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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator: tapioca pudding
Is a textural fusion
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Of creaminess
And chewy tapioca pearls.
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The recipe
Is at least a century old,
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And there are
Conflicting theories
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About when and where
It was invented --
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Britain or the united states.
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With its distinctive chewiness,
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It brings something entirely
Different to the table.
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Today factories whip up
Tapioca pudding in big batches.
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Times have changed,
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But the appetite for this
Pearly pudding hasn't waned.
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The proof
Is truly in the pudding.
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The tapioca pearls, of course,
Define this dish.
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The opaque, little balls
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Are processed from a vegetable
Grown in south america
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Called cassava root.
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The recipe also calls for more
Traditional baking ingredients
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Like whole milk, eggs...
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Sugar...
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And vanilla.
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They pipe the whole milk
Into a giant mixing kettle.
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This kettle
Has steam-heated steel walls
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To gently cook the ingredients
While blending them.
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As the milk froths, the cook
Measures the tapioca pearls.
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The pearls arrive at
The factory already processed,
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Formed by grinding
The root vegetable into powder
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And tumbling it to shape it
Into properly sized pearls.
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As the pearls cook in the milk,
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They will soften and swell
To double the size,
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Just like rice.
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But unlike rice,
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They'll take on an almost
Jellylike, chewy consistency.
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He adds sugar
To sweeten the mix.
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The cook then leaves
The swirling and foaming mix
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To cook for over an hour.
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Meanwhile, at another station,
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They add tapioca starch to a
Different blender full of milk.
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This blender is unheated
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And has higher speed for mixing
That's fast and furious.
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He adds eggs...
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And he flavors the mix
With salt.
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The tapioca starch
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Acts as a thickening agent
For this separate mix,
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As the blender whips it
To a frothy state.
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They transfer the starch blend
To the main mixing kettle.
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The cook
Adds a natural food coloring
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To make the pudding beige along
With some vanilla flavoring.
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The tapioca pearls
Are just the right consistency.
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This pudding is now fully cooked
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And ready to move on
To the filling line.
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They pump it
While it's still steaming hot
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Into single-serve plastic cups.
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Packaging the pudding
While it's still hot
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Is an act of food preservation,
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Which, not surprisingly,
Is called hot fill.
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The hot-fill technique
Locks in nutrients
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And ensures freshness,
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Giving the product a shelf life
Of about 70 days.
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Suctioning arms swiftly transfer
Foil lids to cover the cups,
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Giving the pudding
No time to cool down.
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With the lids in place,
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The filler
Moves the cups forward
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To meet up
With heat-sealer heads.
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They fuse the foil lids
To the plastic cup rims.
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It's taken just seconds
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To fill these cups
With hot tapioca pudding
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And seal them,
Effectively preserving them.
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The pudding-filled cups
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Now funnel into a lane
To position them single file.
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Then they travel between
Rubber belts that squeeze them.
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If they can take the pressure,
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It confirms that the cups
Are tightly sealed.
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A printer
Sprays the expiration date
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And other pertinent information
Onto the cup.
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After weighing to confirm
There's enough pudding inside,
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An x-ray machine
Scans the contents
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To confirm
That there are no contaminants.
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Then they're on the way
To the chilling line.
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Inside the tubs,
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The tapioca pudding
Is still hot and fluid.
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The cups ride a system
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Of spiraling,
Refrigerated conveyors
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Bringing
The pudding's temperature down
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To about
100-degrees fahrenheit
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And thickening it substantially.
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The pudding-filled containers
Now pass through gates
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That separate them
Into two lanes
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And then arrange them
In groups of three.
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Machinery places
One group of three onto another,
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And then all that's left
Is the packaging.
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Mechanical arms
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Place the paperboard sleeve
On the top three cups.
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Traveling through a narrow lane,
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Guides fold the paperboard down
Around the bottom three cups
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As a sprayer
Applies hot glue to the flaps.
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A worker
Pulls off one pack of six
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And sends it over
To a panel of testers
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For an inspection and taste.
