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Narrator: THE ORIGIN OF SO MANY
USEFUL THINGS IS MUDDY --
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FROM BRICKS TO TILES
TO DINNERWARE.
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00:00:57,965 --> 00:01:01,000
EVEN THE KITCHEN SINK
CAN BE MADE FROM CLAY.
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00:01:01,000 --> 00:01:02,517
CLAY IS A COMPONENT OF SOIL
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00:01:02,517 --> 00:01:05,206
THAT, WHEN WET,
HAS A CERTAIN PLASTICITY
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00:01:05,206 --> 00:01:08,517
THAT ALLOWS IT TO BE SHAPED
INTO HUNDREDS OF THINGS.
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THERE ARE MANY SHADES OF CLAY.
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THE WHITEST IS THE PUREST
AND USED TO MANUFACTURE
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00:01:17,310 --> 00:01:21,137
THINGS LIKE DINNERWARE,
SINKS, AND TILES.
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CLAY ISN'T JUST DIRT.
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00:01:22,655 --> 00:01:25,482
IT'S ONE OF THE MOST VALUABLE
RESOURCES ON EARTH.
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00:01:25,482 --> 00:01:27,827
TO FIND IT,
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00:01:27,827 --> 00:01:30,931
THEY EXCAVATE TOPSOIL AND GRAVEL
AT THIS SITE IN KENTUCKY.
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00:01:30,931 --> 00:01:34,275
THEY DIG DOWN AS FAR AS 80 FEET.
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00:01:34,275 --> 00:01:39,620
THE DEEPER THEY GO,
THE WHITER THE CLAY.
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A LOADER TRANSFERS IT TO A TRUCK
FOR TRANSPORT.
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FRESH FROM THE EARTH,
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THE MOISTURE CONTENT OF THE CLAY
IS BETWEEN 15% AND 22%.
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00:01:49,793 --> 00:01:52,103
THE PARTICLES OF CLAY
CLUMP TOGETHER,
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00:01:52,103 --> 00:01:55,793
BUT THE CLUMPS
CAN BE EASILY BROKEN UP.
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00:01:55,793 --> 00:02:00,137
THE CLAY WILL NOW BE PROCESSED
TO A WORKABLE FORM.
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00:02:00,137 --> 00:02:04,862
IT'S A SHORT DRIVE FROM
THE CLAY PIT TO THE FACTORY.
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00:02:04,862 --> 00:02:07,344
THEY UNLOAD IT
IN A BUILDING WITHOUT WALLS
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00:02:07,344 --> 00:02:10,862
SO IT WILL AIR DRY A BIT.
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00:02:10,862 --> 00:02:14,034
THEY DO A VISUAL INSPECTION
OF THE COLOR AND CONSISTENCY.
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EVERY FEW LOADS,
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00:02:15,379 --> 00:02:18,724
THEY ALSO DO A CHEMICAL ANALYSIS
OF THE MINERAL CONTENT.
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THIS ALLOWS THEM
TO CATEGORIZE THE CLAY
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00:02:20,655 --> 00:02:21,793
FOR SPECIFIC PURPOSES
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00:02:21,793 --> 00:02:26,793
AND FOR BLENDING
IN DIFFERENT CLAY RECIPES.
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00:02:26,793 --> 00:02:31,620
NEXT, THEY TRANSFER THE CLAY
TO A REVOLVING TUB.
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THE TUB HAS KNIVES
THAT PROTRUDE UP INTO IT.
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AS IT SPINS,
THE KNIVES HIT THE LUMPS OF CLAY
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00:02:37,241 --> 00:02:41,758
TO CHOP THEM
INTO SMALLER PIECES.
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00:02:41,758 --> 00:02:44,586
THESE SMALLER CLAY CHUNKS
FLOW OUT OF THE CHOPPER
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00:02:44,586 --> 00:02:47,137
AND RIDE A CONVEYOR
INTO A HOPPER.
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THE HOPPER FEEDS THE CLAY
TO A MILL.
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EN ROUTE TO THE MILL,
THE CLAY TRAVELS THROUGH FIRE --
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00:02:56,827 --> 00:02:59,655
A FLAME GENERATED
BY A FURNACE BELOW.
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00:02:59,655 --> 00:03:02,551
THIS IS CALLED FLASH DRYING,
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00:03:02,551 --> 00:03:05,724
AND IT BRINGS THE MOISTURE
CONTENT DOWN TO 1% TO 2% --
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00:03:05,724 --> 00:03:07,862
THE RIGHT CONSISTENCY
TO NOW GRIND IT
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00:03:07,862 --> 00:03:10,034
INTO A FINE POWDER.
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00:03:13,758 --> 00:03:16,620
THE GRINDING MILL IS A SHAFT
WITH NUMEROUS HAMMERS
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SANDWICHED BETWEEN STEEL PLATES.
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AS THE SHAFT TURNS,
THE HAMMERS WILL SWING
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00:03:22,620 --> 00:03:25,620
TO GRIND THE CLAY LUMPS
INTO A POWDER.
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00:03:27,517 --> 00:03:29,827
THE MILL WILL ALSO BLEND
DIFFERENT KINDS OF CLAY
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TO CREATE SPECIFIC PRODUCTS.
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THEY PUT THE COVER ON THE MILL
AND SET IT IN MOTION.
