Types of Generator Sets for Reefer Containers
A generator set (genset) is an essential power source for refrigerated (reefer) containers, ensuring consistent cooling during transport and storage. These units maintain precise temperature control to preserve perishable goods such as food, pharmaceuticals, and chemicals. With various types available, selecting the right generator set depends on factors like noise levels, fuel efficiency, voltage stability, and environmental conditions.
AVR Generators
Equipped with Automatic Voltage Regulation technology, these generators deliver stable and consistent voltage output critical for sensitive refrigeration systems.
Advantages
- Stable voltage output under varying loads
- Low maintenance requirements
- Protects reefer control systems from voltage fluctuations
- Ideal for off-grid and remote operations
- Enhances food safety by preventing temperature swings
Limitations
- Higher initial cost than basic models
- May require professional calibration
- Slightly heavier due to voltage regulation components
Best for: Long-haul transport, cold storage facilities, regions with unstable power infrastructure
Inverter Generators
Advanced gensets that convert AC to DC and back to clean, stable AC power using digital inverter technology.
Advantages
- Extremely quiet operation (as low as 50–60 dB)
- High fuel efficiency (up to 30% savings)
- Precise frequency and voltage control
- Compact and lightweight design
- Reduced emissions and carbon footprint
Limitations
- Lower power output compared to conventional units
- Higher upfront investment
- Sensitive to extreme environmental conditions if not properly housed
Best for: Urban deliveries, residential areas, medical shipments, eco-conscious logistics
Silenced Generators
Designed with sound-dampening enclosures, mufflers, and vibration isolators to minimize operational noise.
Advantages
- Significantly reduced noise pollution (down to 65 dB or less)
- Compliant with urban noise regulations
- Suitable for 24/7 operation near populated zones
- Durable construction with weather-resistant housing
- Effective thermal insulation for consistent performance
Limitations
- Bulkier design due to acoustic enclosures
- Requires more space for ventilation and access
- Premium pricing due to added soundproofing materials
Best for: City centers, hospitals, schools, rural communities, overnight port operations
Stamford Generators
Trusted brand-name alternators known for reliability, efficiency, and global service support in reefer applications.
Advantages
- Industry-leading durability and longevity
- Consistent power delivery in extreme climates
- Backed by global warranty and technical support
- Resistant to dust, moisture, and corrosion
- Optimized for integration with major reefer units (e.g., Carrier, Thermo King)
Limitations
- Higher cost compared to generic brands
- Parts may require specialized suppliers
- Heavier weight impacts portability
Best for: High-reliability operations, international shipping, harsh environments, mission-critical cargo
| Type | Noise Level | Fuel Efficiency | Voltage Stability | Best Use Case |
|---|---|---|---|---|
| AVR Generators | Moderate | Good | Excellent | Temperature-critical cargo, off-grid sites |
| Inverter Generators | Very Low | Excellent | Excellent | Residential areas, short-haul delivery |
| Silenced Generators | Low | Good | Good | Urban zones, noise-sensitive locations |
| Stamford Generators | Moderate | Very Good | Excellent | Heavy-duty transport, global logistics |
Expert Tip: For optimal performance, always match the generator set’s power rating (kVA) to the reefer container’s peak load requirement, including startup surge. A mismatch can lead to voltage drops, compressor failure, or spoilage of temperature-sensitive cargo.
Maintenance Note: Regular servicing—especially air filter cleaning, oil changes, and coolant checks—is crucial for all generator types to ensure uninterrupted cooling and extend equipment lifespan, particularly in continuous-use scenarios.
Industry Applications of Generator Sets for Reefer Containers
Generator sets (gensets) play a vital role in powering refrigerated (reefer) containers across a wide range of industries. These mobile power units ensure uninterrupted temperature control during transportation, storage, and emergency operations, preserving the integrity of sensitive goods. As global supply chains expand and demand for cold chain logistics grows, the use of reefer container gensets has become indispensable in maintaining product quality, safety, and regulatory compliance.
Transportation and Logistics
The transportation and logistics sector represents the most prominent application for reefer container generator sets. These systems enable the long-haul movement of perishable goods such as fresh produce, frozen foods, and temperature-sensitive industrial materials across land, sea, and rail networks. Gensets provide consistent electrical power to maintain precise temperature zones—whether chilled, frozen, or controlled atmosphere—regardless of external conditions or access to shore power.
