Original subtitles

--Captions by VITAC-- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

Narrator: IN THE 21st CENTURY,

THERE'S MORE THAN ONE WAY TO CHASE DOWN A PERPETRATOR.

THE ELECTRIC STAND-UP VEHICLE

GOES WHERE TRADITIONAL POLICE AND SECURITY CARS CAN'T --

SIDEWALKS, PARKS, SHOPPING MALLS, EVEN AIRPORTS.

THE OFFICER STANDS FOR BETTER VISIBILITY.

FOR A SUSPECT, THERE MAY BE NOWHERE TO RUN.

THIS ELECTRIC THREE-WHEELER

IS THE LATEST THING ON THE POLICE BEAT.

NOT ONLY CAN IT TRAVEL IN AREAS THAT ARE INACCESSIBLE TO CARS,

BUT ITS ENVIRONMENTAL FOOTPRINT

IS LIGHTER THAN A REGULAR POLICE CRUISER.

IT'S ENERGY EFFICIENT

AND IT GENERATES NO LOCAL POLLUTANTS.

PRODUCTION STARTS WITH THE VEHICLE'S FRAME.

AN EMPLOYEE ASSEMBLES THE TUBE STEEL PARTS

AND WELDS THEM TOGETHER.

THE NEXT WORKER ATTACHES

THE VEHICLE'S CONTROL-BOARD PANEL

TO THE WELDED FRAME.

HE INSERTS THE STEERING SHAFT INTO THE COLUMN

AND SLIDES A PLASTIC COLLAR ONTO THE BOTTOM OF THE SHAFT.

HE SECURES THE COLLAR WITH SCREWS

AND TIGHTENS THE ADJUSTMENT MECHANISM.

HE INSTALLS THE SECOND COLLAR ON THE UPPER PART

OF THE STEERING SHAFT.

THE TWO COLLARS WILL STABILIZE THE SHAFT

TO KEEP THE FRONT WHEEL OF THE VEHICLE STRAIGHT.

HE PLUGS THE ELECTRIC MOTOR CABLE

INTO THE CONTROL PANEL.

NEXT, ANOTHER MEMBER OF THE TEAM

SPRAYS A UNIFORM LAYER OF A GEL COAT

ONTO A TWO-PART MOLD OF THE VEHICLE CHASSIS.

THE GEL WILL ACT AS A RELEASE AGENT

FOR THE FINISHED CHASSIS.

THEY MAKE THE CHASSIS FROM FIBERGLASS.

HE SPRAYS IT EVENLY INTO THE CREVICES OF THE MOLDS.

HE PRESSES OUT AIR BUBBLES USING A RUBBER ROLLER.

THE FIBERGLASS DRIES AND SOLIDIFIES,

TAKING THE SHAPE OF THE MOLD.

THE SURFACE IS SMOOTH,

BUT THERE ARE SOME RAGGED BITS AROUND THE EDGES.

THOSE ARE SANDED.

HE CUTS OUT A SLOT IN THE UPPER PART OF THE CHASSIS

FOR A POLICE WARNING LIGHT.

FINALLY, THE CHASSIS GETS A COAT OF AUTOMOTIVE-GRADE WHITE PAINT.

HE PAINTS THE WHEEL WELLS BLACK,

AND WITH THAT, THE OUTER CHASSIS IS COMPLETE.

THERE'S AN INTERIOR PANEL

AND IT'S MADE OF FIBERGLASS, TOO.

A MEMBER OF THE TEAM MOUNTS IT

TO THE INSIDE OF THE STEEL-FRAME ASSEMBLY.

HE THEN SECURES THE OUTER PANEL TO THE VEHICLE FRAME.

THIS ELECTRIC THREE-WHEEL VEHICLE IS READY

FOR THE REAR-WHEEL HUBS AND BRAKE ROTORS.

HE CLAMPS BRAKE CALIPERS TO THE ROTORS.

THE WHEELS ARE NEXT.

THE REAR ONES ARE MOTORCYCLE WHEELS.

FOR THE FRONT, THEY USE A GOLF-CART WHEEL.

