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00:00:01,793 --> 00:00:04,793
--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:52,620 --> 00:00:56,275
Narrator:
THE GARDEN FORK WAS ONCE
A VERY PRIZED POSSESSION --
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00:00:56,275 --> 00:00:59,103
SO COVETED, IT WAS OFTEN
THE OBJECT OF THEFT.
5
00:00:59,103 --> 00:01:00,551
THAT WAS CENTURIES AGO,
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00:01:00,551 --> 00:01:04,586
WHEN A FAMILY'S VERY SURVIVAL
DEPENDED ON THE CROPS THEY GREW.
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00:01:04,586 --> 00:01:05,827
TODAY, OF COURSE,
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00:01:05,827 --> 00:01:08,482
FOOD IS MASS PRODUCED
AND SOLD IN SUPERMARKETS.
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00:01:08,482 --> 00:01:12,172
BUT THE GARDEN FORK STILL RULES
IN THE BACKYARD GARDEN.
10
00:01:13,862 --> 00:01:17,517
THERE ARE MANY VERSIONS
OF THE TRUSTY GARDEN FORK.
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00:01:17,517 --> 00:01:21,655
USE ONE TO WORK THE GARDEN,
AND YOU'LL REAP THE BENEFITS.
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00:01:21,655 --> 00:01:24,344
AT THIS FACTORY,
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00:01:24,344 --> 00:01:26,344
THEY'VE BEEN FORGING
GARDEN FORKS
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00:01:26,344 --> 00:01:29,413
FROM A SOLID-STEEL SLAB
FOR OVER TWO CENTURIES.
15
00:01:29,413 --> 00:01:34,931
USING A 660-TON PUNCH PRESS,
THEY CUT TWO BASIC FORK SHAPES
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00:01:34,931 --> 00:01:36,586
FROM THIS HOT
AND MALLEABLE SLAB.
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00:01:36,586 --> 00:01:40,275
THE TINES OR PRONGS FOR
THIS PARTICULAR KIND OF FORK
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00:01:40,275 --> 00:01:43,965
ARE SHORTER THAN MOST
BECAUSE THESE ARE BORDER FORKS
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00:01:43,965 --> 00:01:47,620
USED FOR TURNING SOIL
RATHER THAN DIGGING DEEP.
20
00:01:47,620 --> 00:01:50,137
WITH THE BASIC SHAPE
NOW ESTABLISHED,
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00:01:50,137 --> 00:01:53,448
IT'S BACK INTO THE FURNACE
TO RE-SOFTEN THE STEM.
22
00:01:53,448 --> 00:01:56,827
A WORKER REPEATEDLY FEEDS IT
TO ROLLERS
23
00:01:56,827 --> 00:01:58,482
TO THIN AND WIDEN IT
SUBSTANTIALLY.
24
00:01:58,482 --> 00:02:02,206
HE STRIKES THE STEM
WITH ANOTHER PUNCH PRESS.
25
00:02:02,206 --> 00:02:03,931
THIS ONE HIT TRIMS IT
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00:02:03,931 --> 00:02:06,758
WHILE CUTTING HOLES
FOR ATTACHING THE WOOD SHAFT.
27
00:02:06,758 --> 00:02:10,448
THE TRIMMINGS WILL BE REMELTED
AND RECYCLED INTO NEW FORKS.
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00:02:10,448 --> 00:02:13,793
THE NEXT PRESS SLAMS
THE STEEL STEM
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00:02:13,793 --> 00:02:15,310
INTO A CYLINDRICAL DIE
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00:02:15,310 --> 00:02:18,137
TO FORCE IT INTO THE BASIC SHAPE
OF A SOCKET.
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00:02:18,137 --> 00:02:20,827
HE SLIDES THE SOCKET
ONTO A CONED FORM
32
00:02:20,827 --> 00:02:23,827
AND STRIKES IT REPEATEDLY
TO REFINE THE SOCKET SHAPE.
33
00:02:23,827 --> 00:02:26,724
THIS SIZES IT
FOR A WOODEN SHAFT.
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00:02:26,724 --> 00:02:30,034
THEY TAKE AN ENTIRELY
DIFFERENT APPROACH
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00:02:30,034 --> 00:02:32,206
WHEN MAKING DIGGING FORKS
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00:02:32,206 --> 00:02:34,724
BECAUSE OF THEIR LONGER
CURVED TINES.
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00:02:34,724 --> 00:02:36,896
AFTER FORGING
A KIND OF SPIDER SHAPE,
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00:02:36,896 --> 00:02:40,758
A WORKER BENDS A PRONG AROUND
A POST TO ORIENT IT FOR SHAPING.
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00:02:40,758 --> 00:02:43,931
THIS TWO-PERSON TEAM
WORKS IN TANDEM.
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00:02:43,931 --> 00:02:47,000
ONE FIRES THE SPIDER
AND BENDS THE PRONGS.
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00:02:47,000 --> 00:02:50,655
THE OTHER WORKER INSERTS
THE PRONG IN THE GROOVES
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00:02:50,655 --> 00:02:52,827
OF TWO REVOLVING DIES.
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00:02:52,827 --> 00:02:55,793
THIS ROLLS THE TINE WITHIN
THE CONFINES OF THE GROOVES
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00:02:55,793 --> 00:02:58,137
TO STRETCH IT LONG AND THIN.
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00:02:58,137 --> 00:03:01,206
WITH TWO TINES NOW SHAPED,
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00:03:01,206 --> 00:03:03,724
HIS PARTNER BENDS THEM
OUT OF THE WAY
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00:03:03,724 --> 00:03:06,275
SO HE CAN WORK
ON THE THIRD TINE.
