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These are the user uploaded subtitles that are being translated: 1 00:00:46,965 --> 00:00:49,965 --Captions by VITAC-- www.vitac.com 2 00:00:49,965 --> 00:00:52,965 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 3 00:00:52,965 --> 00:00:55,482 Narrator: THERMOPLASTIC FIRE HELMETS ARE LIGHTWEIGHT, 4 00:00:55,482 --> 00:00:57,586 BUT THAT DOESN'T MEAN THEY AREN'T TOUGH. 5 00:00:57,586 --> 00:00:59,620 BECAUSE OF THEIR CHEMICAL COMPOSITION, 6 00:00:59,620 --> 00:01:00,896 THESE PLASTIC HELMETS 7 00:01:00,896 --> 00:01:03,724 REMAIN STURDY, EVEN WHEN EXPOSED TO TEMPERATURES 8 00:01:03,724 --> 00:01:06,103 OF OVER 500 DEGREES FAHRENHEIT. 9 00:01:06,103 --> 00:01:08,241 DEVELOPED IN THE 1970s, 10 00:01:08,241 --> 00:01:10,137 THE HELMETS HAVE BECOME STANDARD ISSUE 11 00:01:10,137 --> 00:01:12,413 AT MANY FIRE STATIONS. 12 00:01:13,793 --> 00:01:16,896 THERE ARE FEW SITUATIONS MORE DANGEROUS THAN ENTERING 13 00:01:16,896 --> 00:01:18,689 A BURNING BUILDING. 14 00:01:18,689 --> 00:01:21,620 THERMOPLASTIC FIRE HELMETS WEIGH SUBSTANTIALLY LESS 15 00:01:21,620 --> 00:01:23,172 THAN OTHER ALTERNATIVES. 16 00:01:23,172 --> 00:01:25,310 THESE HELMETS ARE ONE PIECE OF EQUIPMENT 17 00:01:25,310 --> 00:01:27,862 THAT WON'T SLOW DOWN THE RESCUE MISSION. 18 00:01:27,862 --> 00:01:32,172 PRODUCTION STARTS WITH A SPECIAL BLEND OF THERMOPLASTIC PELLETS. 19 00:01:32,172 --> 00:01:34,551 A VACUUM PULLS THE PELLETS INTO A HOPPER. 20 00:01:34,551 --> 00:01:38,241 THE PELLETS THEN FLOW INTO AN INJECTION-MOLDING MACHINE. 21 00:01:38,241 --> 00:01:43,517 IT MELTS AND MOLDS THE PELLETS INTO THE SHAPE OF A FIRE HELMET. 22 00:01:43,517 --> 00:01:45,137 A ROBOT RETRIEVES THE HELMET 23 00:01:45,137 --> 00:01:47,689 AND TRANSFERS IT TO A COOLING STATION. 24 00:01:51,379 --> 00:01:54,413 A WORKER THEN CLIPS OFF PLASTIC THAT SOLIDIFIED 25 00:01:54,413 --> 00:01:57,241 AS IT FLOWED THROUGH A CHANNEL AND INTO THE MOLD. 26 00:01:57,241 --> 00:02:00,896 THIS UNWANTED BIT IS CALLED SPRUE. 27 00:02:00,896 --> 00:02:03,896 SHE WIPES OFF FINGERPRINTS AND INSPECTS THE CONDITION 28 00:02:03,896 --> 00:02:05,413 OF THE HELMET SHELL. 29 00:02:09,275 --> 00:02:12,793 THE NEXT WORKER TRIMS THE BRIM TO REMOVE EXCESS PLASTIC 30 00:02:12,793 --> 00:02:15,000 THAT FORMED WHEN THE MOLD CLOSED. 31 00:02:15,000 --> 00:02:19,862 FOR THIS PROCESS, HE USES A BLADE WITH A CURVED EDGE. 32 00:02:19,862 --> 00:02:22,896 NEXT, HE APPLIES REFLECTIVE STRIPS 33 00:02:22,896 --> 00:02:26,172 THAT WILL ALLOW THE FIREFIGHTER TO BE SEEN IN THE DARK. 34 00:02:29,482 --> 00:02:33,896 HE DRILLS HOLES FOR ATTACHING EITHER GOGGLES OR FACE SHIELDS. 35 00:02:36,517 --> 00:02:40,275 AND THE WORKER ADDS A LAST REFLECTIVE STRIP. 36 00:02:40,275 --> 00:02:42,896 HE SCREWS A SUPPORT PLATE FOR THE I.D. SHIELD 37 00:02:42,896 --> 00:02:46,310 TO THE FRONT OF THE HELMET SHELL. 38 00:02:46,310 --> 00:02:49,172 HE USES PLASTIC SCREWS RATHER THAN METAL 39 00:02:49,172 --> 00:02:51,724 BECAUSE METAL IS ELECTRICALLY CONDUCTIVE 40 00:02:51,724 --> 00:02:53,517 AND WOULD PUT THE FIREFIGHTER AT RISK 41 00:02:53,517 --> 00:02:56,482 IN THE EVENT OF ELECTRICAL SPARKING DURING A FIRE. 42 00:03:05,137 --> 00:03:07,344 ANOTHER WORKER NOW APPLIES LABELS 43 00:03:07,344 --> 00:03:10,000 TO THE INSIDE OF THE HELMET SHELL. 