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Minimizing Waste in Press Brake Operations

January 22, 2025

Imagine a world where every bend in a sheet of metal is precisely calculated to maximize material usage and minimize waste. In the high-stakes realm of press brake operations, achieving this level of efficiency can significantly impact both profitability and sustainability. But how can you master the art of optimizing bending sequences, selecting the right materials, and maintaining tools to perfection? This article dives deep into the strategies that can transform your press brake operations. From leveraging cutting-edge technologies like IoT and CNC controls to implementing sustainable practices, we’ll guide you through best practices and innovative solutions. Ready to revolutionize your approach and cut down on waste? Let’s get started.

Optimizing Bending Sequences for Material Utilization Efficiency

Automated Sequencing

Automated sequencing software, such as SigmaBEND, can greatly improve the efficiency of bending operations. This software analyzes multiple parts to determine the optimal bending sequence, minimizing tool changes and reducing redundant activities. By performing multiple bends in a single station setup, machine throughput and shop capacity are increased, leading to reduced waste from unnecessary tool swaps and setups.

Optimal Tooling Selection

Selecting the appropriate tooling is vital for achieving precise and consistent bends. The tooling, which includes a punch and die, should be chosen based on the material type, thickness, and specific bend requirements. Choosing the right punch and die combination ensures accurate bends and efficient material use. Proper tooling selection helps reduce the need for rework and minimizes material waste.

Bending Sequence Planning

Planning the bending sequence carefully is essential to avoid interference between bends and ensure the part is formed correctly. For complex parts that require multiple setups, a well-thought-out sequence can achieve the desired shape with minimal waste. Factors such as material properties, bend radius, and punch angle should be considered to ensure accurate and consistent bends. This planning helps in avoiding errors and reducing material waste.

Material-Specific Settings

Adjusting the press brake settings according to the material being used is crucial. CNC-controlled back gauges and dynamic pressure control can maintain consistent pressure and accurate bends, even with varying material properties. This consistency helps prevent over-bending or under-bending, thereby reducing material waste. Ensuring that the press brake settings are optimized for the specific material can significantly enhance bending efficiency.

Energy Efficiency and Machine Configuration

Optimizing machine settings to match the job requirements can help reduce unnecessary energy usage and material waste. Modern press brakes with energy-saving features, such as regenerative braking systems and variable speed drives, can minimize energy consumption. Adjusting the tonnage and stroke length for each bend prevents the machine from using more energy than necessary, contributing to precise bends and less material waste.

Precision Bending Techniques

Utilizing precise bending techniques, such as air bending, bottoming, and coining, can help achieve accurate and consistent bends. When applied correctly, these techniques reduce the likelihood of errors and rework, thereby minimizing material waste. For example, the bottoming technique is particularly useful for achieving tight bend radii and precise angles with reduced springback, which is critical in minimizing waste.

Reduced Material Waste Through CNC Automation

CNC-controlled press brakes produce less material waste compared to other fabrication methods, as their automation and precision ensure accurate bending, cutting, or curving of sheet metal. The automation and precision of CNC processes ensure that sheet metal is curved, cut, or bent into accurate pieces, following a well-set-up procedure that minimizes waste and shortens manufacturing lead times. Implementing CNC automation can significantly enhance material utilization and reduce waste in press brake operations.

Best Practices for Tool Maintenance and Storage

Cleaning Tools

Regularly cleaning press brake tools helps maintain their performance and extend their lifespan. Accumulation of dust, debris, and metal shavings can lead to tool damage and affect the quality of bends. Here are some best practices for cleaning tools:

  • Daily Cleaning: Use a clean, lint-free cloth to wipe down the tools and press brake surfaces daily. This helps prevent the build-up of contaminants that can cause wear and tear.
  • Debris Removal: Utilize compressed air to blow out any debris from hard-to-reach areas, and ensure that all metal shavings and dust are removed to avoid interference with tool operation.
  • Inspection During Cleaning: While cleaning, inspect the tools for any signs of wear, nicks, or chips. Early detection of damage can prevent further deterioration and ensure consistent bending quality.

