August 22 - 25, 2018

Georgia World Congress Center | Atlanta, GA| USA

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Multi-Step Coloring

by Dakota 8. August 2016 14:01

Multi-step Coloring

Mitch Kohanek

A multi-step wood finishing schedule is for custom coloring. Obtaining a visual presentation on wood that goes way beyond “brown and shiny”. Color(s) built on top of color(s) that attracts the customers’ eye.

There are basically only three coloring agents to choose from, one of them being on the exotic side. Those three are pigments (which I refer to as stains) dyes (which are not pigmented) and chemical coloring. Chemical coloring, sometimes called “reactive” coloring is the exotic coloring agent is not widely used. The use of chemical “reactive” coloring is to create colors dyes and pigments can’t. The chemicals used will react the woods chemistry such as the tannin's. Since it is a chemical reaction the color presentation is not as predictable as using dyes and stains.

Dyes by nature penetrate into the woods structure. Consider them “molecules” of color. The solvent of the dye dictates how deep it penetrates into the wood. The first use of a dye in the coloring process is to change the base color of the wood. Poplar wood is naturally a light tan (sapwood) and a greenish heartwood. A green dye used as the base color and a “reddish” dye on top of that can produce a warm brown hue.

Pigments by nature lay on top of the wood shifting the colors of the large and small pores. It can be a great advantage to have dyes and stains (pigments) that have the correct chemistry so that they can be mixed together and then applied.

Glazes are normally pigmented coloring agents that are applied on top of a coating. Reasons for using glazes are for accented coloring in the recessed areas of the object. They also can create a depth of color even though there can be a loss of transparency.

Toners are made by putting color into the coating before you apply the coating. If you understand the color wheel, toners can be made to correct colors that are already applied to the object. Toners can lay down a “blanket” of color on the entire piece or selective areas. They can hone in sapwood to heartwood or correct the entire object if the color is not the correct hue.

So a finishing schedule may look like this.

Walnut substrate

1. Dyed yellow

2. Stained burnt umber

3. Sealed

4. Scuff sand

5. Glazed raw umber (cools the color and color strikes the larger pores a darker color)

6. Topcoated

7. Scuff sand

8. Amber toner

9. Topcoat without exceeding the recommended dry mil thickness

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Layering Color

by Dakota 8. August 2016 13:32

Layering Color

Mitch Kohanek

When you have damage to the object that includes the loss of the substrate and color, you have a variety of choices of materials to fill the void. These different filling materials come in a wide range of colors to assist you in establishing the background color you need. 

For some repairs, the correct color of filler and a couple of grain lines is all you might need. For repairs requiring more detail, it is going to be more important to concentrate on the colors that go on top of the filled area. The more you understand color, the fewer repair sticks and the fewer powders you actually need. 

Hue is another name for color. If you are able to identify earth tone colors, you would say that the object has a warm burnt umber hue shaded with raw umber hue. If no color name comes to mind, you would begin by identifying the color as having a "warm" or "cool" hue. Warm hues are an orange or reddish hue while cool colors are a greenish or blue hue.

When trying to reestablish color on the repair, if mixing colors together does not work, you will need to layer a color on top of a color. 

Layering thin layers of color on top of the fill allows you to have more color control. An example would be layering your colors from warm to cool. Establishing a yellow background of dye or pigment on the filled area, followed by a warm brown such as burnt umber will create a "brown" you can't make by mixing the two together. A light layer of green, such as raw umber on top of that color will "cool" that color. 

Once you learn how to layer your colors, the color of the filler material is not as critical. 

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Rx FOR MACHINING WOOD- -PRACTICAL TIPS AND TROUBLESHOOTING DEFECTS

by editor 1. August 2016 07:13

By: Eugene Wengert, President: The Wood Doctor's Rx, LLC

Quality loss due to machining issues can be very expensive.  In addition to the basics of machining, the defect causes and cures will be illustrated and discussed.  Quality programs that can be used in the plant will be illustrated.  In addition to traditional machining with heavy machines, we will also discuss sanding and sandpaper issues that cause problems, especially with high end furniture and cabinets.

