Types of Duplicating Inks
Duplicating ink is a specialized type of ink used in offset printing, stencil duplication, and analog copiers. Unlike standard printer inks, duplicating inks are formulated for high-volume reproduction, mechanical transfer processes, and durability under repeated use. Their unique chemical composition allows for consistent image transfer across thousands of copies, making them essential in educational institutions, offices, and industrial printing environments.
This guide explores five primary types of duplicating inks, each engineered for specific substrates, printing methods, and performance requirements. Understanding their properties helps in selecting the right ink for quality output, cost-efficiency, and environmental considerations.
Oil-Based Duplicating Ink
Formulated with an oil carrier, this ink is thick and highly viscous, designed for mechanical duplicators like spirit duplicators or mimeograph machines.
Advantages
- Excellent adhesion to rough and uncoated paper
- High durability and resistance to smudging
- Cost-effective for bulk printing
- Long shelf life when stored properly
Limitations
- Slow drying time
- Strong odor and potential for staining
- Less environmentally friendly
- Not suitable for glossy or non-porous surfaces
Best for: High-volume office documents, school worksheets, newsletters on standard paper
Aqueous (Water-Based) Duplicating Ink
Composed primarily of water and pigments, this eco-friendly ink dries quickly and is safer for indoor environments.
Advantages
- Low toxicity and minimal odor
- Environmentally sustainable
- Fast drying on absorbent paper
- Easy cleanup with water
Limitations
- Poor performance on glossy or coated surfaces
- Less vibrant color output
- Shorter shelf life due to water evaporation
- May feather or bleed on low-quality paper
Best for: Educational handouts, internal memos, eco-conscious printing operations
Solvent-Based Duplicating Ink
Uses organic solvents as carriers, enabling strong bonding to non-porous materials such as plastic, metal, and synthetic fabrics.
Advantages
- Superior adhesion to diverse surfaces
- Highly durable and resistant to moisture
- Bright, long-lasting prints
- Ideal for industrial labeling and packaging
Limitations
- Pungent fumes and health hazards
- Requires proper ventilation
- Longer drying time
- Higher environmental impact
Best for: Industrial tags, product labels, printing on plastic sheets or metal foils
Super Duplicating Ink
A high-viscosity ink with concentrated pigments, designed for precision printing on non-absorbent surfaces.
Advantages
- Exceptional print density and color richness
- Optimized for carbon paper and multi-part forms
- Resists smearing and offsetting
- Excellent performance on glossy labels and coated stock
Limitations
- Higher cost per unit
- Limited compatibility with standard paper
- Requires specialized equipment calibration
- Potential for clogging in older machines
Best for: Commercial forms, invoice printing, barcode labels, high-contrast documentation
Thermal Duplicating Ink
Solid at room temperature, this ink melts under heat during thermal transfer printing, bonding directly to the substrate.
Advantages
- Produces water-resistant, durable prints
- High precision and sharp detail
- Used in automated label and card production
- No liquid mess or evaporation issues
Limitations
- Requires thermal printer or specialized equipment
- Limited to compatible ribbons and substrates
- Higher initial setup cost
- Sensitive to excessive heat after printing
Best for: ID cards, shipping labels, receipts, barcode systems
| Type | Viscosity | Drying Time | Environmental Impact | Best Application |
|---|---|---|---|---|
| Oil-Based | High | Slow | Moderate to High | Office documents, school printing |
| Aqueous (Water-Based) | Low to Medium | Fast | Low | Eco-friendly bulk printing |
| Solvent-Based | Medium to High | Slow | High | Industrial labels, plastic/metal printing |
| Super Duplicating Ink | Very High | Moderate | Moderate | Carbon forms, glossy labels |
| Thermal Duplicating Ink | Solid (melts when heated) | Instant (upon cooling) | Low to Moderate | ID cards, barcodes, receipts |
Expert Tip: When switching between ink types, always clean the printing drum and rollers thoroughly to prevent cross-contamination, which can lead to inconsistent print quality or equipment damage.
Did You Know? Modern duplicating systems often combine ink formulations—such as water-based inks with solvent additives—to balance environmental safety with performance on diverse media.