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They examine the pudding
For color and consistency.
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They also taste a little
From each production batch
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To confirm
That it's sweet enough,
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That the tapioca beads
Are the desired texture,
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And that it meets
All other quality requirements.
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If they like what they taste,
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The entire batch
Is declared ready for retail.
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Three hours in the making,
This tapioca pudding
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Is now ready to add a little
Sweetness to someone's day.
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Narrator: a snowplow
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Is actually the big blade
On a snow-clearing vehicle --
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Not the vehicle itself.
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The first snowplows
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Were wedge-shaped wooden blades
Drawn by horses.
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As cars replaced horses,
These gave way to metal plows
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Mounted to the front of trucks
And other large machines.
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A snowplow is a blade
Made of either stainless steel,
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Which is rust-proof,
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Or carbon steel,
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Which they coat in plastic-based
Powder paint to prevent rust.
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To begin making the blade,
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They take a sheet of metal
About 1/10 of an inch thick
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And insert it in a press.
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The press punches out holes
For the bolts,
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Which attach the blade
To the mounting structure.
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Next, they feed the sheet
Through a rolling press.
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The rollers
Apply 35 to 40 tons of pressure,
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Curving the sheet
To the required shape.
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Workers check
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That the front radius
And top radius of the curve
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Meet the technical
Specifications.
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Next, using a machine
Called a press break,
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They bend over
The top of the sheet.
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This bend will sit on the top
Bar of the mounting structure.
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The mounting structure
Is made of several parts
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Cut from giant plates
Of carbon steel.
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A computer
Guides the cutting machine,
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Which uses
Electrogenerated flames.
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Their intense, focused heat
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Slices through the steel
Literally by melting it.
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The steel is too hot to handle
When the plasma cutting is done,
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So workers lift off the parts
With magnets.
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Then they bend key,
Load-bearing parts
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In a press break to increase
The structural strength.
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They position the parts
For one section of the structure
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In an assembly fixture
And weld them together.
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In a different assembly fixture,
They position the parts
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For another section
Of the structure.
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A robot welds those together.
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Back at the first assembly,
They use pins
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To attach a spring-loaded
Component called a trip edge.
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It protects the vehicle
From damage
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By absorbing the shock
Through the springs,
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Rather than
Through the vehicle frame,
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Should the plow
Hit an obstacle on the road.
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After welding
The two sections together,
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Workers send the structure
To the powder-coating area.
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There, workers spray it first
With powder primer
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Then with powder paint.
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Each coat is baked
To activate the plastic base,
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Which produces an ultra-durable
Shell over the metal.
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Once the structure cools,
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Workers install the springs
For the trip edge,
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Then they attach
The base of the structure
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Called the cutting edge.
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It's made of
A harder type of steel
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Because it scrapes the ground.
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The structure is now finished
And ready to receive the blade.
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This one's getting
A stainless-steel blade.
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The bent top fits over
The structure's top bar,
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The bottom into a slot below.
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Workers secure the blade
With bolts
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Then finish off the plow
With a decal.
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For this model,
They make two plows like this --
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Mirror images of each other.
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They go side-by-side, connected
In the middle by a hinge
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To form a v-shaped snowplow.
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Straight plows
Have a single blade
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Attached to a different type
Of structure.
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All the parts,
Except stainless-steel blades,
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Are powder-painted and baked.
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The v-plow articulates.
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The driver can adjust the width
Of the "V" to direct the snow.
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Another model
Combines a straight blade
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With hinged blades for
Clearing snow in large areas,
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Such as parking lots.
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When it comes to these types
Of machines,
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There's clearly no business
Like snow business.
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Narrator: a paddle boat
Is a small recreational vessel,
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Perfect for a leisurely ride
On a lake.
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It gets its name
From the rotating paddle wheel
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That propels it.
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You simply sit in the seat
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And turn the paddle wheel
By pedaling,
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Which is why this type of boat
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Is also called
A pedal boat or pedalo.
