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Narrator:
Today on "How it's made"...
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Horseshoes...
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...Dishwashers...
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...Graphite fly rods...
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...And frozen pizzas.
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Horses first wore leather
And metal shoes around 500 a.D.
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To protect their hooves
From wear and tear.
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Today, depending
On the animal's vocation,
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Horseshoes are usually made
Of steel, aluminum, or plastic.
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A farrier is someone
Who makes the horseshoes
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And carefully applies them.
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A horse's hoof
Has a hard outer wall
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Like a fingernail,
Only much thicker.
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The farrier attaches
The horseshoe to this wall
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With heat and lead nails.
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The horse feels no pain
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Because the nails don't reach
The sensitive tissues inside.
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Horses get new shoes
About every five weeks.
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After removing the old ones,
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The farrier uses a file
To trim the wall's growth
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Since the last change --
About 1/3 of an inch.
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He measures the hoof's contour,
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Marks the measurement
On a steel bar,
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And cuts it to size
With a rotary saw.
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Steel is the material of choice
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Because it's affordable
And durable.
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Next, he heats the bar
Until the middle's white-hot.
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He brushes off any dirt,
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Then dips the bar in water
To cool it.
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Then he hammers the ends
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To redistribute the metal
Toward the middle.
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This widens and thickens
The part of the horseshoe
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That gets the most wear,
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Since the front of the hoof hits
The ground first and hardest.
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After reheating the bar,
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He hammers it again,
This time with no cooldown.
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For larger shoes,
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Two farriers
Take turns hammering
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So that it goes faster,
And they can shape the steel
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While it's still
Hot and pliable.
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Using a drafting compass,
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The farrier gauges where
Two grooves for nails will go.
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He reheats the bar,
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Then holds
A sharp-ended tool against it,
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While another farrier
Drives it in with a hammer.
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The nails won't protrude when
They're embedded in the grooves.
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These areas will also fill with
Dirt to give the horse traction.
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The farriers round
The sharp edges of the horseshoe
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So the animal won't cut itself
When it's lying down.
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They make the nail holes
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By first driving this tool
Into the grooves.
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Then they use another tool
To perforate the steel,
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Hammering it into the shoe
Over an opening in the anvil
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That lets the tool
Pierce through.
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The farrier then repeats
These steps on the other side.
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It takes 2 farriers
About 15 minutes
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To make a pair of horseshoes.
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The first farrier
Heats one shoe,
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While the second
Hammers the other.
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00:03:29,931 --> 00:03:31,034
Like the hooves,
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The front and back shoes
Are differently shaped.
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The front pair are rounder,
The back ones, more oval,
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Because the horse's
Hind hooves have evolved
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To dig into the ground
For traction.
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The farriers also hammer
Part of both curves,
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Flattening the edges
Into raised sides called clips.
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These help the shoe fit
Onto the hoof.
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00:03:54,310 --> 00:03:56,758
For larger workhorses
Like clydesdales,
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The farriers
Bend the ends downward
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To give the feet more traction.
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It's not uncommon
For a 2,000-pound horse
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To have to pull
Twice its weight.
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Now time for the fitting.
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After heating the shoe,
But not as much this time,
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The farrier uses it to melt
The outer part of the wall.
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This makes an imprint
On the horseshoe
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That later helps him place it
Properly on the hoof.
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Horses first wear shoes
At about 3 years old,
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The age when they start working
Or competing.
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The farrier fine-tunes
The fitting
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With a metal filing tool,
Curving the edges further
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To make them even safer
For the horse.
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Next, he shines the steel
With a metal brush.
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The shine will quickly fade once
The horse takes its first steps.
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Depending on the foot size,
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The finished shoe
Can measure anywhere
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From 2.5 to 9 inches across.
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Now, to attach the shoe,
The farrier first files the hoof
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To remove any dust
Or sharp edges.
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He slips on the shoe,
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Then gently hammers as many
As three nails into each side.
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The nails
Are about 2 inches long.
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They're made of lead --
A metal that's easy to bend --
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And that's he'll do after
Hammering them through the wall.
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He clips off the ends and bends
The rest in towards the wall.
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Then he uses other tools
To gouge small crevices
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In which to bury the ends.
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This makes it easy
To straighten out the nails
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And yank off the shoe
When it's time.
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He also hammers the hoof
Against a template
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To stabilize the shoe.
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Next, he files the hoof so that
It meets the angle of the shoe.
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And, finally,
The horse is ready to stroll.
