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♪♪
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♪♪
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♪♪
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♪♪
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♪♪
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♪♪
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Narrator: manufactured gemstones
Are typically designed
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To imitate genuine
Mined gemstones.
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Not these --
They're made from heather,
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A hardy flowering plant which
Grows wild across scotland.
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For centuries,
Scots used heather to
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Thatch roofs, stuff mattresses,
And even brew ale.
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♪♪
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This scottish company
Turns heather
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Into gemstone material
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For jewelry
And other gift items.
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Heathergems,
As they're called,
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Have veinlike patterns created
Randomly by the plants' stems.
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Therefore, no two gems
Can be identical.
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When the handpicked heather
Arrives at the factory,
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Its green foliage still clings
To the upper part of the stems.
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After cutting the plants
Into lengths of about 10 inches,
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Workers load them
Into a sandblasting machine.
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The drum rotates
For about half an hour
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While tiny iron pellets
Blast the heather inside.
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The pellets chip away the bark
And remove the foliage.
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The heather
Comes out of the machine
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As bare, dried-out,
Delicate wood.
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Workers form
1 1/2-pound bundles
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And place them in
A vacuum-die chamber
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For two whole days.
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First,
The vacuum draws out
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The air in the stems
To clear the way
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For the die to penetrate.
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Then, again under pressure,
The stems slowly absorb the dye.
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♪♪
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This vacuum method
Is far more effective
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Than dipping or soaking
The stems in vats of dye
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Because the color
Penetrates deeply
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Into the heather wood
Rather than
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Merely sitting on the surface.
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They open the bundles and make
New ones of the same weight,
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This time combining colors.
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It's important
To combine thicker stems
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With thinner ones
To create contrasting lines
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In the gem pattern.
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♪♪
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Next,
They soak each bundle
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In epoxy resin
For two or three minutes,
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Ensuring the stems
Are well saturated.
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♪♪
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Then they place the bundles
On racks
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To allow the excess resin to
Drain off.
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♪♪
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They load four bundles
Between
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The top and bottom halves
Of a mold.
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A press
Then slowly closes the mold,
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Applying 88 tons of pressure
For about a minute.
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♪♪
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♪♪
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They clamp the mold closed
And remove it from the press.
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Then they put the mold
Into an oven for an hour
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To cure the resin.
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♪♪
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They open the mold
And remove what is now
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A rock-hard, resin-bonded
Block of heather wood.
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They put the block on a band saw
And trim off the rough edges.
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♪♪
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They cut slices between
4/10 and 5/10 of an inch thick,
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Depending on what shape gem
They'll be making.
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After gluing each slice
Onto a plastic backing,
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A robotic cutting machine
Guided by a computer
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Cuts the gem shapes.
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Then workers simply pop the gems
Off the plastic backing.
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This domed oval shape
Is called a cabochon.
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The finishing team
Smoothes and polishes each gem
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On a belt sander,
Then applies four or five coats
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Of clear lacquer.
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♪♪
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Lacquering
Draws out the colors
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While sealing
And protecting the wood.
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♪♪
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Finally, they glue each gem
Onto the jewelry or gift item.
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Sometimes they dye the heather
Just a single color.
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This still produces
A striking gem,
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Because the dye penetrates the
Wood with different intensities,
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Creating contrasting shades.
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The signature feature
Is the unique veining
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Produced by the heather
Encased within,
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Each and every gemstone
Truly capturing
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The natural beauty
Of the scottish highlands.
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♪♪
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♪♪
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Narrator: invented in the middle
Of the 20th century,
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Instant film
Made photographic images
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Materialize almost magically.
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The picture appeared in minutes.
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No more waiting for days
For film to be processed.
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Today it's a digital world,
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But instant film is still
Getting plenty of exposure.
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♪♪
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With instant film,
You can watch an image develop
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Before your very eyes --
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No film lab
Or digital printer necessary.
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Just say, "Cheese,"
And wait to see what develops.
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Many decades
After its invention,
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Instant photo development
Still seems like a neat trick.
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♪♪
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Making the magic happen
Is a many-layered process,
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One that involves multiple
Materials and chemicals.
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Production begins
With the film negative.
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It takes place in the dark
To prevent pre-exposure.
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The technician dons
Night-vision goggles,
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Allowing him to monitor
Plastic film
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As it unwinds
Into a coating machine.
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Inside,
Various dyes and chemicals
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Will transform the film
Into a negative.
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They switch the lights back on
Briefly for our camera.
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The film travels up and down
Towards the coating machine.
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It's a system that prevents
Any slackening in the feed.