48
00:03:08,379 --> 00:03:13,379
ROLLING TAKES 18 MONTHS
OF TRAINING TO PERFECT.
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00:03:13,379 --> 00:03:15,586
IF THE TINE ISN'T PRECISELY
ALIGNED WITH THE GROOVES,
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00:03:15,586 --> 00:03:19,241
THE EQUIPMENT COULD SEIZE
AND THROW THE WORKER BACKWARDS.
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00:03:19,241 --> 00:03:21,275
NOT ONLY COULD HE BE INJURED,
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00:03:21,275 --> 00:03:25,482
BUT THE FORK AND THE DIES WOULD
MOST CERTAINLY BE WRECKED.
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00:03:25,482 --> 00:03:31,103
WITH A FOURTH TINE NOW STRETCHED
LONG AND THIN LIKE THE REST,
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00:03:31,103 --> 00:03:33,448
THE OTHER MEMBER OF THE TEAM
TWISTS ALL FOUR TINES
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00:03:33,448 --> 00:03:35,620
AROUND THE POST AGAIN,
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00:03:35,620 --> 00:03:38,931
THIS TIME TO BEND THEM ALL
IN THE SAME GENERAL DIRECTION.
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00:03:38,931 --> 00:03:41,275
AFTER ABOUT 10 MINUTES OF WORK,
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00:03:41,275 --> 00:03:44,137
THEY HAVE THE ROUGH SHAPE
OF A DIGGING FORK.
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00:03:44,137 --> 00:03:47,448
THEY THEN FORM THE SOCKET
AND CROP THE TINES.
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00:03:47,448 --> 00:03:49,413
FIRED TO A SUPPLE STATE AGAIN,
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00:03:49,413 --> 00:03:52,586
A WORKER DRIVES TOOLING
BETWEEN THE TINES
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00:03:52,586 --> 00:03:56,241
TO STRAIGHTEN THEM
AND EVEN THE GAPS BETWEEN THEM.
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00:03:56,241 --> 00:04:01,241
HE RESTS THE FORK SOCKET AGAINST
A STEEL SLOPE AND LOWERS A RAM.
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00:04:01,241 --> 00:04:05,103
IT SLAMS INTO THE TINES TO PUSH
THE SOCKET AGAINST THE SLOPE
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00:04:05,103 --> 00:04:06,448
AND BEND IT UPWARD --
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00:04:06,448 --> 00:04:08,448
A MORE EFFECTIVE ANGLE
FOR DIGGING.
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00:04:08,448 --> 00:04:11,827
HE INSERTS THE TINES IN A PRESS
ONE AT A TIME.
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00:04:11,827 --> 00:04:16,275
THE PRESS CLOSES AROUND
EACH TINE TO TAPER THE CORNERS.
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00:04:16,275 --> 00:04:19,931
A RAM NOW POUNDS
THE BASE OF THE TINES
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00:04:19,931 --> 00:04:23,068
AGAINST A SWOOPED ANVIL
TO GIVE IT A GENTLE CURVE.
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00:04:23,068 --> 00:04:26,068
HE PLUNGES THE HOT FORK
INTO COOL WATER,
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00:04:26,068 --> 00:04:29,275
AND THE SHOCK HARDENS THE STEEL.
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00:04:29,275 --> 00:04:32,310
THE NEXT WORKER GRINDS OFF
ANY ROUGH BITS FROM THE SIDES
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00:04:32,310 --> 00:04:34,655
AND SHARPENS THE EDGES.
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00:04:34,655 --> 00:04:37,241
HE NARROWS THE TIPS TO A POINT,
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00:04:37,241 --> 00:04:41,241
AND THIS WILL ENABLE THE FORK
TO PIERCE SOLID EARTH.
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00:04:41,241 --> 00:04:44,448
A WORKER REPAIRS ANY
IRREGULARITIES WITH HIS HAMMER.
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00:04:46,068 --> 00:04:48,758
HERE YOU CAN SEE
THE DIFFERENCE THIS MAKES.
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00:04:48,758 --> 00:04:51,931
THE PRONGS ON THE LEFT
ARE OUT OF ALIGNMENT.
80
00:04:51,931 --> 00:04:54,241
THE ONES ON THE RIGHT
HAVE BEEN FIXED.
81
00:04:54,241 --> 00:04:56,413
THEY APPLY
AN ELECTROSTATIC CHARGE
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00:04:56,413 --> 00:04:59,137
ONTO THE FORKS TO ATTRACT
A GREEN POWDER SPRAY.
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00:04:59,137 --> 00:05:04,172
ONCE CURED, IT FORMS A COLORFUL
SKIN THAT RESISTS CORROSION.
84
00:05:04,172 --> 00:05:06,517
NOW OUT OF THE CURING OVEN,
85
00:05:06,517 --> 00:05:08,482
A WORKER CLAMPS THE ENDS
TO LOCK THE FORK IN PLACE
86
00:05:08,482 --> 00:05:12,965
WHILE HE INSERTS THE
ASH WOOD SHAFT INTO THE SOCKET.
87
00:05:12,965 --> 00:05:15,137
HE SECURES IT WITH RIVETS.
88
00:05:15,137 --> 00:05:16,655
USING A BELT SANDER,
89
00:05:16,655 --> 00:05:20,448
HE BLENDS THE WOOD TO THE METAL
IN A PROCESS KNOWN AS LINISHING.
90
00:05:22,965 --> 00:05:25,000
HE ALSO SANDS THE RIVETS
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00:05:25,000 --> 00:05:29,172
TO MAKE THEM FLUSH
TO THE SURFACE OF THE METAL.
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00:05:29,172 --> 00:05:32,758
THE BOTTOM FORK IS THE ONE
THAT HAS BEEN LINISHED.
