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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: TODAY ON
"HOW IT'S MADE"...
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THE INVENTION OF POLYURETHANE
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SKATEBOARD WHEELS
IN THE EARLY 1970s
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SUDDENLY MADE JUMPS
AND TIGHT CORNERING POSSIBLE
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BECAUSE THESE WHEELS HAD
A BETTER GRIP ON RIDING SURFACES
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00:01:04,310 --> 00:01:07,000
THAN THE OLD METAL
OR CERAMIC WHEELS.
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00:01:07,000 --> 00:01:08,241
THEY WERE MORE DURABLE,
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00:01:08,241 --> 00:01:11,137
AND THE SHOCK ABSORPTION
WAS GREATLY IMPROVED.
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00:01:13,965 --> 00:01:16,862
SKATEBOARD WHEELS COME
IN DIFFERENT SIZES,
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00:01:16,862 --> 00:01:19,551
HARDNESS, COLORS
AND GRAPHIC DESIGNS.
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00:01:19,551 --> 00:01:21,586
FOR THE RIDER,
THERE ARE MAY PRACTICAL
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00:01:21,586 --> 00:01:24,793
AND AESTHETIC CONSIDERATIONS.
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00:01:24,793 --> 00:01:29,068
MAKING SKATEBOARD WHEELS STARTS
WITH A COMPUTER DESIGN.
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00:01:29,068 --> 00:01:32,758
A DESIGNER USES THE SOFTWARE
TO GUIDE CUTTING TOOLS.
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00:01:32,758 --> 00:01:36,344
THE TOOLS CARVE
INTO A SOLID ALUMINUM PUCK
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00:01:36,344 --> 00:01:39,620
AND TRANSFORM IT
INTO ONE HALF OF A WHEEL MOLD.
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00:01:43,172 --> 00:01:46,068
NEXT, THE OTHER HALF
OF THE MOLD TAKES SHAPE
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00:01:46,068 --> 00:01:48,068
AS THE COMPUTERIZED
TOOLING SCULPTS
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00:01:48,068 --> 00:01:50,000
ANOTHER PUCK TO A PROFILE
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00:01:50,000 --> 00:01:52,448
THAT FITS TO THE FIRST
ONE PERFECTLY.
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00:01:56,000 --> 00:02:00,172
NOT ALL OF THE SKATEBOARD WHEEL
MOLDS ARE TWO-PART VERSIONS.
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00:02:00,172 --> 00:02:02,655
OTHERS ARE ONE-PIECE STRUCTURES,
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00:02:02,655 --> 00:02:07,241
EACH WITH A PIN IN THE CENTER
TO FORM A BEARING CAVITY.
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00:02:07,241 --> 00:02:10,413
A NOZZLE DISPENSES FRESHLY
MIXED POLYURETHANE LIQUID
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00:02:10,413 --> 00:02:12,931
INTO THE WHEEL MOLDS.
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00:02:12,931 --> 00:02:15,862
THE LIQUID STARTS
TO SOLIDIFY IMMEDIATELY.
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00:02:17,931 --> 00:02:19,793
TO COMPLETE THE PROCESS,
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00:02:19,793 --> 00:02:22,413
A WORKER LOADS
THE POLYURETHANE-FILLED MOLDS
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00:02:22,413 --> 00:02:24,172
INTO AN OVEN
AND BAKES THEM
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00:02:24,172 --> 00:02:28,103
AT ALMOST 240 DEGREES FAHRENHEIT
FOR 40 MINUTES.
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00:02:30,206 --> 00:02:33,724
DURING BAKING, ANY BUBBLES
IN THE POLYURETHANE RISE
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00:02:33,724 --> 00:02:35,689
TO THE TOP
AND ARE DIFFUSED,
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00:02:35,689 --> 00:02:40,206
LEAVING SOLID FORMS
WITH NO WEAK SPOTS.
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00:02:40,206 --> 00:02:43,275
WORKERS REMOVE THE PINS
FROM THE MOLDS.
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00:02:43,275 --> 00:02:45,448
THEN IT'S ON
TO THE NEXT STATION.
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HERE, A WORKER
BLASTS COMPRESSED AIR
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00:02:51,620 --> 00:02:54,137
BETWEEN THE WHEELS
AND THE MOLDS TO PRY
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00:02:54,137 --> 00:02:56,551
THE WHEELS FREE
AND POP THEM OUT.
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00:02:59,068 --> 00:03:02,379
ANOTHER WORKER PROBES THE WHEEL
USING A DUROMETER GAUGE
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00:03:02,379 --> 00:03:04,379
TO ENSURE THE URETHANE HAS CURED
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00:03:04,379 --> 00:03:07,172
TO THE RIGHT DEGREE OF HARDNESS.
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00:03:07,172 --> 00:03:09,620
IF THE SAMPLE WHEEL
IS SUFFICIENTLY HARD,
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00:03:09,620 --> 00:03:12,551
THE BATCH IS READY
FOR THE NEXT STEP.
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THE WORKER CLAMPS
THE SKATEBOARD WHEEL IN A LATHE.
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THE LATHE SPINS THE WHEEL
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00:03:17,241 --> 00:03:19,137
WHILE AN AUTOMATIC
CUTTER CONTOURS
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00:03:19,137 --> 00:03:22,344
THE EDGES TO A SOFTER,
MORE ROUNDED PROFILE.
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00:03:25,137 --> 00:03:28,379
TO GIVE THE SKATEBOARD
WHEELS SOME VISUAL IMPACT,
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00:03:28,379 --> 00:03:30,379
AN ARTISTS SELECTS
AND ARRANGES GRAPHIC
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DESIGNS ON A COMPUTER.
