Design, Construction and Testing of a Kerosene Powered ...

LAUTECH Journal of Civil and Environmental Studies

Volume 3, Issue 1; September 2019

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Design, Construction and Testing of a Kerosene Powered Multi Bird-Egg Incubator 1Adetola, S.O., 2Adegbite, A.S., 3Adewale, K.A. and 4Ibiwoye, O.S.

1,2,3,4Department of Mechenical Engineering, Ladoke Akintola University of Technology, Ogbomoso, Oyo State,

Nigeria.

*Corresponding E-mail: [email protected]

Abstract

The demand for poultry products such as eggs, meat and birds is on the increase daily that the

world can no longer depend solely on the natural mode of incubation hence, the need for artificial

incubators. But not all countries have stable electricity supply; therefore, there is a need to fabricate

other types of incubators that will not be powered by electricity. Hence the choice of kerosene

powered incubator.

Heat generated by the combustion of kerosene was transferred into the incubator chamber by

conduction and circulated by means of a 12 V D.C fan powered by a 12volt battery device. LM35

temperature sensor was used as the temperature sensing device. Both the turning of eggs and heat

generated from heat source were controlled by mechanically incorporated driver motors. The

LM35 temperature sensor and the two stepper motors were controlled by a PIC16F877

microcontroller. Insulation of the incubator chamber was achieved by lining the inner portion of

the incubator with fiber materials. The incubator was designed and constructed using locally

available material to reduce cost with little or no dependence on electricity and more user friendly.

The incubator was tested with 90 eggs each for the three birds (i.e Chicken, Quail and Turkey).

The result obtained shows that quail has the highest hatchability of 93% followed by Chicken with

84.4% and lastly turkey with 70%. The unit cost for the incubator is ₦95,000.00.

The above average efficiencies implied that the Incubator performed efficiently and effectively.

The birds also look healthy and strong several days after they were hatched.

Keywords: Poultry, incubator, microcontroller, hatchability, sensor

Introduction

Poultry is a category of domesticated birds kept by humans for the purpose of collecting their eggs,

or killing for their meat and/or feathers. These typically are members of the superorder

Galloanserae (fowl), especially the order Galliformes (which includes chickens, quails and

turkeys) and the family Anatidae (in order Anseriformes), commonly known as “waterfowl” (e.g

domestic ducks and domestic geese). Poultry is the second most widely eaten meat in the world,

accounting for about 30% of meat production worldwide, after pork at 38% (Raloff, 2003).

Incubation refers to the process by which certain oviparous (egg-laying) animals hatch their eggs,

and to the development of the embryo within the egg (Ekarius, 2007). A hen can successfully hatch

12-15 eggs depending on her size. A big bird will be able to cover 9-11 duck eggs or 4-6 turkey or

goose eggs. The hen turns the eggs and alters their position in the nest regularly to ensure even

distribution of heat. If too many eggs are placed under the hen the outside ones may not get enough

warmth and during cold weather the embryo will be destroy. The demand for poultry products is

always above the supply and therefore, farmers (poultry operators) can no longer rely solely on

natural incubation and hence, the need for artificial incubation.

Incubation can successfully occur artificially in machines (incubators) that provide the correct,

controlled environment for the developing chick (Philip, 2010). An incubator can be described as

DOI: 10.36108/laujoces/9102/20(0210)

mailto:[email protected]

Design, Construction and Testing of a Kerosene Powered Multi Bird-Egg Incubator

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an enclosure having controlled temperature, humidity and ventilation for successful hatching of

eggs (Akinsanmi, 2000). Its objectives are to construct a kerosene powered incubator which is

independent of electricity and affordable by small scale poultry farmers and that is user friendly

(i.e. does not require technical knowledge for its operation) since most of the developed incubation

process is automated (i.e. automatic incubator).

Due to instability in power generation and distribution in Nigeria and some other African countries,

it is necessary to construct incubators that are independent of electricity. This has been done in

time past with different sources of power and some of the notable ones are the solar powered and

kerosene powered incubators. The solar powered may not be efficiently used in Nigeria due to

weather instability most especially during the raining season when the intensity of the sun is so

low.