Key Features of Duplicating Inks: Performance, Safety, and Efficiency
Duplicating ink supplies are essential components in high-volume printing environments, widely used in offices, educational institutions, and commercial print shops. Unlike standard printer inks, duplicating inks—often referred to as DUP inks—are specially engineered for use in duplicating machines such as spirit duplicators or digital duplicators (e.g., Riso machines). Their unique formulation and physical properties make them highly efficient, reliable, and safe for repeated use. Understanding the core features of these inks helps users maximize print quality, reduce operational costs, and ensure workplace safety.
Cost-Effectiveness for High-Volume Printing
Long-Term Savings
Duplicating inks are designed for mass production, enabling economical output over time. Because they can be manufactured and distributed in bulk, the per-unit cost is significantly lower than traditional toner or inkjet cartridges. This makes them ideal for environments requiring hundreds or thousands of copies, such as schools printing exams or businesses distributing internal memos.
Efficiency in Use
These inks offer high coverage rates with minimal waste. Their consistent formulation ensures even distribution across stencils or masters, reducing the need for reprints due to smudging or fading. As a result, businesses benefit from reduced supply consumption and fewer interruptions in workflow, contributing to overall operational efficiency.
Specialized Formulation for Duplicating Machines
One of the most defining characteristics of duplicating inks is their tailored chemical composition. Unlike standard inkjet or laser toners, duplicating inks are developed specifically to work with the mechanics of duplicator systems, which rely on stencil-based or screen-printing methods.
High Viscosity for Superior Print Quality
Rich, Vibrant Output
The high viscosity (thickness) of duplicating inks allows for greater pigment concentration, resulting in bold, dense, and visually striking prints. This is especially beneficial when reproducing graphics, charts, or dark text where clarity and contrast are critical.
Enhanced Adhesion
Due to their thicker consistency, these inks adhere more effectively to a wide range of paper types—including recycled, textured, and lightweight stocks—without soaking through or feathering. This versatility makes them suitable for diverse printing needs without requiring specialized media.
Non-Toxic and Environmentally Responsible Composition
In response to growing environmental and health concerns, modern duplicating inks are formulated with safety in mind. Manufacturers have shifted toward eco-friendly practices to protect both users and the planet.
| Feature | Benefit | Industry Standard |
|---|---|---|
| Low VOC Content | Reduces indoor air pollution and respiratory risks | Compliant with EPA and EU environmental regulations |
| Biodegradable Solvents | Lowers environmental impact after disposal | Used in leading brands like Riso and Duplo |
| Non-Carcinogenic Components | Ensures operator safety during handling and use | Meets OSHA and REACH safety guidelines |
By minimizing volatile organic compounds (VOCs) and avoiding hazardous solvents, these inks contribute to safer workplaces and align with green printing initiatives. Many are now labeled as soy-based or water-based, further enhancing their sustainability profile.
Important: Always store duplicating inks in a cool, dry place away from direct sunlight to maintain their viscosity and shelf life. Use only manufacturer-recommended inks for your duplicator model to prevent damage and ensure optimal performance. Improper substitutes may void warranties and compromise print quality.
How To Use Duplicating Inks: A Complete Guide
Duplicating inks are essential tools in various printing methods, offering cost-effective and high-quality reproduction across multiple industries. While these inks are inherently versatile, achieving optimal print results depends on proper application techniques and understanding the specific requirements of each printing process. Whether you're producing educational materials, promotional content, or official documents, selecting the right ink and method ensures clarity, durability, and efficiency.
Pro Tip: Always store duplicating inks in a cool, dry place away from direct sunlight to maintain viscosity and prevent premature drying. Shake or stir before use to ensure consistent pigment distribution.
Offset Printing
In offset printing, duplicating inks are first applied to a metal printing plate, which transfers the image to a rubber blanket cylinder. From there, the ink is "offset" onto the final substrate—typically paper. This indirect transfer allows for sharp, clean impressions even on both porous (like standard office paper) and non-porous surfaces (such as coated stock).
- Best suited for high-volume commercial printing including brochures, magazines, and flyers
- Uses fast-drying, oil-based inks that adhere well without smudging
- Requires precise ink viscosity control to avoid slurring or dot gain
- Modern offset systems often include dampening solutions to balance ink and water for optimal image quality
Key Consideration: Always verify ink compatibility with your specific press model and substrate type. Mismatched inks can cause poor adhesion, excessive drying time, or damage to rollers.