Come learn more about this topis at the "Rx for Machining Wood: Practical Tips and Troubleshooting Defects" session at the IWF Education Conference.

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ALL ABOUT WOOD FOR MANUFACTURERS AND WOODWORKERS

by editor 1. August 2016 07:09

By: Eugene Wengert, President: The Wood Doctor's Rx, LLC

The basic wood characteristics and properties certainly affect the manufacturing process.  But what about the special characteristics of wood (like tension wood, bacterial infection, staining, spiral grain, juvenile wood) that cause headaches from time to time?  Is all oak the same?  Is all hickory the same?  Is all pine the same?  Is all soft maple the same?  Is it possible, at the least,  to identify and eliminate problem pieces of wood early in the manufacturing process or should we ignore them and let them go through until the final inspection finds the problem?  Learn some practical aspects of wood that affects profits.

Come learn more about wood manufacturers and woodworkers during the session "Wood 101.  All about Wood for Manufacturers and Woodworkers" at the IWF Education Conference.

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Say "YES" If Your Business Is Positioned for Success

by Christine Correlli 1. August 2016 07:04

By Christine Corelli, IWF Atlanta Speaker

Forget tough. Today, competition is fierce. As never before, whether you are a woodworking machinery manufacturer, cabinetmaker, or company that offers wood products, your business faces sophisticated many new competitors. And these competitors are using some very aggressive marketing strategies to shake up the status quo. 

To survive in this environment, your company needs to have smarter strategies than the competition. Your management team (in fact, everyone who works for your company) must be aligned with those strategies and be committed to working hard to support your company's efforts. Here, market research, customer input, and employee involvement are key.

Take this simple "yes" or "no" test to help you determine whether your company is positioned for future success:

 

1. Have you conducted research to identify consumer or industry trends and do

    you have a formal program to obtain information from your customers regarding

    their needs? ___yes____no

 

2. Have you consulted with groups of end-users to help you reach decisions in

    your strategic initiatives? ___yes____no

 

3. Did you learn what direction your competitors are taking and analyze what you

    can do to differentiate your product or service? ___yes___no

 

4. Have you analyzed what new markets your company can tap into? ___yes___no

 

5. Are you doing business internationally, or preparing to do so? ___yes___no

 

6. Did you involve your customers and your sales force in creating your

   strategic plan? ___yes___no

 

7. Are your sales goals and incentives aligned with your company's marketing

    strategy? ___yes___no

 

8. Did your marketing team involve your entire sales team when creating your

    marketing plan? ___yes___no

 

9. Did your marketing team share the consumer or end user data they obtained to

   create the plan with your sales team? ___yes___no

 

10. Did your company meet with your sales team to discuss strategic areas they

     may disagree with and come to a mutual understanding? ___yes___no

 

11. Do your product manager, chief engineer, director of operations, warehouse

      manager, etc. add their input when your sales people discuss customer needs with

     upper level management? ___yes___no

 

12. Is your sales team committed to "agreeing to disagree," with your plans if

     necessary, and fully support the company effort? ___yes___no

 

13. Does your company, recognize that where there are conflicting opinions,

      creativity is stimulated, and positive results can occur? ___yes__no

 

14. Did management communicate the strategic plan, marketing plan, and sales

      strategy to the entire company and obtain staff input? ___yes___no

 

15. Does everyone in your company—from sales to customer service, from marketing

     to R&D and from the warehouse to the front desk—fully support those plans and

     recognize that everyone must be on the same page if you are to succeed?

                                                                                                            ___yes___no

 

16. Does your company have a diversified team, or several teams, working

      continuously to determine ways to make those plans work? ___yes___no

 

17. Does your company realize that such teams can take fragments of ideas and

     structure a wide variety of options and solutions to problems? ___yes___no

 

18. Does upper level management solicit, listen, and respond to all ideas,

     selecting the best ones to implement? ___yes___no

 

19. Do your sales people enlist the help and expertise of your techs, product

      manager, CSR's, etc. to help their customers and do they recognize that they,

      too, are "in sales?" ___yes___no

 

20. Do your sales people recognize that, regardless of their individual sales

      prowess, it requires a strong sales team for ultimate company success?