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00:11:10,206 --> 00:11:13,379
Steered by rudder
And gliding on two floaters,
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A paddle boat delivers
A smooth, relaxing ride.
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00:11:16,965 --> 00:11:20,068
Boat mechanics don't get
Much simpler than this.
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00:11:20,068 --> 00:11:22,931
In a typical two-seater,
Two sets of pedals,
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Each powering a paddle wheel
At the rear.
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The factory
Molds the top and bottom halves
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Of each floater separately.
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00:11:29,344 --> 00:11:32,172
First, workers spray the mold
With gelcoat,
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A type of polyester.
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00:11:33,827 --> 00:11:36,655
This is the floater's
Surface finish.
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00:11:36,655 --> 00:11:40,241
Next, they cover the entire mold
With fiberglass cloth
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00:11:40,241 --> 00:11:43,172
Then add a second layer
In the front and bottom
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Where the floater
Will be a bit thicker.
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00:11:45,758 --> 00:11:50,034
Then they lower a cover
Onto the mold,
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Latching it down securely
To make the mold airtight.
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00:11:55,448 --> 00:12:00,620
They draw a vacuum to extract
The air trapped inside,
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00:12:00,620 --> 00:12:03,137
Then inject liquid resin.
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00:12:03,137 --> 00:12:05,551
The resin
Saturates the fiberglass cloth
215
00:12:05,551 --> 00:12:09,482
And, within an hour, hardens,
Producing solid fiberglass,
216
00:12:09,482 --> 00:12:11,068
A lightweight material
217
00:12:11,068 --> 00:12:14,068
That's both impact-resistant
And waterproof.
218
00:12:14,068 --> 00:12:16,724
After extracting this half,
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00:12:16,724 --> 00:12:19,482
Workers mold the other half
Of this floater
220
00:12:19,482 --> 00:12:22,379
And the two halves
That make up the other one,
221
00:12:22,379 --> 00:12:25,724
Then they apply fiberglass glue
To the edges...
222
00:12:28,068 --> 00:12:31,206
...And carefully align and mate
Top and bottom.
223
00:12:39,379 --> 00:12:41,000
They position spacers
224
00:12:41,000 --> 00:12:43,758
To put pressure
On the base of the groove,
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00:12:43,758 --> 00:12:46,275
Then clamp the perimeter
For about 45 minutes
226
00:12:46,275 --> 00:12:48,103
Until the glue sets.
227
00:12:51,206 --> 00:12:53,103
When the glue is completely dry,
228
00:12:53,103 --> 00:12:57,724
They trim the perimeter to make
The edge neat and smooth.
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00:12:57,724 --> 00:12:59,862
To make each propulsion wheel,
230
00:12:59,862 --> 00:13:03,379
Workers rivet eight blades
To a fiberglass hub.
231
00:13:03,379 --> 00:13:06,448
These strong plastic blades
Do have some flex in them.
232
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This ensures they won't break,
233
00:13:08,310 --> 00:13:12,137
Should the wheel hit a rock
Or other obstacle.
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00:13:12,137 --> 00:13:14,310
The part of the boat
Where you sit and pedal
235
00:13:14,310 --> 00:13:16,965
Is called the bicycle.
236
00:13:16,965 --> 00:13:19,103
The two bike bodies,
Like the floaters,
237
00:13:19,103 --> 00:13:22,000
Are made of molded fiberglass,
238
00:13:22,000 --> 00:13:24,206
Then jazzed up with decals.
239
00:13:32,310 --> 00:13:36,620
Since the bicycle mechanics
Are routinely exposed to water,
240
00:13:36,620 --> 00:13:39,034
They must be rust-resistant.
241
00:13:39,034 --> 00:13:42,103
Therefore, the pedal mechanism
Is made of chrome-plated steel
242
00:13:42,103 --> 00:13:43,586
And the chains
243
00:13:43,586 --> 00:13:47,551
Of steel that's been treated
With an anti-corrosion coating.