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The coating is also done
In the dark,
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So this worker
Demonstrates the process
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For our camera
On a small research machine.
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Liquid photo chemicals and dyes
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Flow onto the surface
Of the plastic film.
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He spreads the liquids
Across the film
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For an even application.
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This is all done mechanically
Inside the real coating machine.
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Once coated, the film will head
Into the dryer.
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The various coatings
Will dry in separate layers
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Without intermingling.
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Here's a test tube lineup
Of the liquid components
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Of the negative.
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The colorful ones are dyes,
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And the white ones
Are other chemicals.
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They apply black backing
To the negative to block light,
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Again preventing pre-exposure.
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♪♪
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The trip through the dryer
Is 87 yards long.
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Hot air dries the chemicals
On the surface of the film.
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Once again,
It all happens in the dark
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To protect
The light-sensitive film.
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Coiled up and packed
Into lighttight drums,
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The color-negative material is
Now on its way
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To a second factory
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To be assembled
Into the instant film pack.
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Upon arrival, they thread the
Negative onto a machine,
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Along with other materials
For the film pack.
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They include
A plastic base material
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Called the mask
And the positive paper
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That receives the photographic
Image from the negative.
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The various materials are
Steered toward assembly stations
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By a system of rollers.
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Here's a lineup of the various
Materials to be assembled.
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That's the mask on the far left
And the negative in the middle.
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The negative heads towards
A series of hot presses.
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One press laminates
A plastic spacer
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Called the rail to the negative.
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♪♪
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Another lamination head
Applies the mask
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To the positive sheet
That will receive the image.
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On a different machine,
Equipment folds
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A kind of foil pouch and
Injects it with film developer.
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♪♪
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Here's an inside look
At the pouch.
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The blue liquid
Is the developer.
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Encased in
The foil-lined envelope,
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It will stay fresh until needed.
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Back on
The main assembly machine,
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Another hot press
Laminates the developer pouch
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To the other film materials.
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This completes
The film sandwich,
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And it heads into
Another station
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To be sliced
Into photo-sized pieces.
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The photo frames
Ride a wheel with a counter
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That divides them
Into stacks of eight.
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Meanwhile, robot arms deposit a
Rectangular spring on a battery.
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Then they position
The eight pictures
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On the spring-battery assembly,
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Followed by
A light-blocking cover.
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The stack then moves forward
To be squeezed
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Into a plastic cassette.
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A suction type of device
Now picks up a cardboard box
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00:10:19,137 --> 00:10:22,724
And transfers it to the end
Of the film-pack line.
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00:10:22,724 --> 00:10:25,896
Another device
Captures the film pack
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As it comes off the line and
Places it in the cardboard box.
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Once folded closed,
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The box of instant film
Rides the carousel to a scale.
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A quick weighing confirms
There's enough film in the box,
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So it's ready to ship.
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The assembly
Of this instant film pack
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Has taken roughly three minutes.
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Now those instant memories
Are just a few clicks away.
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♪♪
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Narrator: a common assumption
Is that all white sugar
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Is derived from sugar cane,
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But 30% of the world's
White-sugar supply
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Comes from the sugar beet.
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While sugarcane grows
Only in tropical climates,
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The hardier sugar beet
Can be cultivated
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In cooler regions
And in poorer soil.
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00:11:29,482 --> 00:11:31,655
It takes about 7 beets
To produce
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A little more than
2 pounds of sugar.
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The by-products of processing,
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Molasses and beet pulp,
Are used for animal feed.
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00:11:39,517 --> 00:11:43,379
The processing of sugar beets
Yields various grades of sugar.
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The lower ones are reprocessed
To become white sugar.
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Farmers plant beet seeds
In the spring
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And harvest the mature crop
In the fall.
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Mechanical harvesters
Attack six rows at a time.
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00:12:00,724 --> 00:12:03,034
They rip the plant
Out of the ground,
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Chop off the leaves and crown,
Leaving just the bulbous root.
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♪♪
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A beet root typically weighs
About 2 pounds.
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17% to 18% of that is sucrose,
Which is sugar.
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00:12:20,862 --> 00:12:24,586
A loader transfers
The harvested beets into trucks.
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The loader's sieve removes
About a third of the soil
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Along the way.
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♪♪
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When the trucks arrive
At the sugar factory,
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They unload the beets,
Soil and stones included,
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Onto a conveyer belt,
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Which transports them to
A washing station.
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First they head into
A revolving drum,
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Where,
Under a shower of water,
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The beets
Rub against each other,
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Dislodging the soil.
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The water flow floats the beets,
Which then exit the drum.