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So whether you've got
A pony or a stallion,
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Make sure the shoe fits.
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When it comes to horse footwear,
Function, not fashion, dictates.
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Narrator:
In 1886, an american woman
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Invented
The automatic dishwasher.
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Josephine cochran built
A motorized wheel
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00:06:06,517 --> 00:06:08,482
With wire compartments
For dishes,
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Turning inside a copper tank
Filled with soapy boiling water.
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It was a hit
With restaurants and hotels,
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But it wasn't until the 1950s
That affordable dishwashers
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For home kitchens
Came on the market.
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Building a dishwasher
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Starts with a watertight
Container called the tub.
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Some high-end models
Have stainless-steel tubs.
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The rest have tubs
Made of molded plastic,
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Usually polypropylene.
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Workers screw two pairs
Of plastic wheels
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To each side of the tub.
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They'll support the sliders on
Which the upper dish rack moves.
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The lower dish rack rolls
Along the bottom of the tub.
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This steel frame
Helps solidify the tub.
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00:07:01,137 --> 00:07:03,241
They affix a steel plate
At the bottom
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To shield the plastic
From heat of the motor.
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00:07:05,896 --> 00:07:08,206
Then they attach steel legs
To the frame.
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00:07:13,103 --> 00:07:16,172
Here, they install a rubber
Reservoir called the sump.
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It collects the water that flows
To the bottom of the tub.
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00:07:23,000 --> 00:07:27,413
They screw in a two-part ring
To hold the sump in place.
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The heating element is
A ceramic-insulated iron cable.
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This filter traps food particles
Washing off the dishes.
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After fitting an o-ring seal
To make the sump leakproof,
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They secure the heating element
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00:07:42,310 --> 00:07:47,068
By screwing ceramic insulators
To the protruding connectors.
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00:07:47,172 --> 00:07:51,482
Now for the polypropylene
Wash arms.
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This model has one
At the bottom,
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With a tower that juts out
For a larger spray span,
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00:07:56,655 --> 00:07:58,724
And a second wash arm
At the top.
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The motor pumps clean water
Directly to the bottom wash arm
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00:08:06,517 --> 00:08:09,965
And, through this flexible hose,
To the top wash arm.
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Once they connect the hose,
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They spin the wash arm to make
Sure there's no obstruction.
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00:08:21,896 --> 00:08:24,862
Meanwhile,
Workers connect key components
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00:08:24,965 --> 00:08:27,551
To the dishwasher's
Circuit board.
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00:08:27,655 --> 00:08:29,586
This metal box is the timer.
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00:08:29,689 --> 00:08:31,965
It controls
The wash and dry cycles.
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00:08:32,068 --> 00:08:34,965
For example, it activates
This green cam lever
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00:08:35,068 --> 00:08:37,896
To trigger the white lever
To open the detergent dispenser
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00:08:38,000 --> 00:08:40,310
At the right moment
In the wash cycle.
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00:08:45,965 --> 00:08:48,793
The detergent dispenser
Is located on a plastic panel
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00:08:48,896 --> 00:08:50,931
That will line
The dishwasher's door.
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00:08:51,034 --> 00:08:53,758
They call this panel
The inner door.
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00:08:56,275 --> 00:08:59,586
This seal will prevent water
From leaking out
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00:08:59,689 --> 00:09:02,413
And also provide
Some soundproofing.
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00:09:02,517 --> 00:09:04,827
A press runs over
The inner door,
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00:09:04,931 --> 00:09:07,482
Driving in the seal
Evenly all around.
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00:09:10,000 --> 00:09:12,931
Now they screw the inner door
To the outer door.
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00:09:23,827 --> 00:09:28,000
The assembled door hooks onto
Hinges at the base of the tub.
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00:09:31,068 --> 00:09:33,620
This machine presses
The hook and hinge together
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00:09:33,724 --> 00:09:36,000
So that the door
Doesn't come unhinged.
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00:09:44,172 --> 00:09:46,413
The dishwasher's motor
Is relatively quiet
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Because it uses
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00:09:47,827 --> 00:09:50,862
An inherently low-noise
Induction drive design.
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00:09:50,965 --> 00:09:54,689
The white machine attached
To the motor is a food disposer.
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00:09:54,793 --> 00:09:59,758
It grinds up food particles so
That they don't clog the drain.
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00:09:59,862 --> 00:10:03,344
The last technical step
Is to connect the various wires.
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00:10:09,620 --> 00:10:12,172
Before applying
The finishing touches,
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00:10:12,275 --> 00:10:14,241
Workers conduct a seal test.
