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--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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00:00:50,275 --> 00:00:53,827
Narrator: LIQUID MEDICATION
USED TO ALWAYS COME IN A BOTTLE,
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00:00:53,827 --> 00:00:56,724
AND YOU HAD TO POUR
YOUR DOSE WITH A STEADY HAND
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00:00:56,724 --> 00:00:58,275
INTO A SPOON.
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00:00:58,275 --> 00:01:01,034
TODAY, MANY MEDICATIONS
AND SUPPLEMENTS
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00:01:01,034 --> 00:01:03,586
COME INSIDE
SMALL FOOD-SAFE CASINGS
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00:01:03,586 --> 00:01:06,379
THAT ARE EASY TO SWALLOW
AND PORTABLE --
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SOFT GEL CAPSULES.
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00:01:10,655 --> 00:01:13,758
MANY TYPES OF PRODUCTS
COME IN GEL CAPSULES,
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00:01:13,758 --> 00:01:15,379
FROM PRESCRIPTION DRUGS
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00:01:15,379 --> 00:01:18,172
TO HEALTH SUPPLEMENTS
SUCH AS FISH OILS.
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00:01:18,172 --> 00:01:21,896
MANY OF THESE MEDICINE FILLS
GO BAD IF EXPOSED TO OXYGEN,
14
00:01:21,896 --> 00:01:24,724
SO THE GEL CAP,
BESIDES BEING CONVENIENT,
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00:01:24,724 --> 00:01:27,241
ALSO SERVES
AS A PROTECTIVE BARRIER.
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00:01:27,241 --> 00:01:29,620
EVERY INGREDIENT
IN BOTH THE GEL CAP
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00:01:29,620 --> 00:01:31,241
AND THE MEDICINE FILL INSIDE
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00:01:31,241 --> 00:01:34,000
UNDERGOES
EXTENSIVE TESTING FOR PURITY.
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00:01:34,000 --> 00:01:38,310
THE FIRST TEST PHASE CHECKS
FOR BACTERIAL CONTAMINATION.
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00:01:38,310 --> 00:01:41,758
LAB TECHNICIANS DISSOLVE
THE INGREDIENTS IN SOLUTION,
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00:01:41,758 --> 00:01:44,551
APPLY IT TO A FOOD SOURCE
IN A PETRI DISH,
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00:01:44,551 --> 00:01:46,551
THEN INCUBATE
THE DISH FOR 72 HOURS
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00:01:46,551 --> 00:01:49,620
TO ENCOURAGE
ANY EXISTING BACTERIA TO GROW.
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00:01:49,620 --> 00:01:53,241
THEN THEY DRAW SAMPLES AND
EXAMINE THEM UNDER A MICROSCOPE.
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00:01:53,241 --> 00:01:55,620
IF THOSE SAMPLES
ARE BACTERIA-FREE,
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00:01:55,620 --> 00:01:59,103
THE INGREDIENT MOVES ON
TO THE SECOND PHASE OF TESTING,
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00:01:59,103 --> 00:02:02,241
WHICH CHECKS FOR CONTAMINANTS
SUCH AS LEAD, ARSENIC,
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00:02:02,241 --> 00:02:04,241
MERCURY, AND CADMIUM.
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00:02:04,241 --> 00:02:06,965
THIS MACHINE,
CALLED A SPECTROMETER,
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00:02:06,965 --> 00:02:10,275
INJECTS THE INGREDIENT SOLUTION
INTO A PLASMA FLAME,
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00:02:10,275 --> 00:02:13,862
THEN, BY READING THE CHANGES
IN LIGHT WAVELENGTHS,
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00:02:13,862 --> 00:02:15,931
ANALYZES
THE CHEMICAL COMPOSITION.
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00:02:15,931 --> 00:02:17,965
IF THE INGREDIENT
IS CONTAMINANT-FREE,
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00:02:17,965 --> 00:02:20,034
IT GETS THE GO-AHEAD.
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00:02:20,034 --> 00:02:23,586
THE GEL CAP IS MADE ENTIRELY
OF NATURAL INGREDIENTS --
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00:02:23,586 --> 00:02:26,862
GELATIN DERIVED
FROM BEEF BONES,
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00:02:26,862 --> 00:02:28,862
PALM OIL GLYCERIN,
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AND PURIFIED WATER.
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00:02:31,068 --> 00:02:33,344
THE PROPORTIONS ARE TOP-SECRET.
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00:02:33,344 --> 00:02:37,206
AN INDUSTRIAL BLENDER COMBINES
THE THREE INGREDIENTS
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TO A UNIFORM CONSISTENCY,
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THEN HEATS THE MIXTURE
TO 175 DEGREES FAHRENHEIT.
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00:02:42,241 --> 00:02:44,275
A VACUUM SUCKS OUT
THE AIR BUBBLES
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00:02:44,275 --> 00:02:48,000
AS THIS NOW-READY GEL MATERIAL
FLOWS INTO A HOLDING TANK.
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SIMULTANEOUSLY, THEY PREPARE
THE MEDICINE FILL --
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IN THIS CASE, VITAMIN D.
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THEY COMBINE IT WITH SOYBEAN OIL
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00:02:56,241 --> 00:02:59,000
TO ADJUST THE POTENCY
TO THE SPECIFIED STRENGTH.
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00:02:59,000 --> 00:03:02,724
MEANWHILE, THEY MAINTAIN
THE GEL-CAP MATERIAL
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00:03:02,724 --> 00:03:05,965
IN THE HOLDING TANK
AT 140 DEGREES FAHRENHEIT
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00:03:05,965 --> 00:03:08,413
TO PREVENT IT
FROM PREMATURELY SOLIDIFYING.