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00:05:34,344 --> 00:05:37,689
HE DIPS THE WOOD SHAFT
AND HANDLE IN VARNISH,
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00:05:37,689 --> 00:05:40,827
GIVING IT A GLOSSY STAIN
THAT ENHANCES THE GRAIN.
95
00:05:40,827 --> 00:05:43,862
THIS GARDEN FORK IS NOW DONE.
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00:05:43,862 --> 00:05:46,034
IT WON'T LOOK SHINY
AND NEW FOR LONG,
97
00:05:46,034 --> 00:05:49,758
BECAUSE THINGS ARE SURE TO GET
DIRTY VERY SOON.
98
00:06:00,310 --> 00:06:03,689
Narrator: TOFFEE IS A TYPE
OF CANDY TRADITIONALLY MADE
99
00:06:03,689 --> 00:06:06,689
OF CARAMELIZED SUGAR
OR MOLASSES AND BUTTER.
100
00:06:06,689 --> 00:06:09,000
THERE ARE MANY
DIFFERENT VARIETIES --
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00:06:09,000 --> 00:06:11,344
SOFT AND CHEWY
OR HARD AND BRITTLE.
102
00:06:11,344 --> 00:06:12,517
ENGLISH TOFFEE,
103
00:06:12,517 --> 00:06:15,000
WHICH IS ACTUALLY
AN AMERICAN STYLE OF TOFFEE,
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00:06:15,000 --> 00:06:16,172
IS VERY BUTTERY
105
00:06:16,172 --> 00:06:19,310
AND TYPICALLY HAS A TOPPING
OF CHOPPED NUTS.
106
00:06:21,620 --> 00:06:22,758
THIS ENGLISH TOFFEE
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00:06:22,758 --> 00:06:24,862
IS COMPLETELY FREE
OF DAIRY INGREDIENTS
108
00:06:24,862 --> 00:06:28,206
AND IS KOSHER CERTIFIED,
MAKING IT IDEAL
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00:06:28,206 --> 00:06:32,172
FOR TOFFEE LOVERS WITH
CERTAIN DIETARY RESTRICTIONS.
110
00:06:32,172 --> 00:06:35,827
THE WORKERS AT THIS
SMALL AMERICAN CONFECTIONER
111
00:06:35,827 --> 00:06:38,965
MAKE THIS SPECIAL RECIPE
ENTIRELY BY HAND
112
00:06:38,965 --> 00:06:41,137
ONE SMALL BATCH AT A TIME.
113
00:06:41,137 --> 00:06:44,482
THEY START BY COMBINING
WATER AND SUGAR.
114
00:06:44,482 --> 00:06:47,655
THEY HEAT THE MIXTURE
UNTIL THE SUGAR DISSOLVES.
115
00:06:47,655 --> 00:06:49,793
THEN THEY ADD A FORMULA
SO TOP-SECRET
116
00:06:49,793 --> 00:06:51,310
THEY WON'T LET US SEE IT.
117
00:06:51,310 --> 00:06:53,482
ALL THEY'LL REVEAL
IS THAT IT CONTAINS
118
00:06:53,482 --> 00:06:56,344
A COMBINATION OF VEGETABLE OILS
AND SHORTENING
119
00:06:56,344 --> 00:06:59,827
WHICH ARE NON-DAIRY SUBSTITUTES
FOR BUTTER AND BETA CAROTENE
120
00:06:59,827 --> 00:07:03,206
TO GIVE THE TOFFEE
THAT FAMILIAR GOLDEN COLOR.
121
00:07:03,206 --> 00:07:06,000
THEY ADD AN EMULSIFIER
CALLED LECITHIN
122
00:07:06,000 --> 00:07:08,586
TO STABILIZE
ALL THESE INGREDIENTS.
123
00:07:08,586 --> 00:07:12,137
AS SOON AS THE MIXTURE
REACHES THE BOILING POINT,
124
00:07:12,137 --> 00:07:13,310
THEY ADD SALT.
125
00:07:13,310 --> 00:07:14,965
THIS ENHANCES THE FLAVOR
126
00:07:14,965 --> 00:07:19,034
AND HELPS PRODUCE A RAPID BOIL
THAT CONTINUES FOR SEVERAL HOURS
127
00:07:19,034 --> 00:07:22,620
UNTIL THE MIXTURE HITS
A TOP-SECRET TARGET TEMPERATURE.
128
00:07:22,620 --> 00:07:26,793
BY THAT POINT, MOST OF THE WATER
HAS EVAPORATED,
129
00:07:26,793 --> 00:07:30,793
PRODUCING SWEET, THICK,
LIQUID TOFFEE.
130
00:07:30,793 --> 00:07:34,448
NOW THEY OPEN A HOT-WATER VALVE
THAT HEATS UP A TABLE,
131
00:07:34,448 --> 00:07:37,827
THEN CAREFULLY POUR THE TOFFEE
ONTO THE SURFACE.
132
00:07:43,793 --> 00:07:46,931
THE HEAT
KEEPS THE TOFFEE PLIABLE
133
00:07:46,931 --> 00:07:49,068
WHILE THEY SPREAD IT OUT.
134
00:07:51,034 --> 00:07:53,034
THEY SPREAD IT WIDER AND WIDER
135
00:07:53,034 --> 00:07:55,655
UNTIL THE TOFFEE SHEET
IS EVENLY THICK.
136
00:07:55,655 --> 00:07:57,413
THEY DON'T ACTUALLY MEASURE.
137
00:07:57,413 --> 00:08:01,758
THEY JUST EYEBALL IT, SO
THE THICKNESS VARIES SOMEWHAT.