Lubrication Schedules

Proper lubrication is crucial for the smooth operation of press brake tools and to prevent corrosion. Establishing a regular lubrication schedule ensures that all moving parts remain in optimal condition. Consider the following guidelines:

  • Routine Lubrication: After each use, apply a thin layer of oil to the tools. This helps prevent rust and ensures smooth operation. Use high-quality lubricants recommended by the tool manufacturer.
  • Specific Areas: Focus on areas prone to friction, such as hinges, slides, and clamping mechanisms. These areas require consistent lubrication to maintain their functionality.
  • Long-Term Storage: For tools that will not be used for an extended period, apply a preservation lubricant to protect them from moisture and corrosion. Ensure that tools are stored in a dry, climate-controlled environment to prevent degradation.

Tooling Organization and Storage

Organizing and storing press brake tools efficiently is vital to maintain their condition and ensure quick access during operations. Implementing a systematic storage solution can significantly enhance productivity and reduce downtime.

  • Tool Racks and Cabinets: Invest in durable tool racks, strong drawer systems, or custom cabinets. These storage solutions should be designed to protect tools from damage and keep them easily accessible.
  • Visual Management: Use color-coding, labels, and pictograms to identify tool locations quickly. This reduces the time spent searching for tools and ensures that each tool is returned to its designated spot after use.
  • Modular Storage Units: Choose modular storage units that can be reconfigured as tooling needs change. Ensure these units are stable, lockable, and portable if necessary, to provide flexibility in the workshop.

Tool Care and Protection

Proper care and protection of press brake tools are essential to maintain their performance and longevity. Implement the following practices to ensure tools remain in top condition:

  • Regular Cleaning: Clean tools regularly to remove dust and debris. After cleaning, apply a thin layer of oil to prevent corrosion. Handle tools with gloves to avoid transferring oils from your hands to the tool surfaces.
  • Non-Porous Storage: Store tools in cabinets made of non-porous materials to protect against moisture and corrosion. Use silica gel packets in storage areas to keep the environment dry, especially in regions with high humidity.
  • Preservation Lubricants: For long-term storage, apply preservation lubricants to tools to prevent corrosion and degradation. Ensure tools are stored in a dry, temperature-controlled environment to maintain their integrity.

Efficient Tool Utilization

Optimizing the use of press brake tools can enhance bending quality and reduce material waste. Employ dedicated tooling and specialized aids to achieve precise bends and minimize scrap.

  • Dedicated Tooling: Invest in dedicated tools for specific bending applications. Using the right tool for the job ensures consistent bending quality and reduces material waste.
  • Bend Aids: Utilize specialized bend aids such as finger stops, backstops, and radius gauges. These aids help in achieving accurate bends and minimize scrap due to operator error.
  • Tool Utilization Planning: Plan the use of tools effectively to avoid unnecessary tool changes and setups. This improves efficiency and reduces the potential for tool damage.

Continuous Improvement

Regularly reviewing and improving tool maintenance and storage practices can lead to better efficiency and reduced waste in press brake operations.

  • Data Collection: Collect data on tool performance and maintenance activities to identify improvement areas and implement corrective actions.
  • Training: Ensure that all operators are trained in proper tool maintenance and storage practices. Well-trained operators can handle tools more effectively, reducing the risk of damage and ensuring consistent quality in bending operations.

By adhering to these best practices, manufacturers can maintain their press brake tools in optimal condition, reduce material waste, and enhance overall operational efficiency.

Selecting the Right Materials for Press Brake Operations

Material Thickness

Choosing the correct material thickness is crucial for efficient press brake operations. Thicker materials require higher tonnage and more robust tooling, while thinner materials need precise handling to avoid deformation.

  • Gauge Measurement: Understanding the gauge of the metal is essential. Thicker gauges (lower numbers) require more force and sturdier tools, whereas thinner gauges (higher numbers) are more prone to bending errors if not handled correctly.
  • Bend Radius: The material thickness directly impacts the bend radius. Thicker materials necessitate larger bend radii to prevent cracking and maintain structural integrity.
  • Stress and Strain: Consider the stress and strain characteristics of the material. Thicker materials can withstand higher stress but may also require more careful handling to avoid strain-related issues such as cracking.

Energy-Efficient Machines

Energy-efficient press brake machines play a vital role in reducing operational costs and minimizing waste. These machines are designed to optimize energy consumption while maintaining high precision and efficiency, utilizing features like variable speed drives that adjust motor speed to match load requirements.

