How It's Made (2001–…): Season 19, Episode 1 - Garden Forks/English Toffee/Paint Chip Cards/Bundt Pans - full transcript
Garden Forks; English Toffee; Paint Chip Cards; Bundt Pans
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
Narrator:
THE GARDEN FORK WAS ONCE
A VERY PRIZED POSSESSION --
SO COVETED, IT WAS OFTEN
THE OBJECT OF THEFT.
THAT WAS CENTURIES AGO,
WHEN A FAMILY'S VERY SURVIVAL
DEPENDED ON THE CROPS THEY GREW.
TODAY, OF COURSE,
FOOD IS MASS PRODUCED
AND SOLD IN SUPERMARKETS.
BUT THE GARDEN FORK STILL RULES
IN THE BACKYARD GARDEN.
THERE ARE MANY VERSIONS
OF THE TRUSTY GARDEN FORK.
USE ONE TO WORK THE GARDEN,
AND YOU'LL REAP THE BENEFITS.
AT THIS FACTORY,
THEY'VE BEEN FORGING
GARDEN FORKS
FROM A SOLID-STEEL SLAB
FOR OVER TWO CENTURIES.
USING A 660-TON PUNCH PRESS,
THEY CUT TWO BASIC FORK SHAPES
FROM THIS HOT
AND MALLEABLE SLAB.
THE TINES OR PRONGS FOR
THIS PARTICULAR KIND OF FORK
ARE SHORTER THAN MOST
BECAUSE THESE ARE BORDER FORKS
USED FOR TURNING SOIL
RATHER THAN DIGGING DEEP.
WITH THE BASIC SHAPE
NOW ESTABLISHED,
IT'S BACK INTO THE FURNACE
TO RE-SOFTEN THE STEM.
A WORKER REPEATEDLY FEEDS IT
TO ROLLERS
TO THIN AND WIDEN IT
SUBSTANTIALLY.
HE STRIKES THE STEM
WITH ANOTHER PUNCH PRESS.
THIS ONE HIT TRIMS IT
WHILE CUTTING HOLES
FOR ATTACHING THE WOOD SHAFT.
THE TRIMMINGS WILL BE REMELTED
AND RECYCLED INTO NEW FORKS.
THE NEXT PRESS SLAMS
THE STEEL STEM
INTO A CYLINDRICAL DIE
TO FORCE IT INTO THE BASIC SHAPE
OF A SOCKET.
HE SLIDES THE SOCKET
ONTO A CONED FORM
AND STRIKES IT REPEATEDLY
TO REFINE THE SOCKET SHAPE.
THIS SIZES IT
FOR A WOODEN SHAFT.
THEY TAKE AN ENTIRELY
DIFFERENT APPROACH
WHEN MAKING DIGGING FORKS
BECAUSE OF THEIR LONGER
CURVED TINES.
AFTER FORGING
A KIND OF SPIDER SHAPE,
A WORKER BENDS A PRONG AROUND
A POST TO ORIENT IT FOR SHAPING.
THIS TWO-PERSON TEAM
WORKS IN TANDEM.
ONE FIRES THE SPIDER
AND BENDS THE PRONGS.
THE OTHER WORKER INSERTS
THE PRONG IN THE GROOVES
OF TWO REVOLVING DIES.
THIS ROLLS THE TINE WITHIN
THE CONFINES OF THE GROOVES
TO STRETCH IT LONG AND THIN.
WITH TWO TINES NOW SHAPED,
HIS PARTNER BENDS THEM
OUT OF THE WAY
SO HE CAN WORK
ON THE THIRD TINE.
ROLLING TAKES 18 MONTHS
OF TRAINING TO PERFECT.
IF THE TINE ISN'T PRECISELY
ALIGNED WITH THE GROOVES,
THE EQUIPMENT COULD SEIZE
AND THROW THE WORKER BACKWARDS.
NOT ONLY COULD HE BE INJURED,
BUT THE FORK AND THE DIES WOULD
MOST CERTAINLY BE WRECKED.
WITH A FOURTH TINE NOW STRETCHED
LONG AND THIN LIKE THE REST,
THE OTHER MEMBER OF THE TEAM
TWISTS ALL FOUR TINES
AROUND THE POST AGAIN,
THIS TIME TO BEND THEM ALL
IN THE SAME GENERAL DIRECTION.
AFTER ABOUT 10 MINUTES OF WORK,
THEY HAVE THE ROUGH SHAPE
OF A DIGGING FORK.
THEY THEN FORM THE SOCKET
AND CROP THE TINES.
FIRED TO A SUPPLE STATE AGAIN,
A WORKER DRIVES TOOLING
BETWEEN THE TINES
TO STRAIGHTEN THEM
AND EVEN THE GAPS BETWEEN THEM.
HE RESTS THE FORK SOCKET AGAINST
A STEEL SLOPE AND LOWERS A RAM.
IT SLAMS INTO THE TINES TO PUSH
THE SOCKET AGAINST THE SLOPE
AND BEND IT UPWARD --
A MORE EFFECTIVE ANGLE
FOR DIGGING.
HE INSERTS THE TINES IN A PRESS
ONE AT A TIME.
THE PRESS CLOSES AROUND
EACH TINE TO TAPER THE CORNERS.
A RAM NOW POUNDS
THE BASE OF THE TINES
AGAINST A SWOOPED ANVIL
TO GIVE IT A GENTLE CURVE.
HE PLUNGES THE HOT FORK
INTO COOL WATER,
AND THE SHOCK HARDENS THE STEEL.
THE NEXT WORKER GRINDS OFF
ANY ROUGH BITS FROM THE SIDES
AND SHARPENS THE EDGES.
HE NARROWS THE TIPS TO A POINT,
AND THIS WILL ENABLE THE FORK
TO PIERCE SOLID EARTH.
A WORKER REPAIRS ANY
IRREGULARITIES WITH HIS HAMMER.
HERE YOU CAN SEE
THE DIFFERENCE THIS MAKES.
THE PRONGS ON THE LEFT
ARE OUT OF ALIGNMENT.
THE ONES ON THE RIGHT
HAVE BEEN FIXED.
THEY APPLY
AN ELECTROSTATIC CHARGE
ONTO THE FORKS TO ATTRACT
A GREEN POWDER SPRAY.
ONCE CURED, IT FORMS A COLORFUL
SKIN THAT RESISTS CORROSION.
NOW OUT OF THE CURING OVEN,
A WORKER CLAMPS THE ENDS
TO LOCK THE FORK IN PLACE
WHILE HE INSERTS THE
ASH WOOD SHAFT INTO THE SOCKET.
HE SECURES IT WITH RIVETS.