138
00:08:01,758 --> 00:08:03,931
BUT THAT LACK OF UNIFORMITY
139
00:08:03,931 --> 00:08:07,103
IS PART OF THE CHARM
OF HANDMADE SWEETS.
140
00:08:07,103 --> 00:08:10,551
THEY TAKE A TOOL
WITH MULTIPLE CUTTING WHEELS
141
00:08:10,551 --> 00:08:12,448
SPACED ABOUT TWO INCHES APART.
142
00:08:12,448 --> 00:08:15,724
THEY RUN IT OVER THE
TOFFEE SHEET IN ONE DIRECTION,
143
00:08:15,724 --> 00:08:18,206
THEN IN THE OTHER.
144
00:08:21,724 --> 00:08:24,034
THEN THEY SHUT OFF
THE HOT-WATER VALVE
145
00:08:24,034 --> 00:08:27,103
AND OPEN THE COLD-WATER ONE
TO COOL THE TABLE SURFACE
146
00:08:27,103 --> 00:08:30,344
AND HARDEN WHAT ARE NOW
TOFFEE SQUARES.
147
00:08:31,931 --> 00:08:36,206
WITHIN MINUTES, THE SQUARES ARE
HARD ENOUGH TO BE BROKEN APART.
148
00:08:40,034 --> 00:08:42,413
NEXT, THE FIRST
OF TWO INGREDIENTS
149
00:08:42,413 --> 00:08:45,206
THAT WILL TURN THIS
INTO ENGLISH TOFFEE --
150
00:08:45,206 --> 00:08:49,034
MOLTEN SEMI-SWEET CHOCOLATE.
151
00:08:49,034 --> 00:08:50,379
ONCE THIS TEMPERING MACHINE
152
00:08:50,379 --> 00:08:52,379
HEATS IT
TO THE RIGHT CONSISTENCY,
153
00:08:52,379 --> 00:08:54,551
A PUMP FEEDS IT
TO THE ENROBING MACHINE
154
00:08:54,551 --> 00:08:57,586
THAT COATS THE TOFFEE SQUARES
IN TWO STAGES,
155
00:08:57,586 --> 00:08:59,551
STARTING ON THE BOTTOM.
156
00:09:10,137 --> 00:09:11,793
THE UNDERSIDE NOW COATED,
157
00:09:11,793 --> 00:09:14,551
THE SQUARES MOVE ON
TO A REFRIGERATED BELT.
158
00:09:14,551 --> 00:09:17,965
THE COLD QUICKLY HARDENS
THE CHOCOLATE.
159
00:09:17,965 --> 00:09:20,310
THEN THEY MOVE INTO
THE NEXT STATION
160
00:09:20,310 --> 00:09:23,724
WHICH COVERS THE TOP
WITH CHOCOLATE.
161
00:09:28,689 --> 00:09:31,689
AS THE NOW FULLY-COATED SQUARES
EXIT THE ENROBING MACHINE,
162
00:09:31,689 --> 00:09:36,344
THE BELT VIBRATES, SHAKING OFF
THE EXCESS CHOCOLATE.
163
00:09:44,689 --> 00:09:47,689
THE SQUARES MOVE ON
TO ANOTHER REFRIGERATED BELT
164
00:09:47,689 --> 00:09:49,689
AND A WORKER
MANUALLY SPRINKLES THEM
165
00:09:49,689 --> 00:09:51,137
WITH THE SECOND INGREDIENT
166
00:09:51,137 --> 00:09:53,896
THAT MAKES THIS
ENGLISH TOFFEE --
167
00:09:53,896 --> 00:09:55,206
CHOPPED PECANS.
168
00:10:02,517 --> 00:10:05,344
THE SQUARES TRAVEL THROUGH
A COOLING TUNNEL
169
00:10:05,344 --> 00:10:07,482
FOR SEVERAL MINUTES TO SET.
170
00:10:09,034 --> 00:10:11,482
AS THEY REACH
THE END OF THE LINE,
171
00:10:11,482 --> 00:10:15,310
EXCESS NUTS DROP OFF
AND COLLECT IN A PAN BELOW,
172
00:10:15,310 --> 00:10:18,586
READY FOR SPRINKLING
ONTO NEW SQUARES.
173
00:10:24,931 --> 00:10:29,379
SOME ENGLISH TOFFEE RECIPES CALL
FOR ALMONDS RATHER THAN PECANS.
174
00:10:29,379 --> 00:10:31,206
WHICHEVER VARIETY OF NUT,
175
00:10:31,206 --> 00:10:33,862
EVERY RECIPE FOLLOWS
THE SAME STRUCTURE.
176
00:10:33,862 --> 00:10:36,931
LAYERING
SWEET AND CRUNCHY TOFFEE,
177
00:10:36,931 --> 00:10:41,620
SMOOTH AND CREAMY CHOCOLATE,
AND COARSELY CHOPPED NUTS --
178
00:10:41,620 --> 00:10:44,620
THREE DIFFERENT TEXTURES,
TASTES, AND SENSATIONS
179
00:10:44,620 --> 00:10:47,275
BROUGHT TOGETHER
IN A SINGLE CONFECTION.
180
00:10:47,275 --> 00:10:51,482
AND JUST LIKE OTHER
DECADENTLY DELICIOUS DESSERTS,
181
00:10:51,482 --> 00:10:53,586
ENGLISH TOFFEE IS HEAVEN
182
00:10:53,586 --> 00:10:56,034
TO ANYONE
WITH A SERIOUS SWEET TOOTH.
183
00:11:07,586 --> 00:11:11,103
Narrator: TRYING TO DECIDE
ON A PAINT COLOR?
