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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:
CAST-IRON COOKWARE IS RENOWNED
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FOR ITS SUPERIOR ABILITY
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TO RETAIN HEAT
AND DIFFUSE IT EVENLY.
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00:00:57,241 --> 00:00:58,862
BARE CAST IRON, HOWEVER,
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REQUIRES REGULAR OILING
TO WARD OFF RUST --
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NOT SO WITH ENAMELED CAST IRON.
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A GLASS-ENAMEL COATING
ENCASES THE IRON,
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00:01:06,379 --> 00:01:10,103
MAKING THE COOKWARE ENTIRELY
MAINTENANCE-FREE, FOREVER.
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SINCE 1925, THIS FRENCH COMPANY
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HAS BEEN PRODUCING
ENAMELED CAST-IRON COOKWARE.
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ITS HIGH-END PRODUCTS ARE
RENOWNED FOR THEIR THIN WALLS,
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WHICH MAKES IT THE MOST
LIGHTWEIGHT CAST-IRON
COOKWARE AVAILABLE.
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THE SECRET -- THE MINERAL LEVELS
IN THE IRON RECIPE.
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00:01:28,068 --> 00:01:30,689
AT THE FOUNDRY,
THEY BEGIN WITH PIG IRON,
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WHICH HAS HIGH CARBON CONTENT.
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THEN THEY MELT
IN A CALCULATED AMOUNT OF STEEL
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TO FURTHER BOOST
THE CARBON LEVEL.
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THE MELTING OVEN HEATS THE
METALS TO 1,520 DEGREES CELSIUS,
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LIQUEFYING THEM
IN JUST 45 MINUTES.
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00:01:51,103 --> 00:01:53,206
WORKERS ADD A POWDERED CHEMICAL
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TO AGGLOMERATE THE NATURAL
IMPURITIES IN THE IRON,
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THEN SCOOP
THOSE BONDED IMPURITIES OUT.
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00:01:58,724 --> 00:02:02,310
MEANWHILE, WORKERS MOUNT
A TWO-PART MOLD TEMPLATE
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ONTO A MACHINE WHICH PRODUCES
THE SAND MOLDS
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WITH WHICH THEY'LL CAST
THE COOKWARE.
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THE MACHINE INJECTS THE SAND MIX
INTO THE TEMPLATES.
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00:02:10,551 --> 00:02:14,172
THE MIX CONTAINS CLAY, WATER,
AND PROPRIETARY INGREDIENTS
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WHICH MAKES
THE SAND COMPACT WELL.
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COMPACTION IS CRITICAL
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BECAUSE JUST ONE SINGLE GRAIN
OF SAND DISPLACING FROM THE MOLD
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WOULD PRODUCE A FLAW
ON THE COOKWARE.
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IT'S ESSENTIAL
THAT THE POURING TEMPERATURE
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BE PRECISE AND CONSISTENT,
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SO THEY TRANSFER THE IRON
FROM THE MELTING OVEN
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TO A TEMPERATURE-MAINTENANCE
OVEN.
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FROM THERE,
THEY POUR THE MOLTEN METAL
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THROUGH A MERE 1/10th-OF-AN-INCH
GAP BETWEEN THE MOLD HALVES.
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THE PROCESS
IS ENTIRELY AUTOMATED
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00:02:48,724 --> 00:02:52,413
BECAUSE THE POURING ANGLE
AND SPEED ARE CRITICAL.
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00:02:52,413 --> 00:02:56,586
THE MOLTEN IRON COOLS
AND SOLIDIFIES IN 20 MINUTES.
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THEN THE MOLDS DROP
ONTO A VIBRATING MESH CONVEYOR.
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THE SHAKING RELEASES
THE CAST COOKWARE FROM THE MOLD,
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ALONG WITH THE METAL THAT
SOLIDIFIED IN THE FLOW CHANNELS
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LEADING TO THE MOLD CAVITY.
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THE COOKWARE MOVES
INTO A CLOSED CHAMBER
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00:03:13,448 --> 00:03:16,793
WHERE A HIGH-PRESSURE GUN BLASTS
THE SURFACE WITH STEEL BALLS
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TO REMOVE ALL REMAINING GRAINS
OF SAND.
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AT THIS STAGE, THE COOKWARE
HAS ROUGH EXCESS METAL
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WHERE THE TWO PARTS
OF THE MOLD MET.
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SO NOW WORKERS
SMOOTH AWAY THESE BURRS
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USING A GRINDING WHEEL
ON THE OUTSIDE...
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...AND A GRINDING PIN
IN THE TIGHT SPOTS.
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THE COOKWARE IS NOW READY
TO BE PREPPED FOR ENAMELING.
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A MACHINE NOW BLASTS THE ENTIRE
PIECE WITH STEEL GRITS,
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MAKING THE SURFACE TEXTURE
UNIFORM
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SO THE ENAMEL
WILL ADHERE EVENLY.
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THE FIRST COAT OF ENAMEL
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IS STRICTLY TO PROTECT
THE CAST IRON
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AND PREVENT IT FROM RUSTING.
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00:04:02,724 --> 00:04:04,758
ENAMEL IS A FORM OF GLASS.