HE EQUIPS THE WHEEL WITH A PULLEY SYSTEM

TO TRANSFER ENERGY FROM THE MOTOR.

HE INSTALLS THE 1-HORSEPOWER MOTOR

AND ATTACHES THE PULLEY TO IT.

THE MOTOR IS THE SIZE OF A LUNCH BUCKET,

BUT CAN PULL UP TO 450 POUNDS AND REACH 20 MILES PER HOUR.

HE HOOKS UP THE FRONT WHEEL TO TESTING EQUIPMENT AND POWERS UP.

IT EVALUATES THE MOTOR SPEED AND NOISE.

IT ALSO DETECTS ANY UNDUE STRAIN OR WHEEL WOBBLING.

SATISFIED WITH THE FRONT-WHEEL ASSEMBLY,

HE INSTALLS IT ON THE VEHICLE.

HE WIRES, AND THEN ATTACHES THE THROTTLE AND BRAKE CONTROL

TO THE HANDLEBAR.

THEY CARPET THE FLOOR WITH NON-SLIP RUBBERIZED FOAM

AND THEN SLIDE THE TWO RECHARGEABLE BATTERIES

INTO THEIR RESPECTIVE COMPARTMENTS.

THE CHARGE TIME IS THREE TO FOUR HOURS.

NEXT, THIS GRAB HANDLE GIVES THE DRIVER

SOMETHING EXTRA TO HANG ON TO.

THEY EQUIP THE VEHICLE WITH WARNING LIGHTS

AND A HIGH-BEAM HEADLIGHT.

THIS ELECTRIC PATROL VEHICLE

HAS BEEN SIX HOURS IN THE MAKING,

AND IT'S NOW READY FOR A SPIN.

Narrator: NOWADAYS, YOU DON'T HAVE TO WAIT

FOR YOUR FAVORITE FRUIT TO BE IN SEASON.

YOU CAN BUY IT YEAR-ROUND

IN THE FREEZER SECTION OF YOUR LOCAL SUPERMARKET.

FROZEN FRUIT IS USEFUL TO HAVE ON HAND

FOR BAKING,

FOR MAKING FRUIT SALADS OR SMOOTHIES,

TO USE AS A TOPPING,

OR TO EAT AS A HEALTHY SNACK.

TIMING IS EVERYTHING.

FOR EXAMPLE, STRAWBERRIES, WHEN SOLD FRESH,

ARE PICKED WELL BEFORE THEY'RE RIPE

SO THEY WON'T SPOIL BEFORE REACHING STORE SHELVES

AS MUCH AS A WEEK LATER.

BUT IF THE BERRIES ARE FOR THE FREEZER SECTION,

THEY'RE HARVESTED WHEN FULLY RIPE.

THAT STATE OF PERFECTION WILL BE FROZEN IN TIME

WITHIN 36 HOURS.

FARM WORKERS PICK THE BERRIES BY HAND

AND TRIM THEM RIGHT IN THE FIELD

WITH ONE SWIPE OVER A SHARP STAINLESS-STEEL BLADE.

WITHIN 90 MINUTES OF HARVESTING,

THE STRAWBERRIES ARE ON THEIR WAY

BY REFRIGERATED TRUCK TO THE NEARBY PROCESSING PLANT

FOR CLEANING, SORTING, AND QUICK FREEZING.

FIRST STOP ON THE PROCESSING LINE,

A BATH IN FRESH WATER TO REMOVE FIELD DIRT.

THIS WHEEL GENTLY SUBMERGES EVERY LAST STRAWBERRY.

THEN, A SHOWER OF CLEAN RINSE WATER.

FOLLOWED BY A SPRAY RINSE WITH HIGHLY-CHLORINATED WATER

TO SANITIZE THE BERRIES.

NEXT, EAGLE-EYED WORKERS PICK OUT AND DISCARD

ANY BRUISED OR UNDER-RIPE BERRIES.

THE REST RECEIVE A FINAL RINSE EN ROUTE TO THE FREEZING TUNNEL.

TEMPERATURE -- -34 DEGREES FAHRENHEIT.

THE COOLING COILS CONTAIN LIQUID AMMONIA --

A REFRIGERANT COMMONLY USED FOR INDUSTRIAL-SCALE FREEZING.