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The stones stay behind,
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Collected in separator buckets
Along the edge.
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A screw conveyer moves the beets
To a transfer system,
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Which brings them
Inside the factory
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To be processed into sugar.
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♪♪
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Inside, slicing machines cut the
Incoming beets into cassettes,
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Strips about the shape
Of french fries but smaller.
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♪♪
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00:13:36,000 --> 00:13:38,620
The cassettes travel
On a conveyer belt
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Into a large tank of hot water,
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00:13:40,586 --> 00:13:42,931
Where they soak
For a few minutes.
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This gets their cell membranes
To begin opening,
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Clearing the way
For the sucrose to exit
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During the next operation,
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In which the cassettes
Are pumped to the bottom
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Of a 22-yard-high
Extraction tower.
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A rotating shaft
Within the tower
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Transports them slowly upward
Against the downward flow
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00:14:01,241 --> 00:14:02,241
Of hot water.
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This draws out the sucrose,
251
00:14:04,896 --> 00:14:09,103
Producing a sugary water
Called raw juice.
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00:14:09,103 --> 00:14:12,344
The next step is to purify
This raw juice.
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00:14:12,344 --> 00:14:15,827
In a giant kiln,
They burn limestone with coke
254
00:14:15,827 --> 00:14:19,586
To produce the chemical compound
Calcium hydroxide,
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00:14:19,586 --> 00:14:21,275
Also called lime milk.
256
00:14:21,275 --> 00:14:24,689
They add it, in several stages,
To the raw juice.
257
00:14:24,689 --> 00:14:28,172
Meanwhile, they press the
Sucrose-stripped cassettes
258
00:14:28,172 --> 00:14:30,586
Into pulp
To sell as animal feed.
259
00:14:30,586 --> 00:14:34,448
They add carbon dioxide to the
Lime milk-and-juice mixture.
260
00:14:34,448 --> 00:14:37,517
This absorbs 1/3
Of the juice's impurities,
261
00:14:37,517 --> 00:14:40,655
Enabling a filtration system
To remove them.
262
00:14:40,655 --> 00:14:44,241
The raw juice
Exits as a golden sugar solution
263
00:14:44,241 --> 00:14:45,758
Called thin juice.
264
00:14:45,758 --> 00:14:49,241
The thin juice then enters a
6-step evaporation process,
265
00:14:49,241 --> 00:14:54,068
Which reduces it to
A thick syrup-like juice.
266
00:14:54,068 --> 00:14:58,793
From there, they pump it into a
4-phase crystallization system.
267
00:14:58,793 --> 00:15:02,206
In phase 1,
They heat and add seed crystals,
268
00:15:02,206 --> 00:15:05,068
Tiny, identical-sized
Sugar crystals
269
00:15:05,068 --> 00:15:09,689
Made separately using a complex
Cooling and evaporating process.
270
00:15:09,689 --> 00:15:12,275
As the water
In the juice evaporates,
271
00:15:12,275 --> 00:15:14,965
About half
Of the sucrose crystallizes,
272
00:15:14,965 --> 00:15:16,758
Growing the seed crystals.
273
00:15:16,758 --> 00:15:20,172
Then a centrifuge machine
Separates the crystals,
274
00:15:20,172 --> 00:15:23,413
Called refined sugar,
From the remaining syrup.
275
00:15:23,413 --> 00:15:24,793
The syrup goes through
276
00:15:24,793 --> 00:15:28,275
This crystallization-centrifuge
Process three more times,
277
00:15:28,275 --> 00:15:32,103
Producing a lesser grade
Of sugar each time.
278
00:15:32,103 --> 00:15:37,137
The factory dissolves
And recrystallizes
279
00:15:37,137 --> 00:15:39,965
The lowest two grades.
280
00:15:39,965 --> 00:15:43,482
The highest grades of sugar
Go into dryers,
281
00:15:43,482 --> 00:15:46,379
On the way, passing through
A screening machine
282
00:15:46,379 --> 00:15:49,413
Which separates any crystals
Which are too large.
283
00:15:49,413 --> 00:15:51,724
The factory dissolves
These crystals,
284
00:15:51,724 --> 00:15:53,310
Then puts the sugary liquid
285
00:15:53,310 --> 00:15:55,896
Through the
Crystallization process again.
286
00:15:55,896 --> 00:15:58,965
So, in the end, there are
Two grades of beet sugar
287
00:15:58,965 --> 00:16:01,586
Which go into silos,
Where they're stored
288
00:16:01,586 --> 00:16:04,137
Until it's time to
Package them for sale
289
00:16:04,137 --> 00:16:06,275
As refined sugar
And white sugar.
