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Narrator: A supercar is
overtaking its rivals
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00:00:06,240 --> 00:00:11,844
With formula one science
and sophisticated production.
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♪
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Robots and humans
are working in tandem
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To create a high tech tool
that chops down the competition.
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♪
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Modern technology is keeping
a centuries old
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Writing tradition alive
on a super scale.
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00:00:32,767 --> 00:00:38,203
And the world's oldest condiment
is being made for the masses.
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♪
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These groundbreaking
innovations are all taking place
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Inside some of the most
incredible factories
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On the planet.
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-- Captions by vitac --
www.Vitac.Com
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Captions paid for by
discovery communications
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♪
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Surrounded by the green fields
of woking, England
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Is a factory producing
a vehicle unlike any other.
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♪
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This is the mclaren 720s.
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It's sleek, fast,
and very expensive.
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One of these supercars
will set you back
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Nearly $300,000.
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Mclaren cars are a unique
type of car.
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They're something special.
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They're not cars
that people need,
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They're cars that people want.
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Narrator: The 720s
is brought to life here
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At the mclaren
production center.
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This 371,000 square foot
facility
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Was designed by superstar
architect norman foster in 2004
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At an estimated cost
of $386 million.
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And the inside of
the mclaren production center
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Is as impressive
as its exterior.
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It's bright, spacious, quiet,
and extremely clean.
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Most high volume
car manufacturers,
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You'll see hundreds of robots
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Making thousands
of identical cars.
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Well, not here.
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Narrator: Mclaren makes fewer
than 5,000 cars a year
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And each one is special.
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Assembling a road car
is a very, very complex process.
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Mclaren make a car to order.
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It's like a bespoke suit.
They are handcrafted.
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♪
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Narrator: And that requires
a very hands on approach
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Down on the factory floor.
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Because of their decades
of experience
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Building formula one race cars,
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This individual craft-based
approach to car manufacturing
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Lies deep in mclaren's dna.
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Breece mclaren, the founder,
was from new zealand.
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He built his first
formula one car in 1966.
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Only ferrari has been
in the racing game longer.
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In the early '90s, they got into
road cars with the seminal f1.
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A lot of the lessons
of the racetrack
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Are then brought over
into their production cars.
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Narrator: This is
the main building block,
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Or chassis of a mclaren car.
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It's called
a monocell or cage
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And the rest of the car
is built around it.
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The monocells are
premanufactured in austria
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And are made
from the same material
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Used in the modern
formula one race car.
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One of the major parts
or major materials we use
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Is carbon fiber.
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Carbon fiber is at the heart
of every mclaren.
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Mclaren revolutionized
formula one
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When they brought
in carbon fiber in 1981.
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It made the chassis five times
lighter and 10 times stronger
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And it is a key component
in the road cars today.
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If you compare carbon fiber
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To something like aluminum
or steel,
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00:03:46,827 --> 00:03:50,596
That can be strong, actually
the strength to weight ratio
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Of carbon fiber
is what's so important.
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You don't need very much of it
to get the equivalent strength
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Of a much bigger amount
of another material.
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Narrator: But what exactly is
this wonder material,
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Carbon fiber?
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Carbon fiber is really
high-performance
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00:04:05,946 --> 00:04:07,713
Composite material.
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00:04:07,715 --> 00:04:11,583
It's something which contains
thin fibers of carbon,
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00:04:11,585 --> 00:04:13,585
Which on their own
would be sort of floppy,
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00:04:13,587 --> 00:04:16,321
But they have a certain
tensile strength to them.
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00:04:16,323 --> 00:04:19,424
And then those fibers
are embedded in a polymer resin,
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Which is strong and has
a certain flexibility to it.
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But actually,
when you combine the two,
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You get something that's greater
than the sum of its parts.
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You get a super lightweight
high-performance material.
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Narrator: Just like their
formula one cars,
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Mclarens road cars are designed
with the driver in mind.
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They are built and designed
around the driver,
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So the driver is literally
at the center of the action.
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And then the monocage
and monocell
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Designed around the occupant.
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Narrator:
As soon as the monocage
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Chassis arrives
on the production line,
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The team starts to assemble
a car around this
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00:04:54,228 --> 00:04:57,229
One essential building block.
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00:04:57,231 --> 00:04:59,898
The first stage
is to add crumple zones
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00:04:59,900 --> 00:05:03,468
And crash protection
around the car's interior.
