How It's Made

Narrator: CAVIAR IS MADE

BY PROCESSING THE UNFERTILIZED EGGS OF CERTAIN SPECIES OF FISH.

FOR THOSE WHO LOVE THE TASTE BUT NOT THE PRICE,

THERE'S SIMULATED CAVIAR MADE OF KELP, A TYPE OF SEAWEED.

A FRACTION OF THE COST,

IT LOOKS, SMELLS, AND TASTES SIMILAR TO THE REAL THING.

UNLIKE FISH CAVIAR, THE SOURCE OF KELP CAVIAR IS A PLANT,

SO IT'S FAT-FREE, CHOLESTEROL-FREE,

AND HAS ZERO CALORIES.

THIS COMPANY MAKES ITS KELP CAVIAR PLAIN,

WHICH IS VEGETARIAN,

AS WELL AS IN SEVERAL FLAVORS.

KELP IS CHOCK-FULL OF VITAMINS AND MINERALS

AND IS ESPECIALLY RICH IN IODINE.

BEING A MARINE PLANT, IT'S QUITE DIFFERENT FROM LAND PLANTS

IN THAT ITS CONSISTENCY IS GELATINOUS,

WHICH MAKES IT IDEAL FOR PRODUCING LITTLE RUBBERY BALLS

THAT RESEMBLE FISH EGGS.

AT THE KELP CAVIAR FACTORY,

THEY BEGIN PRODUCTION WITH KELP THAT'S BEEN DRIED NATURALLY,

THEN GROUND INTO A FINE POWDER.

THE OTHER INGREDIENTS ARE SALT, CITRIC ACID,

AND, IF THEY'RE MAKING A FLAVORED VARIETY,

NATURAL FLAVORING IN LIQUID FORM.

THEY ADD THE INGREDIENTS ONE AT A TIME TO WATER.

THE MIXER BLENDS THEM THOROUGHLY FOR ABOUT AN HOUR,

PRODUCING A THICK, GELATINOUS LIQUID.

THEY TRANSFER THE MIXTURE INTO A POT

CONNECTED TO AN EXTRUSION MACHINE.

THE MACHINE PUMPS THE MIXTURE

THROUGH WHAT LOOKS LIKE A SHOWERHEAD,

ONLY INSTEAD OF OUTPUTTING A STEADY STREAM,

IT SQUEEZES OUT DROPLETS,

PRODUCING TINY KELP BALLS CALLED PEARLS,

WHICH LOOK EXACTLY LIKE FISH EGGS.

THE PEARLS DROP INTO A COAGULATION SOLUTION.

BESIDES PROVIDING A SOFT LANDING,

THIS SOLUTION HELPS HOLD THE PEARLS' SHAPE.

THE PEARLS ROLL DOWN A CHUTE INTO WAITING CONTAINERS.

THE WATER DRAINS OUT THE BOTTOM.

WORKERS EMPTY THE CONTAINERS INTO LARGE COLANDERS.

THEN THEY RINSE AND STRAIN THE PEARLS

TO ENSURE THEY'RE ALL A CERTAIN MINIMUM SIZE.

PEARLS THAT ARE TOO SMALL

SIMPLY FALL THROUGH THE COLANDER'S HOLES.

THEY WEIGH OUT A SPECIFIC QUANTITY

AND MIX IN AN ALL-NATURAL STABILIZER

REQUIRED TO MAINTAIN THE PEARLS' TEXTURE AND ROUND SHAPE.

THE FACTORY'S QUALITY-CONTROL LAB

TESTS A SAMPLE FROM THE BATCH

TO MAKE SURE THE pH LEVEL IS JUST RIGHT.

CAREFUL pH CONTROL, COUPLED WITH PASTEURIZATION,

IS WHY THIS PRODUCT DOESN'T REQUIRE ANY PRESERVATIVES.

AT THE PACKAGING STATION, WORKERS FILL GLASS JARS,

THEN TWIST A TIN LID ONTO EACH ONE.

THEN THE JARS GO INTO A PASTEURIZATION MACHINE.

IT HEATS THE CAVIAR TO A HIGH TEMPERATURE

FOR A SPECIFIC PERIOD OF TIME,

WHICH KILLS OFF ANY BACTERIA.

THIS ENSURES A TWO-YEAR SHELF LIFE WITHOUT REFRIGERATION.

ONCE OPENED, THE PRODUCT STAYS FRESH IN THE FRIDGE

FOR THREE MONTHS.

AFTER PRINTING EACH LID WITH A LOT NUMBER

FOR TRACKING PURPOSES,

ALL THAT'S LEFT TO DO IS DRESS THE JAR IN A CARDBOARD LABEL.

KELP CAVIAR CONTAINS NO ARTIFICIAL COLORS OR FLAVORS.

UNLIKE CERTAIN TYPES OF CAVIAR,

IT DOESN'T BLEED COLOR TO THE SURROUNDING FOOD,

EVEN WHEN BAKED.

AND WHILE REAL CAVIAR

IS TYPICALLY EITHER BLACK STURGEON ROE OR RED SALMON ROE,

KELP CAVIAR COMES IN ADDITIONAL FLAVORS,

SUCH AS TRUFFLE, COGNAC, AND WASABI.

