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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: THE INVENTION
OF MECHANIZED GAME CALLS
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IN THE MIDDLE
OF THE 19th CENTURY
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ALLOWED HUNTERS TO MIMIC
THE SOUNDS OF THEIR PREY.
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BEFORE THESE DEVICES CAME ALONG,
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HUNTERS WHISTLED AND MADE NOISES
WITH THEIR HANDS
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TO LURE BIRDS OR ANIMALS
INTO SHOOTING RANGE,
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00:01:08,655 --> 00:01:12,413
AND THEIR EFFORTS
WEREN'T ALWAYS ON THE MARK.
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00:01:15,586 --> 00:01:19,137
WHETHER IT'S A MATING CALL
OR JUST A SOCIABLE "HEY, THERE,"
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A GAME CALL IS ABOUT
SPEAKING THE LANGUAGE.
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00:01:21,862 --> 00:01:24,413
OF COURSE, IT ALL TRANSLATES
INTO BIG TROUBLE
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00:01:24,413 --> 00:01:27,655
FOR BIRDS AND ANIMALS
WHO RESPOND.
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00:01:27,655 --> 00:01:31,344
THERE ARE DOZENS
OF DIFFERENT GAME CALLS,
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00:01:31,344 --> 00:01:33,655
FROM DUCK TO GOOSE TO ELK.
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00:01:33,655 --> 00:01:38,275
EACH GAME CALL IS
A PRECISELY CRAFTED INSTRUMENT.
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00:01:38,275 --> 00:01:42,275
TO MAKE ONE, THEY DON'T HAVE TO
LOOK FAR FOR RAW MATERIAL.
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00:01:42,275 --> 00:01:44,068
A BAMBOO CROP FLOURISHES
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IN THE BACKYARD
OF THE LOUISIANA FACTORY.
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BAMBOO IS ONE OF
THE FASTEST-GROWING PLANTS
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00:01:51,206 --> 00:01:56,275
ON THE PLANET, SO THERE'S ALWAYS
A READY SUPPLY.
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00:01:56,275 --> 00:01:57,724
THE STEM IS HOLLOW,
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WHICH MAKES IT IDEAL FOR
THE GAME CALL'S LARGER BARREL.
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AFTER THE BAMBOO CANE HAS BEEN
DRIED FOR SIX TO EIGHT WEEKS,
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THEY CUT IT TO LENGTH --
ABOUT 3 INCHES.
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00:02:08,137 --> 00:02:10,137
BUT BAMBOO ISN'T THE ONLY WOOD
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00:02:10,137 --> 00:02:12,551
THEY USE
FOR MAKING CALL BARRELS.
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OTHERS ARE CONSTRUCTED FROM
WALNUT, CHERRY, OR EXOTIC WOODS.
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00:02:16,862 --> 00:02:19,172
THEY'RE HARDER
AND A BIT MORE RUGGED,
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00:02:19,172 --> 00:02:21,379
BUT, OF COURSE,
THEY'RE ALSO SOLID.
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00:02:21,379 --> 00:02:25,275
A BORING MACHINE HOLLOWS OUT
THESE SOLID WALNUT BLANKS.
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00:02:25,275 --> 00:02:29,103
THEY LOAD THEM SIX AT A TIME
INTO THE MACHINE'S SLOTS,
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00:02:29,103 --> 00:02:33,034
AND THEN LOWER A HOLDING BAR
TO SECURE THEM FOR DRILLING.
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00:02:33,034 --> 00:02:36,448
A CARRIAGE MOVES
THE DRILL BITS FORWARD,
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00:02:36,448 --> 00:02:40,137
AND THEY HIT THE WALNUT BLANKS
DEAD CENTER.
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A WORKER LOCKS A HOLLOW BARREL
IN A LATHE.
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AS IT SPINS,
HE MANIPULATES A BLADE
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00:02:45,758 --> 00:02:48,379
TO CARVE
A SLIGHTLY CONCAVE PROFILE.
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00:02:48,379 --> 00:02:50,655
THIS WILL MAKE IT
EASIER TO GRIP.
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00:02:50,655 --> 00:02:53,034
HE ALSO CUTS DESIGNS
INTO THE WOOD,
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00:02:53,034 --> 00:02:57,103
WHICH IDENTIFY THIS INSTRUMENT
AS A CERTAIN DUCK CALL.
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00:02:57,103 --> 00:03:00,517
EACH CALL HAS ITS OWN
DISTINGUISHING DESIGN.
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00:03:00,517 --> 00:03:03,655
AS THE DUCK-CALL BARREL
CONTINUES TO SPIN,
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00:03:03,655 --> 00:03:06,379
HE SANDS AWAY
ANY BURRS OR SPLINTERS.
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00:03:06,379 --> 00:03:08,482
WHAT WAS A SIMPLE, WOODEN TUBE
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00:03:08,482 --> 00:03:12,206
NOW HAS FLOWING LINES
AND A DEFINING DESIGN.
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00:03:12,206 --> 00:03:15,620
NEXT, THEY SPIN A STONE
ON EACH END OF THE BARREL,
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00:03:15,620 --> 00:03:19,172
CREATING A BURN THAT BLACKENS
AND SMOOTHES THE RIMS.
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00:03:19,172 --> 00:03:21,655
THE GAME-CALL BARRELS
THEN FUNNEL
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INTO THE CLUTCH OF PRONGS
ON A REVOLVING WHEEL.