Furthermore, kerosene gotten from crude oil is in abundant in Nigeria and is readily available. It

can then be concluded that kerosene powered incubator is the most appropriate for Nigerians,

which makes this study not only relevant to the small-scale poultry farmers but also to the nation

at large. This study was limited to design, construction and testing of kerosene powered multi-egg

bird incubator.

Overview of incubation

Artificial incubation of poultry eggs is an ancient practice. Aristotle writing in the year 400 B.C.

reported of Egyptians incubating eggs spontaneously in dung heaps. The Chinese developed

artificial incubation at least as early as 246 B.C. These early incubation methods were often

practiced on a large scale, a single location perhaps having capacity of 36 000 eggs. The proper

temperature was judged by placing an incubating egg in one’s eye socket for accurate

determination. Temperature changes were effected in the incubator by moving the eggs, by adding

additional eggs to use the heat of embryological development of older eggs and by regulating the

flow of fresh air through the hatching area. Turning was done as often as five times in a 24-hour

period after the fourth day of incubation. Smith incubator was patented in 1918 and it was a

forerunner of today’s efficient, large-scale incubator, used for the hatching of chicken, turkey,

duck and other eggs (Philip, 2010).

Types of Incubator

Incubators have been categorized based on various factors some of which are; capacity, air

circulation mechanism and source of heat etc. According to Philip (2010), there are two types of

incubators commonly used which are forced-air incubators which have an in-built fan for air

circulation and still-air incubators with no in-built fan but air is allowed to stratify. Various types

of incubators have been developed with source of heat as a major factor. Different sources of heat

can be used to warm the eggs, the most common being electricity, solar energy or fuel such as

charcoal, kerosene or gas.

Environmental Conditions, Position and Turning of Eggs for Incubation

According to Brinsea (2013), all birds require five environmental conditions to be controlled to

enable the correct development of the embryo these are; eggs must be maintained at the right

temperature to enable the metabolic processes within the developing embryo to occur at the correct

rate, it must be frequently turned and carefully positioned so that the embryo passes through fresh



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nutrients in the white portion of the eggs while forming in the correct position for hatching,

humidity of the air around it must be controlled to ensure the right amount of water lost over the

incubation period, regular supply of fresh air to provide oxygen and to remove waste carbon-

dioxide and a clean, disinfected environment must be provided because eggs are susceptible to

infection.

Eggs should be placed in the incubation compartment with their large ends up for best result.

However, a fairly good hatch can be obtained if the eggs are placed on their sides. An extremely

poor hatch will occur if the eggs are placed in the incubator with the small end up. The eggs must

be turned automatically several times a day for best result. The turning should be repeated

throughout the entire 24-hour and should be turned at least four times each 24-hour period through

a 90-degree plane as gently as possible. Turning should continue until one to three days prior to

hatching and or until the eggs has “piped”; position or turning will then have no effect on hatching

(Philip, 2010).

Candling Incubated Eggs

Incubated eggs are candled to determine their fertility. Also, if fertile, to check growth and

development of the embryo is difficult. White shelled eggs should be tested for fertility on the third

day while brown shelled eggs should be tested on the fifth or sixth day because it is difficult to see

the embryo before this time. A small reddish area with blood vessels extending away from it will

be visible in fertile eggs. This is the embryo floating around inside the egg, looking like a huge red

spider. If the embryo dies, the blood draws away from the embryo and forms a blood ring. If eggs

are not candled during the early stages of incubation, it will be difficult to determine whether the

egg was fertile.

Design Procedure and Operation of the Incubator

The incubator was designed and powered by kerosene. The heat generated by the combustion of

kerosene was transferred into the incubator chamber by conduction through the worm duct and

circulated by means of a 12 V D.C fan powered by a 12 V battery. DHT11 temperature and

humidity sensor were used as the sensing device. Both the turnings of the eggs and heat generated

from heat source were controlled by mechanically incorporated stepper motors. The DHT11

temperature and humidity sensor and the stepper motors were controlled by a PIC16F628A

microcontroller. Insulation of the incubation chamber was achieved by lining the inner portion of

the incubator with fibre materials to cover as much as possible leaving clearance for air circulation

around the fan and the two ends of the air hallway. The whole assembly was made up of two major

parts which are; mechanical parts and mechatronic. The incubator has three compartments of egg

trays and was designed with a capacity of 270 eggs for chicken and/or turkey and 810 for quail per

time.