Modern logistics companies rely on smart gensets equipped with remote monitoring and telemetry systems to track container conditions in real time. This ensures full visibility throughout the supply chain, reduces spoilage risks, and supports compliance with international shipping standards such as the Cold Chain Guidelines from the World Health Organization (WHO) and FDA regulations.
Agriculture
In the agricultural industry, timely and temperature-controlled transport is critical to reducing post-harvest losses. Farmers and agribusinesses increasingly utilize reefer containers powered by generator sets to store and transport fruits, vegetables, dairy products, and livestock by-products over long distances. By maintaining optimal humidity and cooling levels, these systems significantly extend shelf life and preserve nutritional value.
Gensets are especially valuable in rural or off-grid regions where access to reliable grid electricity is limited. Mobile refrigeration units powered by diesel or biodiesel generators allow farmers to move harvests directly from farms to markets or processing facilities without compromising freshness, improving market competitiveness and reducing food waste.
Pharmaceuticals
The pharmaceutical industry demands strict adherence to temperature control protocols, particularly for products like vaccines, insulin, blood plasma, biologics, and certain antibiotics. Even minor deviations in temperature can render these high-value medical supplies ineffective or unsafe. Reefer containers powered by reliable generator sets ensure that these products remain within the required thermal range (typically 2°C to 8°C or frozen at -20°C) during transit and temporary storage.
With the rise of global vaccine distribution and personalized medicine, genset-powered cold chain solutions have become essential in both developed and developing countries. Advanced gensets often integrate data loggers and alarm systems to provide auditable temperature records, ensuring compliance with Good Distribution Practice (GDP) and other regulatory frameworks.
Emergency Response and Humanitarian Aid
In disaster-stricken areas affected by earthquakes, hurricanes, floods, or conflict zones, infrastructure—including power grids—is often destroyed or non-existent. Emergency response teams and humanitarian organizations depend on reefer containers with onboard generator sets to deliver life-saving supplies such as vaccines, blood, insulin, and ready-to-eat meals.
These self-sufficient refrigeration units serve as mobile cold storage hubs in temporary medical clinics, refugee camps, and field hospitals. Gensets ensure uninterrupted operation even in extreme environments, enabling aid workers to maintain the cold chain under challenging conditions. Their portability and rapid deployment capabilities make them a cornerstone of modern disaster relief logistics.
Food and Beverage Industry
The food and beverage industry relies heavily on reefer container generator sets to preserve the quality and safety of raw ingredients and finished products throughout the production and distribution cycle. From seafood and meat to dairy, confectionery, and beverages like beer and wine, temperature fluctuations can lead to spoilage, bacterial growth, and compromised taste.
Gensets support just-in-time inventory models by enabling secure temporary storage at ports, distribution centers, or event venues. They also facilitate international exports by ensuring that food products meet the sanitary and phytosanitary (SPS) standards of importing countries. With increasing consumer demand for freshness and traceability, continuous refrigeration powered by reliable gensets has become a key factor in brand reputation and regulatory compliance.
| Industry | Critical Temperature Range | Key Benefits of Genset-Powered Reefers |
|---|---|---|
| Transportation & Logistics | Chilled (2–8°C), Frozen (-25°C to -15°C) | End-to-end cold chain integrity, real-time monitoring, global compliance |
| Agriculture | 0–15°C (varies by produce) | Reduced post-harvest loss, extended shelf life, improved market access |
| Pharmaceuticals | 2–8°C, -20°C, or -70°C (ultra-cold) | Regulatory compliance, product efficacy, audit-ready documentation |
| Emergency & Humanitarian Aid | 2–8°C (vaccines), -20°C (blood) | Off-grid operation, rapid deployment, life-saving reliability |
| Food & Beverage | 0–4°C (dairy/meat), 10–15°C (beverages) | Safety assurance, spoilage prevention, brand protection |
Important: Selecting the right generator set for reefer container applications requires careful consideration of fuel type, runtime, emissions standards, noise levels, and integration with container control systems. Regular maintenance and fuel quality management are essential to prevent unexpected failures, especially in critical operations such as medical supply transport or disaster relief. Always ensure gensets meet ISO, IMO, and local regulatory requirements for safe and compliant operation.
