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--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,793
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: CLASSIC CHINESE
FURNITURE IS MADE OF RICH,
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00:00:55,137 --> 00:00:57,793
LACQUERED WOODS
WITH INTRICATE CARVINGS
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00:00:57,793 --> 00:01:02,034
AND ORNATE ARTWORK
IN MOTHER-OF-PEARL INLAY.
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00:01:02,034 --> 00:01:04,344
FOR CENTURIES,
THE SPECIALIZED SKILLS
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00:01:04,344 --> 00:01:07,034
REQUIRED TO CRAFT
THESE FUNCTIONAL WORKS OF ART
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00:01:07,034 --> 00:01:11,655
HAVE BEEN PASSED DOWN
FROM GENERATION TO GENERATION.
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00:01:13,068 --> 00:01:15,896
THE STYLE OF THIS STRIKING
ROSEWOOD SIDEBOARD
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00:01:15,896 --> 00:01:20,379
DATES TO THE TANG DYNASTY
OF THE 7th AND 9th CENTURIES --
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00:01:20,379 --> 00:01:24,206
A PERIOD CONSIDERED
A GOLDEN AGE OF CHINESE ARTS.
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00:01:24,206 --> 00:01:27,068
THIS MANUFACTURER
IS LOCATED IN THAILAND.
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00:01:27,068 --> 00:01:30,206
ITS DESIGN TEAM CONSISTS
OF A CONCEPTUAL DESIGNER
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00:01:30,206 --> 00:01:33,655
WHO MERGES THE STRUCTURE
AND AESTHETIC FEATURES,
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00:01:33,655 --> 00:01:36,344
A SPECIALIST WHO ENSURES
THE HISTORICAL ACCURACY
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00:01:36,344 --> 00:01:37,448
OF THE PIECE,
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00:01:37,448 --> 00:01:39,172
AND ARTISTS
WHO DRAW THE PATTERNS
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00:01:39,172 --> 00:01:41,655
FOR THE ELABORATE WOOD CARVING
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AND THE INTRICATE
MOTHER-OF-PEARL INLAYS.
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00:01:44,586 --> 00:01:47,586
THE TEAM PRODUCES
A HIGHLY DETAILED BLUEPRINT
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00:01:47,586 --> 00:01:49,965
AND MAKES SEVERAL COPIES
OF THE ARTWORK PATTERNS
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00:01:49,965 --> 00:01:53,137
FOR THE CRAFTSPEOPLE TO USE.
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00:01:53,137 --> 00:01:55,482
TO MAKE EACH
INLAID CABINET DOOR,
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00:01:55,482 --> 00:01:58,344
A WOODWORKER GLUES
THE PATTERN ONTO THE WOOD,
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00:01:58,344 --> 00:02:00,896
MAKING SURE
THAT IT'S PERFECTLY CENTERED.
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00:02:03,068 --> 00:02:07,068
THEN USING A ROUTER, HE CUTS
ABOUT 3 MILLIMETERS DEEP,
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00:02:07,068 --> 00:02:09,689
MAKING A GROOVE
ALONG THE PATTERN'S PERIMETER
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00:02:09,689 --> 00:02:11,000
AND CUTTING OUT THE PARTS
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00:02:11,000 --> 00:02:13,448
THAT WILL BE INLAID
WITH MOTHER-OF-PEARL.
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00:02:16,896 --> 00:02:19,655
MEANWHILE, USING ANOTHER COPY
OF THE PATTERN,
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00:02:19,655 --> 00:02:21,137
A WORKER MAKES TEMPLATES
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BY CUTTING OUT THE SAME PARTS
THE WOODWORKER ROUTED
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00:02:23,896 --> 00:02:26,758
OUT OF THE CABINET DOOR.
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00:02:26,758 --> 00:02:31,310
EACH TEMPLATE IS MARKED
EITHER PINK, WHITE, OR GREEN.
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00:02:31,310 --> 00:02:33,896
SHE GLUES IT
INTO A 3-MILLIMETER-THICK PIECE
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00:02:33,896 --> 00:02:36,724
OF THE CORRESPONDING COLOR
OF MOTHER-OF-PEARL.
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00:02:38,827 --> 00:02:42,517
THE NEXT CRAFTSPERSON
TAKES ONE PIECE AT A TIME,
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00:02:42,517 --> 00:02:44,551
AND HOLDING IT
STEADY WITH PLIERS,
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00:02:44,551 --> 00:02:46,586
CAREFULLY SAWS
AROUND THE TEMPLATE
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00:02:46,586 --> 00:02:49,448
WITH A 1-MILLIMETER-WIDE BLADE.
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00:02:49,448 --> 00:02:51,413
ONCE SHE'S CUT ALL THE PIECES,
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00:02:51,413 --> 00:02:53,827
SHE REASSEMBLES THE PATTERN.
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00:02:53,827 --> 00:02:55,620
THE NEXT CRAFTSPERSON SPREADS
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00:02:55,620 --> 00:02:59,137
ADHESIVE PASTE INTO THE CUTOUTS
IN THE CABINET DOOR.
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00:03:02,068 --> 00:03:03,896
THEN HE FILLS EACH CUTOUT
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00:03:03,896 --> 00:03:06,862
WITH ITS CORRESPONDING PIECE
OF MOTHER-OF-PEARL.
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00:03:09,689 --> 00:03:11,379
FIVE HOURS FROM NOW,
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00:03:11,379 --> 00:03:13,275
ONCE THE ADHESIVE HAS DRIED,
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00:03:13,275 --> 00:03:16,620
HE RUNS A SANDER OVER THE DESIGN
TO REMOVE THE PAPER
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00:03:16,620 --> 00:03:18,206
AND EXCESS ADHESIVE,
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00:03:18,206 --> 00:03:21,586
SMOOTH THE WOOD,
AND POLISH THE MOTHER-OF-PEARL.