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THE HAMMERS PULVERIZE THE
DIFFERENT CLAYS INTO A POWDER.
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OVERHEAD, A MACHINE
SUCKS UP THE GROUND CLAY,
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USING SPINNING BLADES
AND A VACUUM.
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THE CYCLONE EFFECT
LIFTS UP THE CLAY PARTICLES
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00:03:48,862 --> 00:03:52,689
AND LEAVES HEAVIER IMPURITIES
LIKE SAND BEHIND.
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00:03:52,689 --> 00:03:56,103
THE RESULT
IS A PURER CLAY BLEND.
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HERE ARE VARIOUS CLAYS
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00:03:57,275 --> 00:04:01,000
NOW DRIED, PULVERIZED,
AND PURIFIED.
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00:04:01,000 --> 00:04:04,034
THEY RUN NUMEROUS TESTS ON CLAY.
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00:04:04,034 --> 00:04:06,862
FOR THIS ONE, THE TECHNICIAN
PRESSES THE CLAY POWDER
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00:04:06,862 --> 00:04:10,172
INTO A CAKE-LIKE DISC,
USING A HYDRAULIC PRESS.
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00:04:10,172 --> 00:04:12,448
AT THE SAME TIME,
HE WEIGHS THE CLAY.
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00:04:12,448 --> 00:04:15,448
WEIGHT CAN INDICATE
THE CLAY'S PLIABILITY
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00:04:15,448 --> 00:04:19,137
AND THE SPEED
AT WHICH IT CAN BE CAST.
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00:04:19,137 --> 00:04:21,758
HE FIRES THE CLAY DISC
IN AN OVEN OVERNIGHT
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00:04:21,758 --> 00:04:23,103
AND EXAMINES THE COLOR
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00:04:23,103 --> 00:04:26,931
TO CONFIRM
THAT IT'S THE DESIRED HUE.
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00:04:26,931 --> 00:04:29,862
OVER AT THE PACKAGING STATION,
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00:04:29,862 --> 00:04:32,206
A WORKER HANGS OPEN BAGS
ON SPOUTS,
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00:04:32,206 --> 00:04:35,689
WHICH WILL FILL THE BAGS
FULL OF DRY POWDERED CLAY.
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00:04:38,793 --> 00:04:41,827
THE CUSTOMER WILL ADD WATER
AND OTHER INGREDIENTS
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00:04:41,827 --> 00:04:44,000
TO TURN THIS PARTICULAR BLEND
INTO A GLAZE
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00:04:44,000 --> 00:04:45,620
FOR THINGS LIKE TILES AND SINKS.
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IN POWDERED FORM, THE CLAY
IS LIGHTER AND CHEAPER TO SHIP.
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00:04:51,137 --> 00:04:53,655
SOME CUSTOMERS PREFER
WET-PROCESSED CLAY,
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EVEN THOUGH IT'S HEAVIER.
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00:04:55,206 --> 00:04:58,862
FOR THAT, THEY ADD WATER
AND CHEMICALS TO MAKE A SLURRY.
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00:05:00,896 --> 00:05:02,448
THEY PUMP THE SLURRY
THROUGH A SIEVE
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00:05:02,448 --> 00:05:05,448
TO SCREEN OUT IMPURITIES.
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00:05:05,448 --> 00:05:08,620
THE CLAY SLURRY NOW FLOWS
INTO BIG MIXING TANKS,
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00:05:08,620 --> 00:05:12,862
WHERE IT REMAINS IN
A CONSTANT STATE OF AGITATION.
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00:05:12,862 --> 00:05:15,896
CONTINUOUS MIXING
KEEPS IT FLUID.
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00:05:15,896 --> 00:05:17,206
WITHOUT IT,
THE CLAY WOULD THICKEN
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00:05:17,206 --> 00:05:19,068
TO THE CONSISTENCY
OF PEANUT BUTTER.
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00:05:20,655 --> 00:05:24,137
ON DELIVERY DAY,
THEY PUMP IT INTO TANKER TRUCKS.
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00:05:24,137 --> 00:05:26,655
AT ANOTHER FACTORY,
THIS PARTICULAR BATCH
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WILL BE USED
TO MAKE SINKS OR TUBS.
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THE NEXT TRUCKS WILL LIKELY
BE HEADED SOMEWHERE ELSE.
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YOU NEVER KNOW WHAT WILL BE MADE
FROM THIS PRODUCT OF THE EARTH.
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00:05:50,862 --> 00:05:53,172
Narrator:
AMONG DRIED FRUITS,
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00:05:53,172 --> 00:05:55,827
NONE INSPIRES A GUT REACTION
LIKE PRUNES.
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00:05:55,827 --> 00:05:57,344
EATING THEM IS ONE WAY
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TO KICK-START A LETHARGIC
GASTROINTESTINAL SYSTEM.
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00:06:00,517 --> 00:06:05,586
HIGH IN FIBER, SWEET AND CHEWY,
PRUNES ARE ACTUALLY DRIED PLUMS,
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00:06:05,586 --> 00:06:10,413
AND THEY'RE A DELICACY THAT'S
AS OLD AS CIVILIZATION ITSELF.
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00:06:13,103 --> 00:06:16,586
PRUNES HAVE BEEN FOUND
IN ANCIENT EGYPTIAN TOMBS,
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PLACED THERE TO SNACK ON
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00:06:17,931 --> 00:06:20,241
DURING THE JOURNEY
TO THE NEXT WORLD.