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00:04:04,758 --> 00:04:08,241
HOWEVER, THIS ENAMEL IS
ENGINEERED TO BE FLEXIBLE
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00:04:08,241 --> 00:04:12,310
BECAUSE METAL COOKWARE
NATURALLY EXPANDS AS IT HEATS
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00:04:12,310 --> 00:04:14,379
AND CONTRACTS AS IT COOLS.
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00:04:14,379 --> 00:04:15,862
AFTER A TRIP THROUGH A DRYER,
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THE ENAMEL GOES INTO AN OVEN
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AT MORE
THAN 1,500 DEGREES FAHRENHEIT
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FOR ABOUT 45 MINUTES.
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00:04:21,896 --> 00:04:23,482
DURING THIS FIRING,
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THE HAIR-THIN ENAMEL COATING
BECOMES TRANSLUCENT.
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00:04:26,724 --> 00:04:28,448
THE SECOND COAT OF ENAMEL
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COMPLETELY SEALS
THE POROUS SURFACE.
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IT'S MADE OF SOME 20 COMPONENTS,
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INCLUDING ENAMEL CHIPS,
PIECES OF CLEAR GLASS,
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AND PIGMENT POWDERS FOR COLOR.
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AN AUTOMATED SPRAY SYSTEM
COATS THE INSIDE FIRST.
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WORKERS WIPE THE EDGE
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TO PREVENT THE PIECE
FROM STICKING TO THE CONVEYOR,
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00:04:53,413 --> 00:04:54,620
THEN THE HANDLE
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00:04:54,620 --> 00:04:57,551
BECAUSE THEY'LL PAINT THAT
A DIFFERENT COLOR.
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THEY SPRAY THE HANDLE MANUALLY,
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00:05:00,000 --> 00:05:02,620
THEN THE AUTOMATED SYSTEM COATS
THE REST.
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00:05:02,620 --> 00:05:06,827
THE IRON RECIPE CONTAINS A HIGH
LEVEL OF THE MINERAL SILICATE,
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00:05:06,827 --> 00:05:08,793
WHICH HELPS THE ENAMEL
ADHERE WELL.
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ONCE AGAIN, THE COOKWARE
GOES THROUGH THE DRYER,
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THEN INTO THE OVEN AT MORE
THAN 1,500 DEGREES FAHRENHEIT
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00:05:19,172 --> 00:05:22,482
FOR ABOUT 45 MINUTES
TO VITRIFY THE ENAMEL.
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00:05:22,482 --> 00:05:24,137
ONCE THE COOKWARE COOLS,
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IT UNDERGOES
A FINAL VISUAL INSPECTION,
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00:05:26,965 --> 00:05:29,586
THE LAST OF 30
QUALITY-CONTROL CHECKS
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THROUGHOUT
THE PRODUCTION PROCESS.
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ENAMELED CAST-IRON COOKWARE
LASTS FOR GENERATIONS
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BECAUSE IT DOESN'T WARP
OVER TIME
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AND REMAINS FOOD-SAFE FOR LIFE.
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Narrator: BIODIESEL IS
A MORE ECO-FRIENDLY DIESEL FUEL
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THAT'S MADE FROM VEGETABLE OIL
OR ANIMAL FAT.
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00:05:57,517 --> 00:05:59,931
UNLIKE REGULAR DIESEL
AND GASOLINE,
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00:05:59,931 --> 00:06:03,241
PRODUCING BIODIESEL
DOESN'T REQUIRE PETROLEUM.
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00:06:03,241 --> 00:06:06,620
INSTEAD, THE RAW MATERIALS
ARE LOCALLY AVAILABLE
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00:06:06,620 --> 00:06:09,000
AND CAN BE RECYCLED FROM WASTE.
102
00:06:11,689 --> 00:06:16,344
IF YOUR CAR HAS A DIESEL ENGINE,
IT CAN RUN ON BIODIESEL FUEL,
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00:06:16,344 --> 00:06:19,172
USUALLY WITHOUT REQUIRING
ANY MODIFICATIONS.
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00:06:19,172 --> 00:06:21,482
WHILE BIODIESEL
AND PETROLEUM DIESEL
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00:06:21,482 --> 00:06:24,517
ARE SIMILAR IN ENERGY EFFICIENCY
AND FUEL ECONOMY,
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00:06:24,517 --> 00:06:27,137
BIODIESEL IS MORE ECO-FRIENDLY.
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00:06:27,137 --> 00:06:29,551
FOR STARTERS, IT CAN BE MADE
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FROM WHAT WOULD OTHERWISE
HAVE BEEN WASTE --
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00:06:31,310 --> 00:06:33,620
FOR EXAMPLE, FROM VEGETABLE OIL
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00:06:33,620 --> 00:06:37,965
FROM THE KITCHEN
OF YOUR LOCAL FAST-FOOD JOINT.
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00:06:37,965 --> 00:06:41,034
THE RESTAURANT SIMPLY DISCARDS
ITS USED FRYER OIL
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00:06:41,034 --> 00:06:43,344
IN A RECEPTACLE OUT BACK.
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00:06:45,931 --> 00:06:50,344
EVERY FEW DAYS, A VACUUM TRUCK
COMES BY TO COLLECT IT.
