
With a mild dose of vaccine.
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Poultry farmers raise chicks
For their meat or eggs.
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Females used for egg production
Begin laying eggs
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At about 20 weeks of age.
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For meat production,
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Females reach slaughter weight
At about 38 days.
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Males, depending on market size,
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Take from 40 to 65 days.
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Narrator:
If you like greek food,
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Then you've probably tasted
Baklava.
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It's made with a paper-thin,
Flaky dough called "Phyllo,"
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The greek word for "Leaf."
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Phyllo dough itself
Is low-fat and cholesterol-free.
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Unfortunately, the stuff
They usually fill it with isn't.
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Phyllo dough can be made by hand
Or by machine.
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Either way, it starts
With the same dough recipe.
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The proportions are roughly
40% water to 60% flour.
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They use two types
Of wheat flour --
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High-protein flour to make
The dough strong and flexible
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And low-protein flour
To make its texture smooth.
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They also add sorbate,
A preservative,
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To increase shelf life.
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After about 15 minutes
Of mixing, the dough is ready.
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They cut off a section
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And feed it into a machine
Called the divider,
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Which transforms it
Into a cylindrical wad.
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They hand-roll the wad
Into a rough ball,
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Then feed it two or three times
Through a machine
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That kneads the dough
Into a rounder, harder ball
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With no air bubbles
Trapped inside.
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They can tell when it's ready
Just by feeling it.
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Then a machine called
The sheeter flattens the ball
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Into what looks like
Pizza dough.
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Workers stack about 30 sheets
With craft paper in between
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To absorb some of the moisture.
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Now the key step --
Opening the dough.
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First, they lay a large cotton
Cloth over the work surface.
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It must be 100% cotton
To absorb the moisture.
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Otherwise,
The dough would stick together.
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They take the sheet of dough
And begin stretching it by hand
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Until it's approximately
27 square feet.
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Even though the dough
Is stretched thin,
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It doesn't tear.
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This is due partly
To its protein content
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And partly
To the skill of the worker.
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They repeat the process
With all 30 sheets,
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Stacking them
One on top of the other.
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Then they take a plank of wood,
Called a "Sanida" in greek,
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And roll the dough sheets
Onto it one by one,
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Removing the cloths
That were in between.
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They sprinkle corn starch
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On the dough,
Just enough to prevent sticking.
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Too much corn starch
Will burn the dough.
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00:13:44,689 --> 00:13:47,172
Now they move the sanida
To another table
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And cut along one side
Of the dough.
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00:13:50,034 --> 00:13:52,793
They remove the wood
And open the sheets flat.
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Then they cut rectangles
Measuring 13x17 inches,
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Standard phyllo size.
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00:14:02,793 --> 00:14:05,448
Each sheet of phyllo dough
Is about as thin
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As a sheet of tissue paper,
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00:14:08,137 --> 00:14:11,103
But it's strong
And flexible enough not to tear
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When a baker works with it.
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00:14:12,793 --> 00:14:16,620
Machine-made phyllo dough
Is a much faster method,
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00:14:16,620 --> 00:14:20,275
Used primarily for mass-produced
Frozen-food items.
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00:14:20,275 --> 00:14:22,827
An automated machine
Called the stretcher
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00:14:22,827 --> 00:14:25,344
Transforms a big wad of dough
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Into a thin, flat sheet,
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00:14:27,862 --> 00:14:30,172
Applying just the right amount
Of corn starch.
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00:14:30,172 --> 00:14:33,517
A continuous air current
Coming from underneath
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Creates an air bubble.
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00:14:34,862 --> 00:14:37,034
The height
Of the bubble tells them
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00:14:37,034 --> 00:14:40,034
Whether the dough
Is the right consistency.
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00:14:40,034 --> 00:14:43,000
The dough dries
Under infrared lamps.
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This step is necessary
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00:14:46,103 --> 00:14:48,758
Because this method
Doesn't use craft paper
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00:14:48,758 --> 00:14:52,241
And cotton cloths to absorb
The excess moisture.
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00:14:52,241 --> 00:14:55,586
The dried sheet of dough
Rolls onto a spool.