184
00:11:11,103 --> 00:11:14,413
EACH CARD IS A SMALL SAMPLE
OF RELATED SHADES,
185
00:11:14,413 --> 00:11:16,758
ALLOWING YOU
TO VIEW THE ACTUAL HUES
186
00:11:16,758 --> 00:11:19,793
WITHOUT PRYING OFF THE LIDS
OF PAINT CANS.
187
00:11:19,793 --> 00:11:23,034
WITH THOUSANDS OF SHADES
TO CHOOSE FROM,
188
00:11:23,034 --> 00:11:26,034
HOW DO THEY GET IT ALL
DOWN ON PAPER?
189
00:11:30,413 --> 00:11:33,241
WHETHER YOU'RE LOOKING
FOR A BRILLIANT BLUE
190
00:11:33,241 --> 00:11:34,655
OR A MARVELOUS MAUVE,
191
00:11:34,655 --> 00:11:37,965
CAREFUL SCRUTINY OF PAINT CHIP
CARDS CAN HELP YOU GET IT RIGHT
192
00:11:37,965 --> 00:11:40,448
BEFORE THE PAINT HITS THE WALL.
193
00:11:42,310 --> 00:11:45,310
HIGHLY CONCENTRATED COLORANTS
STORED IN TANKS
194
00:11:45,310 --> 00:11:48,586
WILL BE USED TO REPRODUCE
PAINT COLORS IN LACQUER
195
00:11:48,586 --> 00:11:51,344
SIMILAR TO THE KIND
USED IN NAIL POLISH.
196
00:11:51,344 --> 00:11:55,000
LACQUER PRODUCES BETTER RESULTS
ON PAPER THAN ACTUAL PAINT.
197
00:11:55,000 --> 00:11:58,344
THEY PIPE THE COLORANTS
TO A DISPENSER.
198
00:11:58,344 --> 00:11:59,896
AT THE SAME TIME,
199
00:11:59,896 --> 00:12:02,482
A BUCKET CONTAINING LACQUER
HEADS TOWARD IT.
200
00:12:02,482 --> 00:12:04,241
THE DISPENSER HAS MANY TENTACLES
201
00:12:04,241 --> 00:12:07,103
WITH NOZZLES
AT THE END OF EACH ONE
202
00:12:07,103 --> 00:12:10,931
AND EACH TENTACLE IS CONNECTED
TO ONE OF THE COLORANT TANKS.
203
00:12:10,931 --> 00:12:14,068
A COMPUTERIZED MECHANISM GRABS
THE NOZZLES
204
00:12:14,068 --> 00:12:16,482
TO DISPENSE DIFFERENT COLORANTS
205
00:12:16,482 --> 00:12:19,172
FOLLOWING
A SPECIFIC PAINT-COLOR FORMULA.
206
00:12:19,172 --> 00:12:20,862
THE BUCKET SITS ON A SCALE
207
00:12:20,862 --> 00:12:23,655
AND THE WEIGHT IS CONSTANTLY
MONITORED BY THE COMPUTER
208
00:12:23,655 --> 00:12:27,379
TO CONFIRM THAT EXACT AMOUNTS
ARE BEING ADDED.
209
00:12:27,379 --> 00:12:31,000
A BLENDER MIXES THE COLORANTS
IN THE LACQUER.
210
00:12:31,000 --> 00:12:33,827
THE MIXING SPEED AND TIME
HAVE BEEN PRESET
211
00:12:33,827 --> 00:12:36,344
TO AVOID OVER OR UNDER MIXING.
212
00:12:36,344 --> 00:12:40,034
AND NOW FOR THE COLOR TEST.
213
00:12:40,034 --> 00:12:43,758
A TECHNICIAN PULLS A BIT
OF THE LACQUER-BASED PAINT
214
00:12:43,758 --> 00:12:47,000
ON A SHEET OF PAPER
JUST UNDER A STEEL BAR.
215
00:12:47,000 --> 00:12:53,310
USING THAT BAR, HE SPREADS THE
COLOR EVENLY ACROSS THE PAPER.
216
00:12:53,310 --> 00:12:55,965
THEN IT'S INTO A KIND OF
MOVING CONVECTION OVEN
217
00:12:55,965 --> 00:12:57,620
TO DRY THE COLOR.
218
00:13:00,310 --> 00:13:03,862
THE TECHNICIAN COMPARES
THE COLOR AND GLOSS
219
00:13:03,862 --> 00:13:05,724
TO THAT OF THE STANDARD.
220
00:13:05,724 --> 00:13:09,000
HE ALSO DOES A COMPUTER ANALYSIS
221
00:13:09,000 --> 00:13:13,034
AND SENDS THE FORMULA BACK
FOR TWEAKING WHEN NECESSARY.
222
00:13:13,034 --> 00:13:15,862
ONCE THEY PERFECT
THE HUE AND GLOSS,
223
00:13:15,862 --> 00:13:19,068
PRODUCTION IS READY TO ROLL.
224
00:13:19,068 --> 00:13:22,241
A WORKER POURS THE APPROVED
LACQUER-BASED PAINTS
225
00:13:22,241 --> 00:13:25,344
INTO CYLINDRICAL TANKS
ABOVE THE COATING MACHINE.
226
00:13:25,344 --> 00:13:27,965
THERE ARE OVER TWO DOZEN
OF THESE TANKS
227
00:13:27,965 --> 00:13:30,448
BECAUSE THEY'LL BE PUTTING
THAT MANY COLORS ON PAPER
228
00:13:30,448 --> 00:13:32,413
IN ONE PRODUCTION RUN.
229
00:13:32,413 --> 00:13:34,586
HE CONNECTS PLASTIC TUBING
TO THE TANKS
230
00:13:34,586 --> 00:13:38,413
TO NARROW THE FLOW AND AIM IT
AT THE DIE BLOCK BELOW.
