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-- captions by vitac --
Www.Vitac.Com
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>> narrator: today on "How
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It's made," ccd
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Semiconductors...
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Airline meals...
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Paper cups...
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And trumpets.
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A ccd semiconductor is the image
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Sensor in a digital camera or
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Camcorder.
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When you snap the shutter or
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Press record, you expose the
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Ccd to patterns of light.
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It captures them electronically
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By converting them into millions
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Of electrical charges.
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The camera's processor then
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Reads these charges and
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Translates them into pictures or
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Movies.
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Ccds, or charge couple devices,
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Are made of silicon, the main
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Element in sand.
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What's special about silicon?
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When light hits it, you get
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Electrons.
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Production begins with a round
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Silicon wafer six inches in
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Diameter and about as thick as a
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Shirt cardboard.
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It goes into a steam oven for
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Three to four hours.
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The intense heat, along
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With oxygen and hydrogen
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Gases in the steam, create a
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Glass-like layer on the wafer.
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This insulates the silicon
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Against the miniature
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Electrical circuitry that will
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Be built on top of it.
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But first, the wafer is covered
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In conductive material.
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This layer measures less than a
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Micron.
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A human hair is 100 times
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Thicker.
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Next, a robot applies a
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One-micron-thick layer of
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Photo-sensitive resin, which
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Will undergo a chemical reaction
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When exposed to light.
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A technician places a mask over
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The wafer.
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The pattern on this mask is the
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Scheme attic for part of the
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Circuitry.
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When you take a picture, you
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Expose the silicon wafer to
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Light and that generates
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Electrons.
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The circuitry carries those
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Electrons to the camera's
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Processor, which reads the
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Charges and translates them
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Into an image.
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This machine exposes the masked
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Wafer to ultraviolet light.
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The resin underneath
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The circuitry pattern
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Remains intact,
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Protecting the conductive layer
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Beneath it.
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The resin on the areas not
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Masked by the circuitry pattern
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Needs to be removed.
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Chemicals are sprayed on.
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This dissolves the resin
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Exposing the conductive layer
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Underneath.
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Technicians repeat this entire
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Process with anywhere from 13 to
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30 masks until they've built up
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The full circuitry pattern on
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The wafer.
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Next, technicians submerge the
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Wafer in acid, which eats away
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The uncovered conductive layer.
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So, now, the only conductive
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Material left on the wafer is
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The actual circuitry.
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Next step, a thorough rinsing in
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Tap water to remove the residue.
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Then a rinse with purified water
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To remove any impurities left
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By the tap water.
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Throughout production,
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Contamination is a concern.
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A single speck of dust can ruin
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An entire wafer.
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To protect and insulate the
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Circuitry, the wafer is coated
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In liquid glass, then baked for
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Two hours, until the glass
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Hardens.
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The wafer surface is divided
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Into 25 million tiny square
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Cells called pixels.
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When you take a photo, each
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Pixel records the light
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Intensity of a minute portion of
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The scene, generating an
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Electrical charge.
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A filter on the ccd translates
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Each pixel charge into color.
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The company makes this filter
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With three pigment powders --
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Red, green and blue.
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These three colors combined in
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Varying ratios can reproduce any
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Color.
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The camera's processor reads and
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Then reconstructs the photograph
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Scene pixel by pixel.
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Each finished ccd undergoes a
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Battery of automated tests to
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Ensure that all the circuits are
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Functional.
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The machine marks faulty
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Circuits with ink.
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Just one bad circuit means the
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Entire ccd needs to be
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Discarded.
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Technicians then check every ccd
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Under a microscope looking for
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Scratches that might have
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Occurred during the production
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Process.
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The number of pixels on a ccd
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Varies depending on what type of
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Camera it's for.
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This one is a 25 megapixel ccd,
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Meaning it has 25 million
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Pixels.
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This company even produces a
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Single ccd that has 111
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Megapixels.
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So the next time you say,
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"Cheese," remember that you're
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Producing a digital photo thanks
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To all that painstaking work
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That went into the sophisticated
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Ccd semiconductor inside your
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Camera.
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>> when we return, creating the
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Ultimate to-go meals for
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Today's highflyers.