  • Regenerative Braking Systems: These systems capture and reuse energy during deceleration, further enhancing energy efficiency.
  • Precision Control: Energy-efficient machines often feature advanced control systems that ensure precise bending, reducing the need for rework and minimizing scrap.

Optimal Materials for Tooling

Choosing the right materials for press brake tooling is essential for achieving high-quality bends and extending tool life.

  • Tooling Materials: Materials like high-strength hardened steels, Chromoly, tungsten carbide, and high-speed steel (HSS) are commonly used for their durability and wear resistance.

Material Properties

Understanding the properties of the materials used in press brake operations is crucial for selecting the appropriate tooling and ensuring high-quality bends.

  • Hardness: High hardness materials, such as HSS and carbide, resist wear and maintain sharp edges, making them ideal for precision tasks.
  • Toughness: Materials like low alloy tool steels and Chromoly steel offer excellent toughness, preventing die cracking and deformation under high stress.
  • Wear Resistance: Tool steels and carbide materials provide significant wear resistance, balancing hardness and toughness for various high-production environments.

Compatibility with Metal Types

The type of metal being processed significantly influences the choice of tooling and operational settings.

  • Aluminum: Requires tooling with sharper angles and radii due to its malleability and tendency to wrap around the tool.
  • Carbon Steel: Demands tooling that can handle high stress and pressure, often with broader angles and larger radii.
  • Stainless Steel: Requires tooling capable of managing its hard nature without compromising the bend angle or causing surface damage.

Calculating Tonnage and Working Length

Accurately calculating the necessary tonnage and ensuring the working length of the machine are crucial steps in minimizing waste and ensuring consistent bends.

  • Material Considerations: Factors such as material type, thickness, and bend length are essential when calculating tonnage, ensuring the machine can provide the necessary force without causing excessive wear.
  • Machine Compatibility: Ensure the press brake machine’s working length is adequate for the metal being bent, maintaining consistency across bends and reducing material waste.

Tooling Flexibility and Maintenance

Flexibility in tooling and regular maintenance are essential for efficient press brake operations.

  • Tooling Versatility: Flexible tooling allows operators to utilize the full range of the press brake machine, accommodating various bending tasks with minimal tool changes.
  • Regular Inspections: Conduct regular inspections for wear and damage, ensuring tools are clean and stored properly to prevent corrosion and extend tool life.

Precision and Tolerance

Selecting tools that can achieve the necessary accuracy and tolerance levels is paramount for high-quality production.

  • Precision Tooling: Required for projects demanding tight tolerances, precision tooling helps avoid minor deviations that can affect the functionality or aesthetics of the piece.
  • Consistency: Ensuring consistent accuracy in bends reduces the need for rework and minimizes material waste.

Calibration and Setup

Proper calibration and setup of the press brake machine are essential for accurate bending and minimizing material wastage.

  • Bend Deduction Calculations: Accurate bend deduction calculations and consideration of the K factor are critical for precise bends.
  • Setup Accuracy: Ensuring the machine is correctly set up for the specific material and bend requirements helps reduce errors and material waste.

Implementing Sustainable Practices in Press Brake Operations

Energy Efficiency and Optimization

Optimizing energy use is essential for sustainable press brake operations. Several strategies can help achieve significant energy savings:

  • Variable Frequency Drives (VFDs): VFDs can reduce energy consumption by up to 50% by adjusting motor speed to match the specific requirements of each operation. This ensures that energy is only used as needed, avoiding wastage.
  • Energy Recovery Systems: Using systems that capture and reuse energy from the braking process can further reduce energy use.
  • Optimized Settings: Fine-tuning press brake settings such as tonnage, speed, and dwell time can lead to substantial energy savings. Ensuring that these settings are precisely matched to the material and bending requirements helps in minimizing unnecessary energy use.

Material Waste Minimization

Reducing material waste through effective planning and material selection is crucial for sustainable operations:

  • Bending Sequence Planning: Carefully planning the bending sequence to consider bend allowances, bend radii, and flange lengths optimizes material utilization and reduces scrap rates.
  • Material Selection: Choosing materials with the appropriate thickness, strength, and bendability for the intended application avoids over-specifying material thickness and reduces waste.
  • Nesting Software: Utilizing nesting software to optimize the arrangement of parts on the material blank can significantly reduce material waste and increase production efficiency.