44 00:03:12,448 --> 00:03:15,241 THE LABELS INDICATE THAT THIS MODEL OF FIRE HELMET 45 00:03:15,241 --> 00:03:19,931 IS IN COMPLIANCE WITH THE SAFETY REQUIREMENTS. 46 00:03:19,931 --> 00:03:22,862 THE WORKER INSERTS HIGH-DENSITY FOAM PADDING 47 00:03:22,862 --> 00:03:24,620 IN THE HELMET SHELL. 48 00:03:24,620 --> 00:03:26,655 THE PADDED CAP WILL CUSHION THE WEARER 49 00:03:26,655 --> 00:03:29,413 FROM THE FORCE OF AN IMPACT. 50 00:03:29,413 --> 00:03:32,862 THIS WEB OF STRAPS WILL SERVE AS A SUSPENSION LINER 51 00:03:32,862 --> 00:03:35,827 AND WILL ALSO SUPPORT THE HELMET ON THE WEARER'S HEAD. 52 00:03:40,068 --> 00:03:43,034 ANOTHER WORKER INSTALLS A RATCHET SYSTEM FOR ADJUSTING 53 00:03:43,034 --> 00:03:46,172 THE FIT OF THE LINER TO THE FIREFIGHTER'S HEAD. 54 00:03:46,172 --> 00:03:48,344 POSITIONED AT THE NAPE OF THE NECK, 55 00:03:48,344 --> 00:03:50,034 THE FIREFIGHTER CAN TURN THE KNOB 56 00:03:50,034 --> 00:03:53,448 TO PULL THE SUSPENSION WEB TIGHTER. 57 00:03:55,448 --> 00:03:58,137 ATTACHMENTS ON THE SUSPENSION LINER FIT INTO SOCKETS 58 00:03:58,137 --> 00:04:01,000 ON THE HELMET TO LOCK IT IN PLACE. 59 00:04:05,344 --> 00:04:07,931 HE FASTENS THE CHIN STRAP TO THE HELMET 60 00:04:07,931 --> 00:04:10,344 BY WRAPPING THE ENDS AROUND MOLDED STRUTS 61 00:04:10,344 --> 00:04:12,689 ON BOTH SIDES OF THE SHELL. 62 00:04:12,689 --> 00:04:15,310 THE CHIN STRAP HAS A QUICK-RELEASE BUTTON 63 00:04:15,310 --> 00:04:16,827 IN THE EVENT THAT THE FIREFIGHTER 64 00:04:16,827 --> 00:04:20,034 HAS TO REMOVE THE HELMET FAST. 65 00:04:23,655 --> 00:04:27,896 ANOTHER WORKER NOW FOLDS UP FLAME-RESISTANT EARFLAPS. 66 00:04:27,896 --> 00:04:29,482 THE FLAPS ARE EQUIPPED WITH HOOKED 67 00:04:29,482 --> 00:04:33,379 AND LOOPED FASTENING STRIPS THAT FIT TO THE HELMET. 68 00:04:33,379 --> 00:04:36,620 HE SETS THE EARFLAPS ASIDE WHILE HE INSERTS SNAPS 69 00:04:36,620 --> 00:04:39,206 FOR GOGGLES INTO BRACKETS ON THE HELMET. 70 00:04:45,344 --> 00:04:50,620 HE SCREWS THE SNAPS SNUGLY TO THE HELMET. 71 00:04:50,620 --> 00:04:53,758 THE WORKER THEN WRAPS THE FIRE-AND-FOG-RESISTANT GOGGLES 72 00:04:53,758 --> 00:04:57,000 AROUND THE HELMET AND SNAPS THEM TO IT. 73 00:05:01,103 --> 00:05:04,413 HE TUCKS THE MAINTENANCE INSTRUCTIONS INTO THE HELMET, 74 00:05:04,413 --> 00:05:08,482 FOLLOWED BY THE FOLDED EARFLAPS. 75 00:05:08,482 --> 00:05:12,068 THIS THERMOPLASTIC FIRE HELMET IS NOW COMPLETE, 76 00:05:12,068 --> 00:05:16,379 BUT THERE'S STILL ONE LAST BIT OF OFFICIAL BUSINESS. 77 00:05:16,379 --> 00:05:19,172 THE WORKER SCREWS THE LARGE LEATHER I.D. SHIELD 78 00:05:19,172 --> 00:05:20,724 TO THE SUPPORT PLATE. 79 00:05:20,724 --> 00:05:23,310 THE SHIELD BEARS THE NAME OF THE FIRE DEPARTMENT 80 00:05:23,310 --> 00:05:25,896 AND A SYMBOL THAT DENOTES RANK. 81 00:05:28,965 --> 00:05:32,379 THIS FIRE HELMET IS NOW READY FOR DUTY. 82 00:05:32,379 --> 00:05:34,862 IT WILL BE ONE OF THE FIRST THINGS THE FIREFIGHTER 83 00:05:34,862 --> 00:05:38,344 REACHES FOR WHEN HE OR SHE GETS AN EMERGENCY CALL. 84 00:05:52,931 --> 00:05:55,034 Narrator: CONTEMPORARY ARTISTS ARE CHALLENGING 85 00:05:55,034 --> 00:05:57,137 OUR PERCEPTION OF BASKETRY. 86 00:05:57,137 --> 00:05:59,827 FOCUSING ON FORM RATHER THAN FUNCTION, 87 00:05:59,827 --> 00:06:01,517 ARTISANS ARE WEAVING GRASSES 88 00:06:01,517 --> 00:06:04,000 AND OTHER FIBERS INTO SCULPTURAL ART. 89 00:06:04,000 --> 00:06:05,551 THESE BASKETRY SCULPTURES 90 00:06:05,551 --> 00:06:07,689 USUALLY AREN'T MEANT TO CONTAIN ANYTHING. 