Types of Hard Nut Shell Crushers
A hard nut shell crusher is a specialized machine designed to efficiently break open tough nutshells—such as those of coconuts, walnuts, almonds, or macadamias—while minimizing kernel damage. These machines are essential in both small-scale artisanal operations and large commercial processing facilities. With various mechanisms available, selecting the right type depends on production volume, nut type, desired output quality, and budget.
Manual Crushers
Operated by hand, these crushers are ideal for home use, small farms, or low-volume processing. They offer direct control over crushing pressure, reducing the risk of kernel breakage.
Advantages
- Affordable and accessible
- No electricity required
- Portable and easy to maintain
- Allows precise pressure control
Limitations
- Labor-intensive and time-consuming
- Low throughput (suitable for small batches)
- Not scalable for commercial use
Best for: Home kitchens, small farms, hobbyists, and educational purposes
Electric Nut Crushers
Powered by electric motors, these machines automate the crushing process, significantly increasing output and consistency. Ideal for medium to large-scale operations.
Advantages
- High processing speed and efficiency
- Consistent crushing results
- Reduces labor costs and physical strain
- Suitable for continuous operation
Limitations
- Higher initial investment
- Requires reliable power supply
- More complex maintenance needs
Best for: Commercial processing, food manufacturing, and agribusiness operations
Cylindrical Nut Crushers
Equipped with a rotating cylinder embedded with protruding screws or teeth, this design applies steady pressure to crack shells evenly. Excellent for uniform, tough shells like coconuts.
Advantages
- Effective on very hard shells
- Even and controlled cracking
- Durable construction
- Minimal kernel damage when calibrated
Limitations
- Bulky design requires more space
- May need manual feeding
- Less versatile for mixed nut types
Best for: Coconut processing, industrial applications with uniform nut sizes
Rotating Blade/Hammer Crushers
Utilize high-speed rotating blades or hammers to pulverize nuts. These models are powerful and fast, ideal for high-volume processing.
Advantages
- Extremely high throughput
- Fast processing speeds
- Effective for bulk crushing
Limitations
- Produces fine shell particles (risk of contamination)
- Higher kernel breakage rate
- Expensive to maintain due to blade wear
- Louder operation
Best for: Large-scale operations where kernel integrity is less critical
Screw Propeller (Archimedean) Crushers
Use a helical screw to gradually compress and crush nuts against a perforated screen. Material advances as it’s crushed, allowing adjustable output size.
Advantages
- Controlled, gradual crushing reduces kernel damage
- Adjustable screen size for different outputs
- Good separation of shell and kernel
- Energy-efficient design
Limitations
- Slower than hammer-type crushers
- May clog with fibrous materials
- Requires regular cleaning
Best for: Small to medium operations, specialty nut processing, and value-added products
Hydraulic Nut Shell Crushers
Use hydraulic pressure to apply immense, controlled force, making them ideal for the toughest shells. Known for reliability and efficiency in industrial settings.
Advantages
- Exceptional crushing power
- High efficiency and consistency
- Low operating costs over time
- Minimal wear and long service life
Limitations
- High initial purchase cost
- Bulky and requires fixed installation
- Needs trained operators and maintenance
Best for: Industrial-scale processing of macadamia, pistachio, and other premium hard-shell nuts
| Type | Durability | Efficiency | Kernal Protection | Best Application |
|---|---|---|---|---|
| Manual Crushers | High | Low | Excellent | Home use, small batches |
| Electric Crushers | Very High | High | Good | Commercial production |
| Cylindrical Crushers | Very High | Medium-High | Good | Hard-shell nuts (e.g., coconut) |
| Rotating Blade Crushers | High | Very High | Fair | Bulk processing, low kernel value |
| Screw Propeller Crushers | High | Medium | Excellent | Specialty nuts, artisanal production |
| Hydraulic Crushers | Exceptional | Very High | Very Good | Industrial premium nut processing |
Expert Tip: For optimal kernel recovery, pair your crusher with a winnowing or air separation system to effectively remove shell fragments and minimize contamination, especially when using high-speed or hammer-type models.
Key Industrial Applications of Hard Nut Shell Crushers
Hard nut shell crushers are versatile industrial machines that go far beyond basic food processing. These robust systems transform tough nut shells—particularly coconut, walnut, and almond shells—into valuable raw materials across multiple industries. By efficiently breaking down shells into fine particles or granules, these crushers enable sustainable, high-value applications in agriculture, manufacturing, cosmetics, and environmental management.
Food Processing
Coconut shell crusher machines are essential in modern food processing facilities. They enable the efficient separation of edible nut meats from hard outer shells, significantly increasing throughput for high-demand nuts like almonds, walnuts, and macadamias.