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>> narrator: in the earliest
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Days of air travel, passengers
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Really lived the high life.
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They were served
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Multi-course meals that
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Were actually prepared during
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Flight.
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But as air travel boomed, this
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Kind of service became
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Impractical, and airlines turned
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To premade meals.
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Not all food fares well at high
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Altitudes.
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That's why you don't see any
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Souffles at 30,000 feet.
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They couldn't possibly rise to
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The occasion.
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It's just one of the
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Restrictions airline chefs need
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To consider when preparing a
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Menu.
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Airline meals start with tons of
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Ingredients, literally.
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Just one facility can turn out
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45,000 meals in a single day.
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Of course, the cooks wash their
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Hands very thoroughly because
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They don't want any germs stowed
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Away in the meal.
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They cook on grills that are
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Five feet long.
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At one end, they stir-fry
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Vegetables, while at the other,
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They sauté potatoes.
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Then, they spice it up.
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Airline food isn't as bland as
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It's reputed to be.
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Researchers believe that low
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Humidity and the pressurized
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Environment cause our taste buds
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To work less efficiently in an
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Airplane, something to take into
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Account when you're traveling
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By air.
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Recipes vary according to the
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Route.
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Flights to more exotic locales
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Will offer spicier dishes, while
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A domestic north american flight
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Usually calls for more moderate
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Seasoning.
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Cooks fire up different grills
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For the meat.
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They prepare food for the crew
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As well as the passengers.
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On many airlines, the pilot and
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Co-pilot must eat different
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Meals to minimize the risk of
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Food-related illness
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Compromising the flight.
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The cooked food will now be
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Blast chilled in special
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Fridges.
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Cooks scrub up again as they
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Prepare to assemble the meals.
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They start with the food that
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Needs to be reheated on the
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Plane.
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It goes into foil containers.
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Smaller containers inside help
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Control the portion sizes.
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Cooks must be careful not to
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Overstuff them because that
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Could cause messy spills later.
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A little sauce and a generous
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Dab of herb butter, and you have
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The makings of a first-class
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Meal.
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Finally, the food is covered
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With a vented lid.
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With each menu change, chefs
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Must meet with airline
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Representatives.
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They serve up sample dishes and
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Discuss the ingredients with
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Them.
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There's often a lot of
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Negotiation before the final
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Menu is agreed upon.
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Every detail about an airline
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Meal is carefully planned right
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Down to the plates and bowls and
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How they're placed on the
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Serving tray.
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It takes a bit of arranging to
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Make everything fit.
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Once planners finalize the
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Arrangements, they follow that
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Formula in the kitchen.
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As with any meal, presentation
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Counts for a lot.
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Of course, meals in economy
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Class are more simple, and the
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Planning less detailed.
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The food-laden trays go onto
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Trolleys and are rolled into a
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Big, refrigerated room, where
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They're arranged according to
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The flight number.
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They won't be here for long
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Because every meal is made to be
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Served that day.
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And all the groundwork
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Beforehand is sure to pay off
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Once passengers and crew are in
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The air.
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Up next, a popular product that
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Lets us all enjoy one for the
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Road.
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>> narrator: the paper cup was
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Invented around the turn of the
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20th century to stop the spread
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Of disease.
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Today, it's an integral part of
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Our culture.
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Paper cups provide a convenient
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And hygienic way to serve food
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And beverages, and the lining of
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Water-tight plastic or wax
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Prevents any nasty leaks.
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And where would we be without
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Our disposable coffee cups?
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Production starts with paper
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That has a thin plastic coating.
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It unrolls into a printer that's
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As long as a bowling lane.
293
00:11:47,700 --> 00:11:49,267
As the paper weaves through the
294
00:11:49,267 --> 00:11:50,767
Machine, printing cylinders
295
00:11:50,767 --> 00:11:52,400
Layer an image onto the paper
296
00:11:52,400 --> 00:12:02,500
One color at a time.
297
00:12:02,500 --> 00:12:04,200
When the image is complete, a
298
00:12:04,200 --> 00:12:05,700
Rotary die cuts the paper
299
00:12:05,700 --> 00:12:07,167
Into what's called a flat.