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00:03:24,344 --> 00:03:28,413
THEN AN ARTIST ETCHES FINE
DETAIL INTO THE MOTHER-OF-PEARL.
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00:03:33,206 --> 00:03:36,206
THIS PROVIDES TEXTURE,
DIMENSION, AND EXPRESSION
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00:03:36,206 --> 00:03:37,724
TO OBJECTS AND CHARACTERS,
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00:03:37,724 --> 00:03:40,896
WHICH, UNTIL NOW,
WERE MERELY BLANK SHAPES.
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00:03:44,000 --> 00:03:46,517
HIGH-END CHINESE-STYLE FURNITURE
LIKE THIS
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00:03:46,517 --> 00:03:50,689
IS TRADITIONALLY MADE
OF HEAVY AND STURDY ROSEWOOD.
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00:03:50,689 --> 00:03:55,862
THEY FIRST DRY THE WOOD
TO A HUMIDITY LEVEL OF 11%.
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00:03:55,862 --> 00:03:58,000
THIS PREVENTS COMPONENTS
FROM EXPANDING
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00:03:58,000 --> 00:03:59,862
OR CONTRACTING SIGNIFICANTLY
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00:03:59,862 --> 00:04:02,482
WITH TEMPERATURE CHANGES,
WHICH IS CRITICAL
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00:04:02,482 --> 00:04:03,724
BECAUSE THE SIDEBOARD
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00:04:03,724 --> 00:04:06,310
IS MADE OF TRADITIONAL
JOINTED CONSTRUCTION.
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00:04:06,310 --> 00:04:08,344
THE PARTS LOCK TOGETHER
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00:04:08,344 --> 00:04:11,206
WITHOUT ANY NAILS,
SCREWS, OR GLUE.
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00:04:14,103 --> 00:04:17,413
TO PREPARE PIECES
THAT WILL HAVE A CARVED DESIGN,
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00:04:17,413 --> 00:04:20,655
A WORKER GLUES A COPY
OF THE PATTERN ONTO THE WOOD.
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00:04:26,793 --> 00:04:30,241
NEXT, A WOODWORKER DRILLS
A SMALL HOLE IN EACH AREA
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00:04:30,241 --> 00:04:33,620
OF THE PATTERN TO BE CUT OUT.
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HE FEEDS A THIN SAW BLADE
THROUGH THE HOLE...
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00:04:39,034 --> 00:04:41,000
...THEN SAWS OUT THE AREA.
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00:04:46,034 --> 00:04:48,344
ONCE HE CUTS OUT
ALL THE REQUIRED AREAS,
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00:04:48,344 --> 00:04:51,551
HE HANDS THE PIECE TO ONE
OF THE COMPANY'S CARVERS.
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00:04:54,068 --> 00:04:56,137
THESE ARTISANS
APPRENTICE FOR YEARS
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00:04:56,137 --> 00:04:59,586
WITH THE MASTER CARVER
TO LEARN THIS ANCIENT CRAFT.
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00:05:01,793 --> 00:05:03,862
WORKING WITH A COLLECTION
OF CHISELS,
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00:05:03,862 --> 00:05:06,172
THEY GRADUALLY
FOLLOW THE PATTERN.
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00:05:09,000 --> 00:05:10,551
IT TAKES TREMENDOUS TALENT
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00:05:10,551 --> 00:05:14,137
AND SKILL TO KNOW
HOW TO READ A DRAWING
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00:05:14,137 --> 00:05:17,586
AND, BIT BY BIT, TRANSFORM
THE FLAT WOOD BENEATH IT
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00:05:17,586 --> 00:05:20,896
INTO A THREE-DIMENSIONAL DESIGN.
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00:05:20,896 --> 00:05:23,137
ONCE ALL THE COMPONENTS
ARE READY,
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00:05:23,137 --> 00:05:27,448
WORKERS ASSEMBLE THE SIDEBOARD
FROM THE FOOTED BASE UPWARD.
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00:05:27,448 --> 00:05:30,586
THE DRAWERS MOVE
ON MODERN DRAWER SLIDES,
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00:05:30,586 --> 00:05:32,103
AND THE CABINET DOORS ATTACH
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00:05:32,103 --> 00:05:35,068
WITH BRONZE
CHINESE-STYLE HARDWARE.
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00:05:35,068 --> 00:05:36,862
THEY BRING OUT THE RICH COLOR
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00:05:36,862 --> 00:05:38,689
AND GRAIN OF THE WOOD
WITH FOUR COATS
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00:05:38,689 --> 00:05:41,379
OF TRADITIONAL LACQUER
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00:05:41,379 --> 00:05:44,344
MADE ENTIRELY FROM TREE SAP.
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00:05:44,344 --> 00:05:47,620
IT HIGHLIGHTS THE ETCHED DETAILS
IN THE MOTHER-OF-PEARL
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00:05:47,620 --> 00:05:51,241
AND PROTECTS THE SIDEBOARD
WITH A GLOSSY SHIELD.
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00:06:02,758 --> 00:06:06,068
Narrator: LIGHT SWITCHES PUT A
LOT OF POWER AT YOUR FINGERTIPS.
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00:06:06,068 --> 00:06:09,103
ONE QUICK FLICK,
AND THE LIGHTS GO ON OR OFF.
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00:06:09,103 --> 00:06:11,103
WHEN SWITCHES ARE PAIRED
WITH SOCKETS,
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00:06:11,103 --> 00:06:14,206
APPLIANCES AND GADGETRY
CAN ALSO BE POWERED UP.
