All language subtitles for S27E02 - Chemical Tank Pressure Vents; Candy Wafers; Food Trucks; Traditional Ropes (1080p AMZN WEB-DL x265 Garshasp)_track4_[eng]
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Narrator:
Today, on "How it's made"...
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It's common for pressure
To build up
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00:00:56,517 --> 00:00:59,172
Inside chemical tanker trucks
During transport.
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00:01:02,241 --> 00:01:04,551
Special vents
Regulate that pressure,
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Preventing
Any unwanted gas build-up,
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00:01:06,482 --> 00:01:08,655
Which could lead
To an explosion.
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00:01:15,724 --> 00:01:17,793
Pressure relief vents
Are standard equipment
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On chemical tanker trucks.
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They ensure tanks can hold up
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To the pressures
Inherent to this industry.
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Production starts with a bin
Of wax pellets.
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They use pellets to make models
Of the vent's parts
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In a process
Called lost-wax casting.
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Pellets are fed
Into an injection machine.
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The wax melts into a mold
Of the vent's lower housing.
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Four wax models are fused
To a single wax tree stand.
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The tree stand is left to cure
For a couple of hours.
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00:02:01,448 --> 00:02:04,206
Once cured, a worker
Dips the wax tree
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Into a slurry of ceramic.
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00:02:06,689 --> 00:02:08,931
He removes the stand
Of wax models,
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Then twirls it to drain
Any excess ceramic.
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This is the first
Of several ceramic coatings.
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Between coatings,
He applies silica sand
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To the wet ceramic.
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The sand rains
Down onto the ceramic,
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Creating a stucco effect.
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The first layer of stucco
Is finally granulated.
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The next few layers
Will be coarse.
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By building up progressively
Coarser layers of stucco,
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He creates a ceramic shell
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With the desired thickness
And strength.
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The final layer of sand
Is very coarse.
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Air pumps through the sand
As the worker dumps the models.
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00:03:03,689 --> 00:03:07,931
This process ensures uniform
Coverage of the heavier sand.
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They bake the forms next,
Melting out the wax
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And hardening the ceramic
Into shells.
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Next, a team pours blazing
Liquid steel into a ladle.
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The ceramic shells
Have been heated
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To around 3,000 degrees
In an oven.
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Workers pour hot, liquid steel
Into the hollow tree.
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They add a chemical sealer,
Then top the molten metal
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With a piece
Of ceramic-fiber insulation.
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After about 3 hours in an oven,
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The steel castings are solid.
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A worker shatters the ceramic,
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Revealing
The vent-housing parts.
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A powerful circular saw slices
The parts off the tree.
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00:04:07,413 --> 00:04:10,344
Workers clean off
Any ceramic residue.
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00:04:12,482 --> 00:04:15,793
Computer-guided tools calibrate
The pressure-vent housing part
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To precise specifications.
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After cleaning and polishing,
The part is complete.
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It's time for assembly.
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The worker starts with the top
Of the pressure vent.
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A large spring is inserted
To aid pressure relief.
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A metal plate is added
To seal the top of the vent
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To the lower part.
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The lower vent housing is then
Seated on the metal plate.
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00:04:46,413 --> 00:04:49,413
He moves the assembly
Under a hydraulic ram.
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00:04:49,413 --> 00:04:51,689
The ram presses
The lower housing,
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00:04:51,689 --> 00:04:55,931
The sealer plate, and the spring
To a specific tension.
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00:04:55,931 --> 00:05:00,482
He then screws the lower housing
To the top of the vent.
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00:05:00,482 --> 00:05:03,000
A metal ring inscribed
With the vent's model
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And flow rate
Is attached at the top.
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This chemical tank pressure vent
Is now ready for testing.
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The technician screws it
To the test stand.
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He activates a system
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That forces compressed air
Into the vent.
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This confirms whether the vent
Works at the desired setting.
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Once approved,
He attaches a cover
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To shield the vent
From rain and snow.
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The trackable serial number
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Is etched into the top
Using a laser.
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This vent is now ready
To prevent hazardous situations.
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Narrator: the candy wafer
Is a classic american treat.
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Invented in 1847,
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It's a thin, lightweight disk
Of sugary candy.
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It's softer and dissolves
Faster than hard candy.
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You can bite into it right away
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Or let it melt in your mouth.
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These candy wafers
Come in eight different flavors.
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The original roll
Has a random assortment
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Of 38 pieces.
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Part of the fun is seeing how
Many of your favorite flavors
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You get.
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This factory makes one flavor
At a time.