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00:03:26,310 --> 00:03:28,310
AS THE WHEEL TURNS,
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00:03:28,310 --> 00:03:31,586
THE BARRELS BRUSH AGAINST
A SERIES OF SANDING BELTS,
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00:03:31,586 --> 00:03:34,344
EACH ONE WITH A FINER GRIT
THAN THE LAST.
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00:03:34,344 --> 00:03:37,517
THIS FINAL SANDING
MAKES THE BARRELS SUPER SMOOTH.
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WITH A SET OF PINCERS, HE DIPS
THE BARRELS IN A SOLUTION
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00:03:41,103 --> 00:03:43,931
TO SEAL THE WOOD INSIDE AND OUT.
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THE SEALANT WILL PROTECT
THE WOODEN BARREL
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00:03:47,655 --> 00:03:51,241
FROM RAIN, HUMIDITY,
AND THE USER'S SALIVA.
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00:03:51,241 --> 00:03:53,793
AFTER DIPPING,
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00:03:53,793 --> 00:03:56,482
HE LEAVES THE PARTS IN THE SUN
FOR SEVERAL HOURS
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00:03:56,482 --> 00:03:58,034
TO BAKE ON THE SEALANT.
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00:03:58,034 --> 00:04:00,758
MEANWHILE, THEY MACHINE
A SMALLER BARREL
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00:04:00,758 --> 00:04:03,482
WHICH WILL HOLD
THE NOISE-MAKING PARTS.
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00:04:03,482 --> 00:04:04,862
USING A REAMING TOOL,
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00:04:04,862 --> 00:04:07,965
THE WORKER TAPERS THE OPENING
OF THE LARGER BARREL,
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00:04:07,965 --> 00:04:10,793
AND THE TWO BARRELS
NOW FIT SNUGLY TOGETHER.
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00:04:10,793 --> 00:04:13,482
A WORKER BUFFS THE BARREL
WITH STEEL WOOL
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00:04:13,482 --> 00:04:15,241
AS IT SPINS ON A MANDREL.
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00:04:15,241 --> 00:04:18,275
THE BUFFING GIVES THE WOOD
A SILKY TEXTURE,
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00:04:18,275 --> 00:04:23,034
AND PREPARES IT
FOR A FINAL SEALANT.
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00:04:23,034 --> 00:04:26,586
PRODUCTION NOW TURNS
TO THE NOISE-MAKING INSERT.
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00:04:26,586 --> 00:04:29,758
A WORKER POUNDS A DIE
INTO A STRIP OF RIGID PLASTIC
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00:04:29,758 --> 00:04:31,379
TO PUNCH OUT THE REEDS.
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00:04:31,379 --> 00:04:34,758
IT'S THIS PART THAT VIBRATES
AGAINST THE TONE BOARD
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00:04:34,758 --> 00:04:36,206
TO PRODUCE SOUND.
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00:04:36,206 --> 00:04:38,068
THE REED'S SHAPE VARIES
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00:04:38,068 --> 00:04:40,448
DEPENDING ON THE KIND OF CALL
BEING MADE.
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00:04:40,448 --> 00:04:43,241
HE ALIGNS THE REED
WITH THE WOODEN TONE BOARD,
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00:04:43,241 --> 00:04:44,586
AND THEN INSERTS THEM
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00:04:44,586 --> 00:04:47,103
PART OF THE WAY INTO THE BARREL
OF THE GAME CALL.
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00:04:47,103 --> 00:04:49,310
HE SANDS A LITTLE, WOODEN WEDGE
82
00:04:49,310 --> 00:04:52,000
THAT WILL HOLD EVERYTHING
IN PLACE.
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00:04:52,000 --> 00:04:53,827
HE PUSHES IT INTO THE SPACE
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00:04:53,827 --> 00:04:56,931
BETWEEN THE BARREL AND THE REED
AND TONE BOARD.
85
00:04:56,931 --> 00:04:58,482
THEN, USING A METAL FILE,
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00:04:58,482 --> 00:05:01,517
HE FORCES THE WEDGE
EVEN FURTHER INTO THE OPENING
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00:05:01,517 --> 00:05:03,655
TO ENSURE THE PARTS WON'T BUDGE.
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00:05:03,655 --> 00:05:05,482
HE SLIDES THE LARGER BARREL
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00:05:05,482 --> 00:05:08,310
OVER THE PROTRUDING REED
AND TONE BOARD.
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00:05:12,275 --> 00:05:15,655
AFTER SOME TUNING,
THE GAME CALL IS READY.
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00:05:17,379 --> 00:05:21,137
IN A WAY, HUNTING CALLS
ARE LIKE MUSICAL INSTRUMENTS --
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00:05:21,137 --> 00:05:25,000
IT TAKES PRACTICE AND KNOW-HOW
TO USE ONE SUCCESSFULLY.
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BUT ONCE MASTERED,
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00:05:31,344 --> 00:05:35,689
THIS INSTRUMENT COULD ATTRACT
FLOCKS OF ADMIRERS.
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00:05:37,000 --> 00:05:40,482
AFTER ALL, EVERY GAME CALL
HAS A TARGET AUDIENCE.