231
00:13:38,413 --> 00:13:41,103
HE ACTIVATES THE MACHINE
232
00:13:41,103 --> 00:13:44,413
AND ADJUSTS THE TENSION OF
THE PAPER AS IT MOVES FORWARD.
233
00:13:44,413 --> 00:13:47,896
LACQUER FLOWS INTO A DIE,
234
00:13:47,896 --> 00:13:51,103
COATING THE PAPER WITH
AN ENDLESS RAINBOW OF COLOR.
235
00:13:51,103 --> 00:13:53,827
A BAR OVERHEAD SPREADS
THE LACQUER EVENLY
236
00:13:53,827 --> 00:13:57,103
WITHOUT ACTUALLY TOUCHING
THE PAPER.
237
00:13:59,482 --> 00:14:02,689
THE STRIPED PAPER
THEN TRAVELS THROUGH AN OVEN.
238
00:14:02,689 --> 00:14:04,275
THE SOLVENTS EVAPORATE,
239
00:14:04,275 --> 00:14:07,034
LEAVING A DRIED LACQUER SKIN
ON THE PAPER.
240
00:14:07,034 --> 00:14:09,000
IF REGULAR PAINT HAD BEEN USED,
241
00:14:09,000 --> 00:14:12,000
THE PAPER WOULD HAVE ABSORBED IT
AND ENDED UP WAVY.
242
00:14:12,000 --> 00:14:15,103
BUT WITH THE LACQUER PAINT,
IT REMAINS FLAT.
243
00:14:15,103 --> 00:14:19,379
ROTARY BLADES CUT
THE COATED PAPER
244
00:14:19,379 --> 00:14:21,517
INTO SHEETS SIZED
TO FIT PRINTING MACHINERY
245
00:14:21,517 --> 00:14:22,551
DOWN THE LINE.
246
00:14:22,551 --> 00:14:25,517
THEY LAND IN A NEAT STACK.
247
00:14:27,034 --> 00:14:29,137
USING A TRANSPARENT TEMPLATE,
248
00:14:29,137 --> 00:14:32,827
THE NEXT WORKER MEASURES
THE WIDTH OF EACH STRIPE.
249
00:14:32,827 --> 00:14:36,206
HE THEN CONFIRMS THAT THE COLORS
ARE IN THE CORRECT ORDER
250
00:14:36,206 --> 00:14:39,275
BY CHECKING EACH STRIPE
AGAINST THE APPROVED PROOFS.
251
00:14:43,310 --> 00:14:46,206
HE CHECKS THE GLOSS
WITH A GLOSSMETER.
252
00:14:46,206 --> 00:14:50,034
IT AIMS LIGHT ON AN ANGLE
AND REGISTERS THE REFLECTION
253
00:14:50,034 --> 00:14:53,172
TO CONFIRM THAT THE GLOSS
IS CONSISTENT.
254
00:14:53,172 --> 00:14:55,448
WITH THE OKAY FROM THE TESTER,
255
00:14:55,448 --> 00:14:58,206
THE ENTIRE PRODUCTION RUN
RECEIVES THE GO-AHEAD.
256
00:14:58,206 --> 00:15:00,517
THE PRESS OPERATOR STACKS THEM
FACEDOWN
257
00:15:00,517 --> 00:15:02,689
FOR LOADING INTO THE PRINTER.
258
00:15:02,689 --> 00:15:05,517
A FEEDER SERVES UP
THE STRIPED SHEETS
259
00:15:05,517 --> 00:15:08,275
TO THE PRINTING LINE
ONE AT A TIME.
260
00:15:08,275 --> 00:15:10,586
IT'S A 4-STATION PRINTING PRESS.
261
00:15:10,586 --> 00:15:14,068
EACH CYLINDER IS EQUIPPED
WITH AN INK OF A DIFFERENT COLOR
262
00:15:14,068 --> 00:15:17,206
TO STAND OUT AGAINST
THE VARIOUS PAINT-CARD STRIPES.
263
00:15:17,206 --> 00:15:20,965
THEY PRINT THE PAINT COLOR NAMES
AND NUMBERS ON BOTH SIDES.
264
00:15:20,965 --> 00:15:24,172
THEY ALSO APPLY VARNISH
TO THE BACK OF THE SHEETS
265
00:15:24,172 --> 00:15:26,724
SO THE PAINT CHIP CARDS
WON'T STICK TO ONE ANOTHER
266
00:15:26,724 --> 00:15:28,241
WHEN STACKED.
267
00:15:28,241 --> 00:15:33,000
NAMED AND NUMBERED, THE COLOR
STRIPES ARE NOW IDENTIFIABLE.
268
00:15:34,551 --> 00:15:37,137
THE SHEETS GO UNDER
A GUILLOTINE BLADE
269
00:15:37,137 --> 00:15:39,896
WHICH SLICES THEM
INTO PAINT CHIP CARDS.
270
00:15:39,896 --> 00:15:42,827
POWERED BY HYDRAULICS
AND SUPER SHARP,
271
00:15:42,827 --> 00:15:46,862
THE BLADE CUTS THROUGH HUNDREDS
OF PAPER SHEETS LIKE BUTTER.
272
00:15:48,344 --> 00:15:52,000
THEY PRODUCE 3 1/2 MILLION
PAINT CHIP CARDS A DAY
273
00:15:52,000 --> 00:15:54,517
AT THIS FACTORY.
274
00:15:54,517 --> 00:15:57,344
WITH SO MANY OPTIONS,
275
00:15:57,344 --> 00:16:00,896
THE CARDS ARE STACKED
AGAINST A QUICK DECISION.