91 00:06:07,689 --> 00:06:12,206 INSTEAD, THEY'RE MEANT TO CAPTURE AND HOLD OUR ATTENTION. 92 00:06:15,275 --> 00:06:17,965 IS IT ART, OR IS IT A BASKET? 93 00:06:17,965 --> 00:06:20,413 A BASKETRY SCULPTURE IS BOTH. 94 00:06:20,413 --> 00:06:23,137 IT CELEBRATES THE TRADITION OF THE CRAFT 95 00:06:23,137 --> 00:06:27,310 WHILE ELEVATING BASKETRY TO AN ART FORM. 96 00:06:27,310 --> 00:06:29,275 MATERIALS FOR A BASKETRY SCULPTURE 97 00:06:29,275 --> 00:06:32,793 CAN INCLUDE A MIX OF THING, FROM NATURAL FIBERS, 98 00:06:32,793 --> 00:06:38,068 TO METALLIC PIECES, WIRE, AND BEADS. 99 00:06:38,068 --> 00:06:40,379 SOAKING FIBERS LIKE PALM-TREE STRANDS 100 00:06:40,379 --> 00:06:42,241 IN HOT WATER WILL SOFTEN THEM 101 00:06:42,241 --> 00:06:44,862 AND MAKE THE FIBERS FLEXIBLE ENOUGH FOR WEAVING, 102 00:06:44,862 --> 00:06:48,931 BUT THEY WON'T LOSE THEIR INTERESTING CRINKLY TEXTURE. 103 00:06:51,172 --> 00:06:54,275 ABOUT TWO HOURS IN, THE ARTIST CHECKS THE SUPPLENESS 104 00:06:54,275 --> 00:06:55,551 OF THE FIBERS. 105 00:06:55,551 --> 00:06:57,896 THEY CAN NOW BE BENT WITHOUT BREAKING, 106 00:06:57,896 --> 00:07:00,137 BUT THEY NEED A BIT MORE SOFTENING UP. 107 00:07:00,137 --> 00:07:03,620 SO SHE COVERS THE FIBERS WITH PLASTIC AND LEAVES THEM 108 00:07:03,620 --> 00:07:06,000 TO SOAK A LITTLE LONGER. 109 00:07:06,000 --> 00:07:09,172 SHE TURNS HER ATTENTION TO THE SCULPTURE'S CENTERPIECE, 110 00:07:09,172 --> 00:07:11,034 WHICH WILL BE MADE OF COPPER. 111 00:07:11,034 --> 00:07:12,482 SHE DRAWS A DESIGN 112 00:07:12,482 --> 00:07:16,275 ONTO THE COPPER'S PROTECTIVE PLASTIC LINER. 113 00:07:16,275 --> 00:07:19,689 USING METAL SHEARS, SHE CUTS OUT THE SHAPE. 114 00:07:24,586 --> 00:07:27,413 THE ARTIST PEELS OFF THE PLASTIC LINER 115 00:07:27,413 --> 00:07:29,137 THAT HAS PROTECTED THE COPPER, 116 00:07:29,137 --> 00:07:32,068 REVEALING THE GLOSSY, UNTARNISHED SURFACE. 117 00:07:38,206 --> 00:07:42,000 SHE NOW PLACES THE COPPER ABOVE A BAG FULL OF SMALL PELLETS 118 00:07:42,000 --> 00:07:46,206 AND POUNDS IT USING A NYLON MALLET. 119 00:07:46,206 --> 00:07:51,206 THIS PROCESS GIVES THE COPPER AN AGED, HAMMERED TEXTURE. 120 00:07:51,206 --> 00:07:54,413 SHE GIVES SOME AREAS ON THE OTHER SIDE THE SAME TREATMENT. 121 00:07:54,413 --> 00:08:00,206 THE HAMMERING ALSO BOWLS OUT THE PROFILE OF THE PIECE. 122 00:08:00,206 --> 00:08:02,758 USING A MARKER, THE ARTIST DRAWS A LINE 123 00:08:02,758 --> 00:08:05,724 ABOUT 1/3 OF AN INCH IN FROM THE EDGE. 124 00:08:10,931 --> 00:08:14,379 SHE MARKS DOTS ONTO THIS NEWLY DEFINED BORDER, 125 00:08:14,379 --> 00:08:16,862 SPACING THEM EVENLY APART. 126 00:08:21,241 --> 00:08:23,827 SHE THEN PUNCHES HOLES THROUGH ALL THE DOTS, 127 00:08:23,827 --> 00:08:26,620 USING A LEVER-OPERATED DRILL PRESS. 128 00:08:32,241 --> 00:08:34,931 SHE CUTS OUT THE SPACE BETWEEN THE HOLES, 129 00:08:34,931 --> 00:08:38,517 AND THIS PROCESS CREATES SEPARATE TABS FOR EACH HOLE. 130 00:08:38,517 --> 00:08:40,965 THE ARTISAN NOW BENDS BACK THE TABS, 131 00:08:40,965 --> 00:08:42,965 FOLLOWING THE MARKED LINE. 132 00:08:42,965 --> 00:08:47,310 THE APPLICATION OF A CLEAR POWDER COAT PREVENTS TARNISHING. 133 00:08:47,310 --> 00:08:49,620 AFTER A FEW HOURS, THE PALM STRANDS 134 00:08:49,620 --> 00:08:51,275 ARE NOW SUFFICIENTLY SOFTENED. 