26x08 - Stile & Rail Doors, Steam Cleaners, Hand-Held Pizzas, Power Brushes

[bunniefuu]

♪♪

Narrator:
today on "how it's made" --

...stile and rail doors...

...steam cleaners...

...hand-held pizzas...

...and power brushes.

Many doors are made
of a single piece of wood.

But stile and rail doors
contain a rectangular frame

Around one
or more central panels.

The term stile refers
to the frame's vertical pieces.

And rail refers
to its horizontal ones.

♪♪

Stile and rail doors come in
many different shapes and sizes.

They have several components.

Some even have
sectioned glass panels.

They use poplar wood
for paint-grade doors.

If the door will be stained,

Customers can choose from
several different wood options,

Including oak, cherry,
maple, and african mahogany.

They feed the rough lumber
through a planer.

The first two stations

Simultaneously shave the top
and bottom of the wood.

The third station
has multiple saw blades

That cut the piece
into several strips.

Workers line up the strips
and coat one side with glue.

Then they transfer the wood
strips to a clamping machine.

They stack one piece
of linear-strand lumber

In between the glued sides
of two solid-wood strips.

Linear-strand lumber,
called lsl for short,

Is a piece of lumber
made from glued wood fibers.

The robot holds the assembly
in place for an hour

Until the glue dries.

Then they put this engineered
lumber through a glue spreader.

It coats the top
and bottom surfaces

With heat-activated glue.

They sandwich the lumber

Between two thin sheets of wood
called veneer.

For a paint-grade door,

They use ultra-thin mdf,

Medium-density fiberboard,
instead.

Mdf is a man-made material

With a smooth,
paint-friendly surface.

They place the pieces into
a hot press for two minutes.

The heat activates the glue,

While the pressure flattens
the veneer against the lumber.

These pieces will become
the door's stiles and rails.

The panels inside the stiles
and rails are made of mdf.

For a stained door,

Workers apply the veneer
before they contour the pieces.

Workers carve the pieces
using a shaper machine.

They change the machine heads in
order to cut different designs.

The workers
used a different shaper machine

To carve the inside edge
of the stiles.

They also drilled holes
for the dowels

Of the adjoining rails.

They apply glue,

Then attach the matching bottom
rail to the first stile.

They insert the panel into
a groove in the rail and stile.

They are assembling
a two-panel door.

So next, they fit a middle rail
and another panel.

They install a top rail
and then the second stile.

They place
the newly-assembled door

In a large clamping machine.

It applies pressure on the door
for an hour

While the glue dries.

The machine transfers the door
to a cutting table.

Then a computer-guided saw trims
the top and bottom of the door.

The machine switches
to a different tool

That bevels the edge
of the door.

It switches tools again

And drills holes
for the door's hardware.

The stile and rail door
is now ready for finishing.

Workers sand the surface

To prepare it
for either staining or painting.

Then the stained doors

Receive a coat of sealer
and two coats of clear lacquer.

This protects
the wood's surface.

The panels used
in stile and rail doors

Are never glued in place.

They sit inside the frame.

This leaves space for the wood
and mdf to naturally expand

Without warping
or cracking the door.

Narrator: in the 1960s,

Italian boilermakers figured out
how to harness steam to clean.

Steam cleaning is much safer
than traditional methods

Because dirt and bacteria
can be eliminated

Without the use
of harmful chemicals.

High-pressure,
low-moisture steam is enough

To vaporize most germs.

♪♪

The water in a steam cleaner

Is heated
to over 200 degrees fahrenheit.

It's safe to use
on both hard and soft surfaces.

Steam cleaners start out
as a computer design.

This is a commercial model

That will be used
to clean hotels, restaurants,

Offices, and schools.

They make the components using
polycarbonate plastic pellets.

A molding machine
heats the plastic,

Then injects it into molds.

The plastic hardens
into the shape of parts.

This one is the cover
for the steam cleaner's boiler.

A robot with vacuum-suction
grippers extracts the cover

From the mold.

They mold other parts,

Including the base,
extension tubes,

Handles, and hooks the same way.