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00:06:14,206 --> 00:06:17,517
INVENTED AS AN IMPROVEMENT
OVER PULL CORDS A CENTURY AGO,
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00:06:17,517 --> 00:06:20,310
SWITCHES DELIVER POWER
TO THE PEOPLE.
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00:06:23,724 --> 00:06:25,965
FLIP A SWITCH, AND THE WORLD
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00:06:25,965 --> 00:06:28,344
INSTANTLY BECOMES
A BRIGHTER PLACE.
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00:06:28,344 --> 00:06:33,379
SWITCHES GIVE US POWER
OVER ELECTRICAL POWER.
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00:06:35,689 --> 00:06:39,275
MAKING SWITCHES STARTS
WITH BIG SHEETS OF METAL.
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00:06:39,275 --> 00:06:42,620
IN THIS CASE,
THE SHEETS ARE BRASS.
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00:06:42,620 --> 00:06:46,551
A WORKER SERVES THEM UP
TO A HYDRAULIC GUILLOTINE.
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00:06:46,551 --> 00:06:48,310
IT CHOPS THE BRASS INTO STRIPS
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00:06:48,310 --> 00:06:50,413
THAT WILL BE USED
TO MAKE FACEPLATES
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00:06:50,413 --> 00:06:54,137
FOR CUSTOM-SIZED SWITCHES
AND SOCKETS.
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00:06:54,137 --> 00:06:56,310
FOR SWITCHES THAT ARE
A STANDARD SIZE,
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00:06:56,310 --> 00:06:59,172
THEY SIMPLY ORDER
THE STRIPS PRECUT.
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00:07:01,586 --> 00:07:04,000
COMPUTERIZED PUNCHES CUT HOLES
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00:07:04,000 --> 00:07:05,620
AND ROUGH OUT
BOTH THE FACEPLATES
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00:07:05,620 --> 00:07:06,896
AND THE STEEL GRIDS
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00:07:06,896 --> 00:07:09,344
THAT HOLD THE ELECTRICAL
STRUCTURE TOGETHER.
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00:07:13,586 --> 00:07:15,379
ALL THE HOLES IN THE GRID PLATES
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00:07:15,379 --> 00:07:17,862
WILL CORRESPOND TO HOLES
IN THE FACEPLATES
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00:07:17,862 --> 00:07:20,137
IN ORDER
TO PUT THE TWO TOGETHER.
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00:07:20,137 --> 00:07:22,310
THESE PLATES ARE FOR SWITCHES
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00:07:22,310 --> 00:07:24,655
THAT WILL BE INSTALLED
IN HOTEL ROOMS,
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00:07:24,655 --> 00:07:29,793
AND THEY WILL INCLUDE SOCKETS
FOR THREE-PIN BRITISH PLUGS.
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00:07:29,793 --> 00:07:33,206
NEXT, MORE STEEL UNWINDS
INTO A PUNCH PRESS,
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00:07:33,206 --> 00:07:35,724
WHICH TRANSFORMS IT
INTO A FRAMEWORK TO SUPPORT
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00:07:35,724 --> 00:07:38,827
THE ELECTRICAL COMPONENTS.
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00:07:38,827 --> 00:07:41,275
THE AUTOMATED TOOLING
WRAPS THE PUNCHED METAL
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00:07:41,275 --> 00:07:45,275
AROUND A FORM
TO GIVE IT THE DESIRED SHAPE.
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00:07:45,275 --> 00:07:47,241
THIS FRAMEWORK WILL ALSO SERVE
126
00:07:47,241 --> 00:07:49,862
AS AN ELECTRICAL
GROUNDING PLATE,
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00:07:49,862 --> 00:07:51,379
DISCHARGING ELECTRICAL ENERGY
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00:07:51,379 --> 00:07:53,931
FROM THE SOCKET
TO PREVENT SHOCKS.
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00:07:57,103 --> 00:07:59,655
A WORKER NOW ATTACHES
A MOLDED PLASTIC PART
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00:07:59,655 --> 00:08:01,862
TO A GROUNDING PLATE.
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00:08:01,862 --> 00:08:04,241
HE INSERTS A SCREW
IN A BRASS CONNECTOR
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00:08:04,241 --> 00:08:07,172
AND INSTALLS IT IN A SLOT
IN THE MOLDED PLASTIC.
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00:08:09,793 --> 00:08:13,000
HE INSTALLS A SERIES
OF BRASS TERMINALS.
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00:08:15,724 --> 00:08:16,896
AT THE NEXT STATION,
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00:08:16,896 --> 00:08:19,034
A WORKER ASSEMBLES FUSE HOLDERS,
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00:08:19,034 --> 00:08:22,275
CONTACTS, AND SPRINGS
TO THE PLASTIC STRUCTURE.
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00:08:28,862 --> 00:08:32,103
NEXT UP ARE LITTLE SPRING-
OPERATED PLASTIC SHUTTERS.
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00:08:32,103 --> 00:08:33,413
THEY BLOCK THE SOCKETS
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00:08:33,413 --> 00:08:35,344
WHEN NOTHING
IS PLUGGED INTO THEM.
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00:08:37,827 --> 00:08:39,551
MOVING DOWN THE ASSEMBLY LINE,
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00:08:39,551 --> 00:08:44,586
A WORKER INSERTS SPRINGS
INTO TWIN ROCKER SWITCHES.
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00:08:44,586 --> 00:08:45,896
SHE LOWERS A PRESS
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00:08:45,896 --> 00:08:48,482
TO SQUEEZE ALL THE SWITCH
COMPONENTS TOGETHER,
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00:08:48,482 --> 00:08:53,724
THEN TRANSFERS THE SWITCHES
TO THE ELECTRICAL UNIT.
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00:08:53,724 --> 00:08:56,586
ANOTHER TECHNICIAN
SNAPS A COVER ONTO IT.