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00:03:08,413 --> 00:03:11,551
EVEN THE HOSE LEAVING THAT TANK
IS WRAPPED IN HEATER TAPE
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TO KEEP THE GEL LIQUID.
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A SEPARATE HOSE FEEDS
THE VITAMIN D SOLUTION
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00:03:16,689 --> 00:03:18,137
FROM ANOTHER HOLDING TANK
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00:03:18,137 --> 00:03:20,241
DOWN TO THE PRODUCTION FLOOR,
AS WELL.
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00:03:20,241 --> 00:03:22,724
THIS HOSE DOESN'T
REQUIRE HEATING
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00:03:22,724 --> 00:03:27,793
BECAUSE VITAMIN D AND SOYBEAN
OIL DON'T SOLIDIFY WHEN COOL.
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00:03:27,793 --> 00:03:30,620
ON THE PRODUCTION LINE,
TWO STATIONS SIMULTANEOUSLY
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00:03:30,620 --> 00:03:33,241
SPREAD A THIN LAYER
OF MOLTEN GEL
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ACROSS A COOLING DRUM.
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00:03:34,724 --> 00:03:38,379
THE GEL HARDENS INTO
A SOLID, YET MALLEABLE, SHEET
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00:03:38,379 --> 00:03:40,482
ABOUT THE THICKNESS
OF CARDBOARD.
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00:03:40,482 --> 00:03:43,034
EACH SHEET PASSES OVER
A ROTATING DIE
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WITH CAPSULE-SHAPED CAVITIES.
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00:03:45,793 --> 00:03:48,068
JUST BEFORE THE TWO GEL SHEETS
COME TOGETHER,
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00:03:48,068 --> 00:03:50,379
PUMPS INJECT
THE REQUIRED QUANTITY
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00:03:50,379 --> 00:03:53,517
OF VITAMIN D SOLUTION
INTO EACH CAVITY,
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00:03:53,517 --> 00:03:55,965
THE PRESSURE PUSHING
THE GELATIN INTO THE CAVITY.
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00:03:55,965 --> 00:03:59,172
AT THE SAME TIME,
THE MACHINE HEATS THE GEL SHEETS
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00:03:59,172 --> 00:04:02,379
SO THAT WHEN THEY MEET,
THEY ADHERE TO EACH OTHER,
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00:04:02,379 --> 00:04:03,862
FORMING FULL CAPSULES
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00:04:03,862 --> 00:04:06,689
WITH THE VITAMIN D SOLUTION
SEALED INSIDE.
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00:04:06,689 --> 00:04:08,068
IN THE FINAL SECOND,
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00:04:08,068 --> 00:04:11,241
THE DIE'S SHARP EDGES SLICE
THE GEL CAPS FREE,
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00:04:11,241 --> 00:04:13,655
AND THEY FALL
TO A CONVEYER BELT BELOW.
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00:04:13,655 --> 00:04:15,275
AT THIS POINT,
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00:04:15,275 --> 00:04:17,655
THE FILLED GEL CAPS CONTAIN
A FAIR BIT OF MOISTURE,
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00:04:17,655 --> 00:04:20,172
SO THEY'RE QUITE SOFT.
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00:04:20,172 --> 00:04:22,137
IF THEY LAY
ON A SURFACE TOO LONG,
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00:04:22,137 --> 00:04:23,275
THEY'D FLATTEN,
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00:04:23,275 --> 00:04:25,344
SO THE CONVEYER BELT WHISKS THEM
VERY QUICKLY
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00:04:25,344 --> 00:04:27,034
INTO A ROTATING DRUM,
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00:04:27,034 --> 00:04:29,517
WHERE THEY TUMBLE
IN SLIGHTLY COLD, DRY AIR
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00:04:29,517 --> 00:04:31,793
FOR ABOUT THREE HOURS.
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00:04:31,793 --> 00:04:35,172
THIS REMOVES ENOUGH MOISTURE
TO MAKE THE GEL CAPS HARD ENOUGH
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00:04:35,172 --> 00:04:37,931
TO LIE ON A SURFACE
WITHOUT FLATTENING.
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00:04:37,931 --> 00:04:42,551
AFTER EXITING, THE GEL CAPS MOVE
INTO A SECOND DRYER,
89
00:04:42,551 --> 00:04:44,586
WHERE,
SPREAD OUT ON TRAYS THIS TIME,
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00:04:44,586 --> 00:04:47,482
THEY DRY FOR ABOUT 36 HOURS.
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00:04:47,482 --> 00:04:48,827
AFTER THAT,
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00:04:48,827 --> 00:04:51,965
THE GEL CAPS ARE HARD ENOUGH
TO BE SAFELY PACKAGED.
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00:04:51,965 --> 00:04:55,034
THE GEL CAPS --
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00:04:55,034 --> 00:04:58,241
THE ONES BEING PACKAGED HERE
CONTAIN FLAX OIL --
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00:04:58,241 --> 00:05:00,517
TRAVEL DOWN A SERIES
OF VIBRATING PLATES,
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00:05:00,517 --> 00:05:03,827
WHICH PROGRESSIVELY LINE THEM UP
IN SINGLE FILE.
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00:05:03,827 --> 00:05:06,689
AS THEY PASS BY,
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00:05:06,689 --> 00:05:08,689
ELECTRONIC EYES COUNT OUT
THE NUMBER
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00:05:08,689 --> 00:05:10,275
OF CAPSULES PER BOTTLE,
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00:05:10,275 --> 00:05:13,068
TRIGGERING THE FILLING MECHANISM
TO COLLECT THAT QUANTITY
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00:05:13,068 --> 00:05:15,862
AND RELEASE IT
INTO AN EMPTY BOTTLE.