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The first step
Is to add food coloring
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And flavoring
To pulverized sugar.
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This pink color
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And mint flavoring
Produces a wintergreen taste.
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Corn syrup comes next,
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Along with a binding solution
Of vegetable gums
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And gelatin dissolved in water.
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After mixing
For about 8 minutes,
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The candy dough's
Consistency is checked.
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If it isn't thick,
Elastic, or sticky enough,
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More binding solution is added
Until the dough is just right.
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Workers divide the dough
Into chunks,
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Then feed them
Into a dough shooter.
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This is the first station
On the wafer-forming line.
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The black dough
Is licorice flavor.
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A conveyor
Returns leftover dough
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From the end of the line
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To be reused
For making new wafers.
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They're pushed through a slot,
Forming the dough sheet
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That's 20 inches wide
By about an inch thick.
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00:07:44,862 --> 00:07:47,896
This yellow dough
Is lemon flavored.
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00:07:54,206 --> 00:07:56,034
A steady sprinkle of cornstarch
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Prevents the sheet
From sticking to the equipment.
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Rollers compress
And stretch the dough forward,
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Flattening the sheet
To an inch thick.
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The next station stamps
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On the company logo,
Then cuts out the wafers.
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The cutter moves up and down
180 times per minute.
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The wafers fall through a gap
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To a moving conveyor belt below.
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The conveyor belt
Moves the wafers
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To a multilevel tunnel dryer.
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00:08:34,000 --> 00:08:35,724
They pass through the dryer
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13 times
Over the course of an hour.
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00:08:45,344 --> 00:08:48,758
These green wafers
Are lime flavored.
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00:08:48,758 --> 00:08:52,896
The dryer temperature
Is about 150 degrees fahrenheit,
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Warm enough to remove
Half of the moisture
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00:08:54,862 --> 00:08:57,965
Without melting the sugar.
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00:08:57,965 --> 00:09:00,931
These brown wafers
Are chocolate flavor.
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00:09:00,931 --> 00:09:03,068
Once out of the dryer,
The wafers
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Pile up in trays
Without sticking.
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00:09:08,413 --> 00:09:11,413
Workers stack the trays
In a drying room.
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00:09:11,413 --> 00:09:15,931
It's heated
And humidified with steam.
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00:09:15,931 --> 00:09:18,551
The candy wafers stay here
Until their moisture level
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00:09:18,551 --> 00:09:22,206
Drops to between 0.75% and 1%.
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The factory tests a few samples
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00:09:27,586 --> 00:09:30,172
Using a device
Called a penetrometer.
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00:09:30,172 --> 00:09:33,137
It measures the force required
To penetrate the candy wafer
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00:09:33,137 --> 00:09:36,482
To the point of breaking it.
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00:09:36,482 --> 00:09:41,620
This ensures the candies
Are the correct consistency.
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When the trays come
Out of the drying room,
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Workers send the candies
To the packaging line.
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The colors are mixed together,
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00:09:51,241 --> 00:09:56,000
Ensuring every roll of candy has
A random assortment of flavors.
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The wafers flow into channels,
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00:10:00,172 --> 00:10:02,344
Which stand them on their sides.
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00:10:05,620 --> 00:10:07,827
Workers grab
About two rolls' worth,
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00:10:07,827 --> 00:10:09,965
Then fill two channels
Of a feeder
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00:10:09,965 --> 00:10:12,241
That takes them
To the wrapping station.
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00:10:15,172 --> 00:10:17,034
Another worker
Fills in the gaps,
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00:10:17,034 --> 00:10:19,758
Ensuring each roll
Has 38 pieces.
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00:10:19,758 --> 00:10:23,103
The wrapping machine
Cuts printed,
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Translucent paper wrapping
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00:10:24,896 --> 00:10:28,793
And applies a bead of glue
To one edge.
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00:10:28,793 --> 00:10:31,793
In a matter of seconds,
The machine lifts the roll
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Into the wrapper,
Seals the edges,
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And twists the ends closed.
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As the sealed rolls move
On a conveyor belt,
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Heated blocks iron
The twisted ends flat.
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Each candy wafer roll
Weighs 2 ounces.
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Workers pack 24 rolls
Per retail box,
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00:10:49,482 --> 00:10:52,206
Then pack the boxes
In shipping cases.
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00:10:54,896 --> 00:10:58,172
In addition to a traditional
Roll with assorted flavors,
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The factory also
Produces chocolate-only rolls.
