1 00:00:03,170 --> 00:00:06,238 Narrator: A supercar is overtaking its rivals 2 00:00:06,240 --> 00:00:11,844 With formula one science and sophisticated production. 3 00:00:11,846 --> 00:00:14,947 ♪ 4 00:00:14,949 --> 00:00:18,317 Robots and humans are working in tandem 5 00:00:18,319 --> 00:00:22,721 To create a high tech tool that chops down the competition. 6 00:00:22,723 --> 00:00:24,757 ♪ 7 00:00:24,759 --> 00:00:27,893 Modern technology is keeping a centuries old 8 00:00:27,895 --> 00:00:32,765 Writing tradition alive on a super scale. 9 00:00:32,767 --> 00:00:38,203 And the world's oldest condiment is being made for the masses. 10 00:00:38,205 --> 00:00:39,471 ♪ 11 00:00:39,473 --> 00:00:42,908 These groundbreaking innovations are all taking place 12 00:00:42,910 --> 00:00:46,378 Inside some of the most incredible factories 13 00:00:46,380 --> 00:00:48,781 On the planet. 14 00:00:48,783 --> 00:00:51,784 -- Captions by vitac -- www.Vitac.Com 15 00:00:51,786 --> 00:00:54,787 Captions paid for by discovery communications 16 00:00:54,789 --> 00:00:59,892 ♪ 17 00:00:59,894 --> 00:01:03,429 Surrounded by the green fields of woking, England 18 00:01:03,431 --> 00:01:07,299 Is a factory producing a vehicle unlike any other. 19 00:01:07,301 --> 00:01:10,235 ♪ 20 00:01:10,237 --> 00:01:13,572 This is the mclaren 720s. 21 00:01:13,574 --> 00:01:18,077 It's sleek, fast, and very expensive. 22 00:01:18,079 --> 00:01:20,679 One of these supercars will set you back 23 00:01:20,681 --> 00:01:24,116 Nearly $300,000. 24 00:01:24,118 --> 00:01:27,486 Mclaren cars are a unique type of car. 25 00:01:27,488 --> 00:01:29,254 They're something special. 26 00:01:29,256 --> 00:01:30,756 They're not cars that people need, 27 00:01:30,758 --> 00:01:33,292 They're cars that people want. 28 00:01:33,294 --> 00:01:36,195 Narrator: The 720s is brought to life here 29 00:01:36,197 --> 00:01:39,398 At the mclaren production center. 30 00:01:39,400 --> 00:01:43,302 This 371,000 square foot facility 31 00:01:43,304 --> 00:01:48,173 Was designed by superstar architect norman foster in 2004 32 00:01:48,175 --> 00:01:53,412 At an estimated cost of $386 million. 33 00:01:53,414 --> 00:01:56,482 And the inside of the mclaren production center 34 00:01:56,484 --> 00:01:59,418 Is as impressive as its exterior. 35 00:01:59,420 --> 00:02:04,990 It's bright, spacious, quiet, and extremely clean. 36 00:02:04,992 --> 00:02:07,159 Most high volume car manufacturers, 37 00:02:07,161 --> 00:02:08,994 You'll see hundreds of robots 38 00:02:08,996 --> 00:02:11,196 Making thousands of identical cars. 39 00:02:11,198 --> 00:02:12,731 Well, not here. 40 00:02:12,733 --> 00:02:16,502 Narrator: Mclaren makes fewer than 5,000 cars a year 41 00:02:16,504 --> 00:02:19,138 And each one is special. 42 00:02:19,140 --> 00:02:23,208 Assembling a road car is a very, very complex process. 43 00:02:23,210 --> 00:02:25,444 Mclaren make a car to order. 44 00:02:25,446 --> 00:02:28,580 It's like a bespoke suit. They are handcrafted. 45 00:02:28,582 --> 00:02:31,717 ♪ 46 00:02:31,719 --> 00:02:34,887 Narrator: And that requires a very hands on approach 47 00:02:34,889 --> 00:02:36,989 Down on the factory floor. 48 00:02:36,991 --> 00:02:38,924 Because of their decades of experience 49 00:02:38,926 --> 00:02:41,460 Building formula one race cars, 50 00:02:41,462 --> 00:02:45,531 This individual craft-based approach to car manufacturing 51 00:02:45,533 --> 00:02:48,600 Lies deep in mclaren's dna. 52 00:02:48,602 --> 00:02:51,069 Breece mclaren, the founder, was from new zealand. 53 00:02:51,071 --> 00:02:54,206 He built his first formula one car in 1966. 54 00:02:54,208 --> 00:02:57,209 Only ferrari has been in the racing game longer. 55 00:02:57,211 --> 00:03:01,480 In the early '90s, they got into road cars with the seminal f1. 56 00:03:01,482 --> 00:03:02,948 A lot of the lessons of the racetrack 57 00:03:02,950 --> 00:03:06,385 Are then brought over into their production cars. 58 00:03:06,387 --> 00:03:07,920 Narrator: This is the main building block, 59 00:03:07,922 --> 00:03:10,455 Or chassis of a mclaren car. 60 00:03:10,457 --> 00:03:13,258 It's called a monocell or cage 61 00:03:13,260 --> 00:03:16,128 And the rest of the car is built around it. 62 00:03:16,130 --> 00:03:19,498 The monocells are premanufactured in austria 63 00:03:19,500 --> 00:03:21,366 And are made from the same material 64 00:03:21,368 --> 00:03:25,270 Used in the modern formula one race car. 65 00:03:25,272 --> 00:03:27,539 One of the major parts or major materials we use 66 00:03:27,541 --> 00:03:28,707 Is carbon fiber. 67 00:03:28,709 --> 00:03:31,109 Carbon fiber is at the heart of every mclaren. 68 00:03:31,111 --> 00:03:33,245 Mclaren revolutionized formula one 69 00:03:33,247 --> 00:03:36,748 When they brought in carbon fiber in 1981. 70 00:03:36,750 --> 00:03:40,285 It made the chassis five times lighter and 10 times stronger 71 00:03:40,287 --> 00:03:43,555 And it is a key component in the road cars today. 72 00:03:43,557 --> 00:03:44,823 If you compare carbon fiber 73 00:03:44,825 --> 00:03:46,825 To something like aluminum or steel, 74 00:03:46,827 --> 00:03:50,596 That can be strong, actually the strength to weight ratio 75 00:03:50,598 --> 00:03:52,698 Of carbon fiber is what's so important. 76 00:03:52,700 --> 00:03:55,734 You don't need very much of it to get the equivalent strength 77 00:03:55,736 --> 00:03:58,604 Of a much bigger amount of another material. 78 00:03:58,606 --> 00:04:02,007 Narrator: But what exactly is this wonder material, 79 00:04:02,009 --> 00:04:03,609 Carbon fiber? 80 00:04:03,611 --> 00:04:05,944 Carbon fiber is really high-performance 81 00:04:05,946 --> 00:04:07,713 Composite material. 82 00:04:07,715 --> 00:04:11,583 It's something which contains thin fibers of carbon, 83 00:04:11,585 --> 00:04:13,585 Which on their own would be sort of floppy, 84 00:04:13,587 --> 00:04:16,321 But they have a certain tensile strength to them. 85 00:04:16,323 --> 00:04:19,424 And then those fibers are embedded in a polymer resin, 86 00:04:19,426 --> 00:04:22,728 Which is strong and has a certain flexibility to it. 87 00:04:22,730 --> 00:04:24,296 But actually, when you combine the two, 88 00:04:24,298 --> 00:04:26,832 You get something that's greater than the sum of its parts. 89 00:04:26,834 --> 00:04:31,370 You get a super lightweight high-performance material. 90 00:04:31,372 --> 00:04:33,872 Narrator: Just like their formula one cars, 91 00:04:33,874 --> 00:04:38,243 Mclarens road cars are designed with the driver in mind. 92 00:04:38,245 --> 00:04:40,045 They are built and designed around the driver, 93 00:04:40,047 --> 00:04:42,614 So the driver is literally at the center of the action. 94 00:04:42,616 --> 00:04:44,549 And then the monocage and monocell 95 00:04:44,551 --> 00:04:47,619 Designed around the occupant. 