You must have noticed when picking up change at the supermarket that we're getting some new sports-themed coins. That's why today, Manual do Mundo is here in Rio de Janeiro to see the factory that everyone dreams of having in the backyard, but can't. The Mint of Brazil.
We will see how our rich money is made and this is also where the medals for 2016 will be made. Let's go! The mint is over three hundred years old and is located in an industrial complex in the West Zone of Rio de Janeiro.
The company has three factories: a print shop that makes passports, stamps and other products, a coin factory and a banknote factory. And that's where we're going first. This one is the paper that arrives at the mint.
It is no longer a common paper. It's a prepared paper. If you held up a sheet like this to the light, you would already be able to see the watermarks, which are those thinner and thicker parts of the paper that form an impression.
This pile of paper, which is already colored and with the magnetic wire, goes to an offset printer, which works in a similar way to a magazine printer. But a common printer usually creates images by creating only four colors. Here, banknotes come in twenty-seven different colors, and printing is done on both sides of the paper at the same time.
These are the machines that put the invisible inks on the paper that can only be seen using ultraviolet light and those micro-prints that we can only understand using a magnifying glass. The notes are left to dry for seventy-two hours and then go to a machine that makes a type of impression called calcography. It is the one who puts the vat in high relief, that is, the ink is very thick on the paper, and you can see it when you pass your hand.
On a counterfeit banknote, the forger, it cannot make this relief in the calcography printing, right. So, in order to identify a banknote, it is essential to have this high relief. Not having the high relief, it can be said that this banknote is certainly fake.
When the printing is finished, the banknotes go for a visual check. It is a team of well-prepared women who are able to see very small printing defects. Only after this fine-tooth comb are the banknotes numbered, which is a kind of ID.
And it is this numbering that will guarantee the control and security of the ballots. Then, finally, the notes will fall apart. First, a guillotine removes the edge of the paper, and then the banknotes are separated and packaged at the same time.
In the case of one hundred thousand reais notes, it is organized in ten thousand Reais packages and then packed in a hundred thousand Reais package that goes inside a box. If you won one million in a game show, it would be more or less a package like this one that you would take home. This here has one million six hundred thousand Reais in one hundred Reais banknotes.
It is all already numbered, packaged and ready to be sent to the Central Bank. We just saw how banknotes are made, let's see how coins are made. What's enough to make the coin are these little pieces of metal.
This one, you must have guessed, is a real one coin. It has a stainless steel core and the outside is stainless steel with a bronze coating. This one is completely bare.
There's nothing printed on it yet. It will enter through this machine, and the minting will take place inside, a kind of stamp that will hit very hard on top of this here. Inside the machine, these three pieces here are what prints the coins.
Two stamps called imprints, and a ferrule, which is this metal ring. Each stamp has a coin side, one for Heads and one for Tails. And the ferrule serves to mark the edges and make sure the coin is the right size.
Here you can see that sports-themed coins are already being produced. When the metal discs enter the machine, it has the cleats at the bottom and the top, and the ferrule around it. Then a seventy-five ton press makes the metal knead and fit into the die and ferrule.
And that's how a metal plate turns into a coin. Just take a look at what comes out of the coin minting machine! It is warm because it has just been pressed.
What prevents a person from taking a piece of metal and making a coin at home? Why is it difficult, and what guarantees that no one will counterfeit a coin? First of all, this product, the Brazilian currency, is rich in details.
It would be very difficult for you to manufacture a matrix with this same level of complexity. It needs extremely expensive machinery. Which is what discourages the counterfeiter's investment.
When the coins are ready, it is counted by two different sensors, and then packaged. The one-real coins are placed in bags of fifty coins, which go inside a larger bag with ten bags each. Each bag that is passing here has five hundred reais in currency.
One way to count how many coins you have is to weigh them. It has to be three kilos, five hundred and twenty grams. And it's this machine that does it.
So what I'm going to do is try to sabotage a bag by putting in a few extra coins. Oh, it's passing by. I'll add fifty more coins, let's see what happens.
The bag of coins was rejected. These bags get a stamp, and then a robot places eight of each inside a cardboard box. I'm sitting here on the final product of coin minting.
It's this pallet, the pallets of one-real coins have one hundred and twenty-eight thousand coins of one real, which go to the Central Bank. There are thirty-two of these boxes inside the pallet, and each box holds four thousand reais and weighs thirty kilos. You can find more videos like this one at Manual do Mundo.
If you also want to visit the Mint of Brazil, the visit is allowed. All you have to do is go to their website and register. Once a week a bus arrives here full of people wanting to know how banknotes and coins are made.
This video is part of the project "All Brazil play", if you want to know the project or see other videos I'm leaving the links below.