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Production has modernized
Over the years,
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00:11:03,931 --> 00:11:06,413
But the recipe
Itself hasn't changed much
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Since the first candy wafer
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00:11:08,068 --> 00:11:12,034
Rolled off
The production line in 1847.
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Narrator: food trucks used to
Only sell sandwiches
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And other prepackaged food.
Not anymore.
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The modern food truck
Is a mobile restaurant
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00:11:32,103 --> 00:11:34,931
With a full kitchen inside.
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00:11:34,931 --> 00:11:36,310
Food is cooked fresh
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00:11:36,310 --> 00:11:38,896
And sold to customers
Through a service window.
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00:11:43,241 --> 00:11:46,068
Most food trucks
Are standard panel trucks.
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Their cargo area is a fully
Equipped commercial kitchen
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With a service window
On one side.
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They're usually customized
By boutique companies,
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00:11:58,413 --> 00:12:02,034
So there's no standard method.
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00:12:02,034 --> 00:12:05,758
However, certain modifications
To the panel trucks are common,
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Like enhancing
The truck's suspension system
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00:12:08,413 --> 00:12:10,413
Or reinforcing
The flooring and walls
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To support the kitchen's weight.
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The lighten the load,
This company
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00:12:15,586 --> 00:12:17,689
Builds the kitchen's
Structural components
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00:12:17,689 --> 00:12:20,965
Out of aluminum bars
Rather than heavy steel.
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Once the pieces are cut,
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A worker assembles,
Then welds them together.
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00:12:31,448 --> 00:12:35,241
This structure will support
A stainless-steel countertop.
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00:12:42,482 --> 00:12:44,724
Workers cut the countertops
And cabinets
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00:12:44,724 --> 00:12:47,137
From thick sheets
Of stainless steel.
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00:12:51,758 --> 00:12:55,310
They bend the sheets using
A machine called a press break.
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00:13:01,448 --> 00:13:02,620
For this countertop,
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00:13:02,620 --> 00:13:04,896
They bend a 90-degree angle
On the front end
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00:13:04,896 --> 00:13:08,206
To form a 1.5-inch square edge.
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00:13:10,517 --> 00:13:12,517
To construct walls and ceilings,
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00:13:12,517 --> 00:13:15,413
They rivet thin sheets
Of stainless steel or aluminum
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00:13:15,413 --> 00:13:17,172
To panels of wood.
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00:13:19,482 --> 00:13:23,068
Fire-retardant plywood
Is used for the kitchens.
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00:13:23,068 --> 00:13:28,068
The boards are installed
Over styrofoam insulation.
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00:13:28,068 --> 00:13:31,620
They leave the truck's
Aluminum floor as is.
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00:13:31,620 --> 00:13:35,241
Once the walls, ceiling,
And flooring are complete,
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00:13:35,241 --> 00:13:38,241
It's time to install the
Kitchen's cabinets and counters.
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00:13:40,965 --> 00:13:42,655
Workers screw
Each counter support
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00:13:42,655 --> 00:13:45,000
To the wooden structure
Of the wall,
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00:13:45,000 --> 00:13:48,000
Then fasten the countertop
With rivets.
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00:13:56,172 --> 00:13:57,448
They peel off the film
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00:13:57,448 --> 00:14:00,448
That was protecting
The stainless-steel surface.
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00:14:02,655 --> 00:14:05,758
Next, they install
The major appliances,
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00:14:05,758 --> 00:14:07,724
Which include
A commercial refrigerator,
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00:14:07,724 --> 00:14:10,000
Freezer, and cooking equipment.
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00:14:12,551 --> 00:14:15,448
Then the electrical box
Is installed.
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00:14:15,448 --> 00:14:17,586
They connect wiring
For the outlets,
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00:14:17,586 --> 00:14:19,758
Lighting, water heater,
Water pump,
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00:14:19,758 --> 00:14:21,827
And air-conditioning system.
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00:14:28,241 --> 00:14:32,172
The generator is installed
Underneath the nearest counter.
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00:14:32,172 --> 00:14:35,275
It supplies the truck
With electricity.
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00:14:35,275 --> 00:14:39,344
Next to the electrical box is
The power-transfer box.
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00:14:39,344 --> 00:14:40,827
It contains a switch
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00:14:40,827 --> 00:14:44,206
That enables the truck
To use an outdoor power source.
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00:14:44,206 --> 00:14:47,000
The switches for the interior
And exterior lighting
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00:14:47,000 --> 00:14:49,310
Are underneath
The electrical box.
