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--Captions by VITAC--
www.vitac.com
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00:00:20,448 --> 00:00:22,310
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:22,310 --> 00:00:25,965
Narrator: TODAY ON
"HOW IT'S MADE" --
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00:00:25,965 --> 00:00:28,000
PéTANQUE BALLS...
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BIOLOGIC MEDICINES...
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ASPHALT PAVERS...
7
00:00:44,068 --> 00:00:45,793
...AND BASQUE ESPADRILLES.
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00:00:52,482 --> 00:00:56,034
THE FRENCH GAME OF PéTANQUE
IS SOMEWHAT SIMILAR
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00:00:56,034 --> 00:00:58,068
TO THE ITALIAN GAME OF BOCCE
10
00:00:58,068 --> 00:01:00,517
AND THE BRITISH GAME
OF LAWN BOWLING.
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00:01:00,517 --> 00:01:02,655
IT'S PLAYED WITH
HOLLOW STEEL BALLS
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00:01:02,655 --> 00:01:06,379
CALLED BOULES
ON A DIRT OR GRAVEL SURFACE.
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00:01:06,379 --> 00:01:08,896
THE OBJECT OF THE GAME
IS TO TOSS THE BALLS
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00:01:08,896 --> 00:01:13,620
AS CLOSE AS POSSIBLE
TO A SMALL WOODEN BALL.
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00:01:13,620 --> 00:01:17,344
THE FIRST PéTANQUE PLAYERS
CARVED THEIR BALLS FROM WOOD.
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00:01:17,344 --> 00:01:20,655
BY THE LATE 1800s,
PLAYERS HAMMERED IN NAILS
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00:01:20,655 --> 00:01:22,379
TO MAKE THEIR BALLS HEFTIER
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00:01:22,379 --> 00:01:25,586
AND LESS LIKELY TO CRACK
WHEN HITTING OTHER BALLS.
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THEN CAME BRASS BALLS
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00:01:27,137 --> 00:01:29,827
AND LATER THE HOLLOW
STEEL BALLS USED TODAY.
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00:01:31,517 --> 00:01:34,586
MANUFACTURING BEGINS
WITH LONG BARS OF CARBON
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00:01:34,586 --> 00:01:36,000
OR STAINLESS STEEL,
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00:01:36,000 --> 00:01:38,586
ABOUT 1 1/2 INCHES IN DIAMETER.
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00:01:38,586 --> 00:01:40,275
THIS IS STAINLESS STEEL.
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00:01:40,275 --> 00:01:45,137
AN AUTOMATED SAW CUTS PIECES
ABOUT 1 3/4 INCH LONG.
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00:01:45,137 --> 00:01:47,551
WORKERS PLACE THE PIECES
ON A CONVEYER,
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00:01:47,551 --> 00:01:50,241
WHICH MOVES THEM
INTO AN INDUCTION OVEN.
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00:01:50,241 --> 00:01:53,620
THE OVEN HEATS THEM
TO BETWEEN 1,650
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00:01:53,620 --> 00:01:56,344
AND 2,190 DEGREES FAHRENHEIT,
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00:01:56,344 --> 00:01:58,862
SOFTENING THE STEEL.
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00:01:58,862 --> 00:02:01,241
AS SOON AS A PIECE
COMES OUT OF THE OVEN,
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00:02:01,241 --> 00:02:04,413
THE FORGING PRESS
STRIKES IT THREE TIMES,
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00:02:04,413 --> 00:02:07,758
FIRST FLATTENING IT INTO A DISK.
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00:02:07,758 --> 00:02:10,724
NEXT, THINNING THE DISK,
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00:02:10,724 --> 00:02:13,689
THEN STAMPING THE DISK
INTO A HALF SPHERE.
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00:02:19,413 --> 00:02:21,586
WORKERS MILL THE FORGED
HALF SPHERE
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00:02:21,586 --> 00:02:23,896
ON A LATHE TO REFINE THE SHAPE
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00:02:23,896 --> 00:02:27,344
AND TO CREATE A GAP THEY LATER
FILL WITH METAL WIRE
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00:02:27,344 --> 00:02:31,862
WHEN THEY WELD THIS HALF TO
ANOTHER HALF TO FORM THE BALL.
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A WORKER DROPS THE MILLED HALVES
DOWN TWO SEPARATE CHUTES
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00:02:35,896 --> 00:02:40,655
AND DELIVER TWO HALVES AT A TIME
TO AN AUTOMATED WELDING MACHINE.
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00:02:40,655 --> 00:02:42,965
THE MACHINE CLAMPS
THE HALVES TOGETHER
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00:02:42,965 --> 00:02:45,482
AND WELDS THEM TO EACH OTHER.
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00:02:45,482 --> 00:02:48,655
A ROBOT REMOVES THE BALL
FROM THE WELDING MACHINE
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00:02:48,655 --> 00:02:52,448
AND TRANSFERS IT TO A
COMPUTER-GUIDED MILLING MACHINE.
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00:02:52,448 --> 00:02:56,482
AS THE MACHINE'S LATHE SPINS
THE BALL, A KNIFE SHAVES OFF
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00:02:56,482 --> 00:02:59,206
THIN LAYERS OF STEEL
TO SMOOTH THE BALL
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00:02:59,206 --> 00:03:01,413
AND MAKE THE WELD INVISIBLE.