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00:10:14,344 --> 00:10:17,896
They flush each tub with water
To check for leaks.
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00:10:18,000 --> 00:10:20,000
In this portable dishwasher,
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00:10:20,103 --> 00:10:23,551
Workers install cement blocks
As a counterweight
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00:10:23,655 --> 00:10:27,000
So that the washer won't tip
Forward when you open the door.
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00:10:27,103 --> 00:10:29,758
And because a portable
Usually sits in full view,
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00:10:29,862 --> 00:10:32,620
It also needs sides and a top.
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00:10:32,724 --> 00:10:36,793
The top is decorative laminate
On medium-density fiberboard.
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00:10:36,896 --> 00:10:38,862
They screw it
To what's called the wrapper,
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00:10:38,965 --> 00:10:40,793
A three-sided panel
Made of painted steel
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00:10:40,896 --> 00:10:44,000
That covers
The sides and back --
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00:10:44,103 --> 00:10:47,379
A clean look to go
With your clean dishes.
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00:11:07,655 --> 00:11:10,137
Narrator: fishing
May not be rocket science,
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00:11:10,241 --> 00:11:12,448
But the graphite fly rod
Certainly is.
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00:11:12,551 --> 00:11:14,620
Graphite
Is a space-age material --
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00:11:14,724 --> 00:11:16,724
Lightweight,
Flexible, and strong.
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00:11:16,827 --> 00:11:19,448
The very qualities
That make it useful in space
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00:11:19,551 --> 00:11:21,827
Also come in handy
At the river or lake.
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00:11:21,931 --> 00:11:23,896
It explains
Why graphite fly rods
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00:11:24,000 --> 00:11:26,344
Are now popular
In the fishing world.
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00:11:32,103 --> 00:11:35,068
To make one, they start
With a sheet of graphite.
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00:11:35,172 --> 00:11:38,448
They cut out shapes,
Following precise measurements.
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00:11:38,551 --> 00:11:39,793
One mistake here,
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00:11:39,896 --> 00:11:42,758
And the performance of the rod
Will be compromised.
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00:11:47,724 --> 00:11:49,862
This will be a three-piece rod,
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00:11:49,965 --> 00:11:52,275
With a butt piece,
Midsection, and tip.
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00:11:55,586 --> 00:11:59,344
They place a shape
On a tapered steel mandrel...
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00:11:59,448 --> 00:12:02,034
And peel away the paper backing.
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00:12:10,206 --> 00:12:13,931
This machine rolls the graphite
Shape around the mandrel.
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00:12:16,034 --> 00:12:20,793
They make all three sections
Of the fishing rod the same way.
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00:12:24,034 --> 00:12:27,655
A graphite strip
At the end reinforces it all.
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00:12:29,241 --> 00:12:32,551
The graphite remains on
The mandrel for the next step.
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00:12:32,655 --> 00:12:35,413
They wind polypropylene tape
Around the graphite
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00:12:35,517 --> 00:12:38,689
To squeeze out any air pockets
Between the layers.
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00:12:44,655 --> 00:12:48,103
Then it's into the oven to cook
At 257 degrees fahrenheit
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00:12:48,206 --> 00:12:49,655
For an hour and a half.
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00:12:49,758 --> 00:12:53,000
The tape won't melt,
But resins in the graphite will,
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00:12:53,103 --> 00:12:55,413
Baking the rolled layers
Together.
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00:13:01,379 --> 00:13:04,724
Afterwards,
They remove the shrink tape
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00:13:04,827 --> 00:13:07,068
And pull the graphite blank
Off the steel mandrel.
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00:13:12,413 --> 00:13:15,241
Then the rod blanks go
For a dip in a special finish,
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00:13:15,344 --> 00:13:17,068
Which turns it a deep blue.
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00:13:22,310 --> 00:13:23,931
They bake on the finish
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00:13:24,034 --> 00:13:27,206
For a half-hour
At 257 degrees fahrenheit.
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00:13:32,068 --> 00:13:34,448
Afterwards,
They measure the rod sections
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00:13:34,551 --> 00:13:39,103
And cut them to size
So they all fit together.
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00:13:43,241 --> 00:13:47,172
Bending without snapping is
The graphite rod's strong point.
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00:13:48,724 --> 00:13:52,241
They hot-glue the
Stainless-steel tip to the end.
217
00:14:01,379 --> 00:14:05,000
Then they piece together the
Retainer for the fishing reel.