135 00:08:51,275 --> 00:08:53,827 SHE RETRIEVES THE STRANDS FROM THE HOT-WATER SOAK 136 00:08:53,827 --> 00:08:55,793 AND SETS THEM ASIDE. 137 00:08:55,793 --> 00:08:58,689 THE ARTIST RETURNS TO THE COPPER CENTERPIECE 138 00:08:58,689 --> 00:09:02,310 AND BEGINS TO WEAVE, STARTING WITH RATTAN REEDS 139 00:09:02,310 --> 00:09:05,413 THAT HAVE ALSO SOAKED TO MAKE THEM MORE PLIABLE. 140 00:09:05,413 --> 00:09:08,413 SHE PULLS THE REEDS THROUGH THE TABS AND INTERCROSSES THEM 141 00:09:08,413 --> 00:09:12,068 SO THAT THEY FAN OUT IN TWO DIRECTIONS. 142 00:09:12,068 --> 00:09:15,517 SHE THEN BRAIDS COTTON STRING AGAINST THE CENTERPIECE. 143 00:09:15,517 --> 00:09:19,034 THIS CREATES A NEAT AND STURDY BORDER ALL THE WAY AROUND. 144 00:09:21,241 --> 00:09:23,620 SHE CLIPS CLOTHESPINS TO THE RATTAN 145 00:09:23,620 --> 00:09:24,931 TO HOLD THE BRAIDED BORDER 146 00:09:24,931 --> 00:09:29,275 IN PLACE AGAINST THE CENTERPIECE. 147 00:09:29,275 --> 00:09:32,103 SHE THEN TRIMS THE ENDS OF THE STRINGS. 148 00:09:36,310 --> 00:09:39,000 NEXT, THE ARTIST WEAVES RATTAN REEDS 149 00:09:39,000 --> 00:09:41,000 PARALLEL TO THE COTTON BRAID, 150 00:09:41,000 --> 00:09:44,379 ENTWINING THEM WITH THE REEDS THAT EXTEND OUTWARD. 151 00:09:44,379 --> 00:09:49,275 SHE CREATES ONE ROW OF THESE RIGID FIBERS FOR STRUCTURE. 152 00:09:49,275 --> 00:09:51,931 SHE'S NOW READY FOR THE PALM STRANDS. 153 00:09:51,931 --> 00:09:53,862 AFTER THE SOAKING, THE STRANDS 154 00:09:53,862 --> 00:09:56,413 REMAIN SOFT AND PLIABLE FOR MANY HOURS, 155 00:09:56,413 --> 00:09:58,862 SO SHE DOESN'T HAVE TO RUSH THE WORK. 156 00:10:02,241 --> 00:10:05,310 AS SHE CONTINUES, SHE ALTERNATES ROWS OF PALM 157 00:10:05,310 --> 00:10:07,034 AND RATTAN FIBERS. 158 00:10:07,034 --> 00:10:09,551 THE DIFFERENT TEXTURES ADD VISUAL INTEREST 159 00:10:09,551 --> 00:10:13,448 TO THE BASKETRY SCULPTURE. 160 00:10:13,448 --> 00:10:17,482 IT WILL TAKE TWO MONTHS TO COMPLETE THIS WORK. 161 00:10:23,034 --> 00:10:25,241 WHEN THE BASKETRY WORK IS DONE, 162 00:10:25,241 --> 00:10:27,620 THE ARTIST TAKES THE PIECE OUTSIDE 163 00:10:27,620 --> 00:10:31,103 AND AIRBRUSHES THEM WITH ACRYLIC PAINT. 164 00:10:35,000 --> 00:10:37,344 SHE SOMETIMES RELIES ON A METAL TEMPLATE 165 00:10:37,344 --> 00:10:41,758 TO MORE EVENLY DEFINE THE PAINT BORDER. 166 00:10:41,758 --> 00:10:45,551 IT'S THE FINISHING TOUCH TO THE BASKETRY SCULPTURE, 167 00:10:45,551 --> 00:10:48,724 AND NOW IT'S UP TO THE PUBLIC TO UNDERSTAND THE STORY 168 00:10:48,724 --> 00:10:51,310 THAT THE ARTIST HAS WOVEN. 169 00:11:03,448 --> 00:11:06,896 Narrator: THE EARLIEST TOOLS FOR ROASTING COFFEE BEANS WERE PANS 170 00:11:06,896 --> 00:11:09,896 YOU WOULD HOLD OVER HOT COALS OR AN OPEN FIRE, 171 00:11:09,896 --> 00:11:11,655 BUT, TODAY, COFFEE ROASTING 172 00:11:11,655 --> 00:11:14,413 IS A FAR MORE SOPHISTICATED PROCESS, 173 00:11:14,413 --> 00:11:17,620 USING LARGE, OFTEN FULLY AUTOMATED MACHINES 174 00:11:17,620 --> 00:11:19,034 WITH BUILT-IN GAS BURNERS 175 00:11:19,034 --> 00:11:23,344 THAT HEAT AIR TO ROAST THE BEANS. 176 00:11:23,344 --> 00:11:26,000 THIS COFFEE ROASTER IS BOTH PROGRAMMABLE 177 00:11:26,000 --> 00:11:28,379 AND MANUALLY ADJUSTABLE BY TOUCH PANEL. 178 00:11:28,379 --> 00:11:31,620 THE ROAST MASTER CAN TAILOR THE TEMPERATURE 179 00:11:31,620 --> 00:11:34,137 AND ROASTING TIME TO INFLUENCE FLAVOR, 180 00:11:34,137 --> 00:11:37,655 ACIDITY, AND OTHER CHARACTERISTICS OF COFFEE. 