Product Specifications and Features of Generator Sets for Reefer Containers
Reefer container generator sets (gensets) are essential power sources that maintain precise temperature control in refrigerated shipping containers. These specialized units ensure uninterrupted cooling during transport, protecting perishable goods across global supply chains. Designed for durability, efficiency, and reliability, reefer gensets must meet stringent performance standards to operate effectively in diverse environmental conditions.
Core Features
Modern reefer gensets incorporate advanced technologies to deliver clean, stable, and uninterrupted power tailored to sensitive refrigeration systems.
- Automatic Voltage Regulator (AVR): Maintains consistent voltage output under varying loads, preventing fluctuations that could damage refrigeration controls or compressors.
- Inverter Technology: Converts raw AC power into smooth, sine-wave output ideal for sensitive electronics, reducing harmonic distortion and improving energy efficiency.
- Silenced Operation: Integrated sound-dampening enclosures reduce noise levels to below 75 dB(A) at 7 meters, making them suitable for urban ports, residential drop-off zones, and night operations.
- Fuel Efficiency: Equipped with electronically controlled fuel injection and smart load management, these gensets optimize combustion for up to 20% better fuel economy compared to conventional models.
- Durable Build: Constructed with corrosion-resistant materials and sealed components to withstand salt spray, extreme temperatures (-30°C to +50°C), and constant vibration during transit.
Technical Specifications
Understanding the technical parameters ensures compatibility with reefer units and compliance with international shipping standards.
- Power Output: Typically ranges from 8 kVA to 40 kVA depending on container size and cooling demand.
- Voltage & Frequency: Standard outputs include 400V/50Hz or 480V/60Hz, with dual-voltage models available for global deployment.
- Engine Type: Diesel-powered, 4-stroke, turbocharged engines with electronic governor control for precise speed regulation.
- Fuel Tank Capacity: 100–300 liters, supporting 7–14 days of continuous operation at partial load.
- Starting System: Electric start with 12V or 24V battery, often featuring remote start capability via GSM or satellite link.
- Protection Ratings: IP55 or higher for dust and water resistance; compliant with ISO, IEC, and IMO regulations.
Pro Insight: Always verify genset compatibility with the specific reefer unit model (e.g., ThermoKing, Carrier, or Daikin). Mismatched voltage profiles or control signal protocols can lead to communication errors or compressor shutdowns.
Installation Guide for Reefer Container Gensets
Proper installation is critical to ensure safe, reliable, and efficient operation of the generator set. Incorrect setup can lead to overheating, poor performance, safety hazards, or premature failure. Follow these best practices for optimal results.
- Assess Power Requirements: Calculate the total electrical load of the reefer unit, including compressor, fans, defrost cycle, and control systems. Include a 15–20% safety margin to handle peak loads.
- Select the Right Unit: Match the genset’s voltage, frequency, phase (single or three-phase), and kVA rating to the reefer container’s specifications. Consider ambient temperature derating for tropical or arctic environments.
- Secure Mounting Location: Install the genset in a dedicated, weatherproof compartment within or adjacent to the container. Ensure it's protected from direct rain, flooding, and excessive dust.
- Stable Mounting Platform: Fix the genset on a level, vibration-absorbing base using anti-vibration mounts to minimize wear and noise transmission.
- Fuel and Electrical Connections: Use high-quality, fuel-resistant hoses and marine-grade electrical cables. Install a manual or automatic transfer switch to seamlessly switch between shore power and generator power.
- Ventilation and Exhaust: Provide adequate airflow for cooling and combustion. Route exhaust pipes outside the container with downward-facing outlets to prevent backflow. Use spark arrestors in fire-prone areas.
- Testing and Commissioning: After installation, conduct a full operational test: verify automatic start/stop functionality, check voltage stability under load, confirm proper grounding, and ensure all alarms (low oil, high temp) function correctly.
Maintenance and Repair Best Practices
Regular maintenance extends the lifespan of reefer gensets, reduces downtime, and ensures compliance with emissions and safety regulations. A well-maintained genset can operate reliably for over 10,000 hours.
- Regular Oil Changes: Change engine oil and filter every 100–200 operating hours or at least every six months. Use manufacturer-recommended viscosity-grade oil suitable for temperature extremes.