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00:05:23,379 --> 00:05:26,689
THE NEXT STATION APPLIES
A PLASTIC TWIST CAP,
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00:05:26,689 --> 00:05:28,793
THEN THE BOTTLES MOVE ONWARD,
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00:05:28,793 --> 00:05:31,586
EACH ONE PLOWING
DIRECTLY INTO THE CENTER
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00:05:31,586 --> 00:05:33,448
OF AN ADHESIVE-BACKED LABEL,
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00:05:33,448 --> 00:05:37,241
WHICH ROLLERS THEN APPLY
AROUND HE SIDES.
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00:05:37,241 --> 00:05:38,448
BEFORE SHIPPING,
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00:05:38,448 --> 00:05:41,206
THE QUALITY-CONTROL LAB TESTS
RANDOM SAMPLES
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00:05:41,206 --> 00:05:42,655
FROM THE PRODUCTION BATCH
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00:05:42,655 --> 00:05:46,068
TO VERIFY THAT THE GEL CAPS
MEET ALL SPECIFICATIONS.
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Narrator:
IT'S A PLAYGROUND STAPLE --
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A STATIONARY
RIDE-ON CARTOON ANIMAL
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THAT BOUNCES UP AND DOWN
AND ROCKS BACK AND FORTH,
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COURTESY OF
A HUGE SPRING UNDERNEATH
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00:06:08,172 --> 00:06:09,758
SECURED INTO THE GROUND.
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00:06:09,758 --> 00:06:12,551
THE BOUNCY COIL BASE
IS WHAT GIVES THIS TYPE
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00:06:12,551 --> 00:06:15,724
OF PLAYGROUND EQUIPMENT
ITS NAME -- A SPRING RIDER.
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THE SPRING RIDER
IS A PLAYGROUND FAVORITE.
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00:06:22,758 --> 00:06:24,965
TO WITHSTAND YEARS
OF RAMBUNCTIOUS RIDERS,
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00:06:24,965 --> 00:06:27,379
IT HAS TO BE SOLID AND DURABLE,
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00:06:27,379 --> 00:06:30,586
YET FOR A TODDLER TO BE ABLE
TO ROCK BACK AND FORTH,
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00:06:30,586 --> 00:06:32,034
IT CAN'T BE TOO HEAVY.
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00:06:32,034 --> 00:06:34,931
THAT'S WHY THE SPRING IS MADE
OF THICK STEEL,
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00:06:34,931 --> 00:06:37,517
AND THE ANIMAL
OF LIGHTWEIGHT ALUMINUM.
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00:06:37,517 --> 00:06:42,137
THAT SAND CORE
IS COMPRISED OF TWO HALVES,
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00:06:42,137 --> 00:06:44,689
EACH MADE
WITH AN ALUMINUM MOLD --
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00:06:44,689 --> 00:06:46,517
DUCK-SHAPED IN THIS CASE.
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00:06:46,517 --> 00:06:49,482
WORKERS FILL IT
WITH SAND AND ADHESIVE MIX
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00:06:49,482 --> 00:06:51,448
THAT SETS INTO A SOLID BLOCK.
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00:06:51,448 --> 00:06:55,482
THEY INSERT
SEVERAL STEEL SUPPORT RODS,
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00:06:55,482 --> 00:06:59,931
FILL TO THE TOP,
AND EVEN OUT THE SURFACE,
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00:06:59,931 --> 00:07:02,793
THEN EXPOSE TWO HOOKS
THEY'LL LATER GRAB
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00:07:02,793 --> 00:07:05,931
TO EXTRACT THE CORE HALF
ONCE THE SAND HARDENS
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00:07:05,931 --> 00:07:07,517
IN ABOUT 20 MINUTES.
135
00:07:07,517 --> 00:07:11,068
MEANWHILE, OTHER WORKERS USE
AN ALUMINUM PATTERN
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00:07:11,068 --> 00:07:13,655
TO MAKE EACH HALF
OF THE DUCK CASTING MOLD.
137
00:07:13,655 --> 00:07:16,793
AFTER APPLYING
A POWDER RELEASE AGENT
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TO PREVENT STICKING,
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00:07:18,517 --> 00:07:20,379
THEY COVER THE PATTERN
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00:07:20,379 --> 00:07:23,689
WITH A SIEVED MIXTURE
OF SAND AND CLAY.
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00:07:23,689 --> 00:07:26,344
THEY MOUNT A FRAME
AROUND THE PATTERN
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00:07:26,344 --> 00:07:27,758
TO CONTAIN THE SAND,
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00:07:27,758 --> 00:07:29,482
AS THEY ADD MORE AND MORE,
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00:07:29,482 --> 00:07:32,103
REPEATEDLY PACKING IT DOWN
IN ALL AREAS
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00:07:32,103 --> 00:07:35,827
WITH A PNEUMATIC RAMMING TOOL.
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00:07:35,827 --> 00:07:38,241
THEN THEY REMOVE THE FRAME
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00:07:38,241 --> 00:07:40,586
AND COVER THE SAND
WITH A WOODEN BOARD.
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00:07:40,586 --> 00:07:42,931
THIS PROVIDES
A HARD SURFACE FOR THE PRESS,
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00:07:42,931 --> 00:07:47,000
WHICH NOW APPLIES THE WEIGHT
OF ABOUT FOUR MID-SIZED S.U.V.s.
150
00:07:47,000 --> 00:07:49,137
THEN THEY FLIP OVER THE MOLD
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00:07:49,137 --> 00:07:53,000
AND REMOVE THE PATTERN
WHICH FORMED THE MOLD CAVITY.