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HE PRINTS A FILM NEGATIVE
OF THE IMAGES HE'S CHOSEN.
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00:03:39,379 --> 00:03:42,448
A WORKER WILL USE THIS NEGATIVE
TO PRODUCE A PRINTING PLATE
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00:03:42,448 --> 00:03:44,482
FROM A PIECE OF METAL
THAT'S BEEN COATED
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00:03:44,482 --> 00:03:48,137
WITH A LIGHT-SENSITIVE
SUBSTANCE KNOWN AS EMULSION.
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00:03:48,137 --> 00:03:50,172
HE PLACES THE FILM NEGATIVE
ON THE PLATE
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00:03:50,172 --> 00:03:52,620
INSIDE A UV LIGHT CHAMBER.
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00:03:52,620 --> 00:03:56,344
HE CLOSES THE LID
AND ACTIVATES THE UV LIGHT.
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00:03:56,344 --> 00:03:58,448
THIS TRIGGERS
A PHOTOCHEMICAL REACTION
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00:03:58,448 --> 00:04:01,793
THAT TRANSFERS THE IMAGE
FROM THE NEGATIVE TO THE PLATE.
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00:04:04,551 --> 00:04:07,310
THE WORKER THEN APPLIES
A SOLUTION THAT REMOVES
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00:04:07,310 --> 00:04:09,965
UNEXPOSED EMULSION AND,
IN THE PROCESS,
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00:04:09,965 --> 00:04:14,413
ETCHES THE IMAGE
INTO THE PRINTING PLATE.
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00:04:14,413 --> 00:04:16,620
HE RINSES OFF THE CHEMICALS.
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00:04:19,620 --> 00:04:23,241
NEXT, HE DRIES THE PLATE
TO REVEAL THE ETCHED ARTWORK.
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00:04:25,620 --> 00:04:27,862
ANOTHER WORKER POSITIONS
A MAGNETIZED
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00:04:27,862 --> 00:04:29,413
INK CUP OVERVIEW THE IMAGE
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00:04:29,413 --> 00:04:32,000
AND INSTALLS IT
IN A PAD PRINTING MACHINE.
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00:04:34,965 --> 00:04:37,862
AN OPERATOR LOADS SKATEBOARD
WHEELS ONTO POSTS
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THAT INDEX THEM FORWARD
FOR PRINTING.
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00:04:44,448 --> 00:04:48,413
THE INK CUP DEPOSITS
INK ON THE PRINTING PLATE.
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00:04:48,413 --> 00:04:51,586
A SILICONE PAD PICKS UP
THE INKED IMAGE AND STAMPS
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00:04:51,586 --> 00:04:54,034
IT ONTO THE SKATEBOARD WHEEL.
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00:04:54,034 --> 00:04:57,000
THE OPERATOR REMOVES
THE PRINTED WHEEL
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00:04:57,000 --> 00:05:00,310
AND SETS IT ON A TRAY.
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00:05:00,310 --> 00:05:01,896
A TECHNICIAN NOW CLAMPS
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00:05:01,896 --> 00:05:03,758
ONE OF THE WHEELS
IN A TESTING DEVICE,
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00:05:03,758 --> 00:05:06,275
WHICH WILL GAUGE THE REBOUND.
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00:05:06,275 --> 00:05:09,310
HE DROPS A METAL BALL
ONTO THE WHEEL AND MEASURES
81
00:05:09,310 --> 00:05:13,000
HOW HIGH IT BOUNCES
OR REBOUNDS.
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00:05:13,000 --> 00:05:16,931
A HIGH REBOUND IS DESIRABLE.
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00:05:16,931 --> 00:05:21,482
THESE SKATEBOARD WHEELS
ARE NOW CLEARED FOR SHIPPING.
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00:05:21,482 --> 00:05:25,172
A WORKER WRAPS THE WHEELS
IN PLASTIC AND HEAT SHRINKS IT.
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IT TAKES ABOUT 3 DAYS
TO MAKE THESE SKATEBOARD WHEELS.
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00:05:31,655 --> 00:05:35,068
BUT HOW LONG THEY'LL
LAST DEPENDS A LOT ON THE RIDER
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00:05:35,068 --> 00:05:37,448
AND HOW HE OR SHE ROLLS.
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Narrator:
GALAKTOBOUREKO AND BAKLAVA
ARE TRADITIONAL GREEK DESSERTS.
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00:05:56,344 --> 00:05:58,931
ALTHOUGH SEVERAL EUROPEAN
AND MIDDLE EASTERN COUNTRIES
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00:05:58,931 --> 00:06:00,689
HAVE VERSIONS OF BAKLAVA,
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00:06:00,689 --> 00:06:02,724
MOST CONSIST OF FILO PASTRY
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00:06:02,724 --> 00:06:05,931
FILLED WITH NUTS DRENCHED
IN HONEY OR SYRUP.
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GALAKTOBOUREKO IS FILO FILLED
WITH CUSTARD
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00:06:08,758 --> 00:06:12,310
AND COATED WITH SWEET SYRUP.
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00:06:12,310 --> 00:06:15,137
THIS VARIETY OF BAKLAVA
CALLED BURMA
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00:06:15,137 --> 00:06:18,413
IS MADE NOT WITH FILO DOUGH,
LIKE CLASSIC BAKLAVA,
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00:06:18,413 --> 00:06:21,655
BUT WITH KATAIFI,
SHREDDED WHEAT DOUGH.
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00:06:21,655 --> 00:06:24,000
BURMA, LIKE CLASSIC
FILO BAKLAVA,
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00:06:24,000 --> 00:06:28,068
CONTAINS WHOLE PISTACHIOS,
NEVER PISTACHIO POWDER.