USING A BELT SANDER,
HE BLENDS THE WOOD TO THE METAL
IN A PROCESS KNOWN AS LINISHING.
HE ALSO SANDS THE RIVETS
TO MAKE THEM FLUSH
TO THE SURFACE OF THE METAL.
THE BOTTOM FORK IS THE ONE
THAT HAS BEEN LINISHED.
HE DIPS THE WOOD SHAFT
AND HANDLE IN VARNISH,
GIVING IT A GLOSSY STAIN
THAT ENHANCES THE GRAIN.
THIS GARDEN FORK IS NOW DONE.
IT WON'T LOOK SHINY
AND NEW FOR LONG,
BECAUSE THINGS ARE SURE TO GET
DIRTY VERY SOON.
Narrator: TOFFEE IS A TYPE
OF CANDY TRADITIONALLY MADE
OF CARAMELIZED SUGAR
OR MOLASSES AND BUTTER.
THERE ARE MANY
DIFFERENT VARIETIES --
SOFT AND CHEWY
OR HARD AND BRITTLE.
ENGLISH TOFFEE,
WHICH IS ACTUALLY
AN AMERICAN STYLE OF TOFFEE,
IS VERY BUTTERY
AND TYPICALLY HAS A TOPPING
OF CHOPPED NUTS.
THIS ENGLISH TOFFEE
IS COMPLETELY FREE
OF DAIRY INGREDIENTS
AND IS KOSHER CERTIFIED,
MAKING IT IDEAL
FOR TOFFEE LOVERS WITH
CERTAIN DIETARY RESTRICTIONS.
THE WORKERS AT THIS
SMALL AMERICAN CONFECTIONER
MAKE THIS SPECIAL RECIPE
ENTIRELY BY HAND
ONE SMALL BATCH AT A TIME.
THEY START BY COMBINING
WATER AND SUGAR.
THEY HEAT THE MIXTURE
UNTIL THE SUGAR DISSOLVES.
THEN THEY ADD A FORMULA
SO TOP-SECRET
THEY WON'T LET US SEE IT.
ALL THEY'LL REVEAL
IS THAT IT CONTAINS
A COMBINATION OF VEGETABLE OILS
AND SHORTENING
WHICH ARE NON-DAIRY SUBSTITUTES
FOR BUTTER AND BETA CAROTENE
TO GIVE THE TOFFEE
THAT FAMILIAR GOLDEN COLOR.
THEY ADD AN EMULSIFIER
CALLED LECITHIN
TO STABILIZE
ALL THESE INGREDIENTS.
AS SOON AS THE MIXTURE
REACHES THE BOILING POINT,
THEY ADD SALT.
THIS ENHANCES THE FLAVOR
AND HELPS PRODUCE A RAPID BOIL
THAT CONTINUES FOR SEVERAL HOURS
UNTIL THE MIXTURE HITS
A TOP-SECRET TARGET TEMPERATURE.
BY THAT POINT, MOST OF THE WATER
HAS EVAPORATED,
PRODUCING SWEET, THICK,
LIQUID TOFFEE.
NOW THEY OPEN A HOT-WATER VALVE
THAT HEATS UP A TABLE,
THEN CAREFULLY POUR THE TOFFEE
ONTO THE SURFACE.
THE HEAT
KEEPS THE TOFFEE PLIABLE
WHILE THEY SPREAD IT OUT.
THEY SPREAD IT WIDER AND WIDER
UNTIL THE TOFFEE SHEET
IS EVENLY THICK.
THEY DON'T ACTUALLY MEASURE.
THEY JUST EYEBALL IT, SO
THE THICKNESS VARIES SOMEWHAT.
BUT THAT LACK OF UNIFORMITY
IS PART OF THE CHARM
OF HANDMADE SWEETS.
THEY TAKE A TOOL
WITH MULTIPLE CUTTING WHEELS
SPACED ABOUT TWO INCHES APART.
THEY RUN IT OVER THE
TOFFEE SHEET IN ONE DIRECTION,
THEN IN THE OTHER.
THEN THEY SHUT OFF
THE HOT-WATER VALVE
AND OPEN THE COLD-WATER ONE
TO COOL THE TABLE SURFACE
AND HARDEN WHAT ARE NOW
TOFFEE SQUARES.
WITHIN MINUTES, THE SQUARES ARE
HARD ENOUGH TO BE BROKEN APART.
NEXT, THE FIRST
OF TWO INGREDIENTS
THAT WILL TURN THIS
INTO ENGLISH TOFFEE --
MOLTEN SEMI-SWEET CHOCOLATE.
ONCE THIS TEMPERING MACHINE
HEATS IT
TO THE RIGHT CONSISTENCY,
A PUMP FEEDS IT
TO THE ENROBING MACHINE
THAT COATS THE TOFFEE SQUARES
IN TWO STAGES,
STARTING ON THE BOTTOM.
THE UNDERSIDE NOW COATED,
THE SQUARES MOVE ON
TO A REFRIGERATED BELT.
THE COLD QUICKLY HARDENS
THE CHOCOLATE.
THEN THEY MOVE INTO
THE NEXT STATION
WHICH COVERS THE TOP
WITH CHOCOLATE.
AS THE NOW FULLY-COATED SQUARES
EXIT THE ENROBING MACHINE,
THE BELT VIBRATES, SHAKING OFF
THE EXCESS CHOCOLATE.
THE SQUARES MOVE ON
TO ANOTHER REFRIGERATED BELT
AND A WORKER
MANUALLY SPRINKLES THEM
WITH THE SECOND INGREDIENT
THAT MAKES THIS
ENGLISH TOFFEE --
CHOPPED PECANS.
THE SQUARES TRAVEL THROUGH
A COOLING TUNNEL
FOR SEVERAL MINUTES TO SET.
AS THEY REACH
THE END OF THE LINE,
EXCESS NUTS DROP OFF
AND COLLECT IN A PAN BELOW,
READY FOR SPRINKLING
ONTO NEW SQUARES.
SOME ENGLISH TOFFEE RECIPES CALL
FOR ALMONDS RATHER THAN PECANS.
WHICHEVER VARIETY OF NUT,
EVERY RECIPE FOLLOWS
THE SAME STRUCTURE.
LAYERING
SWEET AND CRUNCHY TOFFEE,
SMOOTH AND CREAMY CHOCOLATE,
AND COARSELY CHOPPED NUTS --
THREE DIFFERENT TEXTURES,
TASTES, AND SENSATIONS
BROUGHT TOGETHER
IN A SINGLE CONFECTION.
AND JUST LIKE OTHER
DECADENTLY DELICIOUS DESSERTS,
ENGLISH TOFFEE IS HEAVEN
TO ANYONE
WITH A SERIOUS SWEET TOOTH.
