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-- Captions by VITAC --
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www.vitac.com
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CAPTIONS PAID FOR BY
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DISCOVERY COMMUNICATIONS
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**
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Narrator: TODAY ON
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"HOW IT'S MADE"...
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THE INVENTION OF POLYURETHANE
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SKATEBOARD WHEELS
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IN THE EARLY 1970s
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SUDDENLY MADE JUMPS
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AND TIGHT CORNERING POSSIBLE
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BECAUSE THESE WHEELS HAD
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A BETTER GRIP ON RIDING SURFACES
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THAN THE OLD METAL
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OR CERAMIC WHEELS.
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THEY WERE MORE DURABLE,
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AND THE SHOCK ABSORPTION
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WAS GREATLY IMPROVED.
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SKATEBOARD WHEELS COME
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IN DIFFERENT SIZES,
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HARDNESS, COLORS
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AND GRAPHIC DESIGNS.
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FOR THE RIDER,
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THERE ARE MAY PRACTICAL
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AND AESTHETIC CONSIDERATIONS.
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MAKING SKATEBOARD WHEELS STARTS
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WITH A COMPUTER DESIGN.
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A DESIGNER USES THE SOFTWARE
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TO GUIDE CUTTING TOOLS.
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THE TOOLS CARVE
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INTO A SOLID ALUMINUM PUCK
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AND TRANSFORM IT
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INTO ONE HALF OF A WHEEL MOLD.
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NEXT, THE OTHER HALF
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OF THE MOLD TAKES SHAPE
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AS THE COMPUTERIZED
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TOOLING SCULPTS
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ANOTHER PUCK TO A PROFILE
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THAT FITS TO THE FIRST
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ONE PERFECTLY.
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NOT ALL OF THE SKATEBOARD WHEEL
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MOLDS ARE TWO-PART VERSIONS.
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OTHERS ARE ONE-PIECE STRUCTURES,
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EACH WITH A PIN IN THE CENTER
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TO FORM A BEARING CAVITY.
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A NOZZLE DISPENSES FRESHLY
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MIXED POLYURETHANE LIQUID
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INTO THE WHEEL MOLDS.
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THE LIQUID STARTS
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TO SOLIDIFY IMMEDIATELY.
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TO COMPLETE THE PROCESS,
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A WORKER LOADS
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THE POLYURETHANE-FILLED MOLDS
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INTO AN OVEN
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AND BAKES THEM
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AT ALMOST 240 DEGREES FAHRENHEIT
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FOR 40 MINUTES.
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DURING BAKING, ANY BUBBLES
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IN THE POLYURETHANE RISE
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TO THE TOP
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AND ARE DIFFUSED,
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LEAVING SOLID FORMS
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WITH NO WEAK SPOTS.
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WORKERS REMOVE THE PINS
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FROM THE MOLDS.
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THEN IT'S ON
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TO THE NEXT STATION.
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HERE, A WORKER
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BLASTS COMPRESSED AIR
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BETWEEN THE WHEELS
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AND THE MOLDS TO PRY
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THE WHEELS FREE
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AND POP THEM OUT.
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ANOTHER WORKER PROBES THE WHEEL
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USING A DUROMETER GAUGE
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TO ENSURE THE URETHANE HAS CURED
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TO THE RIGHT DEGREE OF HARDNESS.
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IF THE SAMPLE WHEEL
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IS SUFFICIENTLY HARD,
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THE BATCH IS READY
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FOR THE NEXT STEP.
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THE WORKER CLAMPS
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THE SKATEBOARD WHEEL IN A LATHE.
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THE LATHE SPINS THE WHEEL
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WHILE AN AUTOMATIC
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CUTTER CONTOURS
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THE EDGES TO A SOFTER,
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MORE ROUNDED PROFILE.
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TO GIVE THE SKATEBOARD
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WHEELS SOME VISUAL IMPACT,
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AN ARTISTS SELECTS
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AND ARRANGES GRAPHIC
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DESIGNS ON A COMPUTER.
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HE PRINTS A FILM NEGATIVE
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OF THE IMAGES HE'S CHOSEN.
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A WORKER WILL USE THIS NEGATIVE
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TO PRODUCE A PRINTING PLATE
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FROM A PIECE OF METAL
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THAT'S BEEN COATED
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WITH A LIGHT-SENSITIVE
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SUBSTANCE KNOWN AS EMULSION.
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HE PLACES THE FILM NEGATIVE
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ON THE PLATE
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INSIDE A UV LIGHT CHAMBER.
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HE CLOSES THE LID
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AND ACTIVATES THE UV LIGHT.
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THIS TRIGGERS
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A PHOTOCHEMICAL REACTION
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THAT TRANSFERS THE IMAGE
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FROM THE NEGATIVE TO THE PLATE.
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THE WORKER THEN APPLIES
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A SOLUTION THAT REMOVES
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UNEXPOSED EMULSION AND,
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IN THE PROCESS,
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ETCHES THE IMAGE
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INTO THE PRINTING PLATE.
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HE RINSES OFF THE CHEMICALS.
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NEXT, HE DRIES THE PLATE
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TO REVEAL THE ETCHED ARTWORK.
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ANOTHER WORKER POSITIONS
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A MAGNETIZED
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INK CUP OVERVIEW THE IMAGE
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AND INSTALLS IT
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IN A PAD PRINTING MACHINE.
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AN OPERATOR LOADS SKATEBOARD
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WHEELS ONTO POSTS
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THAT INDEX THEM FORWARD
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FOR PRINTING.
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THE INK CUP DEPOSITS
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INK ON THE PRINTING PLATE.
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A SILICONE PAD PICKS UP
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THE INKED IMAGE AND STAMPS
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IT ONTO THE SKATEBOARD WHEEL.
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THE OPERATOR REMOVES
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THE PRINTED WHEEL
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AND SETS IT ON A TRAY.
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A TECHNICIAN NOW CLAMPS
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ONE OF THE WHEELS
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IN A TESTING DEVICE,
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WHICH WILL GAUGE THE REBOUND.
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HE DROPS A METAL BALL
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ONTO THE WHEEL AND MEASURES
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HOW HIGH IT BOUNCES
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OR REBOUNDS.