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IN ITS CURRENT STATE,
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THE OIL CONTAINS WATER
AND FOOD PARTICLES,
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MAKING IT UNUSABLE
FOR BIODIESEL PRODUCTION,
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SO THE TRUCK TRANSPORTS IT
TO A FILTERING PLANT.
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THERE, THEY PUMP THE OIL
INTO A HOLDING TANK,
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00:07:04,551 --> 00:07:07,482
THEN HEAT IT UP
TO DRAW OUT THE WATER.
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00:07:10,172 --> 00:07:11,896
ONCE THEY DRAIN THE WATER,
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00:07:11,896 --> 00:07:15,344
THE OIL IS READY TO ENTER
A MULTI-STAGE FILTERING PROCESS.
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00:07:17,689 --> 00:07:21,172
FIRST, THE OIL GOES
THROUGH A VIBRATING SIEVE
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00:07:21,172 --> 00:07:24,965
WHICH STRAINS OUT
THE LARGER PIECES OF DEBRIS.
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00:07:24,965 --> 00:07:27,655
AFTER THIS FIRST FILTERING,
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00:07:27,655 --> 00:07:30,896
THE OIL IS
ALREADY VISIBLY CLEANER.
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00:07:30,896 --> 00:07:33,896
NEXT, IT PASSES THROUGH
A SECOND VIBRATING SIEVE.
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00:07:33,896 --> 00:07:35,896
THIS ONE HAS A FINER MESH.
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00:07:35,896 --> 00:07:38,827
THEREFORE, IT CATCHES
SMALLER PARTICLES OF DEBRIS.
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00:07:38,827 --> 00:07:41,103
AFTER THIS SECOND STAGE,
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00:07:41,103 --> 00:07:45,827
THE OIL LOOKS CLEAN BUT STILL
CONTAINS MICROSCOPIC DEBRIS,
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00:07:45,827 --> 00:07:50,068
SO IT ENTERS THE THIRD
AND FINAL FILTERING STAGE --
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00:07:50,068 --> 00:07:52,965
PASSING THROUGH
20 ULTRA-FINE FILTER CLOTHS
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00:07:52,965 --> 00:07:56,482
WHICH TRAP ANY PARTICLE
LARGER THAN ONE MICRON IN SIZE.
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00:07:56,482 --> 00:07:58,758
A MICRON IS
ABOUT 80 TIMES SMALLER
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THAN THE WIDTH
OF A HUMAN HAIR.
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00:08:00,896 --> 00:08:06,344
THE CAPTURED DEBRIS LEAVES
A MUDDY RESIDUE ON THE FILTERS.
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00:08:06,344 --> 00:08:09,517
THAT VEGETABLE OIL,
WHICH ONCE DEEP-FRIED POTATOES,
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00:08:09,517 --> 00:08:12,931
IS NOW READY TO COOK UP
SOME DIESEL FUEL.
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00:08:14,758 --> 00:08:17,448
ANOTHER SOURCE OF OIL
FOR MAKING BIODIESEL
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00:08:17,448 --> 00:08:20,724
IS BEEF TALLOW --
OIL DERIVED FROM COW FAT.
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00:08:20,724 --> 00:08:23,448
BIODIESEL PRODUCERS
TYPICALLY BUY TALLOW
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00:08:23,448 --> 00:08:26,620
FROM FACILITIES LIKE THIS ONE,
WHICH SPECIALIZE
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00:08:26,620 --> 00:08:29,586
IN CLEANING COW HIDES
FOR LEATHER TANNERIES.
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00:08:29,586 --> 00:08:31,965
SHARP, REVOLVING BLADES
145
00:08:31,965 --> 00:08:36,448
SHEAR OFF THE FAT
FROM THE BACK OF THE HIDE.
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00:08:36,448 --> 00:08:39,000
THE FAT DROPS ONTO A CONVEYOR,
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00:08:39,000 --> 00:08:42,068
WHICH MOVES IT INTO
A STEAM-INJECTION COOK TANK.
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00:08:42,068 --> 00:08:45,068
THE TANK HEATS THE FAT
TO A GENTLE BOIL,
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00:08:45,068 --> 00:08:46,586
EXTRACTING THE OIL.
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00:08:46,586 --> 00:08:48,482
EVERYTHING ELSE LEAVES THE TANK
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00:08:48,482 --> 00:08:51,793
AND DROPS
INTO A WASTE CONTAINER.
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00:08:51,793 --> 00:08:54,448
THE OIL MOVES ONWARD,
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00:08:54,448 --> 00:08:57,758
PASSING THROUGH
A TWO-STAGE FILTRATION PROCESS.
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00:09:05,103 --> 00:09:09,517
WHETHER THE RAW MATERIAL IS
VEGETABLE OIL OR BEEF TALLOW,
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00:09:09,517 --> 00:09:11,379
THE BIODIESEL PRODUCERS
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00:09:11,379 --> 00:09:14,000
REFER TO THIS MAIN INGREDIENT
AS FEEDSTOCK.