Narrator: TRYING TO DECIDE
ON A PAINT COLOR?
EACH CARD IS A SMALL SAMPLE
OF RELATED SHADES,
ALLOWING YOU
TO VIEW THE ACTUAL HUES
WITHOUT PRYING OFF THE LIDS
OF PAINT CANS.
WITH THOUSANDS OF SHADES
TO CHOOSE FROM,
HOW DO THEY GET IT ALL
DOWN ON PAPER?
WHETHER YOU'RE LOOKING
FOR A BRILLIANT BLUE
OR A MARVELOUS MAUVE,
CAREFUL SCRUTINY OF PAINT CHIP
CARDS CAN HELP YOU GET IT RIGHT
BEFORE THE PAINT HITS THE WALL.
HIGHLY CONCENTRATED COLORANTS
STORED IN TANKS
WILL BE USED TO REPRODUCE
PAINT COLORS IN LACQUER
SIMILAR TO THE KIND
USED IN NAIL POLISH.
LACQUER PRODUCES BETTER RESULTS
ON PAPER THAN ACTUAL PAINT.
THEY PIPE THE COLORANTS
TO A DISPENSER.
AT THE SAME TIME,
A BUCKET CONTAINING LACQUER
HEADS TOWARD IT.
THE DISPENSER HAS MANY TENTACLES
WITH NOZZLES
AT THE END OF EACH ONE
AND EACH TENTACLE IS CONNECTED
TO ONE OF THE COLORANT TANKS.
A COMPUTERIZED MECHANISM GRABS
THE NOZZLES
TO DISPENSE DIFFERENT COLORANTS
FOLLOWING
A SPECIFIC PAINT-COLOR FORMULA.
THE BUCKET SITS ON A SCALE
AND THE WEIGHT IS CONSTANTLY
MONITORED BY THE COMPUTER
TO CONFIRM THAT EXACT AMOUNTS
ARE BEING ADDED.
A BLENDER MIXES THE COLORANTS
IN THE LACQUER.
THE MIXING SPEED AND TIME
HAVE BEEN PRESET
TO AVOID OVER OR UNDER MIXING.
AND NOW FOR THE COLOR TEST.
A TECHNICIAN PULLS A BIT
OF THE LACQUER-BASED PAINT
ON A SHEET OF PAPER
JUST UNDER A STEEL BAR.
USING THAT BAR, HE SPREADS THE
COLOR EVENLY ACROSS THE PAPER.
THEN IT'S INTO A KIND OF
MOVING CONVECTION OVEN
TO DRY THE COLOR.
THE TECHNICIAN COMPARES
THE COLOR AND GLOSS
TO THAT OF THE STANDARD.
HE ALSO DOES A COMPUTER ANALYSIS
AND SENDS THE FORMULA BACK
FOR TWEAKING WHEN NECESSARY.
ONCE THEY PERFECT
THE HUE AND GLOSS,
PRODUCTION IS READY TO ROLL.
A WORKER POURS THE APPROVED
LACQUER-BASED PAINTS
INTO CYLINDRICAL TANKS
ABOVE THE COATING MACHINE.
THERE ARE OVER TWO DOZEN
OF THESE TANKS
BECAUSE THEY'LL BE PUTTING
THAT MANY COLORS ON PAPER
IN ONE PRODUCTION RUN.
HE CONNECTS PLASTIC TUBING
TO THE TANKS
TO NARROW THE FLOW AND AIM IT
AT THE DIE BLOCK BELOW.
HE ACTIVATES THE MACHINE
AND ADJUSTS THE TENSION OF
THE PAPER AS IT MOVES FORWARD.
LACQUER FLOWS INTO A DIE,
COATING THE PAPER WITH
AN ENDLESS RAINBOW OF COLOR.
A BAR OVERHEAD SPREADS
THE LACQUER EVENLY
WITHOUT ACTUALLY TOUCHING
THE PAPER.
THE STRIPED PAPER
THEN TRAVELS THROUGH AN OVEN.
THE SOLVENTS EVAPORATE,
LEAVING A DRIED LACQUER SKIN
ON THE PAPER.
IF REGULAR PAINT HAD BEEN USED,
THE PAPER WOULD HAVE ABSORBED IT
AND ENDED UP WAVY.
BUT WITH THE LACQUER PAINT,
IT REMAINS FLAT.
ROTARY BLADES CUT
THE COATED PAPER
INTO SHEETS SIZED
TO FIT PRINTING MACHINERY
DOWN THE LINE.
THEY LAND IN A NEAT STACK.
USING A TRANSPARENT TEMPLATE,
THE NEXT WORKER MEASURES
THE WIDTH OF EACH STRIPE.
HE THEN CONFIRMS THAT THE COLORS
ARE IN THE CORRECT ORDER
BY CHECKING EACH STRIPE
AGAINST THE APPROVED PROOFS.
HE CHECKS THE GLOSS
WITH A GLOSSMETER.
IT AIMS LIGHT ON AN ANGLE
AND REGISTERS THE REFLECTION
TO CONFIRM THAT THE GLOSS
IS CONSISTENT.
WITH THE OKAY FROM THE TESTER,
THE ENTIRE PRODUCTION RUN
RECEIVES THE GO-AHEAD.
THE PRESS OPERATOR STACKS THEM
FACEDOWN
FOR LOADING INTO THE PRINTER.
A FEEDER SERVES UP
THE STRIPED SHEETS
TO THE PRINTING LINE
ONE AT A TIME.
IT'S A 4-STATION PRINTING PRESS.
EACH CYLINDER IS EQUIPPED
WITH AN INK OF A DIFFERENT COLOR
TO STAND OUT AGAINST
THE VARIOUS PAINT-CARD STRIPES.
THEY PRINT THE PAINT COLOR NAMES
AND NUMBERS ON BOTH SIDES.
THEY ALSO APPLY VARNISH
TO THE BACK OF THE SHEETS
SO THE PAINT CHIP CARDS
WON'T STICK TO ONE ANOTHER
WHEN STACKED.
NAMED AND NUMBERED, THE COLOR
STRIPES ARE NOW IDENTIFIABLE.
THE SHEETS GO UNDER
A GUILLOTINE BLADE
WHICH SLICES THEM
INTO PAINT CHIP CARDS.
POWERED BY HYDRAULICS
AND SUPER SHARP,
THE BLADE CUTS THROUGH HUNDREDS
OF PAPER SHEETS LIKE BUTTER.
THEY PRODUCE 3 1/2 MILLION
PAINT CHIP CARDS A DAY
AT THIS FACTORY.