96 00:04:47,621 --> 00:04:49,121 Narrator: As soon as the monocage 97 00:04:49,123 --> 00:04:51,256 Chassis arrives on the production line, 98 00:04:51,258 --> 00:04:54,226 The team starts to assemble a car around this 99 00:04:54,228 --> 00:04:57,229 One essential building block. 100 00:04:57,231 --> 00:04:59,898 The first stage is to add crumple zones 101 00:04:59,900 --> 00:05:03,468 And crash protection around the car's interior. 102 00:05:03,470 --> 00:05:06,104 It's then taken for what they call geometric 103 00:05:06,106 --> 00:05:08,273 And surface validation. 104 00:05:08,275 --> 00:05:12,344 Here, over 450 different points of the car 105 00:05:12,346 --> 00:05:15,614 Are measured to make sure every curve, line, 106 00:05:15,616 --> 00:05:18,550 And corner is perfectly aligned 107 00:05:18,552 --> 00:05:20,152 And in proportion. 108 00:05:20,154 --> 00:05:22,187 We ensure each mclaren car is perfect 109 00:05:22,189 --> 00:05:23,422 In every detail. 110 00:05:23,424 --> 00:05:24,790 Really, right from the off, right from when we start 111 00:05:24,792 --> 00:05:28,894 The whole project it's almost like watchmaking. 112 00:05:28,896 --> 00:05:30,095 Narrator: Once the body has passed 113 00:05:30,097 --> 00:05:32,664 The surface validation test, 114 00:05:32,666 --> 00:05:36,668 The team can then start to build up the car's exterior -- 115 00:05:36,670 --> 00:05:40,439 The wing panels, side panels, 116 00:05:40,441 --> 00:05:43,942 And for non-convertibles -- the roof. 117 00:05:43,944 --> 00:05:46,645 Now it's ready to be painted. 118 00:05:46,647 --> 00:05:48,213 Before spraying, 119 00:05:48,215 --> 00:05:50,682 The whole body is wrapped in plastic 120 00:05:50,684 --> 00:05:53,352 And the individual panels are exposed, 121 00:05:53,354 --> 00:05:56,321 Primed, and sanded flat. 122 00:05:56,323 --> 00:06:01,793 Any contaminants are removed with an anti-static gun 123 00:06:01,795 --> 00:06:05,197 And mclaren's secret to their supercar's high speed 124 00:06:05,199 --> 00:06:10,302 Can be found in the painting process. 125 00:06:10,304 --> 00:06:12,270 By using special particles within the paint 126 00:06:12,272 --> 00:06:13,638 And a special paint process, 127 00:06:13,640 --> 00:06:15,107 We're actually able to decrease the amount of paint 128 00:06:15,109 --> 00:06:16,408 We have to put on the car. 129 00:06:16,410 --> 00:06:21,313 And essentially deliver... [ speaks indistinctly ] 130 00:06:21,315 --> 00:06:25,584 Narrator: It takes 24 hours to paint a typical mclaren car 131 00:06:25,586 --> 00:06:29,554 And another 40 minutes in a hot oven for it to fully dry. 132 00:06:29,556 --> 00:06:33,191 Finally, it's time to start putting the car together. 133 00:06:33,193 --> 00:06:35,394 A loom of wires is fed through the car 134 00:06:35,396 --> 00:06:37,195 To provide it with power. 135 00:06:37,197 --> 00:06:40,866 A typical mclaren is made up of over a mile of cables 136 00:06:40,868 --> 00:06:43,802 And 2,000 individual circuits. 137 00:06:43,804 --> 00:06:46,605 Next, the beating heart of the car. 138 00:06:46,607 --> 00:06:48,340 The most common engine type 139 00:06:48,342 --> 00:06:53,412 Is the m83018, a 3.8 liter 90 degree twin turbo 140 00:06:53,414 --> 00:06:55,881 Charged flat plain v8. 141 00:06:55,883 --> 00:06:59,518 The mclaren 720 s goes from not 62 miles per hour 142 00:06:59,520 --> 00:07:01,787 In 2.9 seconds. 143 00:07:01,789 --> 00:07:05,190 Top speed -- 212 miles per hour. 144 00:07:05,192 --> 00:07:09,060 ♪ 145 00:07:09,062 --> 00:07:10,362 Narrator: Like most of the other parts 146 00:07:10,364 --> 00:07:14,699 That make up the mclaren, the engine is made offsite. 147 00:07:14,701 --> 00:07:17,536 For mclaren, outsourcing the parts 148 00:07:17,538 --> 00:07:20,639 Makes the most economic sense. 149 00:07:20,641 --> 00:07:24,009 To try to actually build every single little bit of a car 150 00:07:24,011 --> 00:07:26,478 As well as assemble the cars themselves 151 00:07:26,480 --> 00:07:28,647 Would be inefficient from a process perspective, 152 00:07:28,649 --> 00:07:31,116 But also from a cost perspective. 153 00:07:31,118 --> 00:07:33,118 Narrator: Back on the assembly line, 154 00:07:33,120 --> 00:07:35,554 The brake discs and pistons are installed. 155 00:07:35,556 --> 00:07:38,223 The brakes will slow these high-performance wheels 156 00:07:38,225 --> 00:07:40,892 From 124 miles per hour 157 00:07:40,894 --> 00:07:45,630 To zero in just 4.6 seconds. 158 00:07:45,632 --> 00:07:49,835 Now another team finishes the interior of the car. 159 00:07:49,837 --> 00:07:51,236 A mclaren supercar 160 00:07:51,238 --> 00:07:55,207 Is made up of over 1,200 individual components. 161 00:07:55,209 --> 00:07:59,244 It takes two to three weeks to put one of these cars together. 162 00:07:59,246 --> 00:08:02,681 But no car is really complete until it's been taken 163 00:08:02,683 --> 00:08:06,318 For a spin out on the test track. 164 00:08:06,320 --> 00:08:15,760 ♪ 165 00:08:15,762 --> 00:08:24,836 ♪ 166 00:08:24,838 --> 00:08:34,112 ♪ 167 00:08:34,114 --> 00:08:35,914 ♪ 168 00:08:35,916 --> 00:08:39,317 The final stage consists of an inspection and clean 169 00:08:39,319 --> 00:08:41,419 And polish of the vehicle. 170 00:08:41,421 --> 00:08:46,324 Then it's off to the customer and out onto the open road. 171 00:08:46,326 --> 00:08:49,027 We have this incredible passion for what we do. 172 00:08:49,029 --> 00:08:50,362 We're normally very, very precise 173 00:08:50,364 --> 00:08:53,131 And logical in our approach. 174 00:08:53,133 --> 00:08:56,635 But actually, no, the thing that drives it is pure passion. 175 00:08:56,637 --> 00:08:57,802 Narrator: Mclaren is one of the world's 176 00:08:57,804 --> 00:09:01,239 Most high-tech brands. 177 00:09:01,241 --> 00:09:02,874 The skill and sophistication 178 00:09:02,876 --> 00:09:05,277 Found inside their production center 179 00:09:05,279 --> 00:09:11,182 Make it one of the world's most spectacular super factories. 180 00:09:11,184 --> 00:09:14,853 Coming up, an american icon is 181 00:09:14,855 --> 00:09:17,355 Chopping down the competition. 182 00:09:17,357 --> 00:09:20,358 And later, new technology is keeping one of 183 00:09:20,360 --> 00:09:24,729 The world's oldest writing traditions alive. 184 00:09:26,800 --> 00:09:33,038 ♪ 185 00:09:33,040 --> 00:09:36,875 Narrator: In a popular beach town along the east coast, 186 00:09:36,877 --> 00:09:38,710 One factory is manufacturing 187 00:09:38,712 --> 00:09:44,683 One of the most iconic products in america -- 188 00:09:44,685 --> 00:09:49,654 The mighty chainsaw. 189 00:09:49,656 --> 00:09:52,924 With teeth turning at 60 miles per hour, 190 00:09:52,926 --> 00:09:58,663 Some chainsaws can fell trees in minutes 191 00:09:58,665 --> 00:10:03,635 And cut logs even faster. 192 00:10:03,637 --> 00:10:07,272 Behind all that power is a polished production line 193 00:10:07,274 --> 00:10:12,010 That harnesses more than 40 years of expertise and skill. 