244
00:13:47,551 --> 00:13:50,241
Each bike has two chains --
245
00:13:50,241 --> 00:13:53,379
The first linking the pedals
To one side of a central gear,
246
00:13:53,379 --> 00:13:56,241
The second linking the
Other side of the central gear
247
00:13:56,241 --> 00:13:58,344
To the propulsion wheel.
248
00:13:58,344 --> 00:14:00,241
So, once they're both hooked up,
249
00:14:00,241 --> 00:14:03,241
Pedaling moves the first chain,
Which rotates the gear,
250
00:14:03,241 --> 00:14:07,241
Which moves the second chain,
Which turns the wheel.
251
00:14:07,241 --> 00:14:09,586
Final assembly
Is relatively simple.
252
00:14:09,586 --> 00:14:11,965
First, workers
Connect the floaters
253
00:14:11,965 --> 00:14:14,482
With three painted
Aluminum crossbars.
254
00:14:14,482 --> 00:14:17,103
The paint is baked on
To make it extra durable.
255
00:14:17,103 --> 00:14:20,206
Then, on one of the crossbars,
256
00:14:20,206 --> 00:14:22,793
They install
A pair of aluminum rudders,
257
00:14:22,793 --> 00:14:26,000
The boat's steering mechanism.
258
00:14:27,172 --> 00:14:29,517
They link the rudders
With an aluminum bar
259
00:14:29,517 --> 00:14:31,793
So that they move in unison.
260
00:14:34,551 --> 00:14:36,896
A hitch pin locks the bar
Securely in place,
261
00:14:36,896 --> 00:14:39,275
While this rubber cap
Prevents paint chipping
262
00:14:39,275 --> 00:14:43,000
When the rudders
Hit the crossbar.
263
00:14:43,000 --> 00:14:45,172
After mounting
The first bicycle,
264
00:14:45,172 --> 00:14:48,206
Workers install a console
In the center of the boat.
265
00:14:48,206 --> 00:14:50,758
It contains
A waterproof storage compartment
266
00:14:50,758 --> 00:14:53,551
And the handle,
Which directs the rudders.
267
00:14:53,551 --> 00:14:56,758
It connects to the rudders
With a long bar called a tiller.
268
00:15:05,310 --> 00:15:07,551
Next they mount the second bike.
269
00:15:07,551 --> 00:15:09,034
Like the first one,
270
00:15:09,034 --> 00:15:12,482
It's designed to snap securely
Onto the crossbars.
271
00:15:13,586 --> 00:15:17,517
The adjustable fiberglass seats
Slide onto aluminum rails.
272
00:15:17,517 --> 00:15:21,758
The seats have fixed cushions
And rugged, waterproof fabric.
273
00:15:21,758 --> 00:15:23,620
The boat's retractable canopy
274
00:15:23,620 --> 00:15:28,172
Is made of the same fabric
On an aluminum structure.
275
00:15:28,172 --> 00:15:30,620
A paddle boat
Is virtually maintenance-free.
276
00:15:30,620 --> 00:15:32,620
You just have to oil
The mechanisms
277
00:15:32,620 --> 00:15:34,586
A couple of times per season,
278
00:15:34,586 --> 00:15:37,379
And from then on,
It's smooth sailing.
279
00:15:49,862 --> 00:15:52,689
Narrator: every home
Needs a tough exterior.
280
00:15:52,689 --> 00:15:55,344
Fiber cement siding
Is a concrete option.
281
00:15:55,344 --> 00:15:57,758
Made of cement, sand,
And wood pulp,
282
00:15:57,758 --> 00:16:02,034
It's engineered to be fireproof,
Insectproof, and weatherproof.
283
00:16:02,034 --> 00:16:05,172
Embossed with various
Wood-grain patterns,
284
00:16:05,172 --> 00:16:08,172
It has a natural look
That's big on the street.
285
00:16:11,448 --> 00:16:14,586
Fiber cement cladding
Is a century-old product
286
00:16:14,586 --> 00:16:17,482
That was actually reinvented
In the 1980s.