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00:14:55,586 --> 00:14:58,275
They cut along the side
To release the dough
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00:14:58,275 --> 00:15:00,103
And lay it flat.
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00:15:00,103 --> 00:15:01,862
Using a template,
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00:15:01,862 --> 00:15:04,103
They cut
The standard size rectangle,
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00:15:04,103 --> 00:15:06,931
Yielding about 800 sheets
Of phyllo dough.
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00:15:10,275 --> 00:15:13,517
They roll about 20 sheets
Together at a time
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00:15:13,517 --> 00:15:15,517
And wrap them in plastic.
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00:15:15,517 --> 00:15:19,275
Then, they vacuum-pack
And heat-seal the package.
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00:15:25,793 --> 00:15:27,827
Phyllo dough stays fresh
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00:15:27,827 --> 00:15:30,793
For six weeks
In the refrigerator,
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00:15:30,793 --> 00:15:33,034
Six months in the freezer.
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Narrator: cross-country skis
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00:15:46,103 --> 00:15:48,758
Used to look pretty much
All the same --
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00:15:48,758 --> 00:15:51,034
Long, narrow, and wooden.
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00:15:51,034 --> 00:15:55,586
Today's skis, however,
Come in many different styles,
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00:15:55,586 --> 00:15:59,034
Specifically designed for the
Many types of cross-country --
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00:15:59,034 --> 00:16:01,275
Telemark, back-country,
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00:16:01,275 --> 00:16:04,379
All-terrain, touring,
And racing.
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00:16:10,448 --> 00:16:12,448
Archeologists in scandinavia
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00:16:12,448 --> 00:16:16,724
Have uncovered ski artifacts
5,000 years old.
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00:16:16,724 --> 00:16:18,758
These stone-age skis
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00:16:18,758 --> 00:16:21,758
Enabled people
To hunt during the winter.
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Skiing became so vital
A means of transportation
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That the vikings worshipped
A god and goddess of skiing.
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00:16:30,103 --> 00:16:33,586
19th-century scandinavian
Soldiers wore skis
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In winter warfare.
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They held races
In their spare time,
253
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Turning cross-country skiing
Into a popular sport.
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From there, it just snowballed.
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00:16:51,931 --> 00:16:55,586
One way to make cross-country
Skis is compression molding,
256
00:16:55,586 --> 00:16:58,068
A process
That uses heat and pressure
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To bond the components together.
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First, a computer-guided blade
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00:17:02,827 --> 00:17:05,965
Cuts out what will become
The ski's underside,
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Called the gliding surface.
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00:17:07,482 --> 00:17:10,172
It's made of pre-assembled
Fiberglass laminate
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And polyethylene thermoplastic,
A friction-resistant material.
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00:17:14,551 --> 00:17:17,206
They lay it into the bottom half
Of a mold,
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00:17:17,206 --> 00:17:20,206
Then glue on steel edges
For grip.
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00:17:20,206 --> 00:17:23,551
This spray
Makes the adhesive dry faster
266
00:17:23,551 --> 00:17:28,206
So that they can apply
The principle adhesive -- epoxy.
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00:17:28,206 --> 00:17:31,724
A rubber shock absorber
Goes on the back,
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Followed by
A durable plastic reinforcement
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Called
The heel-piece protector.
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The ski's wooden core
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Is made of aspen
And birch laminated together.
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00:17:44,379 --> 00:17:48,034
Next comes a sheet of fiberglass
Impregnated with epoxy
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For extra reinforcement.
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00:17:50,241 --> 00:17:51,931
The wood core
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00:17:51,931 --> 00:17:55,896
Is now sandwiched between
Two high-resistance layers.
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00:17:55,896 --> 00:17:57,931
Then, for decoration,
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A plastic film
With a silk-screen design.
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00:18:01,103 --> 00:18:04,137
With everything now
In the bottom half of the mold,
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They clamp on the top
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00:18:06,000 --> 00:18:09,379
And tape it up to ensure
Nothing shifts out of place.
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00:18:11,379 --> 00:18:14,551
Then it's into a press
That compresses the mold
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00:18:14,551 --> 00:18:18,689
And heats it
To 185 degrees fahrenheit.
