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Spiral stairs were part of a strategy
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00:00:55,756 --> 00:00:58,690
to defend the towers
of medieval castles.
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00:00:58,692 --> 00:01:01,026
Attackers had to
climb single-file
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00:01:01,028 --> 00:01:04,129
and couldn't storm
the castle all at once.
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00:01:04,131 --> 00:01:05,664
And at the top of the stairs,
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00:01:05,666 --> 00:01:08,967
the guardsmen could more easily
maneuver their swords,
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00:01:08,969 --> 00:01:11,003
giving them the upper hand.
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Spiral stairs take people
to the next level
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without taking up
a lot of space.
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They're compact, and with
their corkscrew curvature,
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00:01:23,384 --> 00:01:27,519
they can also be
architectural features.
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Production starts with
the steel hubs
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00:01:29,957 --> 00:01:32,558
cut to the desired riser height.
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00:01:32,560 --> 00:01:35,294
A worker files
the sharp edges smooth
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00:01:35,296 --> 00:01:36,662
and drills a threaded hole
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00:01:36,664 --> 00:01:39,965
which will be used to fasten
the treads in place.
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00:01:42,369 --> 00:01:46,405
A computer-driven plasma system
cuts through a sheet of steel
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00:01:46,407 --> 00:01:51,243
to produce the pie-shaped
stair treads.
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00:01:51,245 --> 00:01:53,645
A worker nestles a tread
to the hub
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and clamps them
in a weld fixture.
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He also clamps
structural supports
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00:01:58,385 --> 00:02:02,154
to the base of the tread.
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00:02:02,156 --> 00:02:04,556
With everything in
the right configuration,
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00:02:04,558 --> 00:02:07,826
he welds the supports
to the tread and the hub.
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00:02:07,828 --> 00:02:12,397
He'll make 12 of these hub
and tread assemblies.
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00:02:12,399 --> 00:02:16,535
He chips off the weld slag
for cleaner seams.
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00:02:16,537 --> 00:02:19,371
A team slides the hub
and tread assemblies
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00:02:19,373 --> 00:02:20,939
on to the center pole
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00:02:20,941 --> 00:02:23,976
and rotates them
to the correct position.
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00:02:23,978 --> 00:02:27,346
The design geometry
dictates the rotation.
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00:02:27,348 --> 00:02:29,047
Once rotated correctly,
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00:02:29,049 --> 00:02:31,583
the workers fasten the hubs
to the pole
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00:02:31,585 --> 00:02:34,052
and add a platform
for the top step.
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00:02:36,724 --> 00:02:40,826
A baluster spins in a lathe,
as tools cut it to length
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00:02:40,828 --> 00:02:43,996
and round the end
to the correct diameter.
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00:02:43,998 --> 00:02:46,565
The operator measures
the diameter.
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He inserts the rounded end
in a dye
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00:02:48,669 --> 00:02:52,871
that carves the thread into it.
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00:02:52,873 --> 00:02:54,740
A worker welds a steel cup
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00:02:54,742 --> 00:02:57,776
just above the threaded part
of the baluster.
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00:02:57,778 --> 00:02:59,611
This cup will support
the baluster
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00:02:59,613 --> 00:03:02,080
once it's been installed
on the thread.
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00:03:02,082 --> 00:03:04,783
He grinds the weld scale
from the cup.
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00:03:04,785 --> 00:03:06,952
He inserts the baluster
through holes
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in a metal spacer in the tread.
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00:03:09,123 --> 00:03:12,257
He screws a nut on to the end
to secure it.
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00:03:14,628 --> 00:03:18,463
Using rollers now, another
worker twists long strips
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00:03:18,465 --> 00:03:21,300
of metal into spiraling
hand rails that match
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00:03:21,302 --> 00:03:23,635
the rise of the stairs.
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00:03:23,637 --> 00:03:25,971
He fits the rail
to the top balusters
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00:03:25,973 --> 00:03:29,541
and clamps it in place.
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00:03:29,543 --> 00:03:33,045
He then welds the balusters
to the rail.
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00:03:33,047 --> 00:03:36,148
He adds more railing until
it spirals all the way down
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00:03:36,150 --> 00:03:39,218
to the first step.
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00:03:39,220 --> 00:03:42,654
The team secures it
to the platform.