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00:03:01,413 --> 00:03:04,448
THIS ALSO PUTS THE BALL
WITHIN A SPECIFIC DIAMETER
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00:03:04,448 --> 00:03:07,724
AND WEIGHT RANGE IN ACCORDANCE
WITH INTERNATIONAL RULES
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00:03:07,724 --> 00:03:10,448
GOVERNING THE SPORT.
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00:03:10,448 --> 00:03:13,655
THE MACHINE ALSO ENGRAVES
A PATTERN TO HELP IDENTIFY
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WHOSE BALLS ARE WHOSE.
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INTERNATIONAL PéTANQUE RULES
REQUIRE A BALL
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TO HAVE FOUR ITEMS
ENGRAVED INTO ITS SURFACE --
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00:03:25,724 --> 00:03:28,172
THE BRAND NAME,
THE PATTERN NAME,
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00:03:28,172 --> 00:03:30,586
THE WEIGHT OF THE BALL,
AND A SERIAL NUMBER
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FOR THE SET TO WHICH
IT BELONGS.
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00:03:34,034 --> 00:03:37,068
ONCE THE BRAND, PATTERN
AND WEIGHT ARE ENGRAVED,
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00:03:37,068 --> 00:03:41,310
THE BALLS MOVE ALONG A CONVEYOR
TOWARD THE TEMPERING STATION.
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00:03:41,310 --> 00:03:43,172
CUTTING, HEATING, FORGING,
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00:03:43,172 --> 00:03:46,275
AND MACHINING STEEL
MAKES IT BRITTLE AND WEAK.
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00:03:46,275 --> 00:03:48,517
TEMPERING IS THE PROCESS
OF HARDENING IT
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00:03:48,517 --> 00:03:50,448
TO RESTORE ITS STRENGTH.
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00:03:50,448 --> 00:03:54,275
AFTER HEATING THE BALL
TO BETWEEN 1,470
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00:03:54,275 --> 00:03:57,482
AND 1,830 DEGREES FAHRENHEIT,
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00:03:57,482 --> 00:04:01,620
THEY IMMEDIATELY COOL IT IN
WATER THAT'S ABOUT 104 DEGREES,
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00:04:01,620 --> 00:04:04,000
A PROCESS KNOWN AS QUENCHING.
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00:04:04,000 --> 00:04:07,620
AFTER TEMPERING THE STEEL,
MANUFACTURERS POLISH THE BALL
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00:04:07,620 --> 00:04:09,965
WITH AN AUTOMATED SANDER.
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00:04:09,965 --> 00:04:12,413
THE FINISHED BALLS
DO VARY SLIGHTLY,
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00:04:12,413 --> 00:04:15,931
SO THIS LAST AUTOMATED MACHINE
WEIGHS EACH ONE
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00:04:15,931 --> 00:04:18,344
AND SORTS IT IN ROWS
OF IDENTICAL WEIGHT.
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00:04:21,000 --> 00:04:24,379
THEN, EQUAL WEIGHT BALLS
ARE GROUPED IN SETS OF THREE
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00:04:24,379 --> 00:04:28,551
AND ARE ENGRAVED WITH
THE SAME SERIAL NUMBER.
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00:04:28,551 --> 00:04:31,827
THESE PéTANQUE BALLS
ARE MADE OF CARBON STEEL.
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00:04:31,827 --> 00:04:34,137
TO PREVENT OXIDATION
AND CORROSION,
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00:04:34,137 --> 00:04:36,965
THE FACTORY ELECTROPLATES
ITS CARBON STEEL BALLS
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00:04:36,965 --> 00:04:40,000
WITH A PROTECTIVE
LAYER OF CHROMIUM.
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00:04:40,000 --> 00:04:43,206
IT SUBMERGES THE BALLS
IN A SERIES OF CHEMICAL BATHS
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00:04:43,206 --> 00:04:45,896
AND WATER BATHS
TO PREP THE SURFACE
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00:04:45,896 --> 00:04:48,931
FOR THE FINAL DIP
IN AN ELECTROPLATING TANK
83
00:04:48,931 --> 00:04:51,655
IN WHICH AN ELECTRICAL CURRENT
DRAWS CHROMIUM PARTICLES
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00:04:51,655 --> 00:04:56,689
THROUGH THE WATER AND DEPOSITS
THEM ONTO THE BALL'S SURFACE.
85
00:04:56,689 --> 00:05:00,551
THE CHROMIUM TREATMENT
LEAVES A WHITE FILM.
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00:05:00,551 --> 00:05:06,896
THIS BRUSHING MACHINE REMOVES IT
AND RESTORES THE SHINY FINISH.
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00:05:06,896 --> 00:05:10,551
INTERNATIONAL RULES REQUIRE
PéTANQUE BALLS TO BE 2 3/4
88
00:05:10,551 --> 00:05:13,206
TO JUST OVER
3 INCHES IN DIAMETER
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00:05:13,206 --> 00:05:17,517
AND WEIGH BETWEEN 1 1/2
TO 1 3/4 POUNDS.
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00:05:17,517 --> 00:05:20,896
THE RETAIL BOX CONTAINS
THREE IDENTICAL BALLS
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00:05:20,896 --> 00:05:23,241
ENGRAVED WITH THE SAME
SERIAL NUMBER,
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00:05:23,241 --> 00:05:25,206
ALONG WITH
THE WOOD TARGET BALL,
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00:05:25,206 --> 00:05:29,655
A CLEANING CLOTH,
AND A WARRANTY CARD.