INSIDE THE TUNNEL,

WHERE THE FRIGID AIR CIRCULATES AT HIGH SPEED,

THE BERRIES FREEZE IN ABOUT 20 MINUTES.

UPON EXITING, THEY RIDE THROUGH A SORTING MACHINE.

THE SMALLER BERRIES DROP THROUGH NARROWER GAPS

BETWEEN THE ROLLERS NEAR THE TOP,

THE MEDIUM-SIZE ONES THROUGH WIDER GAPS PARTWAY DOWN,

WHILE THE LARGER ONES CONTINUE TO THE BOTTOM.

THESE PEACHES, ALSO HANDPICKED WHEN RIPE,

GO THROUGH THE SAME CLEANING PROCESS AS THE STRAWBERRIES.

FIRST A BATH, THEN A SHOWER.

THEN A SANITIZING RINSE WITH CHLORINATED WATER.

AFTER WORKERS PICK OUT LEAVES, TWIGS,

AND ANY LESS-THAN-PERFECT FRUIT,

A SORTING MACHINE SORTS THE PEACHES BY SIZE --

SMALL, MEDIUM, AND LARGE --

SENDING EACH SIZE TO A SEPARATE CONVEYOR BELT.

EACH BELT LEADS TO A DIFFERENT LINE

OF STAINLESS-STEEL PITTING MACHINES,

ADJUSTED FOR THE SIZE OF THE INCOMING FRUIT.

FIRST, THE MACHINE PLACES THE PEACHES STEM-DOWN.

NEXT, A KNIFE CUTS THE PEACH IN HALF ALONG ITS NATURAL LINE.

THEN MECHANICAL JAWS GRAB THE STONE INSIDE

AND DISLODGE IT BY TWISTING THE TWO HALVES OF THE PEACH

IN OPPOSITE DIRECTIONS.

EACH MACHINE CAN PIT 90 PEACHES PER MINUTE,

SO THE ONLY WAY TO SEE THAT ACTION IS IN SLOW MOTION.

ALL THE PEACH HALVES AND STONES COMING OUT OF THE PITTERS

TUMBLE ONTO A VIBRATING CONVEYOR.

THE STONES FALL THROUGH THE HOLES

WHILE THE PEACHES, LARGER THAN THE HOLES,

CONTINUE ON.

A CONVEYOR FLIPS THEM CUT-SIDE UP

SO THAT WORKERS CAN INSPECT AND REMOVE ANY STONE FRAGMENTS.

THE NEXT CONVEYOR GRADUALLY LINES THEM UP IN SINGLE FILE

TO ENTER THE SLICING MACHINES.

THE SLICER BLADES CUT EACH HALF INTO FOUR TO SIX PIECES,

DEPENDING ON WHAT FORMAT THE CUSTOMER ORDERED.

THEN THE SLICES GO INTO THE FREEZING TUNNEL.

PEACH SLICES TAKE SLIGHTLY LONGER

THAN STRAWBERRIES TO FREEZE -- ABOUT 25 MINUTES.

TO PREVENT THE FROZEN FRUIT FROM DEFROSTING,

THE AIR TEMPERATURE IN THE PACKAGING AREA

IS A FRIGID 39 DEGREES FAHRENHEIT.

AN AUTOMATED SCALES WEIGHS OUT THE PER-PACKAGE QUANTITY,

THEN DROPS THE BERRIES INTO A RETAIL BAG.

THE MACHINE THEN HEAT SEALS THE BAG

AND DEPOSITS IT ON THE FINAL CONVEYOR,

WHICH GOES TO THE PRE-SHIPPING FREEZER.

ONLY 15 MINUTES HAVE PASSED SINCE THE FRUIT WAS FROZEN,

AND JUST 24 HOURS SINCE IT WAS FIELD PICKED.

Narrator: LIQUID REFRESHMENT CAN LEAVE ITS MARK ON THE TABLE.

COASTERS COME BETWEEN THE GLASS AND THAT.

BUT TWO CENTURIES AGO, COASTERS WERE MAINLY PLACED

ON THE RIM OF THE GLASS TO KEEP OUT FLIES.