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00:06:00,931 --> 00:06:03,241
Narrator:
ACCORDING TO ONE THEORY,
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MAYONNAISE ORIGINATED
IN THE TOWN OF MAHóN IN SPAIN,
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00:06:06,448 --> 00:06:09,068
WHERE IT WAS KNOWN
AS "SALSA MAHONESA."
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00:06:09,068 --> 00:06:11,551
MAYONNAISE
MAKES SANDWICHES ZESTIER,
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00:06:11,551 --> 00:06:13,896
TURNS CANNED TUNA
INTO TUNA SALAD,
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00:06:13,896 --> 00:06:15,896
HARD-BOILED EGGS INTO EGG SALAD,
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00:06:15,896 --> 00:06:19,137
AND IS A CREAMY DIP FOR
FRENCH FRIES, BELGIAN-STYLE.
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00:06:23,103 --> 00:06:25,620
MAYONNAISE RECIPES VARY,
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00:06:25,620 --> 00:06:28,758
BUT ALL HAVE EGGS AND OIL
AS THE MAIN INGREDIENTS.
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00:06:30,413 --> 00:06:32,103
THE EGGS CAN BE ALL YOLKS,
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00:06:32,103 --> 00:06:34,724
ALL WHITES,
OR A COMBINATION OF BOTH.
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00:06:37,241 --> 00:06:39,137
AT THIS MAYONNAISE FACTORY,
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THE RAW EGGS ARRIVE
IN LIQUID FORM BY TANKER TRUNK.
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00:06:42,620 --> 00:06:43,965
THEY'VE BEEN PASTEURIZED
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00:06:43,965 --> 00:06:47,379
TO KILL OFF SALMONELLA
AND OTHER COMMON BACTERIA.
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00:06:47,379 --> 00:06:48,517
THE EGG SUPPLIER
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00:06:48,517 --> 00:06:51,275
HAS ALSO CLEANED
AND SEALED THE TANK VALVE,
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00:06:51,275 --> 00:06:53,758
AN ADDITIONAL
FOOD-SAFETY PRECAUTION.
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00:06:53,758 --> 00:06:57,758
A WORKER CLAMPS A SANITARY
EVACUATION HOSE TO THE TANK.
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00:06:57,758 --> 00:07:02,586
THEN, WITH A FEW BLOWS
OF A MALLET, RELEASES THE VALVE.
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00:07:02,586 --> 00:07:05,172
A PUMP DRAWS THE EGGS
THROUGH THE HOSE
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00:07:05,172 --> 00:07:07,655
INTO A REFRIGERATED
RECEIVING TANK.
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00:07:07,655 --> 00:07:10,413
THE SECOND MAIN INGREDIENT,
SOY BEAN OIL,
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00:07:10,413 --> 00:07:12,379
ARRIVES BY RAILWAY TANKER CAR.
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00:07:12,379 --> 00:07:14,931
LIKE ALL BULK-INGREDIENT
DELIVERIES,
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00:07:14,931 --> 00:07:18,793
FOR FOOD SAFETY, THE TANK
IS SEALED AT THE SUPPLIER
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00:07:18,793 --> 00:07:22,482
TO ENSURE IT ISN'T OPENED
PRIOR TO ARRIVAL HERE.
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00:07:22,482 --> 00:07:27,620
A PUMPING SYSTEM TRANSFERS
THE OIL TO A LARGE HOLDING TANK.
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00:07:27,620 --> 00:07:31,379
MEANWHILE, FACTORY WORKERS
WEIGH OUT THE INGREDIENTS
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00:07:31,379 --> 00:07:35,379
THAT MAKE UP THIS COMPANY'S
SECRET BLEND OF SPICES.
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00:07:35,379 --> 00:07:37,758
NEXT, THEY MIX THIS SPICE BLEND
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00:07:37,758 --> 00:07:41,206
WITH WHITE VINEGAR,
CIDER VINEGAR, AND SALT.
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00:07:44,068 --> 00:07:47,206
THEN THEY ADD
LIQUID NATURAL FLAVORS.
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00:07:50,965 --> 00:07:52,482
THEY POUR THIS MIXTURE
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00:07:52,482 --> 00:07:55,413
INTO A LARGE TANK
OF ROOM-TEMPERATURE WATER,
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00:07:55,413 --> 00:07:57,965
PRODUCING WHAT THEY CALL
A "SLURRY."
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00:08:01,793 --> 00:08:04,034
THE RAW EGGS, MEANWHILE,
HAVE BEEN TRANSFERRED
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00:08:04,034 --> 00:08:08,103
INTO A LARGE,
REFRIGERATED HOLDING TANK.
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00:08:08,103 --> 00:08:11,517
SO NOW THERE ARE THREE
HOLDING TANKS AT THE READY --
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00:08:11,517 --> 00:08:15,310
A SLURRY TANK, AN EGG TANK,
AND AN OIL TANK.
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00:08:15,310 --> 00:08:17,068
A COMPUTERIZED
PROPORTIONING SYSTEM
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00:08:17,068 --> 00:08:20,137
EXTRACTS THE REQUIRED AMOUNT
FROM EACH TANK
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00:08:20,137 --> 00:08:22,344
AND SENDS IT TO A MIXING VESSEL.
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00:08:25,206 --> 00:08:28,689
A COUPLE OF MINUTES OF MIXING
AT HIGH AGITATION
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00:08:28,689 --> 00:08:33,103
MERGES THE EGGS, OIL, AND SLURRY
INTO TANGY, CREAMY MAYONNAISE.