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00:07:53,000 --> 00:07:55,379
THE SAND
IS NOW SO FIRMLY COMPACTED
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00:07:55,379 --> 00:07:57,482
THAT IT HOLDS THE SHAPE.
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00:07:57,482 --> 00:08:00,689
ONE HALF OF THE SAND MOLD
HAS CHANNELS
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00:08:00,689 --> 00:08:03,862
THROUGH WHICH THE MOLTEN METAL
WILL FLOW INTO THE CAVITY.
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00:08:03,862 --> 00:08:07,896
WORKERS NOW POSITION SEVERAL
QUARTER-INCH-THICK FOAM SPACERS
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00:08:07,896 --> 00:08:08,965
IN THE CAVITY
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00:08:08,965 --> 00:08:11,586
AND PLACE
HALF OF THE CORE ON TOP OF THEM.
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00:08:11,586 --> 00:08:13,689
THE SPACERS ELEVATE THE CORE,
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00:08:13,689 --> 00:08:17,517
CREATING A QUARTER-INCH CAVITY
BETWEEN CORE AND MOLD.
161
00:08:17,517 --> 00:08:20,448
THE OTHER HALF OF THE CORE
GOES ON TOP.
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00:08:22,482 --> 00:08:25,068
AFTER PLACING SPACERS
ON TOP OF THAT
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00:08:25,068 --> 00:08:28,482
TO CREATE A QUARTER-INCH GAP
ON THIS SIDE, AS WELL,
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00:08:28,482 --> 00:08:32,000
THEY CAREFULLY LOWER
THE OTHER HALF OF THE SAND MOLD.
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00:08:32,000 --> 00:08:34,517
NOW THEY'RE READY
TO CAST THE DUCK.
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00:08:34,517 --> 00:08:36,448
THE MELTING POINT OF ALUMINUM
167
00:08:36,448 --> 00:08:39,517
IS JUST OVER
1,090 DEGREES FAHRENHEIT.
168
00:08:39,517 --> 00:08:42,931
HOWEVER, THEY HEAT MUCH HIGHER,
TO 1,400 DEGREES,
169
00:08:42,931 --> 00:08:46,689
SO IT'LL FLOW FASTER
AND FILL THE ENTIRE CAVITY
170
00:08:46,689 --> 00:08:49,655
BEFORE BEGINNING TO SOLIDIFY.
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00:08:49,655 --> 00:08:52,000
THEY POUR THE METAL
THROUGH HOLES ON TOP.
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00:08:52,000 --> 00:08:54,793
IT FLOWS THROUGH THE RUNNERS
INTO THE MOLD CAVITY,
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00:08:54,793 --> 00:08:56,482
WHICH IS THAT QUARTER-INCH GAP
174
00:08:56,482 --> 00:08:58,482
SURROUNDING
THE DUCK-SHAPED CORE.
175
00:08:58,482 --> 00:09:04,103
ABOUT 20 MINUTES LATER, THE
METAL HAS COOLED AND SOLIDIFIED.
176
00:09:04,103 --> 00:09:07,344
THEY BREAK THE MOLD APART
ON A VIBRATING SIEVE,
177
00:09:07,344 --> 00:09:10,551
RELEASING THE ALUMINUM DUCK
AND SHAKING OUT THE CORE SAND
178
00:09:10,551 --> 00:09:13,000
THROUGH A HOLE
AT THE BOTTOM OF THE DUCK.
179
00:09:13,000 --> 00:09:15,034
AFTER CUTTING OFF
EXCESS ALUMINUM
180
00:09:15,034 --> 00:09:16,655
THAT HARDENED IN THE RUNNERS,
181
00:09:16,655 --> 00:09:18,793
THEY GRIND DOWN THE SEAM,
182
00:09:18,793 --> 00:09:22,482
WHICH FORMED IN BETWEEN
THE TWO HALVES OF THE MOLD.
183
00:09:22,482 --> 00:09:25,172
NEXT, THEY WELD ON
ALUMINUM HANDLES
184
00:09:25,172 --> 00:09:27,862
FOR THE CHILD
TO GRIP WHEN RIDING.
185
00:09:27,862 --> 00:09:31,586
THESE HANDLES ARE CAST IN
SAND MOLDS JUST LIKE THE DUCK.
186
00:09:34,758 --> 00:09:37,275
WORKERS GRIND DOWN
THE WELD AND ANY SHARP EDGES,
187
00:09:37,275 --> 00:09:43,206
MAKING THE ENTIRE SURFACE
NICE AND SMOOTH.
188
00:09:43,206 --> 00:09:46,620
NEXT --
A COAT OF POLYESTER POWDER
189
00:09:46,620 --> 00:09:50,896
IN BRIGHT RUBBER-DUCKY YELLOW.
190
00:09:50,896 --> 00:09:54,275
THEN -- A 20-MINUTE TRIP
THROUGH AN OVEN
191
00:09:54,275 --> 00:09:57,965
TO BAKE THE COATING,
MAKING IT ULTRA-DURABLE.
192
00:09:57,965 --> 00:10:03,137
NOW, DELICATELY AIRBRUSHED
WITH THE URETHANE ENAMEL PAINT,
193
00:10:03,137 --> 00:10:06,034
THE DETAILS
THAT BRING MR. DUCK TO LIFE --
194
00:10:06,034 --> 00:10:09,793
HIS FEET, WINGS, BILL, AND EYES.