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Table 1: Average Incubation Period for Some Bird Species Birds Incubation period (days)

Chicken 21

Pheasant 23

Duck 28

Pea foul 29

Guinea 27

Quail (Coturnix) 16

Duck (Muscovy) 36

Ostrich 42

Goose 32

Turkey 28

Pigeon 18

Quail 23

Canary 13

Parakeet 19

Prairie Chicken 23

Grouse 23

Source: Philip (2010)

Material and Methods

The materials used for the design were sourced locally which are plywood, hardwood, fibre

material, steel pipe, metal sheet, wire gauze, nail, gum, hinges and bolt and nut. This was aimed at

producing an incubator of a very low cost, increased economic and mechanical efficiency and to

make it readily available to local farmers.

The materials selected were considered based on their availability locally, cost (i.e. low prices yet

efficient and meeting the required standard), appearance (i.e materials used possess good

finishing), size and weight and mechanical properties (machinability, strength, durability and

conductivity).

Egg Tray and Hatcher with Its Support

The egg tray used was the commercial egg tray (crate). This was used to hold eggs in safe position

for turning, (18 days for chicken, 25 days for turkey and 20 days for quail). The trays are of plastic

material with overall dimensions of approximately 290×290×400 mm. The trays sit in tray

supports which were fixed in the incubator such that the trays can be removed and replaced with

hatchers during hatching. The hatcher was based on the dimension of the tray/hatcher support.

This held the eggs in position during the last three days of incubation (i.e. hatching period). It is a

flat surface material made of hardboard (straw board) was considered for this purpose because of



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its ability to absorb the fluid discharged during hatching. The overall dimension is 395×395×1.5

mm.

The tray and hatcher support are composed of plywood with hard wood strips and wire gauze.

Three of this were used, each of which were positioned inside the incubator such that they can

undergo an oscillatory motion through 90o (for the turning of the eggs). It supported each of the

three egg trays and hatcher in position inside the incubator. The dimensions are as given in Table

2.The various parts described in Table 3 were nailed and glued together with wire gauze spread

and glue on the web as shown in Figure 1. Holes of 30 mm diameter were drilled through the

thickness of 10 mm on the lower part of the two side panels to house the bearings. Another hole

of 10 mm diameter was drilled through the entire thickness of the side panels and boundary. This

accommodated the connecting rod and bearing assembly that served as the fulcrum for the tray

support to undergo a reciprocating motion also shown in Figure 2. The tray supports are mounted

on a pie (π) shaped frame at the sides of the unit. This frame was located at the center of the

incubator unit. Holes of 10 mm diameters were drilled at predefined locations on the vertical

support mount which serves as points of attachments for the metal rod that formed the fulcrum for

the tray supports. The overall dimension of the system is 400×400×600 mm. Figure 3 shows the

exploded view of the incubator. Table 4 shows the parts list of the exploded view of the incubator.

Table 2: Description of Tray and Hatcher Support Quantity Length (mm) Thickness (mm) Height (mm) Description Material

6 400.0 20.0 50.0 Boundary (A) Hardwood

6 360.0 20.0 20.0 Boundary (B) Hardwood

6 408.0 4.0 10.0 Side Panel (C) Plywood

6 392.0 4.0 10.0 End Panel (D) Plywood

6 360.0 20.0 20.0 Web (E) Hardwood

Table 3: Description of Tray and Hatcher Support Mount Quantity Length (mm) Thickness (mm) Width (mm) Description

2 1200.0 20.0 50.0 Vertical support mount

1 550.0 20.0 50.0 Horizontal support mount


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Figure 1: Egg Tray and Hatcher

Figure 2: Tray and Support inside the Incubator



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Figure 3: Exploded View of the Incubator


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Table 4: Parts List for the Exploded View

Mounting the Automatic Egg Turner and Temperature and Humidity Sensor System

The system consists of a stepper motor, a crank mechanism made up of a crank rod and a

connecting rod, and the microcontroller that gave it the required voltage signals. The

stepper motor was mounted on the rear of the incubator behind the tray and hatcher support

system. This connection ensured that the rotary motion of the stepper motor was converted

to the oscillatory motion of the tray and hatcher support system using crank mechanism.