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A HIGH REBOUND IS DESIRABLE.
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THESE SKATEBOARD WHEELS
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ARE NOW CLEARED FOR SHIPPING.
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A WORKER WRAPS THE WHEELS
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IN PLASTIC AND HEAT SHRINKS IT.
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IT TAKES ABOUT 3 DAYS
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TO MAKE THESE SKATEBOARD WHEELS.
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BUT HOW LONG THEY'LL
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LAST DEPENDS A LOT ON THE RIDER
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AND HOW HE OR SHE ROLLS.
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**
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**
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Narrator:
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GALAKTOBOUREKO AND BAKLAVA
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ARE TRADITIONAL GREEK DESSERTS.
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ALTHOUGH SEVERAL EUROPEAN
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AND MIDDLE EASTERN COUNTRIES
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HAVE VERSIONS OF BAKLAVA,
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MOST CONSIST OF FILO PASTRY
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FILLED WITH NUTS DRENCHED
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IN HONEY OR SYRUP.
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GALAKTOBOUREKO IS FILO FILLED
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WITH CUSTARD
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AND COATED WITH SWEET SYRUP.
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THIS VARIETY OF BAKLAVA
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CALLED BURMA
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IS MADE NOT WITH FILO DOUGH,
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LIKE CLASSIC BAKLAVA,
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BUT WITH KATAIFI,
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SHREDDED WHEAT DOUGH.
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BURMA, LIKE CLASSIC
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FILO BAKLAVA,
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CONTAINS WHOLE PISTACHIOS,
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NEVER PISTACHIO POWDER.
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THIS BURMA CHEF POURS
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GRANULATED SUGAR OVER
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THE PISTACHIO KERNELS.
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NEXT, HE SPRINKLES ROSE WATER,
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ALTHOUGH THIS INGREDIENT
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IS OPTIONAL,
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THEN SYRUP MADE
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WITH SUGAR,
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WATER, CINNAMON AND NUTMEG
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AS WELL AS LEMON
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TO PREVENT THE SUGAR
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FROM LATER CRYSTALLIZING.
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HE MIXES BY HAND TO
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THOROUGHLY COAT THE KERNELS.
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THE KATAIFI IS MADE
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OF ALL-PURPOSE FLOUR,
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MILK AND WATER.
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THE CHEF LAYS OUT
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A SECTION OF DOUGH,
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THEN TAKES A HANDFUL
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OF PISTACHIO
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FILLING AND PLACES
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IT ON THE DOUGH,
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FORMING A LINE
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RUNNING DOWN THE MIDDLE.
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FOR A BURMA LOAF THIS SIZE,
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THE FILLING IS ABOUT
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AN INCH WIDE AND HIGH.
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HE FOLDS THE END CLOSED
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AND ROLLS THE DOUGH AT AN ANGLE
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DOWN THE LENGTH OF THE BURMA,
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TIGHTLY ENCASING
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THE FILLING AS HE GOES.
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00:07:30,067 --> 00:07:33,300
AT THE END, HE FOLDS
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THE OPPOSITE END CLOSED.
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IT TAKES A BURMA CHEF MONTHS
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TO PERFECT THIS TECHNIQUE.
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HE PLACES IT ON A TRAY
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00:07:38,067 --> 00:07:41,833
TO AIR-DRY FOR 24 HOURS
219
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TO ENSURE THE DOUGH
220
00:07:41,833 --> 00:07:46,067
MAINTAINS ITS ROLLED SHAPE.
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00:07:46,067 --> 00:07:50,167
UNLIKE CLASSIC BAKLAVA,
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WHICH IS BAKED, BURMA IS FRIED.
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00:07:50,167 --> 00:07:52,267
AND THE RISK OF
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00:07:50,167 --> 00:07:52,267
BURNING THE PISTACHIOS
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MAKES THIS THE MOST TECHNICALLY
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CHALLENGING TYPE
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OF BAKLAVA TO MAKE.
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00:07:56,733 --> 00:07:58,567
THE CHEF FRIES THE LOAVES
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00:07:58,567 --> 00:08:00,267
FOR 3 MINUTES IN OIL HEATED
230
00:08:00,267 --> 00:08:02,800
TO AROUND
231
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350 DEGREES FAHRENHEIT,
232
00:08:02,800 --> 00:08:05,233
TURNING THEM
233
00:08:02,800 --> 00:08:05,233
ONCE PER MINUTE.
234
00:08:05,233 --> 00:08:09,133
HE LETS THE OIL DRAIN
235
00:08:05,233 --> 00:08:09,133
OFF FOR HALF AN HOUR.
236
00:08:09,133 --> 00:08:11,367
THEN, HE POURS
237
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WARM CARAMELIZED
238
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SUGAR OVER THE LOAVES
239
00:08:12,967 --> 00:08:15,333
AND LETS THEM SOAK
240
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FOR 20 MINUTES.
241
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THE SUGAR-TO-WATER RATIO
242
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AND THE BOILING TIME
243
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OF THE CARAMELIZED
244
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SUGAR HAVE TO BE JUST RIGHT.
245
00:08:21,900 --> 00:08:24,333
OTHERWISE, IT WILL BECOME
246
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EITHER TOO HARD
247
00:08:24,333 --> 00:08:28,200
OR TO GOOEY WHEN IT COOLS.
248
00:08:28,200 --> 00:08:30,167
AFTER LETTING
249
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THE EXCESS DRAIN OFF,
250
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THE LOAVES REST
251
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FOR ABOUT 3 HOURS.
252
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THEN THE CHEF ROLLS
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THE LOAF TO FLATTEN
254
00:08:37,400 --> 00:08:38,867
OUT THE BUMPS
255
00:08:38,867 --> 00:08:41,567
AND SLICES
256
00:08:38,867 --> 00:08:41,567
IT INTO EQUAL PIECES.
