How It's Made

>> Narrator: THE CLAY LIQUOR JUG

IS A PRODUCT WITH AN ELICIT

PAST.

IN 19th-CENTURY AMERICA, THIS

DISTINCT STONEWARE JUG WAS USED

TO CONTAIN BACKWOODS BREW,

MOONSHINE WHISKEY THAT WAS

PRODUCED UNDER THE COVER OF

NIGHT TO AVOID SCRUTINY FROM THE

AUTHORITIES SO IT COULD BE SOLD

TAX FREE.

TODAY THEY STILL UNCORK THE

LITTLE BROWN JUG TO SERVE UP

OLD-TIME CORN WHISKEY.

REPLICAS LIKE THIS ONE ADD AN

AUTHENTIC TOUCH TO THE

TRADITIONAL BREW.

THE JUG STARTS WITH RAW CLAY DUG

OUT OF THE GROUND AND CRUSHED

INTO LITTLE PARTICLES.

THEY ALSO BREAK UP DEFECTIVE AND

DAMAGED POTTERY AND RECYCLE IT

INTO THE PROCESS SO NOTHING IS

WASTED.

NEXT, A SHAFT WITH PROTRUDING

KNIVES MIXES THE CLAY WITH WATER

AND FORTIFYING CHEMICALS.

WHEN THE CLAY REACHES A DOUGHY

CONSISTENCY, A VACUUM SUCKS OUT

THE AIR POCKETS, AND THEN

MACHINERY FORCES IT THROUGH A

DYE TO FORM A LONG LOG.

IN LOG FORM, THE CLAY IS EASIER

TO HANDLE.

THE POTTER PULLS OFF SOME

CHUNKS OF CLAY AND SHAPES THEM

INTO PATTIES.

HE PRESSES THE PATTIES INTO

MOLDS OF THE TOP AND BOTTOM

PARTS OF THE CLAY LIQUOR JUG.

HE INSERTS EACH MOLD IN A

HOLDING RING AND SPINS IT.

A WOODEN TOOL NOW SCULPTS THE

JUG'S TOP SECTION FROM THE

INSIDE.

CLAY MIGRATES UP THE WALLS OF

THE MOLD AND TAKES ITS SHAPE.

THE POTTER POKES A WOODEN DOWEL

IN THE NECK OF THE JUG TO ROUND

IT OUT.

AS TOOLS SHAPE THE LOWER BODY OF

THE LIQUOR JUG, THE POTTER

SPRAYS WATER ON THE RIM.

THIS MAKES THE RIM STICKY, WHICH

WILL ALLOW THE BOTTOM PORTION OF

THE JUG TO ADHERE TO THE TOP.

STILL IN THE MOLDS, HE PRESSES

THE TWO PARTS OF THE JUG

TOGETHER, AND THE MOISTENED CLAY

BONDS.

ONCE THE CLAY IS DRIED, THE NEXT

CRAFTSPERSON PRIES IT FROM THE

MOLDS, AND IT COMES OUT IN ONE

PIECE.

SHE REMOVES ANY UNWANTED BITS

AND TRANSFERS THE JUG TO THE

WORKBENCH.

SHE LEVELS THE LIP OF THE JUG

WITH A STICK AND SPINS THE JUG

ON A POTTERY WHEEL TO SCRAPE OFF

SURPLUS CLAY AT THE SEAM.

SHE SMOOTHS DOWN ROUGH SPOTS ON

THE EXTERIOR SURFACE WITH A WET

SPONGE.

AT THIS POINT, THE CLAY IS STILL

FAIRLY SUPPLE AND RESPONDS TO

MOISTURE.

MEANWHILE, JUG HANDLES ARE

TAKING SHAPE IN THIS TUB.

STEEL PADDLES FORCE THE CLAY

THROUGH HOLES IN THE BOTTOM,

PRODUCING RIBBONS OF CLAY THAT

WILL NOW BE SHAPED INTO CURVED

HANDLES.

THE POTTER MOISTENS ONE END OF

THE CLAY RIBBON AND PRESSES IT

TO THE NECK OF THE JUG.

SHE MUST APPLY JUST THE RIGHT

AMOUNT OF PRESSURE, OR IT WILL

FALL OFF.

SHE PULLS THE CLAY RIBBON INTO A

DISTINCTIVE CURVE AND PRESSES

THE OTHER END TO THE SIDE OF THE

JUG.

THE CURVATURE MUST BE SIMILAR

FROM JUG TO JUG, AND PRODUCING A

CONSISTENT SHAPE EVERY TIME

TAKES PRACTICE.

AT THE GLAZING STATION, AN

OPERATOR TESTS A PUMP THAT

SPURTS GLAZE UPWARDS, CREATING A

BRIEF FOUNTAIN OF GLAZE.