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00:03:42,656 --> 00:03:46,491
The spiral staircase's metal
structure is now complete.
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00:03:46,493 --> 00:03:48,827
It's ready for
the wooden accents.
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00:03:50,931 --> 00:03:54,433
A worker applies glue
to pieces of red oak.
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00:03:54,435 --> 00:03:57,603
He'll use two of them
to make one stair tread.
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00:03:57,605 --> 00:04:01,573
He clamps two tread sets in
a fixture while the glue sets.
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00:04:01,575 --> 00:04:03,075
He inserts a shim
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00:04:03,077 --> 00:04:07,246
and tightens the clamp
to apply downward pressure.
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00:04:07,248 --> 00:04:10,749
Once the glue has cured,
a planer shaves the tread
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00:04:10,751 --> 00:04:14,920
perfectly flat
and to the desired thickness.
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00:04:14,922 --> 00:04:16,788
After refining the profile,
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00:04:16,790 --> 00:04:21,126
a worker rounds the edge of
the stair tread using a router.
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00:04:22,830 --> 00:04:25,230
After gluing strips of wood
together to create
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00:04:25,232 --> 00:04:28,767
a curved railing,
he sands the excess adhesive,
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00:04:28,769 --> 00:04:32,237
and with a file,
removes more of the glue.
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00:04:32,239 --> 00:04:36,341
He turns the railing over
and carves a groove in the wood.
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00:04:36,343 --> 00:04:38,610
This will enable the railing
to be installed
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00:04:38,612 --> 00:04:40,846
over the metal rail support.
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00:04:40,848 --> 00:04:44,650
He adds some detailing
along the edge.
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00:04:44,652 --> 00:04:46,618
A team then fits
the wooden railing
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00:04:46,620 --> 00:04:49,054
to the metal support structure.
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00:04:49,056 --> 00:04:53,158
All of the rail sections
fit together perfectly.
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After the pre-fit,
they remove the railing
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00:04:55,963 --> 00:04:58,363
and sculpt the edges
to be rounder.
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00:04:58,365 --> 00:05:03,302
The rounded edges complement
the overall spiral design.
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00:05:03,304 --> 00:05:06,972
A worker pre-fits the wooden
treads to the metal structure
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00:05:06,974 --> 00:05:10,409
and then disassembles
the entire spiral staircase
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for painting and staining.
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00:05:14,281 --> 00:05:17,883
The spiral stairs are then ready
for reassembly in the building
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00:05:17,885 --> 00:05:19,584
they were designed for.
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They'll definitely add a certain
twist to the interior design.
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narrator:
Originating in the middle east,
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pita bread has been around
for thousands of years.
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00:05:42,109 --> 00:05:46,178
Today, its popularity continues
to grow around the globe.
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Part of its appeal
is its versatility.
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00:05:48,882 --> 00:05:51,149
People can stuff
their pita's pockets,
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00:05:51,151 --> 00:05:54,486
use it as a sandwich wrap,
or slice it for dipping.
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00:05:57,858 --> 00:05:59,491
Pita bread may be flat,
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but that doesn't mean
it's boring.
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00:06:01,662 --> 00:06:03,829
Anyone can use pita
to make any number
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00:06:03,831 --> 00:06:08,166
of interesting
lunchtime combinations.
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00:06:08,168 --> 00:06:11,937
Making pita bread starts
with silos full of flour.
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00:06:11,939 --> 00:06:15,674
A blower system delivers the
flour to an automated sifter.
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00:06:15,676 --> 00:06:18,910
The sifter shakes the flour
through three levels of mesh
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00:06:18,912 --> 00:06:21,046
to filter out impurities.
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00:06:21,048 --> 00:06:24,783
Magnets extract
any metal contaminants.
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00:06:24,785 --> 00:06:28,420
Workers prepare a pre-mix
of sugar, salt, yeast,
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and preservatives.
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00:06:30,124 --> 00:06:32,691
They combine these ingredients
with the sifted flour
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00:06:32,693 --> 00:06:35,894
in a big mixer and add water.
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00:06:35,896 --> 00:06:38,096
The mixer is equipped
with numerous bars
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00:06:38,098 --> 00:06:42,300
that rotate horizontally
to blend the ingredients.