257
00:08:45,267 --> 00:08:46,967
BUT IF THERE'S
258
00:08:45,267 --> 00:08:46,967
A PROTRACTED BATTLE
259
00:08:46,967 --> 00:08:51,233
WAGING BETWEEN YOUR SWEET
260
00:08:46,967 --> 00:08:51,233
TOOTH AND YOUR WILLPOWER,
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YOU'VE GOT PLENTY OF TIME
262
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TO WORK YOUR WAY
263
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THROUGH A BOX OF BURMA
264
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BECAUSE IT STAYS
265
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FRESH FOR 2 WEEKS.
266
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TO MAKE GALAKTOBOUREKO,
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THE CHEF BEGINS
268
00:09:03,867 --> 00:09:06,700
WITH TWO INGREDIENTS,
269
00:09:06,700 --> 00:09:10,167
MILK AND SEMOLINA.
270
00:09:10,167 --> 00:09:12,233
AFTER BRINGING THE MILK
271
00:09:10,167 --> 00:09:12,233
TO A BOIL,
272
00:09:12,233 --> 00:09:14,267
HE GRADUALLY ADDS THE SEMOLINA
273
00:09:14,267 --> 00:09:17,200
WHILE WHISKING AND LOWERING
274
00:09:14,267 --> 00:09:17,200
THE TEMPERATURE.
275
00:09:17,200 --> 00:09:21,167
ONCE THE MIX THICKENS,
276
00:09:17,200 --> 00:09:21,167
HE SETS IT ASIDE TO COOL.
277
00:09:21,167 --> 00:09:25,300
IN A SEPARATE BOWL,
278
00:09:21,167 --> 00:09:25,300
THE CHEF WHISKS EGGS,
279
00:09:25,300 --> 00:09:27,300
ADDS VANILLA,
280
00:09:27,300 --> 00:09:29,600
THEN LEMON OR ORANGE RIND.
281
00:09:29,600 --> 00:09:34,133
OTHER OPTIONS ARE ORANGE
282
00:09:29,600 --> 00:09:34,133
BLOSSOM OR ROSE WATER EXTRACT.
283
00:09:34,133 --> 00:09:37,500
HE TRANSFERS THE INGREDIENTS
284
00:09:34,133 --> 00:09:37,500
TO AN ELECTRIC MIXER,
285
00:09:37,500 --> 00:09:39,100
ADDS BUTTER AND SUGAR.
286
00:09:39,100 --> 00:09:42,267
THEN HE ADDS THE SEMOLINA
287
00:09:39,100 --> 00:09:42,267
AND MILK MIXTURE.
288
00:09:42,267 --> 00:09:44,567
THIS MIXTURE MUST BE COOL
289
00:09:44,567 --> 00:09:48,300
SO THAT THE EGGS DON'T COOK.
290
00:09:48,300 --> 00:09:50,367
ONCE EVERYTHING
291
00:09:48,300 --> 00:09:50,367
IS THOROUGHLY BLENDED,
292
00:09:50,367 --> 00:09:53,367
THE GALAKTOBOUREKO
293
00:09:50,367 --> 00:09:53,367
CUSTARD IS READY.
294
00:09:56,433 --> 00:09:59,600
THE CHEF NOW TURNS HIS ATTENTION
295
00:09:56,433 --> 00:09:59,600
TO THE FILO DOUGH.
296
00:09:59,600 --> 00:10:01,967
HE STACKS 24
297
00:09:59,600 --> 00:10:01,967
PARCHMENT-THIN SHEETS
298
00:10:01,967 --> 00:10:05,667
OF FILO AND SLICES
299
00:10:01,967 --> 00:10:05,667
THEM INTO SQUARES.
300
00:10:05,667 --> 00:10:07,567
HE PLACES ONE SCOOPFUL
301
00:10:05,667 --> 00:10:07,567
OF CUSTARD
302
00:10:07,567 --> 00:10:09,133
IN THE CENTER OF EACH SQUARE.
303
00:10:09,133 --> 00:10:13,067
THE TRADITIONAL GREEK WAY
304
00:10:09,133 --> 00:10:13,067
IS TO ROLL THE SQUARES
305
00:10:13,067 --> 00:10:16,100
OR BAKE A LARGE GALAKTOBOUREKO
306
00:10:13,067 --> 00:10:16,100
IN A PAN
307
00:10:16,100 --> 00:10:18,300
AND THEN CUT IT
308
00:10:16,100 --> 00:10:18,300
INTO SQUARES.
309
00:10:18,300 --> 00:10:20,633
HOWEVER, THIS CHEF FOLDS
310
00:10:18,300 --> 00:10:20,633
OVER EACH SQUARE
311
00:10:20,633 --> 00:10:24,133
TO MAKE LEBANESE-STYLE
312
00:10:20,633 --> 00:10:24,133
TRIANGLES.
313
00:10:24,133 --> 00:10:27,200
HE DOUSES THE TOP
314
00:10:24,133 --> 00:10:27,200
WITH CLARIFIED BUTTER,
315
00:10:27,200 --> 00:10:30,200
BUTTER THAT'S BEEN BOILED
316
00:10:27,200 --> 00:10:30,200
TO SEPARATE OUT THE SOLIDS
317
00:10:30,200 --> 00:10:32,300
AND LEAVE JUST THE OIL.
318
00:10:32,300 --> 00:10:33,667
THEN HE BAKES THE PASTRIES
319
00:10:33,667 --> 00:10:38,367
FOR 45 MINUTES
320
00:10:33,667 --> 00:10:38,367
AT 325 DEGREES FAHRENHEIT.
321
00:10:38,367 --> 00:10:40,100
THE GOLDEN-BAKED TOP SHINES
322
00:10:40,100 --> 00:10:42,533
THANKS TO THE CLARIFIED BUTTER.
323
00:10:42,533 --> 00:10:45,933
THE CHEF COOKS THE SAME SYRUP
324
00:10:42,533 --> 00:10:45,933
HE MADE FOR THE BAKLAVA,
325
00:10:45,933 --> 00:10:47,833
SUGAR, WATER, CINNAMON,
326
00:10:47,833 --> 00:10:49,333
NUTMEG AND LEMON
327
00:10:49,333 --> 00:10:50,700
AND GENEROUSLY DRIZZLES
328
00:10:50,700 --> 00:10:53,967
THE MIXTURE ALL OVER
329
00:10:50,700 --> 00:10:53,967
THE GALAKTOBOUREKOS.