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00:06:28,068 --> 00:06:29,758
THIS BURMA CHEF POURS
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00:06:29,758 --> 00:06:32,931
GRANULATED SUGAR OVER
THE PISTACHIO KERNELS.
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00:06:32,931 --> 00:06:35,586
NEXT, HE SPRINKLES ROSE WATER,
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00:06:35,586 --> 00:06:37,931
ALTHOUGH THIS INGREDIENT
IS OPTIONAL,
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00:06:37,931 --> 00:06:40,034
THEN SYRUP MADE
WITH SUGAR,
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00:06:40,034 --> 00:06:42,586
WATER, CINNAMON AND NUTMEG
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00:06:42,586 --> 00:06:44,482
AS WELL AS LEMON
TO PREVENT THE SUGAR
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00:06:44,482 --> 00:06:47,172
FROM LATER CRYSTALLIZING.
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00:06:47,172 --> 00:06:50,068
HE MIXES BY HAND TO
THOROUGHLY COAT THE KERNELS.
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00:06:50,068 --> 00:06:54,896
THE KATAIFI IS MADE
OF ALL-PURPOSE FLOUR,
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00:06:54,896 --> 00:06:57,931
MILK AND WATER.
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00:06:57,931 --> 00:07:01,551
THE CHEF LAYS OUT
A SECTION OF DOUGH,
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00:07:01,551 --> 00:07:03,517
THEN TAKES A HANDFUL
OF PISTACHIO
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00:07:03,517 --> 00:07:05,655
FILLING AND PLACES
IT ON THE DOUGH,
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00:07:05,655 --> 00:07:08,689
FORMING A LINE
RUNNING DOWN THE MIDDLE.
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00:07:08,689 --> 00:07:10,344
FOR A BURMA LOAF THIS SIZE,
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00:07:10,344 --> 00:07:13,172
THE FILLING IS ABOUT
AN INCH WIDE AND HIGH.
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00:07:16,172 --> 00:07:19,793
HE FOLDS THE END CLOSED
AND ROLLS THE DOUGH AT AN ANGLE
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00:07:19,793 --> 00:07:21,275
DOWN THE LENGTH OF THE BURMA,
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00:07:21,275 --> 00:07:24,379
TIGHTLY ENCASING
THE FILLING AS HE GOES.
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00:07:27,068 --> 00:07:30,344
AT THE END, HE FOLDS
THE OPPOSITE END CLOSED.
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00:07:30,344 --> 00:07:35,068
IT TAKES A BURMA CHEF MONTHS
TO PERFECT THIS TECHNIQUE.
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00:07:35,068 --> 00:07:38,827
HE PLACES IT ON A TRAY
TO AIR-DRY FOR 24 HOURS
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00:07:38,827 --> 00:07:43,000
TO ENSURE THE DOUGH
MAINTAINS ITS ROLLED SHAPE.
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00:07:43,000 --> 00:07:47,137
UNLIKE CLASSIC BAKLAVA,
WHICH IS BAKED, BURMA IS FRIED.
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00:07:47,137 --> 00:07:49,241
AND THE RISK OF
BURNING THE PISTACHIOS
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00:07:49,241 --> 00:07:51,000
MAKES THIS THE MOST TECHNICALLY
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00:07:51,000 --> 00:07:53,689
CHALLENGING TYPE
OF BAKLAVA TO MAKE.
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00:07:53,689 --> 00:07:55,551
THE CHEF FRIES THE LOAVES
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00:07:55,551 --> 00:07:57,172
FOR 3 MINUTES IN OIL HEATED
130
00:07:57,172 --> 00:07:59,793
TO AROUND
350 DEGREES FAHRENHEIT,
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00:07:59,793 --> 00:08:02,241
TURNING THEM
ONCE PER MINUTE.
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00:08:02,241 --> 00:08:06,137
HE LETS THE OIL DRAIN
OFF FOR HALF AN HOUR.
133
00:08:06,137 --> 00:08:08,379
THEN, HE POURS
WARM CARAMELIZED
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00:08:08,379 --> 00:08:10,000
SUGAR OVER THE LOAVES
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00:08:10,000 --> 00:08:12,344
AND LETS THEM SOAK
FOR 20 MINUTES.
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00:08:12,344 --> 00:08:14,344
THE SUGAR-TO-WATER RATIO
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00:08:14,344 --> 00:08:16,206
AND THE BOILING TIME
OF THE CARAMELIZED
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00:08:16,206 --> 00:08:18,931
SUGAR HAVE TO BE JUST RIGHT.
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00:08:18,931 --> 00:08:21,344
OTHERWISE, IT WILL BECOME
EITHER TOO HARD
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00:08:21,344 --> 00:08:25,206
OR TO GOOEY WHEN IT COOLS.
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00:08:25,206 --> 00:08:27,172
AFTER LETTING
THE EXCESS DRAIN OFF,
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00:08:27,172 --> 00:08:31,931
THE LOAVES REST
FOR ABOUT 3 HOURS.
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00:08:31,931 --> 00:08:34,413
THEN THE CHEF ROLLS
THE LOAF TO FLATTEN
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00:08:34,413 --> 00:08:35,862
OUT THE BUMPS
145
00:08:35,862 --> 00:08:38,517
AND SLICES
IT INTO EQUAL PIECES.
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00:08:42,241 --> 00:08:43,965
BUT IF THERE'S
A PROTRACTED BATTLE
147
00:08:43,965 --> 00:08:48,206
WAGING BETWEEN YOUR SWEET
TOOTH AND YOUR WILLPOWER,
148
00:08:48,206 --> 00:08:49,620
YOU'VE GOT PLENTY OF TIME
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00:08:49,620 --> 00:08:51,896
TO WORK YOUR WAY
THROUGH A BOX OF BURMA
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00:08:51,896 --> 00:08:54,793
BECAUSE IT STAYS
FRESH FOR 2 WEEKS.