            __yes___no

 

21. Does your company strive to outdistance your current and future competitors

     with innovation? __yes___no

 

22. Is your company willing to take calculated risks to diversify what they

     offer and introduce new products to the market place that customers are

     demanding? __yes___no

 

 

23. Does your company strive to leverage vendor expertise and partner for

      success through strategic alliances? __yes___no

 

24. Does your company invest in training and learn faster than your competitors?

      __yes___no

 

25. Is there a sense of urgency to solve any service problems, quality problems,

      or problems with employee morale? __yes___no

 

There are many more questions we can add to this list. For now, your goal is to

answer "yes" TO AS MANY AS possible. If you can, your company is in a better

position to grow and prosper.

 

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Mass Customization Drives Woodworking Suppliers to Adopt Digital Print for Decorative Products!

by jk@iwfatlanta.com 27. July 2016 15:15

By: Ron Gilboa Director, Functional & Industrial Printing Service: InfoTrends

During the biennial International Woodworking Fair (IWF), I am always amazed to see the variety of businesses and brands that impact our living spaces and work environments. Scheduled for August 24 to 27 in Atlanta, Georgia, this year’s event is expected to attract over 20,000 attendees. IWF is a great place for small professional shops, furniture manufacturers, mills, and others to gather together and learn about the latest solutions and technological advancements. In 2014, over 14,000 buyers—10% of them from international countries—made their way through the halls to peruse the products and attend the educational sessions.

As the woodworking industry continues to adapt to new supply chain realities, the demand for unique, environmentally-friendly, and functional solutions is ever increasing among consumers as well as institutional clients. Professionals like architects and interior designers are seeking innovative ways to create unique spaces, and they are relying on a wide range of materials and surfaces to achieve their goals.

The demand for an ever-expanding range of substrates, materials, and surfaces is fueling the growth in digital printing. By their very nature, many decorative surfaces are made from a range of materials, including natural or raw materials like wood, metal, or glass. In cases where these surfaces are uniquely decorated or printed to create the look of a natural material, cost parameters may unfortunately limit their use. Technologies are improving all the time though, and lamination/direct decoration of wall coverings, flooring, and wood products is becoming very common. Decorated surfaces are now available to furniture manufacturers and consumers via wholesale suppliers of raw materials, big box distributors, and/or local home improvement stores.

Figure 1: Formica Envision Retail Display

 

Today’s flooring products and laminates are available in a dizzying array of designs that can meet almost anyone’s needs, but a large initial order is often required to ensure a low per-unit cost. Due to high setup costs that must amortize over a longer job, some orders of décor papers for high-pressure laminates may require a minimum print run of one ton of décor paper material. However, growing demand for unique designs is driving new product innovations that bring more choices to consumers. Today’s web/Internet-enabled business model enables end-users to design and produce creative woodworking products with ease. This is enabled by a new generation of digital printing devices that make it possible to print very short runs with minimal setup and associated fees.

Figure 2: Digitally Printed Bedroom Décor from Mimaki

 

 

A new generation of inkjet printing solutions based on UV curable as well as water-based inks is also making an impact on the industry, In addition to enabling new levels of creativity and operational efficiency, these inkjet solutions are also creating new business opportunities. From high-pressure laminate décor paper printed for a single piece of furniture to a high-volume printer that is capable of customizing thousands of square meters of output, turnkey solutions are available today. Inkjet printing devices are capable of producing up to 500 feet per minute in a timely manner with reduced inventory. Furthermore, they are able to create even the most creative designs based on clients’ demands. Meanwhile, a generation of printing systems that can print directly onto natural or manmade wood products (e.g., MDF) provides another path for decorative surfaces that are durable, eye-catching, and cost-effective.

Figure 3: Building Material Sampler from SFC Graphics

 

 

Digitally printed decorative products are part of an industry that generated over $460 billion in value during 2015. Although this market is small in its adoption today, InfoTrends believes that the opportunity for mass customization will generate a compound annual growth rate (CAGR) of about 13% through the year 2020.

