All language subtitles for How.Its.Made.S30E11.1080p.WEB.x264_Eng_01

Today on "how it's made" --

rubber balls.

motion chairs.

montreal smoked meat.

and motorized scooters.

a lot happens when an inflated
rubber ball hits the ground.

The rubber compresses
and quickly snaps

back to its round shape.

That snapping back
makes the ball bounce.

In addition, the air
inside the ball acts

as a tightly coiled spring
increasing the rebound.

When an inflated rubber ball
falls to the ground,

it bounces back,

and players catch it
on the rebound.

This type of ball is
at the heart of many games,

from basketball
to soccer to volleyball.

At the core is an inflated
rubber bladder.

Making it starts with a sheet
of natural rubber.

The factory worker folds it
in a specific configuration.

He places a die on top
and activates a press

to force it through the layers,
which cuts out the shape.

He now has the bladder
of a sports ball.

He brushes an adhesive
around the hole in the bladder

and inserts a plug.

Another worker inflates
the rubber bladder

as she places it
in a spherical chamber.

It heats and cures
the rubber for 5 minutes

at a temperature of
284 degrees fahrenheit.

The rubber bladder spins
on a revolving cylinder,

causing it to take up
nylon threads.

The threads twist around
the bladder and form a layer

that both strengthens it
and keeps it round.

The material that will form
the exterior of the ball

is made using colored synthetic
rubber, natural rubber,

magnesium carbonate,
and mineral oil.

Once it cures, a worker
rolls it into thick sheets

and slices it
to a specific width.

He folds it several times.

This blue rubber will be used
for volleyballs.

The folded rubber now travels
between a series of rollers.

They flatten it and press
it extremely thin,

and it becomes both
lightweight and formable.

An automated blade slices
the rubber into shorter pieces.

A metal pattern cutter
will now be used

to cut the rubber into strips,

which will fit together
to form the outside of the ball.

These particular strips
are for a basketball.

The worker places the pattern
on several pieces of rubber.

A press forces the sharp-edged
pattern through the rubber

to cut out fish-shaped strips

that are designed to fit
around the round bladder.

She lines the two halves of a
bonding shaper with the strips.

she inserts the bladder
and re-inflates it.

She closes the bonding
chamber and activates it.

Inside, heat and pressure
cause the strips

to stick to the bladder.

To make a medicine ball,
which is used for exercising,

a different pattern cutter
is used.

The forming process is the same,

but this ball has a unique
visual impact very different

from that of the basketball.

Back at the basketball station,

a worker applies the brand name
to the outer skin in two places.

Glue helps the decals
stick to the rubber.

This mold will now transfer
a pattern onto the rubber ball

while also baking
the lettering into it.

Another worker places the ball
in the mold and pumps more air

into the bladder.

He closes the lid.

The mold applies heat
and pressure

to emboss the pattern
onto the rubber.

The lettering has
penetrated the rubber,

and the worker peels
off the decal plastic.

Another worker replenishes
the air that's been lost

to make the ball
completely full and round.

The ball is now ready
to receive its stripes.

The worker paints black rubber
into grooves

that were formed
during embossing.

This rubber quickly cures
to become part of the ball.

Another worker inserts
a fill valve into the hole.

Then, mechanical fists
squeeze the ball to deflate it.

This prepares it for packaging.

With the valve inside,
it can be easily re-inflated

by the customer.

A worker wraps it in plastic
and ships it to the retailer.

Making this rubber basketball
has only taken

a couple of hours,

but it should be able
to take a lot of knocks

and bounce right back.

Narrator:
Having a desk job

doesn't mean
one has to sit still.

With a motion chair, the office
worker can keep moving

while staying seated.

The support structure is
engineered for flexibility,

so while sitting, a person
can bounce, tilt, and sway.

Motion chairs redefine
the act of sitting.

The stem is springy,

and the connection
to the seat is elastic.

This allows the office worker
to be active while sitting.

Making a motion chair starts
with glass-reinforced plastic,

which is a strong
and lightweight material.

These granules will be used
to make the core of the seat.

A robot inserts a steel fastener
in the center of the seat mold.

The mold closes, and the machine
melts the plastic

and injects it into the mold.

The plastic quickly solidifies
around the steel fastener,

and it becomes part
of the seat core.

A robot with suctioning grippers

pulls the convex-shaped
seat core out.

A worker assembles
a height-adjustment

lever in the hole beside
the one for the seat stem.

A molded plastic top
completes the seat core.

He anchors it to the core
with numerous screws,

so even with heavy use, the top
should stay firmly in place.

He visually inspects
the seat core and confirms

that it looks solid.

