Ep 12. Aluminum Screw Caps, Chocolate, Pills, Pasta

How It's Made is a documentary-style television show that explores the manufacturing processes of various everyday objects and goods. Season 1, episode 12 delves into the creation of aluminum screw caps, chocolate, pills, and pasta.

The episode starts by showcasing how aluminum screw caps are made. Viewers are taken behind the scenes to a factory where workers are demonstrated molding metal into cap shapes. The viewer is shown a machine where a roll of flat aluminum is fed into a machine where the caps are stamped out of the metal sheet. The individual caps are then coated with a food-safe polymer and baked to ensure they have a protective layer that stops food or drink from contamination.

The show then shifts gears to look at the process of making chocolate. Viewers are given a tour of a chocolate factory that explains the various processes that chocolate goes through from bean to bar. First, the cocoa beans are roasted, and the outer shell is removed. Then, the beans are crushed to create a paste called cocoa mass. The machine separates the heavy cocoa butter, and the cocoa solids then processed into cocoa powder. Sugar and milk powder are then added into the mix to create chocolate. The chocolatey mixture is then transferred to a conche, which grinds and mixes the chocolate to create the smooth texture and flavors we know and love.

The episode then explores how pills are made. A factory that produces pills is shown, and viewers are given a closer look at how tablets are formed using a process called compression. The powders that make up the pills are mixed thoroughly, and the blend is processed in an encapsulation machine. Hardened forms of the powdered medications are then transferred to a tablet making machine where compression molding happens. The compressed powder is then released from its molds, dried, and coated to provide a nicely finished product.

Finally, the show takes the viewer through the production of pasta. It begins with the creation of semolina - a flour made from hard durum wheat. Semolina is mixed with water to an allergen-safe dough that is forced through small holes to make pasta shapes. The noodles then dry in a low-temperature room. The final step involves carefully packaging the pasta in boxes to prevent breakage and make storage easier.

Overall, How It's Made season 1 episode 12 showcases the manufacturing process of four different items that we use regularly. From aluminum screw caps to chocolate and pills to pasta, viewers are taken behind the scenes of these factories to see the various processes that go into making these items. The attention to detail and careful quality control measures used in producing these everyday goods are demonstrated, giving the viewer a unique look at the inner workings of different industries.