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Line design: aluminum and non-ferrous metal

Designing an aluminum recovery line

A non-ferrous recovery line is a chain of machines, each preparing the stream for the next, so that the eddy current separator gets steel-free material in a single layer and in a size range its rotor suits.

By [author name, role and employer] · Technical review by [reviewer name, role and employer] · Updated

  • Aluminum and non-ferrous
  • Ferrous
  • Fiber
  • Glass
  • Film
  • Other and residue

1Putting the machines in order

The separator only acts on what reaches it. The machines ahead of it decide whether the metal arrives free, without steel, in a narrow size range and in one layer.

Published lines follow a common order. Not every stream needs every step.

  1. Free the metal. In bottom ash, shredding or crushing frees small metal trapped in mineral clumps and raises separator recovery. Source: Šyc et al., Metal recovery from incineration bottom ash, 2020.
  2. Screen into size bands. In bottom-ash practice, sorting by size ahead of the separators is crucial, and each size fraction runs through its own separator train. Source: Bunge, Recovery of metals from waste incinerator bottom ash, 2019.
  3. Take the steel out. IMI's manual calls for at least one magnet ahead of the separator: a drum, a magnetic head pulley or a cross-belt magnet, alone or together. No process removes all ferrous metal, so more than one magnet lowers the risk. Source: IMI, Eddy Current Separator Service Manual, undated. Placing the magnet: removing ferrous metal before the separator.
  4. Meter to one layer. A feeder or a metered conveyor spreads the stream into a single, steady layer across the belt (section 2). Source: IMI, service manual.
  5. Separate. The eddy current separator throws conductive non-ferrous metal over a splitter (sections 4 and 5).
  6. Refine and check. Sensor sorting, density separation or a quality-control station follows where a cleaner product is needed (section 8).
Published sequences, by stream (examples from the sources named; not a ranking)
StreamSequence describedSource
MRF container lineScreens split flat fiber from round containers. On the container line, magnets come first and the eddy current separator follows. A quality-control station may clean the product.GBB for CMI, 2020; Kessler Consulting for Pinellas County, 2009
Auto shredder, one plantShredder; magnetic separation; a trommel with 1.5 in and 6 in holes and a 12 mm flip-flow screen; eddy current separator; induction sorter for stainless steel.Argonne National Laboratory, 2011
Incinerator bottom ash, one Copenhagen plantAsh aged two to three months; ferrous metal removed; screened into seven fractions; an eddy current separator on each of six fractions from 0.5 to 50 mm, with induction sorters for stainless on the two coarsest. About 90% of the non-ferrous metal is recovered at 4 to 50 mm, and 60 to 75% at 1 to 4 mm. These rates are calculated on metal sold, not metal sorted out.Šyc et al., 2020, citing Kallesøe and Dyhr-Jensen, 2018

Each row is one source's own example. Full references are in the Sources list.

Who publishes this. Recyclers Guide is published by [LLC name], an affiliate of Remcon Equipment, Inc. Remcon designs and builds conveyors and eddy current separator systems around rotors or complete separators made by others, builds overhead magnet units, magnetic head pulleys and trommels, resells screens and feeders, and integrates equipment discussed on this site.

Steel has to come out before the separator

Steel held in the rotor's field superheats and can damage the shell, belt and rotor, and heat damage to the magnets is permanent. IMI does not cover this "ferrous burnout" under its warranty. Bunting adds that on a concentric rotor, held steel stays at the bottom of the rotor and can burn through the belt into the shell when the belt stops; an eccentric rotor lets it drop out of the field. Sources: IMI, service manual; Eriez, RevX-E manual, 2015; Bunting, 5 key operating parameters, 2020.

This guide follows the separator makers' manuals: magnets go ahead of the separator, and the separator is not relied on to remove steel.