276
00:16:15,310 --> 00:16:17,310
Narrator: A BUNDT PAN
277
00:16:17,310 --> 00:16:19,965
IS FOR BAKING A DENSE,
RING-SHAPED CAKE CALLED A BUNDT.
278
00:16:19,965 --> 00:16:23,206
IT TYPICALLY HAS
A FLUTED OR A SWIRL DESIGN.
279
00:16:23,206 --> 00:16:26,517
IT ORIGINATED IN EUROPE
HUNDREDS OF YEARS AGO
280
00:16:26,517 --> 00:16:30,172
AND QUITE POSSIBLY GETS ITS NAME
FROM THE GERMAN BUNDKUCHEN --
281
00:16:30,172 --> 00:16:31,862
"KUCHEN" MEANING "CAKE"
282
00:16:31,862 --> 00:16:34,482
AND "BUND" MEANING
"A GATHERING OF PEOPLE."
283
00:16:36,724 --> 00:16:38,896
BUNDT PANS
WERE ORIGINALLY CERAMIC,
284
00:16:38,896 --> 00:16:42,724
WHICH IS FRAGILE,
OR CAST IRON, WHICH IS HEAVY.
285
00:16:42,724 --> 00:16:46,379
TODAY'S VERSION IS TYPICALLY
MADE OF CAST ALUMINUM --
286
00:16:46,379 --> 00:16:49,241
UNBREAKABLE
AND INFINITELY LIGHTER.
287
00:16:49,241 --> 00:16:51,413
IT ALSO HAS A NONSTICK COATING.
288
00:16:51,413 --> 00:16:54,965
AT THE FACTORY, THEY BEGIN
THE PRODUCTION PROCESS
289
00:16:54,965 --> 00:16:59,137
BY MELTING INGOTS
OF RECYCLED ALUMINUM.
290
00:16:59,137 --> 00:17:02,413
THE FURNACE HEATS THE INGOTS
TO 1,300-DEGREES FAHRENHEIT,
291
00:17:02,413 --> 00:17:05,931
AT WHICH POINT,
THEY LIQUIFY IN ABOUT A MINUTE.
292
00:17:05,931 --> 00:17:07,862
FROM THE MELTING FURNACE,
293
00:17:07,862 --> 00:17:10,000
WORKERS TRANSFER
THE MOLTEN ALUMINUM
294
00:17:10,000 --> 00:17:11,344
TO A HOLDING FURNACE
295
00:17:11,344 --> 00:17:15,862
WHICH KEEPS IT IN A LIQUID STATE
UNTIL CASTING.
296
00:17:15,862 --> 00:17:19,000
THE CASTING PROCESS
IS ENTIRELY AUTOMATED.
297
00:17:19,000 --> 00:17:21,413
A LADLE DESCENDS
INTO THE HOLDING FURNACE
298
00:17:21,413 --> 00:17:25,068
AND SCOOPS UP JUST OVER
TWO POUNDS OF ALUMINUM,
299
00:17:25,068 --> 00:17:27,310
ENOUGH TO MAKE ONE BUNDT PAN.
300
00:17:27,310 --> 00:17:30,965
THE LADLE THEN POURS
THE MOLTEN METAL INTO A SLEEVE
301
00:17:30,965 --> 00:17:33,931
WHICH A HIGH-SPEED RAM
IMMEDIATELY PUSHES
302
00:17:33,931 --> 00:17:36,241
INTO A STEEL BUNDT-PAN MOLD.
303
00:17:36,241 --> 00:17:38,793
THE PRESSURE AND SPEED COMBINED
304
00:17:38,793 --> 00:17:41,448
SHOOT THE MOLTEN ALUMINUM
INTO EVERY NOOK AND CRANNY
305
00:17:41,448 --> 00:17:43,137
OF THE MOLD CAVITY.
306
00:17:43,137 --> 00:17:45,965
AS THE HOT ALUMINUM
HITS THE COOLER MOLD,
307
00:17:45,965 --> 00:17:48,620
IT SOLIDIFIES
IN ABOUT 10 SECONDS,
308
00:17:48,620 --> 00:17:52,103
THEN THE TWO HALVES OF
THE MOLD AUTOMATICALLY SEPARATE
309
00:17:52,103 --> 00:17:55,413
AND A ROBOTIC ARM EXTRACTS
THE CAST PAN.
310
00:17:56,965 --> 00:18:00,275
BETWEEN CASTINGS,
A ROBOT CLEANS THE MOLD
311
00:18:00,275 --> 00:18:03,344
WITH A BLAST OF AIR, WATER,
AND LUBRICANT.
312
00:18:03,344 --> 00:18:05,689
THIS REMOVES
ANY ALUMINUM RESIDUE,
313
00:18:05,689 --> 00:18:08,206
LEAVING THE MOLD SURFACE
PRISTINE.
314
00:18:08,206 --> 00:18:12,827
THIS IS CRITICAL, BECAUSE EVEN
A TINY SPECK OF DUST LEFT BEHIND
315
00:18:12,827 --> 00:18:15,000
WOULD MAR THE NEXT CASTING.
316
00:18:15,000 --> 00:18:17,896
AS EACH PAN COMES OFF
THE MACHINE,
317
00:18:17,896 --> 00:18:21,137
WORKERS INSPECT IT
FOR ANY CASTING FLAWS.
318
00:18:22,862 --> 00:18:26,517
WHEN IT COMES TIME TO PRODUCE
A DIFFERENT STYLE BUNDT PAN,
319
00:18:26,517 --> 00:18:29,103
LIKE THIS ONE
WITH SIX MINI-CAKE FORMS,
320
00:18:29,103 --> 00:18:31,103
THEY SIMPLY MOUNT
THE CORRESPONDING MOLD
321
00:18:31,103 --> 00:18:33,103
ONTO THE CASTING MACHINE.
