Asahi OEE Reloaded. A Handy Video for the Flexo Printer

Improve your print production capacity by up to 1/3 by just changing your plate!

Asahi Photoproducts has published a brief, educational video that provides a simple but effective explanation of the value to a flexo plant of calculating, monitoring and managing the operation’s Overall Equipment Effectiveness (OEE) percentage.

The video also links to a simple-to-use OEE calculator that allows owners and managers of flexo operations to calculate OEE using their own data.

Over the years, Asahi Photoproducts has published much information about OEE and the role our plates can play in improving a flexo operation’s OEE percentage,” says Dieter Niederstadt, Technical Marketing Manager of Asahi Photoproducts Europe. “Although not rocket science for many operations, the OEE concept has remained complicated and how to actually calculate it a bit obscure. There was no handy explanation for a quick and easy calculation of the OEE specific to flexography for a specific operation or press. With the release of this video and our easy-to-use OEE calculator, this all changes. Now, the meaning of OEE for flexo operations and how they can determine the operation’s OEE is no longer obscure or complicated.”

In Asahi’s experience, customers who simply switch to Asahi CleanPrint water-washable plates can improve their print production capacity by up to 1/3 with little requirement for change in the overall plant workflow. This was learned both from customers with long run jobs as well as customers with frequent job changes. As part of calculating the total cost of ownership (TCO) of prepress and the pressroom in a flexo plant, OEE is a significant factor. “Many operations limit their view by focusing mainly on the cost of flexo plates,” Niederstadt adds, “but once you examine the operation more holistically as you calculate your own OEE, you will note that the cost of plates is actually a significantly smaller percentage of the overall picture than you might have realized. The value gained by improving OEE boils down to the ability to increase throughput of sellable finished product while reducing waste, making it easier to meet the tighter production deadlines imposed by today’s brands, who are anxious to improve their time to market.”

To better understand how OEE applies to the flexo industry, how it is calculated, and the impact of improving it, view our educational video here. Then download the OEE calculator, and you’ll be on the road to improved overall performance and profitability!

Asahi Demonstrates Remote Smart Glass Machine Installation

FIRST-IN-HISTORY REMOTE SMART GLASS MACHINE INSTALLATION DEMONSTRATED BY ASAHI


Re-post of original article from asahi-photoproducts.com

The first AWP™ 4835-P water washable plate processor was put into operation at the Comexi Manel Xifra Boada Technology Center following innovative installation approach By Pedro Hernandez, Engineering Manager, Asahi Photoproducts

At Asahi Photoproducts, we were thrilled to see the Comexi Turnkey Project come to fruition. It was designed to demonstrate how simple and clean the flexo platemaking process can be, making it easier than ever for flexographic print houses to bring platemaking in house, gaining control over the process and saving valuable time.

To facilitate the project, an AWP™ 4835-P water-washable plate processor was installed at the Comexi Manel Xifra Boada Technology Center in Girona, Spain.

What was unique about the installation was the fact that it was the first-ever installation done remotely with Smart Glass support! This approach was driven by pandemic-imposed travel restrictions, forcing a decision to either delay the project or utilize alternative technologies to start up the system. The fact that Comexi had already experienced Smart Glass technology as part of their service offering significantly helped make the process smooth between both companies and resulted in defining our standard remote support operating procedures which can be used for future installations, saving time, eliminating the need for travel, and providing an overall more effective experience for the operators at the installation site.

“The Smart Glass installation was great! Everything was well prepared, and it went smoothly from the very beginning,” says Yago Lulin, Technical Consultant & Prepress Manager at Comexi. He continues by saying, “The installation was done in a few days, and the Comexi team was given a subsequent training on platemaking in detail. Smart Glass support for this type of activity is ideal as it provides flexibility regarding the installation date when it comes to any last minute changes, but it also saves 2-3 days of engineering travel time and costs”.

We see this approach as a major advance for the “next normal”. While Asahi Photoproducts’ expert technical team is always available to come on site to help with technical or training issues, being able to remotely do a full installation using modern communications technologies means a more cost-efficient and timely approach to many of the activities that normally would have required the time and travel cost associated with conventional technical support approaches. This was a great learning experience for both teams, and proof that it is a viable approach for the future.