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00:06:20,241 --> 00:06:21,931
FAST-FORWARD TO TODAY,
100
00:06:21,931 --> 00:06:24,758
AND PEOPLE ARE STILL SNACKING
ON PRUNES.
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00:06:24,758 --> 00:06:27,103
THEY ALSO ADD THEM TO SALADS,
MUFFINS,
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00:06:27,103 --> 00:06:29,793
AND MAIN-COURSE RECIPES.
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IT ALL STARTS
WITH THE GROWING STOCK.
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00:06:31,965 --> 00:06:35,275
NOT ALL VARIETIES OF PLUMS
ARE SUITABLE FOR DRYING.
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00:06:35,275 --> 00:06:37,448
AT THIS CALIFORNIA ORCHARD,
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00:06:37,448 --> 00:06:41,137
THEY GROW THE D'AGEN PLUM --
A EUROPEAN VARIETY.
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HARVESTING MACHINES
SHAKE THE TREES BY THE TRUNKS,
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00:06:43,793 --> 00:06:47,103
AND THE FRUIT RAINS DOWN
ONTO A CONVEYOR,
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00:06:47,103 --> 00:06:49,620
WHICH DELIVERS IT TO BINS.
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00:06:49,620 --> 00:06:52,068
THEY THEN TRUCK THE PLUMS
TO THE RECEIVING PLANT...
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00:06:54,586 --> 00:06:59,103
...AND UNLOAD THEM
DIRECTLY INTO A WASHING SYSTEM.
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00:06:59,103 --> 00:07:02,413
TREE LEAVES FLOAT TO THE SURFACE
OF THE WATER TO BE REMOVED.
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00:07:02,413 --> 00:07:05,655
THE PLUMS EXIT ONTO A TABLE
THAT VIBRATES
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00:07:05,655 --> 00:07:06,827
TO DISTRIBUTE THEM EVENLY
115
00:07:06,827 --> 00:07:09,551
SO THEY LAND ON TRAYS
IN FAIRLY EQUAL AMOUNTS.
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00:07:09,551 --> 00:07:14,206
A PADDLE OVERHEAD
LEVELS THEM ON THE TRAYS.
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00:07:14,206 --> 00:07:17,379
MACHINERY STACKS
THE TRAYS OF PLUMS ON RACKS.
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00:07:17,379 --> 00:07:19,896
THE PLUMS ARE NOW READY TO DRY.
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00:07:19,896 --> 00:07:23,379
THEY'RE ABOUT 80% WATER
WHEN THEY ENTER THE DRYER.
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00:07:23,379 --> 00:07:25,551
16 HOURS OF HEAT EXPOSURE
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00:07:25,551 --> 00:07:29,724
BRINGS THE MOISTURE CONTENT
DOWN TO 19%.
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00:07:29,724 --> 00:07:32,896
PLUMS WERE ONCE SUN-DRIED
AS A MEANS OF PRESERVATION,
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00:07:32,896 --> 00:07:38,000
BUT A MODERN INDUSTRIAL DRYER
PRODUCES MORE UNIFORM RESULTS.
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00:07:38,000 --> 00:07:40,137
THE DRIED PLUMS
TRAVEL UNDER A VACUUM
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00:07:40,137 --> 00:07:43,137
THAT SUCKS OUT STICKS OR STEMS.
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THEN THE PRUNES TRAVEL
TO A SHAKING CONVEYOR
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00:07:46,655 --> 00:07:50,137
WITH A LOT
OF DIFFERENT-SIZED HOLES.
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00:07:50,137 --> 00:07:52,482
THE FIRST HOLES
ARE THE SMALLEST,
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00:07:52,482 --> 00:07:54,482
AND THEY BECOME
PROGRESSIVELY LARGER
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00:07:54,482 --> 00:07:56,965
TO SORT THE PRUNES BY SIZE.
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00:07:56,965 --> 00:07:59,827
THEY FALL
INTO SEPARATE BINS BELOW.
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00:07:59,827 --> 00:08:04,206
THE SMALLEST FRUIT WILL BE USED
FOR BREAKFAST OR DICED PRODUCT.
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00:08:04,206 --> 00:08:08,551
THE LARGEST PRUNES
WILL END UP AS SNACK FOOD.
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00:08:08,551 --> 00:08:10,896
PRESERVED BY DRYING
AND NOW SORTED,
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00:08:10,896 --> 00:08:14,862
THEY CAN BE STORED FOR MONTHS
UNTIL PROCESSING.
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00:08:14,862 --> 00:08:16,724
AT THE PROCESSING PLANT,
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00:08:16,724 --> 00:08:19,034
THE PRUNES HEAD INTO
A SUPER-SIZED STEAM COOKER.
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00:08:19,034 --> 00:08:22,620
THEY SPEND 18 MINUTES IN THERE.
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00:08:24,241 --> 00:08:26,586
THE STEAM COOKING
PARTIALLY REHYDRATES THEM,
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00:08:26,586 --> 00:08:31,724
SOFTENING THE PRUNES SO THE PITS
CAN BE REMOVED MORE EASILY.