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00:14:55,000 --> 00:14:56,862
Workers install
The light fixtures,
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00:14:56,862 --> 00:14:59,793
Cabinetry, sink,
And serving window.
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00:15:04,206 --> 00:15:06,103
They also install the gas lines
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00:15:06,103 --> 00:15:09,482
That power the commercial
Cooking equipment.
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00:15:09,482 --> 00:15:12,586
This truck has
Several gas appliances --
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00:15:12,586 --> 00:15:15,482
A six-burner gas range
With large oven,
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00:15:15,482 --> 00:15:20,310
A deep fryer, a charcoal grill,
And a flattop cooking surface.
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00:15:22,827 --> 00:15:24,931
The kitchen is equipped
With a ventilation hood
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00:15:24,931 --> 00:15:27,517
Over the cooking area.
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00:15:27,517 --> 00:15:29,896
Its powerful fan gathers smoke
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00:15:29,896 --> 00:15:33,724
And sends it out a vent
On top of the truck.
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00:15:33,724 --> 00:15:36,586
It's time
To outfit the exterior.
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00:15:39,862 --> 00:15:43,482
Some food trucks are painted,
But most use graphics
231
00:15:43,482 --> 00:15:46,103
That are digitally printed
On adhesive vinyl.
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00:15:50,482 --> 00:15:53,310
After positioning each panel
Of the design,
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00:15:53,310 --> 00:15:55,448
They apply heat with a torch.
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00:15:55,448 --> 00:15:57,206
This removes trapped air,
235
00:15:57,206 --> 00:16:00,655
Stretching the vinyl over rivets
And other protrusions.
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00:16:09,172 --> 00:16:12,517
This mobile eatery
Is ready to roll with a kitchen
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00:16:12,517 --> 00:16:16,310
That meets fire-code
And food-service regulations.
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00:16:18,103 --> 00:16:21,103
It may not provide the ambiance
Of a sit-down restaurant,
239
00:16:21,103 --> 00:16:25,931
But when a food truck pulls up,
You never need a reservation.
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00:16:38,275 --> 00:16:41,931
Narrator: rope has been made out
Of plant fibers for centuries.
241
00:16:41,931 --> 00:16:44,931
Stronger synthetic
And steel cords are available,
242
00:16:44,931 --> 00:16:47,827
But there's still a market
For traditional twine.
243
00:16:48,551 --> 00:16:51,172
They have their own
Unique strengths,
244
00:16:51,172 --> 00:16:54,586
And that's why we are still
Bound by their ties.
245
00:16:58,413 --> 00:17:01,896
Woven from manila, sisal,
Or flax fibers,
246
00:17:01,896 --> 00:17:06,896
Traditional ropes are
A binding element in our world.
247
00:17:06,896 --> 00:17:08,413
They're easier to grip
248
00:17:08,413 --> 00:17:12,931
And stretch
Less than synthetics.
249
00:17:12,931 --> 00:17:14,931
At this deep
And narrow building,
250
00:17:14,931 --> 00:17:16,965
They've been
Twisting fibers into rope
251
00:17:16,965 --> 00:17:19,413
For more than two centuries.
252
00:17:19,413 --> 00:17:22,517
They're still producing rope
The old-fashioned way.
253
00:17:22,517 --> 00:17:27,241
The process starts with racks
Of natural-fiber yarns.
254
00:17:27,241 --> 00:17:29,793
The yarns are funneled
Through separators,
255
00:17:29,793 --> 00:17:32,689
Which configure them
To twist evenly together.
256
00:17:32,689 --> 00:17:34,931
The fibers
Then travel through tubes
257
00:17:34,931 --> 00:17:38,000
That squeeze them into bundles.
258
00:17:38,000 --> 00:17:39,758
Workers tie the ends
Of the bundles
259
00:17:39,758 --> 00:17:44,310
Onto a wheeled vehicle
Called the forming machine.
260
00:17:44,310 --> 00:17:45,793
They roll the machine back
261
00:17:45,793 --> 00:17:48,241
Until there's no slack
In the bundles.
262
00:17:48,241 --> 00:17:52,482
The machine is then sent
To the opposite end
263
00:17:52,482 --> 00:17:55,827
Of the factory,
Over 1,000 feet away.
264
00:17:58,620 --> 00:18:01,413
As the machine
Travels backwards, its gears
265
00:18:01,413 --> 00:18:06,689
Turn hooks, twisting the yarns
Into a tight configuration.
266
00:18:06,689 --> 00:18:08,206
The formation of the twists
267
00:18:08,206 --> 00:18:10,379
Ensure an even distribution
Of tension.