Narrator: LUXURY SAILBOATS EVOKE THOUGHTS OF FREEDOM

AND SUNSETS ON THE OCEAN,

BUT IN THE FACTORY, IT'S ALL ABOUT HARD WORK,

BECAUSE LUXURY SAILBOATS ARE STILL MOSTLY MADE BY HAND.

JUST A FEW HUNDRED UNITS ARE PRODUCED EVERY YEAR,

EACH BOAT REQUIRING UP TO 3,000 HOURS OF WORK.

SAILBOATS HAVE COME A LONG WAY

SINCE THEY WERE FIRST USED ON THE NILE RIVER

SOME 6,000 YEARS AGO.

THESE LUXURY SAILBOATS ARE DESIGNED

USING COMPUTER-AIDED DESIGN SOFTWARE,

WHICH ALLOWS THE ENGINEERS TO OPTIMIZE THE HULL SHAPE

FOR STABILITY AND SPEED

BEFORE ACTUALLY BUILDING THE BOAT.

THEY BUILD THE HULL FROM FIBERGLASS,

WHICH COMES AS KNITTED FABRIC

AND AS MATS OF RANDOM STRANDS PRESSED TOGETHER.

THESE TWO LAYERS ARE HYBRIDIZED

TO FORM A LIGHT BUT VERY STRONG MATERIAL.

HUGE MOLDS ARE USED TO BUILD THE HULL OF THIS 45-FOOT BOAT.

WORKERS UNROLL THE FIBERGLASS AND SPRAY IT WITH RESIN.

THEN THEY UNROLL THE NEXT LAYER OF FIBERGLASS,

WHICH OVERLAPS THE PREVIOUS ONE,

MAKING FOR A VERY STRONG CONSTRUCTION.

THE RESIN HARDENS AS IT CURES.

BOAT PARTS ARE SO LARGE AND HEAVY

THAT THEY MUST BE MOVED WITH CRANES.

THIS PART IS CALLED THE TRANSOM.

IT WILL BE ATTACHED TO THE HULL WITH FIBERGLASS

WHILE IT AND THE HULL ARE STILL IN THE MOLDS,

CREATING WHAT'S CALLED A MONACO CONSTRUCTION.

THIS HULL SURFACE WILL RECEIVE THE STRUCTURAL GRID,

WHICH WILL SUPPORT THE ENGINE, MAST, FUEL TANK,

AND WATER TANKS.

MEANWHILE, CARPENTERS FASHION THE WOOD COMPONENTS.

THIS DOOR IS MADE OF SOLID TEAK,

A DURABLE HARDWOOD THAT DOESN'T ROT.

THE WOOD PARTS ARE THEN PUT INTO A CURING OVEN

AT 122 DEGREES FAHRENHEIT.

AIR IS CIRCULATED TO CURE THE VARNISH IN ABOUT 11 MINUTES.

BRIGHT LIGHTS ALSO HELP CURE THE VARNISH.

IT'S TIME TO PUT THE DIVISIONS IN PLACE.

THE HULL LINER HAS SLOTS

DESIGNED TO RECEIVE THE VARIOUS WOOD COMPONENTS.

EACH PART IS FITTED TWICE --

FIRST TO CHECK THE FIT,

THEN PERMANENTLY WITH HIGH-STRENGTH ADHESIVE.

IT'S TIME TO INSTALL THE ENGINE.

WITH ITS 54 HORSEPOWER, THE BOAT CAN CRUISE AT 8 KNOTS,

EVEN WHEN THE WIND ISN'T BLOWING.

THIS STAINLESS-STEEL STRUCTURE SERVES TO REINFORCE THE RUDDER.

IT'S ATTACHED WITH EPOXY GLUE.

AFTER CLOSING THE RUDDER MOLD, THEY INSERT A PAPER CONE

TO COMPLETELY FILL THE RUDDER WITH URETHANE FOAM.

THE FOAM EXPANDS AS IT CURES.

THEY FINISH BY CAREFULLY SANDING THE EDGES OF THE RUDDER,

WHICH IS NOW ATTACHED UNDERNEATH THE HULL.

TO BUILD THE BOAT'S DECK,

MOLDS FOR THE TOP AND BOTTOM PARTS MUST BE ALIGNED.

HIGH-STRENGTH BONDING MATERIAL IS APPLIED AT SPECIFIC SPOTS.

THE TWO MOLDS ARE CAREFULLY FITTED TOGETHER.

WHEN THE PARTS ARE PERFECTLY JOINED, THE MOLD IS REMOVED.

THE DECK IS NOW READY TO BE FITTED ON THE BOAT.

WORKERS CAREFULLY LINE EVERYTHING UP.

LUXURY SAILBOATS HAVE ENOUGH SPACE FOR MANY ROOMS

AND CAN BE CUSTOMIZED WITH APPLIANCES AND ELECTRONICS

THAT SUIT THE CUSTOMER'S NEEDS AND TASTES.

ALL THAT'S NEEDED NOW IS A DIP IN THE TEST POOL

FOR A CHECK OF THE ENGINE, GENERATOR,

AND OTHER MECHANICAL SYSTEMS.

AFTER ABOUT THREE MONTHS OF HARD WORK,

THE BOAT IS NOW READY TO SET SAIL FOR OFFSHORE ADVENTURES.

Narrator: DENTAL WORK DATES BACK TO ANCIENT EGYPT,

WHEN PEOPLE USED ANIMAL TEETH AND PIECES OF BONE

TO REPLACE THEIR OWN TEETH.