194 00:10:12,012 --> 00:10:16,848 This is the steel super factory in virginia beach, virginia. 195 00:10:16,850 --> 00:10:20,418 Inside this 1,000,000 square foot facility, 196 00:10:20,420 --> 00:10:22,787 Man, machine, and robots 197 00:10:22,789 --> 00:10:26,858 Assemble more than 12,000 products a day. 198 00:10:26,860 --> 00:10:32,097 Once you get inside, you realize what a super factory is. 199 00:10:32,099 --> 00:10:35,567 Narrator: Steel has produced a staggering 75 million 200 00:10:35,569 --> 00:10:40,972 Chainsaws since it opened here in 1974. 201 00:10:40,974 --> 00:10:46,144 But the origins of the chainsaw itself go back much further. 202 00:10:46,146 --> 00:10:49,714 The first ever chainsaw wasn't invented by a lumberjack. 203 00:10:49,716 --> 00:10:54,419 Actually, it was invented by a physician. 204 00:10:54,421 --> 00:10:57,188 The concept of a saw tooth chain device dates 205 00:10:57,190 --> 00:11:00,358 From the 18th century and was worked by hand 206 00:11:00,360 --> 00:11:04,929 When surgeons needed a quick way to cut through bone. 207 00:11:04,931 --> 00:11:08,500 Narrator: In the 1920s, inventors began looking for ways 208 00:11:08,502 --> 00:11:12,370 To further develop the concept for the forest industry. 209 00:11:12,372 --> 00:11:16,374 Swiss born, andreas stihl was one of the pioneers. 210 00:11:16,376 --> 00:11:21,479 He produced his first powered chainsaw in 1926. 211 00:11:21,481 --> 00:11:24,883 The advent of the chainsaw completely revolutionized 212 00:11:24,885 --> 00:11:26,785 The forestry industry. 213 00:11:26,787 --> 00:11:29,220 Before then, you had gangs of men 214 00:11:29,222 --> 00:11:32,090 Toiling with axes and hand saws. 215 00:11:32,092 --> 00:11:37,762 Now one man could do the work of a half a dozen, 216 00:11:37,764 --> 00:11:40,699 And stihl's plans have come a long way. 217 00:11:40,701 --> 00:11:44,235 ♪ 218 00:11:44,237 --> 00:11:45,837 In the '70s, when we started, 219 00:11:45,839 --> 00:11:48,106 We were just building one product -- 220 00:11:48,108 --> 00:11:51,776 A small handheld chainsaw. 221 00:11:51,778 --> 00:11:53,344 But we always had a vision. 222 00:11:53,346 --> 00:11:57,682 And now we are the world's largest selling chainsaw. 223 00:11:57,684 --> 00:12:00,885 Narrator: Several hundred components make up a chainsaw. 224 00:12:00,887 --> 00:12:04,856 It needs to have an incredible strength to weight ratio. 225 00:12:04,858 --> 00:12:07,525 Magnus: The chainsaw is quite a complex machine. 226 00:12:07,527 --> 00:12:09,193 You've got to start with the crankshaft, 227 00:12:09,195 --> 00:12:10,962 The piston, and the cylinder. 228 00:12:10,964 --> 00:12:13,665 Eventually, that crankshaft turns the clutch drum, 229 00:12:13,667 --> 00:12:15,900 Which in turn, turns the chain on the bar, 230 00:12:15,902 --> 00:12:17,769 Which you use to cut wood. 231 00:12:17,771 --> 00:12:19,204 But it's not quite that simple. 232 00:12:19,206 --> 00:12:23,675 There's a lot of parts in there that make that chain turn. 233 00:12:23,677 --> 00:12:25,477 Narrator: Production of every chainsaw 234 00:12:25,479 --> 00:12:27,612 Starts with the piston. 235 00:12:27,614 --> 00:12:30,849 Its main function is to transfer explosive energy 236 00:12:30,851 --> 00:12:34,419 From inside the engine to the cutting chain. 237 00:12:34,421 --> 00:12:37,155 Leaves are like small racing engines, 238 00:12:37,157 --> 00:12:41,760 Turning as many as 10 and 11,000 rpm piston. 239 00:12:41,762 --> 00:12:46,131 It is the heart of the engine. 240 00:12:46,133 --> 00:12:48,800 Narrator: Raw piston castings made of aluminum 241 00:12:48,802 --> 00:12:51,703 Are placed into a machine to be shaped, drilled, 242 00:12:51,705 --> 00:12:54,205 Cut, board, and finished 243 00:12:54,207 --> 00:12:57,375 With computer controlled precision. 244 00:12:57,377 --> 00:12:59,444 I know it just looks very simple, 245 00:12:59,446 --> 00:13:02,881 But the intricate machining 246 00:13:02,883 --> 00:13:05,517 Is not just a round piston. 247 00:13:05,519 --> 00:13:09,220 It's actually oval shape in this direction 248 00:13:09,222 --> 00:13:15,160 And barrel shape in this direction. 249 00:13:15,162 --> 00:13:16,895 Narrator: These pistons need to be milled 250 00:13:16,897 --> 00:13:18,696 With incredible precision. 251 00:13:18,698 --> 00:13:21,933 They're measured in microns. 252 00:13:21,935 --> 00:13:23,635 If I were to measure the thickness 253 00:13:23,637 --> 00:13:25,804 Of a sheet of notebook paper, 254 00:13:25,806 --> 00:13:29,174 It would measure .1 of a millimeter thick. 255 00:13:29,176 --> 00:13:30,875 In order to achieve the micron, 256 00:13:30,877 --> 00:13:32,710 You would have to slice the thickness 257 00:13:32,712 --> 00:13:36,314 Of a sheet of notebook paper 100 times. 258 00:13:36,316 --> 00:13:38,283 Narrator: The room for error on these pistons 259 00:13:38,285 --> 00:13:40,618 Is just two microns 260 00:13:40,620 --> 00:13:45,290 About 25 times smaller than the width of a human hair. 261 00:13:45,292 --> 00:13:49,527 I have measured the outside diameter of pistons 262 00:13:49,529 --> 00:13:52,897 And had fingerprints on the piston, 263 00:13:52,899 --> 00:13:54,833 Making it out of specification. 264 00:13:54,835 --> 00:14:00,004 ♪ 265 00:14:00,006 --> 00:14:05,310 ♪ 266 00:14:05,312 --> 00:14:08,346 The perfect piston has been engineered, 267 00:14:08,348 --> 00:14:11,082 But to transfer power to the cutting chain, 268 00:14:11,084 --> 00:14:14,085 You need a crankshaft. 269 00:14:14,087 --> 00:14:16,955 The crankshaft transfers that in and out, back and forth, 270 00:14:16,957 --> 00:14:20,058 Energy of the piston into a rotational force, 271 00:14:20,060 --> 00:14:21,559 And that rotation turns 272 00:14:21,561 --> 00:14:24,329 The gears and fixes to an exact sprocket 273 00:14:24,331 --> 00:14:27,365 That is the thing that's driving the chain round and round. 274 00:14:27,367 --> 00:14:29,567 ♪ 275 00:14:29,569 --> 00:14:32,370 Narrator: Using computerized milling machines, 276 00:14:32,372 --> 00:14:34,372 The steel forgings are transformed 277 00:14:34,374 --> 00:14:36,674 Into the crankshaft components 278 00:14:36,676 --> 00:14:39,043 In just 12 seconds, 279 00:14:39,045 --> 00:14:41,145 But before they can be used, 280 00:14:41,147 --> 00:14:44,015 They need to be strengthened. 281 00:14:44,017 --> 00:14:45,717 We're taking crankshafts and putting them 282 00:14:45,719 --> 00:14:47,852 Inside of the furnace to make them very hot. 283 00:14:47,854 --> 00:14:50,255 It's 1,700 degrees to make them porous. 284 00:14:50,257 --> 00:14:51,522 So that way the air comes out 285 00:14:51,524 --> 00:14:55,260 And the carbon is pumped in to harden the metal. 286 00:14:55,262 --> 00:14:57,695 Narrator: The carbon-infused components are baked 287 00:14:57,697 --> 00:15:00,765 At 3,900 degrees fahrenheit, 288 00:15:00,767 --> 00:15:03,201 Which gives them an extremely durable 289 00:15:03,203 --> 00:15:06,170 And wear-resistant surface. 