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00:08:56,586 --> 00:08:59,103
HE PLUGS IT INTO A LIGHT BOX
TO TEST IT,
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00:08:59,103 --> 00:09:01,241
AND THE BULBS OF THE BOX
ILLUMINATE.
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00:09:01,241 --> 00:09:03,586
THIS CONFIRMS
THAT THE SWITCHES
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00:09:03,586 --> 00:09:06,103
AND SOCKETS
ARE FULLY OPERATIONAL.
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00:09:08,655 --> 00:09:11,931
HE PULLS THE PLUG
AND SETS THE ASSEMBLY ASIDE.
151
00:09:14,862 --> 00:09:16,517
IT HAS TAKEN
ROUGHLY FOUR MINUTES
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00:09:16,517 --> 00:09:19,137
TO ASSEMBLE THE SWITCH
AND SOCKET UNIT.
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00:09:21,793 --> 00:09:24,517
A WORKER NOW FITS
THE STEEL GRID PLATE TO IT
154
00:09:24,517 --> 00:09:29,137
WITH THE SWITCHES AND SOCKETS
PROTRUDING THROUGH IT.
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00:09:29,137 --> 00:09:30,379
THIS PARTICULAR UNIT
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00:09:30,379 --> 00:09:33,758
IS ALSO EQUIPPED
WITH A ROUND EUROPEAN PLUG
157
00:09:33,758 --> 00:09:39,724
AND A USB CHARGING PORT
FOR MOBILE DEVICES.
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00:09:39,724 --> 00:09:42,137
AT THE NEXT STATION,
AN OPERATOR SERVES UP
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00:09:42,137 --> 00:09:46,965
BRASS FACEPLATES
TO A PRESS THAT BENDS THE RIMS,
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00:09:46,965 --> 00:09:50,241
FORMING A THIN LIP THAT WILL
FIT AROUND THE GRID PLATE.
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00:09:53,137 --> 00:09:55,482
A COMPUTERIZED WELDER
FUSES STUDS
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00:09:55,482 --> 00:09:57,172
TO THE BACK OF THE FACEPLATES,
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00:09:57,172 --> 00:09:59,586
PLACING ONE AT EACH CORNER.
164
00:09:59,586 --> 00:10:01,586
THESE STUDS WILL FIX
THE FACEPLATE
165
00:10:01,586 --> 00:10:03,103
TO THE GRID PLATE
166
00:10:03,103 --> 00:10:05,724
AND PROVIDE A SCREWLESS FINISH
ON THE FRONT.
167
00:10:07,862 --> 00:10:10,413
WHEN IT COMES TO SWITCH
AND SOCKET COMBINATIONS,
168
00:10:10,413 --> 00:10:13,689
THERE'S NO SHORTAGE OF OPTIONS.
169
00:10:13,689 --> 00:10:15,689
AT THIS STATION,
A WORKER ASSEMBLES
170
00:10:15,689 --> 00:10:17,896
A PARTICULARLY LARGE ONE
WITH SWITCHES,
171
00:10:17,896 --> 00:10:21,689
CHARGING PORTS, AND SOCKETS.
172
00:10:21,689 --> 00:10:23,482
IT'S ALSO DESIGNED
FOR INSTALLATION
173
00:10:23,482 --> 00:10:27,827
IN A HOTEL ROOM.
174
00:10:27,827 --> 00:10:31,172
HE SECURES THE CHARGING PORT
TO THE GRID PLATE
175
00:10:31,172 --> 00:10:33,103
AND IS READY FOR THE FACEPLATE.
176
00:10:38,689 --> 00:10:41,344
HE ATTACHES IT
USING THE WELDED STUDS,
177
00:10:41,344 --> 00:10:46,620
AND WITH THE FOLDED EDGING, IT
ENCASES THE GRID PLATE NEATLY.
178
00:10:46,620 --> 00:10:49,689
THIS SWITCH AND SOCKET ASSEMBLY
IS NOW COMPLETE.
179
00:10:51,827 --> 00:10:54,517
WHEN SWITCHED ON,
THE CIRCUIT WILL BE CLOSED,
180
00:10:54,517 --> 00:10:57,344
AND THE ELECTRICAL CURRENT
WILL FLOW.
181
00:10:57,344 --> 00:10:59,724
WHEN SWITCHED OFF,
THE CIRCUIT WILL OPEN,
182
00:10:59,724 --> 00:11:03,000
AND THINGS WILL GO DARK.
183
00:11:03,000 --> 00:11:05,172
IT SHOULD WORK EVERY TIME.
184
00:11:17,517 --> 00:11:19,241
Narrator:
IN MANY EAST ASIAN CULTURES,
185
00:11:19,241 --> 00:11:22,862
SALT IS NOT TRADITIONALLY USED
AS A CONDIMENT.
186
00:11:22,862 --> 00:11:26,137
IN ITS PLACE,
COOKS USE HIGH-SODIUM SAUCES
187
00:11:26,137 --> 00:11:28,103
SUCH AS FISH SAUCE.
188
00:11:28,103 --> 00:11:30,862
IN THAILAND, FISH SAUCE
IS A KEY INGREDIENT
189
00:11:30,862 --> 00:11:33,310
IN TRADITIONAL DISHES,
GIVING THEM A RICH
190
00:11:33,310 --> 00:11:35,586
AND DISTINCTIVE
SAVORY TASTE.
191
00:11:39,482 --> 00:11:41,724
USED IN COOKING
OR AS A DIPPING SAUCE,
192
00:11:41,724 --> 00:11:43,896
THAI FISH SAUCE
BRINGS OUT THE FLAVORS
193
00:11:43,896 --> 00:11:48,620
OF OTHER INGREDIENTS.