The sensor sends appropriate voltage signals corresponding to the temperature and

humidity detected at regular interval to the microcontroller which in turn sends the actual

values of temperature and humidity detected to the display unit (seven segment display)

for visual inspection. Depending on the value of the temperature sensed, the

microcontroller also sends required voltage signals to the stepper motor incorporated with

the heat source (lantern) in order to adjust the height of the wick, which brings about

increase or decrease in heat generated.

Heating Source and System

A suitable stove burner with wicks was used as the means of combustion for this work.

Small gears were attached to the adjusting knob of the burner and to the rotating shaft of a

stepper motor which were connected with the driving belt linearly. The stepper motor was

properly configured with the microcontroller so that it only moves at the impulse of the

Item Quantity Part Number Description

1 1 Frame Wood

2 1 Ground Insulator Styrofoam

3 1 Tray Support Mount Wood

4 3 Tray Support Wood

5 3 Metal Rod Mild Steel

6 1 Bowl Plastic

7 1 Top Insulator Styrofom

8 1 Top Cover Plywood

9 2 Side Insulator Styrofoam

10 2 Side Cover Plywood

11 1 Worm Duct Flexible Steel Pipe

12 1 Cooling Fan Purchased

13 1 Back Insulator Styrofoam

14 1 Back Cover Plywood

15 3 1so 4034 – M10 Hexagon Nuts

16 2 Din En Iso 2010 – M10x14 Slotted Raised Counter Sunk Flat Head

Screws

17 6 Gb/T 283-94 – Nh 202 E – Nh Rolling Bearings – Cylindrical Roller

Bearings

18 1 Front Insulator Styrofoam

19 1 Front Door Plywood

20 1 Tank Metal Sheet

21 3 Tray Purchased

22 1 Sensor Purchased

23 2 Sheet Metal Strap Mild Steel

24 6 Din En Iso 4015 – M6x25 Hexagon Head Bolts

25 1 Rotor Purchased

26 1 Connecting Rod Mild Steel

27 1 Glass Purchased



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microcontroller. It was ensured that the wick holder is relatively free to move through the

burner so that it can be raised or lowered with very little torque/ power from the stepper

motor.

The heating system involved two circulations which are internal and external. The external

circulation begins at the kerosene flame. Air enters the base of a burner through small holes

in the base. The hot air passes into a short vertical pipe, makes an abrupt 900 bend which

was wrapped with high temperature insulation (Styrofoam), and passes into an S-shaped 40

mm (diameter) stainless steel pipe in which winds find its way to the top and out. The S-

bends promotes heat transfer and extend the length of the pipe exposed to the incubation

chamber. The internal circulation was driven by a 12 V fan which required a 12 V battery.

The fan was located at the lower portion of the incubator closer to the hotter part of the

steel pipe. The internal circulation was in opposite direction to the external one. Warm air

will be drawn in from the top and drawn down over the S-shaped steel pipe where it passes

over its increasingly hotter surface before being expelled into the incubation cabinet by the

fan at the bottom. A small amount of air enters the system at the bottom where the hottest

gas passes into the S-shape steel pipe and cools the pipe to reduce the danger of burning

the cabinet wood.

Tank and Chimney

The tank and chimney were fabricated with acetylene welding equipment. A small collar

was fabricated on the tank to hold/attach the base of the burner to the tank along a corner

of the tank top surface. A filling hole was also fabricated on the tank which was made

accessible enough for re-filling without turning off the heat supplied to the incubator. The

outside dimension of the tank was 500×800×50 mm.