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00:05:29,655 --> 00:05:32,206
THE GOAL OF THE GAME
IS TO TOSS THE BALLS AS CLOSE
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00:05:32,206 --> 00:05:34,586
AS POSSIBLE TO THE TARGET BALL
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00:05:34,586 --> 00:05:37,586
WHILE KNOCKING THE OPPONENTS'
BALLS AWAY FROM IT.
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00:05:37,586 --> 00:05:40,000
AND THE PLAYER'S FEET MUST
REMAIN PLANTED INSIDE
98
00:05:40,000 --> 00:05:41,896
A SMALL CIRCLE WHEN TOSSING.
99
00:05:44,655 --> 00:05:47,206
YOU CAN PLAY PéTANQUE INDOORS
IN A VENUE
100
00:05:47,206 --> 00:05:50,000
KNOWN AS A BOULODROME
OR BOULE BAR,
101
00:05:50,000 --> 00:05:51,724
OR YOU CAN PLAY OUTDOORS
102
00:05:51,724 --> 00:05:55,275
ANYWHERE THERE'S A PATCH
OF RELATIVELY FLAT GROUND.
103
00:06:07,551 --> 00:06:09,931
Narrator: BIOLOGIC MEDICINES
ARE PROTEINS
104
00:06:09,931 --> 00:06:12,275
PRODUCED INSIDE LIVING CELLS,
105
00:06:12,275 --> 00:06:14,448
WHICH ARE MINI FACTORIES
GENERATING
106
00:06:14,448 --> 00:06:17,206
THE GENETICALLY ENGINEERED
PROTEIN TREATMENTS.
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00:06:17,206 --> 00:06:20,137
IT'S A DIFFERENT APPROACH
FROM TRADITIONAL DRUGS,
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00:06:20,137 --> 00:06:23,379
WHICH ARE MANUFACTURED
USING CHEMICAL SYNTHESIS.
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00:06:23,379 --> 00:06:27,344
BIOLOGICS OFFER HOPE WHERE
OTHER THERAPIES HAVE FAILED.
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00:06:29,482 --> 00:06:32,068
TO MASS-PRODUCE
THESE BIOLOGIC MEDICINES,
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00:06:32,068 --> 00:06:37,448
SCIENTISTS USE THE MOLECULAR
MACHINERY INSIDE LIVING CELLS.
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00:06:37,448 --> 00:06:40,965
THE PROCESS STARTS WITH THE
INSERTION OF GENETIC MATERIAL
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00:06:40,965 --> 00:06:44,172
INTO CHINESE HAMSTER
OVARIAN CELLS.
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00:06:44,172 --> 00:06:46,931
THEY'RE KNOWN AS CHO CELLS.
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00:06:46,931 --> 00:06:51,275
THEY KEEP THEM FROZEN IN LIQUID
NITROGEN UNTIL THE NEXT STEP.
116
00:06:51,275 --> 00:06:55,413
IN THE SEED LAB, A TECHNICIAN
THAWS THE CELLS IN WARM WATER.
117
00:06:59,000 --> 00:07:01,896
HE TRANSFERS THEM
TO A GLASS FLASK
118
00:07:01,896 --> 00:07:05,413
THAT CONTAINS GROWTH MEDIA.
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00:07:05,413 --> 00:07:08,689
THE GROWTH MEDIA IS COMPRISED
OF HUNDREDS OF NUTRIENTS,
120
00:07:08,689 --> 00:07:10,793
INCLUDING VITAMINS AND MINERALS.
121
00:07:10,793 --> 00:07:13,551
IT'S A RECIPE TO HELP
THE CELLS MULTIPLY.
122
00:07:17,241 --> 00:07:20,862
A WORKER TRANSFERS THE FLASK
THAT CONTAINS THE CELLS
123
00:07:20,862 --> 00:07:24,379
TO THE PRODUCTION SIDE
OF THE PLANT.
124
00:07:24,379 --> 00:07:26,241
THE TEAM INJECTS THE MIXTURE
125
00:07:26,241 --> 00:07:31,000
INTO A 5-GALLON-CAPACITY
BIOREACTOR.
126
00:07:31,000 --> 00:07:35,862
INSIDE, A PROPELLER AGITATES
THE MIXTURE TO STIMULATE GROWTH.
127
00:07:35,862 --> 00:07:37,517
OVER A 3-WEEK PERIOD,
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00:07:37,517 --> 00:07:40,931
THE NUMBER OF CELLS
INCREASES EXPONENTIALLY.
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00:07:40,931 --> 00:07:42,586
EACH NEW CELL IS PROGRAMMED
130
00:07:42,586 --> 00:07:45,896
TO PRODUCE THE TARGET
BIOLOGIC PROTEIN.
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00:07:45,896 --> 00:07:50,551
A WORKER STERILIZES THIS
21-GALLON-CAPACITY BIOREACTOR
132
00:07:50,551 --> 00:07:53,413
TO PREPARE IT TO RECEIVE
THE CELL MIXTURE.
133
00:07:53,413 --> 00:07:57,137
UNDER PRECISELY CONTROLLED
CONDITIONS IN THE BIOREACTOR,
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00:07:57,137 --> 00:08:00,448
THE CELLS MULTIPLY
SUBSTANTIALLY.