Another important advantage noted by Yago Lulin was the fact that by its very nature, the process gave staff more hands-on experience with the equipment than they might have had during a normal on-site installation. He adds: “All members who participated in the installation were really motivated to learn how the processor works, both for operation and for future maintenance. This approach is ideal for this type of installation!”

Bringing Pre-Press Home: Closing the Gap in the Printed Package Value Chain

As digital technologies progressed in offset, the printing industry saw a rapid migration of plate making from outside resources to on-site production.

The same thing is positioned to occur in flexography, as technology has evolved to streamline and simplify the plate making process. Flexographic converters in the labels and packaging space are in a growth business. Still, they face a number of challenges in a highly competitive marketplace. At the same time, they confront challenges from alternative technologies such as offset and gravure printing. Customers are increasingly looking for shorter and more varied runs, faster delivery times, and, of course, a competitive cost structure. Plus, the interest in a more sustainable environmental footprint on the part of brands and consumers is growing.

There are a number of technological developments underway in flexography that will help flexographic printers meet these tests and retain existing customers while also acquiring new ones. One such development is being demonstrated through the Turnkey Project, hosted by Comexi, in which Asahi Photoproducts is a partner. The Turnkey Project is designed to demonstrate the value of bringing flexographic plate making in-house to flexible packaging converters. Today’s technology makes it easy.

For the flexographic printing operation, bringing plate making in-house is one way to improve operational efficiency by providing more control over the cost, scheduling and timeframes for making plates. It also makes it faster for replacement plates to be made when required, reducing press downtime and keeping jobs running through the plant more efficiently. But in the past, making high-quality flexographic plates could be tricky, deterring many printers from bringing the operation in-house. This project demonstrates how that is changing.

Beyond this project, our industry is focused on bringing even more automation and operational efficiency to the flexographic prepress process, adding to the contributions already made to improved quality, profitability and sustainability.

The faster and more efficiently a press-ready print form can be generated, the more flexibility a plant will have in what it can produce. But as always, quality is a key consideration and must be balanced with efficiency for a holistic approach to the process of producing press-ready print forms.

By removing even more manual touches from the flexographic plate making process, we will be able to deliver a more efficient and profitable prepress process, as well as a high level of standardization through automation, thereby reducing the skill level required for operators in an environment where skilled prepress operators are often hard to find.

Among the resulting benefits, the process speeds production times, allowing companies to produce more jobs in a day with the same or less labor, while simultaneously reducing the opportunity for costly errors along the way. That’s the vision the next generation of flexographic prepress solutions will be about.

Turnkey Project Details

An important milestone on the route toward this vision for Asahi and several other industry partners is our participation in the Comexi Turnkey Project at its Manel Xifra Boada Technology Center in Girona, Spain. The project features water wash equipment and water washable plates with CleanPrint technology. Water wash processors are generally considered to be more in harmony with the environment than conventional solvent systems. Many, in fact, credit them with producing plates that achieve the highest level of quality in flexographic printing.

In addition, the water wash process is much faster than solvent. While it may take up to two hours for solvent-based plates to dry, Asahi’s complete AWP plate making process, serving as one example, delivers a plate to the mounting department in less than one hour. That same example plate is specifically engineered to transfer all remaining ink to the printed substrate, reducing makeready time and press cleaning stops.

The Manel Xifra Boada Technology Center—Comexi CTec—specializes in training, advice and technical process support for the printing and converting sectors of the flexible packaging industry. It has incorporated into its portfolio this new service, whose objective is to help flexographic printing operations integrate the prepress process, from ground zero, into their own facilities.

The project culminates once the client independently completes the prepress process while adhering to all defined quality standards. The estimated time to complete the project is approximately six months.

Word on Overall Equipment Effectiveness (OEE)

In any industry, Overall Equipment Effectiveness (OEE) is a measurement of the performance of a machine. It’s a calculation—OEE = Availability x Performance x Quality—that delivers a percentage. OEE is a fact-based way to measure the efficiency of your operation and identify ways to continuously improve it over time.

Print production inefficiencies can occur due to a combination of elements, such as printing shift length, press makeready time, press stop downtimes, actual press speed, run lengths and total material waste.