An eddy current line, side elevation Material rides an inclined infeed conveyor with a magnetic head pulley that drops steel into its own chute. The rest falls onto a vibratory feeder, which spreads it into one layer on a short eddy current separator belt. At the separator head, aluminum is thrown over an adjustable splitter into the product bin and everything else drops into the residue bin. 1 2 3 4 5 6 A B C D The separator end of an eddy current line, side elevation Material that has already passed the infeed conveyor and magnet falls onto a vibratory feeder, which spreads it into one layer on a short eddy current separator belt. At the separator head, aluminum is thrown over an adjustable splitter into the product bin and everything else drops into the residue bin. From the infeed and magnet (1, 2) 3 4 A B C 5 D 6
  1. 1Infeed conveyor. Material arrives in a deep, uneven layer.
  2. 2Magnetic head pulley. Steel stays on the belt around the pulley and drops into its own chute.
  3. 3Vibratory feeder. Spreads the flow evenly across its tray.
  4. 4Eddy current separator. A short belt with the magnetic rotor inside its head pulley.
  5. 5Residue. Everything that is not thrown.
  6. 6Non-ferrous product. Metal thrown over the splitter.
  7. AFeed onto the separator. Section 2.
  8. BLayer depth. Section 3.
  9. CBelt speed. Section 4.
  10. DSplitter position. Section 5.
Figure 1. One common arrangement of the separator end of a line, side elevation. Schematic, not to scale. Plants also use overhead magnets, screens and second separators.

Worked example: [an anonymised line from the affiliate's own jobs, pending permission to publish it and the shop's answer on machine order]

2Getting the feed onto the separator

An eddy current separator acts on volume. IMI's manual says recovery depends heavily on how material is presented, and calls for a metering device, such as a vibratory feeder, to hold the feed to a single layer. Source: IMI, service manual.

Bunting describes two stages. The feeder spreads material across its tray. The separator belt, running faster, then thins it to one piece deep. Source: Bunting, 5 key operating parameters, 2020.

When a conveyor feeds the separator instead, IMI says the speed ratio between the two belts must be set so the material spreads. Source: IMI, service manual. None of the makers' manuals read for this page gives a number for that ratio: [feed-to-separator speed ratio: no published figure; each maker's design ratio would fill it].

The hopper above a feeder

A feeder can only meter what its hopper lets through. Eriez's feeder brochure sets these rules:

  • A poor transition from hopper to feeder can cost up to 30% of feeder capacity.
  • The hopper bottom should be nearly as wide as the tray, with about 1 in of clearance.
  • The throat should be 2.5 to 3 times the largest piece for mixed sizes, or 3 to 4 times for pieces of similar size, and no more than 30% of the tray length.
  • The gate should be at least twice the largest piece.

Source: Eriez, VB-3301 Heavy Duty Vibratory Feeders, 2021. Eriez's 2009 and 2010 manuals give slightly different ratios.

Feed presentation on the affiliate's site

Remcon Equipment, the publisher's affiliate, publishes a guide to feed presentation for optical sorters. It sets out the feed variables, the speed-ratio principle between belts and a ten-minute check at the belt. This page links to it rather than repeating it.

The affiliate also builds equipment that meters feed: live floor bins, infeed conveyors, and the hoppers and frames around the vibratory feeders it buys in. Its incline-angle guide covers how steep a feed conveyor can run.

3Layer depth on the separator belt

Burden depth is how deep the material lies on the belt. Goudsmit defines a monolayer as a layer about as deep as the largest piece, with no piece lying on another. It says this matters most for fines of 0 to 10 mm. Source: Goudsmit, EddyFines eddy current separators, undated.

A deeper burden lowers both recovery and purity. Source: IMI, service manual.

Depth follows from feed rate, belt width, belt speed and bulk density. Eriez prints the arithmetic for its feeders. The belt feed-rate calculator runs the same arithmetic.

Feed rateQ (US tons/h) = W (in) × d (in) × D (lb/ft³) × v (ft/min) ÷ 4,800
Rearranged for depthd = 4,800 × Q ÷ (W × D × v)
Example, hypothetical inputs5 US tons/h of whole loose cans at about 2.4 lb/ft³, on a 48 in belt at 200 ft/min: d = 4,800 × 5 ÷ (48 × 2.4 × 200), about 1.0 in

Sources: Eriez, SM-780-1 REA manual, 2010, and Eriez, VM-3660C feeder manual, 2009, for the formula; US EPA, Standard Volume-to-Weight Conversion Factors, 2006, for whole cans at 65 lb/yd³, about 2.4 lb/ft³. The feed rate, belt width and belt speed are made up for the arithmetic.

Treat the result as a rough check. A density measured in a container or a bale is not the density of one layer on a belt. Weigh a known volume of your own material, and compare the depth with the largest piece in your feed. The bulk density reference lists sourced ranges by stream.