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00:06:43,137 --> 00:06:47,105
The operator opens the mixer
and spins it one more time
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00:06:47,107 --> 00:06:49,541
to eject the dough into a bin.
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He rolls the bin
to the next station.
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Here the pita dough
goes into a hopper.
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00:07:00,120 --> 00:07:02,721
And from there,
it drops into a machine
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00:07:02,723 --> 00:07:04,256
called a dough divider.
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00:07:10,030 --> 00:07:14,900
this machine turns big chunks
of dough into many small blobs.
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00:07:14,902 --> 00:07:18,637
To do this, it forces the dough
through a round hole,
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00:07:18,639 --> 00:07:24,042
and a guillotine blade chops it
to the correct thickness.
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00:07:24,044 --> 00:07:27,245
The dough blobs ride a conveyor
and pass under a roller
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00:07:27,247 --> 00:07:29,948
that flattens them.
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00:07:29,950 --> 00:07:33,885
Flour from an overhead sifter
dusts the dough blobs
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00:07:33,887 --> 00:07:38,123
to keep them from sticking
to the machinery.
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00:07:38,125 --> 00:07:39,991
Each one of these flattened
dough blobs
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00:07:39,993 --> 00:07:41,927
will eventually become a pita.
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00:07:45,165 --> 00:07:46,998
The round pieces of dough
now ride
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00:07:47,000 --> 00:07:49,668
a conveyor up to a warm zone.
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00:07:49,670 --> 00:07:53,338
Over a period of 15 minutes,
the yeast ferments,
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00:07:53,340 --> 00:07:56,007
causing the dough to rise.
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00:07:56,009 --> 00:07:57,943
Out of the fermentation station,
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00:07:57,945 --> 00:08:03,114
a roller flattens
the pita dough segments again.
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00:08:03,116 --> 00:08:05,517
They're now ready
to be rolled very thin
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00:08:05,519 --> 00:08:07,886
in a process known as sheeting.
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00:08:10,224 --> 00:08:13,625
The next roller presses
the pita dough much thinner.
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00:08:13,627 --> 00:08:15,327
Rolling it in one direction
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00:08:15,329 --> 00:08:17,896
makes the dough segments
oval-shaped.
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00:08:21,068 --> 00:08:23,235
The oval pitas ride by a pusher
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00:08:23,237 --> 00:08:28,173
that now shoves them
towards the final roller.
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00:08:28,175 --> 00:08:31,810
It rolls the dough in the other
direction to round out the shape
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00:08:31,812 --> 00:08:33,578
and make it even thinner.
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00:08:37,317 --> 00:08:39,184
Perfectly round and thin,
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00:08:39,186 --> 00:08:43,054
the pitas now travel up to
another fermentation operation.
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00:08:45,192 --> 00:08:47,826
Inside, the temperature
is toasty.
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00:08:47,828 --> 00:08:50,228
It's warm enough to reawaken
the yeast
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00:08:50,230 --> 00:08:52,597
and cause the dough
to rise again.
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00:08:55,936 --> 00:08:59,471
Conveyors move in criss-cross
directions to take the pitas
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00:08:59,473 --> 00:09:01,206
back and forth.
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00:09:01,208 --> 00:09:06,077
This zig-zagging journey
lasts about 15 minutes.
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00:09:06,079 --> 00:09:08,346
When the pitas emerge
from the chamber,
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00:09:08,348 --> 00:09:12,083
they have thickened up
substantially.
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00:09:12,085 --> 00:09:15,353
They head into an oven
where the magic happens.
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00:09:15,355 --> 00:09:18,390
The oven's temperature is
between 750
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00:09:18,392 --> 00:09:20,959
and 930 degrees fahrenheit.
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00:09:20,961 --> 00:09:23,428
They spend just
15 seconds in it.
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00:09:23,430 --> 00:09:26,131
This flash-baking causes
the water in the dough
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00:09:26,133 --> 00:09:27,566
to turn to steam.
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00:09:27,568 --> 00:09:31,836
The steam puffs the pitas,
creating pockets inside.
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00:09:31,838 --> 00:09:33,171
The pitas then travel
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00:09:33,173 --> 00:09:35,974
on conveyors
for a 20 minute cool down.
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00:09:35,976 --> 00:09:38,910
As they cool, they deflate.
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00:09:38,912 --> 00:09:42,180
The process has created pockets
in the pitas.