MADE OF FELT, THEY UNFORTUNATELY SPREAD GERMS,

SO THE CARDBOARD COASTER WAS INVENTED

TO IMPROVE HYGIENE ON THE PUB SCENE.

BEVERAGE COASTERS PROTECT THE TABLE

AND ARE ALSO A MARKETING TOOL.

RAISE THE GLASS, AND YOU'LL SEE ADVERTISING CATCHPHRASES

AND PROMOTIONAL GRAPHICS.

IN FACT, SOME BAR HOPPERS CONSIDER COASTERS PUB ART

AND ACCUMULATE VAST COLLECTIONS.

PRODUCTION AT THIS FACILITY IN GERMANY

STARTS WITH SPRUCE WOOD.

IN THIS CASE, IT'S FROM THE BLACK FOREST NEARBY.

THEY SPRAY THE WOOD WITH WATER TO MOISTEN THE BARK.

THEN IT'S INTO A TUMBLER THAT TOSSES THE WOOD LOGS.

AS THEY KNOCK AGAINST EACH OTHER, THE BARK PEELS OFF.

THE DE-BARKED WOOD EXITS ONTO A CONVEYOR WITH SLOTS

TO CORRECTLY ORIENT IT FOR ENTRY INTO A MASSIVE GRINDER.

INSIDE, CHAINS PRESS THE WOOD LOGS

AGAINST THE GRINDING STONE, SHREDDING THEM INTO CHIPS.

WATER FLOWS OVER THE GRINDING STONE

TO COOL IT AND CARRY AWAY THE CHIPS,

WHICH ARE THEN MIXED INTO A MASH

THAT HAS A PORRIDGE-LIKE CONSISTENCY.

IT'S PURE WOOD PULP.

THEY NOW ADD LEFTOVER PRODUCT

FROM PREVIOUS BEER-COASTER PRODUCTION TO THE PULP.

THIS WILL BE USED TO MAKE

THE MIDDLE LAYER OF THE BEER COASTERS.

FINALLY, THEY MIX RESIDUAL PAPER FROM THE MANUFACTURER

OF MAGAZINES AND ENVELOPES WITH WATER.

THIS CREATES A LIGHTER-COLORED PULP.

IT WILL BE USED FOR THE PRINTABLE SURFACES

OF THE BEER COASTER.

THEY SPRAY THE PULP ONTO A MESH THAT DRAINS WATER FROM IT.

THE FIBROUS WOOD CORE GOES BETWEEN THE LAYERS

OF THE LIGHTER PULP.

SPIGOTS APPLY A MIX OF WHEAT STARCH AND WATER

THAT ACTS AS A GLUE BETWEEN THE LAYERS.

OFF THE MESH CONVEYORS NOW,

THE PULP BOARD TRAVELS BETWEEN CYLINDERS

THAT SQUEEZE OUT THE MOISTURE.

MORE HEATED CYLINDERS DRY IT.

KNIVES NOW CUT THE BOARD INTO LARGE RECTANGLES

SIZED FOR THE COASTER-PRINTING AND CUTTING MACHINERY.

THIS SPECIALTY CARDBOARD IS KNOWN AS WOOD-PULP BOARD.

IT'S LIGHTWEIGHT YET HIGHLY ABSORBENT.

NEXT IT'S OVER TO THE PRINTING DEPARTMENT

TO PUT THE BEER-COASTER ARTWORK ON THE WOOD-PULP BOARD.

THEY USE OFFSET PRINTING --

A PROCESS THAT INVOLVES MORE REVOLVING CYLINDERS.

COLOR CYLINDERS PICK UP INK AND TRANSFER IT

TO THE PRINTING CYLINDERS.

FROM THERE, THE IMAGE GOES TO A RUBBER-WRAPPED CYLINDER

THAT THEN PRINTS IT ONTO THE SHEETS.

A PRINT SPECIALIST SCRUTINIZES THE PRINT JOB CLOSE UP

WITH A MAGNIFYING GLASS.

HE CHECKS THE COLOR AND CLARITY OF THE IMAGES

AND CONFIRMS THAT THEY'RE CORRECTLY POSITIONED

ON THE SHEET.