WITH SO MANY OPTIONS,
THE CARDS ARE STACKED
AGAINST A QUICK DECISION.
Narrator: A BUNDT PAN
IS FOR BAKING A DENSE,
RING-SHAPED CAKE CALLED A BUNDT.
IT TYPICALLY HAS
A FLUTED OR A SWIRL DESIGN.
IT ORIGINATED IN EUROPE
HUNDREDS OF YEARS AGO
AND QUITE POSSIBLY GETS ITS NAME
FROM THE GERMAN BUNDKUCHEN --
"KUCHEN" MEANING "CAKE"
AND "BUND" MEANING
"A GATHERING OF PEOPLE."
BUNDT PANS
WERE ORIGINALLY CERAMIC,
WHICH IS FRAGILE,
OR CAST IRON, WHICH IS HEAVY.
TODAY'S VERSION IS TYPICALLY
MADE OF CAST ALUMINUM --
UNBREAKABLE
AND INFINITELY LIGHTER.
IT ALSO HAS A NONSTICK COATING.
AT THE FACTORY, THEY BEGIN
THE PRODUCTION PROCESS
BY MELTING INGOTS
OF RECYCLED ALUMINUM.
THE FURNACE HEATS THE INGOTS
TO 1,300-DEGREES FAHRENHEIT,
AT WHICH POINT,
THEY LIQUIFY IN ABOUT A MINUTE.
FROM THE MELTING FURNACE,
WORKERS TRANSFER
THE MOLTEN ALUMINUM
TO A HOLDING FURNACE
WHICH KEEPS IT IN A LIQUID STATE
UNTIL CASTING.
THE CASTING PROCESS
IS ENTIRELY AUTOMATED.
A LADLE DESCENDS
INTO THE HOLDING FURNACE
AND SCOOPS UP JUST OVER
TWO POUNDS OF ALUMINUM,
ENOUGH TO MAKE ONE BUNDT PAN.
THE LADLE THEN POURS
THE MOLTEN METAL INTO A SLEEVE
WHICH A HIGH-SPEED RAM
IMMEDIATELY PUSHES
INTO A STEEL BUNDT-PAN MOLD.
THE PRESSURE AND SPEED COMBINED
SHOOT THE MOLTEN ALUMINUM
INTO EVERY NOOK AND CRANNY
OF THE MOLD CAVITY.
AS THE HOT ALUMINUM
HITS THE COOLER MOLD,
IT SOLIDIFIES
IN ABOUT 10 SECONDS,
THEN THE TWO HALVES OF
THE MOLD AUTOMATICALLY SEPARATE
AND A ROBOTIC ARM EXTRACTS
THE CAST PAN.
BETWEEN CASTINGS,
A ROBOT CLEANS THE MOLD
WITH A BLAST OF AIR, WATER,
AND LUBRICANT.
THIS REMOVES
ANY ALUMINUM RESIDUE,
LEAVING THE MOLD SURFACE
PRISTINE.
THIS IS CRITICAL, BECAUSE EVEN
A TINY SPECK OF DUST LEFT BEHIND
WOULD MAR THE NEXT CASTING.
AS EACH PAN COMES OFF
THE MACHINE,
WORKERS INSPECT IT
FOR ANY CASTING FLAWS.
WHEN IT COMES TIME TO PRODUCE
A DIFFERENT STYLE BUNDT PAN,
LIKE THIS ONE
WITH SIX MINI-CAKE FORMS,
THEY SIMPLY MOUNT
THE CORRESPONDING MOLD
ONTO THE CASTING MACHINE.
AS THE MACHINE FILLS
THE MOLD UNDER PRESSURE,
SOME ALUMINUM OOZES OUT BETWEEN
THE TWO HALVES OF THE MOLD.
NOW A WORKER CUTS OFF
THAT EXCESS
WITH A SINGLE STRIKE
OF A TRIM PRESS.
THE SCRAP PIECES GO BACK INTO
THE FURNACE TO BE REMELTED.
NEXT, A COMPUTER-GUIDED ROUTER
WORKING TWO PANS AT A TIME,
SMOOTHES THE ROUGH EDGES.
THEN IT REFINES THE HANDLE
SLOTS, FINALIZING THE SHAPE.
THE ALUMINUM SURFACE
MUST BE PRISTINE
FOR THE NONSTICK COATING
TO ADHERE PROPERLY,
SO THE PANS NOW GO THROUGH
AN INDUSTRIAL WASHING MACHINE --
ONE WASH AND THREE RINSE CYCLES,
AND THEN, BEFORE EXITING,
A DRYING CYCLE.
WORKERS PUT THE PANS UPSIDE DOWN
ON FIXTURES
WHICH TRAVEL DOWN
THE EXTERIOR COASTING LINE.
AS THE PAN SPINS BY,
SPRAY GUNS APPLY
A SILICONE-BASED DECORATIVE
COATING TO THE OUTSIDE SURFACE.
THE PANS THEN TRAVEL THROUGH
AN OVEN FOR 15 MINUTES
TO CURE THE COATING.
THEN THE WORKERS FLIP THE PANS
RIGHT-SIDE UP
AND PLACE THEM ON FIXTURES,
WHICH SPIN THEM
THROUGH ANOTHER SPRAY LINE.
THIS TIME, TO COAT THE INSIDE.
THE INTERIOR COATING
IS A FOOD-SAFE
SILICONE-POLYESTER MATERIAL
DESIGNED TO RELEASE THE CAKE
EASILY FROM THE PAN.
IT'S SIMILAR TO A
NONSTICK COATING ON A FRY PAN,
THE DIFFERENCE BEING
THAT THE CHEMICAL COMPOSITION
IS DESIGNED TO PREVENT SUGAR,
RATHER THAN PROTEIN,
FROM STICKING.
AGAIN, THE PANS GO THROUGH
AN OVEN FOR 15 MINUTES
TO CURE THE COATING.
ONCE THE FINISHED PANS
EXIT THE OVEN,
WORKERS INSPECT THEM THOROUGHLY,
CHECKING FOR ANY FLAWS
IN THE COATINGS.
FROM A PRACTICAL PERSPECTIVE,
A BUNDT PAN'S RINGED SHAPE
HAS DEFINITE ADVANTAGES
OVER AN ORDINARY BAKING PAN.
THE TUBE IN THE MIDDLE
FUNNELS HEAT TO THE CENTER
OF THE CAKE BATTER,
HELPING IT BAKE QUICKER
AND MORE THOROUGHLY.
FROM A DECORATIVE PERSPECTIVE,
WHEN YOU COMPARE AN ORDINARY PAN
TO AN ELEGANT BUNDT,
THE LATTER
CERTAINLY TAKES THE CAKE.