The chimney was made up of two parts: the elbow pipe and sight glass. The elbow pipe

will turn the heat of the flame into the incubator through an abrupt 90o bend. Tiny breathing

holes were drilled on the chimney to ensure necessary air circulation (oxygen gets to the

wick for proper combustion).

Water Supply

Incubating eggs requires a high humidity (50-55%) to prevent desiccation. The fan in the

internal circulation system blows warm air over a shallow pan of water located at the

bottom of the incubator. The water evaporates; thereby maintaining the high humidity but

also cools the air. The surface area of the pan determines the humidity level. If a higher

humidity is needed, the diameter of the evaporating pan will be increased. The bottom of a

plastic container trimmed to 20 mm depth was used. The water supply was maintained by

siphon just as in most chick water. A liter plastic bottle with a threaded plastic cap was

used as the reservoir. A hole was drilled a bit smaller than the rubber hose that was used to

transport wetter into the incubation cabinet to the evaporation pan. A 10 mm rubber hose

was used. The hose was properly fixed on the rim of the plastic bottle to make an air tight

and water tight seal.

Insulation and Casing

Fibre materials were used as insulation material for the incubator. About 30 mm thick layer

of fibre was applied to cover as much of the internal surface of the incubation chamber as

possible leaving clearance for air circulation around the fan, DHT11 temperature and


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humidity sensor and the two ends of the hallway. A sheet of insulation material was placed

at the internal part of the door, leaving a little clearance for visual inspections of the

condition of the eggs. Another sheet of insulation material was attached over the entire rear

panel to prevent heat loss through the wood closest to the flexible heating pipe.

The outside was made up of 19 mm thick plywood. Wood screws was used to assemble it

so that it can be disassembled easily if need be. A tight fit is not critical as the door

insulation creates an effective seal against air escape. Low kerosene consumption and good

temperature control depends on preventing unwanted air leakage from the unit and so

silicon sealant was applied on appropriate places to prevent air escape. The overall

dimension of the unit was 1300×730×700 mm. Hence the internal volume of the incubator

was 664300000 mm3 (664.3 liters).

Microcontroller Unit

This unit will control all the automatic processes of the incubator such as turning of eggs

at regular intervals, temperature regulation and heat regulation. All these were achieved

with a program code that was written on the programmable interface controller (PIC

microcontroller) in the microcontroller unit. This unit was powered by a 12 V rechargeable

battery that was recharged at regular intervals. The unit was mounted at a suitable location

inside the incubator for optimum performance.

Results and Discussion

Results of the Tests Carried out on the Incubator

The incubator was tested with chicken, quail and turkey eggs respectively and the results

of the temperature variation and activities carried out for the incubation period of each of

the eggs are given in Tables 5, 6 and 7, respectively. 90 eggs were set for each of the bird.

Result of the Incubated Chicken, Quail and Turkey Eggs

The result obtained from the incubation of chicken eggs is presented in Table 8. It shows

that the numbers of eggs set were 90, the number of infertile and fertile eggs were 23 and

67 respectively, while the percentage fertility was 85.1%. Also, the result obtained from

the incubation of quail eggs is presented in Table 9. It shows that the numbers of eggs set

were 90, the numbers of infertile and fertile eggs were 12 and 78 respectively, and the

percentage fertility was 93.6%. Similarly, the result obtained from the incubation of turkey

eggs is presented in Table 10 which shows that the number of eggs set were 90 and the

number of infertile and fertile eggs through candling were 31 and 59 respectively, while

the percentage fertility was 67.8%.The result of hatchability of 84.4% was obtained for

chicken egg in this study while Bakare, 1996 obtained 62.4% for the same type of egg. The

study considered multi-egg incubator but Bakare, 1996 considered only chicken egg. Bill

of materials is presented in Table 11.