Scrap Management and Recycling

Managing and recycling scrap effectively is vital for reducing environmental impact and promoting sustainability:

  • Closed-Loop Scrap Systems: Implementing closed-loop systems that automatically convey scrap metal to recycling or collection areas eliminates manual handling, reduces labor costs, and prevents scrap from entering landfills.
  • Comprehensive Recycling Programs: Establishing programs for recycling scrap metal and consumables, such as hydraulic oil and filters, ensures these materials are diverted from landfills and reused in new products.

Environmental Sustainability

Adopting measures to minimize the environmental impact of press brake operations is crucial for sustainable manufacturing:

  • Noise and Emission Control: Using noise enclosures, dust extraction systems, and emission control devices helps minimize the environmental impact of noise, dust, and emissions generated by press brakes.
  • Water Conservation: Implementing closed-loop cooling systems or efficient cooling towers reduces water consumption and minimizes wastewater discharge.
  • Environmentally-Friendly Fluids: Using bio-based hydraulic fluids lowers toxicity and air pollution, contributing to a healthier environment.

Operational Efficiency and Training

Ensuring operational efficiency and thorough training for operators can significantly reduce waste and improve sustainability:

  • Process Optimization: Adjusting press brake parameters such as bending speed and pressure to minimize material damage and scrap is essential. Continuous analysis and refinement of the bending process through data collection and corrective actions help identify areas for waste reduction.
  • Operator Training: Thoroughly training operators ensures accurate and efficient bending, reducing scrap due to mishandling and ensuring consistent part quality. Well-trained operators are crucial for maintaining high productivity and minimizing material waste.

Technological Integration

Incorporating advanced technologies can enhance press brake efficiency and sustainability:

  • IoT Technology: Integrating IoT for predictive diagnostics helps monitor machine performance, alert operators to potential issues, and ensure consistent productivity while reducing maintenance costs.
  • Energy-Efficient Press Brakes: Investing in energy-efficient press brakes, such as electric servo-driven models, which consume less energy than hydraulic counterparts, further enhances energy savings and reduces operational costs.

By implementing these sustainable practices, manufacturers can significantly reduce their environmental footprint, optimize energy efficiency, and minimize waste, ultimately promoting sustainability in press brake operations.

Technological Upgrades for Press Brake Efficiency

IoT Technology and Predictive Diagnostics

Integrating Internet of Things (IoT) technology into press brakes enables real-time monitoring and predictive diagnostics. Sensors embedded within the machinery collect data on performance metrics, such as pressure, temperature, and cycle times, which is then analyzed to predict potential issues before they lead to downtime. This proactive approach ensures consistent productivity. By receiving alerts on maintenance needs and operational anomalies, operators can address problems promptly, reducing unexpected breakdowns and maintenance costs.

CNC Controls

Computer Numerical Control (CNC) systems significantly enhance the precision and efficiency of press brake operations. CNC technology automates the bending process, ensuring each bend is made to exact specifications. This automation reduces the likelihood of errors, minimizes the need for rework, and lowers material waste. CNC press brakes can store multiple programs, allowing for quick setup changes and increased flexibility in production. Features like automatic crowning and angle correction enhance bending accuracy and consistency.

Automated Tool Loading

Automated tool loading systems streamline the process of changing press brake tooling, reducing setup time and enhancing productivity. These systems automatically select and position the necessary tools based on the programmed bending sequence, eliminating manual handling and potential errors. Automated tool loading ensures the correct tools are used, maintaining bending quality and preventing damage to tools and workpieces.

Modern Control Upgrades

Upgrading the control systems of older press brakes can bring significant improvements in performance and efficiency. Modern control systems provide enhanced accuracy and productivity, making older machines operate similarly to new models. Upgrades may include remachining components to achieve better parallelism and precision, leading to more accurate parts and increased operational efficiency. These upgrades also often include user-friendly interfaces and advanced software capabilities, simplifying machine operation and programming.

High-Quality Tooling and Specialized Tools

Investing in high-quality, dedicated tooling for specific bend applications is crucial for optimizing bending quality and reducing material waste. High-quality tools, made from durable materials like hardened steel or carbide, ensure consistent performance and longevity. Specialized tools, such as finger stops, backstops, and radius gauges, facilitate accurate bending by providing precise positioning and support, minimizing operator errors and scrap rates.