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
DROP US A LINE AT...
DISCOVERY COMMUNICATIONS
Narrator:
THE GARDEN FORK WAS ONCE
A VERY PRIZED POSSESSION --
SO COVETED, IT WAS OFTEN
THE OBJECT OF THEFT.
THAT WAS CENTURIES AGO,
WHEN A FAMILY'S VERY SURVIVAL
DEPENDED ON THE CROPS THEY GREW.
TODAY, OF COURSE,
FOOD IS MASS PRODUCED
AND SOLD IN SUPERMARKETS.
BUT THE GARDEN FORK STILL RULES
IN THE BACKYARD GARDEN.
THERE ARE MANY VERSIONS
OF THE TRUSTY GARDEN FORK.
USE ONE TO WORK THE GARDEN,
AND YOU'LL REAP THE BENEFITS.
AT THIS FACTORY,
THEY'VE BEEN FORGING
GARDEN FORKS
FROM A SOLID-STEEL SLAB
FOR OVER TWO CENTURIES.
USING A 660-TON PUNCH PRESS,
THEY CUT TWO BASIC FORK SHAPES
FROM THIS HOT
AND MALLEABLE SLAB.
THE TINES OR PRONGS FOR
THIS PARTICULAR KIND OF FORK
ARE SHORTER THAN MOST
BECAUSE THESE ARE BORDER FORKS
USED FOR TURNING SOIL
RATHER THAN DIGGING DEEP.
WITH THE BASIC SHAPE
NOW ESTABLISHED,
IT'S BACK INTO THE FURNACE
TO RE-SOFTEN THE STEM.
A WORKER REPEATEDLY FEEDS IT
TO ROLLERS
TO THIN AND WIDEN IT
SUBSTANTIALLY.
HE STRIKES THE STEM
WITH ANOTHER PUNCH PRESS.
THIS ONE HIT TRIMS IT
WHILE CUTTING HOLES
FOR ATTACHING THE WOOD SHAFT.
THE TRIMMINGS WILL BE REMELTED
AND RECYCLED INTO NEW FORKS.
THE NEXT PRESS SLAMS
THE STEEL STEM
INTO A CYLINDRICAL DIE
TO FORCE IT INTO THE BASIC SHAPE
OF A SOCKET.
HE SLIDES THE SOCKET
ONTO A CONED FORM
AND STRIKES IT REPEATEDLY
TO REFINE THE SOCKET SHAPE.
THIS SIZES IT
FOR A WOODEN SHAFT.
THEY TAKE AN ENTIRELY
DIFFERENT APPROACH
WHEN MAKING DIGGING FORKS
BECAUSE OF THEIR LONGER
CURVED TINES.
AFTER FORGING
A KIND OF SPIDER SHAPE,
A WORKER BENDS A PRONG AROUND
A POST TO ORIENT IT FOR SHAPING.
THIS TWO-PERSON TEAM
WORKS IN TANDEM.
ONE FIRES THE SPIDER
AND BENDS THE PRONGS.
THE OTHER WORKER INSERTS
THE PRONG IN THE GROOVES
OF TWO REVOLVING DIES.
THIS ROLLS THE TINE WITHIN
THE CONFINES OF THE GROOVES
TO STRETCH IT LONG AND THIN.
WITH TWO TINES NOW SHAPED,
HIS PARTNER BENDS THEM
OUT OF THE WAY
SO HE CAN WORK
ON THE THIRD TINE.
ROLLING TAKES 18 MONTHS
OF TRAINING TO PERFECT.
IF THE TINE ISN'T PRECISELY
ALIGNED WITH THE GROOVES,
THE EQUIPMENT COULD SEIZE
AND THROW THE WORKER BACKWARDS.
NOT ONLY COULD HE BE INJURED,
BUT THE FORK AND THE DIES WOULD
MOST CERTAINLY BE WRECKED.
WITH A FOURTH TINE NOW STRETCHED
LONG AND THIN LIKE THE REST,
THE OTHER MEMBER OF THE TEAM
TWISTS ALL FOUR TINES
AROUND THE POST AGAIN,
THIS TIME TO BEND THEM ALL
IN THE SAME GENERAL DIRECTION.
AFTER ABOUT 10 MINUTES OF WORK,
THEY HAVE THE ROUGH SHAPE
OF A DIGGING FORK.
THEY THEN FORM THE SOCKET
AND CROP THE TINES.
FIRED TO A SUPPLE STATE AGAIN,
A WORKER DRIVES TOOLING
BETWEEN THE TINES
TO STRAIGHTEN THEM
AND EVEN THE GAPS BETWEEN THEM.
HE RESTS THE FORK SOCKET AGAINST
A STEEL SLOPE AND LOWERS A RAM.
IT SLAMS INTO THE TINES TO PUSH
THE SOCKET AGAINST THE SLOPE
AND BEND IT UPWARD --
A MORE EFFECTIVE ANGLE
FOR DIGGING.
HE INSERTS THE TINES IN A PRESS
ONE AT A TIME.
THE PRESS CLOSES AROUND
EACH TINE TO TAPER THE CORNERS.
A RAM NOW POUNDS
THE BASE OF THE TINES
AGAINST A SWOOPED ANVIL
TO GIVE IT A GENTLE CURVE.
HE PLUNGES THE HOT FORK
INTO COOL WATER,
AND THE SHOCK HARDENS THE STEEL.
THE NEXT WORKER GRINDS OFF
ANY ROUGH BITS FROM THE SIDES
AND SHARPENS THE EDGES.
HE NARROWS THE TIPS TO A POINT,
AND THIS WILL ENABLE THE FORK
TO PIERCE SOLID EARTH.
A WORKER REPAIRS ANY
IRREGULARITIES WITH HIS HAMMER.
HERE YOU CAN SEE
THE DIFFERENCE THIS MAKES.
THE PRONGS ON THE LEFT
ARE OUT OF ALIGNMENT.
THE ONES ON THE RIGHT
HAVE BEEN FIXED.
THEY APPLY
AN ELECTROSTATIC CHARGE
ONTO THE FORKS TO ATTRACT
A GREEN POWDER SPRAY.
ONCE CURED, IT FORMS A COLORFUL
SKIN THAT RESISTS CORROSION.
NOW OUT OF THE CURING OVEN,
A WORKER CLAMPS THE ENDS
TO LOCK THE FORK IN PLACE
WHILE HE INSERTS THE
ASH WOOD SHAFT INTO THE SOCKET.
HE SECURES IT WITH RIVETS.
USING A BELT SANDER,
HE BLENDS THE WOOD TO THE METAL
IN A PROCESS KNOWN AS LINISHING.