At the same feed rate, a faster belt gives a thinner layer. That is one reason belt speed matters. Section 4 covers the others.

4Belt speed and rotor speed

Three speeds meet at the separator head: the step from the feeder or feed belt onto the separator belt, the separator belt itself, and the rotor. IMI says belt speed, rotor speed and splitter are separate settings that must be tuned together. Source: IMI, service manual.

What each speed changes (from makers' published material)
SpeedWhat it changesWhat the sources warnAdjusted on site?
Step onto the separator beltThins the layer as material moves onto the faster belt.The ratio has to be right for the material to spread.No maker read publishes a ratio to aim for.
Separator belt speedLayer depth, the time each piece spends in the field, and the path everything takes off the belt.Too fast carries material through the field too quickly. A faster belt throws everything farther and does not necessarily separate better.On some machines. Others run a fixed belt speed.
Rotor speedHow often the field reverses under each piece.Throw gains little past an optimum speed. Running faster than designed can damage the rotor and its bearings.Usually not. IMI says it needs no change once set, and Bunting tunes the other settings on site instead.

Sources: IMI, service manual; Bunting, 5 key operating parameters, 2020; Bunting, Eddy current separator rotor speed review, 2018.

Separator belt speed

Two peer-reviewed studies, one on crushed toner cartridges and one on crushed refrigerator cabinets, found that separation efficiency fell as feed speed rose. It improved as the gap between rotor surface speed and belt speed grew. Sources: Ruan and Xu, 2012; Ruan et al., 2017.

Published belt speeds are examples, not norms:

Ask each maker whether belt speed is fixed or adjustable, and over what range.

Rotor speed

Rotor speed sets how often the field reverses under a piece. The pole-change frequency is (poles ÷ 2) × (rpm ÷ 60). A 22-pole rotor at 4,000 rpm changes pole about 733 times a second, or 733 Hz. Source: worked from that definition; IFE lists a 22-pole rotor that turns up to 4,000 rpm (IFE, brochure, 2026).

Rotor speeds commonly run 2,000 to 5,000 rpm, and faster is not always better. On its concentric design, Bunting found little extra throw above about 3,000 rpm. It tunes belt speed, splitter and layer depth at commissioning instead. Sources: Bunting, 2020; Bunting, 2018.

IMI warns that running a rotor faster than designed can cause vibration, permanent rotor damage and bearing failure, and does not always improve recovery. Source: IMI, service manual.

5Setting the splitter

The splitter is the adjustable edge between the product and the residue. Its position trades recovery against purity; both are defined in the aluminum recovery guide. The purity to aim for comes from your buyer: see aluminum scrap grades and what buyers accept.

Small moves matter. In plant and lab tests on 1 to 6 mm bottom ash, a 10 mm shift in splitter distance can change metal recovery by about 10% and grade by about 18%. Source: Rahman and Bakker, 2013. Check both output streams after each change.

Where each maker starts, what moves the right setting, and the splitter options makers sell: setting the splitter.

6Particle size and fines

IMI says particle size is the key to setting the splitter position and belt speed, and that the two must be set together. Source: IMI, service manual.

Why size matters and how plants narrow the band: screening ahead of separation; pieces under about 10 mm: recovering fine non-ferrous metal.

7Moisture and dust

Moist pieces stick to each other and to the belt. Outdoors, wind disturbs their paths. Source: Goudsmit, What determines the separation efficiency of eddy current systems, undated.

Damp, sticky streams such as bottom ash and refuse-derived fuel build up on vibratory chutes. Goudsmit answered with a conveyor feed with product distributors for 0 to 50 mm material. Its fines machine offers a conveyor module with a belt scraper. Sources: Recycling Product News, 2018; Goudsmit, EddyFines, undated.

For wet fines such as bottom ash, STEINERT offers a splitter variant that reduces caking on the blade. Source: STEINERT, EddyC FINES, undated.

Wet feed costs recovery. Very wet feed lowered recovery in plant tests on bottom ash. Source: Rahman and Bakker, 2013.

In a 2026 study, fluidized-bed ash with dry discharge gave 97% aluminum extraction into metal concentrates, against 78% for grate ash. The authors credit the dry discharge and a lower bed temperature. Source: Mika, Mühl and Lederer, 2026.