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00:09:14,000 --> 00:09:17,068
WHEN THE FEEDSTOCK ARRIVES
AT THE BIODIESEL PLANT,
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00:09:17,068 --> 00:09:21,344
IT GOES INTO A HOLDING TANK
UNTIL PRODUCTION TIME.
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00:09:21,344 --> 00:09:26,344
THIS DEMONSTRATION ILLUSTRATES
THE PRODUCTION RECIPE.
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00:09:26,344 --> 00:09:28,172
THEY TAKE THE FEEDSTOCK
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00:09:28,172 --> 00:09:32,103
AND COMBINE IT WITH METHANOL,
A TYPE OF WOOD ALCOHOL,
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00:09:32,103 --> 00:09:33,862
AS WELL AS WITH A CATALYST,
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00:09:33,862 --> 00:09:36,241
WHICH TRIGGERS
A CHEMICAL REACTION.
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00:09:36,241 --> 00:09:38,896
A PROCESSING UNIT
MIXES EVERYTHING THOROUGHLY
165
00:09:38,896 --> 00:09:41,068
WHILE APPLYING
HEAT AND PRESSURE.
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00:09:41,068 --> 00:09:44,379
THE RESULTING CHEMICAL REACTION
PRODUCES A HARMLESS BYPRODUCT,
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00:09:44,379 --> 00:09:48,827
GLYCERIN, A COMMON INGREDIENT
IN SOAPS AND COSMETICS.
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00:09:48,827 --> 00:09:52,000
PROCESSING CONSUMES
MUCH OF THE METHANOL.
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00:09:52,000 --> 00:09:54,068
THEN THEY REMOVE EVEN MORE,
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00:09:54,068 --> 00:09:56,172
LEAVING JUST
A TINY PERCENTAGE OF IT
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00:09:56,172 --> 00:09:57,827
IN THE FINISHED BIODIESEL.
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00:09:57,827 --> 00:09:59,517
TO ENSURE THEIR FUEL MEETS
173
00:09:59,517 --> 00:10:01,896
INTERNATIONAL
REGULATORY STANDARDS,
174
00:10:01,896 --> 00:10:04,482
THE PLANT'S
QUALITY-CONTROL LAB SAMPLES
175
00:10:04,482 --> 00:10:06,862
FROM EACH PRODUCTION RUN.
176
00:10:08,241 --> 00:10:10,586
IN THIS FLAMMABILITY TEST,
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00:10:10,586 --> 00:10:13,965
THEY HEAT THE FUEL
TO 275 DEGREES FAHRENHEIT,
178
00:10:13,965 --> 00:10:16,931
THEN APPLY A FLAME TO SEE
WHETHER THE GASES IGNITE.
179
00:10:16,931 --> 00:10:19,931
IF THEY DO, THEY HAVE
TO REMOVE MORE METHANOL
180
00:10:19,931 --> 00:10:21,620
TO MAKE THE FUEL SAFE.
181
00:10:21,620 --> 00:10:23,103
IF THEY DON'T IGNITE,
182
00:10:23,103 --> 00:10:25,586
THE FUEL MEETS
INTERNATIONAL SAFETY STANDARDS.
183
00:10:27,724 --> 00:10:30,379
BIODIESEL COSTS MORE
AT THE PUMP,
184
00:10:30,379 --> 00:10:34,517
BUT EMITS SIGNIFICANTLY LESS
CARBON DIOXIDE AND MONOXIDE
185
00:10:34,517 --> 00:10:37,793
AND 85% FEWER
CANCER-CAUSING AGENTS
186
00:10:37,793 --> 00:10:40,068
INTO THE AIR WE BREATHE.
187
00:10:51,103 --> 00:10:53,137
Narrator:
UNTIL THE MID-1800s,
188
00:10:53,137 --> 00:10:55,724
PEOPLE FOLDED
OR LAID THEIR CLOTHES FLAT
189
00:10:55,724 --> 00:10:57,655
OR HUNG THEM ON HOOKS OR PEGS.
190
00:10:57,655 --> 00:11:01,068
ONCE IT BECAME MORE COMMON
TO STORE CLOTHES IN A WARDROBE,
191
00:11:01,068 --> 00:11:04,103
SOMEONE -- HISTORIANS
DON'T KNOW EXACTLY WHO --
192
00:11:04,103 --> 00:11:05,896
INVENTED THE CLOTHES HANGER,
193
00:11:05,896 --> 00:11:09,103
A HANGING DEVICE
SHAPED LIKE HUMAN SHOULDERS.
194
00:11:11,241 --> 00:11:13,000
SINCE THE MID 19th CENTURY,
195
00:11:13,000 --> 00:11:16,620
HUNDREDS OF INVENTORS HAVE
PATENTED VARIOUS SHAPED HANGERS,
196
00:11:16,620 --> 00:11:19,206
MANY OF WHICH ARE
STILL BEING PRODUCED TODAY.
197
00:11:19,206 --> 00:11:23,655
THIS CZECH COMPANY MAKES WOODEN
HANGERS IN SEVERAL STYLES.
198
00:11:23,655 --> 00:11:27,655
IT USES BEECH,
A HARD AND DURABLE TYPE OF WOOD.