Stencil Duplicating (Ditto Machines)
Also known as mimeography or "spirit duplication," stencil duplicating is a low-cost, high-volume method ideal for schools, churches, offices, and community organizations. A master stencil is created by typing or writing on a wax-coated sheet, which is then wrapped around a rotating drum. Duplicating ink is forced through the cut areas of the stencil onto paper.
- Perfect for producing hundreds of copies quickly and affordably
- Manual pressure control allows adjustment of ink saturation and copy count
- Typically uses alcohol-based inks for rapid drying and minimal bleed-through
- Ideal for newsletters, worksheets, and event programs
Operational Tip: Replace stencils regularly to avoid ink buildup and blurred text. Clean the drum after each use to extend machine life and maintain print clarity.
Screen Printing
Screen printing uses a fine mesh screen stretched over a frame, with certain areas blocked off to form a stencil. Duplicating ink is pressed through the open mesh onto the substrate using a squeegee. This technique deposits thick, opaque layers of ink, making it perfect for vibrant designs on diverse materials.
- Commonly used on textiles (t-shirts, banners), plastics, glass, metal, and wood
- Thicker inks provide better coverage and durability, especially on dark or textured surfaces
- Water-based, plastisol, and solvent-based inks are available depending on the material and finish desired
- Multiple screens allow for multi-color designs with precise registration
Expert Insight: Adjust ink viscosity based on mesh count—finer meshes require thinner inks to pass through effectively without clogging.
Digital Duplicating
Digital duplicators combine the affordability of traditional stencil printing with the precision of digital imaging. A digital master is automatically created from a scanned original and wrapped around the drum. Duplicating ink is then transferred through the master to produce high-quality, full-color prints at a fraction of the cost of laser or inkjet printing.
- Excellent for short to mid-run jobs (50–1,000 copies)
- Produces sharp text and vivid colors ideal for brochures, catalogs, and training manuals
- Energy-efficient and low-maintenance compared to digital presses
- Specialized inks are formulated for quick drying and minimal odor
Cost-Saving Benefit: Digital duplicators use significantly less energy and consumables than copiers, reducing operational costs by up to 60% per copy.
Carbon Paper & Carbon Duplicating Ink
One of the simplest and oldest duplication methods, carbon paper is coated with a layer of carbon-based duplicating ink on one side. When placed between two sheets of paper and pressure is applied via handwriting or typewriter, the ink transfers to the underlying sheet, creating an instant copy.
- Widely used for receipts, forms, contracts, and invoices before digital adoption
- No electricity or machinery required—ideal for remote or field use
- Available in single-use and multi-copy sets (e.g., NCR paper)
- Produces instant duplicates without processing delays
Historical Note: Modern carbonless copy paper (NCR) has largely replaced traditional carbon paper, but both rely on pressure-sensitive ink transfer principles.
Emerging & Hybrid Applications
Advancements in ink formulation and printing technology have expanded the use of duplicating inks into hybrid and specialty applications.
- Pad Printing: Uses silicone pads to transfer ink from an etched plate to irregular surfaces like curved plastics or medical devices
- Foil Stamping: Combines heat and pressure with metallic inks for decorative finishes on packaging and certificates
- DIY Craft Printing: Artists and educators use duplicating inks for stamp-making, block printing, and classroom projects
- Security Printing: Specialized inks with UV-reactive or tamper-evident properties are used in official documents
Innovation Spotlight: Eco-friendly duplicating inks made from soy or vegetable bases are gaining popularity due to lower VOC emissions and easier cleanup.
Professional Recommendation: For best results, always match the ink type to both the printing method and the substrate. Test a small batch before full production to evaluate color accuracy, drying time, and adhesion. Keep detailed records of ink batches and machine settings to ensure consistency across reprints.