300
00:12:07,167 --> 00:12:08,867
The dimensions of the flat vary
301
00:12:08,867 --> 00:12:10,600
Depending on the size of the cup
302
00:12:10,600 --> 00:12:11,600
Being made.
303
00:12:11,600 --> 00:12:13,300
Each flat will eventually become
304
00:12:13,300 --> 00:12:14,333
A paper cup.
305
00:12:14,333 --> 00:12:16,333
They land on a conveyor in a
306
00:12:16,333 --> 00:12:18,700
Shingle-like lineup.
307
00:12:18,700 --> 00:12:20,600
A computerized system counts the
308
00:12:20,600 --> 00:12:22,367
Flats and divvies them up into
309
00:12:22,367 --> 00:12:31,533
Stacks of 200.
310
00:12:31,533 --> 00:12:33,300
The flats drop into an elevator
311
00:12:33,300 --> 00:12:34,833
Stacker.
312
00:12:34,833 --> 00:12:36,467
It creates piles that workers
313
00:12:36,467 --> 00:12:39,567
Can easily collect.
314
00:12:39,567 --> 00:12:40,867
They load them into another
315
00:12:40,867 --> 00:12:42,300
Conveyor in a different part of
316
00:12:42,300 --> 00:12:43,867
The factory.
317
00:12:43,867 --> 00:12:45,133
It moves the flats in a
318
00:12:45,133 --> 00:12:46,667
Vibrating shuffle up into the
319
00:12:46,667 --> 00:12:52,567
Cup machine.
320
00:12:52,567 --> 00:12:54,433
Meanwhile, a roll of paper winds
321
00:12:54,433 --> 00:12:56,067
Into the other side of that
322
00:12:56,067 --> 00:12:58,067
Machine, where a die punches out
323
00:12:58,067 --> 00:13:06,067
Bottoms for the paper cups.
324
00:13:06,067 --> 00:13:07,467
This leaves a long strip of
325
00:13:07,467 --> 00:13:08,967
Scrap paper which gets sucked
326
00:13:08,967 --> 00:13:10,867
Away for recycling.
327
00:13:22,067 --> 00:13:24,300
Meanwhile, the flats are relayed
328
00:13:24,300 --> 00:13:29,067
To a carousel.
329
00:13:29,067 --> 00:13:31,300
Now the paper cup takes shape.
330
00:13:31,300 --> 00:13:33,267
Mechanical jaws wrap each flat,
331
00:13:33,267 --> 00:13:41,467
And a heat gun seals the seam.
332
00:13:41,467 --> 00:13:43,267
And now, you have a paper cup
333
00:13:43,267 --> 00:13:46,867
With no bottom.
334
00:13:46,867 --> 00:13:49,233
That crucial step comes next.
335
00:13:57,367 --> 00:13:59,733
Bottoms are shoved onto the cups
336
00:13:59,733 --> 00:14:01,300
And heat-sealed in place by
337
00:14:01,300 --> 00:14:02,733
Melting the plastic backing on
338
00:14:02,733 --> 00:14:05,533
The unprinted side of the paper.
339
00:14:05,533 --> 00:14:07,467
The cups then fall down a chute
340
00:14:07,467 --> 00:14:09,133
To the next operation, which
341
00:14:09,133 --> 00:14:10,833
Will give the cups a rim and
342
00:14:10,833 --> 00:14:12,200
Allow you to take a sip without
343
00:14:12,200 --> 00:14:20,200
Spilling.
344
00:14:20,200 --> 00:14:22,333
A hot tool curls the top edge of
345
00:14:22,333 --> 00:14:23,733
The paper.
346
00:14:23,733 --> 00:14:26,067
Then, the vacuum sucks each cup
347
00:14:26,067 --> 00:14:28,600
Into ductwork overhead.
348
00:14:28,600 --> 00:14:29,900
Each piece of ductwork comes
349
00:14:29,900 --> 00:14:31,133
From a different production
350
00:14:31,133 --> 00:14:32,333
Line.