Table 5: Daily Temperature Readings and Activities for Chicken Eggs Day Temperature Variation (oC) Activities for the Day

Morning Afternoon Evening

1 36.0 39.5 37.5 Eggs were set

2 37.5 39.0 36.0 Eggs were observed

3 36.5 39.0 36.5 Water reservoir was refilled

4 35.0 40.0 36.0 The kerosene reservoir was refilled



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5 37.5 38.5 35.0 The incubator chimney was cleared

36.5 38.5 36.0 Eggs were candled to separate infertile eggs

7 37.0 39.0 36.5 Eggs were candled the second time






13 36,5 38.0 36.5 Water reservoir was refilled





18 36.5 36.5 36.5 The eggs were removed from the trays in

preparations for hatching

19 36.0 35.5 35.0 Temperature was lowered in preparation for

hatching as the chicks began to peck

20 35.5 36.0 36.0 Hatching begins

21 36.5 36.5 35.5 Hatching continues

22 36.0 35.5 35.5 Hatching ends

Table 6: Daily Temperature Readings and Activities for Quail Eggs Day Temperature Variation (oC) Activities for the Day


1 36.0 39.5 37.5 Eggs were set





6 36.5 38.5 36.0 Eggs were candled to separate infertile eggs







13 36,5 38.0 36.5 Water reservoir was refilled



16 38.0 39.0 38.0 The eggs were removed from the trays in

preparations for hatching


hatching as the chicks began to peck

18 36.0 36.5 35.5 Hatching begins


20 36.5 37.0 36.0 Hatching ends

Table 7: Daily Temperature Readings and Activities for Turkey Eggs Day Temperature Variation (oC) Activities for the Day


1 36.0 39.5 37.5 Eggs were set




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9 37.5 39.5 38.0 Eggs were candled to separate infertile eggs




13 36,5 38.0 36.5 The kerosene reservoir was refilled





18 36,5 38.0 36.5 Eggs were observed








26 37.0 39.5 37.0 Eggs were removed from tray in preparation

for hatching


Hatching

28 36.5 37.5 35.5 Hatching starts


30 36.0 37.0 35.5 Hatching ends

Table 8: Result Obtained from the Incubation of Chicken Eggs Data Bird One (Chicken)

Date Set 7th July, 2014

Incubation period 21-23 days

Number of Egg Set 90eggs

Number Infertile Eggs 23

Number of Fertile Eggs 67

Percentage Fertile 74.4%

Date Hatching started 27th July, 2014

Number Unhatched Eggs 10

Number of Hatched Eggs 57

Percentage Hatchability of Total Eggs 63.3%

Percentage Hatchability of Fertile Eggs 85.1%

Table 9: Result Obtained from the Incubation of Quail Eggs Data Bird Two (Quail)

Date Set 3rd August, 2014

Incubation period 18-19 days






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Date Hatching started 21st August, 2014

Number Unhatched Eggs 5




Table 10: Result obtained from the Incubation of Turkey Eggs Data Bird Three (Turkey)

Date Set 24th August, 2014

Incubation period 28-30days





Date Hatching started 21st September, 2014

Number unhatched Eggs 19




Table 11: Bill of Materials

Conclusion

An automatic and user friendly kerosene powered incubator which is independent of

electricity was designed, constructed and tested with three different bird eggs - chicken,

quail and turkey. The result of the test carried out on the kerosene powered incubator gives

high percentage of hatchability for each of the eggs tested which shows that the machine

Materials Quantity Cost (N)

Plywood 5 pieces 9,000

Hardwood 10 pieces 2,000

Fiber materials 2 bags 4,000

Steel pipe 1 piece 5,000

Steel metal sheet 1 pieces 2,000

Battery 1 piece 12,000

Automation components 10,000

Aluminum metal sheet 5 pieces 3,000

Stove 1 piece 1,500

Kerosene 68 liters 8,840

Workmanship (Carpentry and Welding) 11,000

Programming workmanship 20,000

Miscellaneous 10,000

Transportation 10,000

Total 104,340


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is highly efficient and effective. It also shows that for the same number of eggs set, quail

has the highest hatchability of and 93.6% while the turkey has the lowest of 67.8%.

A single incubator can be used to hatch more than one species of bird effectively (i.e.

chicken, quail and turkey). A locally fabricated incubator can be automated with almost

the same cost as the cost of manual one.

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