287
00:16:17,482 --> 00:16:20,413
Asbestos was removed
Due to health concerns
288
00:16:20,413 --> 00:16:22,620
And replaced with wood pulp.
289
00:16:22,620 --> 00:16:26,000
The pulp provides the fiber
That prevents cracking.
290
00:16:26,000 --> 00:16:28,655
Production begins
With silica sand.
291
00:16:28,655 --> 00:16:32,034
A loader shovels it
Into an underground conveyor.
292
00:16:32,034 --> 00:16:35,172
The sand particles, which are
About the size of beach sand,
293
00:16:35,172 --> 00:16:38,448
Are about to be ground down
To a fine powder.
294
00:16:38,448 --> 00:16:42,379
The conveyor takes the sand up
To a revolving cylinder grinder
295
00:16:42,379 --> 00:16:43,862
Called a ball mill --
296
00:16:43,862 --> 00:16:47,655
So named because, inside,
Steel balls tumble around
297
00:16:47,655 --> 00:16:51,482
To smash the sand particles
Into much smaller bits.
298
00:16:51,482 --> 00:16:54,068
They pipe in water
To keep the dust down
299
00:16:54,068 --> 00:16:56,586
And eliminate the need
For an exhaust system.
300
00:16:56,586 --> 00:16:58,965
This also liquefies the sand,
301
00:16:58,965 --> 00:17:01,551
Making it easier
To pipe it through the plant
302
00:17:01,551 --> 00:17:03,862
During the various stages
Of processing.
303
00:17:03,862 --> 00:17:07,931
But the sandy liquid needs
To be thickened substantially,
304
00:17:07,931 --> 00:17:10,862
So it's into a tank
To drain off much of the water.
305
00:17:10,862 --> 00:17:14,344
What's left is about 80% sand.
306
00:17:14,344 --> 00:17:16,448
The next ingredient
Is wood pulp,
307
00:17:16,448 --> 00:17:19,379
Which gives the cement siding
Bending strength.
308
00:17:19,379 --> 00:17:20,724
Without it,
309
00:17:20,724 --> 00:17:24,517
The fiber cement siding would be
Brittle and crack easily.
310
00:17:24,517 --> 00:17:28,586
They add water and stir
To soften and liquefy the pulp
311
00:17:28,586 --> 00:17:30,758
So it can be easily pumped
Around the factory
312
00:17:30,758 --> 00:17:32,482
For processing.
313
00:17:35,551 --> 00:17:37,344
At the end of the mixing,
314
00:17:37,344 --> 00:17:40,344
The pulp looks like
Thick oatmeal.
315
00:17:41,551 --> 00:17:46,103
Next, they lower cylindrical
Sieves into position.
316
00:17:46,103 --> 00:17:48,172
But first they blend together
317
00:17:48,172 --> 00:17:50,896
The liquefied sand,
Cement, and pulp,
318
00:17:50,896 --> 00:17:54,862
Along with some additives,
Creating a fiber cement slurry.
319
00:17:54,862 --> 00:17:59,965
They pipe the cement slurry into
A trough beneath the sieves.
320
00:17:59,965 --> 00:18:02,413
As the sieves rotate
Through the slurry,
321
00:18:02,413 --> 00:18:04,931
Residual water
Drains through the mesh walls,
322
00:18:04,931 --> 00:18:08,275
Leaving a fiber cement film
On the surface.
323
00:18:08,275 --> 00:18:11,827
The film transfers
To a felt belt moving overhead.
324
00:18:11,827 --> 00:18:13,137
Through the felt,
325
00:18:13,137 --> 00:18:16,379
A vacuum mechanism sucks
More moisture from the film
326
00:18:16,379 --> 00:18:20,068
Until it forms
A solid fiber cement sheet.
327
00:18:20,068 --> 00:18:22,655
Rollers squeeze
Numerous sheets together.
328
00:18:22,655 --> 00:18:24,724
They're still moist enough
To stick together,
329
00:18:24,724 --> 00:18:27,586
And they fuse
Into one thick board.