351
00:14:32,333 --> 00:14:34,067
There are big cups and small
352
00:14:34,067 --> 00:14:35,567
Cups, all traveling to the
353
00:14:35,567 --> 00:14:37,100
Packing department, where they
354
00:14:37,100 --> 00:14:41,633
Land in stacking tubes.
355
00:14:41,633 --> 00:14:43,467
A counter keeps a running tally
356
00:14:43,467 --> 00:14:45,833
And portions out the stacks.
357
00:14:56,633 --> 00:14:58,133
The stacks then slide into a
358
00:14:58,133 --> 00:15:00,067
Curtain of plastic.
359
00:15:00,067 --> 00:15:01,967
Hot jaws seal the plastic wrap
360
00:15:01,967 --> 00:15:10,533
Around the stack.
361
00:15:10,533 --> 00:15:12,267
And now, the cups are ready to
362
00:15:12,267 --> 00:15:15,767
Be packed and shipped.
363
00:15:15,767 --> 00:15:18,133
Meanwhile, over in the testing
364
00:15:18,133 --> 00:15:20,400
Department, this is no coffee
365
00:15:20,400 --> 00:15:21,767
Break.
366
00:15:21,767 --> 00:15:23,233
Inspectors have pulled some cups
367
00:15:23,233 --> 00:15:24,467
Off the production line to
368
00:15:24,467 --> 00:15:25,633
Check for leaks.
369
00:15:25,633 --> 00:15:27,400
A mirror below reflects the
370
00:15:27,400 --> 00:15:29,633
Bottom line, but leaks are one
371
00:15:29,633 --> 00:15:31,867
In a million, so they made one
372
00:15:31,867 --> 00:15:33,100
Leak deliberately for
373
00:15:33,100 --> 00:15:36,133
Demonstration.
374
00:15:36,133 --> 00:15:37,667
In the case of a real leak,
375
00:15:37,667 --> 00:15:39,067
Production is halted and
376
00:15:39,067 --> 00:15:40,700
Inspectors follow the paper
377
00:15:40,700 --> 00:15:42,500
Trail until they determine the
378
00:15:42,500 --> 00:15:46,800
Problem.
379
00:15:46,800 --> 00:15:48,167
It takes about a minute to
380
00:15:48,167 --> 00:15:49,800
Transform pieces of paper into a
381
00:15:49,800 --> 00:15:52,133
Cup.
382
00:15:52,133 --> 00:15:53,833
Now, it's time to hit the road
383
00:15:53,833 --> 00:15:56,100
Without any leakage.
384
00:16:05,600 --> 00:16:07,600
When we return, a factory
385
00:16:07,600 --> 00:16:09,733
With something to trumpet about.
386
00:16:13,533 --> 00:16:15,333
>> narrator: the ancestor of the
387
00:16:15,333 --> 00:16:16,800
Modern trumpet was a straight
388
00:16:16,800 --> 00:16:18,367
Horn that could emit just a few
389
00:16:18,367 --> 00:16:19,167
Notes.
390
00:16:19,167 --> 00:16:21,800
By the 15th century, instrument
391
00:16:21,800 --> 00:16:23,133
Makers learned how to bend a
392
00:16:23,133 --> 00:16:24,633
Horn, allowing for more notes to
393
00:16:24,633 --> 00:16:26,067
Be produced.
394
00:16:26,067 --> 00:16:28,900
The invention of the valve in
395
00:16:28,900 --> 00:16:31,100
The mid-1800s finally allowed
396
00:16:31,100 --> 00:16:38,400
The trumpet to play in any key.
397
00:16:38,400 --> 00:16:40,300
A trumpet is made up of five
398
00:16:40,300 --> 00:16:41,467
Feet of tubing.
399
00:16:41,467 --> 00:16:43,067
Three valves allow air to flow
400
00:16:43,067 --> 00:16:44,533
Through additional tubing to
401
00:16:44,533 --> 00:16:47,667
Alter the trumpet's pitch.
402
00:16:47,667 --> 00:16:49,833
Trumpets are made from sheets of
403
00:16:49,833 --> 00:16:51,533
Metal, most often brass.