135
00:08:00,448 --> 00:08:03,896
OVER SEVERAL WEEKS, THE TEAM
TRANSFERS THE CELLS
136
00:08:03,896 --> 00:08:07,172
TO PROGRESSIVELY
LARGER BIOREACTORS.
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00:08:07,172 --> 00:08:10,068
THE CELLS GROW UNTIL
THERE ARE TRILLIONS,
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00:08:10,068 --> 00:08:13,379
EACH PRODUCING
THE TARGET PROTEIN.
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00:08:13,379 --> 00:08:18,517
NEXT, A TECHNICIAN MEASURES
SALTS AND OTHER DRY INGREDIENTS.
140
00:08:18,517 --> 00:08:22,206
HE'S PREPARING A RECIPE
FOR PURIFYING THE PROTEIN LIQUID
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00:08:22,206 --> 00:08:26,379
ONCE IT'S BEEN SEPARATED
FROM THE CELLS.
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00:08:26,379 --> 00:08:29,034
HE LABELS THE BAG AND RECORDS
THE INFORMATION
143
00:08:29,034 --> 00:08:33,896
SEPARATELY AS REQUIRED
BY GOVERNMENT REGULATIONS.
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00:08:33,896 --> 00:08:38,068
HE ADDS THE INGREDIENTS TO
PURIFIED WATER IN A MIXING TANK.
145
00:08:38,068 --> 00:08:40,793
AN AUTOMATED SYSTEM KEEPS TABS
ON THE CONDITION
146
00:08:40,793 --> 00:08:43,275
OF THE PURIFICATION SOLUTION.
147
00:08:47,137 --> 00:08:49,379
AFTER SEPARATING
CELLULAR MATERIAL
148
00:08:49,379 --> 00:08:51,068
FROM THE PROTEIN MIXTURE,
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00:08:51,068 --> 00:08:54,517
THE TEAM PUMPS IT THROUGH
STEEL AND GLASS COLUMNS.
150
00:08:54,517 --> 00:08:58,172
HERE, THE PURIFICATION SOLUTION
WORKS WITH RESIN BEADS
151
00:08:58,172 --> 00:09:00,931
TO SEPARATE THE PROTEIN
FROM THE IMPURITIES.
152
00:09:04,758 --> 00:09:07,620
THE PURIFIED PROTEIN
IS STORED IN STEEL TANKS
153
00:09:07,620 --> 00:09:10,310
AT -4 DEGREES FAHRENHEIT.
154
00:09:10,310 --> 00:09:14,931
IT KEEPS THE BIOLOGIC MEDICINE
IN A STABLE STATE.
155
00:09:14,931 --> 00:09:17,517
MEANWHILE,
IN THE QUALITY CONTROL LAB,
156
00:09:17,517 --> 00:09:22,448
A TECHNICIAN INJECTS A SAMPLE
INTO GLASS CAPSULES.
157
00:09:22,448 --> 00:09:26,931
SHE PLACES THE CAPSULES INTO
A ROBOTIC ANALYTICAL INSTRUMENT.
158
00:09:26,931 --> 00:09:30,413
THIS SOPHISTICATED EQUIPMENT
MEASURES THE POTENCY AND PURITY
159
00:09:30,413 --> 00:09:32,517
OF THE BIOLOGIC MEDICINE.
160
00:09:35,482 --> 00:09:38,413
ONCE THE BIOLOGIC MEDICINE
PASSES THE TESTS,
161
00:09:38,413 --> 00:09:41,275
THEY PREPARE GLASS VIALS
TO RECEIVE IT.
162
00:09:41,275 --> 00:09:43,551
THAT MEANS
AN INTENSIVE CLEANING.
163
00:09:45,344 --> 00:09:49,206
THE AUTOMATED SYSTEM LOADS
THE VIALS INTO INDIVIDUAL SLOTS,
164
00:09:49,206 --> 00:09:52,206
AND SPRAYERS RINSE THEM.
165
00:09:52,206 --> 00:09:55,551
THE SYSTEM THEN TRANSPORTS
THE VIALS THROUGH A HEAT TUNNEL
166
00:09:55,551 --> 00:10:01,793
THAT STERILIZES THEM TO REMOVE
ANY POTENTIALLY HARMFUL TOXINS.
167
00:10:01,793 --> 00:10:04,413
MOVING THROUGH AN ISOLATED
STERILE ZONE,
168
00:10:04,413 --> 00:10:08,931
THE VIALS FUNNEL
INTO A FILL STATION.
169
00:10:08,931 --> 00:10:12,586
NOZZLES DISPENSE A SPECIFIC
DOSE OF BIOLOGIC MEDICINE
170
00:10:12,586 --> 00:10:16,034
INTO THE VIALS.
171
00:10:16,034 --> 00:10:19,724
HERE, PLUNGERS INSERT
STOPPERS IN THE VIALS.
172
00:10:19,724 --> 00:10:21,724
A CAMERA THEN TAKES A PICTURE,
173
00:10:21,724 --> 00:10:24,206
AND A COMPUTER
INSTANTLY ANALYZES IT
174
00:10:24,206 --> 00:10:29,310
TO CONFIRM THAT THE STOPPERS
HAVE BEEN CORRECTLY INSTALLED.