A worker installs a water-level
probe on the steel boiler.

He also screws on a fitting
for the fill hose.

He adds two solenoid valves.

They turn the steam on and off
and control its intensity.

Then he places the boiler
in a test device.

The device verifies
that the electrical parts

Are insulated properly.

He tightens the solenoid valves
to complete the installation.

After the hoses
are attached to the boiler,

They place it in the base
of the steam cleaner.

A worker plugs
in the electrical contacts.

They will power
the steam hose's controls.

Then he connects the steam hose
to a fitting

Next to the contacts.

He tightens a metal clip around
it to reinforce the connection.

He links the main
electronic board

To temperature sensors that have
been installed on the boiler.

The worker also wires
the steam-pressure sensors.

He covers the top of the boiler
with melamine insulation.

Then he slides a heat-resistant
plastic cover over the boiler.

He attaches the fill hose
to the fitting

On the top of the boiler.

He connects the other end
to the water tank.

The worker equips the tank
with two water-level sensors.

He hooks up a gauge
for the steam pressure.

Then he fills the tank
with water

And tests the steam cleaner.

He uses a small mirror
to check for leaks.

Another worker
assembles the steam g*n.

He attaches a plastic joint
to the steam hose,

Then installs a nozzle
on the end.

He slides the joint forward
to surround the spray nozzle

And screws a plastic wand
to the end of the joint.

He tucks the hose on one side
of the handle's plastic casing

And installs a trigger.

Then he snaps on the cover.

He screws the handle together.

He connects the steam g*n
to the boiler unit.

He turns it on.

And the sprayer shoots out
a hot, pressurized mist

Known as dry steam.

Its moisture content

Is only 5%, allowing
cleaned surfaces to dry quickly.

The steam cleaner
also comes with a vacuum.

It sucks up residual water
and dirt after a steam cleaning.

He attaches the vacuum motor
to the filter.

He places the motor and filter
into the base canister

And locks the assembly together
with clips at the sides.

The worker transfers
the steam cleaner to a cart.

Once the vacuum is on board,

This duo is ready to eradicate
dirt, grease, and pathogens.

Just aim and pull the trigger.

The steam will do the rest.

Narrator: a slice of pizza
isn't always a portable snack.

The toppings can slide off
while you're eating it.

These hand-held, individual
pizzas solve that problem.

The toppings are safely encased
inside the pizza dough.

Hand-held pizzas are small
enough for kids to easily hold.

They're made
without preservatives,

And all the ingredients
are organic,

Making them the perfect frozen
snack for hungry children.

One main ingredient
is cauliflower.

It packs a strong
nutritional punch

Without altering the flavor.

Cauliflower is low in calories

But high in vitamins, minerals,
and dietary fiber.

It also helps
thicken the filling.

After removing the stems,

The cooks boil the
cauliflower heads until tender.

They remove them from the pot
with a slotted spoon

To let the water drain away.

They puree the cauliflower
in a food processor.

♪♪

The cooks also boil
and puree butternut squash,

Which is full
of vitamin a, vitamin c,

And many other nutrients.

The squash puree
slightly sweetens the filling

And helps thicken it.

Other ingredients
that go into the filling are

Tomato paste,
parmesan and mozzarella cheeses,

Potato flakes, sea salt,
spices, and water.

After measuring out
the required amounts,

Workers pour the ingredients
into a large bowl.

They manually blend
the ingredients

With a large whisk to keep
the filling's texture coarse.

The pizza dough
is made with wheat flour,

Unbleached all-purpose flour,
and baking soda.

They also add
palm fruit shortening

And water
to make the dough pliable.

They combine all the ingredients
in a mixer.

The mixer blends the ingredients
thoroughly

Until the dough
reaches the right consistency.

After mixing,
they let the dough rest.

Next, they transform
the blocks of dough into sheets.

They place
an 8-inch block of dough

On a machine
called the dough sheeter.

The dough moves back and forth
beneath a roller

Until it's flat.

They add flour so the dough
won't stick to the roller.