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00:08:39,413 --> 00:08:41,793
THE FACTORY
DRAWS SAMPLES PERIODICALLY
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00:08:41,793 --> 00:08:44,344
AND SENDS THEM TO
ITS QUALITY-CONTROL DEPARTMENT
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00:08:44,344 --> 00:08:46,517
FOR ANALYSIS.
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00:08:46,517 --> 00:08:50,655
THE LAB TECHNICIANS THERE
EVALUATE SEVERAL CRITERIA,
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00:08:50,655 --> 00:08:55,068
SUCH AS COLOR, CONSISTENCY,
AND, OF COURSE, FLAVOR.
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00:08:55,068 --> 00:08:56,689
IN THIS TEST, FOR EXAMPLE,
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00:08:56,689 --> 00:08:59,172
THEY MIX THE MAYO
WITH PHENOLPHTHALEIN,
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00:08:59,172 --> 00:09:00,931
A PH-LEVEL INDICATOR,
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00:09:00,931 --> 00:09:05,344
AND DE-IONIZED WATER
TO CHECK THE ACIDITY LEVEL.
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00:09:05,344 --> 00:09:09,068
ONCE THE MAYONNAISE PASSES
QUALITY-CONTROL INSPECTION,
151
00:09:09,068 --> 00:09:11,206
THIS ROTARY FILLER DISPENSES IT
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00:09:11,206 --> 00:09:16,758
INTO RECYCLABLE
POLYETHYLENE JARS.
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00:09:16,758 --> 00:09:19,793
IT FILLS EACH JAR
IN JUST A QUARTER SECOND.
154
00:09:25,793 --> 00:09:28,620
THE NEXT MACHINE
TWISTS ON A PLASTIC CAP.
155
00:09:35,103 --> 00:09:38,310
INSIDE THE CAP IS A FOIL SEAL.
156
00:09:38,310 --> 00:09:41,206
THIS MACHINE
USES TARGETED INDUCTION HEAT
157
00:09:41,206 --> 00:09:43,931
TO FUSE THE SEAL
TO THE RIM OF THE JAR
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00:09:43,931 --> 00:09:45,965
WITHOUT HEATING THE MAYONNAISE
IN THE PROCESS.
159
00:09:45,965 --> 00:09:48,931
THE SEAL PRESERVES FRESHNESS
160
00:09:48,931 --> 00:09:50,827
AND INDICATES THE JAR
WASN'T TAMPERED WITH
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00:09:50,827 --> 00:09:53,275
AFTER LEAVING THE FACTORY.
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00:09:53,275 --> 00:09:56,551
THE LABELING MACHINE
GLUES ON ONE END OF THE LABEL,
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00:09:56,551 --> 00:09:59,172
SPINS THE JAR
TO WRAP THE LABEL AROUND,
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00:09:59,172 --> 00:10:01,448
THEN GLUES DOWN THE OTHER END.
165
00:10:05,724 --> 00:10:07,413
THE QUALITY-CONTROL LAB
166
00:10:07,413 --> 00:10:10,758
ALSO PERFORMS SOME
POST-PRODUCTION SPOT-CHECKS.
167
00:10:10,758 --> 00:10:14,620
IN THIS TEST, TECHNICIANS USE
A MACHINE CALLED A VISCOMETER
168
00:10:14,620 --> 00:10:18,310
TO MEASURE
THE PRODUCT'S CONSISTENCY.
169
00:10:23,034 --> 00:10:25,655
THE FACTORY
ALSO PACKAGES ITS MAYO
170
00:10:25,655 --> 00:10:27,655
INTO SINGLE-SERVING POUCHES.
171
00:10:27,655 --> 00:10:30,517
THEY'RE MADE OF POLYETHYLENE
FILM ON ONE SIDE,
172
00:10:30,517 --> 00:10:35,241
FOIL PRINTED WITH THE
PRODUCT LABEL ON THE OTHER.
173
00:10:35,241 --> 00:10:38,655
THIS MULTI-TASKING MACHINE
FORMS ROWS OF POUCHES,
174
00:10:38,655 --> 00:10:41,620
INSERTS ABOUT FOUR OUNCES
OF MAYONNAISE PER POUCH,
175
00:10:41,620 --> 00:10:44,620
THEN SEALS AND SEPARATES
THE POUCHES.
176
00:10:46,551 --> 00:10:49,482
THESE POUCHES ARE SHIPPED
TO READY-MADE SANDWICH VENDORS
177
00:10:49,482 --> 00:10:54,827
AND FAST-FOOD RESTAURANTS WHOSE
CUSTOMERS NEED MAYO ON THE GO.
178
00:11:08,448 --> 00:11:11,000
Narrator: CAVEMEN
SHARPENED PIECES OF FLINT
179
00:11:11,000 --> 00:11:13,448
AND USED THEM
TO SHAVE THEIR FACIAL HAIR.
180
00:11:13,448 --> 00:11:17,103
MODERN MAN CAN SIMPLY GO
PURCHASE A PACK OF RAZOR BLADES
181
00:11:17,103 --> 00:11:18,344
FOR HIS SHAVER.