175
00:10:29,310 --> 00:10:32,413
THE SYSTEM THEN CAPS THE
STOPPERS TO COMPLETELY SEAL THEM
176
00:10:32,413 --> 00:10:34,448
FROM CONTAMINANTS.
177
00:10:34,448 --> 00:10:37,551
THIS MACHINERY HYGIENICALLY
FILLS AND CAPS
178
00:10:37,551 --> 00:10:40,724
OVER 100 VIALS PER MINUTE.
179
00:10:40,724 --> 00:10:43,827
A WORKER VISUALLY
INSPECTS EACH VIAL.
180
00:10:43,827 --> 00:10:48,241
HE CAREFULLY SWIRLS THE CONTENTS
AS HE LOOKS FOR IMPURITIES.
181
00:10:48,241 --> 00:10:52,000
IF HE SEES ANY, THE VIAL
OF MEDICINE WILL BE REJECTED.
182
00:10:54,241 --> 00:10:58,034
FINALLY, THIS TECHNICIAN TAKES
A SAMPLE AND CONDUCTS A TEST
183
00:10:58,034 --> 00:11:00,310
TO ENSURE THE MEDICINE
IS STERILE.
184
00:11:02,482 --> 00:11:04,275
GROWN IN LIVING CELLS,
185
00:11:04,275 --> 00:11:07,103
THESE BIOLOGIC MEDICINES
ARE NOW ON THEIR WAY
186
00:11:07,103 --> 00:11:11,000
TO POTENTIALLY MAKING
A DIFFERENCE IN PEOPLE'S LIVES.
187
00:11:22,689 --> 00:11:24,758
Narrator: THE DEVELOPMENT
OF THE ASPHALT PAVER
188
00:11:24,758 --> 00:11:27,034
IN THE EARLY PART
OF THE 20th CENTURY
189
00:11:27,034 --> 00:11:29,620
CHANGED THE WAY ROADS
WERE BUILT.
190
00:11:29,620 --> 00:11:32,482
THE PAVING MACHINE TOOK OVER
FROM LARGE CREWS
191
00:11:32,482 --> 00:11:36,379
WHO PAVED SURFACES MANUALLY
USING PICKS AND SHOVELS.
192
00:11:36,379 --> 00:11:40,206
THIS INVENTION HAS MADE IT
A LOT EASIER TO PAVE THE WAY.
193
00:11:43,931 --> 00:11:48,413
THE ASPHALT PAVER TRANSFORMS
ROUGH ROADS INTO SMOOTH ONES.
194
00:11:48,413 --> 00:11:51,758
THIS PAVING MACHINE DISTRIBUTES
ASPHALT, LEVELS IT,
195
00:11:51,758 --> 00:11:54,482
AND ALSO PROVIDES
THE INITIAL COMPACTION.
196
00:11:57,103 --> 00:12:00,793
MAKING ONE STARTS WITH
A COMPUTERIZED PLASMA CUTTER.
197
00:12:00,793 --> 00:12:03,724
THE OPERATOR PROGRAMS IT
TO CUT OUT ALL THE PARTS OF
198
00:12:03,724 --> 00:12:07,620
THE PAVER STRUCTURE
FROM HEAVY-GAUGE STEEL PLATES.
199
00:12:07,620 --> 00:12:11,586
IT ALSO CONFIGURES THE CUTTING
TO MINIMIZE WASTE.
200
00:12:11,586 --> 00:12:14,551
THE PLASMA TOOLING ALSO CUTS
AND THREADS HOLES
201
00:12:14,551 --> 00:12:17,758
FOR BOLTING THE PARTS TOGETHER.
202
00:12:17,758 --> 00:12:19,689
ONCE THE PARTS HAVE BEEN CUT,
203
00:12:19,689 --> 00:12:23,000
A CRANE TRANSFERS THEM
TO A WELDING FIXTURE.
204
00:12:25,034 --> 00:12:27,517
THE FIXTURE HOLDS THE PARTS
FOR THE PAVER FRAME
205
00:12:27,517 --> 00:12:28,965
IN TIGHT ALIGNMENT
206
00:12:28,965 --> 00:12:31,344
WHILE A WELDER TACKS
THEM TOGETHER.
207
00:12:34,206 --> 00:12:37,379
HE ALSO TACK WELDS SMALLER PARTS
LIKE ENGINE MOUNTS
208
00:12:37,379 --> 00:12:39,827
TO THE STRUCTURE.
209
00:12:39,827 --> 00:12:44,103
ONCE THE TACK WELDS ARE DONE,
HE DOES FULL WELDS THROUGHOUT,
210
00:12:44,103 --> 00:12:46,827
CREATING STRONG, THICK SEAMS.
211
00:12:49,827 --> 00:12:53,862
A TEAM LOADS MORE STEEL INTO
A COMPUTERIZED PRESS BREAK.
212
00:12:53,862 --> 00:12:55,275
IT CLAMPS THE STEEL PLATE
213
00:12:55,275 --> 00:12:57,896
BETWEEN
A MATCHING PUNCH AND DIE.
214
00:12:57,896 --> 00:13:00,172
THEN, USING HYDRAULIC POWER,
215
00:13:00,172 --> 00:13:02,965
THE PRESS BREAK MAKES
PRECISE BENDS
216
00:13:02,965 --> 00:13:08,103
TO SHAPE THE STEEL INTO
A SECTION OF THE PAVER HOPPER.