| Printing Method | Ink Type | Best For | Copy Volume | Drying Time |
|---|---|---|---|---|
| Offset Printing | Oil-based, quick-set | Magazines, brochures, catalogs | 500–100,000+ | 5–30 minutes (air dry) |
| Stencil Duplicating | Alcohol-based fluid ink | School handouts, bulletins | 50–5,000 | Instant to 1 minute |
| Screen Printing | Plastisol, water-based, or solvent | T-shirts, posters, signage | 1–500 | 1–10 minutes (heat-set or air dry) |
| Digital Duplicating | Low-odor, fast-drying fluid | Newsletters, manuals, flyers | 20–2,000 | 10–60 seconds |
| Carbon Paper | Wax-resin carbon coating | Forms, receipts, contracts | 1–6 copies | Instant (pressure transfer) |
Best Practices for Using Duplicating Inks
- Storage: Keep inks sealed in their original containers at room temperature (68–77°F / 20–25°C)
- Mixing: Stir thoroughly before use; do not thin with arbitrary solvents unless specified by the manufacturer
- Cleaning: Use appropriate cleaners (e.g., mineral spirits for oil-based, water for water-based) to maintain equipment
- Safety: Use in well-ventilated areas; wear gloves and eye protection when handling concentrated inks
- Environmental: Dispose of used inks and cleaning solvents according to local regulations; consider recyclable or biodegradable options
How To Choose Duplicating Inks: A Comprehensive Guide
Selecting the right duplicating ink is essential for achieving high-quality, durable, and cost-effective prints. The choice of ink significantly impacts print clarity, adhesion, drying time, and environmental safety. Whether you're using a mimeograph, spirit duplicator, or modern digital duplicator, understanding the key factors—such as surface compatibility, ink viscosity, printing volume, environmental impact, and desired finish—can help you make an informed decision. This guide breaks down each critical consideration to help you optimize your printing process and results.
Important Note: Always test a small batch before full-scale printing. Compatibility with your specific duplicator model and paper type can vary, and preliminary testing helps avoid costly mistakes and ensures consistent output quality.
Surface Compatibility
The surface or substrate being printed on is one of the most critical factors in selecting the appropriate duplicating ink. Different materials absorb and interact with ink in unique ways, affecting adhesion, drying time, and final appearance.
- Porous Surfaces (e.g., standard paper, newsprint): These materials readily absorb ink, so high-viscosity or solvent-based inks are unnecessary. Water-based or oil-based inks are ideal, offering sufficient pigment transfer without smudging or bleeding.
- Non-Porous Surfaces (e.g., glossy paper, coated stock, plastic films): These require thicker, high-viscosity inks to ensure proper adhesion. Solvent-based or oil-based inks are typically recommended as they sit on the surface rather than being absorbed, resulting in sharper, more vibrant prints.
- Recycled or Low-Quality Paper: May have inconsistent absorbency; opt for balanced-formula inks that resist feathering while drying quickly.
Ink Viscosity
Viscosity—essentially the thickness or flow resistance of the ink—plays a pivotal role in print quality and application performance. Matching the ink’s viscosity to your duplicator’s mechanics and your desired output ensures clean, consistent results.
- High-Viscosity Inks: Ideal for applications requiring thick, opaque layers. These are best suited for carbon paper, glossy sheets, or when printing bold text and graphics. They resist dripping and are less likely to bleed on smooth surfaces.
- Low-Viscosity Inks: Flow more easily and are perfect for fine detail work, halftones, or high-speed duplicating. They work exceptionally well on absorbent papers, allowing for quick drying and reduced smudging.
- Adjustable-Viscosity Formulas: Some premium inks allow viscosity modification with thinners or extenders, offering flexibility across different jobs and conditions.
Pro Tip: In humid environments, lower-viscosity inks may dry too slowly. Consider slightly thicker formulations or ensure adequate ventilation to prevent smearing.
Volume and Frequency of Printing
Your printing volume and frequency directly influence the type of ink that offers the best value and performance. Cost-efficiency and consistency are key considerations.
- High-Volume Printing: For frequent or large-batch jobs (e.g., newsletters, forms, educational materials), cost-effective, durable inks are essential. Oil-based or hybrid inks often provide better yield and longer drum life, reducing long-term expenses.
- Low-Volume or Occasional Use: When printing infrequently, prioritize ink stability and shelf life. Water-based inks are often preferred as they are less prone to drying out in the machine, minimizing maintenance and waste.
- Budget Planning: Bulk purchasing of compatible inks can reduce per-unit costs, but ensure the ink has a long shelf life to avoid expiration before use.
Environmental and Health Considerations
With growing emphasis on workplace safety and environmental responsibility, the ecological footprint of your ink choice matters. Solvent-based inks, while effective, can pose health and environmental risks.