HE ALSO SANDS THE RIVETS
TO MAKE THEM FLUSH
TO THE SURFACE OF THE METAL.
THE BOTTOM FORK IS THE ONE
THAT HAS BEEN LINISHED.
HE DIPS THE WOOD SHAFT
AND HANDLE IN VARNISH,
GIVING IT A GLOSSY STAIN
THAT ENHANCES THE GRAIN.
THIS GARDEN FORK IS NOW DONE.
IT WON'T LOOK SHINY
AND NEW FOR LONG,
BECAUSE THINGS ARE SURE TO GET
DIRTY VERY SOON.
Narrator: TOFFEE IS A TYPE
OF CANDY TRADITIONALLY MADE
OF CARAMELIZED SUGAR
OR MOLASSES AND BUTTER.
THERE ARE MANY
DIFFERENT VARIETIES --
SOFT AND CHEWY
OR HARD AND BRITTLE.
ENGLISH TOFFEE,
WHICH IS ACTUALLY
AN AMERICAN STYLE OF TOFFEE,
IS VERY BUTTERY
AND TYPICALLY HAS A TOPPING
OF CHOPPED NUTS.
THIS ENGLISH TOFFEE
IS COMPLETELY FREE
OF DAIRY INGREDIENTS
AND IS KOSHER CERTIFIED,
MAKING IT IDEAL
FOR TOFFEE LOVERS WITH
CERTAIN DIETARY RESTRICTIONS.
THE WORKERS AT THIS
SMALL AMERICAN CONFECTIONER
MAKE THIS SPECIAL RECIPE
ENTIRELY BY HAND
ONE SMALL BATCH AT A TIME.
THEY START BY COMBINING
WATER AND SUGAR.
THEY HEAT THE MIXTURE
UNTIL THE SUGAR DISSOLVES.
THEN THEY ADD A FORMULA
SO TOP-SECRET
THEY WON'T LET US SEE IT.
ALL THEY'LL REVEAL
IS THAT IT CONTAINS
A COMBINATION OF VEGETABLE OILS
AND SHORTENING
WHICH ARE NON-DAIRY SUBSTITUTES
FOR BUTTER AND BETA CAROTENE
TO GIVE THE TOFFEE
THAT FAMILIAR GOLDEN COLOR.
THEY ADD AN EMULSIFIER
CALLED LECITHIN
TO STABILIZE
ALL THESE INGREDIENTS.
AS SOON AS THE MIXTURE
REACHES THE BOILING POINT,
THEY ADD SALT.
THIS ENHANCES THE FLAVOR
AND HELPS PRODUCE A RAPID BOIL
THAT CONTINUES FOR SEVERAL HOURS
UNTIL THE MIXTURE HITS
A TOP-SECRET TARGET TEMPERATURE.
BY THAT POINT, MOST OF THE WATER
HAS EVAPORATED,
PRODUCING SWEET, THICK,
LIQUID TOFFEE.
NOW THEY OPEN A HOT-WATER VALVE
THAT HEATS UP A TABLE,
THEN CAREFULLY POUR THE TOFFEE
ONTO THE SURFACE.
THE HEAT
KEEPS THE TOFFEE PLIABLE
WHILE THEY SPREAD IT OUT.
THEY SPREAD IT WIDER AND WIDER
UNTIL THE TOFFEE SHEET
IS EVENLY THICK.
THEY DON'T ACTUALLY MEASURE.
THEY JUST EYEBALL IT, SO
THE THICKNESS VARIES SOMEWHAT.
BUT THAT LACK OF UNIFORMITY
IS PART OF THE CHARM
OF HANDMADE SWEETS.
THEY TAKE A TOOL
WITH MULTIPLE CUTTING WHEELS
SPACED ABOUT TWO INCHES APART.
THEY RUN IT OVER THE
TOFFEE SHEET IN ONE DIRECTION,
THEN IN THE OTHER.
THEN THEY SHUT OFF
THE HOT-WATER VALVE
AND OPEN THE COLD-WATER ONE
TO COOL THE TABLE SURFACE
AND HARDEN WHAT ARE NOW
TOFFEE SQUARES.
WITHIN MINUTES, THE SQUARES ARE
HARD ENOUGH TO BE BROKEN APART.
NEXT, THE FIRST
OF TWO INGREDIENTS
THAT WILL TURN THIS
INTO ENGLISH TOFFEE --
MOLTEN SEMI-SWEET CHOCOLATE.
ONCE THIS TEMPERING MACHINE
HEATS IT
TO THE RIGHT CONSISTENCY,
A PUMP FEEDS IT
TO THE ENROBING MACHINE
THAT COATS THE TOFFEE SQUARES
IN TWO STAGES,
STARTING ON THE BOTTOM.
THE UNDERSIDE NOW COATED,
THE SQUARES MOVE ON
TO A REFRIGERATED BELT.
THE COLD QUICKLY HARDENS
THE CHOCOLATE.
THEN THEY MOVE INTO
THE NEXT STATION
WHICH COVERS THE TOP
WITH CHOCOLATE.
AS THE NOW FULLY-COATED SQUARES
EXIT THE ENROBING MACHINE,
THE BELT VIBRATES, SHAKING OFF
THE EXCESS CHOCOLATE.
THE SQUARES MOVE ON
TO ANOTHER REFRIGERATED BELT
AND A WORKER
MANUALLY SPRINKLES THEM
WITH THE SECOND INGREDIENT
THAT MAKES THIS
ENGLISH TOFFEE --
CHOPPED PECANS.
THE SQUARES TRAVEL THROUGH
A COOLING TUNNEL
FOR SEVERAL MINUTES TO SET.
AS THEY REACH
THE END OF THE LINE,
EXCESS NUTS DROP OFF
AND COLLECT IN A PAN BELOW,
READY FOR SPRINKLING
ONTO NEW SQUARES.
SOME ENGLISH TOFFEE RECIPES CALL
FOR ALMONDS RATHER THAN PECANS.
WHICHEVER VARIETY OF NUT,
EVERY RECIPE FOLLOWS
THE SAME STRUCTURE.
LAYERING
SWEET AND CRUNCHY TOFFEE,
SMOOTH AND CREAMY CHOCOLATE,
AND COARSELY CHOPPED NUTS --
THREE DIFFERENT TEXTURES,
TASTES, AND SENSATIONS
BROUGHT TOGETHER
IN A SINGLE CONFECTION.
AND JUST LIKE OTHER
DECADENTLY DELICIOUS DESSERTS,
ENGLISH TOFFEE IS HEAVEN
TO ANYONE
WITH A SERIOUS SWEET TOOTH.