194
00:11:48,620 --> 00:11:50,413
FISH SAUCE
IS MADE BY FERMENTING
195
00:11:50,413 --> 00:11:53,137
TWO PARTS FISH
WITH ONE PART SALT.
196
00:11:53,137 --> 00:11:55,965
OVER TIME, THE SALT
WILL NATURALLY EXTRACT WATER
197
00:11:55,965 --> 00:12:00,103
FROM THE FISH'S FLESH,
CREATING THE SAVORY SAUCE.
198
00:12:00,103 --> 00:12:04,413
THE FACTORY PROCESSES
100 TONS OF FISH EVERY DAY.
199
00:12:04,413 --> 00:12:09,689
THEY USE WILD-CAUGHT ANCHOVIES
FROM THE GULF OF THAILAND.
200
00:12:09,689 --> 00:12:11,620
ANCHOVIES HAVE A STRONG FLAVOR,
201
00:12:11,620 --> 00:12:16,586
SO EVEN SMALL AMOUNTS
CAN BE USED TO FLAVOR DISHES.
202
00:12:16,586 --> 00:12:20,862
THEY MIX TWO PARTS FISH
WITH ONE PART NATURAL SEA SALT.
203
00:12:20,862 --> 00:12:25,482
THE INGREDIENTS FALL DOWN
A CHUTE INTO A ROTATING DRUM.
204
00:12:25,482 --> 00:12:29,689
AS IT SPINS, IT EVENLY MIXES
THE SALT AND THE FISH.
205
00:12:29,689 --> 00:12:32,137
THIS IS FASTER
THAN MIXING BY HAND,
206
00:12:32,137 --> 00:12:36,379
ENSURING QUICKER
PROCESSING TIMES.
207
00:12:36,379 --> 00:12:37,827
WHEN THE MIX IS READY,
208
00:12:37,827 --> 00:12:42,862
IT'S TAKEN TO ONE OF THE 3,000
FERMENTATION WELLS ON-SITE.
209
00:12:42,862 --> 00:12:47,206
THE BOTTOM OF THE WELL
IS ALREADY FILLED WITH SEA SALT.
210
00:12:47,206 --> 00:12:50,241
THEY ADD THE SALT-FISH MIXTURE
AND SPREAD IT AROUND
211
00:12:50,241 --> 00:12:52,275
SO THAT THE SURFACE IS FLAT.
212
00:12:54,344 --> 00:12:56,206
THEY FINISH
BY COVERING THE MIXTURE
213
00:12:56,206 --> 00:12:59,344
WITH A THICK LAYER OF SEA SALT.
214
00:12:59,344 --> 00:13:05,310
EACH FERMENTATION WELL CAN HOLD
10 TONS OF FISH AND SALT.
215
00:13:05,310 --> 00:13:08,827
THEY COVER THE WELL
WITH A CEMENT CORRUGATED SHEET.
216
00:13:08,827 --> 00:13:13,206
THE TEMPERATURE INSIDE CAN REACH
104 DEGREES FAHRENHEIT.
217
00:13:13,206 --> 00:13:15,172
THEY SOMETIMES
REMOVE THE COVER
218
00:13:15,172 --> 00:13:18,275
TO EXPOSE THE SAUCE TO SUNLIGHT.
219
00:13:18,275 --> 00:13:19,551
FROM TIME TO TIME,
220
00:13:19,551 --> 00:13:22,034
THEY SAMPLE THE SAUCE
FOR INSPECTION.
221
00:13:22,034 --> 00:13:26,517
SALT CRYSTALS FORM NATURALLY
ON THE SURFACE.
222
00:13:26,517 --> 00:13:29,241
AFTER 12 TO 18 MONTHS
OF FERMENTATION,
223
00:13:29,241 --> 00:13:31,379
FIRST-GRADE SAUCE
IS PUMPED OUT
224
00:13:31,379 --> 00:13:33,655
FROM THE BOTTOM
OF THE FERMENTATION WELL
225
00:13:33,655 --> 00:13:38,517
WITH LAYERS OF SALT
ACTING AS A NATURAL FILTER.
226
00:13:38,517 --> 00:13:42,482
FISH SAUCE IS STORED
IN LARGE FIBERGLASS TANKS.
227
00:13:42,482 --> 00:13:44,000
EMPLOYEES TAKE SAMPLES
228
00:13:44,000 --> 00:13:48,448
AND SEND THEM TO THE LAB
FOR QUALITY TESTING.
229
00:13:48,448 --> 00:13:51,068
AFTER FILTERING AND SWEETENING
THE SAUCE SLIGHTLY
230
00:13:51,068 --> 00:13:54,965
WITH 5% SUGAR,
THEY ARE READY FOR BOTTLING.
231
00:13:57,413 --> 00:13:59,206
AFTER A VISUAL INSPECTION,
232
00:13:59,206 --> 00:14:01,310
BOTTLES HEAD
TO THE FILLING AREA.
233
00:14:01,310 --> 00:14:06,034
THE MACHINE GRABS EACH BOTTLE
AND FILLS IT FROM THE BOTTOM UP.
234
00:14:06,034 --> 00:14:08,379
FISH SAUCE DOES NOT NEED
TO BE PASTEURIZED
235
00:14:08,379 --> 00:14:13,103
AS FILTRATION HAS ALREADY
ELIMINATED MOST BACTERIA.
236
00:14:13,103 --> 00:14:16,758
ALSO, THE SAUCE
CONTAINS OVER 25% SALT.
237
00:14:16,758 --> 00:14:18,655
THIS HIGH-SODIUM CONTENT
PREVENTS
238
00:14:18,655 --> 00:14:22,793
ANY HARMFUL BACTERIA
FROM PROLIFERATING.