404
00:16:51,533 --> 00:16:53,467
This factory combines different
405
00:16:53,467 --> 00:16:55,133
Thicknesses of brass in a single
406
00:16:55,133 --> 00:16:56,367
Instrument to attain a
407
00:16:56,367 --> 00:16:58,067
Particular sound.
408
00:16:58,067 --> 00:17:00,067
Workers first lay a template on
409
00:17:00,067 --> 00:17:03,700
A brass sheet and trace it out.
410
00:17:03,700 --> 00:17:05,567
Then they cut along the score
411
00:17:05,567 --> 00:17:07,267
Line with electric shears.
412
00:17:07,267 --> 00:17:08,367
This piece will become the
413
00:17:08,367 --> 00:17:13,067
Trumpet's bell.
414
00:17:13,067 --> 00:17:15,133
A manually operated press forms
415
00:17:15,133 --> 00:17:22,233
A perfect fold down the middle.
416
00:17:22,233 --> 00:17:30,500
Then, they notch the edges.
417
00:17:30,500 --> 00:17:32,167
Then, they close up the bell by
418
00:17:32,167 --> 00:17:33,667
Hammering the notched pieces
419
00:17:33,667 --> 00:17:35,300
Onto the opposite edge.
420
00:17:35,300 --> 00:17:37,200
They use a rawhide mallet
421
00:17:37,200 --> 00:17:38,567
Because anything harder would
422
00:17:38,567 --> 00:17:41,800
Damage the brass.
423
00:17:41,800 --> 00:17:44,067
A brass alloy is melted along
424
00:17:44,067 --> 00:17:45,833
The joint.
425
00:17:45,833 --> 00:17:47,533
It solidifies in a metal seam
426
00:17:47,533 --> 00:17:49,067
That permanently bonds the
427
00:17:49,067 --> 00:17:52,100
Edges.
428
00:17:52,100 --> 00:17:53,967
Next, the bell goes over a
429
00:17:53,967 --> 00:17:56,067
Cone-shaped mandril where the
430
00:17:56,067 --> 00:17:58,067
Brass is hammered until it, too,
431
00:17:58,067 --> 00:18:04,367
Is cone-shaped.
432
00:18:04,367 --> 00:18:05,967
Then the bell goes onto another
433
00:18:05,967 --> 00:18:10,400
Mandril mounted on a lathe.
434
00:18:10,400 --> 00:18:12,400
Here, the brass cone is refined
435
00:18:12,400 --> 00:18:14,867
Into a more refined shape.
436
00:18:14,867 --> 00:18:18,833
Then, the metal is filed smooth.
437
00:18:18,833 --> 00:18:20,700
Now for the bell's rim, called
438
00:18:20,700 --> 00:18:21,533
The bead.
439
00:18:21,533 --> 00:18:23,633
A brass rod with a notch at the
440
00:18:23,633 --> 00:18:25,367
End catches the edge of the bell
441
00:18:25,367 --> 00:18:27,767
And rolls it back into a rim.
442
00:18:27,767 --> 00:18:29,633
Metalworkers use what's called a
443
00:18:29,633 --> 00:18:31,233
Concave roller to round the
444
00:18:31,233 --> 00:18:36,633
Rim's jagged edge.
445
00:18:36,633 --> 00:18:38,400
Then they slide a brass alloy
446
00:18:38,400 --> 00:18:39,733
Wire into the rim pocket.
447
00:18:39,733 --> 00:18:41,367
This makes the bell stronger and
448
00:18:41,367 --> 00:18:42,933
Adds weight to the edge of the
449
00:18:42,933 --> 00:18:44,500
Flare to project the sound
450
00:18:44,500 --> 00:18:49,067
Better.
451
00:18:49,067 --> 00:18:50,667
They roll the rim over even more
452
00:18:50,667 --> 00:18:57,267
To enclose the wire.
453
00:18:57,267 --> 00:18:59,267
Now they heat the rim and apply
454
00:18:59,267 --> 00:19:01,267
Acid flux to clean the surface
455
00:19:01,267 --> 00:19:03,333
For soldering.