- Fuel System Inspection: Replace fuel filters monthly or every 250 hours. Drain water from fuel separators weekly. Test fuel quality annually to prevent microbial growth and injector clogging.
- Cooling System Maintenance: Clean radiator fins and check coolant levels monthly. Inspect hoses for cracks and leaks. Flush the cooling system annually to prevent scale buildup.
- Battery Care: Clean terminals and check electrolyte levels (if applicable) monthly. Replace batteries every 1–2 years or as per manufacturer guidelines. Ensure charging system functions properly.
- Load Testing: Perform monthly load bank tests at 75–100% capacity for at least 30 minutes to prevent "wet stacking" and keep engine components conditioned. Record voltage, frequency, oil pressure, and exhaust temperature.
- Control System Diagnostics: Use onboard diagnostic tools or external software to monitor error codes, runtime hours, and performance trends. Update firmware when available.
Maintenance Tip: Keep a detailed service log for each genset, including oil changes, filter replacements, load test results, and repairs. This supports warranty claims and helps predict component failures before they occur.
| Maintenance Task | Frequency | Key Tools/Components | Purpose |
|---|---|---|---|
| Oil & Filter Change | Every 100–200 hrs or 6 months | Engine oil, oil filter, wrench set | Prevent engine wear and maintain lubrication efficiency |
| Fuel Filter Replacement | Monthly or 250 hrs | Primary/secondary fuel filters | Avoid fuel contamination and ensure clean combustion |
| Cooling System Check | Monthly | Coolant tester, pressure gauge | Prevent overheating and radiator blockages |
| Battery Inspection | Monthly | Multimeter, cleaning brush | Ensure reliable starting and charging |
| Load Bank Testing | Monthly | Load bank, data logger | Verify full-power performance and prevent wet stacking |
Expert Recommendation: For fleets operating in remote or harsh environments, consider gensets with telematics integration. These systems provide real-time monitoring of fuel levels, runtime, fault codes, and location, enabling predictive maintenance and reducing emergency callouts.
Quality and Safety Considerations for Reefer Container Generator Sets
Maintaining generator sets (gensets) for reefer containers is essential to ensure uninterrupted temperature control, protect perishable cargo, and uphold operational safety. These units operate in demanding environments and require strict adherence to quality standards and safety protocols. Below is a comprehensive overview of the key quality and safety factors that must be addressed during genset maintenance and operation.
Safety Warning: Always de-energize and lock out the genset before performing maintenance. Work only in well-ventilated areas to avoid carbon monoxide buildup. Never bypass safety systems or operate a genset with damaged components.
1. Use Quality Parts and Fluids
The reliability and efficiency of a reefer genset depend heavily on the quality of components and consumables used during maintenance. Substandard parts can lead to premature failure, reduced performance, and potential safety hazards.
- Use OEM or certified equivalent parts: Replace filters, fuel injectors, gaskets, and sensors with genuine or high-quality aftermarket alternatives that meet manufacturer specifications.
- Maintain proper fluid levels: Regularly check engine oil, coolant, and fuel levels before startup to prevent overheating, lubrication failure, or fuel starvation.
- Select appropriate fluids: Use engine oil with the correct viscosity and API rating, and ensure coolant is compatible with the genset’s materials to prevent corrosion.
- Follow maintenance intervals: Adhere to the manufacturer’s recommended service schedule for oil and filter changes to extend engine life and maintain consistent output.
Pro Tip: Keep a log of all fluid top-ups and part replacements to track usage patterns and anticipate future maintenance needs.
2. Ensure Proper Grounding and Vibration Dampening
Gensets generate significant electrical current and mechanical vibration, both of which must be properly managed to protect equipment and personnel.
- Electrical grounding: Connect the genset frame to a verified earth ground using a dedicated grounding rod or approved grounding system to prevent electric shock and protect against voltage surges.
- Vibration isolation: Mount the genset on rubber pads, spring isolators, or anti-vibration mounts to minimize transmission of vibrations to the container structure, which can damage cargo, welds, and refrigeration components.
- Noise reduction: Install sound-attenuating enclosures or acoustic barriers around the genset to reduce noise pollution, especially in urban or residential areas.
- Secure mounting: Ensure all mounting bolts are torqued to specification and inspected periodically for loosening due to continuous operation.