199
00:11:27,655 --> 00:11:31,172
THE DAMP LOGS AIR-DRY OUTDOORS
FOR SEVEN MONTHS,
200
00:11:31,172 --> 00:11:33,758
THEN GO INTO A KILN
FOR THREE TO FOUR WEEKS.
201
00:11:33,758 --> 00:11:35,482
DRYING THE WOOD IS CRITICAL.
202
00:11:35,482 --> 00:11:36,896
OTHERWISE, THE HANGERS
203
00:11:36,896 --> 00:11:39,931
WOULD EXPAND AND CONTRACT
WITH TEMPERATURE CHANGES
204
00:11:39,931 --> 00:11:41,724
AND EVENTUALLY CRACK.
205
00:11:41,724 --> 00:11:43,206
WORKERS FIRST USE A BAND SAW
206
00:11:43,206 --> 00:11:46,448
TO SLICE THE LOGS
INTO 2 1/2-INCH-THICK PLANKS.
207
00:11:46,448 --> 00:11:49,758
THEN THEY PUT EACH PLANK
THROUGH A BROACHING MACHINE.
208
00:11:49,758 --> 00:11:52,931
INSIDE, A TOOTHED BLADE
PLANES THE WOOD,
209
00:11:52,931 --> 00:11:56,827
RENDERING THE TOP AND BOTTOM
SURFACES LEVEL AND SMOOTH.
210
00:11:58,758 --> 00:12:03,068
NEXT STOP IS A GRINDING MACHINE
WHICH CONTAINS ABRASIVE BELTS.
211
00:12:10,448 --> 00:12:16,000
WORKERS FEED THE PLANKS
INTO THE MACHINE ONE AT A TIME.
212
00:12:19,034 --> 00:12:21,068
AS EACH PLANK PASSES THROUGH,
213
00:12:21,068 --> 00:12:24,586
THE BELTS ABOVE IT
SAND THE TOPS SILKY SMOOTH.
214
00:12:24,586 --> 00:12:26,862
WHEN THE PLANK
EXITS THE MACHINE,
215
00:12:26,862 --> 00:12:31,241
WORKERS FLIP AND REFEED IT
TO SMOOTH THE OTHER SIDE.
216
00:12:31,241 --> 00:12:35,000
AN AUTOMATED SAW CUTS
EACH PLANK IN HALF...
217
00:12:38,965 --> 00:12:41,931
...AND TRIMS THE HALVES
TO A SPECIFIC DIMENSION.
218
00:12:43,689 --> 00:12:47,068
THE NOW-SMALLER PLANKS GO
INTO ANOTHER GRINDING MACHINE
219
00:12:47,068 --> 00:12:49,758
WHICH SANDS THE SIDES SMOOTH.
220
00:12:53,448 --> 00:12:56,344
NOW THE HANGER SHAPING BEGINS.
221
00:12:56,344 --> 00:12:58,551
WORKERS STACK 10 PLANKS
222
00:12:58,551 --> 00:13:02,103
AND, USING A CIRCULAR SAW,
CUT THEM TO THE SAME LENGTH,
223
00:13:02,103 --> 00:13:04,172
THE ENDS AT A 60-DEGREE ANGLE.
224
00:13:08,758 --> 00:13:11,793
THEY MOUNT FOUR PLANKS AT A TIME
ON A MILLING MACHINE
225
00:13:11,793 --> 00:13:14,689
AND CUT A TONGUE-AND-GROOVE
PROFILE ON THE EDGES.
226
00:13:14,689 --> 00:13:17,034
THEY'LL LATER CONNECT
THE HANGER PARTS
227
00:13:17,034 --> 00:13:19,655
BY FITTING THE TONGUES
INTO THE GROOVES.
228
00:13:21,620 --> 00:13:23,344
STACKING SIX PLANKS NOW,
229
00:13:23,344 --> 00:13:27,034
THEY TRACE A HANGER-SHAPED
TEMPLATE ON THE TOP SURFACE,
230
00:13:27,034 --> 00:13:29,931
THEN CAREFULLY FOLLOW
THE TRACE LINE WITH A JIGSAW.
231
00:13:33,275 --> 00:13:36,379
EACH PLANK IS NOW ROUGHLY SHAPED
INTO A HALF A HANGER,
232
00:13:36,379 --> 00:13:38,758
WHICH THEY CALL A LAMELLA.
233
00:13:41,862 --> 00:13:44,517
THIS PARTICULAR HANGER
IS DESIGNED FOR DRESSES,
234
00:13:44,517 --> 00:13:47,482
SO THEY MILL A GROOVE
IN THE SHOULDER OF EACH LAMELLA
235
00:13:47,482 --> 00:13:50,068
FOR GARMENT STRAPS.
236
00:13:50,068 --> 00:13:52,586
THEN AN AUTOMATED
MILLING MACHINE
237
00:13:52,586 --> 00:13:55,137
REFINES AND FINALIZES
THE HANGER'S SHAPE,
238
00:13:55,137 --> 00:13:58,862
SMOOTHING THE ROUGHLY CUT WOOD
IN THE PROCESS.