Bottom ash can be very wet. Its moisture ran 29 to 66% of dry weight in one US data set, and 22 to 62% in another. Source: US FHWA, FHWA-RD-97-148, MSW combustor ash.

Moisture limit: [moisture level at which a dry separator loses recovery: no published figure found; a test on your own material would fill it]

Dust needs its own review. OSHA lists aluminum among the metals that can form combustible dust. Source: US OSHA, Combustible Dust, undated. This page gives no dust design advice. Take dust collection and housekeeping to the maker and to your safety adviser.

A Dutch government factsheet on eddy current separators lists moistening, enclosure, suction and wind reduction as dust measures. Source: IPLO, factsheet T5.3, undated. Moistening pulls against the sticking problems above, so settle that balance with the maker.

8After the separator

An eddy current separator throws conductive metal as a group. Lines that need a cleaner product add steps after it.

STEINERT's aluminum line runs magnets, then the eddy current separator, then sensor sorters to refine the product. Source: STEINERT, Aluminum recycling, undated.

A sensor sorter downstream needs prepared feed of its own. Source: Van Dyk Recycling Solutions, Five steps to prepare your material for intelligent sorting, RecyclingInside, 2021. Remcon Equipment, the publisher's affiliate, covers sorter feed in its feed-presentation guide.

On ash lines, induction sensor sorting targets stainless steel, and density separation recovers fine heavy non-ferrous metal. Source: Šyc et al., 2020.

On MRF container lines, the separator's product still carries other non-ferrous metal, fiber and plastic. Some MRFs staff a quality-control station to clean it; others sell it as it comes off. Source: GBB for CMI, 2020.

Catching what the first separator missed

A second separator on the residue line is the most common fix MRFs use for missed cans. Source: GBB for CMI, 2020.

Operators quoted by the Can Manufacturers Institute report that second separators on glass discharge lines recover about 15 tons of aluminum a month at each of two MRFs. Another, on the outthrow of a glass cleaning system, captures about 94% of the cans presented to it. These are operator statements. Source: CMI, MRFs that have added can capture equipment, 2020.

9Questions

Does a faster separator belt separate better?

Not necessarily. A faster belt spreads the same feed thinner, but it also shortens the time each piece spends in the field and throws everything farther, metal or not. Two peer-reviewed studies found that separation efficiency fell as feed speed rose. Ask each maker whether its belt speed is fixed or adjustable. Sources: Bunting, 2020; IMI service manual; Ruan and Xu, 2012; Ruan et al., 2017.

Why screen the feed before an eddy current separator?

IMI says particle size is the key to setting the splitter position and belt speed. Small pieces also respond weakly: conventional machines lose effectiveness below about 5 mm. Plants that recover fine metal screen the feed into size fractions and give each fraction its own separator. Sources: IMI service manual; Settimo, Bevilacqua and Rem, 2004; Bunge, 2019.

Does wet material affect an eddy current separator?

Yes. Moist pieces stick to each other and to the belt, and damp, sticky streams build up on vibratory feeder pans. Very wet feed lowered recovery in plant tests on bottom ash. No published source we found gives a moisture level at which a dry separator starts to lose recovery, so ask for a test on your own material. Sources: Goudsmit; Recycling Product News, 2018; Rahman and Bakker, 2013.

10Sources

Every source below was read on 2026-10-06. Manufacturers' figures are their own claims about their own machines; nothing here was tested by the publisher.