290 00:15:06,172 --> 00:15:08,373 The reason why they infuse the steel with carbon 291 00:15:08,375 --> 00:15:10,408 Is basically to make it harder. 292 00:15:10,410 --> 00:15:13,378 And the reason why they need to be hard or strong 293 00:15:13,380 --> 00:15:17,749 Is because these components are under enormous stress. 294 00:15:17,751 --> 00:15:20,785 Narrator: Once out of the oven, the parts are milled some more 295 00:15:20,787 --> 00:15:22,186 And measured. 296 00:15:22,188 --> 00:15:25,823 Anything two microns out of alignment will be rejected. 297 00:15:25,825 --> 00:15:28,426 They are then assembled in a pressing station 298 00:15:28,428 --> 00:15:33,097 Where over 27 tons of pressure can be applied. 299 00:15:33,099 --> 00:15:35,466 Finally, the assembled crankshaft 300 00:15:35,468 --> 00:15:37,335 Is checked for straightness, 301 00:15:37,337 --> 00:15:42,573 Ensuring that it's balanced and runs smoothly. 302 00:15:42,575 --> 00:15:44,008 But there's still a long way 303 00:15:44,010 --> 00:15:46,544 To go before the finished chainsaw 304 00:15:46,546 --> 00:15:49,113 Is ready to leave this factory floor. 305 00:15:49,115 --> 00:15:51,316 To help move things along, 306 00:15:51,318 --> 00:15:55,987 Stihl has invested in some high tech helpers. 307 00:15:57,991 --> 00:16:02,126 ♪ 308 00:16:02,128 --> 00:16:04,829 Narrator: From lumberjacks to landscapers, 309 00:16:04,831 --> 00:16:07,865 Stihl makes a product for everyone. 310 00:16:07,867 --> 00:16:10,168 And when it comes to chainsaws, 311 00:16:10,170 --> 00:16:15,373 They are the number one selling brand in the world. 312 00:16:15,375 --> 00:16:20,144 Inside stihl's state of the art super factory in virginia beach, 313 00:16:20,146 --> 00:16:24,816 Robots mill, test, and deliver a continuous supply of parts 314 00:16:24,818 --> 00:16:29,120 To the assembly line 24 hours a day. 315 00:16:29,122 --> 00:16:31,389 Magnus: There's a central guidance system. 316 00:16:31,391 --> 00:16:34,225 They know exactly where they're at out on the shop floor, 317 00:16:34,227 --> 00:16:36,194 Which assembly line they're going to, 318 00:16:36,196 --> 00:16:38,162 And which material they're dropping off 319 00:16:38,164 --> 00:16:40,098 Or in some cases picking up. 320 00:16:40,100 --> 00:16:43,835 When the battery gets low, they charge themselves up again, 321 00:16:43,837 --> 00:16:47,271 Then they start back in operation. 322 00:16:47,273 --> 00:16:49,140 Narrator: There is even a robot that threads 323 00:16:49,142 --> 00:16:51,476 And ties the knot in the drawstring 324 00:16:51,478 --> 00:16:53,845 That starts the engine. 325 00:16:53,847 --> 00:16:55,947 But when we first started the first year, 326 00:16:55,949 --> 00:16:58,950 We made 12,000 units that first year. 327 00:16:58,952 --> 00:17:01,953 And the process back then was air screwdrivers 328 00:17:01,955 --> 00:17:03,654 And a lot of hand assembly. 329 00:17:03,656 --> 00:17:07,025 So the whole process has really evolved. 330 00:17:07,027 --> 00:17:10,928 And right now, we're producing 12,000 units a day 331 00:17:10,930 --> 00:17:15,233 Out of the facility here in virginia beach. 332 00:17:15,235 --> 00:17:16,901 Narrator: With the engine assembled, 333 00:17:16,903 --> 00:17:21,606 The next step is to make the polymer housing. 334 00:17:21,608 --> 00:17:24,475 It all happens here in the polymer zone 335 00:17:24,477 --> 00:17:27,879 At the north end of the factory. 336 00:17:27,881 --> 00:17:30,815 What's in these are what we call gaylord boxes 337 00:17:30,817 --> 00:17:33,117 Is a raw resin that is applied 338 00:17:33,119 --> 00:17:35,586 To the injection molding machine. 339 00:17:35,588 --> 00:17:38,790 One may be going to a motor housing, 340 00:17:38,792 --> 00:17:40,725 One may be going to shroud. 341 00:17:40,727 --> 00:17:44,829 ♪ 342 00:17:44,831 --> 00:17:46,497 Narrator: The raw resin pellets 343 00:17:46,499 --> 00:17:49,267 Are melted at extremely high temperatures 344 00:17:49,269 --> 00:17:52,904 And injected under tons of pressure into custom made molds. 345 00:17:52,906 --> 00:17:56,307 ♪ 346 00:17:56,309 --> 00:17:58,543 The resin cools, hardens, 347 00:17:58,545 --> 00:18:02,747 And forms the shape of the polymer part. 348 00:18:02,749 --> 00:18:05,349 A chainsaw will turn its cutting chain 349 00:18:05,351 --> 00:18:08,653 At over 10,000 revolutions per minute. 350 00:18:08,655 --> 00:18:12,957 So to be able to safely hold and control the chainsaw, 351 00:18:12,959 --> 00:18:15,660 Stihl has designed its polymer handle 352 00:18:15,662 --> 00:18:19,664 To be lightweight and super strong. 353 00:18:19,666 --> 00:18:22,166 To bring down weight and increase rigidity, 354 00:18:22,168 --> 00:18:24,435 What we do is we actually come in here 355 00:18:24,437 --> 00:18:26,804 And we have a needle valve that opens up, 356 00:18:26,806 --> 00:18:30,441 Injects nitrogen through here and it'll escape 357 00:18:30,443 --> 00:18:32,176 Out through here, through a dam gate. 358 00:18:32,178 --> 00:18:35,279 And it just makes the part real rigid and real lightweight. 359 00:18:35,281 --> 00:18:37,482 ♪ 360 00:18:37,484 --> 00:18:40,651 Narrator: The chainsaw engine is built and housed, 361 00:18:40,653 --> 00:18:44,989 But now it's time to assemble the business end. 362 00:18:44,991 --> 00:18:47,358 This is a guide bar. 363 00:18:47,360 --> 00:18:49,760 A guide bar is basically the blade of a chainsaw. 364 00:18:49,762 --> 00:18:53,297 The part that the chain actually rides around. 365 00:18:53,299 --> 00:18:58,369 Narrator: The process starts with rolls of steel. 366 00:18:58,371 --> 00:19:01,739 Steel is an alloy of iron and carbon. 367 00:19:01,741 --> 00:19:05,643 It's harder and stronger than iron. 368 00:19:05,645 --> 00:19:08,813 To make the guide rail, a steel strip is cut 369 00:19:08,815 --> 00:19:13,317 And stamped into three different pieces, 370 00:19:13,319 --> 00:19:17,989 Which are then fed into a 20-ton metric press. 371 00:19:17,991 --> 00:19:19,991 Here, they're bonded together 372 00:19:19,993 --> 00:19:22,827 With a supercharged electric well 373 00:19:22,829 --> 00:19:26,864 And then hardened with an induction heat treatment. 374 00:19:26,866 --> 00:19:28,366 Well, the guide bar and the chain 375 00:19:28,368 --> 00:19:31,736 Are obviously very critical to the function of a chainsaw 376 00:19:31,738 --> 00:19:32,970 Because you need to cut wood. 377 00:19:32,972 --> 00:19:35,907 The guide bar and the chain 378 00:19:35,909 --> 00:19:37,909 Are matched according to the sprocket 379 00:19:37,911 --> 00:19:38,910 That you have on. 380 00:19:38,912 --> 00:19:40,811 They're different pitches of chain. 381 00:19:40,813 --> 00:19:42,613 Depending on what kind of trees you're cutting 382 00:19:42,615 --> 00:19:46,217 And the area you're cutting in. 383 00:19:46,219 --> 00:19:49,253 Narrator: The chain is manufactured at another factory. 