218
00:14:09,034 --> 00:14:13,172
This locknut will allow the reel
To be tightened.
219
00:14:23,068 --> 00:14:26,620
The plug will keep everything
From sliding off.
220
00:14:30,689 --> 00:14:33,655
They glue cork rings together
To make a handle.
221
00:14:33,758 --> 00:14:36,793
Then they shape it
With a chisel and sandpaper.
222
00:14:41,655 --> 00:14:44,103
The line guides go on next.
223
00:14:44,206 --> 00:14:47,137
They keep things from getting
Into a tangle.
224
00:14:50,655 --> 00:14:52,034
They wind thread around it
225
00:14:52,137 --> 00:14:55,241
To secure it to the rod,
One foot at a time.
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00:15:04,758 --> 00:15:07,896
A final step ensures
The handiwork doesn't unravel.
227
00:15:08,000 --> 00:15:10,034
They place the rod
In a rotating jig
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00:15:10,137 --> 00:15:14,344
And brush three coats of glossy
Epoxy onto the thread wrap.
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00:15:14,448 --> 00:15:17,758
This not only protects it
But gives it a nice finish.
230
00:15:23,862 --> 00:15:27,241
Now they slide a metal foot into
A groove on the reel retainer,
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00:15:27,344 --> 00:15:31,068
And it's ready for the reel
To be attached.
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00:15:31,172 --> 00:15:33,965
But before
You can cast your line,
233
00:15:34,068 --> 00:15:37,448
There is some information
That needs to go on the rod,
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00:15:37,551 --> 00:15:40,206
Like the brand name
And serial number.
235
00:15:43,310 --> 00:15:47,551
A final inspection, and it's
Almost time to test the waters.
236
00:15:50,551 --> 00:15:52,724
The reel snaps into place,
237
00:15:52,827 --> 00:15:55,551
And it's easily adjusted
With the locknut.
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00:15:57,655 --> 00:16:01,689
The rest is a matter of luck
And the right bait.
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00:16:14,241 --> 00:16:16,689
Narrator:
Millions of pizzas travel daily
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00:16:16,793 --> 00:16:19,517
From the frozen-food section
Of the supermarket
241
00:16:19,620 --> 00:16:21,137
To the family dinner table.
242
00:16:21,241 --> 00:16:24,137
Thick or thin crust,
Meat or vegetarian,
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00:16:24,241 --> 00:16:27,931
Their convenience makes them
A staple in the freezer.
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00:16:28,034 --> 00:16:30,517
But how do they end up
Tasting so fresh
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00:16:30,620 --> 00:16:32,896
When they start out so frozen?
246
00:16:40,413 --> 00:16:44,517
Making frozen pizzas
Requires a maze of machines.
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00:16:44,620 --> 00:16:46,896
To make the dough for the crust,
248
00:16:47,000 --> 00:16:51,586
They combine flour, salt, sugar,
Water, yeast, and oil
249
00:16:51,689 --> 00:16:54,482
In a large mixer...
250
00:16:54,586 --> 00:16:58,034
And they throw in
A bit of cornmeal for flavor.
251
00:16:58,137 --> 00:17:01,655
The mixer turns the ingredients
For about four minutes.
252
00:17:01,758 --> 00:17:04,034
This is one powerful machine.
253
00:17:04,137 --> 00:17:07,517
A truck transmission drives the
Steel bars that knead the dough.
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00:17:11,896 --> 00:17:14,034
The dough rises
For about half an hour.
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00:17:14,137 --> 00:17:17,931
Then they feed it
Into a chunking machine,
256
00:17:18,034 --> 00:17:21,379
Which divides the big blob
Into smaller pieces.
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00:17:24,862 --> 00:17:27,275
The chunks travel
To a sheeting machine
258
00:17:27,379 --> 00:17:31,034
That rolls them into
A flat sheet one-inch thick.
259
00:17:31,137 --> 00:17:32,724
A light dusting of flour
260
00:17:32,827 --> 00:17:35,482
Keeps the dough
From sticking to the machinery.
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00:17:35,586 --> 00:17:38,724
A series of rollers
Called quick reducers
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00:17:38,827 --> 00:17:41,448
Gives the dough
An even consistency.
263
00:17:44,137 --> 00:17:46,793
A flour brush
Massages the dough,
264
00:17:46,896 --> 00:17:49,172
Ensuring a smooth surface.
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00:17:49,275 --> 00:17:52,413
Next, stainless-steel spikes
Pierce the dough
266
00:17:52,517 --> 00:17:55,034
With holes
About a quarter-inch deep.