181 00:11:37,655 --> 00:11:41,172 TO SHAPE THE ROAST CHAMBER, WORKERS FEED A SHEET 182 00:11:41,172 --> 00:11:44,793 OF STAINLESS STEEL THROUGH A SHEET-METAL ROLL. 183 00:11:44,793 --> 00:11:47,620 THE ROAST CHAMBER IS THE DRUM IN WHICH THE BEANS ROAST 184 00:11:47,620 --> 00:11:50,896 BY CONVECTION HEAT. 185 00:11:50,896 --> 00:11:54,758 THE NEXT STEP IS TO WELD THE ROLLED SHEET INTO A CYLINDER. 186 00:11:54,758 --> 00:11:58,689 THEN WORKERS GRIND AND POLISH THE WELDS UNTIL THEY'RE FLAT, 187 00:11:58,689 --> 00:12:00,896 SMOOTH, AND SHINY. 188 00:12:00,896 --> 00:12:04,000 ANOTHER WORKER MAKES THE COOLING TRAY IN A SIMILAR WAY, 189 00:12:04,000 --> 00:12:06,689 BUT WITH A SUPPORT BAND WELDED TO THE TOP. 190 00:12:06,689 --> 00:12:10,275 THE COOLING TRAY IS THE DRUM INTO WHICH THE HOT BEANS DROP 191 00:12:10,275 --> 00:12:12,103 WHEN THEY EXIT THE ROAST CHAMBER. 192 00:12:12,103 --> 00:12:16,068 STIRRING ARMS CIRCULATE THE BEANS AS A FAN DRAWS AIR 193 00:12:16,068 --> 00:12:18,413 THROUGH THE TRAY TO COOL THE HOT BEANS. 194 00:12:18,413 --> 00:12:20,413 CERTAIN PARTS OF THE ROASTER 195 00:12:20,413 --> 00:12:22,620 ARE CUT FROM A STAINLESS-STEEL SHEET. 196 00:12:22,620 --> 00:12:25,413 STAINLESS STEEL IS THE IDEAL MATERIAL 197 00:12:25,413 --> 00:12:27,241 NOT ONLY BECAUSE IT'S STYLISH, 198 00:12:27,241 --> 00:12:31,551 BUT ALSO BECAUSE IT'S DURABLE AND CORROSION-RESISTANT. 199 00:12:31,551 --> 00:12:33,827 THIS COMPUTER-GUIDED LASER CUTTER 200 00:12:33,827 --> 00:12:35,620 IS SLICING OUT A SAFETY COMPONENT 201 00:12:35,620 --> 00:12:38,931 CALLED THE HEAT SHIELD, WHICH PREVENTS THE ROAST MASTER 202 00:12:38,931 --> 00:12:41,724 FROM ACCIDENTALLY TOUCHING A HOT SURFACE. 203 00:12:43,793 --> 00:12:46,344 THE HEAT SHIELD, LIKE MANY OTHER PARTS 204 00:12:46,344 --> 00:12:48,413 CUT FROM STAINLESS-STEEL SHEETS, 205 00:12:48,413 --> 00:12:51,931 HAS TO BE FORMED TO A VERY PRECISE SHAPE. 206 00:12:51,931 --> 00:12:54,620 A WORKER BENDS ANGLES AND CURVES INTO THE METAL 207 00:12:54,620 --> 00:12:57,344 WITH A PRESS BRAKE. 208 00:12:57,344 --> 00:13:00,551 ANOTHER COMPONENT, THE TRIER, LETS YOU DRAW A SAMPLE 209 00:13:00,551 --> 00:13:03,448 OF BEANS DURING ROASTING. 210 00:13:03,448 --> 00:13:07,344 A CRAFTSMAN CONSTRUCTS THE TRIER BY WELDING VARIOUS SMALLER PARTS 211 00:13:07,344 --> 00:13:10,034 TO A PIECE OF STAINLESS-STEEL TUBE, 212 00:13:10,034 --> 00:13:11,931 THEN METICULOUSLY GRINDING 213 00:13:11,931 --> 00:13:15,862 AND POLISHING THE WELDS UNTIL THEY'RE SMOOTH. 214 00:13:15,862 --> 00:13:19,448 THIS HIGH-PRESSURE WATER-JET CUTTER ALSO CUTS PARTS 215 00:13:19,448 --> 00:13:21,655 FROM STAINLESS-STEEL SHEETS. 216 00:13:21,655 --> 00:13:24,000 THIS COMPONENT IS ONE OF SIX FLIGHTS, 217 00:13:24,000 --> 00:13:26,000 WHICH IS PART OF THE PADDLE THAT LIFTS 218 00:13:26,000 --> 00:13:28,517 AND MIXES THE BEANS INSIDE THE ROAST CHAMBER 219 00:13:28,517 --> 00:13:32,241 SO THAT THEY ROAST EVENLY. 220 00:13:32,241 --> 00:13:35,000 TO FORM THE FLIGHTS TO THE REQUIRED SHAPE, 221 00:13:35,000 --> 00:13:38,965 A WORKER CURVES THEM ONE AT A TIME IN A PRESS. 222 00:13:45,275 --> 00:13:48,758 NEXT, THE WELDER PLACES ALL THE PADDLE COMPONENTS 223 00:13:48,758 --> 00:13:50,620 INTO A SPECIALIZED FIXTURE, 224 00:13:50,620 --> 00:13:53,172 WHICH POSITIONS THEM CORRECTLY. 225 00:13:53,172 --> 00:13:56,310 FIRST, HE ALIGNS THE SPOKES TO THE PADDLE SHAFT. 