456
00:19:03,333 --> 00:19:05,067
Silver solder ensures the wire
457
00:19:05,067 --> 00:19:06,567
Won't rattle when the bell
458
00:19:06,567 --> 00:19:11,433
Vibrates.
459
00:19:11,433 --> 00:19:13,100
After wiping off the excess
460
00:19:13,100 --> 00:19:15,067
Flux, the bell goes back on the
461
00:19:15,067 --> 00:19:16,767
Lathe to scrape off the excess
462
00:19:16,767 --> 00:19:22,233
Solder.
463
00:19:22,233 --> 00:19:23,833
Using an abrasive sponge,
464
00:19:23,833 --> 00:19:25,300
Workers smooth away any
465
00:19:25,300 --> 00:19:27,533
Scratches left by the scraper.
466
00:19:27,533 --> 00:19:29,700
Then, they remove any solder
467
00:19:29,700 --> 00:19:31,633
Bits trapped in the rim.
468
00:19:31,633 --> 00:19:33,667
Now, the entire bell is filled
469
00:19:33,667 --> 00:19:36,067
With a soapy solution.
470
00:19:36,067 --> 00:19:38,067
Then, it's frozen at minus 56
471
00:19:38,067 --> 00:19:42,667
Degrees.
472
00:19:42,667 --> 00:19:44,433
When the solution is frozen, the
473
00:19:44,433 --> 00:19:48,767
Bell goes into a bending block.
474
00:19:48,767 --> 00:19:50,567
The frozen solution provides
475
00:19:50,567 --> 00:19:52,267
Counter pressure, preventing the
476
00:19:52,267 --> 00:19:54,100
Brass from buckling inward, and
477
00:19:54,100 --> 00:19:55,867
Because there's soap mixed in,
478
00:19:55,867 --> 00:19:57,667
The pliable ice doesn't shatter
479
00:19:57,667 --> 00:19:59,667
Under the pressure.
480
00:20:09,600 --> 00:20:11,200
After the angle of the bend is
481
00:20:11,200 --> 00:20:13,233
Checked with a gauge, the bell
482
00:20:13,233 --> 00:20:17,400
Is defrosted.
483
00:20:17,400 --> 00:20:18,767
In the mounting department,
484
00:20:18,767 --> 00:20:20,033
Workers assemble smaller
485
00:20:20,033 --> 00:20:21,433
Components made of brass and
486
00:20:21,433 --> 00:20:22,267
Nickel.
487
00:20:22,267 --> 00:20:24,833
Valve casings, the sliding tubes
488
00:20:24,833 --> 00:20:26,400
To which they connect, the
489
00:20:26,400 --> 00:20:28,267
Slide for tuning the trumpet,
490
00:20:28,267 --> 00:20:29,800
The pipe that holds the
491
00:20:29,800 --> 00:20:32,233
Mouthpiece, then they solder on
492
00:20:32,233 --> 00:20:38,967
The bell.
493
00:20:39,133 --> 00:20:40,900
They lubricate three pistons and
494
00:20:40,900 --> 00:20:42,333
Install one in each valve
495
00:20:42,333 --> 00:20:42,833
Casing.
496
00:20:46,733 --> 00:20:48,500
These slides have to be loose
497
00:20:48,500 --> 00:20:50,400
Enough to move but tight enough
498
00:20:50,400 --> 00:20:53,033
To prevent air leaks.
499
00:20:53,033 --> 00:20:54,867
One slide has a finger ring for
500
00:20:54,867 --> 00:20:58,700
Holding the trumpet.
501
00:20:58,700 --> 00:21:00,367
After polishing and lacquering
502
00:21:00,367 --> 00:21:02,133
The brass, workers test the
503
00:21:02,133 --> 00:21:03,967
Trumpet for sound quality.
504
00:21:03,967 --> 00:21:05,667
This is one company that likes
505
00:21:05,667 --> 00:21:07,500
To blow its own horn.
506
00:21:13,133 --> 00:21:14,500
If you have any comments about
507
00:21:14,500 --> 00:21:15,767
The show or if you'd like to
508
00:21:15,767 --> 00:21:17,867
Suggest topics for future shows,
509
00:21:17,867 --> 00:21:19,900
Drop us a line at...
32921
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