290
00:16:11,241 --> 00:16:16,620
♪♪
291
00:16:16,620 --> 00:16:20,862
Narrator:
The electric car ruled the road
Early in the 20th century,
292
00:16:20,862 --> 00:16:23,724
And then the technology
Was surpassed by gas.
293
00:16:23,724 --> 00:16:26,482
Today the concept
Is cruising towards a comeback,
294
00:16:26,482 --> 00:16:28,448
Its resurgence
Fueled by concerns
295
00:16:28,448 --> 00:16:30,862
About pollution
From gas-powered vehicles
296
00:16:30,862 --> 00:16:33,689
And by worries about
Overdependence on foreign oil.
297
00:16:37,862 --> 00:16:42,689
This sassy-looking sports car is
Leading the charge for change.
298
00:16:42,689 --> 00:16:45,206
Just plug it into
Any electrical outlet,
299
00:16:45,206 --> 00:16:47,827
And after a few hours,
It has enough juice
300
00:16:47,827 --> 00:16:50,068
For a drive
Through the countryside
301
00:16:50,068 --> 00:16:52,517
Or for quite a few jaunts
Around town.
302
00:16:52,517 --> 00:16:55,827
With no tailpipe,
There are no direct emissions,
303
00:16:55,827 --> 00:16:59,827
And if the power generated by
The electrical plant is clean,
304
00:16:59,827 --> 00:17:02,379
Everyone breathes
A little easier.
305
00:17:02,379 --> 00:17:05,517
But with a price tag
In the 6-figure range,
306
00:17:05,517 --> 00:17:08,896
This eco-friendly roadster
Is a luxury product.
307
00:17:08,896 --> 00:17:12,344
Production begins with
The first half of the gear box.
308
00:17:12,344 --> 00:17:15,137
A worker bolts a brass fitting
To the center
309
00:17:15,137 --> 00:17:17,724
And then attaches
Plastic tubing to it.
310
00:17:17,724 --> 00:17:20,275
The tubing
Will deliver lubricant to
311
00:17:20,275 --> 00:17:22,172
The transmission's bearings.
312
00:17:22,172 --> 00:17:27,068
He inserts those bearings
Into slots in the gearbox
313
00:17:27,068 --> 00:17:31,931
And presses them into place
Using a hydraulic tool.
314
00:17:31,931 --> 00:17:35,000
He drips thread-locking compound
Into screw holes
315
00:17:35,000 --> 00:17:38,137
And installs a device
For locking the transmission.
316
00:17:38,137 --> 00:17:40,379
It's called the parking pawl.
317
00:17:40,379 --> 00:17:42,689
He applies more adhesive
To screws
318
00:17:42,689 --> 00:17:45,827
And threads them
Through the pawl to the gearbox.
319
00:17:45,827 --> 00:17:47,931
Using a calibrated
Torque wrench,
320
00:17:47,931 --> 00:17:50,241
He tightens them to
A precise setting.
321
00:17:50,241 --> 00:17:53,413
The transmission is single speed
With four gears,
322
00:17:53,413 --> 00:17:56,689
Which they install in
The other half of the gearbox.
323
00:17:56,689 --> 00:17:58,517
These are helical gears.
324
00:17:58,517 --> 00:18:00,793
Their teeth
Are cut at an angle
325
00:18:00,793 --> 00:18:03,862
For gradual engagement
And smooth operation.
326
00:18:03,862 --> 00:18:06,413
They're now ready for
The rotor and the stator.
327
00:18:06,413 --> 00:18:08,344
Both are electromagnets,
328
00:18:08,344 --> 00:18:12,793
And together they'll be the
Electric motor's driving force.
329
00:18:12,793 --> 00:18:14,965
They insert the rotor
Into the stator,
330
00:18:14,965 --> 00:18:17,068
Where their two
Electromagnetic fields
331
00:18:17,068 --> 00:18:19,689
Will interact to create torque,
332
00:18:19,689 --> 00:18:24,793
Transforming electrical energy
Into mechanical energy.
333
00:18:24,793 --> 00:18:27,793
They hoist the
Rotor-and-stator assembly
334
00:18:27,793 --> 00:18:30,793
Onto the gearbox
And bolt them together.
335
00:18:30,793 --> 00:18:33,655
They attach cables
For wiring the motor to
336
00:18:33,655 --> 00:18:36,172
The power-electronics module
Later.
337
00:18:36,172 --> 00:18:40,310
It's a crucial part
That processes and regulates
338
00:18:40,310 --> 00:18:43,827
The flow of battery power
To the motor.