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00:08:58,965 --> 00:09:00,862
TO MAKE GALAKTOBOUREKO,
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00:09:00,862 --> 00:09:03,724
THE CHEF BEGINS
WITH TWO INGREDIENTS,
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00:09:03,724 --> 00:09:07,206
MILK AND SEMOLINA.
154
00:09:07,206 --> 00:09:09,241
AFTER BRINGING THE MILK
TO A BOIL,
155
00:09:09,241 --> 00:09:11,275
HE GRADUALLY ADDS THE SEMOLINA
156
00:09:11,275 --> 00:09:14,206
WHILE WHISKING AND LOWERING
THE TEMPERATURE.
157
00:09:14,206 --> 00:09:18,172
ONCE THE MIX THICKENS,
HE SETS IT ASIDE TO COOL.
158
00:09:18,172 --> 00:09:22,310
IN A SEPARATE BOWL,
THE CHEF WHISKS EGGS,
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00:09:22,310 --> 00:09:24,310
ADDS VANILLA,
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00:09:24,310 --> 00:09:26,620
THEN LEMON OR ORANGE RIND.
161
00:09:26,620 --> 00:09:31,172
OTHER OPTIONS ARE ORANGE
BLOSSOM OR ROSE WATER EXTRACT.
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00:09:31,172 --> 00:09:34,517
HE TRANSFERS THE INGREDIENTS
TO AN ELECTRIC MIXER,
163
00:09:34,517 --> 00:09:36,103
ADDS BUTTER AND SUGAR.
164
00:09:36,103 --> 00:09:39,275
THEN HE ADDS THE SEMOLINA
AND MILK MIXTURE.
165
00:09:39,275 --> 00:09:41,586
THIS MIXTURE MUST BE COOL
166
00:09:41,586 --> 00:09:45,275
SO THAT THE EGGS DON'T COOK.
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00:09:45,275 --> 00:09:47,344
ONCE EVERYTHING
IS THOROUGHLY BLENDED,
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00:09:47,344 --> 00:09:50,310
THE GALAKTOBOUREKO
CUSTARD IS READY.
169
00:09:53,413 --> 00:09:56,586
THE CHEF NOW TURNS HIS ATTENTION
TO THE FILO DOUGH.
170
00:09:56,586 --> 00:09:58,965
HE STACKS 24
PARCHMENT-THIN SHEETS
171
00:09:58,965 --> 00:10:02,655
OF FILO AND SLICES
THEM INTO SQUARES.
172
00:10:02,655 --> 00:10:04,551
HE PLACES ONE SCOOPFUL
OF CUSTARD
173
00:10:04,551 --> 00:10:06,137
IN THE CENTER OF EACH SQUARE.
174
00:10:06,137 --> 00:10:10,034
THE TRADITIONAL GREEK WAY
IS TO ROLL THE SQUARES
175
00:10:10,034 --> 00:10:13,068
OR BAKE A LARGE GALAKTOBOUREKO
IN A PAN
176
00:10:13,068 --> 00:10:15,241
AND THEN CUT IT
INTO SQUARES.
177
00:10:15,241 --> 00:10:17,586
HOWEVER, THIS CHEF FOLDS
OVER EACH SQUARE
178
00:10:17,586 --> 00:10:21,068
TO MAKE LEBANESE-STYLE
TRIANGLES.
179
00:10:21,068 --> 00:10:24,172
HE DOUSES THE TOP
WITH CLARIFIED BUTTER,
180
00:10:24,172 --> 00:10:27,137
BUTTER THAT'S BEEN BOILED
TO SEPARATE OUT THE SOLIDS
181
00:10:27,137 --> 00:10:29,241
AND LEAVE JUST THE OIL.
182
00:10:29,241 --> 00:10:30,620
THEN HE BAKES THE PASTRIES
183
00:10:30,620 --> 00:10:35,310
FOR 45 MINUTES
AT 325 DEGREES FAHRENHEIT.
184
00:10:35,310 --> 00:10:37,034
THE GOLDEN-BAKED TOP SHINES
185
00:10:37,034 --> 00:10:39,482
THANKS TO THE CLARIFIED BUTTER.
186
00:10:39,482 --> 00:10:42,862
THE CHEF COOKS THE SAME SYRUP
HE MADE FOR THE BAKLAVA,
187
00:10:42,862 --> 00:10:44,758
SUGAR, WATER, CINNAMON,
188
00:10:44,758 --> 00:10:46,275
NUTMEG AND LEMON
189
00:10:46,275 --> 00:10:47,655
AND GENEROUSLY DRIZZLES
190
00:10:47,655 --> 00:10:50,896
THE MIXTURE ALL OVER
THE GALAKTOBOUREKOS.
191
00:10:50,896 --> 00:10:53,586
HE SPRINKLES ON CINNAMON
FOR TRADITIONAL FLAVOR
192
00:10:53,586 --> 00:10:56,655
AND SOME CRUSHED PISTACHIOS
FOR DECORATION.
193
00:11:06,896 --> 00:11:10,137
Narrator: THE ANNUAL APPLE
HARVEST IS JUST 2 MONTHS LONG.
194
00:11:10,137 --> 00:11:13,068
TO KEEP APPLES FRESH
IN STORAGE FOR SEVERAL MONTHS,
195
00:11:13,068 --> 00:11:15,413
GROWERS LOWER THE STOREROOM
OXYGEN LEVEL
196
00:11:15,413 --> 00:11:17,724
TO PUT THE APPLES
INTO HIBERNATION.