Figure 4: Cefla PixArt Single-Pass Device


During IWF 2016, leaders in the digital transition will gather in the exhibit halls and educational sessions to expand their knowledge about digital printing and its impact on the industry as a whole. Print equipment suppliers such as Cefla, HP, Hymmen, KBA, and Mimaki will be sharing their experiences in developing solutions of for the woodworking industry. Meanwhile, industry pioneers like Formica Corporation, Kodak, and SFC Graphics will also be in attendance to share their experiences with others.

 

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Practical Solutions for Dust Control: Managed vs. Engineered Approach

by Brad Carr 27. July 2016 10:39

By W. Brad Carr, President: SonicAire 

Two strategies address how to control combustible dust:  a managed solution or an engineered solution.  Even though the goal is the same, the principles undergirding each approach are vastly different.  Let’s examine each approach, and determine its strengths and weaknesses.


Managed= Manual Housekeeping


A managed approach is essentially manual housekeeping.  In this scenario, third-party cleaning services or plant employees remove accumulated dust and fiber intermittently.  The interval of cleaning depends on the processing and the type of particles - the more dust generated, the more frequent the cleaning required. 


The approach looks like this:  A person gets up on a ladder (worst case scenario) or on a scissor lift and starts removing the dust from overhead structures and processing equipment.  Once the dust settles on the floor it is them removed from the building.


The cost of cleaning this way varies widely.  A range of prices has been reported to me, including:


•    Larry Baker, president of Fuzion Solution, noted that one company in the paper and pulp industry spends an average $2.40 per square foot on manual cleaning.


•    For one woodworking facility, the cost of cleaning was $0.40 per square foot.


•    One small mill reported spending $10,000 monthly on manual cleaning. 


The cost is there, at whatever level.  Now the question is - is that a good solution for the price?


Benefits of a Managed Approach


A managed approach is the status quo solution.  Before technological advances were made, manual housekeeping was, in fact, the only solution. 


Many people find that ongoing cleaning is an attractive option because there are low upfront costs.  You don’t have to invest a lot of money at one time to continue either using cleaning services or using your employees to manage combustible dust levels. 

What’s more, manual cleaning for combustible dust can even appear not to cost anything, as it is absorbed in operational budgets.  It costs, of course, but that cost is buried, which appeals to some companies’ budgeting process. Continuing in this way just seems like less of a hassle. 


Manual cleaning also does not need a strategic plan, which can be viewed as a benefit.  If companies do not have a capital investment plan, it can be extremely difficult to allocate the funds needed for an engineered approach.  Even if the engineered solutions can show ROI for the installation, some companies can’t secure the initial investment needed.  Within this framework, ongoing manual cleaning is appealing.


Weaknesses of a Managed Approach


A managed approach means that personnel or third party businesses clean the overhead structures on a continuing basis.   This means that these personnel are at risk when cleaning overhead areas, which is considered a mandatory activity.  If you have ever seen anyone on a ladder or scissor lift in those high-ceiling plants, you know exactly what I mean.  This seems to be a solution that uses dangerous practices to eliminate a dangerous situation.   That’s not a trade-off that makes sense to me.


The second weakness in a managed approach is equally problematic.  Given the fact that people are scheduled to clean at certain time intervals, it is axiomatic that there are times when the facility does not comply with safety standards.  As I said earlier, there is basically a zero-tolerance approach to fugitive dust buildup.     The cyclical nature of manual cleaning allows for too much accumulated dust, preventing the plant from being in compliance with OSHA.  


The third weakness is a monetary one.  A managed approach requires never-ending costs.  You have to keep the cleaning services forever because you are always cleaning up after the fact. 


Not only are there ongoing costs that continue for the duration of the life of the plant, but there is also lost production time when the cleaning takes place.  You can’t clean safely when the machines are operating.  Lost production means lost profits. 


Engineered = Automated Housekeeping


The assumption of an engineered approach is that technology can be leveraged to automate cleaning processes and continuously protect against the risks of combustible dust accumulation. 


Two types of engineering solutions exist.  The first is localized filtration.  With this the equipment captures the combustible dust by either vacuuming or suctioning.  This approach is often needed, but the reality is that it can’t be used alone.  Localized filtrations simply can’t capture every particle of fugitive dust.