226 00:13:56,310 --> 00:13:59,310 THEN HE WELDS THE PARTS IN PLACE. 227 00:14:02,655 --> 00:14:06,275 HE POSITIONS THE FLIGHTS, CLAMPS THEM SECURELY, 228 00:14:06,275 --> 00:14:09,034 AND WELDS THEM ON. 229 00:14:12,620 --> 00:14:14,931 THE COMBINATION OF INNER AND OUTER FLIGHTS 230 00:14:14,931 --> 00:14:17,034 LIFTS THE BEANS INTO THE AIRFLOW, 231 00:14:17,034 --> 00:14:19,793 ENSURING THE BEANS ROAST EVENLY. 232 00:14:21,689 --> 00:14:23,827 A CUSTOM-DESIGNED GRINDING MACHINE HONES 233 00:14:23,827 --> 00:14:26,172 THE FLIGHTS TO PRODUCE A SMALL CLEARANCE 234 00:14:26,172 --> 00:14:29,206 OF AROUND 1/10 OF AN INCH BETWEEN THE EDGE OF THE PADDLE 235 00:14:29,206 --> 00:14:32,000 AND THE WALL OF THE ROAST CHAMBER. 236 00:14:32,000 --> 00:14:35,275 THIS DESIGN ENSURES THE PADDLE IS WIDE ENOUGH TO PICK UP 237 00:14:35,275 --> 00:14:36,862 EVERY LAST COFFEE BEAN 238 00:14:36,862 --> 00:14:39,689 WITHOUT TOUCHING THE WALL WHILE ROTATING. 239 00:14:44,172 --> 00:14:47,482 ONCE THEY INSTALL THE PADDLE, A WORKER CLOSES UP 240 00:14:47,482 --> 00:14:49,655 THE ROAST CHAMBER WITH A FACEPLATE. 241 00:14:52,482 --> 00:14:54,655 ALIGNMENT PINS ENSURE THE FACEPLATE 242 00:14:54,655 --> 00:14:57,137 IS PROPERLY POSITIONED. 243 00:14:57,137 --> 00:14:59,000 THE PADDLE SHAFT PROTRUDES 244 00:14:59,000 --> 00:15:02,931 THROUGH A BEARING IN THE FACEPLATE. 245 00:15:02,931 --> 00:15:06,724 THE ASSEMBLY TEAM USES A HOIST TO LIFT THE HEAVY CHAMBER 246 00:15:06,724 --> 00:15:09,034 AND POSITION IT ON TOP OF THE COFFEE ROASTER'S 247 00:15:09,034 --> 00:15:13,034 STAINLESS-STEEL SUPPORT FRAME. 248 00:15:13,034 --> 00:15:16,172 THEY INSTALL THE HEAT SHIELD THAT WAS CUT BY THE LASER CUTTER 249 00:15:16,172 --> 00:15:19,137 AND BENT TO SHAPE IN THE PRESS BRAKE. 250 00:15:22,689 --> 00:15:24,827 ON TOP, THE ASSEMBLY TEAM MOUNTS 251 00:15:24,827 --> 00:15:26,620 THE MACHINE'S FUNNEL-SHAPED HOPPER. 252 00:15:26,620 --> 00:15:29,482 THE HOPPER FEEDS THE UNROASTED COFFEE BEANS 253 00:15:29,482 --> 00:15:33,275 TO THE ROAST CHAMBER BELOW. 254 00:15:33,275 --> 00:15:34,931 THE HOPPER'S LID HAS A TUBE, 255 00:15:34,931 --> 00:15:36,793 WHICH CONNECTS TO A VACUUM SYSTEM 256 00:15:36,793 --> 00:15:42,586 THAT DRAWS THE COFFEE BEANS UP THROUGH A PLASTIC HOSE. 257 00:15:42,586 --> 00:15:44,586 ON THE FRONT OF THE ROASTING CHAMBER, 258 00:15:44,586 --> 00:15:47,586 AN ASSEMBLER HANGS A HINGED DISCHARGE DOOR 259 00:15:47,586 --> 00:15:49,275 THAT HAS A VIEWING WINDOW. 260 00:15:49,275 --> 00:15:51,827 HE PLUGS IN A SENSOR THAT MEASURES THE TEMPERATURE 261 00:15:51,827 --> 00:15:53,931 OF THE BEANS IN THE ROASTING CHAMBER 262 00:15:53,931 --> 00:15:57,758 AND SENDS THAT INFORMATION TO THE MACHINE'S COMPUTER. 263 00:15:57,758 --> 00:16:00,793 MORE TO COME AFTER THIS COFFEE BREAK. 264 00:16:10,103 --> 00:16:11,896 Narrator: THIS COFFEE-ROASTING MACHINE 265 00:16:11,896 --> 00:16:13,965 HAS THREE ADDITIONAL TEMPERATURE SENSORS 266 00:16:13,965 --> 00:16:16,241 THAT SEND DATA TO THE COMPUTER. 267 00:16:16,241 --> 00:16:18,689 THESE SENSORS MEASURE THE TEMPERATURE OF THE AIR 268 00:16:18,689 --> 00:16:21,137 ENTERING AND EXITING THE ROAST CHAMBER 269 00:16:21,137 --> 00:16:22,689 AND THE TEMPERATURE OF THE CLEAN AIR 270 00:16:22,689 --> 00:16:24,517 EXHAUSTING FROM THE MACHINE 271 00:16:24,517 --> 00:16:27,172 AFTER THE BURNER INCINERATES THE SMOKE GENERATED 272 00:16:27,172 --> 00:16:30,448 BY THE ROASTING PROCESS. 