3. Emergency Power Off Systems (EPOS)
An accessible and reliable Emergency Power Off System (EPOS) is critical for immediate shutdown in case of fire, fuel leak, overheating, or electrical fault.
- Strategic placement: Install EPOS buttons at multiple accessible locations—externally near the genset and internally within the reefer container—for quick response from either side.
- Clear labeling: Mark EPOS switches with red-and-white warning signs and ensure they are unobstructed at all times.
- Functional testing: Test the EPOS monthly by activating it to confirm the genset shuts down immediately and does not auto-restart.
- Lockout/tagout (LOTO): Integrate EPOS into your LOTO procedures during maintenance to prevent accidental restarts.
Best Practice: Train all personnel on EPOS location and operation. Post emergency procedures near the genset for quick reference.
4. Water and Dust Protection
Exposure to moisture and particulates is a leading cause of electrical failure and corrosion in outdoor gensets.
- Weatherproof enclosures: House the genset in an IP-rated (Ingress Protection) enclosure that resists water spray and dust ingress (e.g., IP65 or higher).
- Sealed conduit entries: Use waterproof cable glands and sealed conduit fittings for all wiring and hose penetrations to prevent moisture entry.
- Conformal coating: Apply dielectric conformal coating to circuit boards and electrical connections to protect against humidity, salt spray, and condensation—especially in coastal or high-humidity environments.
- Regular inspection: Check seals, gaskets, and housing integrity during each maintenance cycle for cracks, warping, or wear.
5. Regular Testing and Regulatory Compliance
Reefer gensets must comply with environmental, emissions, and safety regulations to operate legally and sustainably.
- Performance testing: Conduct load bank tests annually to verify the genset can deliver rated power under simulated conditions.
- Emissions compliance: Ensure the genset meets local and international emissions standards (e.g., EPA Tier 4, EU Stage V) through proper maintenance and use of low-sulfur or alternative fuels.
- Exhaust treatment: Install and maintain diesel particulate filters (DPFs) or selective catalytic reduction (SCR) systems where required.
- Certified inspections: Schedule periodic inspections by certified technicians or third-party auditors to validate compliance with safety codes and insurance requirements.
- Documentation: Maintain logs of emissions tests, maintenance records, and compliance certifications for audit readiness.
| Safety/Quality Factor | Key Actions | Risks of Neglect | Recommended Frequency |
|---|---|---|---|
| Quality Parts & Fluids | Use OEM filters, correct oil type, regular top-ups | Engine seizure, poor performance, increased downtime | Before each use / per manufacturer schedule |
| Grounding & Vibration Control | Inspect ground wire, check mounts, verify isolation | Electrical shock, structural fatigue, noise complaints | Monthly |
| EPOS Functionality | Test shutdown, verify accessibility, inspect wiring | Inability to stop unit in emergency, fire hazard | Monthly |
| Environmental Protection | Inspect seals, clean enclosures, reapply coatings | Short circuits, corrosion, water damage | Quarterly |
| Compliance & Testing | Load testing, emissions checks, certification renewal | Fines, operational shutdown, environmental violations | Annually or as required by law |
Expert Insight: Implement a preventive maintenance (PM) program tailored to your operating environment—harsh conditions (dust, salt, heat) may require more frequent servicing than standard recommendations.
Additional Recommendations
- Store spare parts and fluids in a clean, dry location to prevent contamination.
- Use digital monitoring systems to track genset runtime, fuel consumption, and fault codes remotely.
- Train operators on basic troubleshooting and emergency response procedures.
- Keep a fire extinguisher (Class C for electrical fires) nearby and ensure it is regularly inspected.
- Label all electrical panels and fuel lines clearly for quick identification during emergencies.
By prioritizing quality maintenance practices and adhering to safety standards, operators can ensure reefer container gensets deliver reliable, efficient, and safe performance throughout their service life. Regular attention to these critical factors not only protects valuable cargo but also enhances operational compliance and reduces long-term costs.
Frequently Asked Questions About Generator Sets in Reefer Containers
The Automatic Voltage Regulator (AVR) plays a critical role in maintaining stable and consistent electrical output from the generator. In reefer containers, refrigeration units are highly sensitive to voltage fluctuations, which can disrupt compressor operation and compromise temperature control.