268
00:18:10,379 --> 00:18:15,137
This is what makes rope
So strong.
269
00:18:15,137 --> 00:18:18,448
This long, indoor space
Is called a ropewalk.
270
00:18:18,448 --> 00:18:21,000
There aren't many of them
Left in the world.
271
00:18:24,310 --> 00:18:27,379
Halfway down,
A worker places a trestle
272
00:18:27,379 --> 00:18:30,310
Underneath the twisting yarns.
273
00:18:30,310 --> 00:18:35,241
This keeps them off the floor
And prevents tangling.
274
00:18:35,241 --> 00:18:38,482
When the machine
Reaches the back wall, it stops,
275
00:18:38,482 --> 00:18:41,862
And workers cut both ends
Of the strands.
276
00:18:44,482 --> 00:18:45,827
They tie them to posts
277
00:18:45,827 --> 00:18:48,931
To maintain tension
And prevent unraveling.
278
00:18:54,413 --> 00:18:56,137
The twisted fibers stretch
279
00:18:56,137 --> 00:18:58,724
From one end of the building
To the other.
280
00:19:03,034 --> 00:19:05,689
On one side,
They tie three of the strands
281
00:19:05,689 --> 00:19:09,000
To a machine that will
Transform them into a rope.
282
00:19:15,103 --> 00:19:17,344
Halfway down,
They bring in a cart
283
00:19:17,344 --> 00:19:20,275
That holds a piece
Of grooved wood known as a top.
284
00:19:22,413 --> 00:19:25,965
They tuck the twisted strands
Into the grooves of the top.
285
00:19:29,965 --> 00:19:31,793
They then roll the cart
286
00:19:31,793 --> 00:19:35,862
Down to face
The rope-making machine.
287
00:19:35,862 --> 00:19:40,344
A worker ties rope
Around the strands in the top.
288
00:19:40,344 --> 00:19:43,689
This holds them in place
As the rope-making machine
289
00:19:43,689 --> 00:19:48,827
Twists the three strands
Into one.
290
00:19:48,827 --> 00:19:53,344
The cart rolls along rails
Propelled by twisting action.
291
00:19:57,965 --> 00:20:01,620
It leaves newly formed rope
In its wake.
292
00:20:01,620 --> 00:20:03,793
The rope machine
With twisting hooks
293
00:20:03,793 --> 00:20:06,379
Remains in the same place.
294
00:20:08,655 --> 00:20:10,620
When the cart arrives
At the opposite side
295
00:20:10,620 --> 00:20:14,103
Of the building,
The rope is formed.
296
00:20:14,103 --> 00:20:17,241
A worker removes
The ties around the top.
297
00:20:17,241 --> 00:20:18,655
They now have a piece of rope
298
00:20:18,655 --> 00:20:20,586
That's over 700 feet long
299
00:20:20,586 --> 00:20:23,275
And almost 5 inches in diameter.
300
00:20:27,655 --> 00:20:30,275
They slice the rope
At both ends.
301
00:20:34,275 --> 00:20:36,724
Then they wind it
Onto a big spool,
302
00:20:36,724 --> 00:20:39,586
Packing it into a tight coil.
303
00:20:39,586 --> 00:20:43,413
This traditional rope
Is almost ready to be shipped.
304
00:20:46,034 --> 00:20:48,068
The customer
Requested looped ends
305
00:20:48,068 --> 00:20:52,275
For securing the rope
With a shackle.
306
00:20:52,275 --> 00:20:54,965
So, the rope-maker
Unravels the ends
307
00:20:54,965 --> 00:20:59,724
And pierces the rope
With a hollow tool called a fid.
308
00:20:59,724 --> 00:21:01,724
He makes a loop
309
00:21:01,724 --> 00:21:05,620
And slides the unraveled strands
Through the fid.
310
00:21:05,620 --> 00:21:08,206
He finishes the job
By weaving the strands
311
00:21:08,206 --> 00:21:10,000
Into the rope.
312
00:21:13,103 --> 00:21:16,068
They're ready to test
A segment of the rope.
313
00:21:16,068 --> 00:21:19,758
Two hydraulic jaws
Pull it until it breaks.
314
00:21:20,137 --> 00:21:24,758
The rope must be able
To handle 55 tons of force.
315
00:21:29,172 --> 00:21:32,344
Traditional ropes have
The strength to carry on,
316
00:21:32,344 --> 00:21:34,724
As they have done
For a very long time.
25383
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