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00:08:31,724 --> 00:08:33,206
THEY MUST NOW REMOVE THE PITS
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00:08:33,206 --> 00:08:35,344
BEFORE THE PRUNES
START TO LOSE MOISTURE
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00:08:35,344 --> 00:08:38,103
AND BECOME TOO DRY FOR THE JOB
TO BE DONE EFFICIENTLY.
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00:08:41,413 --> 00:08:43,724
THE PRUNES SPEED TOWARDS
THE PITTING OPERATION
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00:08:43,724 --> 00:08:44,965
AND FLOW INTO FIVE LANES.
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00:08:44,965 --> 00:08:48,275
EACH ONE LEADS
TO A SEPARATE PITTING LINE.
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00:08:48,275 --> 00:08:50,620
WITH FIVE
DIFFERENT PITTING LINES,
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00:08:50,620 --> 00:08:54,620
THEY'LL PROCESS
HUNDREDS OF PRUNES A MINUTE.
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00:08:54,620 --> 00:08:58,137
CLAMPS CLOSE AROUND THE PRUNES,
150
00:08:58,137 --> 00:09:00,482
SECURING THEM
FOR KNIVES TO PUSH OUT THE PITS.
151
00:09:02,517 --> 00:09:07,689
THE PITS WILL BE GROUND UP
AND ADDED TO ANIMAL FEED.
152
00:09:07,689 --> 00:09:09,103
THE PITTED PRUNES
MAKE A SOFT LANDING
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00:09:09,103 --> 00:09:10,689
ON A RUBBER CONVEYOR,
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00:09:10,689 --> 00:09:14,000
WHICH TAKES THEM
INTO A LASER-DETECTION CENTER.
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00:09:14,000 --> 00:09:16,758
THE LASER FINDS PITS
OR PIT FRAGMENTS
156
00:09:16,758 --> 00:09:19,758
AND RELAYS THE INFORMATION
TO A COMPUTER.
157
00:09:19,758 --> 00:09:21,896
THE COMPUTER ACTIVATES AIR JETS
158
00:09:21,896 --> 00:09:24,827
THAT BLAST OUT
THE UNWANTED MATERIAL.
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00:09:24,827 --> 00:09:28,137
IT HAPPENS SO FAST,
IT'S ALL A BLUR.
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00:09:29,827 --> 00:09:32,862
ON ANOTHER SHAKER CONVEYOR NOW,
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00:09:32,862 --> 00:09:36,689
THE PRUNES BOUNCE
TOWARDS A BIG DRUM.
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00:09:36,689 --> 00:09:40,344
THE DRUM REVOLVES SLOWLY
TO GENTLY TOSS THE PRUNES
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00:09:40,344 --> 00:09:43,862
AS THEY PUMP IN A PRESERVATIVE,
FLAVORINGS, AND OIL.
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00:09:43,862 --> 00:09:45,344
THE PRUNES ABSORB
THE INGREDIENTS
165
00:09:45,344 --> 00:09:49,724
AS THEY TUMBLE AROUND
IN THE DRUM.
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00:09:49,724 --> 00:09:51,241
AT THIS POINT,
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00:09:51,241 --> 00:09:54,827
THEY SAMPLE THE MOISTURE CONTENT
OF THE PRUNES EVERY 15 MINUTES.
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00:09:54,827 --> 00:09:57,482
THE TECHNICIAN GRINDS
AND COMPRESSES SOME PRUNES
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00:09:57,482 --> 00:10:00,137
INTO A DISC.
170
00:10:00,137 --> 00:10:03,103
SHE DRIVES AN ELECTRODE INTO IT
TO GAUGE THE MOISTURE.
171
00:10:03,103 --> 00:10:06,137
IT SHOULD BE BETWEEN
28% AND 32% --
172
00:10:06,137 --> 00:10:09,931
ENOUGH TO IMPROVE THE TEXTURE,
BUT A LOT LESS THAN FRESH FRUIT.
173
00:10:11,482 --> 00:10:17,137
IT'S TIME TO WRAP THINGS UP.
SECTIONING ARMS OPEN THE BAGS.
174
00:10:19,620 --> 00:10:20,793
FEEDERS DISPENSE
175
00:10:20,793 --> 00:10:23,379
A PRECISE AMOUNT
OF PITTED PRUNES INTO THEM.
176
00:10:26,482 --> 00:10:27,793
A HEATED DEVICE THEN MELTS
177
00:10:27,793 --> 00:10:30,275
THE ENDS OF THE PLASTIC BAGS
TOGETHER TO SEAL THEM.
178
00:10:31,965 --> 00:10:36,310
THEY PRODUCE 120 BAGS OF PRUNES
A MINUTE AT THIS FACTORY,
179
00:10:36,310 --> 00:10:39,000
SO ADDING FIBER TO ONE'S DIET
SHOULDN'T BE A PROBLEM.
180
00:10:50,724 --> 00:10:53,551
Narrator:
IF YOU RIDE HORSES REGULARLY,
181
00:10:53,551 --> 00:10:56,379
CHANCES ARE
YOU OWN A PAIR OF SPURS.
182
00:10:56,379 --> 00:10:59,206
SPURS STRAP ONTO THE HEELS
OF RIDING BOOTS.
183
00:10:59,206 --> 00:11:02,620
EACH SPUR HAS A SMALL WHEEL,
USUALLY SPIKED,
184
00:11:02,620 --> 00:11:04,793
WITH WHICH THE RIDER
PRODS THE HORSE
185
00:11:04,793 --> 00:11:08,275
TO GET IT TO START MOVING
OR MOVE FASTER.