182
00:11:18,344 --> 00:11:21,517
WHILE SEVERAL STYLES OF SHAVERS
AND BLADES EXIST,
183
00:11:21,517 --> 00:11:25,310
MANY MEN BELIEVE THE TRADITIONAL
TYPE OF RAZOR BLADE
184
00:11:25,310 --> 00:11:28,103
GIVES THE CLOSEST SHAVE
OF THEM ALL.
185
00:11:31,068 --> 00:11:34,413
THEY'RE PAPER-THIN, YET SHARP
ENOUGH AND STRONG ENOUGH
186
00:11:34,413 --> 00:11:38,758
TO CUT THROUGH
THE COARSEST BEARD.
187
00:11:38,758 --> 00:11:42,000
RAZOR BLADES ARE MADE
FROM A STAINLESS-STEEL STRIP
188
00:11:42,000 --> 00:11:45,172
THAT'S A MERE
.004 OF AN INCH THICK.
189
00:11:45,172 --> 00:11:48,137
THE STRIP FIRST ENTERS
A PUNCHING MACHINE
190
00:11:48,137 --> 00:11:50,758
THAT STAMPS OUT
THE OVERALL BLADE SHAPE.
191
00:11:59,620 --> 00:12:03,379
THESE DULL-EDGED BLADES-TO-BE
ARE CALLED BLANKS.
192
00:12:07,689 --> 00:12:10,000
AT THIS STAGE OF THE PROCESS,
193
00:12:10,000 --> 00:12:14,172
THE STAINLESS STEEL IS VERY
SOFT -- AS PLIABLE AS PAPER --
194
00:12:14,172 --> 00:12:16,793
SO THEY NOW HARDEN
AND STRENGTH IT
195
00:12:16,793 --> 00:12:18,896
THROUGH A FOUR-STEP
HEAT-TREATMENT PROCESS.
196
00:12:18,896 --> 00:12:21,758
STEP ONE -- THEY HEAT THE BLANKS
IN A FURNACE
197
00:12:21,758 --> 00:12:26,172
TO JUST OVER 2,000 DEGREES
FAHRENHEIT FOR ABOUT 30 SECONDS.
198
00:12:26,172 --> 00:12:29,620
STEP TWO -- THEY BRIEFLY
SUBMERGE THEM IN COLD WATER.
199
00:12:29,620 --> 00:12:31,310
THIS IS CALLED QUENCHING.
200
00:12:31,310 --> 00:12:34,931
STEP THREE -- THEY CHILL THEM
FOR ABOUT 20 SECONDS
201
00:12:34,931 --> 00:12:39,206
IN A DEEP-COOLING CHAMBER AT
A TEMPERATURE OF -58 FAHRENHEIT.
202
00:12:39,206 --> 00:12:42,379
ALL THIS PROGRESSIVELY
RE-STRUCTURES THE MOLECULES,
203
00:12:42,379 --> 00:12:43,724
HARDENING THE METAL.
204
00:12:43,724 --> 00:12:46,344
HOWEVER,
THE METAL BECOMES BRITTLE,
205
00:12:46,344 --> 00:12:49,965
NECESSITATING RE-HEATING
THE BLANKS FOR 20 SECONDS.
206
00:12:52,482 --> 00:12:54,896
THE NOW-HARD BLANKS
THEN MOVE THROUGH A PRINTER,
207
00:12:54,896 --> 00:12:59,344
WHICH APPLIES
THE RAZOR-BLADE BRAND NAME.
208
00:12:59,344 --> 00:13:02,379
GAS FLAMES
INSTANTLY DRY THE WET INK.
209
00:13:02,379 --> 00:13:08,172
NOW IT'S TIME FOR THE BLANKS
TO BECOME BLADES.
210
00:13:08,172 --> 00:13:10,827
THEY ENTER A GRINDING
AND POLISHING MACHINE.
211
00:13:10,827 --> 00:13:13,655
WITHIN IT
ARE THREE GRINDING STATIONS
212
00:13:13,655 --> 00:13:15,931
WHICH FIRST SHARPEN THE CONTOUR,
213
00:13:15,931 --> 00:13:19,000
THEN PRODUCE
TWO SUPER-SHARP CUTTING EDGES.
214
00:13:19,000 --> 00:13:22,206
THE BLADES THEN PASS THROUGH
A POLISHING STATION
215
00:13:22,206 --> 00:13:25,034
THAT REMOVES BURRS
LEFT BY THE GRINDING.
216
00:13:25,034 --> 00:13:28,551
UNTIL NOW, THE BLADES HAVE BEEN
CONNECTED TO EACH OTHER.
217
00:13:28,551 --> 00:13:31,931
AS THEY EXIT THIS MACHINE,
A KNIFE SEPARATES THEM.
218
00:13:37,379 --> 00:13:39,551
THE FACTORY'S
QUALITY-CONTROL LAB
219
00:13:39,551 --> 00:13:42,000
PULLS SAMPLES
FROM THE PRODUCTION LINE
220
00:13:42,000 --> 00:13:44,206
AND CHECKS,
AMONG OTHER CRITERIA,
221
00:13:44,206 --> 00:13:47,896
THE QUALITY OF THE GRINDING AND
GEOMETRICS OF THE CUTTING EDGES.
222
00:13:47,896 --> 00:13:50,482
THEN, EVERY SINGLE BLADE
THE FACTORY PRODUCES
223
00:13:50,482 --> 00:13:53,275
IS EXAMINED
FOR CUTTING-EDGE DEFECTS.