  1. Šyc M., Simon F.G., Hykš J., Braga R., Biganzoli L., Costa G. et al., Metal recovery from incineration bottom ash: state-of-the-art and recent developments, Journal of Hazardous Materials 393:122433, 2020 (peer-reviewed; postprint). https://cris.unibo.it/bitstream/11585/762085/5/S%cc%8cyc2020_postprint.pdf. Read 2026-10-06.
  2. Bunge R., Recovery of metals from waste incinerator bottom ash, UMTEC, OST Eastern Switzerland University of Applied Sciences, June 2019 (technical monograph). https://www.ost.ch/fileadmin/dateiliste/3_forschung_dienstleistung/institute/umtec/fachartikel/2019/19-03_recovery_of_metals_from_waste_incinerator_bottom_ash.pdf. Read 2026-10-06.
  3. Industrial Magnetics, Inc. (IMI), Eddy Current Separator Service Manual, endless belt, manual 900505, undated (manufacturer). https://assets.magnetics.com/assets/files/manuals/900505_ECS_Service_Manual_Endless_Belt.pdf. Read 2026-10-06. Industrial Magnetics supplies eddy current separators and magnets to Remcon Equipment, the publisher's affiliate.
  4. Gershman, Brickner & Bratton (GBB) for the Can Manufacturers Institute, Aluminum Beverage Can: Driver of the U.S. Recycling System, 2020-06-23 (commissioned report). https://www.cancentral.com/wp-content/uploads/2023/03/GBB-Report-Aluminum-Can-Drives-U.S.-Recycling-System-Final-2020-0623.pdf. Read 2026-10-06.
  5. Kessler Consulting, Inc., for Pinellas County (FL) Department of Solid Waste Operations, Materials Recovery Facility Technology Review, September 2009 (government-commissioned report). https://www.nswai.org/docs/MATERIALS%20RECOVERY%20FACILITY%20TECHONOLOGY%20REVIEW.pdf. Read 2026-10-06.
  6. Duranceau C., Spangenberger J., Argonne National Laboratory, All Auto Shredding: Evaluation of Automotive Shredder Residue Generated by Shredding Only Vehicles, ANL/ES-C0201801, July 11, 2011 (government). https://publications.anl.gov/anlpubs/2011/09/70931.pdf. Read 2026-10-06.
  7. Eriez, RM-99 RevX-E Eddy Current Separator installation, operation and maintenance manual, April 2015 (manufacturer). https://www.eriez.com/Documents/Literature/IOMs/Metals-Recycling/RM-99-Eriez-RevXE-Eddy-Current-Separator-IOM.pdf. Read 2026-10-06.
  8. Bunting, 5 Key Eddy Current Separator Operating Parameters, 2020-11-10 (manufacturer). https://buntingmagnetics.com/blog/5-key-eddy-current-separator-operating-parameters. Read 2026-10-06.
  9. Eriez, VB-3301 Heavy Duty Vibratory Feeders brochure, 2021 (manufacturer). https://www.eriez.com/Documents/Literature/Brochures/Products/Vibratory/VB-3301-Eriez-Heavy-Duty-Feeders.pdf. Read 2026-10-06.
  10. Goudsmit Magnetics, EddyFines eddy current separators, product page, undated (manufacturer). https://www.goudsmitmagnetics.com/en-us/products/belt-conveyor-magnetic-separators/eddyfines-eddy-current-separators. Read 2026-10-06.
  11. Eriez, SM-780-1 Eddy Current Separator REA Cartridge Design installation, operation and maintenance manual, 2010 (manufacturer). https://www.eriez.com/Documents/Literature/IOMs/Metals-Recycling/SM-780-1-Eriez-Eddy-Current-Separator-REA-Cartridge-Design-IOM.pdf. Read 2026-10-06.
  12. Eriez, VM-3660C Brute Force Feeder installation, operation and maintenance manual, 2009 (manufacturer). https://eriez.com/Documents/Literature/IOMs/Vibratory-Feeders-and-Conveyors/VM-3660-Eriez-Brute-Force-Feeder-IOM.pdf. Read 2026-10-06.
  13. US EPA, Standard Volume-to-Weight Conversion Factors, table last updated 2006-02-28 (government, compiling secondary data). https://www.epa.gov/sites/default/files/2016-03/documents/conversions.pdf. Read 2026-10-06.
  14. Bunting, Eddy Current Separator Rotor Speed Review, 2018-11-13 (manufacturer). https://buntingmagnetics.com/blog/eddy-current-separator-rotor-speed. Read 2026-10-06.
  15. Ruan J., Xu Z., Approaches to improve separation efficiency of eddy current separation for recovering aluminum from waste toner cartridges, Environmental Science and Technology 46(11):6214-6221, 2012 (peer-reviewed; abstract read). https://pubmed.ncbi.nlm.nih.gov/22571825/. Read 2026-10-06.