384 00:19:49,255 --> 00:19:51,189 The cutting teeth and a top plate 385 00:19:51,191 --> 00:19:54,191 Are angled at 30 degrees to aid cutting. 386 00:19:54,193 --> 00:19:59,163 [ chainsaw whirring ] 387 00:19:59,165 --> 00:20:01,866 Finally, before they're shipped out, 388 00:20:01,868 --> 00:20:05,203 Every chainsaw is started up and tested. 389 00:20:05,205 --> 00:20:11,242 ♪ 390 00:20:11,244 --> 00:20:13,144 The stihl factory was founded here 391 00:20:13,146 --> 00:20:18,616 Partly because of its proximity to the port of virginia. 392 00:20:18,618 --> 00:20:22,086 Now, products made in this super factory 393 00:20:22,088 --> 00:20:24,121 Are shipped across the u.S. 394 00:20:24,123 --> 00:20:28,326 And to 80 countries. 395 00:20:28,328 --> 00:20:31,128 Coming up, german technology is keeping 396 00:20:31,130 --> 00:20:34,832 The world's oldest writing traditions alive. 397 00:20:34,834 --> 00:20:39,403 And in japan, a popular condiment is being made 398 00:20:39,405 --> 00:20:41,439 On an industrial scale. 399 00:20:41,441 --> 00:20:44,675 The scale is hard to believe, 400 00:20:44,677 --> 00:20:47,445 And that is really a super factory. 401 00:20:49,582 --> 00:20:55,786 ♪ 402 00:20:55,788 --> 00:20:59,390 Narrator: The city of stein in bavaria, germany 403 00:20:59,392 --> 00:21:03,828 Is home to a uniquely charming super factory. 404 00:21:03,830 --> 00:21:07,598 The facility may have a quaint medieval exterior, 405 00:21:07,600 --> 00:21:12,403 But inside, it is truly an industrial powerhouse. 406 00:21:12,405 --> 00:21:20,177 ♪ 407 00:21:20,179 --> 00:21:22,713 This is faber-castell, 408 00:21:22,715 --> 00:21:26,350 The world's oldest and biggest pencil business. 409 00:21:26,352 --> 00:21:27,818 And in this factory, 410 00:21:27,820 --> 00:21:30,955 They have perfected a centuries old process, 411 00:21:30,957 --> 00:21:35,660 Producing 2.3 billion pencils a year. 412 00:21:35,662 --> 00:21:39,030 The scale is hard to believe. 413 00:21:39,032 --> 00:21:42,667 And that is really a super factory. 414 00:21:42,669 --> 00:21:45,303 Narrator: Faber-castell defines tradition. 415 00:21:45,305 --> 00:21:48,105 Founded in 1761, 416 00:21:48,107 --> 00:21:52,777 It's been in the same family for nine generations. 417 00:21:52,779 --> 00:21:56,147 And despite the current age of computerization, 418 00:21:56,149 --> 00:21:58,649 The pencil business is booming. 419 00:21:58,651 --> 00:22:00,017 Sales have increased 420 00:22:00,019 --> 00:22:04,021 By almost 10% in the last three years. 421 00:22:04,023 --> 00:22:07,792 ♪ 422 00:22:07,794 --> 00:22:09,860 Grown ups really got into coloring, 423 00:22:09,862 --> 00:22:11,162 What, three, four years ago 424 00:22:11,164 --> 00:22:14,231 When mindfulness was a thing and there was a big push 425 00:22:14,233 --> 00:22:18,869 Towards life drawing and landscape drawings. 426 00:22:18,871 --> 00:22:22,106 Narrator: Faber makes two basic types of pencil -- 427 00:22:22,108 --> 00:22:24,075 The traditional lead type 428 00:22:24,077 --> 00:22:26,977 And a wide range of colored pencils. 429 00:22:26,979 --> 00:22:29,680 They may seem similar on the surface, 430 00:22:29,682 --> 00:22:32,083 But the materials that run through them 431 00:22:32,085 --> 00:22:36,520 Are made in very different ways. 432 00:22:36,522 --> 00:22:41,759 What we know as a lead pencil isn't actually made from lead, 433 00:22:41,761 --> 00:22:45,262 But from a soft natural mineral called graphite, 434 00:22:45,264 --> 00:22:48,866 Which was mistaken for lead back in the 16th century. 435 00:22:48,868 --> 00:22:52,937 It was discovered that graphite made legible marks on paper. 436 00:22:52,939 --> 00:22:57,141 So it was trimmed into thin strips wrapped in string. 437 00:22:57,143 --> 00:23:01,445 And lo and behold, the pencil was born. 438 00:23:01,447 --> 00:23:04,882 The word graphite literally means a stone for writing with. 439 00:23:04,884 --> 00:23:07,218 This is a piece of graphite I've got here. 440 00:23:07,220 --> 00:23:10,020 It's basically a crystalline form of carbon and carbon 441 00:23:10,022 --> 00:23:11,489 Takes many forms. 442 00:23:11,491 --> 00:23:14,325 On one end of the spectrum, you've got super hard diamonds. 443 00:23:14,327 --> 00:23:17,428 And at the other end you've got these really soft graphite. 444 00:23:17,430 --> 00:23:20,765 It's so soft. I can rub it off with my finger. 445 00:23:20,767 --> 00:23:26,704 ♪ 446 00:23:26,706 --> 00:23:29,206 Narrator: At faber, the pencil making process 447 00:23:29,208 --> 00:23:31,375 Starts in the measuring room 448 00:23:31,377 --> 00:23:35,613 Where graphite is mixed with clay and water. 449 00:23:35,615 --> 00:23:37,047 The amount of clay 450 00:23:37,049 --> 00:23:39,283 Will determine the grade of the finished pencil. 451 00:23:39,285 --> 00:23:42,453 ♪ 452 00:23:42,455 --> 00:23:47,591 We have 16 grades of pencil going from 8b to 6h. 453 00:23:47,593 --> 00:23:49,894 8b pencil is really soft 454 00:23:49,896 --> 00:23:51,595 Because it contains lots of graphite 455 00:23:51,597 --> 00:23:53,431 Only a small amount of clay. 456 00:23:53,433 --> 00:23:56,100 And the more you move towards the 6h, 457 00:23:56,102 --> 00:23:57,701 The harder the pencil gets. 458 00:23:57,703 --> 00:23:59,603 This is what the h stands for 459 00:23:59,605 --> 00:24:03,574 And the more clay you start adding to the whole thing. 460 00:24:03,576 --> 00:24:07,611 So it is really crucial to get the right ratio into that lead 461 00:24:07,613 --> 00:24:12,082 Before actually starting the pencil making process. 462 00:24:12,084 --> 00:24:14,652 Narrator: Different grades make a significant difference 463 00:24:14,654 --> 00:24:16,887 To the look of a line on the page. 464 00:24:16,889 --> 00:24:20,391 For technical work, hard grades are ideal. 465 00:24:20,393 --> 00:24:22,526 While most artists prefer 466 00:24:22,528 --> 00:24:25,696 The denser black line of the softer grades. 467 00:24:25,698 --> 00:24:28,966 ♪ 468 00:24:28,968 --> 00:24:31,669 When it comes to making colored pencils, 469 00:24:31,671 --> 00:24:33,838 There's no graphite involved, 470 00:24:33,840 --> 00:24:37,808 Different pigments are mixed with china clay or kaolin, 471 00:24:37,810 --> 00:24:41,612 And combined with a binding agent to hold it all together. 472 00:24:41,614 --> 00:24:48,152 ♪ 473 00:24:48,154 --> 00:24:51,755 The mix is squeezed like thin toothpaste 474 00:24:51,757 --> 00:24:53,891 Through a 2 millimeter hole, 475 00:24:53,893 --> 00:24:58,529 Coming out in 18.5 centimeter pencil-sized lengths, 476 00:24:58,531 --> 00:25:01,031 Graphite black or colored, 477 00:25:01,033 --> 00:25:03,334 The leads are still soft and flexible. 478 00:25:03,336 --> 00:25:04,902 At this stage. 479 00:25:04,904 --> 00:25:08,272 So they're dried for 3 1/2 hours in an electric oven 480 00:25:08,274 --> 00:25:14,278 At 248 degrees fahrenheit. 