Springback Compensation and Parameter Adjustment

Springback, the elastic recovery of material after bending, can lead to inaccuracies if not properly managed. Advanced press brakes incorporate springback compensation features, automatically adjusting the bend to achieve the desired final angle. Additionally, operators can fine-tune parameters such as bending speed and pressure to optimize the bending process for different materials, minimizing material damage and reducing waste. Experimenting with these parameters helps identify the optimal settings for each job, ensuring high-quality results.

Energy-Efficient Machines

Energy-efficient press brakes, such as electric servo-driven models, offer significant reductions in operational costs. These machines consume up to 50% less energy than traditional hydraulic models and often include features like regenerative braking systems that further enhance energy savings. By using energy-efficient machinery, manufacturers can lower their environmental impact while maintaining high precision and productivity.

Continuous Improvement and Training

Ongoing training and continuous improvement initiatives are vital for maintaining high efficiency in press brake operations. Thoroughly trained operators are better equipped to handle the machinery, reducing scrap and ensuring consistent part quality. Continuous analysis of the bending process, coupled with data collection and corrective actions, helps identify areas for improvement and implement effective waste reduction strategies. Regularly updating training programs and incorporating feedback from operators ensures best practices are followed. This leads to sustained operational efficiency.

Training Operators for Accurate Bending

Operator Expertise and Training

Operators must receive thorough training on the setup, operation, and maintenance of the press brake. This training should cover both theoretical knowledge and practical skills. Understanding the nuances of working with different materials, their properties, and the importance of precision in the bending process is crucial.

Theoretical Training

Operators should understand the properties of various materials, including aluminum, carbon steel, and stainless steel. This includes knowing how different materials respond to bending forces and how to adjust settings accordingly. Training should cover different bending techniques such as air bending, bottoming, and coining, each with its specific applications and advantages. Additionally, operators need to understand how materials tend to return to their original shape after bending and how to adjust for this to achieve accurate bends.

Practical Training

Operators need hands-on training in setting up the press brake, including selecting the appropriate tooling, calibrating the machine, and programming it for specific jobs to ensure the machine is prepared correctly for the material type, thickness, and desired bend angle. Training should include the use of precision measurement tools such as protractors, angle finders, and laser-based systems to verify the accuracy of each bend and ensure that deviations are caught and corrected early. Operators should also learn how to establish benchmarks and make precise adjustments to maintain bending accuracy, including calibrating pressure settings and ensuring the ram and die are perfectly aligned.

Precision Measurement and Inspection

Regular inspection during production is crucial for maintaining bending accuracy, and operators should be trained to perform continuous checks to catch deviations early and make immediate corrections. Operators should follow a structured inspection protocol, using precision tools to measure angles and dimensions of bends. This helps in maintaining consistency and quality throughout the production process. Training should emphasize the importance of taking corrective actions based on inspection results, enabling operators to adjust machine settings or tooling to correct any identified issues promptly.

Material Handling and Optimization

Effective material handling and optimization are key to reducing waste and improving efficiency.

  • Bending Sequence Planning: Operators should be trained to plan the bending sequence carefully, considering bend allowances, bend radii, and flange lengths. This helps in optimizing material utilization and reducing scrap rates.
  • Material Selection: Training should include guidelines on selecting materials with suitable thickness, strength, and bendability for the intended application. Avoiding over-specification of material properties can lead to significant waste reduction.

Use of Specialized Tools and Technology

Operators should be familiar with specialized tools and modern technologies that facilitate accurate bending.

  • Specialized Bend Aids: Tools such as finger stops, backstops, and radius gauges help achieve precise bends and minimize scrap due to operator error.
  • CNC Controls and Dynamic Pressure Systems: Training on CNC-controlled back gauges and dynamic pressure control systems can help operators produce complex parts with multiple bends accurately and efficiently. This reduces the potential for error and waste.

Continuous Improvement and Quality Assurance

Ongoing training and continuous improvement are essential for maintaining high standards in press brake operations.

Operators should learn to gather and analyze data from bending operations to find areas for improvement. Implementing corrective actions based on this analysis helps in refining the bending process. Training should include establishing and maintaining consistent inspection protocols to verify part quality during and after production. This ensures that any deviations are promptly addressed and corrected.