186
00:11:11,034 --> 00:11:13,206
THE ANATOMY OF A SPUR
IS ELEMENTARY.
187
00:11:13,206 --> 00:11:17,034
THE WHEEL, CALLED THE RAWL,
IS MOUNTED IN THE SHANK.
188
00:11:17,034 --> 00:11:19,517
THE SHANK IS CONNECTED
TO THE HEEL BAND.
189
00:11:19,517 --> 00:11:22,344
THE HEEL BAND IS HELD
TO THE BOOT BY A LEATHER STRAP.
190
00:11:22,344 --> 00:11:24,344
THE METAL PARTS ARE MADE FROM
191
00:11:24,344 --> 00:11:27,793
A STRONG, YET FLEXIBLE,
TYPE OF STEEL.
192
00:11:27,793 --> 00:11:29,034
A COMPUTER-GUIDED LASER
193
00:11:29,034 --> 00:11:31,586
CUTS THE STARTING SHAPE
FOR THE HEEL BANDS.
194
00:11:31,586 --> 00:11:32,620
A QUICK STRIKE OF A PRESS
195
00:11:32,620 --> 00:11:34,965
STAMPS THEM
WITH THE COMPANY NAME.
196
00:11:34,965 --> 00:11:37,965
NEXT, WORKERS SMOOTH
AND BEVEL THE EDGES,
197
00:11:37,965 --> 00:11:40,275
USING A SANDER OUTFITTED
WITH A SPECIAL BELT
198
00:11:40,275 --> 00:11:43,655
FOR GRINDING METAL.
199
00:11:45,551 --> 00:11:49,206
NEXT, THEY HAMMER THE PIECE
AROUND A STEEL BLOCK,
200
00:11:49,206 --> 00:11:50,551
CUSHIONING THE BLOWS
WITH A PIECE OF WOOD
201
00:11:50,551 --> 00:11:53,068
TO AVOID MARRING THE SURFACE.
202
00:11:53,068 --> 00:11:55,896
THE BLOCK IS SHAPED EXACTLY LIKE
THE HEEL OF THE BOOTS
203
00:11:55,896 --> 00:11:58,034
FOR WHICH THE SPURS
HAVE BEEN ORDERED,
204
00:11:58,034 --> 00:12:00,206
ENSURING A CUSTOM FIT.
205
00:12:01,275 --> 00:12:03,793
THEY HEAT EVENLY WITH A TORCH.
206
00:12:03,793 --> 00:12:06,862
THIS RELAXES THE STEEL
AROUND THE BLOCK SO THAT
207
00:12:06,862 --> 00:12:10,379
THE HEEL BAND PERMANENTLY
REGISTERS THIS SHAPE.
208
00:12:10,379 --> 00:12:12,034
THEN, SOME FINAL TAPS
209
00:12:12,034 --> 00:12:15,689
TO LAY THE BAND COMPLETELY FLAT
AGAINST THE BLOCK.
210
00:12:15,689 --> 00:12:17,551
THIS PERFECTS THE SHAPE.
211
00:12:21,379 --> 00:12:24,068
THEY SUBMERGE THE HEEL BAND
IN COOL WATER.
212
00:12:24,068 --> 00:12:29,206
THIS TEMPERS THE FLEXIBLE STEEL,
RENDERING IT HARD AND STIFF.
213
00:12:29,206 --> 00:12:31,379
THEN, WITH A FINE-GRIT BELT,
214
00:12:31,379 --> 00:12:34,551
THEY SAND AWAY
ANY SURFACE IMPERFECTIONS.
215
00:12:34,551 --> 00:12:39,068
A PAIR OF SPURS IS MADE UP
OF SOME TWO DOZEN STEEL PIECES,
216
00:12:39,068 --> 00:12:42,379
ALL OF WHICH GO THROUGH
THE SAME PREP AS THE HEEL BAND.
217
00:12:45,551 --> 00:12:49,551
ONCE ALL THE PARTS ARE READY,
WORKERS PRECISION WELD THE SHANK
218
00:12:49,551 --> 00:12:52,068
TO THE MID-POINT
OF THE HEEL BAND.
219
00:13:01,172 --> 00:13:04,034
NEXT,
TO EACH SIDE OF THE HEEL BAND,
220
00:13:04,034 --> 00:13:06,344
THEY WELD A PIN,
WHICH HOLDS A PIVOTING ARM.
221
00:13:06,344 --> 00:13:09,413
THESE SWINGARMS,
AS THEY'RE CALLED,
222
00:13:09,413 --> 00:13:13,379
HOLD THE LEATHER STRAP THAT
RETAINS THE SPUR TO THE BOOT.
223
00:13:18,724 --> 00:13:22,379
TO MAKE THE RAWLS,
THEY TRACE A TEMPLATE ON STEEL,
224
00:13:22,379 --> 00:13:26,448
THEN CUT ALONG THE LINES
WITH A METAL BAND SAW.
225
00:13:28,103 --> 00:13:30,275
IF THE RAWL SHAPE IS ELABORATE,
226
00:13:30,275 --> 00:13:34,448
A COMPUTER-GUIDED LASER
CUTS THEM OUT.