The OEE calculation provides focus and simplicity to decision making, in respect to availability, performance and quality produced. Having measured all three elements, a focus for improvement in the OEE percentage figure can be established. The higher the OEE percentage is, the more effective your printing shop becomes. The higher the OEE, the better the impact is to the bottom line. Plus, inherent in a higher OEE is an increase in customer satisfaction and retention.

Calculating OEE is not rocket science; it’s easy to understand and involves calculating press availability, performance and quality. For more information on the calculation of OEE, request an easy-to-use OEE calculator by contacting CTGA today.

Asahi Photoproducts and Esko Join Forces

Asahi Photoproducts and Esko Join Forces to Educate Chinese Market on Flexo Platemaking in Harmony with the Environment

Tokyo, Japan & Brussels, Belgium, November 20, 2020. Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today reported it extended its relationship with Esko through an agreement to install Esko plate imaging solutions in the Asahi Tech Center in Suzhou, near Shanghai. The agreement, which was entered into during All-in-Print China, will result in the installation of an Esko CDI Spark 4260 and an XPS Crystal 5080 in the Center.

These industry-leading plate imaging solutions are supported by an Asahi AWP 230W plate processor using Asahi AWPTM CleanPrint water-washable plates to complete the industry’s most balanced flexographic platemaking solution in harmony with the environment, delivering the highest possible quality for China’s demanding flexo customers.

“Asahi Photoproducts has worked together with Esko in China for a decade and this agreement takes the relationship to a new level in our ability to serve the rapidly evolving flexographic market in China,” said Yuji Suzuki, Asahi’s Senior Manager of Customer Technical Service.

Suzuki points out that high-end print quality is increasingly required in China, and many repro houses in the region still have difficulty making plates that deliver the best print quality. “One thing we will be doing in our Tech Center with the new equipment,” he says, “is creating test plates for potential customers so they can see for themselves that we can deliver the quality they need. We will also use the facility to do training and seminars for customers and potential customers.”

Esko will also have access to the Tech Center, offering the possibility to Asahi’s customers to learn more about how the Esko plate imaging system functions with Asahi’s AWPTM CleanPrint water-washable plates. “We are pleased to continue to grow our partnership with Asahi, especially in the highly competitive Chinese market,” said Rocky Zhou, General Manager for Esko in Shanghai. “The solutions being installed at the Asahi Tech Center will benefit both of our businesses as we work to continue to bring the latest state-of-the-art flexographic solutions to this region”.

FFP Packaging Wins Best in Show At the EFIA Awards 2020 Using Asahi AWP Flexo Plate Technology

Tokyo, Japan & Brussels, Belgium, 7 October, 2020 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, is delighted to congratulate its customer FFP Packaging Solutions as winner of ‘Best in Show’ at the recent EFIA Awards 2020. FFP’s entry won Gold in the category ‘Flexo on Film – Reverse Print Wide’ using Asahi’s AWPTM-1.14 plates to achieve the high quality results. FFP’s entry ‘Juicy Meat Company, Large Beef, Easy Cook Pouch’ was acclaimed for superior design and excellent quality printing in CMYK, achieving exceptional density in the black areas alongside perfect soft highlights.

Paul Hesketh, Print Development Manager at FFP says, “Everyone at FFP is absolutely delighted to have won this year’s ‘Best in Show’ at the EFIA awards.”  As a leading flexible packaging innovator and converter with 50 years experience, FFP is unique in comparison to many other companies in their sector as they produce their plates in-house. Hesketh explains, “To take control of plate production we needed to find the best plate technology and a supplier and partner we could work with. Our relationship with Asahi supports our strategy to provide consistent high quality products. We purchased Asahi’s AWPTM 4835 water-wash plate processor around 5 years ago and Asahi supply us with the raw polymer so we can manufacture plates in-house. We decided to produce AWPTM-1.14 plates  after extensively researching the market, we found that Asahi plates gave us consistent and excellent quality results every time, with good ink lay-down and superior ink densities – perfect for very high quality work and challenging designs. The results we are able to achieve with this plate are so good, we offer them to our customers under our ‘Platinum Print’ brand.”