The second technology is barrier technology, which prevents fugitive dust from accumulating on overhead structures.  With barrier technology, a robotic clean fan automatically establishes and maintains OSHA compliance throughout the plant.  With this approach, there is a one-time deep clean of fugitive dust, and once that dust is removed, the barrier technology prevents new dust from ever accumulating again.

Often there is a synergy between the filtration and the barrier technologies for enterprise-wide compliance, since they can be effectively used together in one facility. 


Strengths of an Engineered Approach


The value of using technology stems from its operating principle.  It’s a simple principle, actually:  It’s better to prevent dust from accumulating than clean it up after the fact.  An ounce of prevention is worth a pound of cure.  Only engineered solutions have a proactive approach to prevent dust from accumulating.


The first is that employees are not put at risk to clean.  No longer do people have to climb ladders, mount scaffolds or scissor lifts to reach the fugitive dust in overhead areas.  Often in these cases, personnel have to extend their bodies beyond the confines of the scissor lift to make sure all the dust is removed.  With an engineered approach, these safety hazards are eliminated. 


The second benefit is that a one-time investment means a permanent clean.  Professionals can show the ROI of their expenditures, amortizing the costs against the ongoing costs of manual cleaning.  The duration of the payoff will depend on the technology chosen. An engineered approach allows for automated, controlled cleaning that doesn’t interfere with production. 


Most significant is the benefit that an engineered approach means that plants can now be in continuous compliance.   Depending on the sophistication of the specific technology, it also delivers consistently higher levels of clean to meet or exceed those standards.  Plants can avoid stiff fines and more importantly, keep their employees safe continually. 

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Wood Composites Symposium: Focus on Bio-based adhesives for wood composites and Timber for Tall Buildings

by vyadama 25. July 2016 11:43

 

Washington State University's Composite Materials and Engineering Center Offers:

An all-day education symposium on advances in resins and coating technology for wood composites and utilization of wood composites for mass timber construction at the International Woodworking Fair, 8-4:30pm, Tuesday, August 23, 2016, Atlanta, Georgia

Register Now for early registration price

Agenda:

Session 1: Resins & Coatings 

Overview of Environmental Regulations Facing the Industry, Jackson Morrill, Composite Panel Association

Mycoboard - Wood Composite Panel with Novel No-Formaldehyde Binder, Jeff Betts, Ecovative

The Physicochemical Nature of Protein-Hybrid Adhesives, Joseph J. Marcinko, Evertree, SAS and Polymer Synergies, LLC

Advancements in Sustainable Binder Technology for Composite Wood Panel Applications, James Wright, EcoSynthetix

A Life in the Timber Industry, Stewardship is the Key, Scott McIntyre, Performance Adhesives, Hexion, Inc.

What Today's Outsourcing Shop Does Right, Mike Lee, Cabinotch Cabinet Box Systems

Lunch Provided

Session 2: Mass Timber Construction

What is CLT & Mass Timber Construction?, Vik Yadama, Washington State University

CLT vs. NLT in the first US Mass Timber Building, L. Leif Johnson, Magnusson Klemencic Associates & Amado Guevara III, DLR Group

Performance of SYP CLT, Henry Quesada, Virginia Tech

CLT Manufacturing in Oregon, John Redfield, D.R.Johnson Wood Innovations

Bringing CLT production to scale, Aaron Edewards, Evergreen Engineering

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KICK ASS LEAN - the word is getting out, don't miss it.

by Brad Cairns 6. July 2016 16:02

Are you still sitting on the fence about weather or not you should attend ?  I have a friend with something to say, you may have heard of him, this guy name PAUL AKERS !  check it out...

https://youtu.be/Ct7mJilTMbk

 

Wednesday the 24th at 3:00pm for the most transformative information I could pack into 2 hours.   Thank you all for signing up and allowing me to share what I have learned with you.  SEE YOU THERE !

 

Brad Cairns

Lean Maniac

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Color Matching, - Color Blending

by editor 30. June 2016 11:40

By: Mitch Kohanek

Recently, I was in need of a color match on a 30 year old opaque exterior color.  It was for a few new pieces of Masonite siding I replaced on my house.  “Back in the day” that meant going to your local paint store in hopes of finding someone who had the knowledge and talent to mix colors by eye.