227
00:13:34,448 --> 00:13:36,965
AFTER SANDING
THE RAWL THOROUGHLY
228
00:13:36,965 --> 00:13:39,310
TO SMOOTH SHARP EDGES
WHICH COULD CUT THE HORSE,
229
00:13:39,310 --> 00:13:42,793
THEY MOUNT IT TO THE SHANK
WITH A STAINLESS-STEEL PIN.
230
00:13:46,310 --> 00:13:49,310
THEN THEY WELD
THE BACK OF THE PIN.
231
00:13:53,965 --> 00:13:56,482
NOW THE ARTISTRY BEGINS.
232
00:13:56,482 --> 00:14:00,724
A CRAFTSMAN CREATES DECORATIVE
OVERLAYS IN STERLING SILVER.
233
00:14:00,724 --> 00:14:03,586
HE CUTS THEIR SHAPES
WITH A JEWELER'S SAW,
234
00:14:03,586 --> 00:14:07,103
DRAWS A DESIGN, THEN, USING
AN ARRAY OF ENGRAVING TOOLS,
235
00:14:07,103 --> 00:14:10,620
METICULOUSLY CARVES IT OUT.
236
00:14:16,793 --> 00:14:20,137
HE CLEANS THE BACK
OF THE OVERLAYS WITH FLUX --
237
00:14:20,137 --> 00:14:23,551
AN ACIDIC CHEMICAL --
THEN COATS THEM WITH SOLDER.
238
00:14:23,551 --> 00:14:25,034
THE TRICK IS TO APPLY
JUST ENOUGH
239
00:14:25,034 --> 00:14:27,586
TO BOND THE SILVER TO THE STEEL.
240
00:14:27,586 --> 00:14:31,758
TOO MUCH WOULD OVERFLOW
AND RUIN THE FRONT.
241
00:14:31,758 --> 00:14:35,413
BY THE TIME HE GENTLY APPLIES
EACH OVERLAY TO THE SPUR,
242
00:14:35,413 --> 00:14:37,931
THE SOLDER HAS COOLED
AND SOLIDIFIED,
243
00:14:37,931 --> 00:14:41,068
SO HE WARMS THE STEEL
WITH A TORCH FROM UNDERNEATH.
244
00:14:41,068 --> 00:14:43,758
THIS REHEATS AND LIQUEFIES
THE SOLDER,
245
00:14:43,758 --> 00:14:46,137
WHICH THEN COOLS
AND RESOLIDIFIES,
246
00:14:46,137 --> 00:14:48,241
BONDING THE SILVER TO THE STEEL.
247
00:14:48,241 --> 00:14:50,724
THE HEAT CAUSES
SOME DISCOLORATION,
248
00:14:50,724 --> 00:14:54,551
WHICH HE EASILY REMOVES
WITH A BIT OF FLUX.
249
00:14:54,551 --> 00:14:57,379
ONCE ALL THE SILVER OVERLAYS
ARE SOLDERED TO THE SPUR,
250
00:14:57,379 --> 00:14:59,827
WORKERS POLISH THEM
ON A CLOTH BUFFING WHEEL.
251
00:15:01,448 --> 00:15:05,448
THE FINISHING TOUCH -- THEY
SUBMERGE THE SPURS IN A TANK
252
00:15:05,448 --> 00:15:08,448
CONTAINING A CHEMICAL SOLUTION
CALLED GUN BLUING.
253
00:15:08,448 --> 00:15:11,137
IT TURNS THE SHINY STEEL PARTS
BLACK.
254
00:15:11,137 --> 00:15:14,000
TO PRODUCE AN ANTIQUE BROWN,
RATHER THAN BLACK FINISH,
255
00:15:14,000 --> 00:15:16,931
WORKERS HEAT THE SPURS
IN AN OVEN,
256
00:15:16,931 --> 00:15:20,517
THEN APPLY A CHEMICAL
WHICH TINTS THE STEEL.
257
00:15:20,517 --> 00:15:22,517
NOW FOR THE LEATHER STRAPS.
258
00:15:22,517 --> 00:15:25,344
AN ARTISAN TOOLS THE LEATHER
ENTIRELY BY HAND,
259
00:15:25,344 --> 00:15:29,344
DYES IT, ATTACHES
A STAINLESS-STEEL BUCKLE,
260
00:15:29,344 --> 00:15:33,517
THEN SEWS TABS ON BOTH ENDS
THAT HOOK TO THE SWINGARMS
261
00:15:33,517 --> 00:15:35,689
ON THE HEEL BAND.
262
00:15:35,689 --> 00:15:39,689
THIS SHINY SET OF SPURS IS READY
FOR SOME HORSING AROUND.
263
00:15:49,827 --> 00:15:54,482
Narrator:
MANY LOW-SPEED VEHICLES HAVE
TIRES MADE OF POLYURETHANE FOAM,
264
00:15:54,482 --> 00:15:57,000
RATHER THAN
AIR-FILLED RUBBER TIRES.
265
00:15:57,000 --> 00:15:59,793
POLYURETHANE
DOESN'T DETERIORATE IN SUNLIGHT,
266
00:15:59,793 --> 00:16:02,068
NOR DOES IT DRY OUT OVER TIME.
267
00:16:02,068 --> 00:16:05,551
AND IF THE TIRE IS MADE ENTIRELY
OF THE CLOSED-CELL TYPE OF FOAM,
268
00:16:05,551 --> 00:16:08,034
THE TIRE WON'T GO FLAT.