WITH A PADDLE, HE SWISHES THE

SOLUTION AROUND TO KEEP THE

GLAZE PARTICLES SUSPENDED.

THEN HE IMMERSES THE TOP OF THE

JUG IN THE LIQUID TO GIVE THE

CLAY LIQUOR JUG THAT FAMILIAR

TWO-TONED LOOK.

HE PUMPS GLAZE INSIDE THE JUG,

GIVING IT A LEAKPROOF LINING

THAT WILL ALLOW IT TO HOLD

LIQUIDS.

THE NEXT WORKER STAMPS PRODUCT

INFORMATION ON THE SIDE OF THE

JUG USING CERAMIC INKS.

NEXT, THEY PREPARE A DIFFERENT

GLAZE.

THE WORKER DIPS THE BOTTOM

PORTION OF THE JUG IN IT, AND IT

APPEARS TO COMPLETELY OBSCURE

THE CAREFULLY APPLIED PRODUCT

INFORMATION.

BUT WHEN THE GLAZE DRIES, IT

WILL BECOME TRANSPARENT, AND THE

STAMP WILL BE VISIBLE AGAIN.

THE NEXT WORKER SCUFFS OFF THE

GLAZE ON THE BASE TO KEEP THE

JUG FROM STICKING TO THE SHELVES

IN THE KILN.

THEY FIRE THE WHISKEY JUGS AT

AROUND 2,200 DEGREES FAHRENHEIT

FOR EIGHT HOURS.

THIS HARDENS THE CLAY AND

DEEPENS THE GLAZE.

IT'S TAKEN A TOTAL OF 19 STEPS

AND ONE WEEK TO TRANSFORM A

COUPLE OF LUMPS OF CLAY INTO A

LITTLE BROWN JUG.

AND IT'S SURE TO ADD A TOUCH OF

NOSTALGIA TO COCKTAIL HOUR.

>> Narrator: MAN CANNOT LIVE BY

BREAD ALONE.

BUT ADD A FEW SLICES OF CHICKEN

OR TURKEY DELI MEAT, AND YOU'VE

GOT A MEAL.

POULTRY DELI MEAT IS A POPULAR

ALTERNATIVE TO CORN BEEF OR

SALAMI, AND THAT'S BECAUSE IT'S

LESS FATTY ANY WAY YOU SLICE IT.

WHEN IT COMES TO MAKING DELI

MEATS, IT'S ALL IN THE

SEASONING.

FROM FIERY SOUTHWESTERN TURKEY

TO HOT-SAUCE-MARINATED CHICKEN,

THEY REALLY KNOW HOW TO SPICE IT

UP.

THEY BEGIN WITH PLENTY OF

FILTERED WATER.

IT WILL BE USED TO DISPERSE THE

SPECIALLY FORMULATED SEASONINGS.

THERE'S A DIFFERENT BLEND FOR

EVERY PRODUCT, AND THEY INCLUDE

SALT AND DIFFERENT HERBS AND

SPICES.

THEY ADD HONEY BECAUSE THIS IS A

HONEY MAPLE RECIPE.

AND WHILE THAT'S ALL BEING

MIXED, THEY CHECK THE

TEMPERATURE OF THE RAW POULTRY

TO CONFIRM IT'S IN THE SAFE

RANGE.

IF IT'S EVEN SLIGHTLY OFF,

THERE'S A RISK OF BACTERIAL

GROWTH, SO THE WHOLE BATCH WOULD

HAVE TO BE REJECTED.

BUT THIS POULTRY HAS BEEN

WELL-CHILLED.

THE STITCH PUMP MACHINE'S

LONG STEEL NEEDLES REPEATEDLY

INJECT SEASONING SOLUTIONS INTO

THE BREAST MEAT.

EXCESS LIQUID DRAINS THROUGH THE

CONVEYOR AS THE CHICKEN IS

TRANSFERRED TO A HOLDING AREA TO

MARINATE FOR AT LEAST TWO HOURS.

NEXT, NUMEROUS LUMPY ROLLERS

MASSAGE THE CHICKEN AND BREAK

DOWN FIBER TO TENDERIZE THE

MEAT.

THEN, IN A TUMBLER, METAL

PADDLES VIGOROUSLY KNEAD THE

MEAT.

THIS TENDERIZES IT EVEN MORE AND

RELEASES A NATURAL PROTEIN THAT

WILL EVENTUALLY BIND SEVERAL

BREASTS INTO ONE BIG PIECE.

MEANWHILE IN THE TURKEY KITCHEN,

WORKERS SHAPE AND SEASON

PREVIOUSLY MARINATED MEAT AND