224
00:13:53,275 --> 00:13:56,827
TECHNICIANS ASSEMBLE BLADES
IN PACKS OF UP TO 800,
225
00:13:56,827 --> 00:14:00,896
THEN SHINE FLUORESCENT LIGHT
ON THE TWO CUTTING-EDGE SIDES.
226
00:14:00,896 --> 00:14:03,965
THIS MAKES DEFECTS VISIBLE.
227
00:14:03,965 --> 00:14:06,137
BLADES THAT PASS THIS INSPECTION
228
00:14:06,137 --> 00:14:09,275
ARE WASHED WITH SOLVENT
TO REMOVE CONTAMINANTS...
229
00:14:11,620 --> 00:14:15,000
...THEN DRIED.
230
00:14:15,000 --> 00:14:18,758
THE NOW-PRISTINE RAZOR BLADES
GO INTO A VACUUM CHAMBER.
231
00:14:18,758 --> 00:14:21,827
IT DRAWS A CHROMIUM-BASED
COATING ONTO THE SURFACE,
232
00:14:21,827 --> 00:14:27,620
RENDERING THE CUTTING EDGES
HARDER AND MORE WEAR-RESISTANT.
233
00:14:27,620 --> 00:14:30,965
NEXT, SPRAY NOZZLES
APPLY A NON-STICK COATING,
234
00:14:30,965 --> 00:14:34,827
WHICH WILL HELP THE BLADES
GLIDE SMOOTHLY OVER THE SKIN.
235
00:14:34,827 --> 00:14:37,413
TO ADHERE THE COATING
PERMANENTLY
236
00:14:37,413 --> 00:14:39,034
TO THE BLADE SURFACE,
237
00:14:39,034 --> 00:14:43,724
THEY BAKE IT ON FOR 20 MINUTES
AT ABOUT 660 DEGREES FAHRENHEIT.
238
00:14:45,655 --> 00:14:49,275
QUALITY-CONTROL TECHNICIANS
TEST SAMPLES AGAIN,
239
00:14:49,275 --> 00:14:53,689
THIS TIME TO ENSURE THE BLADES
MEET STRENGTH SPECIFICATIONS.
240
00:14:53,689 --> 00:14:56,931
THIS TEST MACHINE
MEASURES THE FORCE REQUIRED
241
00:14:56,931 --> 00:15:01,448
FOR THE BLADE TO CUT A THICK WAD
OF WET PAPER TO A CERTAIN DEPTH.
242
00:15:09,620 --> 00:15:11,034
BACK IN PRODUCTION,
243
00:15:11,034 --> 00:15:14,241
WORKERS SUBMERGE THE RAZOR
BLADES IN ORGANIC OIL
244
00:15:14,241 --> 00:15:15,862
FOR ABOUT HALF AN HOUR.
245
00:15:15,862 --> 00:15:21,034
THIS PROVIDES ADDITIONAL
PROTECTION AGAINST CORROSION.
246
00:15:21,034 --> 00:15:22,620
ON THE PACKAGING LINE,
247
00:15:22,620 --> 00:15:26,482
THE EQUIPMENT WRAPS EACH BLADE
INDIVIDUALLY IN WAX PAPER.
248
00:15:32,000 --> 00:15:33,586
THE WAX COATING ON THE PAPER
249
00:15:33,586 --> 00:15:36,241
HELPS PROTECT THE RAZOR BLADE
AGAINST CORROSION
250
00:15:36,241 --> 00:15:37,586
DURING STORAGE.
251
00:15:37,586 --> 00:15:41,275
WAX PAPER IS ALSO STRONGER
THAN REGULAR PAPER,
252
00:15:41,275 --> 00:15:46,310
SO THE BLADE'S RAZOR-SHARP EDGES
DON'T CUT THROUGH IT.
253
00:15:46,310 --> 00:15:48,793
THE EDGE OF THESE RAZOR BLADES
254
00:15:48,793 --> 00:15:52,586
ARE ABOUT 10 TIMES THINNER
THAN A HUMAN HAIR.
255
00:15:52,586 --> 00:15:55,275
A BLADE TYPICALLY LASTS
ABOUT SIX SHAVES,
256
00:15:55,275 --> 00:15:58,172
SO THE AVERAGE MALE GOES THROUGH
QUITE A FEW,
257
00:15:58,172 --> 00:16:00,931
CONSIDERING THAT,
OVER THE COURSE OF HIS LIFETIME,
258
00:16:00,931 --> 00:16:06,034
HE'LL HAVE SPENT MORE THAN
3,300 HOURS SHAVING HIS FACE.
259
00:16:16,034 --> 00:16:18,655
Narrator:
IN THE AGE OF DISPOSABLE RAZORS,
260
00:16:18,655 --> 00:16:21,379
THE BUTTERFLY SAFETY RAZOR
STILL HAS AN EDGE.
261
00:16:21,379 --> 00:16:22,965
THIS PRECISION METAL TOOL
262
00:16:22,965 --> 00:16:25,482
IS GOOD FOR A LIFETIME
OF CLEAN SHAVES.