239
00:14:22,793 --> 00:14:25,206
BECAUSE OF THE SAUCE'S
INTENSE FLAVOR,
240
00:14:25,206 --> 00:14:28,068
IT IS GENERALLY
USED IN MODERATION.
241
00:14:28,068 --> 00:14:30,551
SO BOTTLE CAPS
HAVE A SMALL DROPPER HOLE
242
00:14:30,551 --> 00:14:34,379
TO FACILITATE USE
OF THE SAUCE DURING COOKING.
243
00:14:34,379 --> 00:14:37,724
NEXT, BRUSHES APPLY
ADHESIVE LABELS TO THE BODY
244
00:14:37,724 --> 00:14:40,241
AND NECK OF THE BOTTLE.
245
00:14:40,241 --> 00:14:42,551
THIS FACTORY PRODUCES
THREE DIFFERENT GRADES
246
00:14:42,551 --> 00:14:43,931
OF FISH SAUCE
247
00:14:43,931 --> 00:14:47,517
FOR A TOTAL OF 15 MILLION LITERS
EVERY YEAR.
248
00:14:49,586 --> 00:14:51,724
AFTER A SECOND
VISUAL INSPECTION,
249
00:14:51,724 --> 00:14:54,655
BOTTLES PROCEED
TO THE PACKING DEPARTMENT.
250
00:14:54,655 --> 00:14:59,241
THE MACHINE PUSHES THEM FORWARD,
ALIGNING THEM IN POSITION.
251
00:14:59,241 --> 00:15:03,551
BY NOW, THE BOTTLE CAPS
HAVE BEEN SAFETY-SEALED.
252
00:15:03,551 --> 00:15:05,068
A ROBOTIC CARRIER PICKS UP
253
00:15:05,068 --> 00:15:08,758
36 BOTTLES TO FILL
THREE BOXES AT ONCE.
254
00:15:08,758 --> 00:15:12,000
A METAL FRAME
KEEPS THE CARTON CASES OPEN
255
00:15:12,000 --> 00:15:14,275
AS THE MACHINE
INSERTS THE BOTTLES.
256
00:15:14,275 --> 00:15:17,758
THE TASTY SAUCE WILL BE
SOLD LOCALLY OR EXPORTED
257
00:15:17,758 --> 00:15:20,103
TO ONE
OF 70 DIFFERENT COUNTRIES.
258
00:15:22,551 --> 00:15:24,379
IN THE FOOD-SCIENCE LABORATORY,
259
00:15:24,379 --> 00:15:28,379
TECHNICIANS PERFORM
SEVERAL QUALITY-CONTROL TESTS.
260
00:15:28,379 --> 00:15:29,655
THEY START BY MEASURING
261
00:15:29,655 --> 00:15:31,793
THE SALT CONTENT
OF THE PRODUCT
262
00:15:31,793 --> 00:15:33,620
AS THE SALT
WILL AFFECT THE TASTE
263
00:15:33,620 --> 00:15:37,586
AND THE SHELF LIFE OF THE SAUCE.
264
00:15:37,586 --> 00:15:40,482
NEXT, THEY MEASURE
THE PROTEIN CONTENT.
265
00:15:40,482 --> 00:15:43,896
FISH PROTEIN BREAKS DOWN
DURING THE FERMENTATION PROCESS,
266
00:15:43,896 --> 00:15:47,310
RELEASING A COMPOUND
CALLED GLUTAMATE.
267
00:15:47,310 --> 00:15:51,034
GLUTAMATE INCREASES THE FLAVOR
INTENSITY OF THE SAUCE.
268
00:15:51,034 --> 00:15:53,103
HIGHER LEVELS OF PROTEIN
GIVE A TASTIER,
269
00:15:53,103 --> 00:15:55,551
HIGHER-GRADE SAUCE.
270
00:15:55,551 --> 00:15:57,862
THEY ALSO CHECK
THE LEVELS OF HISTAMINE
271
00:15:57,862 --> 00:15:59,172
TO MAKE SURE THEY COMPLY
272
00:15:59,172 --> 00:16:02,103
WITH INTERNATIONAL
FOOD STANDARDS.
273
00:16:02,103 --> 00:16:06,206
HIGH LEVELS OF HISTAMINE
COULD INDICATE SPOILAGE.
274
00:16:06,206 --> 00:16:08,862
THEY END WITH A pH TEST.
275
00:16:08,862 --> 00:16:11,413
GOOD FISH SAUCE
IS SLIGHTLY ACIDIC,
276
00:16:11,413 --> 00:16:16,137
AND THE pH VALUE MUST REMAIN
WITHIN AN ACCEPTABLE RANGE.
277
00:16:16,137 --> 00:16:19,413
PEOPLE NOW USE FISH SAUCE
NOT ONLY IN THAI DISHES,
278
00:16:19,413 --> 00:16:22,482
BUT ALSO TO FLAVOR
THEIR OWN TRADITIONAL FOODS.
279
00:16:31,724 --> 00:16:33,551
Narrator:
CAPPERS ARE AUTOMATED MACHINES
280
00:16:33,551 --> 00:16:35,448
WHICH APPLY CAPS ON BOTTLES
281
00:16:35,448 --> 00:16:38,551
THAT HAVE BEEN FILLED
WITH A FACTORY PRODUCT --
282
00:16:38,551 --> 00:16:41,862
ANYTHING FROM SHAMPOO
TO SOFT DRINKS.
283
00:16:41,862 --> 00:16:45,206
THE CLOSURES THE CAPPERS
APPLY INCLUDE SCREW CAPS,
284
00:16:45,206 --> 00:16:46,827
PUSH-DOWN TOPS,
285
00:16:46,827 --> 00:16:50,068
AND ALUMINUM CAPS MOLDED
TO THE SHAPE OF THE BOTTLE NECK.