339
00:18:43,827 --> 00:18:46,379
This completes the
Electric-motor drivetrain.
340
00:18:46,379 --> 00:18:50,827
♪♪
341
00:18:50,827 --> 00:18:52,862
They lower the drivetrain
Into the back
342
00:18:52,862 --> 00:18:54,344
Of the preassembled car body.
343
00:18:57,310 --> 00:19:00,724
They position the motor mounts
344
00:19:00,724 --> 00:19:04,862
Over slots
In the steel subframe.
345
00:19:04,862 --> 00:19:08,517
And once in place, they bolt
The drivetrain to the chassis.
346
00:19:08,517 --> 00:19:12,965
♪♪
347
00:19:12,965 --> 00:19:14,482
Now, under the car,
348
00:19:14,482 --> 00:19:17,137
They pull back
The rear suspension temporarily
349
00:19:17,137 --> 00:19:19,517
To attach the drive axle
To the gearbox.
350
00:19:21,206 --> 00:19:24,551
The axle is equipped
With a rubber-encased joint
351
00:19:24,551 --> 00:19:28,482
That allows a rear wheel to
React to bumps independently,
352
00:19:28,482 --> 00:19:31,068
Without reverberation to
The other.
353
00:19:31,068 --> 00:19:32,758
The battery is next.
354
00:19:32,758 --> 00:19:36,379
Seen here in a display model
Of the power train,
355
00:19:36,379 --> 00:19:40,517
The metal pack contains more
Than 6,800 lithium-ion cells
356
00:19:40,517 --> 00:19:43,379
And delivers 215 kilowatts
Of power,
357
00:19:43,379 --> 00:19:47,827
Enough juice to enable this
Electric car to accelerate to
358
00:19:47,827 --> 00:19:50,896
60 miles an hour
In under 4 seconds.
359
00:19:50,896 --> 00:19:53,896
Machinery now lowers the car
Onto the battery,
360
00:19:53,896 --> 00:19:56,689
Positioning it in the front
Of the gearbox
361
00:19:56,689 --> 00:19:58,620
And just behind the car seats.
362
00:19:58,620 --> 00:20:02,896
They jack up the battery
For a precision fit.
363
00:20:02,896 --> 00:20:06,655
They connect wiring
For low-voltage systems,
364
00:20:06,655 --> 00:20:08,862
Like the lights and fans.
365
00:20:08,862 --> 00:20:11,931
And now the brains of the
Electric car --
366
00:20:11,931 --> 00:20:14,103
The power-electronics module.
367
00:20:14,103 --> 00:20:17,310
They install it
On top of the motor and battery
368
00:20:17,310 --> 00:20:18,758
And wire it to both.
369
00:20:18,758 --> 00:20:20,827
With all the wires connected,
370
00:20:20,827 --> 00:20:23,931
The module is equipped
To convert dc power
371
00:20:23,931 --> 00:20:26,448
From the battery to
The ac power.
372
00:20:26,448 --> 00:20:29,586
It will then supply
That current to the motor
373
00:20:29,586 --> 00:20:32,379
As the driver steps on
The accelerator.
374
00:20:32,379 --> 00:20:34,034
With the vacuum system,
375
00:20:34,034 --> 00:20:37,965
They drain air from the battery
And pump in liquid coolant.
376
00:20:37,965 --> 00:20:41,275
Coolant continuously flows
Through the battery
377
00:20:41,275 --> 00:20:44,413
To maintain an even temperature
Throughout.
378
00:20:44,413 --> 00:20:47,413
The body panels
Are made of durable,
379
00:20:47,413 --> 00:20:49,413
Lightweight carbon fiber.
380
00:20:49,413 --> 00:20:51,827
And with
The computer software updated
381
00:20:51,827 --> 00:20:54,137
And the car
Now completely assembled,
382
00:20:54,137 --> 00:20:55,689
It's time for a test run.
383
00:20:57,172 --> 00:21:01,137
As this sports car accelerates,
There's no throaty roar.
384
00:21:01,137 --> 00:21:02,862
Unlike a gas-powered engine,
385
00:21:02,862 --> 00:21:05,793
The electric motor takes off
Quietly and quickly.
386
00:21:05,793 --> 00:21:13,896
♪♪
387
00:21:13,896 --> 00:21:22,034
♪♪
388
00:21:22,034 --> 00:21:24,206
If you have any comments
About the show,
389
00:21:24,206 --> 00:21:26,793
Or you'd like to
Suggest topics for future shows,
390
00:21:26,793 --> 00:21:29,379
Drop us a line at...
30555
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