330
00:10:53,967 --> 00:10:56,667
HE SPRINKLES ON CINNAMON
331
00:10:53,967 --> 00:10:56,667
FOR TRADITIONAL FLAVOR
332
00:10:56,667 --> 00:10:59,767
AND SOME CRUSHED PISTACHIOS
333
00:10:56,667 --> 00:10:59,767
FOR DECORATION.
334
00:11:07,633 --> 00:11:09,233
**
335
00:11:12,933 --> 00:11:16,167
Narrator: THE ANNUAL APPLE
336
00:11:12,933 --> 00:11:16,167
HARVEST IS JUST 2 MONTHS LONG.
337
00:11:16,167 --> 00:11:19,100
TO KEEP APPLES FRESH
338
00:11:16,167 --> 00:11:19,100
IN STORAGE FOR SEVERAL MONTHS,
339
00:11:19,100 --> 00:11:21,467
GROWERS LOWER THE STOREROOM
340
00:11:19,100 --> 00:11:21,467
OXYGEN LEVEL
341
00:11:21,467 --> 00:11:23,767
TO PUT THE APPLES
342
00:11:21,467 --> 00:11:23,767
INTO HIBERNATION.
343
00:11:23,767 --> 00:11:27,700
THEN THEY USE MACHINES
344
00:11:23,767 --> 00:11:27,700
CALLED CO2 SCRUBBERS TO ABSORB
345
00:11:27,700 --> 00:11:31,567
AND REMOVE THE CARBON DIOXIDE
346
00:11:27,700 --> 00:11:31,567
GAS THE APPLES GIVE OFF.
347
00:11:33,433 --> 00:11:35,333
THIS CO2 SCRUBBER PULLS AIR
348
00:11:35,333 --> 00:11:38,400
FROM THE AIRTIGHT APPLE STORAGE
349
00:11:35,333 --> 00:11:38,400
ROOM THROUGH CARBON PELLETS,
350
00:11:38,400 --> 00:11:41,433
WHICH ABSORB THE CO2
351
00:11:38,400 --> 00:11:41,433
GAS MOLECULES.
352
00:11:41,433 --> 00:11:44,367
THE MACHINE THEN BLOWS
353
00:11:41,433 --> 00:11:44,367
THE CO2-FREE AIR
354
00:11:44,367 --> 00:11:46,667
BACK INTO THE ROOM.
355
00:11:46,667 --> 00:11:50,667
WORKERS BUILD THE MACHINE'S
356
00:11:46,667 --> 00:11:50,667
FRAME OUT OF TUBULAR STEEL.
357
00:11:50,667 --> 00:11:52,900
THE FRAME SUPPORTS
358
00:11:50,667 --> 00:11:52,900
ALL THE COMPONENTS,
359
00:11:52,900 --> 00:11:56,400
INCLUDING TWO SEALED VESSELS
360
00:11:52,900 --> 00:11:56,400
FILLED WITH CARBON PELLETS.
361
00:11:56,400 --> 00:11:59,667
THE FIRST VESSEL
362
00:11:56,400 --> 00:11:59,667
STARTS ABSORBING CO2,
363
00:11:59,667 --> 00:12:01,433
A PROCESS CALLED SCRUBBING,
364
00:12:01,433 --> 00:12:03,800
UNTIL ITS PELLETS
365
00:12:01,433 --> 00:12:03,800
ARE SATURATED.
366
00:12:03,800 --> 00:12:06,900
THEN THE SECOND VESSEL
367
00:12:03,800 --> 00:12:06,900
TAKES OVER THE SCRUBBING.
368
00:12:06,900 --> 00:12:09,067
THE FIRST VESSEL
369
00:12:06,900 --> 00:12:09,067
AUTOMATICALLY KICKS
370
00:12:09,067 --> 00:12:10,867
INTO A REGENERATION CYCLE,
371
00:12:10,867 --> 00:12:13,567
WHICH BLOWS FRESH AIR
372
00:12:10,867 --> 00:12:13,567
THROUGH THE PELLETS
373
00:12:13,567 --> 00:12:15,767
TO REMOVE THE CO2 MOLECULES
374
00:12:15,767 --> 00:12:17,833
AND EXHAUST THEM
375
00:12:15,767 --> 00:12:17,833
OUT THE BUILDING.
376
00:12:17,833 --> 00:12:20,233
WHEN THE SECOND VESSEL'S
377
00:12:17,833 --> 00:12:20,233
PELLETS MAX OUT,
378
00:12:20,233 --> 00:12:22,333
VESSEL ONE RESUMES SCRUBBING
379
00:12:22,333 --> 00:12:25,267
WHILE VESSEL TWO REGENERATES.
380
00:12:25,267 --> 00:12:27,133
TO CONSTRUCT EACH VESSEL,
381
00:12:27,133 --> 00:12:30,500
WORKERS WELD A STEEL SHEET
382
00:12:27,133 --> 00:12:30,500
INTO A CIRCULAR SHAPE,
383
00:12:30,500 --> 00:12:33,667
THEN WELD ON A BASE
384
00:12:30,500 --> 00:12:33,667
AND A TOP RING.
385
00:12:33,667 --> 00:12:35,900
THE RING HAS HOLES
386
00:12:33,667 --> 00:12:35,900
ALONG ITS PERIMETER
387
00:12:35,900 --> 00:12:37,600
FOR BOLTING ON A LID.
388
00:12:37,600 --> 00:12:39,100
THEY USE A RING TEMPLATE
389
00:12:39,100 --> 00:12:41,867
TO MAKE CORRESPONDING
390
00:12:39,100 --> 00:12:41,867
HOLES IN THE LID,
391
00:12:41,867 --> 00:12:46,467
MAKING THE EXACT CENTER
392
00:12:41,867 --> 00:12:46,467
OF EACH HOLE WITH A PUNCH TOOL.