286
00:16:53,310 --> 00:16:54,931
CAPPERS COME IN DIFFERENT SIZES
287
00:16:54,931 --> 00:16:56,482
TO MEET
THE PRODUCT MANUFACTURERS'
288
00:16:56,482 --> 00:16:59,000
PACKAGING REQUIREMENTS,
289
00:16:59,000 --> 00:17:02,206
FROM THREE-HEAD MACHINES
THAT CAP 40 BOTTLES PER MINUTE,
290
00:17:02,206 --> 00:17:07,655
TO 36-HEAD MACHINES THAT CAP
1,200 BOTTLES PER MINUTE.
291
00:17:07,655 --> 00:17:09,482
EVERY CAPPER IS CUSTOM-DESIGNED
292
00:17:09,482 --> 00:17:11,586
FOR THE PRODUCT BEING PACKAGED,
293
00:17:11,586 --> 00:17:14,586
SO PRODUCERS MUST SUPPLY
THE CAPPER MANUFACTURER
294
00:17:14,586 --> 00:17:19,000
WITH SAMPLES OF
THEIR SPECIFIC BOTTLES AND CAPS.
295
00:17:19,000 --> 00:17:21,103
THE FIRST STEP
OF THE DESIGN PHASE
296
00:17:21,103 --> 00:17:22,689
IS TO PAINT THE SAMPLES WHITE
297
00:17:22,689 --> 00:17:26,275
SO THAT ENGINEERS CAN SCAN THEM
WITH A LASER TO PRODUCE
298
00:17:26,275 --> 00:17:29,655
A THREE-DIMENSIONAL
COMPUTER MODEL.
299
00:17:29,655 --> 00:17:32,620
THEN THE ENGINEERS USE
THAT VIRTUAL BOTTLE AND CAP
300
00:17:32,620 --> 00:17:36,793
TO DESIGN THE MACHINE'S
BOTTLE-HANDLING EQUIPMENT.
301
00:17:36,793 --> 00:17:38,344
THIS REFERS TO THE COMPONENTS
302
00:17:38,344 --> 00:17:40,724
WHICH TRANSPORT THE BOTTLES
THROUGH THE MACHINE
303
00:17:40,724 --> 00:17:44,241
AS OPPOSED TO THE COMPONENTS
THAT APPLY THE CAP.
304
00:17:44,241 --> 00:17:46,793
THIS COMPUTER-GUIDED
WATER-JET CUTTER
305
00:17:46,793 --> 00:17:50,827
SLICES THROUGH A STAINLESS-STEEL
PLATE TO MAKE THE BASES
306
00:17:50,827 --> 00:17:52,965
THAT SUPPORT
THE BOTTLE-HANDLING EQUIPMENT
307
00:17:52,965 --> 00:17:56,000
ON THE CAPPER FROM UNDERNEATH.
308
00:17:56,000 --> 00:17:58,103
A COMPUTER-GUIDED
MACHINING CENTER
309
00:17:58,103 --> 00:18:00,517
SHAPES THE COMPLEX
BOTTLE-HANDLING COMPONENTS
310
00:18:00,517 --> 00:18:02,862
OUT OF STAINLESS-STEEL RODS.
311
00:18:07,034 --> 00:18:08,931
THE CAPPER'S
BOTTLE-CAPPING COMPONENTS
312
00:18:08,931 --> 00:18:11,000
ARE MACHINED THE SAME WAY.
313
00:18:13,241 --> 00:18:17,344
EVERY PART UNDERGOES
A PRECISION INSPECTION.
314
00:18:17,344 --> 00:18:19,827
AN ENGINEER CHECKS
THE DIMENSIONS WITH A DEVICE
315
00:18:19,827 --> 00:18:21,862
CALLED
A COORDINATE MEASURING MACHINE.
316
00:18:29,103 --> 00:18:32,000
A COMPUTER-GUIDED ROUTER
CUTS THE PLASTIC COMPONENTS
317
00:18:32,000 --> 00:18:33,655
OF THE BOTTLE-HANDLING EQUIPMENT
318
00:18:33,655 --> 00:18:36,862
FROM A 19-MILLIMETER-THICK SHEET
OF POLYETHYLENE.
319
00:18:47,172 --> 00:18:51,103
MEANWHILE, AN ELECTRICIAN WIRES
THE CAPPER'S CONTROL PANEL.
320
00:18:51,103 --> 00:18:52,413
IT HOUSES THE COMPONENTS
321
00:18:52,413 --> 00:18:54,448
WHICH REGULATE
THE MACHINE'S SPEED,
322
00:18:54,448 --> 00:18:56,482
AS WELL AS THE COMPUTER
THAT CONTROLS
323
00:18:56,482 --> 00:18:59,413
ALL THE MACHINE'S FUNCTIONS.
324
00:18:59,413 --> 00:19:02,344
THE MACHINE HAS SENSORS THAT
DETECT THE PRESENCE OF A BOTTLE
325
00:19:02,344 --> 00:19:04,931
AND CAP AT THE CAPPING HEAD.
326
00:19:04,931 --> 00:19:09,241
THESE SENSORS ARE WIRED
TO THE COMPUTER.
327
00:19:09,241 --> 00:19:12,448
OTHER WORKERS ASSEMBLE THE
PRODUCTION-LINE CONVEYOR BELT
328
00:19:12,448 --> 00:19:17,413
THAT FERRIES BOTTLES
INTO AND OUT OF THE CAPPER.
329
00:19:17,413 --> 00:19:19,620
THE BELT IS COMPRISED
OF PLASTIC LINKS
330
00:19:19,620 --> 00:19:21,482
CONNECTED WITH PINS.
