Ep 1. Garden Forks; English Toffee; Paint Chip Cards; Bundt Pans

In season 12 episode 1 of How It's Made, viewers are taken behind the scenes to see how ordinary objects like garden forks, English toffee, paint chip cards, and bundt pans are manufactured. The episode kicks off with a look at the production of garden forks, which are hand tools used for digging soil and moving compost. The process involved in making these forks begins with the cutting of steel bars into various sizes and shapes using a plasma cutter. The bars are then heated in a furnace to make them more ductile, before being shaped using a press machine. After heat treatment and surface finishing, the garden forks are painted and polished before being assembled with handles.

Next up is a look at the making of English toffee, which is a candy made from sugar, butter, and milk. The process begins with the cooking of sugar and water to create a solution, which is then heated until it reaches the soft-crack stage. Butter and milk are added, and the mixture is boiled until it reaches the hard-crack stage. The toffee is then cooled and broken into pieces, before being coated with chocolate or nuts.

The episode then moves on to the production of paint chip cards, which are used by designers and homeowners to choose colors for their walls. The process involved in making these cards includes the printing of large sheets of paper with grids of different colors. These sheets are then cut into smaller squares, which are punched with holes and sorted into different shades of the same color. The cards are then assembled by placing the squares onto a cardboard backing, which is then laminated to protect them from wear and tear.

Finally, viewers get a glimpse into how bundt pans are manufactured. These pans are used for baking cakes and feature a distinctive ring shape. The process involved in making these pans begins with the casting of aluminum or steel into the desired shape. The pan is then trimmed and finished using a lathe, before being polished and coated with a non-stick surface. The pans are then ready to be packaged and shipped out to stores and baking enthusiasts.

Overall, this episode of How It's Made offers a fascinating look into the manufacturing processes behind some everyday objects. From the hand tools we use in our gardens to the sweet treats we enjoy as snacks, viewers get a glimpse into the intricate processes that take raw materials and turn them into finished products.