393
00:12:46,467 --> 00:12:49,633
THEN A WORKER MOUNTS
394
00:12:46,467 --> 00:12:49,633
THE LID ON A FIXTURE
395
00:12:49,633 --> 00:12:51,333
AND FOLLOWING THOSE MARKS,
396
00:12:51,333 --> 00:12:54,833
USES AN AUTOMATED STEEL
397
00:12:51,333 --> 00:12:54,833
PUNCH TO PERFORATE THE STEEL.
398
00:13:01,233 --> 00:13:02,800
THE VESSELS GO TO
399
00:13:01,233 --> 00:13:02,800
THE PAINT BOOTH
400
00:13:02,800 --> 00:13:04,767
FOR A COAT OF POWDER PAINT,
401
00:13:04,767 --> 00:13:07,800
THEN INTO AN OVEN
402
00:13:04,767 --> 00:13:07,800
TO BAKE THE PAINT.
403
00:13:07,800 --> 00:13:09,900
WHEN THEY COME OUT,
404
00:13:07,800 --> 00:13:09,900
THE VESSELS ARE READY
405
00:13:09,900 --> 00:13:13,067
TO BE FILLED WITH CARBON
406
00:13:09,900 --> 00:13:13,067
PELLETS AND SEALED.
407
00:13:15,833 --> 00:13:19,667
ONCE FILLED TO THE TOP,
408
00:13:15,833 --> 00:13:19,667
WORKERS LAY IN A STEEL BAFFLE.
409
00:13:21,967 --> 00:13:25,567
ITS HOLES EVENLY DISTRIBUTE
410
00:13:21,967 --> 00:13:25,567
AIR PASSING THROUGH THE VESSEL.
411
00:13:27,067 --> 00:13:29,400
A WORKER THEN PLACES
412
00:13:27,067 --> 00:13:29,400
A FOAM RUBBER GASKET
413
00:13:29,400 --> 00:13:33,167
AROUND THE PERIMETER
414
00:13:33,167 --> 00:13:35,467
AND BOLTS ON THE LID TIGHTLY.
415
00:13:35,467 --> 00:13:38,633
THIS SEALS THE VESSEL
416
00:13:35,467 --> 00:13:38,633
AND PREVENTS THE AIR
417
00:13:38,633 --> 00:13:41,167
BEING BLOWN THROUGH IT
418
00:13:38,633 --> 00:13:41,167
FROM LEAKING OUT.
419
00:13:41,167 --> 00:13:43,600
THE SEALED LID
420
00:13:41,167 --> 00:13:43,600
ALSO PREVENTS OXYGEN
421
00:13:43,600 --> 00:13:45,333
FROM GETTING INTO THE MACHINE
422
00:13:45,333 --> 00:13:48,467
AND FROM THERE INTO
423
00:13:45,333 --> 00:13:48,467
THE APPLE STORAGE ROOM.
424
00:13:48,467 --> 00:13:50,633
NEXT, WORKERS INSTALL THE PVC
425
00:13:50,633 --> 00:13:51,900
PIPING THAT FEEDS AIR
426
00:13:51,900 --> 00:13:55,367
THROUGH THE VESSELS
427
00:13:51,900 --> 00:13:55,367
ALONG WITH TWO BLOWERS.
428
00:13:55,367 --> 00:13:58,067
ONE BLOWER PULLS AIR
429
00:13:55,367 --> 00:13:58,067
FROM THE APPLE STORAGE ROOM
430
00:13:58,067 --> 00:14:00,167
INTO THE MACHINE FOR SCRUBBING.
431
00:14:00,167 --> 00:14:03,200
THE OTHER SENDS IT BACK
432
00:14:00,167 --> 00:14:03,200
TO THE ROOM AFTER SCRUBBING.
433
00:14:05,333 --> 00:14:09,133
THE AIR FLOW THROUGH THE PIPES
434
00:14:05,333 --> 00:14:09,133
IS CONTROLLED BY VALVES,
435
00:14:09,133 --> 00:14:13,067
WHICH ARE WIRED TO THE MACHINE'S
436
00:14:09,133 --> 00:14:13,067
ELECTRICAL PANEL.
437
00:14:13,067 --> 00:14:16,800
THAT ELECTRICAL PANEL,
438
00:14:13,067 --> 00:14:16,800
CONSISTING OF RELAYS, PUMPS,
439
00:14:16,800 --> 00:14:19,100
GAS ANALYZERS
440
00:14:16,800 --> 00:14:19,100
AND A TOUCH SCREEN,
441
00:14:19,100 --> 00:14:22,567
IS BUILT IN-HOUSE
442
00:14:19,100 --> 00:14:22,567
IN ACCORDANCE
443
00:14:22,567 --> 00:14:24,300
WITH THE REQUIRED
444
00:14:22,567 --> 00:14:24,300
ELECTRICAL STANDARDS
445
00:14:24,300 --> 00:14:26,433
OF THE CUSTOMER'S COUNTRY.
446
00:14:26,433 --> 00:14:29,500
THE PANEL IS WIRED
447
00:14:26,433 --> 00:14:29,500
TO A COMPUTER
448
00:14:29,500 --> 00:14:32,167
WHICH CONTROLS
449
00:14:29,500 --> 00:14:32,167
THE ENTIRE OPERATION.
450
00:14:35,767 --> 00:14:38,567
THEN A WORKER INSTALLS
451
00:14:35,767 --> 00:14:38,567
AN ELECTRICAL BOX
452
00:14:38,567 --> 00:14:40,467
INTO THE MACHINE'S FRAME.
453
00:14:45,933 --> 00:14:47,967
AND HE INSTALLS
454
00:14:45,933 --> 00:14:47,967
THE ELECTRICAL PANEL
455
00:14:47,967 --> 00:14:50,500
INSIDE THE BOX.
456
00:14:54,933 --> 00:14:58,333
NEXT, THE WORKER CONNECTS
457
00:14:54,933 --> 00:14:58,333
THE WIRES TO THE VALVES,
458
00:14:58,333 --> 00:15:01,533
INSTALLS THE TOUCH SCREEN
459
00:14:58,333 --> 00:15:01,533
AND HOOKS IT UP TO THE COMPUTER.