481 00:25:14,280 --> 00:25:16,280 The colored leads are removed, 482 00:25:16,282 --> 00:25:20,050 Any longer and their pigments would be destroyed. 483 00:25:20,052 --> 00:25:23,787 But the graphite leads still aren't hard enough for writing. 484 00:25:23,789 --> 00:25:26,290 So they're packed into a second oven 485 00:25:26,292 --> 00:25:28,659 With a much higher temperature. 486 00:25:28,661 --> 00:25:36,567 ♪ 487 00:25:36,569 --> 00:25:40,638 After 45 minutes in the oven, the hardened graphite leads 488 00:25:40,640 --> 00:25:44,008 Are doused into a wax bath. 489 00:25:44,010 --> 00:25:45,943 This increases their strength, 490 00:25:45,945 --> 00:25:48,979 Ensures a smooth stroke when writing or drawing, 491 00:25:48,981 --> 00:25:51,649 And also helps with water resistance. 492 00:25:51,651 --> 00:25:54,518 ♪ 493 00:25:54,520 --> 00:25:57,721 So now we have our pieces of lead ready. 494 00:25:57,723 --> 00:25:59,590 This is where the magic happens. 495 00:25:59,592 --> 00:26:02,560 This is where we start making our pencils. 496 00:26:02,562 --> 00:26:05,396 Narrator: Cedar and lindenwood are used to make up 497 00:26:05,398 --> 00:26:07,531 The casings of faber pencils. 498 00:26:07,533 --> 00:26:10,367 The wood arrives as precut slats. 499 00:26:10,369 --> 00:26:13,704 What's important about the slats themselves is that 500 00:26:13,706 --> 00:26:17,174 They have a really fine grain to allow once 501 00:26:17,176 --> 00:26:18,542 For good production. 502 00:26:18,544 --> 00:26:20,711 But later on, when the customer has the pencil 503 00:26:20,713 --> 00:26:22,513 At home for good sharpening, 504 00:26:22,515 --> 00:26:24,014 We don't want the wood to splinter. 505 00:26:24,016 --> 00:26:25,816 We want it to sharpen nicely 506 00:26:25,818 --> 00:26:28,686 And this is what we need the grain for. 507 00:26:28,688 --> 00:26:32,356 Narrator: Each slat is exactly the length of a pencil, 508 00:26:32,358 --> 00:26:34,191 But just half the thickness. 509 00:26:34,193 --> 00:26:37,561 ♪ 510 00:26:37,563 --> 00:26:43,500 First, grooves have to be cut in the slats. 511 00:26:43,502 --> 00:26:46,403 Glue is now laid into each groove. 512 00:26:46,405 --> 00:26:48,439 This will keep the leads firmly in place 513 00:26:48,441 --> 00:26:51,108 When they're inserted into the wooden casing. 514 00:26:51,110 --> 00:26:55,012 ♪ 515 00:26:55,014 --> 00:26:56,914 Now, a second groove slat 516 00:26:56,916 --> 00:26:59,650 Is placed exactly on top of the first. 517 00:26:59,652 --> 00:27:04,121 The workers here call this das sandwich and each sandwich 518 00:27:04,123 --> 00:27:06,590 Then goes into the drying wheel. 519 00:27:06,592 --> 00:27:09,193 The sandwiches are in the drying wheel for one hour. 520 00:27:09,195 --> 00:27:12,696 The wheel rotates, squeezes the sandwiches together, 521 00:27:12,698 --> 00:27:15,099 And this way leaves no gap. 522 00:27:15,101 --> 00:27:19,670 Just two pieces of wood glued together. 523 00:27:19,672 --> 00:27:22,606 Narrator: A planing machine now cuts them into pencils, 524 00:27:22,608 --> 00:27:27,945 Round, hexagonal, or triangular, depending on the time. 525 00:27:27,947 --> 00:27:32,750 Up to 10 pencils can be cut from a single sandwich. 526 00:27:32,752 --> 00:27:34,151 Faber prides themselves 527 00:27:34,153 --> 00:27:37,821 On producing strong and durable pencils 528 00:27:37,823 --> 00:27:44,428 Qualities they ensure by putting each one through a stress test. 529 00:27:44,430 --> 00:27:47,431 To figure out if a pencil is good or not, 530 00:27:47,433 --> 00:27:51,568 A quick way of doing so is to take a pencil, 531 00:27:51,570 --> 00:27:55,172 Hold it at a 45 degree angle, and push down onto the scale. 532 00:27:55,174 --> 00:27:59,243 And the pencil will not break before 2 1/2 kilos of pressure. 533 00:27:59,245 --> 00:28:00,711 If it would break before, 534 00:28:00,713 --> 00:28:02,613 We'd know there's something wrong with it 535 00:28:02,615 --> 00:28:05,616 And test a couple of more to figure out what's wrong with it. 536 00:28:05,618 --> 00:28:09,319 Let's see if the pencil that we've just made 537 00:28:09,321 --> 00:28:10,954 Is of good quality. 538 00:28:10,956 --> 00:28:13,590 So 45 degrees push down onto the scale 539 00:28:13,592 --> 00:28:18,962 And two and a half. 540 00:28:18,964 --> 00:28:21,098 Way past four or five kilos. 541 00:28:21,100 --> 00:28:23,901 So that pencil is definitely good. 542 00:28:23,903 --> 00:28:26,003 Narrator: The pencils that pass the stress test 543 00:28:26,005 --> 00:28:28,305 Move on to the next stage -- 544 00:28:28,307 --> 00:28:29,973 The paint shop. 545 00:28:29,975 --> 00:28:35,145 This is where the pencils get their first coating of paint. 546 00:28:35,147 --> 00:28:38,582 The pencils come through the machine like that. 547 00:28:38,584 --> 00:28:42,453 So basically from here to here, the felt ring would remove 548 00:28:42,455 --> 00:28:44,922 All the leftover dust on the outside. 549 00:28:44,924 --> 00:28:46,824 In here then is the paint. 550 00:28:46,826 --> 00:28:50,127 In this case, dark green. 551 00:28:50,129 --> 00:28:51,962 The blue ring here removes all the paint 552 00:28:51,964 --> 00:28:54,465 Except for the pencil that has soaked into the wood 553 00:28:54,467 --> 00:28:57,568 And the pencils that come out on the other end 554 00:28:57,570 --> 00:29:00,370 Go onto the band and go through the drying tunnel 555 00:29:00,372 --> 00:29:03,407 To have the paint dry. 556 00:29:03,409 --> 00:29:07,111 Narrator: The graphite pencils are painted faber green 557 00:29:07,113 --> 00:29:08,378 And the colored pencils 558 00:29:08,380 --> 00:29:12,316 Are painted to match whatever color is on the inside. 559 00:29:12,318 --> 00:29:15,185 Once the paint's dried, the pencils come back 560 00:29:15,187 --> 00:29:16,587 And do this again. 561 00:29:16,589 --> 00:29:19,690 They come back and do this again and they do this up to six times 562 00:29:19,692 --> 00:29:22,893 Because the pencils need numerous layers of paint 563 00:29:22,895 --> 00:29:27,464 To have a really nice finished coat. 564 00:29:27,466 --> 00:29:30,801 Narrator: The company's logo, two jousting knights 565 00:29:30,803 --> 00:29:35,339 Is stamped in gold leaf on every pencil, 566 00:29:35,341 --> 00:29:37,374 And the colored pencils are also stamped 567 00:29:37,376 --> 00:29:40,043 With their color identification. 568 00:29:40,045 --> 00:29:44,948 In this case, cadmium red. 569 00:29:44,950 --> 00:29:46,850 So the last thing that we're now missing 570 00:29:46,852 --> 00:29:48,552 Is only the sharpening. 571 00:29:48,554 --> 00:29:51,054 And, of course, quality control. 572 00:29:51,056 --> 00:29:54,024 And this is what's happening here. 573 00:29:54,026 --> 00:29:56,927 Narrator: Each pencil goes through a sharpening machine, 574 00:29:56,929 --> 00:30:00,898 A combination of blades faster than the eye can see. 575 00:30:00,900 --> 00:30:04,234 And an endless belt of sandpaper. 