263
00:16:25,482 --> 00:16:27,137
A FEW TWISTS OF THE HANDLE,
264
00:16:27,137 --> 00:16:29,103
AND THE BUTTERFLY MECHANISM
OPENS
265
00:16:29,103 --> 00:16:32,068
TO ALLOW CLEANING
AND REPLACEMENT OF THE BLADE.
266
00:16:32,068 --> 00:16:35,862
WITH IT, GETTING RID OF STUBBLE
IS VERY LITTLE TROUBLE.
267
00:16:38,448 --> 00:16:40,551
INVENTED IN THE LAST CENTURY,
268
00:16:40,551 --> 00:16:42,206
THE BUTTERFLY SAFETY RAZOR
269
00:16:42,206 --> 00:16:44,689
HAS DONE ITS PART
TO PREVENT INJURIES.
270
00:16:44,689 --> 00:16:46,310
THE BLADE CAN BE REPLACED
271
00:16:46,310 --> 00:16:48,793
WITHOUT ACTUALLY TOUCHING
THE SHARP EDGE.
272
00:16:48,793 --> 00:16:51,586
THE BUTTERFLY DOORS
ALSO CLOSE AROUND THE BLADE
273
00:16:51,586 --> 00:16:52,793
FOR A SAFER SHAVE.
274
00:16:56,241 --> 00:16:59,103
ALSO KNOWN
AS THE TWIST-TO-OPEN RAZOR,
275
00:16:59,103 --> 00:17:02,241
THIS GROOMING TOOL
IS ANYTHING BUT SIMPLE.
276
00:17:02,241 --> 00:17:06,517
IT'S COMPRISED
OF ABOUT 20 PARTS.
277
00:17:06,517 --> 00:17:09,655
PRODUCTION BEGINS
WITH SOLID ZINC BARS.
278
00:17:09,655 --> 00:17:12,206
THEY MELT DOWN THE BARS
IN A BIG CAULDRON.
279
00:17:14,655 --> 00:17:17,379
THE MACHINE
THEN PRESSES THE MELTED ZINC
280
00:17:17,379 --> 00:17:19,689
INTO A MOLD
OF THREE RAZOR PARTS.
281
00:17:19,689 --> 00:17:21,344
THE ZINC INSTANTLY COOLS
282
00:17:21,344 --> 00:17:24,275
AND SOLIDIFIES INTO THE SHAPE
OF THE PARTS.
283
00:17:24,275 --> 00:17:26,551
THEY'RE LINKED
BY MORE HARDENED ZINC.
284
00:17:26,551 --> 00:17:28,000
A WORKER SEPARATES THEM,
285
00:17:28,000 --> 00:17:30,689
REVEALING A SUPPORT STRUCTURE
FOR THE BLADE,
286
00:17:30,689 --> 00:17:32,724
A FRAMEWORK
FOR THE BUTTERFLY FLAPS,
287
00:17:32,724 --> 00:17:37,310
AND THE OUTER CASING
FOR THE BLADE-SUPPORT PART.
288
00:17:37,310 --> 00:17:41,034
BREAKING THEM FREE FROM ONE
ANOTHER LEAVES RAGGED EDGES,
289
00:17:41,034 --> 00:17:43,137
SO A WORKER GRINDS THEM SMOOTH.
290
00:17:46,551 --> 00:17:48,689
BUT THERE ARE STILL
A FEW BLEMISHES
291
00:17:48,689 --> 00:17:50,103
TO RUB OFF THE SURFACE.
292
00:17:50,103 --> 00:17:52,206
THE PARTS TOSS ABOUT
IN A TUMBLER
293
00:17:52,206 --> 00:17:54,586
FILLED WITH ABRASIVE
SYNTHETIC PELLETS.
294
00:17:54,586 --> 00:18:00,413
AFTER ABOUT HALF AN HOUR, THE
SURFACE IRREGULARITIES ARE GONE.
295
00:18:00,413 --> 00:18:02,344
NEXT, A COMPUTERIZED DRILL
296
00:18:02,344 --> 00:18:05,931
BORES INTO THE CENTER OF A
SPINNING ALUMINUM DOWEL
297
00:18:05,931 --> 00:18:09,103
AS A SECOND TOOL
CONTOURS THE OUTSIDE.
298
00:18:09,103 --> 00:18:13,758
THIS TRANSFORMS THE DOWEL INTO
NUTS FOR ADJUSTING THE BLADE.
299
00:18:15,931 --> 00:18:19,551
THEY SHAPE THE ALUMINUM HANDLE
THE SAME WAY.
300
00:18:19,551 --> 00:18:23,241
NOW THEY APPLY
A MORE DURABLE CHROME FINISH.
301
00:18:23,241 --> 00:18:27,482
THIS PROCESS INVOLVES
THREE ELECTRO-PLATING BATHS.
302
00:18:27,482 --> 00:18:31,517
THE FIRST ONE GIVES THE PARTS
A COPPER COATING.
303
00:18:31,517 --> 00:18:34,965
THEN IT'S INTO THE NICKEL BATH.
304
00:18:34,965 --> 00:18:38,448
IN THIS CASE, NICKEL
IS A GO-BETWEEN KIND OF FINISH.
305
00:18:38,448 --> 00:18:41,448
IT WILL ALLOW CHROME
TO STICK TO THE PART.
306
00:18:41,448 --> 00:18:45,172
AFTER A CHEMICAL TREATMENT
FOR A MATTE FINISH,
307
00:18:45,172 --> 00:18:48,655
THEY PLUNGE THE PARTS
INTO THE CHROME BATH.