460
00:15:01,533 --> 00:15:04,267
THE TOUCH SCREEN
461
00:15:01,533 --> 00:15:04,267
LETS THE MACHINE'S OPERATOR
462
00:15:04,267 --> 00:15:08,200
PROGRAM OXYGEN
463
00:15:04,267 --> 00:15:08,200
AND CO2 TARGET LEVELS
464
00:15:08,200 --> 00:15:11,433
SPECIFIC TO THE TYPE OF APPLE
465
00:15:08,200 --> 00:15:11,433
STORED IN THE ROOM.
466
00:15:11,433 --> 00:15:12,867
THIS IS CRITICAL,
467
00:15:12,867 --> 00:15:16,800
AS DIFFERENT VARIETIES OF APPLES
468
00:15:12,867 --> 00:15:16,800
GIVE OFF MORE CO2 THAN OTHERS.
469
00:15:19,067 --> 00:15:20,700
HOW DOES IT ALL WORK?
470
00:15:20,700 --> 00:15:22,633
THE GROWER STACKS
471
00:15:20,700 --> 00:15:22,633
BINS OF APPLES
472
00:15:22,633 --> 00:15:25,133
IN AN AIRTIGHT STOREROOM.
473
00:15:25,133 --> 00:15:27,933
A NITROGEN GENERATOR
474
00:15:25,133 --> 00:15:27,933
FEEDS IN NITROGEN
475
00:15:27,933 --> 00:15:32,167
TO REDUCE THE ROOM'S OXYGEN
476
00:15:27,933 --> 00:15:32,167
LEVEL TO 1.8%.
477
00:15:32,167 --> 00:15:33,467
WHEN THAT HAPPENS,
478
00:15:33,467 --> 00:15:36,167
THE NITROGEN FEED
479
00:15:33,467 --> 00:15:36,167
AUTOMATICALLY STOPS,
480
00:15:36,167 --> 00:15:41,067
AND THE CONTINUOUS CO2 SCRUBBING
481
00:15:36,167 --> 00:15:41,067
AUTOMATICALLY BEGINS.
482
00:15:41,067 --> 00:15:43,267
MANY GROWERS HAVE IN-HOUSE LABS
483
00:15:43,267 --> 00:15:46,100
WHICH CONDUCT QUALITY
484
00:15:43,267 --> 00:15:46,100
CONTROL TESTS ON SAMPLES
485
00:15:46,100 --> 00:15:48,067
TAKEN FROM EACH LOT
486
00:15:46,100 --> 00:15:48,067
OF SCRUBBED APPLES
487
00:15:48,067 --> 00:15:50,767
COMING OUT OF STORAGE.
488
00:15:50,767 --> 00:15:53,100
NO APPLES WOULD PASS
489
00:15:50,767 --> 00:15:53,100
THESE TESTS AFTER
490
00:15:53,100 --> 00:15:54,767
THE 2-MONTH HARVEST SEASON
491
00:15:54,767 --> 00:15:57,667
IF NOT FOR THE CO2 SCRUBBERS.
492
00:15:57,667 --> 00:16:00,500
CO2 SCRUBBERS LENGTHEN
493
00:15:57,667 --> 00:16:00,500
AN APPLE'S FRESHNESS
494
00:16:00,500 --> 00:16:02,067
BY ABOUT 8 MONTHS,
495
00:16:02,067 --> 00:16:05,967
MAKING IT POSSIBLE TO BITE INTO
496
00:16:02,067 --> 00:16:05,967
CRISPY APPLES YEAR-ROUND.
497
00:16:14,267 --> 00:16:15,767
**
498
00:16:19,667 --> 00:16:22,067
NARRATOR: HONEYCOMB CANDLES ARE
499
00:16:19,667 --> 00:16:22,067
GLOWING REMINDERS
500
00:16:22,067 --> 00:16:24,333
OF THE CLEVERNESS
501
00:16:22,067 --> 00:16:24,333
OF THE HONEYBEE.
502
00:16:24,333 --> 00:16:27,400
THESE CANDLES ARE EMBOSSED
503
00:16:24,333 --> 00:16:27,400
WITH A HEXAGONAL PATTERN
504
00:16:27,400 --> 00:16:31,067
THAT MIMICS THE CELL STRUCTURES
505
00:16:27,400 --> 00:16:31,067
BEES BUILD TO STORE THEIR HONEY.
506
00:16:31,067 --> 00:16:32,967
AND INTERESTINGLY,
507
00:16:31,067 --> 00:16:32,967
THESE CANDLES
508
00:16:32,967 --> 00:16:35,667
ARE ACTUALLY MADE
509
00:16:32,967 --> 00:16:35,667
FROM THE WAX FOUNDATION SHEETS
510
00:16:35,667 --> 00:16:38,400
USED FOR BEEKEEPERS'
511
00:16:35,667 --> 00:16:38,400
HIVE FRAMES.
512
00:16:38,400 --> 00:16:41,200
**
513
00:16:41,200 --> 00:16:44,067
HONEYCOMB CANDLES CREATE
514
00:16:41,200 --> 00:16:44,067
A CERTAIN AMBIANCE.
515
00:16:44,067 --> 00:16:45,400
THEY SHINE BRIGHTLY.
516
00:16:45,400 --> 00:16:46,800
AND THE HEXAGONAL PATTERN
517
00:16:46,800 --> 00:16:50,333
THAT'S BORROWED FROM THE BEES
518
00:16:46,800 --> 00:16:50,333
ADDS VISUAL INTEREST.
519
00:16:50,333 --> 00:16:52,733
THE CANDLE MAKERS
520
00:16:50,333 --> 00:16:52,733
START WITH BEESWAX
521
00:16:52,733 --> 00:16:55,067
THAT HAS HAD
522
00:16:52,733 --> 00:16:55,067
THE IMPURITIES FILTERED OUT
523
00:16:55,067 --> 00:16:56,833
AND HAS BEEN BLEACHED.
524
00:16:56,833 --> 00:16:59,067
A WORKER FIRST POURS THE BEESWAX
525
00:16:59,067 --> 00:17:03,633
INTO A BIG GAS-HEATED KETTLE
526
00:16:59,067 --> 00:17:03,633
UNTIL IT MELTS.