With today’s technology, a spectrophotometer made short work of matching an exact color for me. Gave the store a piece of the old siding, they made me a quart of paint that was a spot on color match of my old existing siding.

For transparent and translucent wood coloring using dyes, stains, micro pigments the meter comes close, but it can’t be relied on to be as accurate as it is with opaque colors. It can be a valuable tool, it has its benefits, but in many cases the color often needs to be adjusted “by eye”.

Examples:
1.    The various natural shades of species of wood like white oak.
2.    The natural colors of cherry, walnut, and mahogany.
3.    Red oak and white oak in the same pile of oak that is to be used
4.    Blending Sapwood to Heartwood
5.    Quarter sawn glued next to flatsawn
6.    Veneer next to solid stock wood
7.    New wood that needs to look like old wood colors.
8.    Refinishers who need to strip and sand down an old table top and refinish the top to look like the sides of the cabinet.
9.    What degree of translucency you are looking for.

Because of all those variables color matching is back to being accomplished “by eye”. Whether you are creating color or correcting the color, it is critical for the finisher to be in command of color knowledge.

Basically we only have two main choices of coloring agents, one which contains pigment, which I refer to as stain. Paint falls into the pigmented category. The other coloring agent is a dye, which I categorize as having no pigment. There is a third medium, the chemical coloring of wood sometimes referred to as “reactive” stains or mordants. They do not contain pigments, they are more similar to dyes.  When applied to wood they “react” to the chemistry inside the wood, such as the tannins.  Mordants are often applied before dyes are applied to achieve colors not found any other way. For now, let’s stick with the dyes and stains for understanding color.

Dyes and stains (pigments) are two different tools. Used individually they offer two different visual presentations. Used together they greatly expand the color pallet. There are manufactures that formulate their dyes and stains so they are able to be mixed together. Mixing them together can offer a one-step coloring schedule rather than two.

Approaches to mixing colors
1.    Start with a clear base medium and use stains (pigments) using the primary colors, yellow, red and blue with the addition of white and black.
2.    Start with a clear base medium and use stains (pigments) using yellow, red, black and white
3.    Use premixed colored stains. An example would be using the earth tone colors, Raw Sienna, Burnt Sienna, Burnt Umber, Raw Umber plus black and white.
4.    Use the premixed colored stains plus the primary and/or secondary colors.
5.    Dyes are sold in liquid and powder form.  Decide on using the primary colors or pre-mixed colors such as the earth tones, or use them both.

I teach a systematic approach to using any color system and it all starts with the artists’ terms of hue, chroma, value, shade and tint. When looking at a target color, the first thing to do is identify the hue. Next would be identifying the chroma and then the value of the color. If you understand color theory it does not matter which system of dyes or stains you use.

One reason to start with the earth tones or other similar colors is that hopefully one of them comes close to the target color. Choosing the first earth tone is your base color, your second choice is determined on if you need to “warm up” or “cool off” the first color. It’s not guess work, it’s an educated choice.

Many shades of making “brown” in a one-step application can be made with just one umber and one sienna. Adding a third earth tone color is not unusual. Three well-chosen earth tone colors and the proper proportions of black, white or clear base if needed produces a tremendous amount of colors.

Some finishers would rather work with fewer colors and a clear base. These finishers think of color in “parts”. Example: 100 parts yellow, 10 parts red, 5 parts black is a color. To “tweak” that color is to first understand color and keep track of your “parts”. The results are going to be the same with both systems as long as you understand color theory.

It’s worth mentioning that if you choose to use pre-mixed colors like the earth tones, having the primary colors handy is another valuable addition. An example would be knowing that red needs to be added to your mix.  Burnt Sienna is an orange Hue and is the closest color you have to red.

If the target color can’t be accomplished in a one application step, it will have to involve a color on color finishing schedule. Color knowledge just got more important. A multi-step coloring schedule could involve a dozen or more finishing procedures for a completed color. Those tools for creating color are in the form of dyes, stains, glazes, toners and paint.

I will address those tools in the next blog.

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