- Water-Based Inks: Emit significantly lower levels of volatile organic compounds (VOCs), making them safer for indoor use and more eco-friendly. They are easier to clean up and reduce exposure to harmful fumes.
- Solvent-Based Inks: Offer excellent adhesion and durability but release higher VOC levels. Use only in well-ventilated areas and consider protective equipment for operators.
- Biodegradable and Low-Toxicity Options: Increasingly available, these inks are formulated with renewable resources and are ideal for schools, offices, and environmentally conscious organizations.
Sustainability Tip: Pair eco-friendly inks with recycled paper to maximize your environmental impact and support green printing initiatives.
Color Vibrancy and Finish Options
The desired aesthetic of your printed material should guide your ink selection. Different ink types produce varying levels of gloss, color intensity, and texture.
- Glossy or Vibrant Finishes: Solvent-based and oil-based inks deliver rich, saturated colors with a professional sheen. Ideal for marketing materials, covers, or any print requiring visual impact.
- Matte or Soft-Finish Prints: Aqueous (water-based) inks are excellent for achieving a non-reflective, smooth appearance. Their absorption into the paper reduces glare, making them perfect for reading materials, reports, and internal documents.
- Specialty Effects: Some duplicating inks come in metallic, fluorescent, or pastel variants for creative applications. Ensure compatibility with your duplicator before use.
| Ink Type | Best For | Surface Compatibility | Environmental Impact | Drying Time |
|---|---|---|---|---|
| Water-Based | Low-volume, office use, eco-friendly printing | Porous paper, recycled stock | Low VOCs, biodegradable options available | Fast to moderate |
| Oil-Based | High-volume, durable prints, bold text | Standard and glossy paper | Moderate VOCs, requires proper disposal | Moderate |
| Solvent-Based | Non-porous surfaces, vibrant colors | Glossy sheets, coated paper, synthetics | High VOCs, needs ventilation | Fast (surface drying) |
| Hybrid Formulations | Balanced performance, mixed applications | Versatile (check manufacturer specs) | Varies by formulation | Variable |
Final Recommendation: Always consult your duplicator’s user manual for ink compatibility guidelines. Using non-recommended inks can damage the machine, void warranties, and compromise print quality. When in doubt, contact the manufacturer or supplier for expert advice.
Maintenance and Storage Tips
To extend ink shelf life and duplicator performance:
- Store inks in a cool, dry place away from direct sunlight.
- Keep containers tightly sealed to prevent drying or contamination.
- Clean ink rollers and screens regularly to avoid clogs and streaks.
- Rotate stock to use older inks first (FIFO method).
- Dispose of expired or unused inks according to local environmental regulations.
By carefully evaluating surface type, viscosity needs, print volume, environmental concerns, and desired finish, you can select the optimal duplicating ink for your specific application. Making informed choices not only enhances print quality but also improves efficiency, reduces waste, and supports a safer, more sustainable printing environment.
Frequently Asked Questions About Duplicating Ink
Duplicating ink and offset ink serve different printing technologies and are engineered with distinct properties to meet the demands of their respective systems. Understanding these differences is crucial for selecting the right ink for your printing needs.
- Application: Duplicating ink is specially formulated for use in stencil duplicators (also known as mimeograph or digital duplicator machines), commonly found in schools, offices, and small print shops for high-volume, low-cost printing. Offset ink, on the other hand, is designed for offset lithographic printing presses used in commercial printing for magazines, brochures, and packaging.
- Viscosity: Duplicating ink has a higher viscosity to ensure it transfers properly through a stencil without bleeding. Offset ink has a more fluid consistency, allowing it to spread evenly across the printing plate and transfer cleanly to the rubber blanket before being applied to paper.
- Shelf Life: Duplicating inks typically have a shorter shelf life due to their chemical composition and sensitivity to drying out or clogging. Offset inks are more stable and can be stored for longer periods without degradation, especially when sealed properly.
- Drying Mechanism: Duplicating ink often dries by absorption into the paper, while offset ink may dry through oxidation, penetration, or heat-assisted methods depending on the substrate and press setup.
Choosing the correct ink ensures optimal print quality, machine performance, and longevity of both the printer and consumables.
Yes, duplicating ink can be used on non-porous surfaces, but its effectiveness depends heavily on the specific type of ink and the surface material. Not all duplicating inks are created equal when it comes to adhesion on challenging substrates.