330
00:18:27,586 --> 00:18:30,206
Another roller
Then presses a woodlike pattern
331
00:18:30,206 --> 00:18:32,413
Onto the surface
Of the cement board.
332
00:18:32,413 --> 00:18:35,655
A spray of high-pressure water
333
00:18:35,655 --> 00:18:38,241
Then slices the cement sheet
Into planks.
334
00:18:41,068 --> 00:18:44,517
A robotic suctioning head gently
Picks up the fiber cement planks
335
00:18:44,517 --> 00:18:47,310
And transfers them to a pallet.
336
00:18:47,310 --> 00:18:49,448
The planks are fragile
At this point
337
00:18:49,448 --> 00:18:51,448
And need to be handled
With care.
338
00:18:53,379 --> 00:18:54,965
Loaded into a pallet,
339
00:18:54,965 --> 00:19:00,068
The cement planks are now ready
For some toughening up.
340
00:19:00,068 --> 00:19:03,620
They bake the fiber cement
Siding inside steel tubes.
341
00:19:03,620 --> 00:19:06,379
They're autoclaves,
High-pressure ovens.
342
00:19:06,379 --> 00:19:08,586
Inside, pressurized steam
343
00:19:08,586 --> 00:19:12,517
Enhances the chemical reaction
Between the ingredients
344
00:19:12,517 --> 00:19:15,275
To cure the cement clapboard.
345
00:19:15,275 --> 00:19:19,172
They then load the pallets
Of cement siding onto a railcar,
346
00:19:19,172 --> 00:19:22,310
And it's on to the next station.
347
00:19:22,310 --> 00:19:26,551
Here, machinery does something
They call stack breaking.
348
00:19:26,551 --> 00:19:30,551
During curing, the siding
Planks get stuck together,
349
00:19:30,551 --> 00:19:33,241
So these hydraulic cylinders
Lift and jostle them
350
00:19:33,241 --> 00:19:36,620
To separate them
Into individual boards.
351
00:19:36,620 --> 00:19:39,620
They put a siding sample
To the test.
352
00:19:39,620 --> 00:19:42,000
With both sides
Of the board stabilized,
353
00:19:42,000 --> 00:19:46,034
A rod bends it at the center
To determine the stress point.
354
00:19:46,034 --> 00:19:48,344
If it can take
A lot of pressure,
355
00:19:48,344 --> 00:19:51,034
The whole production line
Moves forward.
356
00:19:51,034 --> 00:19:53,241
Spaced apart now,
357
00:19:53,241 --> 00:19:55,689
The fiber cement planks
Ride by sprayers
358
00:19:55,689 --> 00:20:00,000
That paint the sides and
The ends a nice shade of red.
359
00:20:00,000 --> 00:20:02,103
The siding
Then enters a curtain of paint
360
00:20:02,103 --> 00:20:03,965
Of the exact same color.
361
00:20:03,965 --> 00:20:08,344
The paint adheres
To the front of the boards.
362
00:20:10,448 --> 00:20:13,758
These mirrors
Expose any missed spots.
363
00:20:13,758 --> 00:20:17,275
If there are any,
They'll do touch-ups.
364
00:20:19,137 --> 00:20:22,586
The transformation from a pile
Of sand and other ingredients
365
00:20:22,586 --> 00:20:25,344
To something that looks
A lot like wood siding
366
00:20:25,344 --> 00:20:27,793
Has taken just three days,
367
00:20:27,793 --> 00:20:30,034
And once installed,
368
00:20:30,034 --> 00:20:33,655
These wood-look cement planks
Could fool the neighbors.
369
00:20:33,655 --> 00:20:38,482
After all, it's all about
Putting up a good facade.
370
00:20:51,517 --> 00:20:53,517
If you have any comments
About the show,
371
00:20:53,517 --> 00:20:56,551
Or if you'd like to suggest
Topics for future shows,
372
00:20:56,551 --> 00:20:58,344
Drop us a line at...
30075
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