331
00:19:27,000 --> 00:19:29,068
TO BEGIN ASSEMBLING THE MACHINE,
332
00:19:29,068 --> 00:19:31,241
WORKERS ATTACH
THE THREE CAPPING HEADS
333
00:19:31,241 --> 00:19:33,206
TO THE OVERHEAD CAROUSEL.
334
00:19:33,206 --> 00:19:36,068
THEN THEY INSTALL
A CAPPING CHUCK IN EACH HEAD.
335
00:19:36,068 --> 00:19:38,034
THE CHUCK PICKS UP A CAP.
336
00:19:38,034 --> 00:19:43,137
THEN THE CAPPING HEAD ROTATES
TO SCREW THE CAP ON THE BOTTLE.
337
00:19:43,137 --> 00:19:44,620
A COMPUTER-GUIDED ENGRAVER
338
00:19:44,620 --> 00:19:48,000
LABELS THE CAPPER'S
INFEED STAR WHEEL --
339
00:19:48,000 --> 00:19:52,000
A DISC WITH POCKETS THAT GUIDE
THE BOTTLES INTO THE MACHINE.
340
00:19:52,000 --> 00:19:54,620
WORKERS HIGHLIGHT
THE ENGRAVING WITH PAINT
341
00:19:54,620 --> 00:19:56,103
AND INSET A COLORED DISC
342
00:19:56,103 --> 00:19:58,413
INDICATING
THE SPECIFIC BOTTLE SIZE
343
00:19:58,413 --> 00:20:01,482
THE STAR WHEEL
IS DESIGNED TO RUN.
344
00:20:01,482 --> 00:20:03,000
THEY REPEAT THESE STEPS
345
00:20:03,000 --> 00:20:05,896
WITH THE MACHINE'S
TWO OTHER STAR WHEELS --
346
00:20:05,896 --> 00:20:07,310
ONE IN THE CENTER OF THE MACHINE
347
00:20:07,310 --> 00:20:10,413
THAT MOVES THE BOTTLES
UNDER THE CAPPING HEADS
348
00:20:10,413 --> 00:20:12,206
AND ANOTHER THAT TRANSFERS
THE BOTTLES
349
00:20:12,206 --> 00:20:14,206
TO THE MACHINE'S EXIT.
350
00:20:14,206 --> 00:20:18,482
WORKERS MANUALLY ASSEMBLE
EACH STAR WHEEL.
351
00:20:18,482 --> 00:20:20,758
THEY VERIFY THE POCKET SIZE...
352
00:20:20,758 --> 00:20:22,965
THEN, ON THE CENTER
STAR WHEEL ONLY,
353
00:20:22,965 --> 00:20:25,620
BOLT A STAINLESS-STEEL
REINFORCEMENT LAYER
354
00:20:25,620 --> 00:20:27,655
AND LINE THE POCKETS
WITH A RUBBER MATERIAL
355
00:20:27,655 --> 00:20:29,551
THAT GRIPS BOTTLES.
356
00:20:31,551 --> 00:20:34,724
AFTER INSTALLING THE METAL
SUPPORT BASES ON THE CAPPER,
357
00:20:34,724 --> 00:20:37,310
THEY MOUNT
THE CORRESPONDING STAR WHEELS.
358
00:20:37,310 --> 00:20:40,724
THE CENTER STAR WHEEL AND BASE
HAVE TO BE MADE IN HALVES
359
00:20:40,724 --> 00:20:44,965
TO FIT AROUND
THE MACHINE'S CENTRAL SHAFT.
360
00:20:44,965 --> 00:20:47,379
WORKERS INSTALL
THE CENTER GUIDE.
361
00:20:47,379 --> 00:20:49,103
THE BOTTLES TRAVEL IN THE PATH
362
00:20:49,103 --> 00:20:52,034
BETWEEN THE WHEELS
AND THE GUIDE.
363
00:20:52,034 --> 00:20:54,724
NEXT, WORKERS INSTALL
A RESTRAINT BELT
364
00:20:54,724 --> 00:20:56,241
MADE OF THE SAME RUBBER MATERIAL
365
00:20:56,241 --> 00:21:00,172
THAT LINES THE CENTER
STAR WHEEL POCKETS.
366
00:21:00,172 --> 00:21:01,931
THE BELT AND POCKET
PREVENT THE BOTTLE
367
00:21:01,931 --> 00:21:07,068
FROM SPINNING AS THE CAPPING
HEAD SCREWS ON THE CAP.
368
00:21:07,068 --> 00:21:11,068
NO CAPPER LEAVES THE FACTORY
WITHOUT A TEST RUN.
369
00:21:11,068 --> 00:21:13,137
BEFORE RUNNING
THE MACHINE NORMALLY,
370
00:21:13,137 --> 00:21:15,344
WORKERS RUN IT
AT LOW SPEED TO CHECK
371
00:21:15,344 --> 00:21:17,586
THAT THE COMPONENTS
ARE PROPERLY ALIGNED
372
00:21:17,586 --> 00:21:21,413
AND THE MOVEMENTS
CORRECTLY TIMED.
373
00:21:21,413 --> 00:21:24,206
THE INFEED STAR WHEEL
RECEIVING THE BOTTLES
374
00:21:24,206 --> 00:21:26,103
TRANSFERS THEM
TO THE CENTER STAR WHEEL
375
00:21:26,103 --> 00:21:28,482
UNDER THE CAPPING HEADS.
376
00:21:28,482 --> 00:21:32,793
THE CAPPED BOTTLES THEN TRANSFER
TO THE DISCHARGE STAR WHEEL,
377
00:21:32,793 --> 00:21:34,689
WHICH GUIDES THEM
TO THE CONVEYOR BELT
378
00:21:34,689 --> 00:21:36,586
LEADING TO THE LABELING MACHINE.
30054
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