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Once sliced open,
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00:09:43,584 --> 00:09:47,285
the pockets can be stuffed
to create sandwiches.
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00:09:47,287 --> 00:09:51,990
Workers stack the pitas
six high for packaging.
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00:09:51,992 --> 00:09:54,626
The next conveyor delivers
the stacks into the clutch
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of an automated arm.
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00:09:58,031 --> 00:10:01,266
Just ahead, a burst of air
opens a bag
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00:10:01,268 --> 00:10:03,868
and the arm inserts
the pitas into it.
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00:10:03,870 --> 00:10:09,307
At the same time, it pushes
the bag on to the next conveyor.
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00:10:09,309 --> 00:10:12,444
Moving forward, another device
automatically twists
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00:10:12,446 --> 00:10:15,246
the open end of the bag.
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00:10:15,248 --> 00:10:17,449
The device applies
a plastic lock tab
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00:10:17,451 --> 00:10:23,054
to the twisted end of the bag,
sealing the pita breads inside.
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00:10:23,056 --> 00:10:25,557
The bags pass by
a metal detector,
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00:10:25,559 --> 00:10:28,026
and then they're on their way
to the supermarket.
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00:10:32,332 --> 00:10:36,601
This pita bread has taken
45 minutes to make and package,
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00:10:36,603 --> 00:10:40,472
but it should enable lunch
to come together very quickly.
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00:10:53,720 --> 00:10:55,220
narrator:
Installing exhaust headers
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will add extra power
from a car's engine.
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00:10:58,091 --> 00:11:00,625
They bolt on to the engine,
giving each cylinder
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00:11:00,627 --> 00:11:03,228
its own exhaust pipe
leading to the collector,
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00:11:03,230 --> 00:11:06,531
which connects to the car's
main exhaust pipe.
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00:11:06,533 --> 00:11:09,267
That's more efficient than
having all the cylinders exhaust
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00:11:09,269 --> 00:11:11,202
into a common manifold.
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00:11:13,740 --> 00:11:17,442
A header draws out significantly
more spent exhaust gasses
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00:11:17,444 --> 00:11:20,645
after combustion, leaving room
for a greater amount
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00:11:20,647 --> 00:11:22,280
of new gas and fresh air
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00:11:22,282 --> 00:11:26,685
to enter the cylinder
for the next combustion cycle.
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00:11:26,687 --> 00:11:29,888
Headers are made of steel
or stainless steel.
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00:11:29,890 --> 00:11:33,291
A worker uses a roll cutter
to slice tubes into nearly
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00:11:33,293 --> 00:11:37,462
6-inch-long pieces
for the header's collector.
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00:11:37,464 --> 00:11:39,297
A forming tool on a press
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00:11:39,299 --> 00:11:42,801
stretches one side
of the collector outward.
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00:11:42,803 --> 00:11:47,305
Then the worker places the same
side on an end-forming machine,
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00:11:47,307 --> 00:11:50,542
which shapes it like
a four-leaf clover.
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00:11:50,544 --> 00:11:53,645
He slips a flange over
the unshaped side
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00:11:53,647 --> 00:11:57,115
and widens that side to create
the ball portion
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00:11:57,117 --> 00:11:59,718
of the gasketless ball
and socket connection
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00:11:59,720 --> 00:12:01,953
to the car's main exhaust pipe.
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00:12:04,558 --> 00:12:08,059
Meanwhile, another worker
roll cuts narrower tubes
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00:12:08,061 --> 00:12:12,497
into 32-inch-long pieces to make
the header's primary tubes,
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00:12:12,499 --> 00:12:17,602
the ones that attach at the top
to engine's cylinders.
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00:12:17,604 --> 00:12:20,338
A worker slides a tube
on to a mandrel,
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00:12:20,340 --> 00:12:22,707
then the computer-guided
mandrel bender
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00:12:22,709 --> 00:12:25,310
bends the tube in four places.
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00:12:25,312 --> 00:12:27,979
The mandrel fills the inside
of the tube
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00:12:27,981 --> 00:12:30,915
just up to the bend point,
preventing the tube from
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00:12:30,917 --> 00:12:34,753
compressing or collapsing
under pressure.