The print team at FFP Packaging Solutions quickly recognised the technical difficulty in achieving soft highlights and strong vibrant colors from the CMYK on challenging designs such as the winning entry.  The design on the Juicy Meat Company pack is predominately a dense black with contrasting lighter shades in the product images. To produce award winning designs FFP also has to focus carefully on its color management processes – they use IQC color management software and X-Rite spectrophotometers to measure digital tolerances.

Hesketh continues, “We have a great design and color management team at FFP but at the end of the day, high quality results are a lot to do with the plates and the way we set them up.  The success of the end product is down to achieving the correct balance with the plate, the ink system and the anilox and the key objective is to perfectly match the proof. We found the AWPTM 1.14 plate offers excellent quality and color consistency when used in conjunction with solvent based ink systems on our Windmöller & Hölscher high speed Miraflex Printing press.

All FFPs award entries are selected from the production Print that come off their presses on a daily basis. There is no special preparation made to produce an award winning piece of print. Hesketh explains, “I regularly see great print coming off the end of our presses and think – I’ll keep that.”  These samples build up throughout the year and when its time to send the entries for the awards, Hesketh and his  team review and select the best and the most appropriate print from the samples.  Hesketh works on the principle that everything they produce for their customers is top quality and good enough to win an award.

Hesketh concludes, “We take awards seriously.  Within our industry we regard EFIA as the most prestigious organisation.  We have been members for many years and won many awards but it was very satisfying indeed this year to receive their award for ‘Best in Show’.   Working in-house is fundamental to FFP maintaining the highest levels of quality products in a challenging and ever evolving market.  To do that we had to carefully consider our choice of technology partner.  We chose to partner with Asahi and use their AWPTM plate 5 years ago and we are still winning awards with it. We did look at other suppliers but we are very glad we went with Asahi as we believe their plate technology is top class.   We strive to be the best and use the best equipment available which is why we use Asahi’s AWPTM plates. Our competitors can’t compete.”

Plate Mounting Tape: What you need to know before you choose

Repost of Original Article from tesa.com


With few exceptions, no two plate mounting applications are exactly alike. To choose the right tape, you need to start with four basic questions: Who, where, how and what.

Here’s what we mean:

WHO = Standard Operating Procedures

WHERE = Environment

HOW = Equipment (both mounting and printing)

WHAT = Graphics

Quick and easy, right?

The short answer is, no.

Within each of these questions are lots of variables that you need to take into account. Taking the time to consider them will lead you to the tape that will work best. Along the way, you may also find that some simple changes – like using a different tool or switching out a printing plate – will help you do the same job better, faster and more efficiently.

Let us take you through our matchmaking-like approach to picking the right plate mounting tapes.

WHO = Standard Operating Procedures

We always start with standard operating procedures (SOP), which is really the human factor. After all, it’s people who set up the processes and put them in place (whether or not those processes are followed is a separate issue).

There are lots of different tools and many different ways of applying or mounting a tape. The recommended tape or adhesive will depend on your particular combination.

Maintenance is another key factor. Is the shop or work area kept immaculate or does it tend to get dirty? Are the plates cleaned as thoroughly and regularly as the other equipment?

We’re not judging. Just know that certain adhesives are more forgiving in dirtier conditions, and don’t lose their stickiness even when certain contaminants are left on the plate.

Other tapes perform best on equipment that is consistently kept very clean. They can also allow for an easier demount of the plate or smoother release from the sleeve.

If your company, and, more critically, the shop, are open to change, the benefits of new tools with a different tape may outweigh the time and inconvenience of making the switch and updating the SOP.

WHERE = Environment

Where are you working? To pick the right mounting tape or adhesive package, you need to know the conditions around your equipment. This includes the printing area as well as wherever the sleeves or cylinders are stored before and after the mounting.

Just like you’d look at the weather when packing for a trip, we study several factors to help identify the best tape for your operations:

– Average temperatures during working hours
– Temperature changes overnight
– Extreme temperatures – the highs and the lows
– Minimum and maximum humidity

Some tapes can take the heat, some can withstand the cold. Others are engineered to withstand wide swings in temperature and humidity levels while certain adhesive need regulated temperatures and controlled climates. It comes down to getting the right fit.

HOW = Equipment

The equipment — the “how” question – is closely related to standard operating procedures since whatever your company uses will, of course, impact those processes. Still, it’s worth taking a close look at the materials and the machinery used both in mounting and in the printing itself.