A worker winds the sheet
of dough onto a spool

And transfers it
to the processing line.

Here, four rotary blades
trim the sides

And divide the sheet
into three strips.

Spray nozzles lightly mist
the dough with water

To keep it pliable.

A machine dispenses the filling
at perfectly timed intervals.

It adds one ounce
of filling per pizza

To one side of each strip.

Then the machine
folds the other side over.

A crimping wheel seals the edge
to encase the filling.

They add more flour on top
so the crimper

And rotary cutters can easily
trim off the excess dough.

A chopping blade
separates the filled dough

Into individual pizzas.

Then the crimper
seals the third edge.

Workers transfer the pizzas
by hand onto baking sheets.

They're lined with parchment
paper to prevent sticking.

Then they bake the pizzas
in an oven.

As soon as they come out,
they're flash-frozen.

This rapid deep-freeze
locks in the nutrients

And makes preservatives
unnecessary.

The frozen pizzas go
straight to the packaging room.

It's refrigerated so the pizzas
won't begin to thaw.

The equipment individually
wraps the pizzas in plastic

Then packages them, two per box.

After 60 seconds
in the microwave,

These pizzas are ready to eat.

The thick filling doesn't drip,

Making them
the perfect meal on the go.

Narrator:
wire power brushes rotate
at high speeds to clean metal

Without damaging it.

These industrial tools
can scrub off almost anything,

Including weld splatter,
rust, and paint.

They can also smooth away
sharp edges

And protrusions known as burrs.

♪♪

Wire power brushes come in
many different shapes and sizes.

The bristles are either
knotted or crimped.

There's a wire power brush
for every metal-cleaning job.

Automated tools
work with pinpoint accuracy

To create a wire brush
with knotted bristles.

A tool inserts 22 wires into
each hole of the steel disk.

The wires are made
of high-carbon steel.

Another tool twists
the wire bundle into a knot.

It makes a special knot

Designed for maximum strength
and durability.

The system installs 48 knotted
wire bundles in each brush.

An employee transfers the brush
to a machine

With circular blades.

The blades trim the wires down
and sharpen the ends.

The next worker sandwiches

The brush's center disk
between two larger disks.

A press welder creates
three dimples in the metal.

These dimples tightly hold
the brush structure in place.

A press drives a large nut
into the center hole.

It will be used to securely
attach the wire brush

To a power tool.

This completes the knotted wire
power brush assembly.

Next, they make
the crimped wire brush.

First, a device feeds steel wire

To a cutting machine
in preset increments.

The machine's cutting wheels
slice the wires

To the correct length.

It deposits the wire bundles
on a rack,

And a worker collects them.

Then, another worker
threads a long wire

Between two metal flanges
and a winding machine.

She lines up the pins
around the flanges.

Then she tucks freshly-cut wire
bundles into those slots.

She continues until she's
stacked the wire bundles

All the way around the flanges.

Then she starts the machine.

It winds the long wire
around the shorter wire bundles.

This crimps the short wires
at the center

And holds them in place
between the flanges.

She pulls the end of the wire

To the side
of the brush segment.

Then it's ready
for the next operation.

A 100-ton press

Bends the flanges
over the crimped bristles,

Encasing the longer wire
that holds them together.

Next, a worker

Spins the ends of the brush
between two circular blades.

This is a preliminary trimming.

Then a punch enlarges
the diameter of the center hole.

Next, they combine several
of the crimped brush segments

Together.

An employee
piles up the segments.

He places a tube
in the center and spacers

In between the brushes.

Once the brush
reaches the right size,

He uses a compression tool

To curl the tube's top rim
against the flange.

This secures the segments,
creating one large crimped wire

Brush.

Then he trims the wire bristles
to the correct length.

When attached to a power tool,
knotted bristle wire brushes

Can spin up
to 25,000 rotations per minute.

The brush's high speed
allows it to efficiently scrub

Dirt and grease
from an oil-well drill pipe.

The crimped wire brush
is designed for lighter work,

Like scrubbing rust
off a metal pipe.

These power brushes

Are bristling with cleaning
potential and ready for work.