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00:12:34,755 --> 00:12:38,123
The header they're making here
is for a four-cylinder engine,
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00:12:38,125 --> 00:12:40,725
so it has four primary tubes.
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00:12:40,727 --> 00:12:43,628
An eight-cylinder engine
requires a pair of headers,
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00:12:43,630 --> 00:12:45,096
whereas a six-cylinder engine
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00:12:45,098 --> 00:12:49,501
requires a pair
of three-tube headers.
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00:12:49,503 --> 00:12:51,903
A worker trims the bent
primary tubes
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00:12:51,905 --> 00:12:54,506
to the required length
with a bandsaw.
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00:12:58,478 --> 00:13:01,880
The sawed edges of the tube
are ragged,
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00:13:01,882 --> 00:13:04,516
so the next step
is to grind them smooth.
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00:13:09,556 --> 00:13:13,525
after grinding, the edge
no longer looks like this.
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00:13:19,466 --> 00:13:21,432
workers heat the top end
of the tube
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00:13:21,434 --> 00:13:23,968
with a torch
to soften the steel.
217
00:13:29,643 --> 00:13:33,044
they place the end
into an end-forming machine.
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00:13:33,046 --> 00:13:34,546
The machine shapes the end
219
00:13:34,548 --> 00:13:37,048
to match the top profile
of the cylinder,
220
00:13:37,050 --> 00:13:40,752
to which the tube
will be mounted.
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00:13:40,754 --> 00:13:43,922
Cylinder profiles vary
from engine to engine,
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00:13:43,924 --> 00:13:47,458
so workers simply change
the forming tool on the machine.
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00:13:51,498 --> 00:13:54,699
A worker clamps the header
flange with its four
224
00:13:54,701 --> 00:13:58,169
exhaust ports on to
an assembly jig and positions
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00:13:58,171 --> 00:14:02,674
the top end of
a primary tube in each port.
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00:14:02,676 --> 00:14:04,342
He inserts the bottom ends
227
00:14:04,344 --> 00:14:08,112
into the four-leaf-clover-shaped
collector.
228
00:14:10,483 --> 00:14:13,017
He then welds the top end
of each tube
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00:14:13,019 --> 00:14:16,521
to its exhaust port
on the header flange.
230
00:14:16,523 --> 00:14:19,257
Then he welds a tag
with the company name
231
00:14:19,259 --> 00:14:21,025
on to one of the tubes.
232
00:14:23,530 --> 00:14:26,231
Finally, he welds
the bottom end of the tubes
233
00:14:26,233 --> 00:14:28,099
to the collector.
234
00:14:32,572 --> 00:14:35,406
the header's three sections --
flange, tubes,
235
00:14:35,408 --> 00:14:39,510
and collector -- are now fused.
236
00:14:39,512 --> 00:14:42,313
The worker grinds down the weld
around the ports
237
00:14:42,315 --> 00:14:45,383
until it's nearly flush.
238
00:14:45,385 --> 00:14:48,519
The remaining bit of weld
material encircling the port
239
00:14:48,521 --> 00:14:51,122
will act
as a seal to prevent leakage.
240
00:14:55,462 --> 00:14:58,162
During the welding,
some welding material drips
241
00:14:58,164 --> 00:15:01,132
into the header flange's
openings,
242
00:15:01,134 --> 00:15:03,902
so a worker reams
the bolt holes with a drill
243
00:15:03,904 --> 00:15:06,204
and grinds
the edges of each port.
244
00:15:09,175 --> 00:15:11,676
He mounts the header on
the corresponding engine's
245
00:15:11,678 --> 00:15:16,247
cylinder head to make sure bolt
holes are sufficiently cleared.
246
00:15:16,249 --> 00:15:20,852
Then he runs a torch over all
the joints to check the welds.
247
00:15:20,854 --> 00:15:23,855
The flame would shoot through
any hole in a weld,
248
00:15:23,857 --> 00:15:26,524
alerting them to repair it.
249
00:15:29,162 --> 00:15:33,698
This factory applies one of two
finishes on its exhaust headers.
250
00:15:33,700 --> 00:15:37,068
The basic one is a coat
of black water-based paint
251
00:15:37,070 --> 00:15:39,504
sprayed on and air-dried.
252
00:15:39,506 --> 00:15:41,706
It prevents surface rust
from forming
253
00:15:41,708 --> 00:15:44,008
while the part is warehoused.