Narrator: TRYING TO DECIDE
ON A PAINT COLOR?
EACH CARD IS A SMALL SAMPLE
OF RELATED SHADES,
ALLOWING YOU
TO VIEW THE ACTUAL HUES
WITHOUT PRYING OFF THE LIDS
OF PAINT CANS.
WITH THOUSANDS OF SHADES
TO CHOOSE FROM,
HOW DO THEY GET IT ALL
DOWN ON PAPER?
WHETHER YOU'RE LOOKING
FOR A BRILLIANT BLUE
OR A MARVELOUS MAUVE,
CAREFUL SCRUTINY OF PAINT CHIP
CARDS CAN HELP YOU GET IT RIGHT
BEFORE THE PAINT HITS THE WALL.
HIGHLY CONCENTRATED COLORANTS
STORED IN TANKS
WILL BE USED TO REPRODUCE
PAINT COLORS IN LACQUER
SIMILAR TO THE KIND
USED IN NAIL POLISH.
LACQUER PRODUCES BETTER RESULTS
ON PAPER THAN ACTUAL PAINT.
THEY PIPE THE COLORANTS
TO A DISPENSER.
AT THE SAME TIME,
A BUCKET CONTAINING LACQUER
HEADS TOWARD IT.
THE DISPENSER HAS MANY TENTACLES
WITH NOZZLES
AT THE END OF EACH ONE
AND EACH TENTACLE IS CONNECTED
TO ONE OF THE COLORANT TANKS.
A COMPUTERIZED MECHANISM GRABS
THE NOZZLES
TO DISPENSE DIFFERENT COLORANTS
FOLLOWING
A SPECIFIC PAINT-COLOR FORMULA.
THE BUCKET SITS ON A SCALE
AND THE WEIGHT IS CONSTANTLY
MONITORED BY THE COMPUTER
TO CONFIRM THAT EXACT AMOUNTS
ARE BEING ADDED.
A BLENDER MIXES THE COLORANTS
IN THE LACQUER.
THE MIXING SPEED AND TIME
HAVE BEEN PRESET
TO AVOID OVER OR UNDER MIXING.
AND NOW FOR THE COLOR TEST.
A TECHNICIAN PULLS A BIT
OF THE LACQUER-BASED PAINT
ON A SHEET OF PAPER
JUST UNDER A STEEL BAR.
USING THAT BAR, HE SPREADS THE
COLOR EVENLY ACROSS THE PAPER.
THEN IT'S INTO A KIND OF
MOVING CONVECTION OVEN
TO DRY THE COLOR.
THE TECHNICIAN COMPARES
THE COLOR AND GLOSS
TO THAT OF THE STANDARD.
HE ALSO DOES A COMPUTER ANALYSIS
AND SENDS THE FORMULA BACK
FOR TWEAKING WHEN NECESSARY.
ONCE THEY PERFECT
THE HUE AND GLOSS,
PRODUCTION IS READY TO ROLL.
A WORKER POURS THE APPROVED
LACQUER-BASED PAINTS
INTO CYLINDRICAL TANKS
ABOVE THE COATING MACHINE.
THERE ARE OVER TWO DOZEN
OF THESE TANKS
BECAUSE THEY'LL BE PUTTING
THAT MANY COLORS ON PAPER
IN ONE PRODUCTION RUN.
HE CONNECTS PLASTIC TUBING
TO THE TANKS
TO NARROW THE FLOW AND AIM IT
AT THE DIE BLOCK BELOW.
HE ACTIVATES THE MACHINE
AND ADJUSTS THE TENSION OF
THE PAPER AS IT MOVES FORWARD.
LACQUER FLOWS INTO A DIE,
COATING THE PAPER WITH
AN ENDLESS RAINBOW OF COLOR.
A BAR OVERHEAD SPREADS
THE LACQUER EVENLY
WITHOUT ACTUALLY TOUCHING
THE PAPER.
THE STRIPED PAPER
THEN TRAVELS THROUGH AN OVEN.
THE SOLVENTS EVAPORATE,
LEAVING A DRIED LACQUER SKIN
ON THE PAPER.
IF REGULAR PAINT HAD BEEN USED,
THE PAPER WOULD HAVE ABSORBED IT
AND ENDED UP WAVY.
BUT WITH THE LACQUER PAINT,
IT REMAINS FLAT.
ROTARY BLADES CUT
THE COATED PAPER
INTO SHEETS SIZED
TO FIT PRINTING MACHINERY
DOWN THE LINE.
THEY LAND IN A NEAT STACK.
USING A TRANSPARENT TEMPLATE,
THE NEXT WORKER MEASURES
THE WIDTH OF EACH STRIPE.
HE THEN CONFIRMS THAT THE COLORS
ARE IN THE CORRECT ORDER
BY CHECKING EACH STRIPE
AGAINST THE APPROVED PROOFS.
HE CHECKS THE GLOSS
WITH A GLOSSMETER.
IT AIMS LIGHT ON AN ANGLE
AND REGISTERS THE REFLECTION
TO CONFIRM THAT THE GLOSS
IS CONSISTENT.
WITH THE OKAY FROM THE TESTER,
THE ENTIRE PRODUCTION RUN
RECEIVES THE GO-AHEAD.
THE PRESS OPERATOR STACKS THEM
FACEDOWN
FOR LOADING INTO THE PRINTER.
A FEEDER SERVES UP
THE STRIPED SHEETS
TO THE PRINTING LINE
ONE AT A TIME.
IT'S A 4-STATION PRINTING PRESS.
EACH CYLINDER IS EQUIPPED
WITH AN INK OF A DIFFERENT COLOR
TO STAND OUT AGAINST
THE VARIOUS PAINT-CARD STRIPES.
THEY PRINT THE PAINT COLOR NAMES
AND NUMBERS ON BOTH SIDES.
THEY ALSO APPLY VARNISH
TO THE BACK OF THE SHEETS
SO THE PAINT CHIP CARDS
WON'T STICK TO ONE ANOTHER
WHEN STACKED.
NAMED AND NUMBERED, THE COLOR
STRIPES ARE NOW IDENTIFIABLE.
THE SHEETS GO UNDER
A GUILLOTINE BLADE
WHICH SLICES THEM
INTO PAINT CHIP CARDS.
POWERED BY HYDRAULICS
AND SUPER SHARP,
THE BLADE CUTS THROUGH HUNDREDS
OF PAPER SHEETS LIKE BUTTER.
THEY PRODUCE 3 1/2 MILLION
PAINT CHIP CARDS A DAY
AT THIS FACTORY.
WITH SO MANY OPTIONS,
THE CARDS ARE STACKED
AGAINST A QUICK DECISION.