217
00:13:08,103 --> 00:13:11,137
WITH THE FIRST BEND DONE,
ONE OF THE WORKERS MEASURES
218
00:13:11,137 --> 00:13:13,137
THE ANGLE WITH A DIGITAL LEVEL
219
00:13:13,137 --> 00:13:15,517
TO CONFIRM THAT
IT'S EXACTLY RIGHT.
220
00:13:18,137 --> 00:13:20,896
THE TEAM THEN MOVES THE STEEL
PLATE INTO POSITION
221
00:13:20,896 --> 00:13:22,448
FOR THE NEXT BENDS.
222
00:13:22,448 --> 00:13:26,172
THEY MAKE A TOTAL OF THREE
IN THE HOPPER PART.
223
00:13:26,172 --> 00:13:28,793
THOSE THREE BENDS MUST BE
PERFECTLY ANGLED
224
00:13:28,793 --> 00:13:31,275
AND POSITIONED TO FIT
THE REST OF THE HOPPER.
225
00:13:34,896 --> 00:13:38,827
IT'S WHY PRECISION IS CRITICAL.
226
00:13:38,827 --> 00:13:44,034
THEY DO A FINAL CHECK OF THE
THREE BENDS USING A TEMPLATE.
227
00:13:44,034 --> 00:13:47,344
NEXT, A WELDER JOINS
A SIDE PANEL TO THE HOPPER PART
228
00:13:47,344 --> 00:13:49,241
WITH THE THREE BENDS.
229
00:13:49,241 --> 00:13:52,517
THESE TWO PARTS FORM
THE LEFT SIDE OF THE HOPPER.
230
00:13:54,724 --> 00:13:58,103
AFTER AN ACID WASH, IT'S INTO
THE PAINT BOOTH TO COAT
231
00:13:58,103 --> 00:14:01,517
THE STEEL WITH AN EPOXY PRIMER
AND URETHANE PAINT.
232
00:14:07,896 --> 00:14:10,000
THE PARTS THEN SPEND TIME
IN AN OVEN
233
00:14:10,000 --> 00:14:13,965
TO ACCELERATE THE PAINT CURE.
234
00:14:13,965 --> 00:14:16,034
THEN IT'S OVER TO
THE ASSEMBLY LINE,
235
00:14:16,034 --> 00:14:21,068
WHERE CONSTRUCTION OF THE PAVER
TRACTOR IS ALREADY UNDERWAY.
236
00:14:21,068 --> 00:14:24,413
A WORKER BOLTS GEAR SYSTEMS
TO THE SIDES.
237
00:14:24,413 --> 00:14:27,551
THESE GEARS WILL DRIVE
THE PAVER WHEELS.
238
00:14:30,896 --> 00:14:32,517
WITH THE HELP OF A CRANE,
239
00:14:32,517 --> 00:14:37,068
THE TEAM GUIDES
THE ENGINE INTO POSITION.
240
00:14:37,068 --> 00:14:39,689
THE ENGINE'S MOUNTING STRUCTURE
MATES TO BUSHINGS
241
00:14:39,689 --> 00:14:41,379
IN FOUR LOCATIONS.
242
00:14:43,931 --> 00:14:47,586
THEY NOW ASSEMBLE THE HOPPER TO
THE FRONT OF THE PAVING MACHINE.
243
00:14:49,931 --> 00:14:53,068
HINGE TUBES ON THE HOPPER PART
INTERMESH WITH TUBES
244
00:14:53,068 --> 00:14:55,551
ON THE CENTER
CONVEYOR FRAMEWORK.
245
00:14:55,551 --> 00:14:58,275
THEY'LL RUN A LONG PIN
THROUGH THESE HINGE TUBES
246
00:14:58,275 --> 00:15:01,586
TO COMPLETE THE ASSEMBLY.
247
00:15:01,586 --> 00:15:03,724
WITH EVERYTHING IN GOOD
WORKING ORDER,
248
00:15:03,724 --> 00:15:05,655
THEY'RE READY TO BUILD
THE SCREED,
249
00:15:05,655 --> 00:15:08,000
BEGINNING WITH THE BASE PLATE.
250
00:15:08,000 --> 00:15:10,931
THE SCREED IS A CRITICAL
APPARATUS.
251
00:15:10,931 --> 00:15:13,758
ITS SYSTEM OF VIBRATING
EXTENDERS BOTH LEVELS
252
00:15:13,758 --> 00:15:17,793
AND COMPACTS THE ASPHALT
ONCE IT'S DEPOSITED ON THE ROAD.
253
00:15:17,793 --> 00:15:19,827
THEY'RE ALSO EQUIPPED
WITH HEATING ELEMENTS
254
00:15:19,827 --> 00:15:23,413
TO KEEP THE ASPHALT WORKABLE.
255
00:15:23,413 --> 00:15:26,103
THEY RUN A BATTERY OF TESTS
ON ALL THESE COMPONENTS
256
00:15:26,103 --> 00:15:29,413
TO CONFIRM THAT THE SCREED
IS FULLY OPERATIONAL.
257
00:15:32,482 --> 00:15:37,413
THE SCREED IS NOW READY TO BE
MATED TO THE PAVER TRACTOR.