254
00:15:44,010 --> 00:15:47,812
The higher-end finish is an
aerospace-grade ceramic coating,
255
00:15:47,814 --> 00:15:50,415
available in black or silver.
256
00:15:50,417 --> 00:15:53,751
This baked-on finish protects
the headers from rust
257
00:15:53,753 --> 00:15:56,821
for many years
of high-performance driving.
258
00:16:10,737 --> 00:16:12,570
narrator:
This may look like ivory,
259
00:16:12,572 --> 00:16:14,539
but it's actually limestone.
260
00:16:14,541 --> 00:16:17,241
It looks as though
it's a sculpted work of art,
261
00:16:17,243 --> 00:16:19,077
but it's actually molded.
262
00:16:19,079 --> 00:16:21,312
How does one mold limestone?
263
00:16:21,314 --> 00:16:25,283
200 years ago, some people
in France figured out how,
264
00:16:25,285 --> 00:16:31,189
and their descendents are still
molding limestone artwork today.
265
00:16:31,191 --> 00:16:34,859
This unique art form exists
because, two centuries ago,
266
00:16:34,861 --> 00:16:39,597
a family in France discovered
springs amid volcanic rock,
267
00:16:39,599 --> 00:16:43,301
springs with water so rich
in calcium carbonate
268
00:16:43,303 --> 00:16:45,370
that it petrified into stone.
269
00:16:45,372 --> 00:16:48,106
That is limestone.
270
00:16:48,108 --> 00:16:51,342
The family carved out caves,
then invented a way
271
00:16:51,344 --> 00:16:55,613
to capture the calcium carbonate
and mold sculptures with it.
272
00:16:55,615 --> 00:16:59,884
The descendents of the family
continue that tradition today.
273
00:16:59,886 --> 00:17:03,721
The springwater contains
two grams of calcium carbonate
274
00:17:03,723 --> 00:17:06,457
per liter and a lot
of iron oxide,
275
00:17:06,459 --> 00:17:08,793
which makes the water orange.
276
00:17:08,795 --> 00:17:10,928
The original troughs
direct the water
277
00:17:10,930 --> 00:17:13,398
on to a bed of wood shavings.
278
00:17:13,400 --> 00:17:15,767
The shavings trap
the iron oxide,
279
00:17:15,769 --> 00:17:20,104
and the calcium carbonate floats
to the surface.
280
00:17:20,106 --> 00:17:22,673
In the workshop,
the owner of the company --
281
00:17:22,675 --> 00:17:25,309
the seventh generation
of the founding family --
282
00:17:25,311 --> 00:17:26,811
makes the mold.
283
00:17:26,813 --> 00:17:29,047
He heats something called
gutta-percha
284
00:17:29,049 --> 00:17:31,616
in a pot of water
to soften it up.
285
00:17:31,618 --> 00:17:34,085
Gutta-percha is a natural latex
286
00:17:34,087 --> 00:17:36,354
made from the sap
of the gutta tree.
287
00:17:36,356 --> 00:17:39,457
Once it's soft, he weighs out
the required amount
288
00:17:39,459 --> 00:17:41,959
using the workshop's
original scale.
289
00:17:45,165 --> 00:17:48,366
Then he kneads it to force out
trapped air
290
00:17:48,368 --> 00:17:50,201
and make it more malleable.
291
00:17:53,139 --> 00:17:57,275
After forming it into a ball,
he places it in an old press
292
00:17:57,277 --> 00:17:59,777
made my his great-grandfather.
293
00:17:59,779 --> 00:18:02,013
The press shapes
the gutta-percha
294
00:18:02,015 --> 00:18:05,450
into a rectangle measuring
7-by-10 inches.
295
00:18:09,122 --> 00:18:11,556
After cooling in the press
for 30 minutes,
296
00:18:11,558 --> 00:18:13,357
the gutta-percha has hardened
297
00:18:13,359 --> 00:18:17,328
just enough to maintain
the rectangular shape.
298
00:18:17,330 --> 00:18:19,130
He removes it from the press
299
00:18:19,132 --> 00:18:23,301
and places a silicone-designed
template on top.
300
00:18:23,303 --> 00:18:26,637
He cuts the gutta-percha
to the shape of the template.