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00:05:03,470 --> 00:05:06,104
It's then taken for
what they call geometric
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00:05:06,106 --> 00:05:08,273
And surface validation.
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Here, over 450 different
points of the car
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00:05:12,346 --> 00:05:15,614
Are measured
to make sure every curve, line,
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And corner
is perfectly aligned
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And in proportion.
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We ensure
each mclaren car is perfect
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In every detail.
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Really, right from the off,
right from when we start
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The whole project
it's almost like watchmaking.
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Narrator:
Once the body has passed
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The surface validation test,
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The team can then start to build
up the car's exterior --
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00:05:36,670 --> 00:05:40,439
The wing panels, side panels,
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And for non-convertibles --
the roof.
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Now it's ready to be painted.
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Before spraying,
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00:05:48,215 --> 00:05:50,682
The whole body is wrapped
in plastic
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And the individual panels
are exposed,
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Primed, and sanded flat.
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Any contaminants are removed
with an anti-static gun
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00:06:01,795 --> 00:06:05,197
And mclaren's secret
to their supercar's high speed
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00:06:05,199 --> 00:06:10,302
Can be found
in the painting process.
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By using special particles
within the paint
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And a special paint process,
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We're actually able to decrease
the amount of paint
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We have to put on the car.
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And essentially deliver...
[ speaks indistinctly ]
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Narrator: It takes 24 hours to
paint a typical mclaren car
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And another 40 minutes in a hot
oven for it to fully dry.
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Finally, it's time to start
putting the car together.
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A loom of wires
is fed through the car
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To provide it with power.
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A typical mclaren is made up
of over a mile of cables
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00:06:40,868 --> 00:06:43,802
And 2,000 individual circuits.
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00:06:43,804 --> 00:06:46,605
Next, the beating heart
of the car.
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The most common engine type
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00:06:48,342 --> 00:06:53,412
Is the m83018, a 3.8 liter
90 degree twin turbo
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00:06:53,414 --> 00:06:55,881
Charged flat plain v8.
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00:06:55,883 --> 00:06:59,518
The mclaren 720 s goes from
not 62 miles per hour
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In 2.9 seconds.
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00:07:01,789 --> 00:07:05,190
Top speed --
212 miles per hour.
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♪
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00:07:09,062 --> 00:07:10,362
Narrator:
Like most of the other parts
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00:07:10,364 --> 00:07:14,699
That make up the mclaren,
the engine is made offsite.
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00:07:14,701 --> 00:07:17,536
For mclaren,
outsourcing the parts
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Makes the most economic sense.
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00:07:20,641 --> 00:07:24,009
To try to actually build
every single little bit of a car
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00:07:24,011 --> 00:07:26,478
As well as assemble
the cars themselves
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00:07:26,480 --> 00:07:28,647
Would be inefficient
from a process perspective,
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But also from
a cost perspective.
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Narrator:
Back on the assembly line,
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The brake discs and pistons
are installed.
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The brakes will slow
these high-performance wheels
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00:07:38,225 --> 00:07:40,892
From 124 miles per hour
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00:07:40,894 --> 00:07:45,630
To zero in just 4.6 seconds.
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00:07:45,632 --> 00:07:49,835
Now another team finishes
the interior of the car.
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A mclaren supercar
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00:07:51,238 --> 00:07:55,207
Is made up of over
1,200 individual components.
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It takes two to three weeks to
put one of these cars together.
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But no car is really complete
until it's been taken
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00:08:02,683 --> 00:08:06,318
For a spin
out on the test track.
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♪
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♪
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♪
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♪
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The final stage consists
of an inspection and clean
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And polish of the vehicle.
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Then it's off to the customer
and out onto the open road.
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We have this incredible passion
for what we do.
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We're normally very,
very precise
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And logical in our approach.
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But actually, no, the thing
that drives it is pure passion.
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Narrator: Mclaren is one
of the world's
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00:08:57,804 --> 00:09:01,239
Most high-tech brands.
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The skill and sophistication
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00:09:02,876 --> 00:09:05,277
Found inside
their production center
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00:09:05,279 --> 00:09:11,182
Make it one of the world's most
spectacular super factories.
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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
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00:09:20,360 --> 00:09:24,729
The world's oldest
writing traditions alive.
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00:09:26,800 --> 00:09:33,038
♪
185
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Narrator: In a popular beach
town along the east coast,
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One factory is manufacturing
187
00:09:38,712 --> 00:09:44,683
One of the most iconic products
in america --
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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,
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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.