195
00:10:09,793 --> 00:10:14,103
THE THICK COIL
THAT MAKES THIS A SPRING RIDER
196
00:10:14,103 --> 00:10:17,103
IS MADE
OF A FLEXIBLE TYPE OF STEEL.
197
00:10:17,103 --> 00:10:20,310
THEY BOLT
A STEEL SPACER PLATE TO IT...
198
00:10:22,482 --> 00:10:25,448
...THEN HIDE THE BOLTS
UNDER AN ALUMINUM COVER.
199
00:10:27,931 --> 00:10:31,793
AFTER ATTACHING A FOOT REST --
STEEL, AGAIN --
200
00:10:31,793 --> 00:10:34,827
THEY BOLT THE DUCK TO THE PLATE.
201
00:10:34,827 --> 00:10:38,758
ALL THESE PARTS,
LIKE THE DUCK, ARE PAINTED
202
00:10:38,758 --> 00:10:41,620
WITH BAKED-ON POLYESTER COATING.
203
00:10:41,620 --> 00:10:45,482
THE SPRING BOLTS TO A CONCRETE
BLOCK BURIED UNDERGROUND.
204
00:10:45,482 --> 00:10:48,448
DUCKY AND FRIENDS
ARE DESIGNED TO WITHSTAND
205
00:10:48,448 --> 00:10:50,241
EVEN THE HARSHEST WINTERS,
206
00:10:50,241 --> 00:10:54,000
LETTING CHILDREN ENJOY
A LITTLE SPRING ALL YEAR ROUND.
207
00:11:04,655 --> 00:11:09,103
Narrator: EARLY VERSIONS OF
PANCAKES WERE THIN LIKE CREPES.
208
00:11:09,103 --> 00:11:13,413
BY THE 1780s, AMERICAN COOKS
WERE ADDING A LEAVENING AGENT
209
00:11:13,413 --> 00:11:16,413
FOR A FLUFFIER,
MORE FILLING PANCAKE.
210
00:11:16,413 --> 00:11:19,931
THAT'S WHEN PANCAKES
TRANSITIONED FROM SIDE DISH
211
00:11:19,931 --> 00:11:23,206
TO MAIN COURSE
FOR THE FIRST MEAL OF THE DAY.
212
00:11:26,275 --> 00:11:31,379
CALL THEM HOT CAKES, GRIDDLE
CAKES, FLAPJACKS, OR PANCAKES,
213
00:11:31,379 --> 00:11:34,517
THERE'S NOTHING
LIKE A HEAPING HELPING OF THEM
214
00:11:34,517 --> 00:11:35,896
SPLASHED WITH SYRUP.
215
00:11:35,896 --> 00:11:37,620
AND WITH FROZEN PANCAKES,
216
00:11:37,620 --> 00:11:41,103
WHIPPING UP SOME FOR BREAKFAST
HAS NEVER BEEN EASIER.
217
00:11:43,551 --> 00:11:47,000
PANCAKE PRODUCTION STARTS OFF
WITH A LEAVENING AGENT --
218
00:11:47,000 --> 00:11:48,517
THE BAKING POWDER.
219
00:11:48,517 --> 00:11:52,103
THEY COMBINE SALT, WHEY,
AND VARIOUS FLAVORINGS
220
00:11:52,103 --> 00:11:53,413
IN A BIG BLENDER
221
00:11:53,413 --> 00:11:56,000
TO CREATE
A DRY-INGREDIENT PREMIX.
222
00:11:58,965 --> 00:12:01,689
SINCE THESE WILL BE
BUTTERMILK PANCAKES,
223
00:12:01,689 --> 00:12:07,000
THEY ADD
POWDERED BUTTERMILK FOR FLAVOR.
224
00:12:07,000 --> 00:12:10,275
THEY NOW PUMP LIQUID INGREDIENTS
FROM STORAGE TANKS
225
00:12:10,275 --> 00:12:11,758
INTO A HUGE BLENDER.
226
00:12:14,793 --> 00:12:17,586
THESE INCLUDE WATER AND EGGS,
227
00:12:17,586 --> 00:12:20,586
SWEET CREAM, LIQUEFIED SUGAR,
228
00:12:20,586 --> 00:12:22,310
AND SOYBEAN OIL.
229
00:12:22,310 --> 00:12:24,862
THEY ADD
THE DRY PREMIX AND FLOUR
230
00:12:24,862 --> 00:12:28,344
UNTIL THE BATTER REACHES
THE DESIRED CONSISTENCY.
231
00:12:28,344 --> 00:12:31,103
AN EMPLOYEE TESTS
THE BATTER'S VISCOSITY
232
00:12:31,103 --> 00:12:34,206
BY POURING SOME
IN A DEVICE WITH A LITTLE GATE.
233
00:12:34,206 --> 00:12:38,172
HE OPENS THE GATE AND MEASURES
THE FLOW DOWN A RAMP.
234
00:12:38,172 --> 00:12:40,793
IF IT RUNS
TOO THICK OR TOO THIN,
235
00:12:40,793 --> 00:12:42,689
IT WON'T PRODUCE PANCAKES
236
00:12:42,689 --> 00:12:45,620
THAT ARE THE DESIRED DIAMETER
AND UNIFORMITY.
237
00:12:45,620 --> 00:12:48,551
THE PANCAKE BATTER PASSES
THE VISCOSITY TEST.
238
00:12:48,551 --> 00:12:51,379
THEY RELEASE THE BATTER
FROM THE HOLDING TANK,
239
00:12:51,379 --> 00:12:53,965
AND IT FLOWS
INTO A DEPOSITOR SYSTEM.
240
00:12:56,793 --> 00:12:59,034
THE DEPOSITOR HAS NINE NOZZLES.