301
00:18:32,145 --> 00:18:34,979
he places the gutta-percha
on top of a pattern
302
00:18:34,981 --> 00:18:38,382
created by an artist.
303
00:18:38,384 --> 00:18:41,052
He places the template
on the gutta-percha,
304
00:18:41,054 --> 00:18:43,454
then a plank of wood
on top of that.
305
00:18:46,126 --> 00:18:50,094
He puts the entire assembly
under an old screw press.
306
00:18:54,134 --> 00:18:57,568
An hour later, he removes
the assembly from the press
307
00:18:57,570 --> 00:19:00,104
and gently separates the layers.
308
00:19:02,175 --> 00:19:05,576
The artwork design is now
transferred from the pattern
309
00:19:05,578 --> 00:19:07,478
to the gutta-percha.
310
00:19:07,480 --> 00:19:11,415
He sets it aside to cool
to a hard state.
311
00:19:12,252 --> 00:19:15,286
When the work of art
is either too wide or high
312
00:19:15,288 --> 00:19:17,321
to fit into
the traditional screw press,
313
00:19:17,323 --> 00:19:20,324
the artisan then sculpts
the pattern out of clay.
314
00:19:20,326 --> 00:19:25,363
Once the clay hardens, he coats
it in silicone to make the mold.
315
00:19:25,365 --> 00:19:28,733
This modern mold-making
technique is a bit trickier
316
00:19:28,735 --> 00:19:31,068
because silicone
can't be reheated
317
00:19:31,070 --> 00:19:33,337
and reworked like gutta-percha.
318
00:19:35,742 --> 00:19:37,875
The silicone takes about
24 hours
319
00:19:37,877 --> 00:19:40,845
to harden into a flexible mold.
320
00:19:40,847 --> 00:19:43,814
A silicone mold can be used
only once.
321
00:19:43,816 --> 00:19:47,585
And because it's so flexible,
it has to sit on a support tray
322
00:19:47,587 --> 00:19:52,190
so that it doesn't buckle
when filled or moved.
323
00:19:52,192 --> 00:19:54,492
Now it's time to mold
the limestone.
324
00:19:54,494 --> 00:19:57,195
A craftsman positions
the molds under these
325
00:19:57,197 --> 00:19:59,530
liquid limestone waterfalls.
326
00:19:59,532 --> 00:20:03,267
The carbonic gas in the liquid
gradually evaporates,
327
00:20:03,269 --> 00:20:08,272
leaving accumulating deposits of
calcium carbonate in the molds.
328
00:20:08,274 --> 00:20:12,276
An artisan moves every mold
to a new position daily
329
00:20:12,278 --> 00:20:15,913
so that the dripping water
hits all parts of it.
330
00:20:15,915 --> 00:20:19,417
Artwork just one 1/5 of an inch
thick requires
331
00:20:19,419 --> 00:20:21,786
six months under the fountain.
332
00:20:21,788 --> 00:20:25,923
Artwork 4/5 of an inch thick
requires two years.
333
00:20:28,161 --> 00:20:31,662
To extract the limestone artwork
from a traditional mold,
334
00:20:31,664 --> 00:20:33,998
the artisan immerses it
in hot water
335
00:20:34,000 --> 00:20:38,202
to soften the gutta-percha so
that he can gently peel it off.
336
00:20:38,204 --> 00:20:40,304
Every intricate detail
of the design
337
00:20:40,306 --> 00:20:44,809
in the gutta-percha
is now replicated in limestone.
338
00:20:44,811 --> 00:20:49,747
This molded rock is as strong
and hard as marble.
339
00:20:49,749 --> 00:20:52,717
To extra the artwork
from a silicone mold,
340
00:20:52,719 --> 00:20:57,321
an artisan removes the support
tray and lifts off the silicone.
341
00:20:57,323 --> 00:21:01,259
The company has more than 500
artwork patterns in stock
342
00:21:01,261 --> 00:21:04,262
dating back to 1821.
343
00:21:04,264 --> 00:21:07,064
Not all the molded limestone
looks the same.
344
00:21:07,066 --> 00:21:10,668
The artisans can tailor
the shade from white to ivory
345
00:21:10,670 --> 00:21:13,004
by controlling
how much iron oxide
346
00:21:13,006 --> 00:21:15,406
they remove from the water.
28217
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