THE BORDERS OF THE IMAGES MUST LINE UP

WITH THE GRID OF BLADES ON THE DIE-CUTTING MACHINERY.

IF THE ALIGNMENT IS EVEN SLIGHTLY OFF,

EVERY COASTER ON THE SHEET WOULD BE RUINED

AS THE DIE CUTTER PUNCHES OUT THE COASTERS,

DOZENS OF THEM IN ONE SWOOP.

THE COASTERS END UP OVER LITTLE CHUTES,

AND PUSHERS GIVE THEM A NUDGE.

THEY FALL DOWN THE CHUTES AND LAND NEATLY

ON A PALLET BELOW.

THE COASTERS STACK UP,

AND WHEN THERE ARE 100 OR SO IN EACH PILE,

THEY'RE READY FOR PACKAGING.

MACHINERY SHRINK WRAPS THE STACKS,

AND THEY'RE READY FOR THE THIRSTY MASSES.

THIS FACTORY CAN PRODUCE AND PACKAGE

10 MILLION OFFSET-PRINTED BEER COASTERS EVERY DAY,

SO THERE SHOULD BE NO SHORTAGE AT COCKTAIL HOUR.

THEY ALSO PRINT COASTERS USING A CENTURIES-OLD TECHNOLOGY

KNOWN AS LETTERPRESS.

BLANK COASTERS DROP DOWN INTO THE MACHINE.

A ROLLING WHEEL PRESSES EACH COASTER AGAINST AN INK PLATE.

IT'S A SYSTEM THAT BOTH PRINTS THE IMAGE

AND EMBOSSES IT ON THE CARDBOARD.

IT'S A DIFFERENCE YOU CAN BOTH SEE AND FEEL.

LETTERPRESS PRODUCTION IS LOWER VOLUME THAN OFFSET,

GENERATING 100,000 COASTERS PER DAY.

FOR COASTERS, THE DESIGN POSSIBILITIES ARE ENDLESS.

JUST RAISE A GLASS AND ENJOY.

Narrator: A DOOR HANDLE IS A DECORATIVE DETAIL

THAT DELIVERS TREMENDOUS BANG FOR THE BUCK.

IT'S QUITE INEXPENSIVE,

YET THROUGH ITS DESIGN, MATERIAL, AND FINISH,

CONTRIBUTES IMMENSELY

TO DEFINING THE STYLE OF A SPACE,

FROM TRADITIONAL TO ULTRA MODERN.

THESE HAND-FORGED IRON HANDLES

OPEN THE DOOR TO A RUSTIC ENGLISH COUNTRY DECOR.

WHILE THE HANDLE ITSELF IS IRON,

THE BACKPLATE BEHIND IT IS STEEL.

A COMPUTER-GUIDED WATER MACHINE CUTS THE BACKPLATE

OUT OF A 3-MILLIMETER-THICK STEEL SHEET.

THE MACHINE SLICES THROUGH THE STEEL

NOT WITH A BLADE OR SAW,

BUT WITH A CONCENTRATED HIGH-PRESSURE JET OF WATER.

THE WATER CONTAINS A TINY AMOUNT OF A SUPER-FINE ABRASIVE

AND CUTS THROUGH THE STEEL WITH 2,000 TIMES THE PRESSURE

OF A CAR TIRE.

THE JET CUTS THE CONTOUR OF THE BACKPLATE,

THEN HOLES FOR THE KEY, THE MECHANISM, AND THE SCREWS,

WHICH AFFIX THE PLATE TO THE DOOR.

NEXT, WITH A BEVELING MACHINE, THEY CUT A NEAT ANGLE

ON ALL FOUR SIDES OF THE BACKPLATE.

THIS SMOOTHS THE SHARP EDGES

AND GIVES THE BACKPLATE A FINISHED LOOK.

MEANWHILE, ON A COMPUTER-GUIDED LAVE,

A KNIFE PROGRESSIVELY SHAPES A ROUND STEEL BAR

INTO THE MAIN COMPONENT OF THE DOOR-HANDLE MECHANISM --

THE INNER BARREL.