258
00:15:37,413 --> 00:15:41,137
THEY PUT THE TRACTOR IN REVERSE
AND BACK IT UP TO THE SCREED
259
00:15:41,137 --> 00:15:44,482
UNTIL BRACKETS ON BOTH MEET
IN PERFECT ALIGNMENT.
260
00:15:47,379 --> 00:15:49,931
ONCE THE BRACKETS HAVE BEEN
BOLTED TOGETHER,
261
00:15:49,931 --> 00:15:53,724
THE ASPHALT PAVER
IS READY FOR WORK.
262
00:15:53,724 --> 00:15:57,172
THE ROAD AHEAD WILL BE LONG
AND POTENTIALLY WINDING,
263
00:15:57,172 --> 00:16:01,551
BUT IT SHOULD BE PRETTY SMOOTH,
THANKS TO THIS ASPHALT PAVER.
264
00:16:12,344 --> 00:16:14,482
Narrator: ESPADRILLES
HAVE BEEN A POPULAR STYLE
265
00:16:14,482 --> 00:16:17,206
OF CASUAL FOOTWEAR
FOR DECADES NOW,
266
00:16:17,206 --> 00:16:18,827
YET MOST PEOPLE
LIKELY DON'T KNOW
267
00:16:18,827 --> 00:16:22,137
THE ORIGIN OF THIS
COMFORTABLE CLOTH SHOE.
268
00:16:22,137 --> 00:16:26,310
EUROPEANS HAVE BEEN WEARING
ESPADRILLES SINCE THE 1300s.
269
00:16:26,310 --> 00:16:29,965
THE BASQUE REGION IN NORTHERN
SPAIN IS STILL FAMOUS FOR THEM.
270
00:16:31,896 --> 00:16:36,586
ESPADRILLES ARE FASHION FORWARD
AND A STEP BACK IN TIME.
271
00:16:36,586 --> 00:16:39,517
THE PEOPLE OF THE BASQUE REGION
HAVE BEEN MAKING THESE CLOTH
272
00:16:39,517 --> 00:16:42,344
AND JUTE SHOES
FOR HUNDREDS OF YEARS.
273
00:16:42,344 --> 00:16:48,275
THEY BEGAN REINFORCING THE SOLES
WITH RUBBER IN THE EARLY 1900s.
274
00:16:48,275 --> 00:16:53,103
JUTE IS A PLANT FIBER THAT'S
SPUN INTO STRONG, COARSE TWINE.
275
00:16:53,103 --> 00:16:55,103
FOR TRADITIONAL BASQUE
ESPADRILLES,
276
00:16:55,103 --> 00:16:58,827
THEY USE TWINE THAT'S ABOUT
1/10th OF AN INCH THICK.
277
00:16:58,827 --> 00:17:02,827
LARGE JUTE SPOOLS FEED
AN AUTOMATED BRAIDING MACHINE.
278
00:17:02,827 --> 00:17:05,206
ITS FIVE BOBBINS MOVE
IN A CIRCULAR PATTERN
279
00:17:05,206 --> 00:17:07,413
THAT PRODUCES A NEAT
BRAID MEASURING
280
00:17:07,413 --> 00:17:09,482
ROUGHLY 3/4ths
OF AN INCH WIDE
281
00:17:09,482 --> 00:17:11,620
BY A QUARTER OF AN INCH THICK.
282
00:17:14,241 --> 00:17:16,517
RIGHT AFTER EXITING
THE BRAIDING MACHINE,
283
00:17:16,517 --> 00:17:19,034
THE BRAID ENTERS
A CALIBRATION MACHINE
284
00:17:19,034 --> 00:17:23,620
WHICH APPLIES TENSION
TO MAKE THE DIMENSIONS UNIFORM.
285
00:17:23,620 --> 00:17:28,034
EACH ESPADRILLE SOLE
IS HAND-CRAFTED BY AN ARTISAN.
286
00:17:28,034 --> 00:17:32,413
HE WINDS THE BRAID ON A FORM
THAT'S MORE THAN A CENTURY OLD.
287
00:17:32,413 --> 00:17:35,137
THE POSITIONING OF THE METAL
PEGS IN THE HOLES
288
00:17:35,137 --> 00:17:38,448
CORRESPOND TO THE SIZE
OF THE SHOE HE'S MAKING.
289
00:17:38,448 --> 00:17:40,793
THE CLOSER THE PEGS
ARE TO EACH OTHER,
290
00:17:40,793 --> 00:17:43,172
THE SMALLER THE SHOE SIZE.
291
00:17:43,172 --> 00:17:47,620
AFTER NINE ROTATIONS FOR THIS
SHOE SIZE, HE CUTS THE BRAID,
292
00:17:47,620 --> 00:17:51,310
THEN, USING A LARGE NEEDLE,
TIES OFF THE END.
293
00:17:54,103 --> 00:17:57,034
HE PLACES THE WOUND BRAID
INTO A PRESS
294
00:17:57,034 --> 00:17:59,103
WHICH, AS WE SEE HERE
IN SLOW MOTION,
295
00:17:59,103 --> 00:18:01,758
COMPRESSES IT INTO
THE SHAPE OF THE SOLE.
296
00:18:08,241 --> 00:18:14,068
IN REAL TIME, THIS STEP TAKES
JUST A COUPLE OF SECONDS.
297
00:18:14,068 --> 00:18:17,896
THEN HE PICKS UP THE SOLE
WITH A COMB
298
00:18:17,896 --> 00:18:20,931
AND FEEDS IT INTO
AN AUTOMATED SEWING MACHINE.