273 00:16:30,448 --> 00:16:33,931 WORKERS CONTINUE ASSEMBLY BY INSTALLING THE COOLING TRAY 274 00:16:33,931 --> 00:16:37,310 BENEATH THE DISCHARGE DOOR OF THE ROASTING CHAMBER. 275 00:16:37,310 --> 00:16:39,586 THE COOLING TRAY SITS ON A SUPPORT FRAME, 276 00:16:39,586 --> 00:16:41,103 WHICH CONTAINS A MOTOR 277 00:16:41,103 --> 00:16:44,758 THAT TURNS THE STIRRING ARMS INSIDE THE TRAY. 278 00:16:44,758 --> 00:16:46,344 AT THE BACK OF THE MACHINE, 279 00:16:46,344 --> 00:16:49,000 A WORKER INSTALLS THE TRAY'S COOLING FAN 280 00:16:49,000 --> 00:16:52,689 AND THE MOTOR THAT DRIVES IT. 281 00:16:52,689 --> 00:16:55,206 THIS GAUGE MEASURES THE PRESSURE OF THE AIR 282 00:16:55,206 --> 00:16:58,793 THAT MIXES WITH THE GAS GOING INTO THE MACHINE'S BURNER. 283 00:17:05,000 --> 00:17:07,862 NEXT, THEY INSTALL THE CIRCULATION FAN. 284 00:17:07,862 --> 00:17:10,620 THE FAN IS DESIGNED TO WITHSTAND HIGH HEAT 285 00:17:10,620 --> 00:17:14,034 AND MOVE AIR EFFICIENTLY THROUGHOUT THE COFFEE ROASTER. 286 00:17:18,034 --> 00:17:20,517 THE BOTTOM END OF THIS STAINLESS-STEEL TUBE 287 00:17:20,517 --> 00:17:23,344 CONNECTS TO A VACUUM MOTOR. 288 00:17:23,344 --> 00:17:25,965 THE TOP END CONNECTS TO THE TUBE PROTRUDING 289 00:17:25,965 --> 00:17:28,275 FROM THE FEED HOPPER'S LID. 290 00:17:28,275 --> 00:17:29,793 TO FILL THE ROASTING CHAMBER, 291 00:17:29,793 --> 00:17:32,620 THE VACUUM MOTOR SUCKS THE RAW GREEN COFFEE BEANS 292 00:17:32,620 --> 00:17:34,379 UP INTO THE HOPPER, 293 00:17:34,379 --> 00:17:36,724 WHICH DROPS THE BEANS INTO THE CHAMBER, 294 00:17:36,724 --> 00:17:39,068 WHERE, AS THEY ROAST, THEIR PAPERY SKIN, 295 00:17:39,068 --> 00:17:42,551 CALLED THE CHAFF, BREAKS OFF. 296 00:17:42,551 --> 00:17:45,758 THIS SEPARATING DEVICE, KNOWN AS A CYCLONE, 297 00:17:45,758 --> 00:17:47,931 CONNECTS TO THE CIRCULATION FAN. 298 00:17:47,931 --> 00:17:50,965 THE FAN BLOWS HOT AIR RETURNING FROM THE ROASTING CHAMBER 299 00:17:50,965 --> 00:17:53,241 INTO THE CYCLONE AT HIGH VELOCITY. 300 00:17:53,241 --> 00:17:57,206 THE AIR CIRCULATES IN A DOWNWARD SPIRAL PAST THE BURNER 301 00:17:57,206 --> 00:18:01,137 AT THE BASE OF THE CYCLONE, INCINERATING THE SMOKE. 302 00:18:01,137 --> 00:18:05,000 THIS ALSO DRAWS THE CHAFF OUT OF THE AIR INTO A BARREL. 303 00:18:05,000 --> 00:18:07,655 NOZZLES SPRAY WATER ON THE CHAFF TO PREVENT IT 304 00:18:07,655 --> 00:18:08,965 FROM CATCHING FIRE, 305 00:18:08,965 --> 00:18:10,344 WHICH IS A COMMON HAZARD 306 00:18:10,344 --> 00:18:14,344 WITH TRADITIONAL COFFEE ROASTERS. 307 00:18:14,344 --> 00:18:17,758 THE CIRCULATION FAN THEN FORCES THE CLEAN, HOT AIR 308 00:18:17,758 --> 00:18:20,068 UP AND OUT THE TOP OF THE CYCLONE, 309 00:18:20,068 --> 00:18:22,482 THROUGH THIS "S"-SHAPED, INSULATED AIR DUCT, 310 00:18:22,482 --> 00:18:25,413 BACK INTO THE ROASTING CHAMBER. 311 00:18:28,517 --> 00:18:31,689 A TECHNICIAN IN THE FACTORY'S ELECTRICAL DEPARTMENT ASSEMBLES 312 00:18:31,689 --> 00:18:33,965 THE MACHINE'S CONTROL PANEL. 313 00:18:33,965 --> 00:18:35,344 AMONG OTHER COMPONENTS, 314 00:18:35,344 --> 00:18:37,724 THE CIRCUITRY RUNS CONTROL SYSTEMS 315 00:18:37,724 --> 00:18:39,793 AND THE MACHINE'S SIX ELECTRIC MOTORS, 316 00:18:39,793 --> 00:18:41,620 WHICH OPERATE MOVING PARTS, 317 00:18:41,620 --> 00:18:44,000 SUCH AS THE BEAN-DRAWING VACUUM MOTOR, 318 00:18:44,000 --> 00:18:46,068 THE CIRCULATION FAN, 319 00:18:46,068 --> 00:18:49,310 THE COOLING-TRAY FAN, THE ROASTING-CHAMBER PADDLE, 320 00:18:49,310 --> 00:18:51,620 AND COOLING-TRAY STIRRING ARMS. 321 00:18:56,344 --> 00:18:59,551 WORKERS THEN INSTALL THE CONTROL PANEL IN A CABINET 322 00:18:59,551 --> 00:19:03,172 ON THE SIDE OF THE MACHINE. 