197
00:11:17,724 --> 00:11:21,620
THEN THEY USE MACHINES
CALLED CO2 SCRUBBERS TO ABSORB
198
00:11:21,620 --> 00:11:25,448
AND REMOVE THE CARBON DIOXIDE
GAS THE APPLES GIVE OFF.
199
00:11:27,344 --> 00:11:29,275
THIS CO2 SCRUBBER PULLS AIR
200
00:11:29,275 --> 00:11:32,310
FROM THE AIRTIGHT APPLE STORAGE
ROOM THROUGH CARBON PELLETS,
201
00:11:32,310 --> 00:11:35,344
WHICH ABSORB THE CO2
GAS MOLECULES.
202
00:11:35,344 --> 00:11:38,275
THE MACHINE THEN BLOWS
THE CO2-FREE AIR
203
00:11:38,275 --> 00:11:40,586
BACK INTO THE ROOM.
204
00:11:40,586 --> 00:11:44,586
WORKERS BUILD THE MACHINE'S
FRAME OUT OF TUBULAR STEEL.
205
00:11:44,586 --> 00:11:46,827
THE FRAME SUPPORTS
ALL THE COMPONENTS,
206
00:11:46,827 --> 00:11:50,310
INCLUDING TWO SEALED VESSELS
FILLED WITH CARBON PELLETS.
207
00:11:50,310 --> 00:11:53,551
THE FIRST VESSEL
STARTS ABSORBING CO2,
208
00:11:53,551 --> 00:11:55,310
A PROCESS CALLED SCRUBBING,
209
00:11:55,310 --> 00:11:57,689
UNTIL ITS PELLETS
ARE SATURATED.
210
00:11:57,689 --> 00:12:00,793
THEN THE SECOND VESSEL
TAKES OVER THE SCRUBBING.
211
00:12:00,793 --> 00:12:02,931
THE FIRST VESSEL
AUTOMATICALLY KICKS
212
00:12:02,931 --> 00:12:04,827
INTO A REGENERATION CYCLE,
213
00:12:04,827 --> 00:12:07,517
WHICH BLOWS FRESH AIR
THROUGH THE PELLETS
214
00:12:07,517 --> 00:12:09,724
TO REMOVE THE CO2 MOLECULES
215
00:12:09,724 --> 00:12:11,793
AND EXHAUST THEM
OUT THE BUILDING.
216
00:12:11,793 --> 00:12:14,172
WHEN THE SECOND VESSEL'S
PELLETS MAX OUT,
217
00:12:14,172 --> 00:12:16,275
VESSEL ONE RESUMES SCRUBBING
218
00:12:16,275 --> 00:12:19,206
WHILE VESSEL TWO REGENERATES.
219
00:12:19,206 --> 00:12:21,103
TO CONSTRUCT EACH VESSEL,
220
00:12:21,103 --> 00:12:24,448
WORKERS WELD A STEEL SHEET
INTO A CIRCULAR SHAPE,
221
00:12:24,448 --> 00:12:27,586
THEN WELD ON A BASE
AND A TOP RING.
222
00:12:27,586 --> 00:12:29,793
THE RING HAS HOLES
ALONG ITS PERIMETER
223
00:12:29,793 --> 00:12:31,517
FOR BOLTING ON A LID.
224
00:12:31,517 --> 00:12:33,034
THEY USE A RING TEMPLATE
225
00:12:33,034 --> 00:12:35,793
TO MAKE CORRESPONDING
HOLES IN THE LID,
226
00:12:35,793 --> 00:12:40,379
MAKING THE EXACT CENTER
OF EACH HOLE WITH A PUNCH TOOL.
227
00:12:40,379 --> 00:12:43,551
THEN A WORKER MOUNTS
THE LID ON A FIXTURE
228
00:12:43,551 --> 00:12:45,275
AND FOLLOWING THOSE MARKS,
229
00:12:45,275 --> 00:12:48,724
USES AN AUTOMATED STEEL
PUNCH TO PERFORATE THE STEEL.
230
00:12:55,137 --> 00:12:56,724
THE VESSELS GO TO
THE PAINT BOOTH
231
00:12:56,724 --> 00:12:58,689
FOR A COAT OF POWDER PAINT,
232
00:12:58,689 --> 00:13:01,758
THEN INTO AN OVEN
TO BAKE THE PAINT.
233
00:13:01,758 --> 00:13:03,862
WHEN THEY COME OUT,
THE VESSELS ARE READY
234
00:13:03,862 --> 00:13:06,965
TO BE FILLED WITH CARBON
PELLETS AND SEALED.
235
00:13:09,793 --> 00:13:13,586
ONCE FILLED TO THE TOP,
WORKERS LAY IN A STEEL BAFFLE.
236
00:13:15,931 --> 00:13:19,482
ITS HOLES EVENLY DISTRIBUTE
AIR PASSING THROUGH THE VESSEL.
237
00:13:21,034 --> 00:13:23,344
A WORKER THEN PLACES
A FOAM RUBBER GASKET
238
00:13:23,344 --> 00:13:27,103
AROUND THE PERIMETER
239
00:13:27,103 --> 00:13:29,413
AND BOLTS ON THE LID TIGHTLY.
240
00:13:29,413 --> 00:13:32,551
THIS SEALS THE VESSEL
AND PREVENTS THE AIR
241
00:13:32,551 --> 00:13:35,068
BEING BLOWN THROUGH IT
FROM LEAKING OUT.