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00:17:55,137 --> 00:17:58,206
These holes
Will stop air pockets
268
00:17:58,310 --> 00:18:01,482
From forming in the dough.
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00:18:01,586 --> 00:18:05,103
A large plastic roller
With several round forms
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00:18:05,206 --> 00:18:08,344
Cuts the circular shape
Of the pizza crust.
271
00:18:20,172 --> 00:18:23,758
The machine automatically
Separates the leftover dough.
272
00:18:23,862 --> 00:18:27,413
The factory remixes it with
Fresh dough for the next batch.
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00:18:30,862 --> 00:18:33,793
A conveyor
Takes the dough circles
274
00:18:33,896 --> 00:18:36,241
To their next destination --
The oven.
275
00:18:39,275 --> 00:18:41,413
They bake for two minutes
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00:18:41,517 --> 00:18:44,896
Between 390 and 600 degrees
Fahrenheit.
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00:18:46,655 --> 00:18:48,172
Six chambers inside the oven
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00:18:48,275 --> 00:18:50,862
Automatically control
The temperature pattern
279
00:18:50,965 --> 00:18:53,241
To ensure that each one
Bakes evenly.
280
00:18:55,724 --> 00:18:59,275
Next stop -- the tomato sauce.
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00:19:03,517 --> 00:19:07,793
A tank pumps a steady supply
Of sauce into a reservoir,
282
00:19:07,896 --> 00:19:10,551
Drenching a roller
Turning inside.
283
00:19:12,655 --> 00:19:15,586
A plastic board
Then scrapes the sauce
284
00:19:15,689 --> 00:19:18,172
Onto the crusts passing below.
285
00:19:18,275 --> 00:19:23,034
The excess sauce drips down,
Replenishing the reservoir.
286
00:19:27,344 --> 00:19:32,137
Mounds of preshedded mozzarella
Are ready to be added.
287
00:19:35,000 --> 00:19:37,758
A cheese-applicator machine
Controls the output
288
00:19:37,862 --> 00:19:41,103
So that the mozzarella
Forms an even layer.
289
00:19:51,896 --> 00:19:54,862
Large hoppers load heaps
Of pepperoni, sausage,
290
00:19:54,965 --> 00:19:57,793
And other meat toppings
Into a meat applicator.
291
00:19:57,896 --> 00:20:00,275
As with the tomato sauce
And cheese,
292
00:20:00,379 --> 00:20:04,137
The meat toppings cascade down
On the pizza crusts.
293
00:20:08,103 --> 00:20:11,103
The pizza is now ready
For inspection.
294
00:20:11,206 --> 00:20:12,827
Workers take samples
Off the line
295
00:20:12,931 --> 00:20:16,241
And weigh the crust, sauce,
Cheese, and meat to ensure
296
00:20:16,344 --> 00:20:19,034
The equipment dispensed
The right amount of each.
297
00:20:21,517 --> 00:20:25,344
Next, the pizzas enter a spiral
Freezer called a blast cell,
298
00:20:25,448 --> 00:20:27,206
Where they spend
About 20 minutes
299
00:20:27,310 --> 00:20:29,965
At minus-25 degrees fahrenheit.
300
00:20:32,344 --> 00:20:34,103
An overwrapping machine
301
00:20:34,206 --> 00:20:37,413
Applies a clear layer of plastic
Around each pizza,
302
00:20:37,517 --> 00:20:40,827
Automatically cutting the wrap
To fit.
303
00:20:40,931 --> 00:20:44,137
A vision-control system
Takes a picture of every pizza,
304
00:20:44,241 --> 00:20:46,551
Verifying the size, diameter,
305
00:20:46,655 --> 00:20:48,344
And checking
For any imperfections.
306
00:20:48,448 --> 00:20:51,137
The machine
Automatically rejects
307
00:20:51,241 --> 00:20:52,896
Any less-than-perfect pizzas
308
00:20:53,000 --> 00:20:55,827
By air-blasting them
Into a separate tub.
309
00:20:57,931 --> 00:21:02,586
Finally, an arm pushes
Each pizza into a waiting box.
310
00:21:06,275 --> 00:21:11,448
All that's left now
Is to heat it up and dig in.
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00:21:11,551 --> 00:21:14,448
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00:21:14,551 --> 00:21:17,448
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313
00:21:17,551 --> 00:21:20,034
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About the show,
314
00:21:20,137 --> 00:21:23,000
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315
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