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The Surprising Journey of Making Zinc Rain Gutters and Ham | How It's Made | Science Channel
The Surprising Journey of Making Zinc Rain Gutters and Ham | How It's Made | Science Channel
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0:00
Zinc gutters drain rainwater and in the process develop a natural resistance to
0:05
corrosion. When zinc is exposed to wet and dry cycles, a chemical reaction occurs,
0:12
forming a protective patina on its surface.
0:15
No paint or special treatment needed.
0:18
You can't stop the rain, but you can stop it from damaging buildings and their
0:23
foundations. These U shaped zinc gutters funnel water away from the structures to keep
0:28
them dry. The process starts with the production of these 46 ton coils of zinc.
0:36
The zinc arrives at the factory in the form of thick plates.
0:40
These plates are almost 100% zinc.
0:46
The plates drop into a furnace.
0:48
Inside, the temperature reaches 750°F.
0:52
Workers add a bit of copper and titanium to reinforce the zinc, and it melts into a
0:58
homogeneous liquid.
1:01
The molten zinc then flows into a trough style conveyor system.
1:07
Residues like ashes float to the top of the metal soup, and a worker skims them off.
1:15
A floating puck monitors the speed and depth of the zinc blende to prevent overflow.
1:23
The molten zinc now arrives at the casting machine.
1:27
Here, three foot wide steel unwinds and once linear, the zinc flows onto it.
1:34
The steel acts as a mould to form the zinc into a long rigid sheet.
1:41
Water flows onto the zinc to accelerate cooling and solidification.
1:46
Since water and liquid zinc don't mix, the water simply runs off the surface.
1:53
Now solid, the zinc plate is almost a third of an inch thick, far too thick for making
2:00
lightweight rain gutters.
2:02
The next operation will thin the plate down dramatically.
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This is a powerful rolling mill.
2:09
The pressure on its rollers is so great that they often must be replaced.
2:16
Once the new rollers have been loaded, the mill heats them up.
2:21
The operator activates the rollers as they revolve.
2:25
The hot rollers exert 770 tons of pressure to iron the zinc much thinner.
2:33
Meanwhile, just ahead, a steel belt tensioning system swings into action.
2:39
This system prevents slackening in the zinc sheet as it exits the rolling mill and moves
2:44
forward. You can see the difference the rolling has made.
2:48
It has reduced the thickness of the zinc sheet to about three quarters of a
2:53
millimeter. The steel belt system maintains the tension in the zinc sheet as it's wound
3:00
around a core.
3:01
This produces the 46 ton coil of zinc.
3:05
It's known as the mother coil.
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Approximately 25 miles of rain gutters can be made from this coil.
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Workers slit the mother coil into three.
3:17
Each coil is a foot wide.
3:20
It is now the correct width to be formed into rain gutters.
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A crane lifts one of the narrower coils over the factory floor.
3:30
Its journey is guided by the operator below.
3:35
This puts it in position to be mounted to the next machine, one that will cut it into
3:40
uniform 13 foot long strips.
3:43
That's the standard length for the rain gutters.
3:47
As the zinc uncoils, an overhead mirror provides a top view for the operator.
3:55
In quick swoops.
3:56
The blade slices the zinc sheeting to the correct length.
4:02
The zinc strips then travel through a progressively narrow channel and over a
4:07
cylinder. This rounds the profile.
4:12
More rollers, improve on the U-shape and also curl the edges of the gutters to
4:17
reinforce them.
4:21
This gives the zinc rain gutters their final shape.
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The automated profiler ejects the 13 foot long gutters onto a rounded rack.
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Then it tips to stack the gutters neatly on top of each other.
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The zinc rain gutters are ready to hang.
4:40
On site, they'll be welded together and attach to the roof with special hooks.
4:47
They should come in handy on a rainy day.
4:50
The French Basque Country is culturally quite distinct from the rest of France.
4:55
Located in the southwest bordering Spain, the region is known, among other things, for
5:00
its ham, which is salted and air cured in an old tradition passed down through generations
5:06
of Basque farmers.
5:08
There are several types of traditional Basque ham.
5:11
This one, called quinoa, is marbled with fat and has a deep, strong, fruity flavor.
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Its distinct taste and composition begin with a specific breed of pig.
5:23
The Basque Country piebald refers to the animal's skin.
5:28
This pig breed is native to the Basque region, where livestock are raised on small
5:33
farms in the valleys of the Pyrenees mountains.
5:38
Unlike commercially farmed animals, the female pigs have small litters of 6 to 9
5:43
piglets which grow up roaming and grazing along the vast mountainsides.
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On an average of two acres of land per 30 piglets.
5:53
As a result of this free range rearing, the pigs grow more slowly and become heavier than
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commercially farmed pigs.
6:02
Once the animals reach a weight of about £330, which usually takes a year to 15
6:08
months, they go to the slaughterhouse.
6:12
Each carcass is stamped with an identification number.
6:16
Traditional ham is made from the hind legs.
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After tagging the leg, a worker places it in a machine which brands the canto a symbol
6:27
into the flesh.
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Then another worker spreads dry salt on the exposed portion.
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The salt comes from Sayda debayan, a saltwater spring in a basin bordered by the
6:42
Pyrenees Mountains.
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Theodora River and the Atlantic Ocean.
6:49
Workers leave the salted ham in a cold, damp room for one day per every £2, typically
6:55
about 15 days per ham.
6:58
The salt preserves the meat.
7:00
Next, the ham undergoes a first dry curing.
7:05
It hangs on a stainless steel rack in a temperature and humidity controlled room for
7:09
seven months.
7:14
When the ham comes out of the room, it has lost about 20% of its original weight because
7:19
most of the moisture has evaporated.
7:24
A worker brushes off the surface.
7:30
And coats the exposed part of the ham with a special grease that's made out of pigs
7:35
kidneys, rice flour and water.
7:42
This grease prevents the surface from drying out and crusting during the second dry
7:47
curing. The ham now goes into a second drying room, which dries the ham in the open
7:55
air. Taking advantage of this particular geographic location, a warm southern wind
8:01
from Spain and humid air from the Atlantic Ocean to the west blow into the room through
8:07
windows. Nature does all the work.
8:11
Humans merely regulate the airflow and humidity by lifting or lowering the blinds.
8:18
In this room, the ham hangs from a wooden rather than stainless steel rack.
8:23
That's because the wood absorbs excess humidity and transfers moisture to the meat
8:28
if the air gets too dry.
8:32
As the ham dries, its flavor concentrates the Charcutier, an artisanal pork butcher,
8:39
inspects every ham carefully.
8:46
The wind that dries.
8:47
The ham carries pollen and other natural particles, which give this ham a distinct
8:52
flavor and fragrance.
8:56
The secret is slow curing until the ham reaches optimal maturity.
9:01
That takes approximately one month per £2, so the ham remains in the second drying room
9:07
for more than a year.
9:10
When the cured ham is ready, workers sprinkle it with espelette pepper, a mildly
9:15
hot pepper from the northern Basque Country.
9:19
This gives the ham a fragrance that's as appetizing as its taste.