239
00:14:00,689 --> 00:14:03,344
NEXT, WITH STRONG
CABINETMAKER'S GLUE,
240
00:14:03,344 --> 00:14:06,586
THEY COAT THE TONGUES
AND GROOVES OF TWO LAMELLAS,
241
00:14:06,586 --> 00:14:08,482
THEN FIT THEM TOGETHER
ON A PRESS.
242
00:14:08,482 --> 00:14:10,758
THEY LET THE GLUE DRY
FOR A DAY,
243
00:14:10,758 --> 00:14:13,137
THEN SAW THE POINT OFF THE TOP.
244
00:14:13,137 --> 00:14:15,068
THIS CREATES A FLAT AREA
245
00:14:15,068 --> 00:14:17,655
INTO WHICH TO INSERT
THE HANGER'S HOOK.
246
00:14:17,655 --> 00:14:19,517
THERE'S ALREADY A HOLE
FOR IT THERE,
247
00:14:19,517 --> 00:14:22,034
MADE WHEN THEY MILLED
THE TONGUE-AND-GROOVE PROFILE.
248
00:14:25,310 --> 00:14:28,827
NEXT, THEY SAND THE JOINT
TO REMOVE EXCESS GLUE
249
00:14:28,827 --> 00:14:32,206
AND SMOOTH OUT ANY NICKS
OR TEARS IN THE WOOD.
250
00:14:32,206 --> 00:14:34,275
THEN THEY ROUND
THE ANGULAR JOINT.
251
00:14:38,241 --> 00:14:40,137
TO SEAL AND PROTECT THE WOOD,
252
00:14:40,137 --> 00:14:42,793
THEY NOW SPRAY
THE ENTIRE SURFACE WITH VARNISH.
253
00:14:42,793 --> 00:14:45,620
WHEN IT DRIES,
THEY DO A ROUGH SANDING,
254
00:14:45,620 --> 00:14:49,758
THEN APPLY A SECOND COAT
AND LET THAT DRY.
255
00:14:49,758 --> 00:14:51,620
MANY CUSTOMERS WANT THEIR LOGO
256
00:14:51,620 --> 00:14:53,896
PRINTED ON THE HANGERS
THEY ORDER.
257
00:14:53,896 --> 00:14:55,206
THE PRINTING MACHINE
258
00:14:55,206 --> 00:14:57,517
COATS A LOGO-EMBOSSED RUBBER PAD
WITH INK.
259
00:14:57,517 --> 00:15:00,206
A SPONGE DABS THE PAD,
260
00:15:00,206 --> 00:15:02,586
THEN STAMPS THE LOGO
ONTO THE HANGER.
261
00:15:07,344 --> 00:15:10,172
FINALLY,
THE HANGER'S IRON HOOK --
262
00:15:10,172 --> 00:15:12,655
IT'S EITHER NICKEL-PLATED
FOR A SILVER TONE
263
00:15:12,655 --> 00:15:15,000
OR BRASS-PLATED
FOR A GOLD TONE.
264
00:15:15,000 --> 00:15:16,689
WORKERS POSITION THE HOOK.
265
00:15:16,689 --> 00:15:18,896
THEN A PRESS RAMS IT
INTO THE WOOD
266
00:15:18,896 --> 00:15:20,482
4/10 OF AN INCH DEEP.
267
00:15:20,482 --> 00:15:23,275
THE HOOK HAS SCREWLIKE THREADS
AT THE BASE
268
00:15:23,275 --> 00:15:28,137
WHICH GRAB AND LOCK
INTO THE SURROUNDING WOOD.
269
00:15:28,137 --> 00:15:29,965
FOR CERTAIN MODELS,
270
00:15:29,965 --> 00:15:33,379
THE FACTORY STAINS OR PAINTS
THE WOOD PRIOR TO VARNISHING IT.
271
00:15:33,379 --> 00:15:36,241
AFTER ALL, MANY PEOPLE
LIKE THEIR CLOTHES HANGERS
272
00:15:36,241 --> 00:15:38,827
TO MAKE
A FASHION STATEMENT, TOO.
273
00:15:49,896 --> 00:15:51,793
Narrator:
AN ERUPTING VOLCANO
274
00:15:51,793 --> 00:15:54,413
LED TO THE INVENTION
OF STONE WOOL INSULATION
275
00:15:54,413 --> 00:15:56,103
A CENTURY AND A HALF AGO.
276
00:15:56,103 --> 00:15:58,586
IT WAS OBSERVED
THAT VOLCANIC LAVA
277
00:15:58,586 --> 00:16:02,206
COULD BE WHIPPED INTO WOOLLY
TUFTS BY PREVAILING WINDS.
278
00:16:02,206 --> 00:16:05,275
SOON, THIS WAS BEING REPLICATED
IN FACTORIES
279
00:16:05,275 --> 00:16:07,965
TO PRODUCE STONE WOOL
FOR INSULATION.
280
00:16:11,862 --> 00:16:13,655
SHAPED INTO BATTS,
281
00:16:13,655 --> 00:16:16,241
STONE WOOL INSULATION
CAN BE TUCKED SNUGLY
282
00:16:16,241 --> 00:16:18,517
BETWEEN THE STUDS
OF A FRAMED WALL.
283
00:16:18,517 --> 00:16:23,241
IT ACTS AS BOTH A THERMAL
AND ACOUSTIC INSULATOR.