299
00:18:26,206 --> 00:18:31,137
TWO LARGE NEEDLES, ONE ABOVE,
ONE BELOW, SIMULTANEOUSLY STITCH
300
00:18:31,137 --> 00:18:34,413
ALL THE WAY THROUGH THE SOLE
WITH THICK JUTE THREAD,
301
00:18:34,413 --> 00:18:36,379
BINDING THE WOUND JUTE BRAID.
302
00:18:42,896 --> 00:18:46,758
THIS MACHINE SEWS MORE THAN
100 PAIRS OF SOLES PER HOUR.
303
00:18:50,310 --> 00:18:53,034
BY NOW, THE ESPADRILLES'
SIGNATURE JUTE SOLE
304
00:18:53,034 --> 00:18:54,862
IS FORMED AND SEWN,
305
00:18:54,862 --> 00:18:57,034
BUT IT'S NOT QUITE FINISHED YET.
306
00:18:57,034 --> 00:18:58,827
TO PREVENT IT FROM WEARING OUT,
307
00:18:58,827 --> 00:19:01,448
IT NEEDS A PROTECTIVE LAYER
OF RUBBER.
308
00:19:04,241 --> 00:19:08,344
THE ARTISAN NOW OPENS A MOLD
FOR THE CORRESPONDING SHOE SIZE
309
00:19:08,344 --> 00:19:10,586
AND FILLS
THE SOLE-SHAPED CAVITIES
310
00:19:10,586 --> 00:19:14,517
WITH A PRE-MEASURED QUANTITY
OF COLORLESS RUBBER GRANULES.
311
00:19:17,068 --> 00:19:19,896
THEN, HE PLACES
THE JUTE SOLES ON TOP.
312
00:19:24,172 --> 00:19:28,931
HE CLOSES THE MOLD AND PLACES IT
IN A PRESS FOR 6 MINUTES.
313
00:19:28,931 --> 00:19:32,517
THE PRESS HEATS THE MOLD
TO 300 DEGREES FAHRENHEIT,
314
00:19:32,517 --> 00:19:35,344
MELTING THE RUBBER GRANULES.
315
00:19:35,344 --> 00:19:38,344
THE LIQUID RUBBER SPREADS
THROUGHOUT THE CAVITIES,
316
00:19:38,344 --> 00:19:41,586
PENETRATES THE JUTE FIBERS
AND VULCANIZES,
317
00:19:41,586 --> 00:19:44,758
MEANING IT HARDENS AND CURES.
318
00:19:44,758 --> 00:19:46,724
THIS PRODUCES
A RUBBER OUTER SOLE
319
00:19:46,724 --> 00:19:48,344
ABOUT 1/6th OF AN INCH THICK
320
00:19:48,344 --> 00:19:51,172
THAT PROTECTS
THE JUTE INNER SOLE.
321
00:19:51,172 --> 00:19:55,758
THE ESPADRILLES' UPPERS ARE MADE
OF 100-PERCENT-COTTON CANVAS.
322
00:19:55,758 --> 00:19:58,344
THE ARTISAN STACKS
ABOUT 20 PIECES
323
00:19:58,344 --> 00:20:00,344
AND CUTS THEM SIMULTANEOUSLY
324
00:20:00,344 --> 00:20:04,172
WITH A RAZOR-LIKE BLADE.
325
00:20:04,172 --> 00:20:09,172
EACH UPPER IS COMPRISED OF A
FRONT PIECE AND A BACK PIECE.
326
00:20:09,172 --> 00:20:13,310
A SEAMSTRESS SEWS THE UPPER
ENTIRELY BY HAND.
327
00:20:13,310 --> 00:20:17,068
SHE WEARS A GLOVE THAT HAS A
COPPER CUP BUILT INTO THE PALM,
328
00:20:17,068 --> 00:20:18,344
WHICH SHE USES TO FORCE
329
00:20:18,344 --> 00:20:21,827
THE GIANT NEEDLE
THROUGH THE TOUGH JUTE.
330
00:20:21,827 --> 00:20:25,000
AFTER STITCHING THE FRONT
AND BACK PIECES TO THE SOLE,
331
00:20:25,000 --> 00:20:28,413
SHE SEWS THEM TO EACH OTHER
ALONG THE SIDES.
332
00:20:31,413 --> 00:20:35,482
SHE CLOSES AND REINFORCES THE
TOE WITH THREE ROWS OF STITCHES.
333
00:20:38,793 --> 00:20:42,275
ALL THIS WITH STRONG, THICK
THREAD MADE OF BRAIDED COTTON.
334
00:20:44,379 --> 00:20:47,931
THIS MAKER OF BASQUE ESPADRILLES
PRIDES ITSELF IN USING
335
00:20:47,931 --> 00:20:52,310
ONLY NATURAL MATERIALS,
EVEN IN THE PAPER PACKAGING.
336
00:20:52,310 --> 00:20:55,551
THE RUBBER USED FOR THE SOLES
CONTAINS NO COLORANTS
337
00:20:55,551 --> 00:20:57,862
BUT IS INFUSED WITH CITRONELLA,
338
00:20:57,862 --> 00:21:01,689
A FRAGRANT PLANT OIL BELIEVED
TO HELP REPEL MOSQUITOES.
27946
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