There are important differences in fully automated, semi-automated and manual mounting that will affect the type of tape that we’d recommend. Certain adhesives are definitely more effective when applied by hand. We’d also want to know if you use application tools like squeegees or rollers.

The size and condition of the sleeves or cylinders also come into play. For scored or uneven surfaces, flexible tapes are a good option because they conform closely for the best fit and better results.

On the printing side, the age and condition of presses are the big variables. If your equipment produces some bounce, chatter or vibrations when running, certain foam hardnesses can help compensate for those movements. There may be build-up tape on the presses – and on the cylinders and sleeves, too – for which a more suitable adhesive will be needed.

Don’t forget about the types of inks and solvents used on the machinery, too. They also help determine the chemical resistance of the recommended tapes and adhesives.

WHAT = GRAPHICS

Last, but not least, is the look of the final product. The designs and the types of plates used to create them influence the choice of plate mounting tapes.

Here’s where you consider the plate’s material and hardness (have your tried our Foam Advisor yet?)

The recommendations also consider if you’re printing solids, fine dots, highlights or a combination of all those design elements. The use of screening technology is another factor that will impact the decision-making process.

After all the analysis and discussion, a recommended plate mounting tape is only as good as the results it achieves. A trial run in your shop or factory is the ultimate – and best – test.

Asahi Announces New AFP-Leggero Flexo Plate For Corrugated Board Applications

Super-soft and smooth plate results in no board crush, fewer flute marks, good ink density, for the ultimate in post-print flexographic quality

Tokyo, Japan & Brussels, Belgium, March 26, 2020 – Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today announced the availability of a brand-new flexographic plate. Asahi AFP™-Leggero CleanPrint plates have been specifically designed for printing on lower quality low-liner corrugated board. This super-soft plate delivers kiss-touch printing without board crush, good ink density with reduced washboard effect, and is ideal for simple brown-box corrugated applications such as fruit trays and single-color logo type printing.

“With the growing use of corrugated board packaging around the globe, brands and retailers increasingly seek ways to increase quality appearance and protect their goods at the same time,” said Dieter Niederstadt, Asahi Photoproducts’ Technical Marketing Manager. “Asahi’s AFP™-Leggero flexographic printing plates deliver both higher quality and better protection of the product by not damaging the corrugated box flute structure. This is a very new approach inside Asahi, not only to focus on print quality aspects, but also to add value for protection of the packaged goods. Our ‘Just Kiss. No Crush.’ tagline reinforces this quality and protective result delivered by Asahi AFP™-Leggero CleanPrint plates. In addition, as with all of our CleanPrint plates, the Leggero plates ensure less waste, fewer press stops for plate cleaning and consistent exceptional quality throughout the run, the hallmark of Asahi’s CleanPrint flexo plates. We expect packaging converters will be able to achieve up to 15% improvement in Overall Equipment Effectiveness (OEE) when they use these plates for corrugated post-print, delivering a solution in harmony with the environment.”

CleanPrint plates from Asahi Photoproducts have been specifically engineered to transfer all remaining ink to the printed substrate. The AFP™-Leggero CleanPrint effect is achieved because of the soft plate base material. The result is very clean printing. Another important benefit of Asahi’s CleanPrint plates, including AFP™-Leggero, is that they do not need to be cleaned as often as conventional digital solvent plates. Reduction of plate cleaning stops creates a significant productivity improvement as well as more consistent quality.

“With AFP™-Leggero’s soft-touch kiss printing,” Niederstadt added, “not only is the historical problem of board crush and washboarding virtually eliminated due to the softness of this plate, but there is also virtually no dot bridging and good ink laydown. That means that areas of solid colour as well as highlight areas are clean and crisp, as are fine lines and smaller type. This is the ideal plate for corrugated board post-print and will enable packaging converters to broaden the range of applications they can produce for customers, especially those that are not willing to sacrifice quality.”

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ASAHI PHOTOPRODUCTS TO DEMONSTRATE NEW WATER RECYCLING UNIT AT DRUPA 2020

New Asahi solution reduces platemaking waste water usage by 80%, using no solvents in the washout process, and bringing flexo platemaking more in harmony with the environment.

Asahi will be located in hall 5 C41 at drupa 2020.