241
00:12:59,034 --> 00:13:03,068
EACH NOZZLE SHOOTS AN EXACT
AMOUNT OF THE PANCAKE BATTER
242
00:13:03,068 --> 00:13:07,379
ONTO A HOT MOVING GRIDDLE.
243
00:13:07,379 --> 00:13:09,241
BECAUSE OF
THE PERFECT VISCOSITY,
244
00:13:09,241 --> 00:13:13,862
EACH DEPOSIT OF BATTER RADIATES
OUT TO FORM A NEAT, ROUND SHAPE,
245
00:13:13,862 --> 00:13:16,724
EACH ONE THE SAME SIZE
AS THE NEXT --
246
00:13:16,724 --> 00:13:20,551
ABOUT FOUR INCHES IN DIAMETER.
247
00:13:20,551 --> 00:13:25,275
THEY RUN THREE DEPOSITORS AND
MOVING GRIDDLES SIMULTANEOUSLY
248
00:13:25,275 --> 00:13:28,137
TO PRODUCE
750 PANCAKES A MINUTE.
249
00:13:28,137 --> 00:13:32,206
THAT'S AN INCREDIBLE
45,000 PANCAKES AN HOUR.
250
00:13:35,172 --> 00:13:38,068
AFTER SEVERAL SECONDS
ON THE GRIDDLE,
251
00:13:38,068 --> 00:13:39,586
ONE SIDE IS COOKED,
252
00:13:39,586 --> 00:13:44,827
SO AUTOMATED STAINLESS-STEEL
SPATULAS FLIP THE PANCAKES OVER.
253
00:13:44,827 --> 00:13:47,551
THERE ARE TWO SETS OF FLIPPERS.
254
00:13:47,551 --> 00:13:50,793
AFTER FLIPPING,
THE FIRST SET REPOSITIONS,
255
00:13:50,793 --> 00:13:53,724
AND THE SECOND SET FLIPS
THE NEXT ROW OF PANCAKES.
256
00:13:53,724 --> 00:13:57,137
IT'S MECHANIZED SYNCHRONIZATION.
257
00:13:59,344 --> 00:14:03,482
THE FLIPPERS ARE SPACED APART
EXACTLY AS THE DEPOSITORS ARE
258
00:14:03,482 --> 00:14:07,586
SO THE PANCAKES ARRIVE AT THE
FLIPPERS IN THE CORRECT ORDER
259
00:14:07,586 --> 00:14:09,793
TO BE PICKED UP AND TURNED OVER.
260
00:14:12,862 --> 00:14:14,206
ONCE FLIPPED,
261
00:14:14,206 --> 00:14:16,689
THE PANCAKES CONTINUE
ALONG THE COOKING CONVEYER,
262
00:14:16,689 --> 00:14:18,379
AND THE OTHER SIDE IS COOKED.
263
00:14:18,379 --> 00:14:23,413
IT'S A SHORT RIDE
FOR THESE PANCAKES
264
00:14:23,413 --> 00:14:25,379
TO BE COMPLETELY COOKED.
265
00:14:29,241 --> 00:14:30,724
FROM DOLLOPS OF BATTER
266
00:14:30,724 --> 00:14:33,448
TO UNIFORMLY ROUNDED
AND COOKED PANCAKES,
267
00:14:33,448 --> 00:14:36,965
THIS PROCESS HAS TAKEN
JUST 90 SECONDS.
268
00:14:36,965 --> 00:14:41,034
THE PANCAKES SOMERSAULT OFF
THE COOKING GRIDDLE
269
00:14:41,034 --> 00:14:44,344
AND OVER A ROLLER
TO LAND ON THE NEXT CONVEYER.
270
00:14:44,344 --> 00:14:48,724
THE SOMERSAULT EXIT
HAS A PURPOSE.
271
00:14:48,724 --> 00:14:54,482
IT KEEPS THE PANCAKES FROM
FOLDING OVER SO THEY LAND FLAT.
272
00:14:54,482 --> 00:15:00,448
HOT OFF THE GRIDDLES, THE
PANCAKES COOL DOWN ON THE RIDE,
273
00:15:00,448 --> 00:15:03,344
AS ALL THREE PRODUCTION LINES
MERGE
274
00:15:03,344 --> 00:15:05,172
AND HEAD INTO A FREEZER.
275
00:15:09,793 --> 00:15:12,793
INSIDE THE FREEZER,
276
00:15:12,793 --> 00:15:15,517
IT'S A VERY FRIGID
MINUS-18 DEGREES,
277
00:15:15,517 --> 00:15:19,034
AND THE PANCAKES FREEZE FAST.
278
00:15:19,034 --> 00:15:22,793
NOW IT'S OVER
TO THE PACKAGING LINE.
279
00:15:22,793 --> 00:15:26,206
THIS IS WHERE THE UNIFORMITY
OF THESE PANCAKES PAYS OFF.
280
00:15:26,206 --> 00:15:30,068
THEIR SIMILAR DIAMETER MEANS
THEY CAN BE NEATLY PACKED
281
00:15:30,068 --> 00:15:32,655
IN GROUPS OF SIX.
282
00:15:36,655 --> 00:15:40,758
MACHINERY SEALS TWO STACKS
OF SIX FROZEN PANCAKES
283
00:15:40,758 --> 00:15:45,172
IN ONE WRAPPING.
284
00:15:45,172 --> 00:15:47,137
IT HAS TAKEN
LESS THAN FIVE MINUTES
285
00:15:47,137 --> 00:15:50,620
TO PREPARE, FREEZE,
AND PACKAGE THESE PANCAKES.