THE NEXT TOOL BORES A HOLE IN IT TO RECEIVE THE SPINDLE --

A BOLT THAT RUNS THROUGH THE DOOR,

CONNECTING THE HANDLES ON EITHER SIDE.

TO MAKE THE HANDLE,

A BLACKSMITH HEATS UP AN IRON BAR

IN THE 1,600-DEGREE HEAT OF A FORGE

AND HAMMERS IT TO A TAPERED POINT.

THEN HE REPEATEDLY REHEATS AND WORKS THE IRON,

HAMMERING IT SOME MORE

AND BENDING IT AGAINST A STEEL FORMING JIG.

WITH EACH BEND,

THE HANDLE COMES CLOSER TO THE FINAL SHAPE.

ONCE THE BLACKSMITH HAS COMPLETED HIS WORK

AND THE IRON HANDLE HAS COOLED,

THEY DRILL A HOLE TO RECEIVE THE MECHANISM.

THEN WITH ANOTHER TOOL,

THEY ANGLE THE EDGES OF THE HOLE.

THIS INCREASES THE SURFACE AREA

TO WHICH THEY NOW WELD THE MECHANISM'S INNER BARREL.

THE LARGER THE WELDED AREA, THE STRONGER THE WELD.

THE WELDER PLACES BOTH COMPONENTS

IN A POSITIONING JIG TO GET THE PROPER ALIGNMENT,

THEN WELDS THEM TOGETHER.

HE REMOVES THE ASSEMBLY FROM THE JIG,

FLIPS IT, AND WELDS FROM THE OTHER SIDE.

THEY GRIND THE WELD LINES FLAT, RENDERING THEM UNNOTICEABLE.

IF THE HANDLE IS SUPPOSED TO HAVE A HAMMERED FINISH,

THIS IS WHEN THEY CREATE THAT TEXTURE

WITH, YOU GUESSED IT, A HAMMER.

NOW THEY HEAT THE HANDLE ASSEMBLY

AND THE STEEL BACKPLATE IN THE FORGE,

THEN DIP THEM IN A VAT OF BEESWAX.

THIS PROTECTS AGAINST RUST WHEN USED INDOORS.

WITH THE MAIN COMPONENTS NOW READY,

FINAL ASSEMBLY CAN BEGIN, STARTING WITH THE MECHANISM.

THEY SLIP A NYLON WASHER, THEN A STEEL SPRING

OVER THE INNER BARREL.

NEXT, THEY GREASE THE OUTER BARREL MADE OF FORGED IRON

AND PLACE IT OVER THE INNER BARREL.

THE WASHER IN BETWEEN THE BARRELS ELIMINATES FRICTION

WHEN THEY MOVE AGAINST EACH OTHER.

THIS PREVENTS THE BARREL FROM WEARING OUT AND SQUEAKING.

THEY INSTALL A TAB WASHER MADE OF NICKEL-PLATED STEEL.

THIS TAB RESTRICTS THE BARREL'S ROTATION

SO THAT IT DOESN'T SIMPLY SPIN AROUND AND AROUND.

THIS HIGH-STRENGTH STEEL LOCKING CLIP HOLDS

THE INNER AND OUTER BARRELS

AND THAT IMPORTANT TAB WASHER IN PLACE.

NOW THAT THE HANDLE AND MECHANISM ARE COMPLETE,

ALL THAT REMAINS IS TO ALIGN BACKPLATE TO HANDLE

AND SECURE IT IN POSITION WITH SCREWS.

EACH RETAIL PACKAGE CONTAINS

TWO HANDLES AND TWO BACKPLATES --

ONE FOR EACH SIDE OF THE DOOR.

ALSO IN THE BOX, THE STEEL SPINDLE

THAT GOES THROUGH THE DOOR, CONNECTING THE BARRELS

SO THAT THE HANDLES TURN IN UNISON

TO RETRACT THE LATCH AND OPEN THE DOOR.

WHILE THEIR MECHANICS ARE HIDDEN FROM VIEW,

THESE HAND-FORGED HANDLES ARE CERTAINLY A SIGHT TO BE SEEN.

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