Cushioning foam and fabric
complete the seat.

A worker assembles roller
mechanisms that will facilitate

the vertical movements
of the chair's stem.

Using a special assembly tool,
she presses the plastic roller

and two end brackets
on a metal cylinder.

She then applies an index
to an aluminum support column

that serves as a guide

for setting the tension
of an outer spring.

She inserts the roller
mechanisms in slots

at the other end of the column.

Strips of fabric tape
keep the rollers in place.

An air cylinder presses
the outer sleeve onto the column

so that it sits above
the tension index.

A screw between
the inner and outer cylinders

keeps them in position.

Next up is a compression part

for setting the position
of the outer seat spring.

A worker slides a metal ring
between the compression part

and the support column.

He inserts a gas spring into
the double-walled seat stem.

He now slides the outer
spring onto the assembly.

He installs a plastic casing
over the gas spring.

Then he puts the seat stem
inside a press chamber.

He adds a top collar
to the center of the gas spring

as well as a snap ring.

He activates the press, and
it squeezes everything together.

Next is a stand with
flexible rubber parts

that will make lateral
movement possible while sitting.

The worker attaches the flexible
stand to a circular base.

He confirms that holes
for rolling casters or gliders

in the base are
the correct dimension.

He screws a dial
for setting lateral movement

onto the protruding fastener.

He secures it with a nut
and tightens it.

He covers the nut
with a rubber cap.

A tester will now evaluate
the motion chair's performance.

He attaches the stem
to the base,

and he fastens the seat
to the protruding rod.

He sits down and bounces around
to test the range of movement.

These tests are done
intermittently to confirm

that the the product
consistently meets requirements.

This motion chair is now ready
for shipping.

The packer plugs a hole
in the base ring.

This hole is for attaching
an optional backrest.

He applies a sticker
with the product name.

All of the parts
of the motion chair

can be easily assembled
on location.

Designed to discourage rigid
sitting and encourage movement

in any direction,

it will compel
the person using it

to use his or her core muscles

and be less sedentary
on the job.

With the motion chair,
it just may be possible

to get fit while you sit.

Narrator:
For at least a century,

montreal's jewish delis

have been serving
smoked meat on rye.

The exact origins of this
particular deli meat

are a matter of debate with
many claims to its invention.

The juicy details
have been lost to time,

but montreal smoked meat

continues to have
an enduring appeal.

A cross between corn beef
and pastrami,

montreal smoked meat

has attracted a foodie
following around the world.

Montreal smoked meat
starts with brisket,

which is a cut from
the cow's upper chest.

A worker thaws
the previously frozen briskets

in a refrigerator for 10 hours.

A team slices off
the biggest chunks of fat

using round, air-powered blades.

The excess fat will be shipped
to another factory

and used to make soap.

The workers use a sharp
butcher's knife

to remove smaller pieces of fat,

leaving just enough for flavor.

Next, they prepare the brine.

Along with salt and sugar,
there's a secret recipe

of spices that
includes peppers,

mustard seed,
allspice, and cinnamon.

The operator combines
the salt and sugar

with ice-cold water
in a high-speed mixer.

The spices have been
premixed in water

to produce a spice concentrate.

The next worker loads
the trimmed briskets

onto a conveyor.

It takes the briskets under
an array of long needles

that inject the brine
into the meat repeatedly.

Laced with brine, the briskets
then fall into a bin.

A worker transfers the juicy
briskets into a vacuum tumbler.

It pulls air from the chamber,

causing the briskets
to absorb more brine.

The tumbler tosses
the briskets for 10 hours,

massaging the brine
into the meat.

A layer of protein also
forms on the surface.

This holds the brine in place.

In the meantime, a worker mixes
the ingredients for the dry rub.

It's comprised of the same
spices

that were used in the brine

along with clumps
of fresh garlic.

After the briskets have been
well marinated,

the operator adds the dry rub.

He turns on the tumbler
for another half hour.

The dry rub mixture coats
the surface of the meat.

This system is an alternative

to rubbing the spices
onto the briskets by hand.

It's faster and very efficient.

Coated with smoked meat spices

and injected
with flavorful brine,

the briskets are now
ready for roasting.

An employee rolls racks of the
spicy briskets into a huge oven.

The briskets steam-roast
at 210 degrees fahrenheit

for 8 to 10 hours,

but the workers don't
actually smoke the briskets.

It's the spices and brine
that give them

that montreal
smoked meat flavor.

After the briskets
have been chilled,

workers transfer them
to plastic bags

and place them on a conveyor.