284
00:16:23,241 --> 00:16:25,827
AND HERE'S
THE SOUNDPROOFING PROOF.
285
00:16:25,827 --> 00:16:27,275
IN THIS DEMONSTRATION,
286
00:16:27,275 --> 00:16:31,482
AN ACTIVATED ALARM GOES INTO
A BOX LINED WITH STONE WOOL.
287
00:16:31,482 --> 00:16:34,862
WHEN THE LID IS CLOSED,
THE SOUND IS CONTAINED.
288
00:16:34,862 --> 00:16:38,551
AND WHEN IT'S LIFTED AGAIN,
THE ANNOYING SOUND IS BACK.
289
00:16:42,862 --> 00:16:46,620
THEY MAKE STONE WOOL
FROM BASALT ROCK AND SLAG
290
00:16:46,620 --> 00:16:49,000
RECYCLED
FROM THE STEEL INDUSTRY.
291
00:16:49,000 --> 00:16:52,586
THE PROCESS IS FUELED BY COKE,
WHICH IS A FORM OF COAL.
292
00:16:55,068 --> 00:16:58,172
BASALT ROCK
IS SOLIDIFIED LAVA FORMED
293
00:16:58,172 --> 00:17:01,689
WHEN ROCK MELTS UNDERGROUND
AND THEN QUICKLY COOLS.
294
00:17:01,689 --> 00:17:04,724
AFTER THE ROCK HAS BEEN
PARTIALLY CRUSHED AT THE QUARRY,
295
00:17:04,724 --> 00:17:06,896
A LOADER SCOOPS IT ONTO A SCREEN
296
00:17:06,896 --> 00:17:10,172
TO SEPARATE THE BIGGER PIECES
FROM THE FINE PARTICLES.
297
00:17:10,172 --> 00:17:12,724
THE PARTICLES WILL BE PROCESSED
INTO BRIQUETTES,
298
00:17:12,724 --> 00:17:15,827
WHICH CAN BE USED
IN THE PRODUCTION OF STONE WOOL,
299
00:17:15,827 --> 00:17:18,482
ALONG WITH THE BIGGER PIECES
OF ROCK.
300
00:17:18,482 --> 00:17:21,586
THE ROCK AND BRIQUETTES,
ALONG WITH THE STEEL SLAG,
301
00:17:21,586 --> 00:17:24,000
MELT INTO LAVA IN A FURNACE.
302
00:17:24,000 --> 00:17:26,965
TEMPERATURES REACH
2,700 DEGREES FAHRENHEIT --
303
00:17:26,965 --> 00:17:28,724
AS HOT AS A VOLCANO.
304
00:17:28,724 --> 00:17:30,965
A SPINNING MACHINE
WHIPS THE LAVA
305
00:17:30,965 --> 00:17:32,689
INTO THIN STANDS OF STONE WOOL
306
00:17:32,689 --> 00:17:35,034
IN A PROCESS
THAT'S LIKE MAKING COTTON CANDY.
307
00:17:35,034 --> 00:17:37,103
THE STRANDS FORM TUFTS,
308
00:17:37,103 --> 00:17:40,206
AND A LITTLE BINDING SOLUTION
HOLDS THEM TOGETHER.
309
00:17:40,206 --> 00:17:42,655
A SPRAY OF OIL
ADDS WATER REPELLENCE.
310
00:17:43,551 --> 00:17:46,000
NOW A FLEECY WEB,
311
00:17:46,000 --> 00:17:49,413
THE STONE WOOL RIDES A CONVEYOR
TO THE FACTORY'S UPPER LEVEL,
312
00:17:49,413 --> 00:17:54,482
WHERE IT SPILLS
INTO A HUGE PENDULUM DEVICE.
313
00:17:54,482 --> 00:17:56,862
THE PENDULUM SWINGS TO AND FRO
314
00:17:56,862 --> 00:18:01,034
TO LAYER THE STONE WOOL
IN A ZIGZAG PATTERN.
315
00:18:01,034 --> 00:18:02,586
THE NUMBER OF LAYERS VARIES,
316
00:18:02,586 --> 00:18:04,827
DEPENDING ON THE KIND
OF INSULATION BEING MADE.
317
00:18:04,827 --> 00:18:08,103
THE NOW-LAYERED STONE WOOL
318
00:18:08,103 --> 00:18:11,620
TRAVELS BETWEEN ROLLERS
THAT COMPRESS IT SUBSTANTIALLY,
319
00:18:11,620 --> 00:18:14,275
ADDING DENSITY TO THE WOOL.
320
00:18:14,275 --> 00:18:17,379
AUTOMATED PUSHERS
TUCK IN THE PACK ON EACH SIDE
321
00:18:17,379 --> 00:18:19,862
AS THE WOOL ENTERS A LONG OVEN.
322
00:18:19,862 --> 00:18:22,482
THE HEAT CURES THE BINDER
APPLIED EARLIER,
323
00:18:22,482 --> 00:18:25,586
ALLOWING THE COMPRESSED FIBERS
TO HOLD THEIR SHAPE.