322
00:18:33,103 --> 00:18:35,448
AS THE MACHINE FILLS
THE MOLD UNDER PRESSURE,
323
00:18:35,448 --> 00:18:39,275
SOME ALUMINUM OOZES OUT BETWEEN
THE TWO HALVES OF THE MOLD.
324
00:18:39,275 --> 00:18:41,620
NOW A WORKER CUTS OFF
THAT EXCESS
325
00:18:41,620 --> 00:18:44,172
WITH A SINGLE STRIKE
OF A TRIM PRESS.
326
00:18:44,172 --> 00:18:48,931
THE SCRAP PIECES GO BACK INTO
THE FURNACE TO BE REMELTED.
327
00:18:48,931 --> 00:18:53,724
NEXT, A COMPUTER-GUIDED ROUTER
WORKING TWO PANS AT A TIME,
328
00:18:53,724 --> 00:18:57,034
SMOOTHES THE ROUGH EDGES.
329
00:19:02,793 --> 00:19:06,413
THEN IT REFINES THE HANDLE
SLOTS, FINALIZING THE SHAPE.
330
00:19:11,793 --> 00:19:14,103
THE ALUMINUM SURFACE
MUST BE PRISTINE
331
00:19:14,103 --> 00:19:16,724
FOR THE NONSTICK COATING
TO ADHERE PROPERLY,
332
00:19:16,724 --> 00:19:21,034
SO THE PANS NOW GO THROUGH
AN INDUSTRIAL WASHING MACHINE --
333
00:19:21,034 --> 00:19:23,379
ONE WASH AND THREE RINSE CYCLES,
334
00:19:23,379 --> 00:19:27,517
AND THEN, BEFORE EXITING,
A DRYING CYCLE.
335
00:19:29,724 --> 00:19:33,034
WORKERS PUT THE PANS UPSIDE DOWN
ON FIXTURES
336
00:19:33,034 --> 00:19:36,310
WHICH TRAVEL DOWN
THE EXTERIOR COASTING LINE.
337
00:19:38,965 --> 00:19:42,620
AS THE PAN SPINS BY,
SPRAY GUNS APPLY
338
00:19:42,620 --> 00:19:46,793
A SILICONE-BASED DECORATIVE
COATING TO THE OUTSIDE SURFACE.
339
00:19:50,655 --> 00:19:54,482
THE PANS THEN TRAVEL THROUGH
AN OVEN FOR 15 MINUTES
340
00:19:54,482 --> 00:19:56,482
TO CURE THE COATING.
341
00:19:56,482 --> 00:19:59,862
THEN THE WORKERS FLIP THE PANS
RIGHT-SIDE UP
342
00:19:59,862 --> 00:20:01,620
AND PLACE THEM ON FIXTURES,
343
00:20:01,620 --> 00:20:04,413
WHICH SPIN THEM
THROUGH ANOTHER SPRAY LINE.
344
00:20:04,413 --> 00:20:06,034
THIS TIME, TO COAT THE INSIDE.
345
00:20:09,724 --> 00:20:11,655
THE INTERIOR COATING
346
00:20:11,655 --> 00:20:15,517
IS A FOOD-SAFE
SILICONE-POLYESTER MATERIAL
347
00:20:15,517 --> 00:20:18,620
DESIGNED TO RELEASE THE CAKE
EASILY FROM THE PAN.
348
00:20:18,620 --> 00:20:21,689
IT'S SIMILAR TO A
NONSTICK COATING ON A FRY PAN,
349
00:20:21,689 --> 00:20:24,413
THE DIFFERENCE BEING
THAT THE CHEMICAL COMPOSITION
350
00:20:24,413 --> 00:20:27,034
IS DESIGNED TO PREVENT SUGAR,
RATHER THAN PROTEIN,
351
00:20:27,034 --> 00:20:29,068
FROM STICKING.
352
00:20:29,068 --> 00:20:33,206
AGAIN, THE PANS GO THROUGH
AN OVEN FOR 15 MINUTES
353
00:20:33,206 --> 00:20:35,689
TO CURE THE COATING.
354
00:20:40,620 --> 00:20:43,931
ONCE THE FINISHED PANS
EXIT THE OVEN,
355
00:20:43,931 --> 00:20:45,965
WORKERS INSPECT THEM THOROUGHLY,
356
00:20:45,965 --> 00:20:48,551
CHECKING FOR ANY FLAWS
IN THE COATINGS.
357
00:20:48,551 --> 00:20:52,517
FROM A PRACTICAL PERSPECTIVE,
A BUNDT PAN'S RINGED SHAPE
358
00:20:52,517 --> 00:20:56,206
HAS DEFINITE ADVANTAGES
OVER AN ORDINARY BAKING PAN.
359
00:20:56,206 --> 00:20:58,068
THE TUBE IN THE MIDDLE
360
00:20:58,068 --> 00:21:00,275
FUNNELS HEAT TO THE CENTER
OF THE CAKE BATTER,
361
00:21:00,275 --> 00:21:03,448
HELPING IT BAKE QUICKER
AND MORE THOROUGHLY.
362
00:21:03,448 --> 00:21:05,482
FROM A DECORATIVE PERSPECTIVE,
363
00:21:05,482 --> 00:21:08,931
WHEN YOU COMPARE AN ORDINARY PAN
TO AN ELEGANT BUNDT,
364
00:21:08,931 --> 00:21:11,379
THE LATTER
CERTAINLY TAKES THE CAKE.
365
00:21:20,275 --> 00:21:23,620
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
366
00:21:23,620 --> 00:21:26,620
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
367
00:21:26,620 --> 00:21:29,517
DROP US A LINE AT...
29715
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