242
00:13:35,068 --> 00:13:37,517
THE SEALED LID
ALSO PREVENTS OXYGEN
243
00:13:37,517 --> 00:13:39,241
FROM GETTING INTO THE MACHINE
244
00:13:39,241 --> 00:13:42,379
AND FROM THERE INTO
THE APPLE STORAGE ROOM.
245
00:13:42,379 --> 00:13:44,551
NEXT, WORKERS INSTALL THE PVC
246
00:13:44,551 --> 00:13:45,827
PIPING THAT FEEDS AIR
247
00:13:45,827 --> 00:13:49,275
THROUGH THE VESSELS
ALONG WITH TWO BLOWERS.
248
00:13:49,275 --> 00:13:51,931
ONE BLOWER PULLS AIR
FROM THE APPLE STORAGE ROOM
249
00:13:51,931 --> 00:13:54,034
INTO THE MACHINE FOR SCRUBBING.
250
00:13:54,034 --> 00:13:57,068
THE OTHER SENDS IT BACK
TO THE ROOM AFTER SCRUBBING.
251
00:13:59,275 --> 00:14:03,137
THE AIR FLOW THROUGH THE PIPES
IS CONTROLLED BY VALVES,
252
00:14:03,137 --> 00:14:06,965
WHICH ARE WIRED TO THE MACHINE'S
ELECTRICAL PANEL.
253
00:14:06,965 --> 00:14:10,758
THAT ELECTRICAL PANEL,
CONSISTING OF RELAYS, PUMPS,
254
00:14:10,758 --> 00:14:13,034
GAS ANALYZERS
AND A TOUCH SCREEN,
255
00:14:13,034 --> 00:14:16,517
IS BUILT IN-HOUSE
IN ACCORDANCE
256
00:14:16,517 --> 00:14:18,241
WITH THE REQUIRED
ELECTRICAL STANDARDS
257
00:14:18,241 --> 00:14:20,379
OF THE CUSTOMER'S COUNTRY.
258
00:14:20,379 --> 00:14:23,448
THE PANEL IS WIRED
TO A COMPUTER
259
00:14:23,448 --> 00:14:26,068
WHICH CONTROLS
THE ENTIRE OPERATION.
260
00:14:29,724 --> 00:14:32,517
THEN A WORKER INSTALLS
AN ELECTRICAL BOX
261
00:14:32,517 --> 00:14:34,379
INTO THE MACHINE'S FRAME.
262
00:14:39,862 --> 00:14:41,862
AND HE INSTALLS
THE ELECTRICAL PANEL
263
00:14:41,862 --> 00:14:44,379
INSIDE THE BOX.
264
00:14:48,862 --> 00:14:52,275
NEXT, THE WORKER CONNECTS
THE WIRES TO THE VALVES,
265
00:14:52,275 --> 00:14:55,448
INSTALLS THE TOUCH SCREEN
AND HOOKS IT UP TO THE COMPUTER.
266
00:14:55,448 --> 00:14:58,172
THE TOUCH SCREEN
LETS THE MACHINE'S OPERATOR
267
00:14:58,172 --> 00:15:02,206
PROGRAM OXYGEN
AND CO2 TARGET LEVELS
268
00:15:02,206 --> 00:15:05,413
SPECIFIC TO THE TYPE OF APPLE
STORED IN THE ROOM.
269
00:15:05,413 --> 00:15:06,862
THIS IS CRITICAL,
270
00:15:06,862 --> 00:15:10,758
AS DIFFERENT VARIETIES OF APPLES
GIVE OFF MORE CO2 THAN OTHERS.
271
00:15:13,000 --> 00:15:14,655
HOW DOES IT ALL WORK?
272
00:15:14,655 --> 00:15:16,620
THE GROWER STACKS
BINS OF APPLES
273
00:15:16,620 --> 00:15:19,068
IN AN AIRTIGHT STOREROOM.
274
00:15:19,068 --> 00:15:21,896
A NITROGEN GENERATOR
FEEDS IN NITROGEN
275
00:15:21,896 --> 00:15:26,103
TO REDUCE THE ROOM'S OXYGEN
LEVEL TO 1.8%.
276
00:15:26,103 --> 00:15:27,413
WHEN THAT HAPPENS,
277
00:15:27,413 --> 00:15:30,137
THE NITROGEN FEED
AUTOMATICALLY STOPS,
278
00:15:30,137 --> 00:15:34,931
AND THE CONTINUOUS CO2 SCRUBBING
AUTOMATICALLY BEGINS.
279
00:15:34,931 --> 00:15:37,206
MANY GROWERS HAVE IN-HOUSE LABS
280
00:15:37,206 --> 00:15:40,068
WHICH CONDUCT QUALITY
CONTROL TESTS ON SAMPLES
281
00:15:40,068 --> 00:15:42,000
TAKEN FROM EACH LOT
OF SCRUBBED APPLES
282
00:15:42,000 --> 00:15:44,724
COMING OUT OF STORAGE.
283
00:15:44,724 --> 00:15:47,000
NO APPLES WOULD PASS
THESE TESTS AFTER
284
00:15:47,000 --> 00:15:48,724
THE 2-MONTH HARVEST SEASON
285
00:15:48,724 --> 00:15:51,586
IF NOT FOR THE CO2 SCRUBBERS.
286
00:15:51,586 --> 00:15:54,344
CO2 SCRUBBERS LENGTHEN
AN APPLE'S FRESHNESS
287
00:15:54,344 --> 00:15:55,965
BY ABOUT 8 MONTHS,
288
00:15:55,965 --> 00:15:59,862
MAKING IT POSSIBLE TO BITE INTO
CRISPY APPLES YEAR-ROUND.