- Solvent-Based Inks: These are ideal for non-porous materials like plastic, metal, glass, and vinyl. They work by slightly dissolving the surface to create a strong bond, resulting in durable and smudge-resistant prints.
- Thermal Duplicating Inks: Often used in thermal transfer printing, these solid inks melt during application and adhere well to synthetic fabrics, coated papers, and certain plastics. They are particularly valued for barcode labels and industrial tagging.
- Water-Based (Aqueous) Inks: These perform best on porous surfaces such as plain paper, cardboard, or fabric. On non-porous materials, they tend to sit on the surface rather than bond, leading to poor durability, smudging, or flaking.
For best results on non-porous substrates, always verify compatibility between the ink formulation and the target material. Pre-treatment or primers may also be required to enhance adhesion and longevity of the printed output.
Modern duplicating inks have made significant strides toward sustainability, with many manufacturers now offering eco-conscious alternatives that reduce environmental and health impacts.
- Water-Based Formulations: Increasingly popular, these inks use water as the primary carrier instead of volatile solvents. They emit significantly lower levels of volatile organic compounds (VOCs), improving indoor air quality and reducing hazardous emissions.
- Reduced Toxicity: Eco-friendly duplicating inks often avoid heavy metals, carcinogens, and ozone-depleting substances, making them safer for operators and easier to dispose of responsibly.
- Biodegradability: Some water-based and plant-derived inks are designed to break down more easily in the environment, minimizing long-term pollution.
- Energy Efficiency: Machines using low-VOC or water-based inks typically require less ventilation and air filtration, reducing energy consumption in printing facilities.
Printers using environmentally friendly duplicating inks not only contribute to greener operations but also align with corporate sustainability goals and regulatory compliance (e.g., ISO 14001, REACH). Always check product data sheets for certifications like Cradle to Cradle, Green Seal, or EcoLogo to ensure authenticity.
Thermal duplicating ink—also known as thermal transfer ink—is specifically engineered for use in thermal printers and duplicators. It plays a critical role in producing high-quality, durable prints in applications ranging from label printing to document reproduction.
- Physical State: Unlike liquid inks, thermal duplicating ink is typically supplied in solid form, either as a ribbon or wax-based stick. It remains stable at room temperature, preventing smudging or leakage during storage and handling.
- Printing Process: During printing, the printhead applies precise heat to the ink ribbon, causing the ink to melt and transfer onto the substrate (paper, film, or synthetic material). The heat-controlled process ensures sharp text and graphics with excellent edge definition.
- Adhesion and Durability: Once cooled, the ink solidifies and bonds tightly to the surface, making the print resistant to water, oil, abrasion, and fading—ideal for barcodes, shipping labels, and outdoor signage.
- Variants: Available in wax, resin, or wax-resin blends, each offers different levels of durability and resistance depending on the application. Resin-based inks provide the highest resistance for harsh environments.
Proper selection of thermal duplicating ink ensures reliable performance, extended printhead life, and professional-grade output across various industries.
While traditional duplicating ink is not designed for standard 3D printing processes, certain specialized forms—particularly water-based and oil-based inks—can be adapted for use in specific types of 3D printing technologies, especially those involving inkjet-style deposition.
- Inkjet 3D Printing: Some binder jetting 3D printers use liquid agents (including ink-like materials) to selectively bind powder layers. In these systems, modified water-based duplicating inks can be used as colorants to add full-color detail to 3D-printed objects.
- Surface Coloring: After a 3D object is printed, duplicating inks—especially solvent-based or thermal transfer types—can be applied for labeling, coding, or decorative purposes on both porous and non-porous finished parts.
- Compatibility Limitations: Most fused deposition modeling (FDM) or stereolithography (SLA) 3D printers rely on thermoplastics or photopolymers, not liquid inks. Therefore, duplicating ink cannot replace filament or resin in these systems.
- Customization & Marking: In industrial settings, duplicating inks are sometimes integrated into automated marking systems to print serial numbers, logos, or instructions directly onto 3D-printed components.
In summary, duplicating ink does not function as a primary build material in 3D printing but can play a valuable role in post-processing, coloring, and identification. Always ensure the ink is compatible with the 3D-printed material to prevent damage or poor adhesion.








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