324
00:18:27,965 --> 00:18:31,793
THE NOW-TIGHTER PACK
EXITS THROUGH A COOLING ZONE
325
00:18:31,793 --> 00:18:34,172
AND TRAVELS UNDER A ROLLER
326
00:18:34,172 --> 00:18:36,724
WHICH SQUEEZES IT TO MAKE
THE FIBERS MORE FLEXIBLE.
327
00:18:36,724 --> 00:18:38,758
CIRCULAR BLADES THEN SLICE
328
00:18:38,758 --> 00:18:42,172
THE MOVING MASS OF STONE WOOL
LENGTHWISE.
329
00:18:43,931 --> 00:18:48,068
A BRANDING TOOL BURNS
THE R-VALUE AND COMPANY NAME
330
00:18:48,068 --> 00:18:51,172
ONTO THE SURFACE OF THE
INSULATION AS IT MOVES FORWARD.
331
00:18:54,896 --> 00:18:57,275
ROBOTIC ARMS
SWING BACK AND FORTH
332
00:18:57,275 --> 00:19:01,551
TO SLICE THE INSULATION
TO ITS FINAL DIMENSIONS.
333
00:19:01,551 --> 00:19:03,896
INSTEAD OF SHARP, STEEL BLADES,
334
00:19:03,896 --> 00:19:09,275
THESE ROBOTS USE HIGH-PRESSURE
WATER JETS TO MAKE THEIR CUTS.
335
00:19:09,275 --> 00:19:11,034
THE JETS DO A PRECISE JOB
336
00:19:11,034 --> 00:19:13,551
WITHOUT GENERATING DUST
OR WASTE,
337
00:19:13,551 --> 00:19:17,827
AND THE STONE WOOL DOESN'T
ABSORB THE WATER FROM THE JETS.
338
00:19:17,827 --> 00:19:20,965
THE SHEER DENSITY OF THE WOOL
MAKES IT MOISTURE-RESISTANT,
339
00:19:20,965 --> 00:19:23,965
ALONG WITH THE OIL ADDED
TO THE FIBERS DURING SPINNING.
340
00:19:30,068 --> 00:19:33,137
TO DEMONSTRATE STONE WOOL'S
WATER-REPELLENT QUALITIES,
341
00:19:33,137 --> 00:19:35,965
THEY POUR WATER
DIRECTLY ONTO THE SURFACE.
342
00:19:35,965 --> 00:19:40,000
THERE'S NO ABSORPTION.
THE WATER JUST RUNS OFF.
343
00:19:42,551 --> 00:19:44,448
IN THIS ROUTINE TEST,
344
00:19:44,448 --> 00:19:47,827
A WORKER TORCHES THE WOOL,
AND IT DOESN'T CATCH FIRE.
345
00:19:47,827 --> 00:19:50,655
STONE WOOL
CAN WITHSTAND TEMPERATURES
346
00:19:50,655 --> 00:19:53,965
OF ALMOST 2,200 DEGREES
FAHRENHEIT
347
00:19:53,965 --> 00:19:55,724
DUE TO ITS NATURAL PROPERTIES.
348
00:19:55,724 --> 00:19:59,241
IT'S EVEN COOL TO THE TOUCH
ON THE OTHER SIDE.
349
00:19:59,241 --> 00:20:02,793
ONCE IT'S PASSED
SEVERAL QUALITY-CONTROL TESTS,
350
00:20:02,793 --> 00:20:06,137
THE INSULATION HEADS
FOR THE PACKAGING LINE.
351
00:20:06,137 --> 00:20:10,517
GRIPPERS PULL ON A ROLL
OF PLASTIC TUBE PACKAGING,
352
00:20:10,517 --> 00:20:14,137
AND HOT JAWS CUT AND SEAL
ONE END TO FORM AN OPEN BAG.
353
00:20:14,137 --> 00:20:17,137
MECHANICAL FINGERS HOLD
THE OTHER END OPEN
354
00:20:17,137 --> 00:20:19,068
AS MACHINERY SLIDES IT
OVER A METAL SPOUT.
355
00:20:19,068 --> 00:20:22,724
A COMPRESSED STACK OF INSULATION
IS PUSHED INTO THE SPOUT.
356
00:20:22,724 --> 00:20:24,034
THE SPOUT EXPANDS,
357
00:20:24,034 --> 00:20:26,965
AND THE INSULATION IS RELEASED
INTO THE BAG.
358
00:20:26,965 --> 00:20:31,137
THE SPOUT THEN RETRACTS,
AND THE PROCESS IS REPEATED.
359
00:20:31,137 --> 00:20:34,103
MACHINERY HEAT-SEALS
THE OPEN END.
360
00:20:34,103 --> 00:20:38,586
FROM A PILE OF BASALT ROCK
AND RECYCLED STEEL SLAG
361
00:20:38,586 --> 00:20:40,724
TO A BAG FULL OF INSULATION,
362
00:20:40,724 --> 00:20:43,551
IT'S BEEN
A WILD AND WOOLLY RIDE.
363
00:20:50,931 --> 00:20:53,758
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
364
00:20:53,758 --> 00:20:56,482
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
365
00:20:56,482 --> 00:20:58,586
DROP US A LINE AT...
29424
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