286
00:15:50,620 --> 00:15:53,310
AT HOME,
PREP TIME IN THE MICROWAVE
287
00:15:53,310 --> 00:15:55,068
SHOULD BE MERE SECONDS.
288
00:15:55,068 --> 00:15:58,896
JUST ADD SYRUP, AND
THIS STORY HAS A SWEET ENDING.
289
00:16:11,827 --> 00:16:15,689
Narrator:
NATURAL RUBBER COMES FROM THE
MILKY SAP OF A TROPICAL TREE.
290
00:16:15,689 --> 00:16:17,068
THOUSANDS OF YEARS AGO,
291
00:16:17,068 --> 00:16:19,655
THE NATIVE PEOPLE
OF CENTRAL AND SOUTH AMERICA
292
00:16:19,655 --> 00:16:22,793
DISCOVERED THAT THE HARDENED SAP
WAS ELASTIC AND BOUNCED.
293
00:16:22,793 --> 00:16:25,448
THEY PLAYED GAMES
WITH THE BALLS OF SAP.
294
00:16:25,448 --> 00:16:27,827
WHEN EUROPEAN EXPLORERS
CAME ALONG,
295
00:16:27,827 --> 00:16:30,103
IT WAS SOON
A WHOLE NEW BALL GAME.
296
00:16:33,482 --> 00:16:36,482
TODAY, WE MAKE
THOUSANDS OF USEFUL THINGS
297
00:16:36,482 --> 00:16:40,241
FROM THE FLUID THAT CIRCULATES
THROUGH RUBBER TREES --
298
00:16:40,241 --> 00:16:43,379
EVERYTHING FROM TIRES
TO BALLOONS TO BOOTS.
299
00:16:43,379 --> 00:16:45,482
THE SEEDS ARE SEWN
ON PLANTATIONS
300
00:16:45,482 --> 00:16:47,000
LIKE THIS ONE IN THAILAND.
301
00:16:49,103 --> 00:16:52,724
IT TAKES SEVERAL YEARS
FOR THE RUBBER TREES TO MATURE,
302
00:16:52,724 --> 00:16:55,241
THEN THE SAP IS READY TO TAP.
303
00:16:55,241 --> 00:16:59,379
IN THE COOLNESS OF THE MORNING,
WHEN THE SAP FLOWS FREELY,
304
00:16:59,379 --> 00:17:04,310
THE FARM WORKER SLASHES
THE BARK WITH A HOOK BLADE.
305
00:17:04,310 --> 00:17:06,517
THE SAP OOZES FROM THE ABRASION.
306
00:17:06,517 --> 00:17:09,034
IT SPILLS ONTO A METAL SPOUT
307
00:17:09,034 --> 00:17:11,896
INSERTED
BELOW THE SLASHED SECTION.
308
00:17:11,896 --> 00:17:17,758
THE SPOUT FUNNELS THE SAP
INTO A CERAMIC CUP BELOW.
309
00:17:17,758 --> 00:17:20,517
IT FLOWS
FOR ABOUT FIVE OR SIX HOURS,
310
00:17:20,517 --> 00:17:22,448
PARTIALLY FILLING THE CUP.
311
00:17:22,448 --> 00:17:25,586
THEY WAIT A COUPLE OF DAYS
FOR THE TREE TO RECOVER
312
00:17:25,586 --> 00:17:28,655
AND THEN TAP
ANOTHER SECTION OF THE TREE.
313
00:17:28,655 --> 00:17:32,689
AFTER STRAINING IMPURITIES,
314
00:17:32,689 --> 00:17:37,379
THEY POUR THE RUBBER SAP
INTO A PLASTIC TUB.
315
00:17:37,379 --> 00:17:42,034
THEY ADD FORMIC ACID
AND SWISH IT AROUND.
316
00:17:42,034 --> 00:17:44,896
THE ACID CAUSES
THE SAP TO COAGULATE.
317
00:17:44,896 --> 00:17:48,206
AFTER 15 TO 30 MINUTES,
318
00:17:48,206 --> 00:17:53,896
IT THICKENS
TO THE CONSISTENCY OF TOFU.
319
00:17:53,896 --> 00:17:57,344
THIS TOFU-LIKE SAP HAS
A STICKY STRUCTURE
320
00:17:57,344 --> 00:18:01,896
THAT ALLOWS IT
TO NOW BE ROLLED OUT LIKE DOUGH.
321
00:18:01,896 --> 00:18:04,448
THE ROLLING SQUEEZES OUT
EXCESS WATER
322
00:18:04,448 --> 00:18:07,241
AND LEAVES
A RIBBED PATTERN ON THE SHEETS
323
00:18:07,241 --> 00:18:10,931
THAT INCREASES THE SURFACE AREA
TO HASTEN DRYING.
324
00:18:10,931 --> 00:18:14,965
THEN THEY RINSE OFF
THE FORMIC ACID.
325
00:18:14,965 --> 00:18:19,862
THEY HANG THE RUBBER SHEETS
TO DRY FOR ABOUT FIVE HOURS.
326
00:18:19,862 --> 00:18:23,931
AS THEY DRY, THE RUBBER THICKENS
AND BECOMES STRONGER,
327
00:18:23,931 --> 00:18:26,172
AND THE COLOR DARKENS.
328
00:18:26,172 --> 00:18:30,000
THE COAGULATED RUBBER SAP
HAS BEEN TRANSFORMED.
329
00:18:30,000 --> 00:18:34,482
IN A FEW SHORT STEPS, IT'S GONE
FROM A LIQUID TO A SOLID.