Sustainable Practices

Training should also emphasize sustainable practices to reduce environmental impact and enhance corporate responsibility.

  • Recycling and Waste Management: Operators should be trained on recycling scrap material and managing waste effectively. This includes understanding how to segregate and recycle materials to minimize landfill contributions.
  • Energy-Efficient Operations: Emphasizing the use of energy-efficient bending equipment and practices helps reduce energy consumption and operational costs.

By focusing on these aspects, manufacturers can ensure that their operators are well-equipped to perform accurate bending operations while minimizing material waste, thereby enhancing productivity, efficiency, and sustainability.

Frequently Asked Questions

Below are answers to some frequently asked questions:

How can I optimize the bending sequence to minimize material waste in press brake operations?

To optimize the bending sequence and minimize material waste in press brake operations, focus on precision settings, automated sequencing, and appropriate tool selection. Ensure accurate die and punch dimensions, adjust punch depth, and use CNC controls for precise programming. Implement software for group programming to reduce tool changes and enhance throughput. Maintain machine accuracy with proper ram and frame alignment and advanced control systems. Select compatible materials and tools based on material properties and bend specifications. These strategies, as discussed earlier, enhance efficiency and reduce waste, contributing to more sustainable press brake operations.

What are the best practices for maintaining and storing press brake tools to reduce waste?

To minimize waste in press brake operations through effective tool maintenance and storage, implement daily cleaning and inspection routines to remove debris and check for tool wear. Utilize systematic storage solutions like custom racks and cabinets to keep tools organized and protected from damage and corrosion. Maintain a structured schedule for regular cleaning, lubrication, and inspection, and ensure tools are stored in a clean, dry environment. Additionally, use modern technologies such as CNC systems for precise control and minimize human error. These practices enhance tool longevity and improve overall fabrication efficiency, thereby reducing material waste.

How can I select the right materials to reduce waste in press brake operations?

To select the right materials and reduce waste in press brake operations, choose materials with appropriate thickness, strength, and bendability for the intended application, avoiding over-specification. Optimize material selection by considering properties like tensile strength and ductility, which affect the bending process. Utilize nesting software to arrange parts efficiently on material blanks, and employ dedicated tooling for specific bends to enhance accuracy and minimize scrap. By focusing on these strategies, manufacturers can achieve efficient material utilization and significantly reduce waste, contributing to more sustainable operations.

What sustainable practices can be implemented in press brake operations?

To implement sustainable practices in press brake operations, focus on energy efficiency, material optimization, and recycling. Utilize energy-efficient machines, such as electric servo-driven models, and incorporate variable frequency drives (VFDs) to reduce energy consumption. Optimize material utilization by planning bending sequences and using precision tooling to minimize scrap. Employ nesting software to reduce waste and establish closed-loop scrap systems for recycling. Integrate advanced sensing technologies and use eco-friendly lubricants. Train operators thoroughly to ensure accurate bending, and adopt environmental management systems like ISO 14001 to continuously improve environmental performance.

What technological upgrades can be implemented to improve the efficiency and reduce waste in press brake operations?

To improve the efficiency and reduce waste in press brake operations, several technological upgrades can be implemented. Integrating CNC systems automates bending processes, ensuring consistent results and reducing rework. IoT technology enables predictive diagnostics, alerting operators to potential issues before they cause downtime. Automation through offline programming minimizes human error and increases productivity. Investing in energy-efficient machines, such as electric servo-driven models, significantly reduces energy consumption. Additionally, smart scheduling software and intelligent gripping systems enhance operational efficiency, while regular maintenance ensures optimal machine performance. These upgrades collectively help minimize waste and enhance overall efficiency in press brake operations.

What training should operators receive to ensure accurate and efficient bending?

To ensure accurate and efficient bending in press brake operations and minimize waste, operators should receive comprehensive training in basic mechanical knowledge, operation skills, and various bending methods. They must develop math and measuring skills for precise calculations, undergo safety training, and learn to use advanced technologies like CNC controls and simulation software. Additionally, operators should practice best accuracy techniques, such as making trial bends and keeping detailed records, and participate in ongoing training and certification programs to stay updated with the latest advancements and maintain high efficiency, as discussed earlier.

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