289
00:16:10,620 --> 00:16:13,000
NARRATOR: HONEYCOMB CANDLES ARE
GLOWING REMINDERS
290
00:16:13,000 --> 00:16:15,275
OF THE CLEVERNESS
OF THE HONEYBEE.
291
00:16:15,275 --> 00:16:18,344
THESE CANDLES ARE EMBOSSED
WITH A HEXAGONAL PATTERN
292
00:16:18,344 --> 00:16:21,931
THAT MIMICS THE CELL STRUCTURES
BEES BUILD TO STORE THEIR HONEY.
293
00:16:21,931 --> 00:16:23,896
AND INTERESTINGLY,
THESE CANDLES
294
00:16:23,896 --> 00:16:26,586
ARE ACTUALLY MADE
FROM THE WAX FOUNDATION SHEETS
295
00:16:26,586 --> 00:16:29,344
USED FOR BEEKEEPERS'
HIVE FRAMES.
296
00:16:32,103 --> 00:16:34,965
HONEYCOMB CANDLES CREATE
A CERTAIN AMBIANCE.
297
00:16:34,965 --> 00:16:36,310
THEY SHINE BRIGHTLY.
298
00:16:36,310 --> 00:16:37,724
AND THE HEXAGONAL PATTERN
299
00:16:37,724 --> 00:16:41,241
THAT'S BORROWED FROM THE BEES
ADDS VISUAL INTEREST.
300
00:16:41,241 --> 00:16:43,655
THE CANDLE MAKERS
START WITH BEESWAX
301
00:16:43,655 --> 00:16:45,896
THAT HAS HAD
THE IMPURITIES FILTERED OUT
302
00:16:45,896 --> 00:16:47,758
AND HAS BEEN BLEACHED.
303
00:16:47,758 --> 00:16:49,965
A WORKER FIRST POURS THE BEESWAX
304
00:16:49,965 --> 00:16:54,551
INTO A BIG GAS-HEATED KETTLE
UNTIL IT MELTS.
305
00:16:54,551 --> 00:16:55,793
IT ONLY TAKES AROUND 1/10
306
00:16:55,793 --> 00:16:57,206
OF AN OUNCE OF POWDERED DYE
307
00:16:57,206 --> 00:17:00,655
TO TINT THE BIG VAT OF WAX.
308
00:17:00,655 --> 00:17:02,965
HE MEASURES
THE AMOUNT CAREFULLY.
309
00:17:05,379 --> 00:17:07,344
THE WORKER ADDS THE DYE AND,
310
00:17:07,344 --> 00:17:09,793
AS IT DISSOLVES
IN THE LIQUID BEESWAX,
311
00:17:09,793 --> 00:17:12,275
HE STIRS IT TO DISTRIBUTE
IT EVENLY.
312
00:17:14,655 --> 00:17:16,172
HE THEN OPENS A VALVE,
313
00:17:16,172 --> 00:17:19,551
AND THE WAX FLOWS INTO
A TROUGH BENEATH A LARGE DRUM.
314
00:17:22,517 --> 00:17:26,103
THIS DRUM IS COOLED
BY A SYSTEM OF CHILLERS.
315
00:17:26,103 --> 00:17:28,896
AS IT ROTATES,
IT PICKS UP THE WAX.
316
00:17:28,896 --> 00:17:31,310
AND THE WAX SOLIDIFIES
ON CONTACT
317
00:17:31,310 --> 00:17:33,724
WITH THE DRUM'S COOL SURFACE.
318
00:17:33,724 --> 00:17:35,758
THE SYSTEM THEN PULLS
THE WAX SHEETS
319
00:17:35,758 --> 00:17:40,034
THROUGH A NARROW APERTURE
TO SQUEEZE IT THINNER.
320
00:17:40,034 --> 00:17:41,620
AT THIS POINT,
THE CONSISTENCY
321
00:17:41,620 --> 00:17:45,068
OF THE WAX IS SIMILAR
TO THAT OF TAFFY.
322
00:17:45,068 --> 00:17:48,413
BUT UNLIKE TAFFY,
IT'S NOT VERY STICKY,
323
00:17:48,413 --> 00:17:51,931
SO THE LAYERS DON'T ADHERE
WHEN ROLLED ONTO A SHAFT.
324
00:17:54,551 --> 00:17:56,482
THE NEXT MEMBER OF THE TEAM
325
00:17:56,482 --> 00:17:59,310
NOW PREPARES A BATH
OF WARM WATER AND SOAP.
326
00:18:01,482 --> 00:18:05,620
HE THEN LOOSENS UP
THE COIL OF BEESWAX BY HAND.
327
00:18:05,620 --> 00:18:08,413
THE ROLL SLACKENS.
328
00:18:08,413 --> 00:18:09,896
THE WAX LAYERS SEPARATE,
329
00:18:09,896 --> 00:18:12,241
LEAVING SPACES BETWEEN THEM.
330
00:18:14,724 --> 00:18:16,965
HE IMMERSES THE WAX
IN WARM WATER.
331
00:18:16,965 --> 00:18:19,448
AND IT FLOWS
BETWEEN THE LAYERS.
332
00:18:19,448 --> 00:18:21,793
THE WARM WATER
SOFTENS THE EDGES
333
00:18:21,793 --> 00:18:23,827
AS A THINNING MACHINE
REDUCES THE THICKNESS
334
00:18:23,827 --> 00:18:27,448
OF THE WAX BY HALF.
335
00:18:27,448 --> 00:18:28,793
USING BLOCKS OF ICE,
336
00:18:28,793 --> 00:18:31,413
THE OPERATOR THEN COOLS
THE SOFTENED WAX
337
00:18:31,413 --> 00:18:34,655
TO FIRM IT UP AGAIN.