308
00:18:48,655 --> 00:18:52,448
A QUICK RINSE IN WATER
REVEALS THE RESULT.
309
00:18:52,448 --> 00:18:56,379
THE PARTS NOW HAVE
A RESILIENT MATTE-CHROME FINISH.
310
00:19:01,793 --> 00:19:04,448
ONCE ALL THE PARTS
HAVE BEEN FABRICATED,
311
00:19:04,448 --> 00:19:07,206
IT'S TIME TO ASSEMBLE
THE BUTTERFLY RAZOR.
312
00:19:07,206 --> 00:19:09,517
A WORKER
DRIVES A THREADED INSERT
313
00:19:09,517 --> 00:19:12,448
INTO THE OUTER CASING
FOR THE BLADE SUPPORT.
314
00:19:12,448 --> 00:19:15,793
SHE INSTALLS A SIMILAR INSERT
IN THE ADJUSTMENT NUT
315
00:19:15,793 --> 00:19:20,034
WE SAW BEING FABRICATED
EARLY ON.
316
00:19:20,034 --> 00:19:24,000
THESE INSERTS ENABLE HER
TO SCREW THE TWO PARTS TOGETHER.
317
00:19:24,000 --> 00:19:28,068
SHE SETS ASIDE THE NUT
AND BLADE-SUPPORT ASSEMBLY.
318
00:19:28,068 --> 00:19:32,000
SHE SLIDES A SPRING
ONTO THE RAZOR'S CENTER ROD.
319
00:19:32,000 --> 00:19:37,793
THIS SPRING PUSHES UP THE ROD
TO OPEN THE BUTTERFLY FLAPS.
320
00:19:37,793 --> 00:19:39,379
SHE DABS THREAD-LOCK GLUE
321
00:19:39,379 --> 00:19:43,000
ON THE THREADED SECTION OF
THE BUTTERFLY-FLAP SUPPORT PART,
322
00:19:43,000 --> 00:19:47,172
AND THEN SCREWS THE PART
TO THE RAZOR'S CENTER ROD.
323
00:19:47,172 --> 00:19:52,137
NEXT, SHE INSTALLS THE BUTTERFLY
FLAPS ON THE SUPPORT PART.
324
00:19:55,551 --> 00:19:59,620
THE VARIOUS SUB-ASSEMBLIES
NOW NEED TO COME TOGETHER.
325
00:19:59,620 --> 00:20:02,172
SHE BEGINS WITH
THE BLADE-SUPPORT STRUCTURE
326
00:20:02,172 --> 00:20:03,172
AND BRASS STEM.
327
00:20:03,172 --> 00:20:05,931
SHE ATTACHES A SPRING
328
00:20:05,931 --> 00:20:09,000
AND SLIDES THE ADJUSTMENT-NUT
ASSEMBLY ONTO THE STEM.
329
00:20:10,758 --> 00:20:13,517
SHE INSERTS A PLASTIC WASHER
INTO THE ASSEMBLY,
330
00:20:13,517 --> 00:20:18,241
ALLOWING HER TO SCREW THE HANDLE
ONTO THE ADJUSTMENT NUT.
331
00:20:18,241 --> 00:20:22,862
SHE NOW POPS THE CENTER ROD
WITH THE BUTTERFLY DOORS
332
00:20:22,862 --> 00:20:25,620
INTO THE ASSEMBLED FRAMEWORK
333
00:20:25,620 --> 00:20:28,482
AND ADJUSTS THE ASSEMBLY.
334
00:20:30,586 --> 00:20:34,862
SHE THREADS A SET SCREW ONTO THE
CENTER ROD AND INTO THE HANDLE.
335
00:20:34,862 --> 00:20:38,172
THE SCREW WILL PREVENT THE USER
FROM TURNING THE HANDLE TOO FAR
336
00:20:38,172 --> 00:20:43,137
AND COMPROMISING
THE BUTTERFLY MECHANISM.
337
00:20:43,137 --> 00:20:47,517
AN END CAP ATTACHED TO THE BASE
HOLDS THE CENTER ROD IN PLACE.
338
00:20:47,517 --> 00:20:50,724
FINALLY, SHE TESTS THE HANDLE
AND SCREW-ROD MECHANISM
339
00:20:50,724 --> 00:20:52,517
THAT OPENS THE BUTTERFLY FLAPS
340
00:20:52,517 --> 00:20:56,068
AND CONFIRMS
THAT THEY'RE FULLY FUNCTIONAL.
341
00:20:56,068 --> 00:20:58,000
IT'S TAKEN ABOUT 20 MINUTES
342
00:20:58,000 --> 00:21:00,862
TO PRODUCE
THIS BUTTERFLY SAFETY RAZOR.
343
00:21:00,862 --> 00:21:03,862
WITH REGULAR CLEANING
BETWEEN BLADE CHANGES,
344
00:21:03,862 --> 00:21:05,862
IT SHOULD LAST FOR MANY YEARS.
345
00:21:05,862 --> 00:21:09,241
GOOD THING, BECAUSE THERE WILL
ALWAYS BE A GROWING NEED
346
00:21:09,241 --> 00:21:11,965
FOR THIS REUSABLE SHAVING TOOL.
28278
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