576 00:30:04,236 --> 00:30:07,204 And no pencil leaves the factory 577 00:30:07,206 --> 00:30:09,940 Without one final quality control check. 578 00:30:09,942 --> 00:30:12,543 ♪ 579 00:30:12,545 --> 00:30:17,514 It's taken 15 hours to make pencils from a lump of graphite, 580 00:30:17,516 --> 00:30:20,751 Clay, pigments, and blocks of wood. 581 00:30:20,753 --> 00:30:24,421 ♪ 582 00:30:24,423 --> 00:30:26,123 Now they're packed. 583 00:30:26,125 --> 00:30:30,194 500,000 every day ready to send out 584 00:30:30,196 --> 00:30:34,164 To 100 countries all around the world. 585 00:30:34,166 --> 00:30:38,769 ♪ 586 00:30:38,771 --> 00:30:42,673 Coming up, a centuries old japanese recipe 587 00:30:42,675 --> 00:30:46,677 Is being produced on a massive scale. 588 00:30:46,679 --> 00:30:49,913 It is hard to believe how much they are making 589 00:30:49,915 --> 00:30:51,815 In just one day. 590 00:30:53,953 --> 00:31:01,225 ♪ 591 00:31:01,227 --> 00:31:07,931 ♪ 592 00:31:07,933 --> 00:31:12,769 Narrator: Because of the huge steel vats, 593 00:31:12,771 --> 00:31:16,340 The articulated tankers, 594 00:31:16,342 --> 00:31:19,042 And the network of industrial pipes, 595 00:31:19,044 --> 00:31:22,512 This may look like an oil refinery, 596 00:31:22,514 --> 00:31:24,882 But this massive factory is making something 597 00:31:24,884 --> 00:31:28,418 Perhaps more important to the japanese -- 598 00:31:28,420 --> 00:31:30,954 Soy sauce. 599 00:31:30,956 --> 00:31:34,324 And they're doing it on an industrial scale. 600 00:31:34,326 --> 00:31:39,496 Shoda makes nearly 10 million gallons of soy sauce a year, 601 00:31:39,498 --> 00:31:43,333 Enough to fill 15 olympic swimming pools. 602 00:31:43,335 --> 00:31:46,970 Soy sauce is the most popular condiment in japan, 603 00:31:46,972 --> 00:31:49,706 Featuring in 80% of dishes. 604 00:31:49,708 --> 00:31:52,509 And I would wager if you open any cupboard 605 00:31:52,511 --> 00:31:56,079 In any home across the country, you will find a bottle. 606 00:31:56,081 --> 00:31:58,248 Narrator: Soy sauce is so important, 607 00:31:58,250 --> 00:32:02,085 It's now being referred to as a fifth flavor. 608 00:32:02,087 --> 00:32:04,554 In the west, we've traditionally talked about 609 00:32:04,556 --> 00:32:09,159 Four flavors -- bitter, sweet, salty, and sour. 610 00:32:09,161 --> 00:32:12,396 But in japan and now increasingly in the west, 611 00:32:12,398 --> 00:32:15,399 We also acknowledge a flavor called umami, 612 00:32:15,401 --> 00:32:21,004 Which roughly translates as savory or brothy. 613 00:32:21,006 --> 00:32:22,506 Narrator: Scientists have identified 614 00:32:22,508 --> 00:32:24,608 The common denominator of umami 615 00:32:24,610 --> 00:32:28,245 Tasting foods as having a high concentration 616 00:32:28,247 --> 00:32:30,747 Of certain amino acids. 617 00:32:30,749 --> 00:32:34,718 Naturally brewed soy sauce is one of the most widely used 618 00:32:34,720 --> 00:32:38,455 Umami ingredients in japanese cooking. 619 00:32:38,457 --> 00:32:42,626 Shoda has eight supersized factories across japan, 620 00:32:42,628 --> 00:32:45,495 Producing 375 million 621 00:32:45,497 --> 00:32:48,532 Small bottles of soy sauce a year, 622 00:32:48,534 --> 00:32:52,436 10 million of them are made right here. 623 00:32:52,438 --> 00:32:55,505 Japanese tradition meets modern innovation 624 00:32:55,507 --> 00:32:59,576 On a super scale in this super factory. 625 00:32:59,578 --> 00:33:02,412 It's an intense, exacting process 626 00:33:02,414 --> 00:33:05,716 And it all starts with a simple bean. 627 00:33:05,718 --> 00:33:07,818 The soy bean comes from the pea family. 628 00:33:07,820 --> 00:33:09,886 And it provides essential nutrition, 629 00:33:09,888 --> 00:33:13,123 Especially protein, for millions of people. 630 00:33:13,125 --> 00:33:15,625 It's comprised of about 17% oil 631 00:33:15,627 --> 00:33:19,329 And a high protein content, making it very healthy. 632 00:33:19,331 --> 00:33:23,867 It's economically the most important bean in the world. 633 00:33:23,869 --> 00:33:26,436 Narrator: Making or to be more specific, 634 00:33:26,438 --> 00:33:29,006 Brewing soy sauce, isn't new. 635 00:33:29,008 --> 00:33:32,175 In fact, it's over 2000 years old. 636 00:33:32,177 --> 00:33:35,645 It's a fermentation process similar to making alcohol 637 00:33:35,647 --> 00:33:37,914 Where a few essential ingredients, 638 00:33:37,916 --> 00:33:40,017 In this case soybeans, 639 00:33:40,019 --> 00:33:44,154 Combined with bacteria and yeast to cause chemical reactions. 640 00:33:44,156 --> 00:33:48,825 Those reactions bring out a host of over 200 different flavors 641 00:33:48,827 --> 00:33:52,362 In the dark golden liquid that is soy sauce. 642 00:33:52,364 --> 00:33:55,399 [ speaking japanese ] 643 00:33:59,671 --> 00:34:02,272 The soybean has been farmed throughout asia 644 00:34:02,274 --> 00:34:04,608 For thousands of years. 645 00:34:04,610 --> 00:34:08,211 Chinese buddhist monks introduced soy sauce to japan 646 00:34:08,213 --> 00:34:11,515 In the 7th century. 647 00:34:11,517 --> 00:34:15,385 Narrator: 115 tons of defatted soybean flakes 648 00:34:15,387 --> 00:34:18,321 Arrive at the factory every week. 649 00:34:18,323 --> 00:34:21,858 They're hard and inedible at first, 650 00:34:21,860 --> 00:34:25,562 So they need to be softened with a bit of heat. 651 00:34:25,564 --> 00:34:29,099 The beans are put into a giant rotating pressure cooker 652 00:34:29,101 --> 00:34:33,703 And steamed at 150 degrees for a few minutes. 653 00:34:33,705 --> 00:34:36,973 The softened beans are then turned into a fine mash 654 00:34:36,975 --> 00:34:41,244 By high speed blades that pound the mix to a pulp. 655 00:34:49,221 --> 00:34:51,755 Wheat is the next ingredient. 656 00:34:51,757 --> 00:34:55,158 A cutting machine with powerful blades slices through it 657 00:34:55,160 --> 00:34:58,895 And reduces it to a powdery consistency. 658 00:34:58,897 --> 00:35:03,066 But soy sauce's most important ingredient comes next. 659 00:35:03,068 --> 00:35:07,704 And it's not something you'd normally want in your food. 660 00:35:07,706 --> 00:35:10,373 In order for it to be called natural soy sauce, 661 00:35:10,375 --> 00:35:12,309 It has to use mold. 662 00:35:14,279 --> 00:35:18,582 ♪ 663 00:35:18,584 --> 00:35:21,051 Narrator: At the shoda factory in japan, 664 00:35:21,053 --> 00:35:23,420 Soy sauce is made using soybeans, 665 00:35:23,422 --> 00:35:27,124 Wheat, and a third ingredient that may come as a surprise. 666 00:35:27,126 --> 00:35:30,260 ♪ 667 00:35:30,262 --> 00:35:34,397 Mold is a form of fungus and it gives soy sauce 668 00:35:34,399 --> 00:35:37,167 Its distinct flavor and characteristics 669 00:35:37,169 --> 00:35:39,169 During the fermentation process. 670 00:35:39,171 --> 00:35:41,805 Together, soybeans, wheat, and mold 671 00:35:41,807 --> 00:35:44,608 Make something called koji. 672 00:35:44,610 --> 00:35:47,577 Koji has been declared the national fungus. 