By continuously monitoring and adjusting the generator’s output voltage, the AVR ensures that the refrigeration system receives a clean, steady power supply—typically within ±1–2% of the nominal voltage (e.g., 230V or 460V). This precision prevents equipment stress, reduces the risk of food spoilage, and enhances the overall reliability of cold chain logistics during long-haul transportation.
Generator sets (gensets) can produce significant noise during operation, which may be problematic in urban, residential, or port environments. To minimize sound emissions, several noise-reduction strategies can be implemented:
- Soundproof Enclosures: Installing insulated, acoustically treated enclosures around the genset helps absorb and block noise. These are often made with steel outer shells and inner linings of sound-dampening foam or mineral wool.
- Silencers/Mufflers: Fitting exhaust mufflers and intake silencers reduces engine and airflow noise at key emission points.
- Vibration Dampers: Mounting the genset on anti-vibration pads or rubber mounts prevents structure-borne noise transmission to the container frame.
- Acoustic Baffles: Strategically placed baffles around the cooling fans and air vents can deflect sound waves without restricting airflow.
- Low-Noise Genset Models: Selecting inherently quiet models, such as inverter generators, further enhances noise control.
Together, these measures can reduce genset noise levels from over 80 dB(A) to below 65 dB(A), meeting strict environmental and regulatory standards in noise-sensitive zones.
Inverter generators are increasingly preferred for reefer container applications due to their advanced power delivery and operational efficiency. Unlike conventional generators that produce raw AC power, inverter generators convert AC to DC and then back to a clean, stable AC waveform using digital circuitry.
This process results in a consistent sine wave with minimal harmonic distortion (<1%), making it ideal for powering sensitive electronic controls in modern refrigeration units. Additionally, inverter generators offer several key advantages:
- Quiet Operation: Typically operate between 50–60 dB(A), making them suitable for nighttime or urban use.
- Compact Size: Designed for portability and space-constrained environments like container rooftops or side-mounted compartments.
- Fuel Efficiency: Equipped with smart engines that adjust RPM based on load, significantly reducing fuel consumption and emissions.
- Stable Frequency Control: Maintain precise 50/60 Hz output, essential for compressor timing and temperature consistency.
These features make inverter generators a reliable, eco-friendly choice for maintaining uninterrupted cold chain performance.
Modern generator sets, especially inverter-type models, employ intelligent load management systems to optimize fuel consumption over extended periods. Instead of running at full throttle regardless of demand, these gensets use electronic governors and variable speed engines that dynamically adjust power output to match the actual load.
For example, when a reefer container is maintaining temperature (low cooling demand), the genset may operate at 30–50% capacity, consuming significantly less fuel than if it were running at 100%. This adaptive operation leads to:
- Up to 40% Fuel Savings: Compared to traditional fixed-speed generators under partial load conditions.
- Extended Runtime: Reduced fuel use allows longer operation between refueling, crucial for remote or maritime transport.
- Lower Emissions: Improved combustion efficiency reduces CO₂, NOₓ, and particulate output, supporting environmental compliance.
- Reduced Engine Wear: Lower average RPM extends maintenance intervals and overall genset lifespan.
Some advanced systems also include fuel monitoring and remote diagnostics, enabling fleet managers to track efficiency and schedule maintenance proactively.
Stamford, a brand under the FG Wilson (Cummins) group, is widely recognized for manufacturing high-performance alternators and integrated generator sets trusted across the global logistics and refrigeration industries. Their popularity in reefer container applications stems from a combination of engineering excellence and real-world reliability.
Key reasons for their widespread adoption include:
- Robust Build Quality: Constructed with heavy-duty materials and sealed components to withstand harsh environments, including salt spray, humidity, and extreme temperatures.
- Precision Voltage Regulation: Integrated AVRs ensure stable output even under fluctuating loads, protecting sensitive refrigeration electronics.
- High Efficiency: Optimized electromagnetic design reduces energy losses and heat generation, improving overall fuel economy.
- Global Support Network: Backed by Cummins’ extensive service infrastructure, ensuring easy access to parts, technical support, and field repairs worldwide.
- Certifications: Compliant with ISO, CE, and marine-grade standards, making them suitable for international shipping and intermodal transport.
These attributes make Stamford generators a top choice for operators who prioritize uptime, temperature stability, and long-term cost-effectiveness in cold chain logistics.








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