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00:18:18,689 --> 00:18:20,896
This activates the epoxy,
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00:18:20,896 --> 00:18:23,586
Hardening it
In 12 to 15 minutes,
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00:18:23,586 --> 00:18:26,000
Depending on the thickness
Of the ski.
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00:18:31,413 --> 00:18:35,241
Now they do a rough cut
To trim off the excess.
287
00:18:42,551 --> 00:18:45,482
Then they sand all the edges
Until they're smooth.
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00:18:56,482 --> 00:19:00,275
They run the gliding surface
Across a grinding stone,
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00:19:00,275 --> 00:19:03,344
That white object you see below.
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00:19:03,344 --> 00:19:06,965
This extra step is only
For the higher-end models.
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Another way to make
Cross-country skis
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00:19:12,448 --> 00:19:16,448
Is by a process called
Reaction-injection molding.
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00:19:16,448 --> 00:19:19,620
First, they place
The skis' top layer,
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00:19:19,620 --> 00:19:23,931
A fiberglass-epoxy sheet,
In the mold...
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00:19:23,931 --> 00:19:25,137
Then the gliding surface,
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00:19:25,137 --> 00:19:28,103
Made of pre-assembled
Fiberglass laminate
297
00:19:28,103 --> 00:19:31,724
And polyethylene
With a high-resistance backing.
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00:19:31,724 --> 00:19:33,896
Instead of a wooden core
In the middle,
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00:19:33,896 --> 00:19:37,241
This press injects
A super-resilient plastic.
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00:19:39,275 --> 00:19:43,068
In just three seconds,
The injection phase is over,
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00:19:43,068 --> 00:19:46,068
And the reaction phase begins.
302
00:19:46,068 --> 00:19:49,034
This demonstration
Shows what happens.
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00:19:52,724 --> 00:19:55,551
First,
The polyurethane inflates...
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00:20:01,000 --> 00:20:02,517
...Then it hardens.
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00:20:04,517 --> 00:20:06,034
After eight minutes,
306
00:20:06,034 --> 00:20:08,448
It's hardened enough
To come out of the mold.
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00:20:08,448 --> 00:20:12,103
They let the ski cure
For up to eight hours,
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00:20:12,103 --> 00:20:13,793
At which point
It's strong enough
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To support the weight
Of a skier.
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00:20:19,793 --> 00:20:21,620
Now, these three components --
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00:20:21,620 --> 00:20:24,103
The top layer,
The polyurethane middle,
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00:20:24,103 --> 00:20:26,793
And the gliding surface --
Are one.
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00:20:28,689 --> 00:20:30,724
Now comes the finishing.
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00:20:30,724 --> 00:20:34,275
First they trim
And bevel the edges.
315
00:20:34,275 --> 00:20:36,965
They sand the gliding surface.
316
00:20:38,448 --> 00:20:41,551
Then they carve a groove
Down its length.
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00:20:41,551 --> 00:20:44,482
This gives the ski
Directional stability.
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00:20:46,068 --> 00:20:50,310
All that's left to do now
Is decorate the skis.
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00:20:50,310 --> 00:20:52,068
First the background color
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00:20:52,068 --> 00:20:54,551
And a quick-drying,
Solvent-based lacquer.
321
00:20:58,068 --> 00:21:01,931
They apply the design manually,
One color at a time,
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00:21:01,931 --> 00:21:04,413
Using
The silk-screening process.
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00:21:04,413 --> 00:21:07,655
A typical design consists
Of five to seven colors,
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00:21:07,655 --> 00:21:10,000
Including the background.
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00:21:10,000 --> 00:21:12,206
To keep the skis
Looking vibrant,
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00:21:12,206 --> 00:21:15,931
They protect the paint with
A coat of transparent varnish.
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00:21:15,931 --> 00:21:18,931
--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications, inc.
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00:21:23,172 --> 00:21:25,379
If you have any comments
About the show,
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00:21:25,379 --> 00:21:28,068
Or if you'd like to suggest
Topics for future shows,
331
00:21:28,068 --> 00:21:29,689
Drop us a line at...
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