323 00:19:06,482 --> 00:19:08,862 THEY CONNECT ALL THE WIRES. 324 00:19:11,931 --> 00:19:14,137 THEY MOUNT THE MACHINE'S COMPUTER 325 00:19:14,137 --> 00:19:17,896 ADJACENT TO THE CONTROL-PANEL CABINET. 326 00:19:17,896 --> 00:19:21,827 NEXT, A WORKER ASSEMBLES THE COOLING-TRAY SYSTEM. 327 00:19:21,827 --> 00:19:25,034 A MOTOR UNDER THE TRAY DRIVES THE STIRRING ARMS. 328 00:19:25,034 --> 00:19:27,724 THE HOT ROASTED COFFEE BEANS SIT ON TOP 329 00:19:27,724 --> 00:19:29,413 OF THE STAINLESS-STEEL SCREEN. 330 00:19:29,413 --> 00:19:33,448 THE COOLING FAN PULLS AMBIENT AIR THROUGH THE BEANS, 331 00:19:33,448 --> 00:19:35,551 DOWN THROUGH THE OPENINGS OF THE SCREEN, 332 00:19:35,551 --> 00:19:39,793 THEN OUT AN EXHAUST PIPE TO THE OUTDOORS. 333 00:19:39,793 --> 00:19:42,517 THE STIRRING ARMS MOVE THE BEANS AROUND 334 00:19:42,517 --> 00:19:44,724 SO THAT THEY COOL QUICKLY AND EVENLY, 335 00:19:44,724 --> 00:19:48,172 WHICH PREVENTS THE BEANS FROM CONTINUING TO ROAST. 336 00:19:52,241 --> 00:19:54,689 THE FACTORY RUNS EVERY FINISHED COFFEE ROASTER 337 00:19:54,689 --> 00:19:57,448 THROUGH MULTIPLE TEST ROASTS. 338 00:19:57,448 --> 00:20:00,241 AFTER HEATING THE ROAST CHAMBER TO A SPECIFIC TEMPERATURE, 339 00:20:00,241 --> 00:20:03,034 THE OPERATOR USES THE TOUCH SCREEN TO RELEASE 340 00:20:03,034 --> 00:20:04,931 THE BEANS INTO THE CHAMBER. 341 00:20:04,931 --> 00:20:08,310 THE HOT AIR TRAVELS FROM THE CYCLONE TO THE ROAST CHAMBER, 342 00:20:08,310 --> 00:20:11,344 THEN THROUGH A RETURN PIPE BACK TO THE CYCLONE, 343 00:20:11,344 --> 00:20:15,655 WHERE IT'S CLEANED AND SENT BACK TO THE CHAMBER. 344 00:20:15,655 --> 00:20:18,620 TO KNOW WHEN TO MANUALLY END THE ROAST CYCLE, 345 00:20:18,620 --> 00:20:20,655 THE OPERATOR VIEWS, 346 00:20:20,655 --> 00:20:23,448 SMELLS, AND LISTENS TO THE BEANS. 347 00:20:23,448 --> 00:20:27,206 THAT'S BECAUSE COFFEE BEANS MAKE CRACKLING NOISES AS THEY EXPAND 348 00:20:27,206 --> 00:20:29,448 AND SHED THEIR CHAFF. 349 00:20:29,448 --> 00:20:32,758 THE MACHINE CAN ALSO BE SET TO END 350 00:20:32,758 --> 00:20:34,517 THE ROAST CYCLE AUTOMATICALLY 351 00:20:34,517 --> 00:20:37,551 WHEN THE BEANS REACH THEIR TARGET TEMPERATURE. 352 00:20:37,551 --> 00:20:40,551 A TRAPDOOR OPENS TO DRAW IN AMBIENT AIR. 353 00:20:40,551 --> 00:20:43,586 THIS COOLER AIR PUSHES SMOKE IN THE ROASTING CHAMBER 354 00:20:43,586 --> 00:20:46,000 UP TO THE CYCLONE FOR INCINERATION. 355 00:20:46,000 --> 00:20:48,275 THE COMPUTER CAN AUTOMATICALLY OPEN 356 00:20:48,275 --> 00:20:50,241 THE ROAST CHAMBER'S DISCHARGE DOOR, 357 00:20:50,241 --> 00:20:53,310 OR THE OPERATOR CAN DO SO MANUALLY. 358 00:20:53,310 --> 00:20:55,241 AS SOON AS THE ROASTED COFFEE BEANS 359 00:20:55,241 --> 00:20:56,689 DROP INTO THE COOLING TRAY, 360 00:20:56,689 --> 00:21:00,862 THE STIRRING ARMS AND COOLING FAN AUTOMATICALLY START UP. 361 00:21:00,862 --> 00:21:02,793 IF THE BEANS ARE PERFECTLY ROASTED, 362 00:21:02,793 --> 00:21:04,655 THE MACHINE IS READY TO BE SHIPPED 363 00:21:04,655 --> 00:21:07,275 TO A COFFEE-ROASTING BUSINESS. 29113

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