330
00:18:34,482 --> 00:18:37,620
WORKERS PILE
THE RUBBER SHEETS ONTO PALLETS
331
00:18:37,620 --> 00:18:41,034
AND WEIGH THE LOAD.
332
00:18:41,034 --> 00:18:46,655
THERE'S A LITTLE OVER A TON AND
A HALF OF RUBBER IN THIS STACK.
333
00:18:46,655 --> 00:18:49,206
THEY STORE
THE STACKS IN A WAREHOUSE
334
00:18:49,206 --> 00:18:51,758
UNTIL THE NEXT STAGE
OF PROCESSING.
335
00:18:51,758 --> 00:18:54,275
WHEN THEY'RE READY TO MOVE ON,
336
00:18:54,275 --> 00:18:57,103
WORKERS PEEL
EACH SHEET FROM THE STACK
337
00:18:57,103 --> 00:18:59,689
AND SOAK THEM IN WATER
FOR ABOUT 20 MINUTES.
338
00:18:59,689 --> 00:19:02,862
THIS WASHES AWAY SOME
OF THE SURFACE CONTAMINANTS,
339
00:19:02,862 --> 00:19:03,931
BUT NOT ALL.
340
00:19:06,793 --> 00:19:10,551
THE RUBBER SHEETS THEN GO
INTO A MACHINE WITH MANY BRUSHES
341
00:19:10,551 --> 00:19:13,172
THAT SCRUB OFF MORE OF THE DIRT.
342
00:19:15,413 --> 00:19:20,827
AFTER ONE MORE RINSE, THE
RUBBER SHEETS ARE SQUEAKY-CLEAN.
343
00:19:20,827 --> 00:19:25,379
AS YOU CAN SEE, THE COLOR OF
THE RUBBER SHEETS VARY SOMEWHAT
344
00:19:25,379 --> 00:19:28,103
DEPENDING
ON THE TREE THEY CAME FROM,
345
00:19:28,103 --> 00:19:30,241
THEIR THICKNESS,
AND OTHER FACTORS.
346
00:19:33,689 --> 00:19:36,793
THEY HANG
THE SHEETS ON RACKS TO DRIP DRY.
347
00:19:42,034 --> 00:19:44,931
NEXT, THEY BUILD
A FIRE IN A BRICK OVEN
348
00:19:44,931 --> 00:19:47,310
AND SMOKE THE RUBBER SHEETS
IN A CHAMBER OVERHEAD
349
00:19:47,310 --> 00:19:50,103
FOR FIVE DAYS.
350
00:19:50,103 --> 00:19:53,034
IT'S A SLOW,
LOW-TEMPERATURE SMOKING
351
00:19:53,034 --> 00:19:57,275
THAT PRESERVES THE SHEETS
TO PREVENT THE GROWTH OF MOLD.
352
00:20:01,724 --> 00:20:04,724
AFTER SMOKING,
THEY CLIP OUT CONTAMINANTS
353
00:20:04,724 --> 00:20:08,344
LIKE BARK OR INSECTS THAT HAVE
BECOME IMBEDDED IN THE RUBBER.
354
00:20:08,344 --> 00:20:12,000
IN MANY CASES,
THEY CAN'T GET IT ALL.
355
00:20:12,000 --> 00:20:15,758
THEY GRADE THE RUBBER SHEETS
BY EXAMINING THEM
356
00:20:15,758 --> 00:20:17,758
AGAINST A BRIGHT LIGHT.
357
00:20:17,758 --> 00:20:20,344
SHEETS WITH FEWER
REMAINING CONTAMINANTS
358
00:20:20,344 --> 00:20:21,827
RECEIVE A HIGHER RATING
359
00:20:21,827 --> 00:20:23,965
AND WILL COMMAND A BETTER PRICE.
360
00:20:23,965 --> 00:20:30,034
THEY STACK THE SHEETS
ACCORDING TO THE GRADE,
361
00:20:30,034 --> 00:20:34,206
AND THEN
IT'S INTO A HYDRAULIC BAILER.
362
00:20:34,206 --> 00:20:39,620
IT PRESSES THE STACK OF
RUBBER SHEETS INTO CUBE FORM.
363
00:20:42,275 --> 00:20:43,965
THE DIMENSIONS OF THE CUBES
364
00:20:43,965 --> 00:20:46,793
CONFORM TO INTERNATIONAL
PACKAGING REGULATIONS
365
00:20:46,793 --> 00:20:50,068
SO THEY'LL FIT NEATLY
INTO CONTAINERS FOR SHIPPING.
366
00:20:50,068 --> 00:20:52,068
THEY SPRAY THE RUBBER CUBES
367
00:20:52,068 --> 00:20:55,275
WITH A MIX OF CALCIUM CARBONATE
AND SOLVENT.
368
00:20:55,275 --> 00:20:57,206
THE MIXTURE FORMS
A FILM ON THE CUBES
369
00:20:57,206 --> 00:20:58,275
THAT PREVENTS MOLD
370
00:20:58,275 --> 00:20:59,896
AND KEEPS THEM
FROM STICKING TOGETHER
371
00:20:59,896 --> 00:21:02,103
DURING TRANSPORT.
372
00:21:02,103 --> 00:21:05,344
THIS RUBBER IS NOW READY
FOR THE NEXT FACTORY
373
00:21:05,344 --> 00:21:07,482
AND THE NEXT TRANSFORMATION.
374
00:21:07,482 --> 00:21:09,827
IT COULD BECOME ALMOST ANYTHING.
375
00:21:16,862 --> 00:21:19,413
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
376
00:21:19,413 --> 00:21:22,482
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
377
00:21:22,482 --> 00:21:27,896
DROP US A LINE AT...
29911
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