527
00:17:03,633 --> 00:17:04,933
IT ONLY TAKES AROUND 1/10
528
00:17:04,933 --> 00:17:06,333
OF AN OUNCE OF POWDERED DYE
529
00:17:06,333 --> 00:17:09,767
TO TINT THE BIG VAT OF WAX.
530
00:17:09,767 --> 00:17:12,067
HE MEASURES
531
00:17:09,767 --> 00:17:12,067
THE AMOUNT CAREFULLY.
532
00:17:14,433 --> 00:17:16,400
THE WORKER ADDS THE DYE AND,
533
00:17:16,400 --> 00:17:18,833
AS IT DISSOLVES
534
00:17:16,400 --> 00:17:18,833
IN THE LIQUID BEESWAX,
535
00:17:18,833 --> 00:17:21,367
HE STIRS IT TO DISTRIBUTE
536
00:17:18,833 --> 00:17:21,367
IT EVENLY.
537
00:17:23,700 --> 00:17:25,200
HE THEN OPENS A VALVE,
538
00:17:25,200 --> 00:17:28,633
AND THE WAX FLOWS INTO
539
00:17:25,200 --> 00:17:28,633
A TROUGH BENEATH A LARGE DRUM.
540
00:17:31,567 --> 00:17:35,200
THIS DRUM IS COOLED
541
00:17:31,567 --> 00:17:35,200
BY A SYSTEM OF CHILLERS.
542
00:17:35,200 --> 00:17:37,933
AS IT ROTATES,
543
00:17:35,200 --> 00:17:37,933
IT PICKS UP THE WAX.
544
00:17:37,933 --> 00:17:40,400
AND THE WAX SOLIDIFIES
545
00:17:37,933 --> 00:17:40,400
ON CONTACT
546
00:17:40,400 --> 00:17:42,800
WITH THE DRUM'S COOL SURFACE.
547
00:17:42,800 --> 00:17:44,833
THE SYSTEM THEN PULLS
548
00:17:42,800 --> 00:17:44,833
THE WAX SHEETS
549
00:17:44,833 --> 00:17:49,133
THROUGH A NARROW APERTURE
550
00:17:44,833 --> 00:17:49,133
TO SQUEEZE IT THINNER.
551
00:17:49,133 --> 00:17:50,700
AT THIS POINT,
552
00:17:49,133 --> 00:17:50,700
THE CONSISTENCY
553
00:17:50,700 --> 00:17:54,167
OF THE WAX IS SIMILAR
554
00:17:50,700 --> 00:17:54,167
TO THAT OF TAFFY.
555
00:17:54,167 --> 00:17:57,500
BUT UNLIKE TAFFY,
556
00:17:54,167 --> 00:17:57,500
IT'S NOT VERY STICKY,
557
00:17:57,500 --> 00:18:01,067
SO THE LAYERS DON'T ADHERE
558
00:17:57,500 --> 00:18:01,067
WHEN ROLLED ONTO A SHAFT.
559
00:18:03,633 --> 00:18:05,600
THE NEXT MEMBER OF THE TEAM
560
00:18:05,600 --> 00:18:08,467
NOW PREPARES A BATH
561
00:18:05,600 --> 00:18:08,467
OF WARM WATER AND SOAP.
562
00:18:10,533 --> 00:18:14,700
HE THEN LOOSENS UP
563
00:18:10,533 --> 00:18:14,700
THE COIL OF BEESWAX BY HAND.
564
00:18:14,700 --> 00:18:17,467
THE ROLL SLACKENS.
565
00:18:17,467 --> 00:18:18,967
THE WAX LAYERS SEPARATE,
566
00:18:18,967 --> 00:18:21,333
LEAVING SPACES BETWEEN THEM.
567
00:18:23,767 --> 00:18:26,067
HE IMMERSES THE WAX
568
00:18:23,767 --> 00:18:26,067
IN WARM WATER.
569
00:18:26,067 --> 00:18:28,500
AND IT FLOWS
570
00:18:26,067 --> 00:18:28,500
BETWEEN THE LAYERS.
571
00:18:28,500 --> 00:18:30,833
THE WARM WATER
572
00:18:28,500 --> 00:18:30,833
SOFTENS THE EDGES
573
00:18:30,833 --> 00:18:32,900
AS A THINNING MACHINE
574
00:18:30,833 --> 00:18:32,900
REDUCES THE THICKNESS
575
00:18:32,900 --> 00:18:36,500
OF THE WAX BY HALF.
576
00:18:36,500 --> 00:18:37,833
USING BLOCKS OF ICE,
577
00:18:37,833 --> 00:18:40,500
THE OPERATOR THEN COOLS
578
00:18:37,833 --> 00:18:40,500
THE SOFTENED WAX
579
00:18:40,500 --> 00:18:43,733
TO FIRM IT UP AGAIN.
580
00:18:43,733 --> 00:18:47,533
HE CONSTANTLY ADDS LIQUID
581
00:18:43,733 --> 00:18:47,533
SOAP FOR LUBRICATION.
582
00:18:47,533 --> 00:18:50,600
THIS KEEPS THE BEESWAX MOVING
583
00:18:47,533 --> 00:18:50,600
THROUGH THE THINNING MACHINE
584
00:18:50,600 --> 00:18:52,467
AND PREVENTS SNAGS.
585
00:18:54,600 --> 00:18:57,067
USING A MEASURING INSTRUMENT
586
00:18:54,600 --> 00:18:57,067
CALLED A CALIPER,
587
00:18:57,067 --> 00:18:59,533
HE GAUGES THE THICKNESS
588
00:18:57,067 --> 00:18:59,533
OF THE WAX TO CONFIRM
589
00:18:59,533 --> 00:19:02,100
THAT IT'S 0.16
590
00:18:59,533 --> 00:19:02,100
OF A CENTIMETER.
591
00:19:04,567 --> 00:19:07,767
NEXT, THE OPERATOR REMOVES
592
00:19:04,567 --> 00:19:07,767
THE ROLL OF BEESWAX
593
00:19:07,767 --> 00:19:10,533
FROM THE THINNING MACHINE
594
00:19:07,767 --> 00:19:10,533
SPINDLE AND TRANSFERS IT
595
00:19:10,533 --> 00:19:12,667
TO THE SPINDLE
596
00:19:10,533 --> 00:19:12,667
FOR THE NEXT MACHINE.