Moving forward, a vacuum-sealing
head drops down to shrink-wrap

the plastic to the meat.

The vacuum seal and the
smoked meat spices combined

give the meat a long shelf life.

Refrigerated, it will stay fresh
for up to 45 days.

This plant ships the entire
brisket to restaurants.

At the restaurant,
they will re-steam and slice

the brisket before serving.

Next, the smoked meat
is pre-sliced

to sell in supermarkets.

An automatic meat slicer carves
it into thin pieces in seconds.

A worker retrieves
the sliced smoked meat

and sets it on a tray.

Transferred to a weigh station,

workers divide the slices
into 6-ounce portions.

Then they roll up
the smoked meat slices.

A worker places the rolled meat
into plastic pouches on a rack.

The racks move forward,

and a vacuum sealer
applies a top film,

creating little packets
of sliced smoked meat.

After a quick bake
to pasteurize the meat,

he puts six packets into
compartments on a conveyor.

A pusher moves the six packets
of smoked meat into an open box.

The system seals the ends
of the boxes.

Workers weigh the box
of smoked meat slices.

It has taken about 30 hours

to produce this batch
of montreal smoked meat.

It's time to slice it thin
and pile it thick

between slabs
of mustard-slathered rye.

Now, that's a deli lunch,
montreal-style.

Narrator: A motorized scooter
is a souped-up version

of an ordinary scooter.

Instead of propelling the wheels
by pushing off the ground

with one leg,
an engine does most of the work.

Some motorized scooters
are kids' toys,

but others are sturdy vehicles

suitable for commuting,
utility, and recreation.

This motorized scooter

has wheels large enough
and tires wide enough

to drive on any surface,
even off road.

The manufacturer contracts
this factory

to make the frame components.

Machines cut hollow steel tubes
to the required length.

Then workers program
an automated bending machine

to bend each one
to the required shape.

They make five tubular
frame parts per scooter,

strictly following the
technical drawing supplied

by the manufacturer.

The scooter company subcontracts
the frame assembly

to another factory.

There, a welder mounts
the components on a jig,

which positions them correctly
while he welds them together.

The non-tubular, flat-frame
parts are prepared in house,

cut from sheet steel by
a computer-guided laser cutter.

These flat crossbars
support the footboard

on which the rider stands.

This flat plate
supports the battery,

and these arms support
the rear wheel and motor.

After applying a coat
of anticorrosion paint,

workers install
the side reflectors

and the knob
that secures the battery.

The paint is baked on
for maximum durability.

The scooter manufacturer
subcontracts the wheel rims

to another factory

that specializes in
high-precision metal spinning.

A worker there mounts
an aluminum disk

onto a computer-guided lathe,

positioning it right next
to a rim-shaped steel mold.

Two rollers push and stretch
the disk over the mold,

forming the aluminum
to the rim's shape.

Another worker mounts the rim
on a manual-spinning lathe

to finish the shaping.

First, with a cutting knife,
he trims the edge.

After lubricating
the edge with soap,

he uses a forming bar
to turn it inward to form a lip.

Then, with the forming roller,

he stretches the lip
to shape a flange.

back at the scooter factory,
a worker begins installing

the vehicle's silent
electric motor.

Its cable will plug into
the electronic module

that runs the motor,
accelerator, and battery.

The motor is actually located
inside the hub

of the rear wheel.

This mounting ring
holds it in place.

He installs a brake disc
on top of the motor

and another on the front wheel.

A mechanical cable connects
each handlebar brake lever

to the brake calipers.

When the driver pulls the
levers, the brake calipers clamp

the discs to the wheels,
stopping rotation.

Now the final assembly --

workers bolt the rear wheel
to the frame's support arms.

They insert
the height-adjustable fork,

made of steel and aluminum,
into the steering column.

Next, the worker installs
the handlebars,

which have a thumb-operated
accelerator throttle,

an lcd monitor
and two hand brakes,

each with a mechanical
cable for the calipers.

Each hand brake
also has one electrical cable.

He connects the throttle line

and the electrical cables
to the monitor.

Then he connects the monitor
to the controller.

When the rider brakes,

the controller
also cuts power to the motor,

which allows the scooter's
48-volt lithium ion battery

to regenerate.

This screw knob holds
the battery

securely against
the battery support plate.

He connects the battery
to the controller,

then the mechanical cable
from one hand-brake lever

to the front brake calipers

and from the other hand brake
lever to the rear calipers.

Charging the battery
takes four hours

when plugged in
to a regular household outlet,

and a full charge
lasts 31 to 37 miles.

The scooter can climb
an 11% incline

and reach a top speed
of 20 miles per hour.