269
00:16:10,379 --> 00:16:13,724
POLYURETHANE TIRES ARE DESIGNED
FOR LOW-SPEED VEHICLES,
270
00:16:13,724 --> 00:16:16,724
SUCH AS BAGGAGE CARTS
AND RIDE-ON LAWN MOWERS.
271
00:16:16,724 --> 00:16:19,724
THIS PARTICULAR TYPE
OF POLYURETHANE FOAM
272
00:16:19,724 --> 00:16:21,551
HAS A CLOSED-CELL STRUCTURE,
273
00:16:21,551 --> 00:16:25,241
WHICH PREVENTS A FLAT,
EVEN IF THE TIRE GETS PUNCTURED.
274
00:16:25,241 --> 00:16:27,551
MILLIONS OF AIR BUBBLES
ENCAPSULATED WITHIN THE FOAM
275
00:16:27,551 --> 00:16:31,896
GIVE IT
THE REQUIRED BOUNCE FACTOR.
276
00:16:31,896 --> 00:16:34,000
THE FIRST STEP IS TO TAKE
AN ALUMINUM MODEL OF THE TIRE
277
00:16:34,000 --> 00:16:37,172
AND MAKE A PRODUCTION MOLD
WITH IT.
278
00:16:37,172 --> 00:16:39,517
THIS ONE'S FOR A FORKLIFT.
279
00:16:39,517 --> 00:16:43,310
THE MOLD WILL HAVE TWO HALVES --
EACH ONE LINED WITH A TREAD RING
280
00:16:43,310 --> 00:16:47,620
TO PREVENT THE CAST TIRE FROM
GETTING STUCK IN THE CAVITY.
281
00:16:48,620 --> 00:16:52,310
TO MAKE EACH HALF OF THE MOLD,
THEY CENTER THE MODEL IN A BASE,
282
00:16:52,310 --> 00:16:56,275
THEN FILL THE SPACE AROUND IT
WITH POLYURETHANE ELASTOMER,
283
00:16:56,275 --> 00:16:58,620
WHICH IS A SOLID TYPE
OF POLYURETHANE,
284
00:16:58,620 --> 00:17:03,482
AS OPPOSED TO THE FOAM TYPE
THEY USE TO CAST THE TIRES.
285
00:17:05,551 --> 00:17:09,379
THEY STIR GENTLY TO MOVE
AIR BUBBLES TO THE TOP...
286
00:17:11,655 --> 00:17:14,620
...THEN HEAT THOSE BUBBLES
WITH A SMALL PROPANE TORCH
287
00:17:14,620 --> 00:17:17,655
TO BURST THEM.
288
00:17:17,655 --> 00:17:20,482
WITH THE HELP OF A HEATED TABLE
TO SPEED THINGS ALONG,
289
00:17:20,482 --> 00:17:24,172
THE MATERIAL SOLIDIFIES
IN APPROXIMATELY 15 MINUTES,
290
00:17:24,172 --> 00:17:27,137
AT WHICH POINT,
THEY EXTRACT THE HALF-MOLD...
291
00:17:30,103 --> 00:17:33,241
...AND, WITH THE UTILITY KNIFE,
TRIM ITS ROUGH EDGES
292
00:17:33,241 --> 00:17:36,103
BOTH INSIDE AND OUT.
293
00:17:44,965 --> 00:17:47,137
THEN THEY MATE THE TWO HALVES,
294
00:17:47,137 --> 00:17:49,586
AND THE PRODUCTION MOLD
IS READY.
295
00:17:49,586 --> 00:17:53,068
WHEREAS MOST COMPANIES
BUY FOAM MIXTURES READY-MADE,
296
00:17:53,068 --> 00:17:55,275
THIS ONE BLENDS ITS OWN,
297
00:17:55,275 --> 00:17:59,379
IN ORDER TO HAVE STRICT CONTROL
OVER THE FORMULATION.
298
00:17:59,379 --> 00:18:01,793
TECHNICIANS WEIGH OUT
THE CHEMICAL INGREDIENTS
299
00:18:01,793 --> 00:18:04,137
MANUALLY WITH A HIGH-PRECISION
INDUSTRIAL SCALE
300
00:18:04,137 --> 00:18:07,310
THAT'S ACCURATE
TO WITHIN 1 1/2 OUNCES.
301
00:18:09,793 --> 00:18:11,758
A PROPELLER-SHAPED BLADE
MIXES THE INGREDIENTS
302
00:18:11,758 --> 00:18:13,448
FOR HALF AN HOUR,
303
00:18:13,448 --> 00:18:17,103
MOVING EVERYTHING FROM TOP
TO BOTTOM MORE THAN 300 TIMES
304
00:18:17,103 --> 00:18:20,241
AND DRAWING IT OUT
OF THE CORNERS OF THE CONTAINER.
305
00:18:20,241 --> 00:18:23,551
THIS ENSURES THE MIXTURE
IS EVENLY BLENDED THROUGHOUT.
306
00:18:25,724 --> 00:18:28,689
BEFORE USING THIS FOAM
TO CAST THE TIRES,
307
00:18:28,689 --> 00:18:30,965
A QUALITY-CONTROL TEST.