673 00:35:47,579 --> 00:35:49,513 Not just because it's essential 674 00:35:49,515 --> 00:35:52,048 For the brewing of traditional soy sauce, 675 00:35:52,050 --> 00:35:55,619 But also because it's essential for other traditional japanese 676 00:35:55,621 --> 00:36:01,224 Foods like rice vinegar, miso, and saki. 677 00:36:01,226 --> 00:36:03,827 Narrator: The soybeans and wheat are combined. 678 00:36:03,829 --> 00:36:07,063 It's then transported on a high speed production line 679 00:36:07,065 --> 00:36:11,434 To a massive, heated room where it's put into a giant vat 680 00:36:11,436 --> 00:36:15,071 And air is blown through it for 72 hours. 681 00:36:15,073 --> 00:36:18,608 The mold reacts with the mix, breaking down the wheat 682 00:36:18,610 --> 00:36:21,444 And beans releasing starch and sugars. 683 00:36:21,446 --> 00:36:24,848 When it comes out, it looks slightly green. 684 00:36:24,850 --> 00:36:31,254 ♪ 685 00:36:31,256 --> 00:36:33,857 The second part of the fermentation process 686 00:36:33,859 --> 00:36:36,693 Starts with salt. 687 00:36:36,695 --> 00:36:40,497 It arrives in the factory in 11 ton tankers, 688 00:36:40,499 --> 00:36:43,300 And the sodium chloride is dissolved in water 689 00:36:43,302 --> 00:36:47,003 To produce a huge pool of 20% salt brine. 690 00:36:47,005 --> 00:36:50,106 The brine is pumped through the koji mix. 691 00:36:50,108 --> 00:36:53,877 It prevents the growth of any undesirable microorganisms 692 00:36:53,879 --> 00:36:57,380 And acts as a preservative for the koji. 693 00:36:57,382 --> 00:37:01,017 Once that's done, lactic acid bacteria, 694 00:37:01,019 --> 00:37:05,021 Which is brine-friendly, is added along with yeasts 695 00:37:05,023 --> 00:37:08,792 That further promote the fermentation process. 696 00:37:08,794 --> 00:37:12,963 This transforms the koji into moromi. 697 00:37:12,965 --> 00:37:16,666 The moromi mash is then transported by spiral pumps 698 00:37:16,668 --> 00:37:18,401 Through a network of pipes 699 00:37:18,403 --> 00:37:21,938 Into gigantic steel fermentation vats. 700 00:37:21,940 --> 00:37:25,976 This plant alone has 50 in constant use, 701 00:37:25,978 --> 00:37:29,212 It's stored for six months and watched over as the soy 702 00:37:29,214 --> 00:37:32,282 And wheat paste turns into a semi-liquid, 703 00:37:32,284 --> 00:37:35,118 Reddish brown, mature mash. 704 00:37:35,120 --> 00:37:37,821 A lot of soy sauce you buy in shops will be made 705 00:37:37,823 --> 00:37:39,589 Using chemical processes. 706 00:37:39,591 --> 00:37:43,460 But the traditional method uses mold and is natural. 707 00:37:43,462 --> 00:37:46,296 And in order for it to be called natural soy sauce, 708 00:37:46,298 --> 00:37:49,232 It has to use mold. 709 00:37:49,234 --> 00:37:52,302 Narrator: Aspergillus mold has broken down the grain protein 710 00:37:52,304 --> 00:37:54,571 Into free amino acids 711 00:37:54,573 --> 00:37:57,440 And the protein fragments into starches 712 00:37:57,442 --> 00:37:59,876 And then into simple sugars. 713 00:37:59,878 --> 00:38:03,546 Now the lactic acid bacteria ferments those sugars, 714 00:38:03,548 --> 00:38:04,881 Which gradually develops 715 00:38:04,883 --> 00:38:08,151 The 200 flavors typically found in soy sauce. 716 00:38:08,153 --> 00:38:10,820 ♪ 717 00:38:10,822 --> 00:38:13,390 After six months of fermentation, 718 00:38:13,392 --> 00:38:15,625 It's time to extract the sauce. 719 00:38:15,627 --> 00:38:18,728 ♪ 720 00:38:18,730 --> 00:38:21,798 This step requires linen, 721 00:38:21,800 --> 00:38:23,900 Over a mile of it. 722 00:38:23,902 --> 00:38:28,705 ♪ 723 00:38:28,707 --> 00:38:30,907 The reddish brown mash is spread 724 00:38:30,909 --> 00:38:34,110 Evenly onto the highly permeable cloth, 725 00:38:34,112 --> 00:38:37,514 Which is folded 600 times back on itself. 726 00:38:37,516 --> 00:38:43,620 ♪ 727 00:38:43,622 --> 00:38:48,692 This massive tower is wheeled over to a hydraulic plunger. 728 00:38:48,694 --> 00:38:52,262 Which slowly applies tons of pressure onto the linen. 729 00:38:52,264 --> 00:38:59,569 ♪ 730 00:38:59,571 --> 00:39:02,572 The moromi is continuously squeezed 731 00:39:02,574 --> 00:39:07,177 Until a liquid sauces oozes out through the folds of linen. 732 00:39:07,179 --> 00:39:14,551 ♪ 733 00:39:14,553 --> 00:39:17,187 The process takes three days. 734 00:39:17,189 --> 00:39:22,559 And what's left is a dry stack of linen caked in leftover mash 735 00:39:22,561 --> 00:39:26,663 And 8,000 gallons of raw soy sauce. 736 00:39:26,665 --> 00:39:30,900 The matches emptied into trucks and sold as cattle feed. 737 00:39:30,902 --> 00:39:34,104 The all important liquid stays in the factory. 738 00:39:34,106 --> 00:39:40,076 ♪ 739 00:39:57,229 --> 00:39:59,629 Narrator: Pasteurization is a crucial step 740 00:39:59,631 --> 00:40:02,332 In the soy sauce making process. 741 00:40:28,727 --> 00:40:31,027 The pasteurized raw soy sauce 742 00:40:31,029 --> 00:40:33,763 Needs to be filtered, then blended before 743 00:40:33,765 --> 00:40:36,566 It's ready to be sent to the lab for testing. 744 00:40:36,568 --> 00:40:40,003 Here, its aroma and color are tested 745 00:40:40,005 --> 00:40:42,572 As well as its chemical composition 746 00:40:42,574 --> 00:40:47,844 To determine how much nitrogen is present. 747 00:40:47,846 --> 00:40:50,647 Then it's sent to the bottling plant 748 00:40:50,649 --> 00:40:54,184 Where eight filling lines operate 24/7 749 00:40:54,186 --> 00:40:58,988 To pump the sauce into bottles in seconds. 750 00:40:58,990 --> 00:41:02,659 They can bottle over 20,000 gallons a day. 751 00:41:02,661 --> 00:41:07,330 It is hard to believe how much they are making in just one day. 752 00:41:07,332 --> 00:41:10,800 ♪ 753 00:41:10,802 --> 00:41:13,069 Narrator: Shoda produces several different styles 754 00:41:13,071 --> 00:41:17,440 Of soy sauce at this plant. 755 00:41:17,442 --> 00:41:20,376 Dark soy sauce has a higher bean content 756 00:41:20,378 --> 00:41:22,479 And has been fermented for longer 757 00:41:22,481 --> 00:41:24,380 Giving it a stronger flavor. 758 00:41:24,382 --> 00:41:26,416 Light has more wheat 759 00:41:26,418 --> 00:41:29,252 And is used for delicate foods. 760 00:41:29,254 --> 00:41:33,623 Here, 13,000 gallons of bottled sauce 761 00:41:33,625 --> 00:41:36,459 And 120,000 gallons of commercial tins 762 00:41:36,461 --> 00:41:40,864 Are all labeled and stored on 3,000 pallets. 763 00:41:40,866 --> 00:41:44,400 They even pipe 26,000 gallons of soy sauce 764 00:41:44,402 --> 00:41:48,938 Directly into trucks every day for commercial customers. 765 00:41:48,940 --> 00:41:53,476 In the future, it's possible that advances in biotechnology 766 00:41:53,478 --> 00:41:57,180 Might lead to shorter and better fermentation methods. 767 00:41:57,182 --> 00:42:00,950 For now, though, shoda and its super factory 768 00:42:00,952 --> 00:42:04,687 Is sticking with tradition.