  16. Ruan J., Dong L., Zheng J., Zhang T., Huang M., Xu Z., Key factors of eddy current separation for recovering aluminum from crushed e-waste, Waste Management 60:84-90, 2017 (peer-reviewed; abstract read). https://pubmed.ncbi.nlm.nih.gov/27553908. Read 2026-10-06.
  17. IFE Aufbereitungstechnik, Eddy current separators brochure, 03/2026 (manufacturer). https://www.ife-bulk.com/fileadmin/user_upload/ife-bulk/Produkte/Wirbelstromscheider/IFE-eddy-current-separators_web.pdf. Read 2026-10-06.
  18. Remcon Equipment, Inc. (the publisher's affiliate), Eddy Current Separators for Aluminum Recycling, undated (affiliate's own site). https://www.remconequipment.com/eddy-current-aluminum-separators. Read 2026-10-06.
  19. Rahman M.A., Bakker M.C., Sensor-based control in eddy current separation of incinerator bottom ash, Waste Management 33(6):1418-1424, 2013 (peer-reviewed; abstract read). https://pubmed.ncbi.nlm.nih.gov/23490354/. Read 2026-10-06.
  20. Settimo F., Bevilacqua P., Rem P., Eddy current separation of fine non-ferrous particles from bulk streams, Physical Separation in Science and Engineering 13(1):15-23, 2004 (peer-reviewed). https://repository.tudelft.nl/record/uuid:a219d415-14cf-47ee-84de-719786333cdb. Read 2026-10-06.
  21. STEINERT, EddyC FINES, product page, undated (manufacturer). https://steinertglobal.com/us/sorting-systems/magnetic-separation/eddy-current-separators/steinert-eddyc-fines/. Read 2026-10-06.
  22. Goudsmit Magnetics, What determines the separation efficiency of eddy current systems, knowledge base, undated (manufacturer). https://www.goudsmitmagnetics.com/en-us/knowledge-base-efficiency-of-eddy-current-separators. Read 2026-10-06.
  23. Recycling Product News, New conveyor feed boosts yield of eddy current separator (reporting Goudsmit), 2018-10-26 (trade press). https://www.recyclingproductnews.com/article/29332/new-conveyor-feed-boosts-yield-of-eddy-current-separator. Read 2026-10-06.
  24. Mika S., Mühl J., Lederer J., Extraction of metallic aluminum from fluidized bed and grate incineration bottom ash, Waste Management and Research 44(9):1460-1471, 2026 (peer-reviewed; abstract read). https://pubmed.ncbi.nlm.nih.gov/42068213/. Read 2026-10-06.
  25. US Federal Highway Administration, FHWA-RD-97-148, municipal solid waste combustor ash, material description, 1997 to 1998 (government). https://www.fhwa.dot.gov/publications/research/infrastructure/pavements/97148/033.cfm. Read 2026-10-06.
  26. US Occupational Safety and Health Administration (OSHA), Combustible Dust, undated (government). https://www.osha.gov/combustible-dust. Read 2026-10-06.
  27. IPLO (Informatiepunt Leefomgeving, Netherlands), factsheet T5.3 Wervelstroomscheider, undated (government). https://iplo.nl/thema/lucht/milieubelastende-activiteiten-lucht/maatregelen-stofemissie-overslag-bewerken-goederen/factsheets-sorteren-bulkgoederen/t5-3-wervelstroomscheider/. Read 2026-10-06.
  28. STEINERT, Aluminum recycling, application page, undated (manufacturer). https://steinertglobal.com/us/applications/metal-recycling/aluminum-recycling/. Read 2026-10-06.
  29. Can Manufacturers Institute, Examples of MRFs who have successfully added aluminum can capture equipment, 2020-12-02 (industry association, operator statements). https://www.cancentral.com/sustainability__trashed/examples-mrfs-who-have-successfully-added-aluminum-can-capture-equipment/. Read 2026-10-06.
  30. Van Dyk Recycling Solutions, Five Steps to Prepare Your Material for Intelligent Sorting, RecyclingInside, 2021-01-07 (trade press, dealer author). https://recyclinginside.com/news/five-steps-to-prepare-your-material-for-intelligent-sorting/. Read 2026-10-06.

Also linked, on the affiliate's own site: Optical Sorter Feed Presentation, Live Floor Bins, Infeed Conveyors, Vibratory Feeders and Maximum Conveyor Incline Angle.

Updated . Next review due [date].

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