308
00:18:30,965 --> 00:18:33,620
THEY TAKE A SAMPLE
FROM THE BATCH
309
00:18:33,620 --> 00:18:37,448
AND LET IT RISE AND SET,
WHICH TAKES ABOUT A MINUTE.
310
00:18:41,103 --> 00:18:44,413
THEN THEY CUT A PIECE
OF A SPECIFIC SIZE, WEIGH IT,
311
00:18:44,413 --> 00:18:46,103
AND CALCULATE THE DENSITY.
312
00:18:46,103 --> 00:18:48,517
IF THE SAMPLE
MEETS SPECIFICATIONS,
313
00:18:48,517 --> 00:18:50,172
THE BATCH IS A GO.
314
00:18:52,655 --> 00:18:55,655
JUST BEFORE FILLING
THE TWO HALVES OF THE MOLD
315
00:18:55,655 --> 00:18:57,103
WITH POLYURETHANE FOAM,
316
00:18:57,103 --> 00:18:59,965
THEY LUBRICATE THE CAVITY
WITH A RELEASE AGENT.
317
00:18:59,965 --> 00:19:02,931
THIS PREVENTS THE TIRE
FROM STICKING TO THE MOLD
318
00:19:02,931 --> 00:19:04,965
WHEN THEY EXTRACT IT.
319
00:19:07,241 --> 00:19:10,896
A PRESS KEEPS THE MOLD CLOSED
AND IN PLACE
320
00:19:10,896 --> 00:19:11,896
ON THE FILLING MACHINE.
321
00:19:11,896 --> 00:19:13,620
THE MACHINE SPINS THE MOLD
322
00:19:13,620 --> 00:19:15,862
WHILE THE FOAM FLOWS
INTO THE CAVITY
323
00:19:15,862 --> 00:19:17,413
THROUGH A HOLE AT THE TOP.
324
00:19:17,413 --> 00:19:21,103
THE SPINNING
CREATES CENTRIFUGAL FORCE
325
00:19:21,103 --> 00:19:23,551
THAT DISTRIBUTES THE FOAM
INTO EVERY NOOK AND CRANNY.
326
00:19:28,000 --> 00:19:31,206
IN LESS THAN A MINUTE, THE FOAM,
ALTHOUGH NOT YET FULLY CURED,
327
00:19:31,206 --> 00:19:35,379
IS SOLID ENOUGH TO BE EXTRACTED.
328
00:19:35,379 --> 00:19:38,379
THEY OPEN THE MOLD,
REMOVE THE TREAD RING,
329
00:19:38,379 --> 00:19:40,551
THEN DISLODGE THE CAST TIRE
330
00:19:40,551 --> 00:19:43,551
WITH A SHORT BLAST
OF AN AIR GUN.
331
00:19:43,551 --> 00:19:46,551
THEY TRIM THE EXCESS FOAM
FROM THE CENTER.
332
00:19:46,551 --> 00:19:48,689
IT CAN BE GROUND UP
TO MAKE OTHER PRODUCTS,
333
00:19:48,689 --> 00:19:50,517
SUCH AS FLOOR MATS.
334
00:19:50,517 --> 00:19:55,827
HERE'S WHAT THE TIRE
LOOKS LIKE BEFORE...
335
00:19:55,827 --> 00:19:59,379
AND AFTER TRIMMING.
336
00:19:59,379 --> 00:20:03,344
THE POLYURETHANE FOAM TAKES
24 MORE HOURS TO FULLY CURE,
337
00:20:03,344 --> 00:20:06,379
THEN THE TIRES
ARE READY TO ROLL.
338
00:20:06,379 --> 00:20:10,689
THIS COMPANY SELLS TIRES WITH
AND WITHOUT PAINTED STEEL RIMS.
339
00:20:10,689 --> 00:20:13,034
RIM INSTALLATION IS SIMPLE.
340
00:20:13,034 --> 00:20:16,655
THEY PLACE THE RIM ON A BASE,
FOLLOWED BY A MOUNTING CONE,
341
00:20:16,655 --> 00:20:17,862
THEN THE TIRE.
342
00:20:17,862 --> 00:20:19,689
A PRESS SNAPS
THE CENTER OF THE TIRE
343
00:20:19,689 --> 00:20:22,103
OVER THE EDGE OF THE RIM.
344
00:20:22,103 --> 00:20:23,689
BESIDES MAKING THE TIRE
FLAT-RESISTANT,
345
00:20:23,689 --> 00:20:27,068
THE CLOSED-CELL STRUCTURE
OF THIS POLYURETHANE FOAM
346
00:20:27,068 --> 00:20:29,241
DOESN'T ABSORB WATER,
347
00:20:29,241 --> 00:20:32,448
MEANING WET CONDITIONS
DON'T HAMPER PERFORMANCE.
348
00:20:32,448 --> 00:20:36,517
THE TIRE IS ALSO U.V. RESISTANT
AND WITHSTANDS HIGH ABRASION,
349
00:20:36,517 --> 00:20:39,034
SO IT TYPICALLY LASTS
TWO TO THREE TIMES LONGER
350
00:20:39,034 --> 00:20:42,655
THAN AN AIR-FILLED TIRE
USED ON THE SAME VEHICLE.
351
00:20:50,862 --> 00:20:54,034
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW
352
00:20:54,034 --> 00:20:56,034
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
353
00:20:56,034 --> 00:20:58,241
DROP US A LINE AT...
28646
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