Tokyo, Japan & Brussels, Belgium, 30. January 2020 –Asahi Photoproducts, a pioneer in flexographic photopolymer plate development, today announced the latest development in its CleanPrint strategy, a water recycling unit incorporated in new Asahi platemaking systems as a standard feature. This recycling unit uses 2 litres of water per square meter, versus 10 litres in units without the recycling unit, a reduction in platemaking waste water of 80%! In addition, minimal waste from the system, in the form of dry cake and a highly concentrated liquid extract, can be incinerated, with the liquid contributing to the cooling of the incineration plant, resulting in even more water savings. Existing Asahi platemaking systems can be retrofitted with the recycling unit so that all Asahi platemaking processes are more in harmony with the environment.

“As we have done for the past 45 years, we continue to look for ways to make the flexo printing process more efficient and in harmony with the environment while also improving overall effectiveness,” said Dieter Niederstadt, Asahi Photoproducts’ Technical Marketing Manager. “This latest improvement pushes flexographic printing into an even more environmentally balanced position, preserving precious water resources while maintaining the quality and efficiency our customers have come to expect. It’s another important strategic element of Asahi’s CleanPrint technology.

CleanPrint flexographic plates from Asahi Photoproducts have been specifically engineered by Asahi’s chemical engineers to transfer all remaining ink to the printed substrate, reducing makeready time and press cleaning stops as compared to other platemaking systems while delivering exceptional quality. Asahi CleanPrint flexographic plates are also ideal for fixed colour palette printing, a method that is increasingly being adopted to save time and money while still delivering the quality brands expect. This is made possible by the precise registration of Asahi CleanPrint plates.

Visitors to the Asahi stand at drupa 2020 will be able to get a first look at the new recycling unit to learn more about how it works, its environmental benefits, and the ease with which Asahi platemaking systems can be incorporated into any flexographic workflow with significant time to market and OEE benefits.

“We have even more on our agenda to introduce at drupa 2020,” Niederstadt adds. “Our goal is to continue to bring improved flexographic platemaking solutions to market that position flexo even more competitively with other printing technologies, continuing to grow its market share in packaging printing around the globe.”

 

Techkon – Make The Switch

Are You Ready to Make the Switch? We Make it Easy

Let’s face it, the “switch” is on! At Techkon, they live it, breath it, and sell it every day. Printers in all markets and of all sizes are making the switch from other color management devices and software to newer Techkon solutions. We could go on and on and explain all of the reasons like more innovative products, unlimited customer support, and dedicated customer support. However, that’s not what this blog is about. Instead, this blog is to explain how Techkon can help you make the “switch”. Printers are thrilled to learn about the advantages of Techkon products, but to some, making the “switch” sometimes seems like a daunting task. So, here are the 3 top reasons why some customers dread making the “switch” and how Techkon can make it far easier than you might have imagined.

Customer Worry #1 – Will those new Techkon devices measure the same way as my current color management devices?

Solution – It turns out that Techkon devices are manufactured to be traceable to the same industry standards as other popular color management devices. As a result, new SpectroDens instruments measure almost as close to a competing device as they do to each other. This is big news and this means you don’t have to worry any more about scenarios where (1) color standards were originally created with a competing device or (2) using a mixture of a competing device and SpectroDens instruments across your color production workflow.

Customer Worry #2 – What about all my instruments and software that already have all of my color standards loaded into them?

Solution – No worries! Techkon is here to help and can migrate all of your color standards for you. This is part of the service you can expect from Techkon when making the “switch”. Their color experts can export your color standards out of your current software systems and install them in your new Techkon hardware and software so you don’t have to worry about this one. In fact, if they can get your color standards ahead of time, and can even install them on any new instruments you purchase before it’s shipped out to you! How’s that for easy?

Customer Worry #3 – How am I going to train everyone on using new Techkon hardware and software products?

Solution – First, Techkon designs all of its’ products to be intuitive and easy to use. This is their first design principle and they strive for excellence here. Second, Techkon offers unlimited technical support on their products. Your satisfaction and delight using our products and services is truly their goal here. Techkon offers remote, live training services, video tutorials, and telephone support until your team is fully trained and you are comfortable waving goodbye to your old tools. That’s their promise to you.

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