597
00:19:14,667 --> 00:19:17,700
THIS MACHINE PULLS THE WAX
598
00:19:14,667 --> 00:19:17,700
THROUGH A BATH OF ICY WATER
599
00:19:17,700 --> 00:19:20,067
TO FIRM IT UP EVEN MORE.
600
00:19:20,067 --> 00:19:21,467
THIS WILL TOP THE WAX
601
00:19:21,467 --> 00:19:23,733
FROM STICKING
602
00:19:21,467 --> 00:19:23,733
TO EMBOSSING ROLLERS
603
00:19:23,733 --> 00:19:27,767
THAT NOW IMPRESS
604
00:19:23,733 --> 00:19:27,767
THE HEXAGONAL PATTERN ONTO IT.
605
00:19:27,767 --> 00:19:29,267
EACH OF THE EMBOSSING ROLLERS
606
00:19:29,267 --> 00:19:33,500
IS STUDDED WITH 3,500
607
00:19:29,267 --> 00:19:33,500
HEXAGONAL-SHAPED RIVETS.
608
00:19:33,500 --> 00:19:37,067
THEY STAMP THE PATTERN
609
00:19:33,500 --> 00:19:37,067
ONTO BOTH SIDES OF THE WAX.
610
00:19:37,067 --> 00:19:40,267
A BLADE SLICES THE EMBOSSED
611
00:19:37,067 --> 00:19:40,267
BEESWAX INTO SHEETS
612
00:19:40,267 --> 00:19:44,567
THAT ARE 16 INCHES IN LENGTH.
613
00:19:44,567 --> 00:19:47,100
THE SHEETS PASS
614
00:19:44,567 --> 00:19:47,100
UNDER ANOTHER ROLLER.
615
00:19:47,100 --> 00:19:50,133
AND THIS ONE PROPELS THEM
616
00:19:47,100 --> 00:19:50,133
OFF THE TRACK.
617
00:19:50,133 --> 00:19:52,167
THE SHEETS ARE BRIEFLY AIRBORNE
618
00:19:52,167 --> 00:19:54,500
AND THEN,
619
00:19:52,167 --> 00:19:54,500
THEY LAND IN A NEAT STACK.
620
00:19:54,500 --> 00:19:56,300
**
621
00:20:02,367 --> 00:20:04,133
TO MAKE THEM INTO CANDLES,
622
00:20:04,133 --> 00:20:06,333
ANOTHER MEMBER OF THE TEAM
623
00:20:04,133 --> 00:20:06,333
CUTS THE SHEETS
624
00:20:06,333 --> 00:20:09,667
TO THE DESIRED LENGTH AND WIDTH.
625
00:20:09,667 --> 00:20:11,400
THE DIMENSIONS
626
00:20:09,667 --> 00:20:11,400
WILL VARY DEPENDING ON
627
00:20:11,400 --> 00:20:13,667
THE SIZE OF
628
00:20:11,400 --> 00:20:13,667
THE CANDLES TO BE MADE.
629
00:20:16,767 --> 00:20:18,833
LEFTOVER REMNANTS
630
00:20:16,767 --> 00:20:18,833
WILL BE MELTED DOWN
631
00:20:18,833 --> 00:20:20,600
TO MAKE NEW CANDLES.
632
00:20:22,633 --> 00:20:26,000
THESE BEESWAX SHEETS ARE NOW
633
00:20:22,633 --> 00:20:26,000
READY TO BE ROLLED BY HAND.
634
00:20:28,133 --> 00:20:29,400
THE CANDLE MAKER PLACES
635
00:20:29,400 --> 00:20:33,333
A COTTON WICK
636
00:20:29,400 --> 00:20:33,333
ON ONE EDGE OF THE SHEET.
637
00:20:33,333 --> 00:20:36,200
SHE THEN WRAPS THE WAX
638
00:20:33,333 --> 00:20:36,200
AROUND THE WICK,
639
00:20:36,200 --> 00:20:38,900
APPLYING GENTLE PRESSURE
640
00:20:36,200 --> 00:20:38,900
AS SHE WORKS.
641
00:20:40,967 --> 00:20:43,167
SHE PRESSES THE LAYERS
642
00:20:40,967 --> 00:20:43,167
FIRMLY TOGETHER
643
00:20:43,167 --> 00:20:45,000
BECAUSE THE TIGHTER THE ROLL,
644
00:20:45,000 --> 00:20:46,733
THE LONGER THE CANDLE WILL BURN.
645
00:20:48,700 --> 00:20:50,767
AT ROOM TEMPERATURE,
646
00:20:48,700 --> 00:20:50,767
THE WAX IS WARM,
647
00:20:50,767 --> 00:20:53,367
SO THE LAYERS
648
00:20:50,767 --> 00:20:53,367
OF THE CANDLE ADHERE.
649
00:20:55,700 --> 00:20:59,233
FINALLY, SHE PACKAGES THEM
650
00:20:55,700 --> 00:20:59,233
IN PLASTIC CELLOPHANE
651
00:20:59,233 --> 00:21:02,733
AND APPLIES
652
00:20:59,233 --> 00:21:02,733
ALL THE NECESSARY LABELS.
653
00:21:02,733 --> 00:21:04,633
THESE HONEYCOMB BEESWAX CANDLES
654
00:21:04,633 --> 00:21:06,767
ARE NOW READY
655
00:21:04,633 --> 00:21:06,767
TO LIGHT UP A SPACE
656
00:21:06,767 --> 00:21:08,933
AND HELP SET THE MOOD.
657
00:21:08,933 --> 00:21:11,567
THEY SHOULD BURN
658
00:21:08,933 --> 00:21:11,567
FOR 8 OR 9 HOURS
659
00:21:11,567 --> 00:21:14,100
OR UNTIL IT'S TIME
660
00:21:11,567 --> 00:21:14,100
TO CALL IT A NIGHT.
40409
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