338
00:18:34,655 --> 00:18:38,448
HE CONSTANTLY ADDS LIQUID
SOAP FOR LUBRICATION.
339
00:18:38,448 --> 00:18:41,551
THIS KEEPS THE BEESWAX MOVING
THROUGH THE THINNING MACHINE
340
00:18:41,551 --> 00:18:43,344
AND PREVENTS SNAGS.
341
00:18:45,517 --> 00:18:47,965
USING A MEASURING INSTRUMENT
CALLED A CALIPER,
342
00:18:47,965 --> 00:18:50,448
HE GAUGES THE THICKNESS
OF THE WAX TO CONFIRM
343
00:18:50,448 --> 00:18:53,000
THAT IT'S 0.16
OF A CENTIMETER.
344
00:18:55,482 --> 00:18:58,689
NEXT, THE OPERATOR REMOVES
THE ROLL OF BEESWAX
345
00:18:58,689 --> 00:19:01,517
FROM THE THINNING MACHINE
SPINDLE AND TRANSFERS IT
346
00:19:01,517 --> 00:19:03,586
TO THE SPINDLE
FOR THE NEXT MACHINE.
347
00:19:05,620 --> 00:19:08,620
THIS MACHINE PULLS THE WAX
THROUGH A BATH OF ICY WATER
348
00:19:08,620 --> 00:19:10,965
TO FIRM IT UP EVEN MORE.
349
00:19:10,965 --> 00:19:12,413
THIS WILL TOP THE WAX
350
00:19:12,413 --> 00:19:14,689
FROM STICKING
TO EMBOSSING ROLLERS
351
00:19:14,689 --> 00:19:18,758
THAT NOW IMPRESS
THE HEXAGONAL PATTERN ONTO IT.
352
00:19:18,758 --> 00:19:20,206
EACH OF THE EMBOSSING ROLLERS
353
00:19:20,206 --> 00:19:24,448
IS STUDDED WITH 3,500
HEXAGONAL-SHAPED RIVETS.
354
00:19:24,448 --> 00:19:28,034
THEY STAMP THE PATTERN
ONTO BOTH SIDES OF THE WAX.
355
00:19:28,034 --> 00:19:31,206
A BLADE SLICES THE EMBOSSED
BEESWAX INTO SHEETS
356
00:19:31,206 --> 00:19:35,517
THAT ARE 16 INCHES IN LENGTH.
357
00:19:35,517 --> 00:19:38,034
THE SHEETS PASS
UNDER ANOTHER ROLLER.
358
00:19:38,034 --> 00:19:41,034
AND THIS ONE PROPELS THEM
OFF THE TRACK.
359
00:19:41,034 --> 00:19:43,068
THE SHEETS ARE BRIEFLY AIRBORNE
360
00:19:43,068 --> 00:19:45,413
AND THEN,
THEY LAND IN A NEAT STACK.
361
00:19:53,275 --> 00:19:55,068
TO MAKE THEM INTO CANDLES,
362
00:19:55,068 --> 00:19:57,241
ANOTHER MEMBER OF THE TEAM
CUTS THE SHEETS
363
00:19:57,241 --> 00:20:00,586
TO THE DESIRED LENGTH AND WIDTH.
364
00:20:00,586 --> 00:20:02,310
THE DIMENSIONS
WILL VARY DEPENDING ON
365
00:20:02,310 --> 00:20:04,551
THE SIZE OF
THE CANDLES TO BE MADE.
366
00:20:07,689 --> 00:20:09,689
LEFTOVER REMNANTS
WILL BE MELTED DOWN
367
00:20:09,689 --> 00:20:11,448
TO MAKE NEW CANDLES.
368
00:20:13,517 --> 00:20:16,896
THESE BEESWAX SHEETS ARE NOW
READY TO BE ROLLED BY HAND.
369
00:20:19,000 --> 00:20:20,275
THE CANDLE MAKER PLACES
370
00:20:20,275 --> 00:20:24,206
A COTTON WICK
ON ONE EDGE OF THE SHEET.
371
00:20:24,206 --> 00:20:27,068
SHE THEN WRAPS THE WAX
AROUND THE WICK,
372
00:20:27,068 --> 00:20:29,758
APPLYING GENTLE PRESSURE
AS SHE WORKS.
373
00:20:31,862 --> 00:20:34,034
SHE PRESSES THE LAYERS
FIRMLY TOGETHER
374
00:20:34,034 --> 00:20:35,862
BECAUSE THE TIGHTER THE ROLL,
375
00:20:35,862 --> 00:20:37,586
THE LONGER THE CANDLE WILL BURN.
376
00:20:39,586 --> 00:20:41,655
AT ROOM TEMPERATURE,
THE WAX IS WARM,
377
00:20:41,655 --> 00:20:44,172
SO THE LAYERS
OF THE CANDLE ADHERE.
378
00:20:46,551 --> 00:20:50,068
FINALLY, SHE PACKAGES THEM
IN PLASTIC CELLOPHANE
379
00:20:50,068 --> 00:20:53,586
AND APPLIES
ALL THE NECESSARY LABELS.
380
00:20:53,586 --> 00:20:55,482
THESE HONEYCOMB BEESWAX CANDLES
381
00:20:55,482 --> 00:20:57,620
ARE NOW READY
TO LIGHT UP A SPACE
382
00:20:57,620 --> 00:20:59,793
AND HELP SET THE MOOD.
383
00:20:59,793 --> 00:21:02,482
THEY SHOULD BURN
FOR 8 OR 9 HOURS
384
00:21:02,482 --> 00:21:05,000
OR UNTIL IT'S TIME
TO CALL IT A NIGHT.
29833
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