Narrator: A BUNDT PAN
IS FOR BAKING A DENSE,
RING-SHAPED CAKE CALLED A BUNDT.
IT TYPICALLY HAS
A FLUTED OR A SWIRL DESIGN.
IT ORIGINATED IN EUROPE
HUNDREDS OF YEARS AGO
AND QUITE POSSIBLY GETS ITS NAME
FROM THE GERMAN BUNDKUCHEN --
"KUCHEN" MEANING "CAKE"
AND "BUND" MEANING
"A GATHERING OF PEOPLE."
BUNDT PANS
WERE ORIGINALLY CERAMIC,
WHICH IS FRAGILE,
OR CAST IRON, WHICH IS HEAVY.
TODAY'S VERSION IS TYPICALLY
MADE OF CAST ALUMINUM --
UNBREAKABLE
AND INFINITELY LIGHTER.
IT ALSO HAS A NONSTICK COATING.
AT THE FACTORY, THEY BEGIN
THE PRODUCTION PROCESS
BY MELTING INGOTS
OF RECYCLED ALUMINUM.
THE FURNACE HEATS THE INGOTS
TO 1,300-DEGREES FAHRENHEIT,
AT WHICH POINT,
THEY LIQUIFY IN ABOUT A MINUTE.
FROM THE MELTING FURNACE,
WORKERS TRANSFER
THE MOLTEN ALUMINUM
TO A HOLDING FURNACE
WHICH KEEPS IT IN A LIQUID STATE
UNTIL CASTING.
THE CASTING PROCESS
IS ENTIRELY AUTOMATED.
A LADLE DESCENDS
INTO THE HOLDING FURNACE
AND SCOOPS UP JUST OVER
TWO POUNDS OF ALUMINUM,
ENOUGH TO MAKE ONE BUNDT PAN.
THE LADLE THEN POURS
THE MOLTEN METAL INTO A SLEEVE
WHICH A HIGH-SPEED RAM
IMMEDIATELY PUSHES
INTO A STEEL BUNDT-PAN MOLD.
THE PRESSURE AND SPEED COMBINED
SHOOT THE MOLTEN ALUMINUM
INTO EVERY NOOK AND CRANNY
OF THE MOLD CAVITY.
AS THE HOT ALUMINUM
HITS THE COOLER MOLD,
IT SOLIDIFIES
IN ABOUT 10 SECONDS,
THEN THE TWO HALVES OF
THE MOLD AUTOMATICALLY SEPARATE
AND A ROBOTIC ARM EXTRACTS
THE CAST PAN.
BETWEEN CASTINGS,
A ROBOT CLEANS THE MOLD
WITH A BLAST OF AIR, WATER,
AND LUBRICANT.
THIS REMOVES
ANY ALUMINUM RESIDUE,
LEAVING THE MOLD SURFACE
PRISTINE.
THIS IS CRITICAL, BECAUSE EVEN
A TINY SPECK OF DUST LEFT BEHIND
WOULD MAR THE NEXT CASTING.
AS EACH PAN COMES OFF
THE MACHINE,
WORKERS INSPECT IT
FOR ANY CASTING FLAWS.
WHEN IT COMES TIME TO PRODUCE
A DIFFERENT STYLE BUNDT PAN,
LIKE THIS ONE
WITH SIX MINI-CAKE FORMS,
THEY SIMPLY MOUNT
THE CORRESPONDING MOLD
ONTO THE CASTING MACHINE.
AS THE MACHINE FILLS
THE MOLD UNDER PRESSURE,
SOME ALUMINUM OOZES OUT BETWEEN
THE TWO HALVES OF THE MOLD.
NOW A WORKER CUTS OFF
THAT EXCESS
WITH A SINGLE STRIKE
OF A TRIM PRESS.
THE SCRAP PIECES GO BACK INTO
THE FURNACE TO BE REMELTED.
NEXT, A COMPUTER-GUIDED ROUTER
WORKING TWO PANS AT A TIME,
SMOOTHES THE ROUGH EDGES.
THEN IT REFINES THE HANDLE
SLOTS, FINALIZING THE SHAPE.
THE ALUMINUM SURFACE
MUST BE PRISTINE
FOR THE NONSTICK COATING
TO ADHERE PROPERLY,
SO THE PANS NOW GO THROUGH
AN INDUSTRIAL WASHING MACHINE --
ONE WASH AND THREE RINSE CYCLES,
AND THEN, BEFORE EXITING,
A DRYING CYCLE.
WORKERS PUT THE PANS UPSIDE DOWN
ON FIXTURES
WHICH TRAVEL DOWN
THE EXTERIOR COASTING LINE.
AS THE PAN SPINS BY,
SPRAY GUNS APPLY
A SILICONE-BASED DECORATIVE
COATING TO THE OUTSIDE SURFACE.
THE PANS THEN TRAVEL THROUGH
AN OVEN FOR 15 MINUTES
TO CURE THE COATING.
THEN THE WORKERS FLIP THE PANS
RIGHT-SIDE UP
AND PLACE THEM ON FIXTURES,
WHICH SPIN THEM
THROUGH ANOTHER SPRAY LINE.
THIS TIME, TO COAT THE INSIDE.
THE INTERIOR COATING
IS A FOOD-SAFE
SILICONE-POLYESTER MATERIAL
DESIGNED TO RELEASE THE CAKE
EASILY FROM THE PAN.
IT'S SIMILAR TO A
NONSTICK COATING ON A FRY PAN,
THE DIFFERENCE BEING
THAT THE CHEMICAL COMPOSITION
IS DESIGNED TO PREVENT SUGAR,
RATHER THAN PROTEIN,
FROM STICKING.
AGAIN, THE PANS GO THROUGH
AN OVEN FOR 15 MINUTES
TO CURE THE COATING.
ONCE THE FINISHED PANS
EXIT THE OVEN,
WORKERS INSPECT THEM THOROUGHLY,
CHECKING FOR ANY FLAWS
IN THE COATINGS.
FROM A PRACTICAL PERSPECTIVE,
A BUNDT PAN'S RINGED SHAPE
HAS DEFINITE ADVANTAGES
OVER AN ORDINARY BAKING PAN.
THE TUBE IN THE MIDDLE
FUNNELS HEAT TO THE CENTER
OF THE CAKE BATTER,
HELPING IT BAKE QUICKER
AND MORE THOROUGHLY.
FROM A DECORATIVE PERSPECTIVE,
WHEN YOU COMPARE AN ORDINARY PAN
TO AN ELEGANT BUNDT,
THE LATTER
CERTAINLY TAKES THE CAKE.
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ABOUT THE SHOW,
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