Automated crushing reduces reliance on manual labor, lowering operational costs and improving workplace safety. Beyond kernel extraction, crushed shells are repurposed in food production—used as natural thickeners or fiber additives in coconut milk, cream, and plant-based dairy alternatives. This closed-loop approach enhances resource utilization and supports zero-waste initiatives in food manufacturing.
Agriculture & Soil Enhancement
In sustainable agriculture, crushed nut shells serve as powerful organic soil amendments. Rich in potassium, phosphorus, and trace minerals, they slowly release nutrients into the soil, improving fertility and supporting long-term crop health.
Modern systems like sonic nut shell composters accelerate decomposition, producing nutrient-dense fertilizers that enhance microbial activity and root development. The fibrous texture of crushed shells also improves soil structure by increasing aeration and water retention, reducing erosion and compaction. By replacing synthetic fertilizers, these applications promote eco-friendly farming and reduce chemical runoff into ecosystems.
Manufacturing & Composite Materials
In advanced manufacturing, nut shell cutters supply raw materials for bio-based composites and sustainable plastics. The high lignin and cellulose content in crushed shells provides natural reinforcement, enhancing the strength, heat resistance, and durability of composite materials.
These eco-friendly alternatives are increasingly used in automotive interiors, construction panels, and consumer goods. By substituting petroleum-based fillers, manufacturers reduce carbon emissions and production costs. Additionally, the lightweight nature of shell-reinforced composites supports energy-efficient design in transportation and packaging industries.
Cosmetics & Personal Care
The cosmetic industry leverages crushed nut shells as natural, biodegradable exfoliants in facial scrubs, body washes, and soaps. Unlike harmful microplastics, nut shell granules gently remove dead skin cells without damaging the epidermis or polluting waterways.
Beyond physical exfoliation, these particles possess inherent antimicrobial and antifungal properties, making them ideal for acne treatments, foot care products, and hygiene formulations. Their inclusion in lotions and hair care products helps prevent bacterial growth while promoting scalp health and skin regeneration—offering a sustainable, multifunctional ingredient for green beauty brands.
Bioremediation & Water Purification
Crushed nut shells are emerging as effective adsorbents in environmental cleanup technologies. Their naturally porous structure provides a high surface area for capturing heavy metals (such as lead, cadmium, and mercury), oils, and organic pollutants from industrial wastewater.
Used in filtration systems and constructed wetlands, nut shell media offer a low-cost, renewable alternative to activated carbon. This application is particularly valuable in mining, textile, and chemical processing industries, where it helps meet regulatory standards for effluent discharge. By enabling safer water recycling and reducing environmental contamination, nut shell-based bioremediation supports corporate sustainability goals and ecological protection.
Energy & Fuel Production
While not explicitly mentioned, a growing application of crushed nut shells is in biomass energy generation. Due to their high calorific value, dried and compressed shells are used as solid biofuels in boilers and power plants.
They can be pelletized for consistent combustion, offering a carbon-neutral alternative to fossil fuels. This application not only reduces waste but also contributes to renewable energy portfolios, particularly in tropical regions with abundant coconut production. Integration into cogeneration systems further enhances efficiency by utilizing both heat and power outputs.
| Industry | Primary Use | Environmental Benefit |
|---|---|---|
| Food Processing | Nut meat extraction, coconut milk production | Reduces food waste, supports plant-based diets |
| Agriculture | Organic fertilizer, soil conditioner | Lowers chemical fertilizer use, improves soil health |
| Manufacturing | Bio-composites, sustainable plastics | Replaces petroleum-based materials, reduces plastic pollution |
| Cosmetics | Natural exfoliants, antimicrobial agents | Eliminates microplastics, biodegradable |
| Environmental | Water filtration, pollutant adsorption | Cleans industrial runoff, protects aquatic ecosystems |
Important: The effectiveness of nut shell applications depends on proper crushing size, moisture content, and contamination control. Using industrial-grade crushers designed for high-density materials ensures consistent particle size and maximizes downstream usability. Always source equipment and processes that comply with environmental and safety regulations to fully realize the sustainability benefits of nut shell recycling.
What Makes Hard Nut Shell Crushers Durable?
Hard nut shell crushers are engineered for long-term, reliable performance in demanding environments. Built to handle tough materials like walnuts, pecans, coconuts, and almonds, these machines must endure continuous operation, high impact forces, and abrasive conditions. Their durability stems from a combination of robust materials, intelligent engineering, and user-focused design that ensures years of efficient service with minimal breakdowns.
High-Quality Materials
At the core of every durable nut shell crusher is the use of premium-grade materials designed to resist corrosion, impact, and fatigue. Stainless steel and hardened alloy steels are commonly used for critical components due to their exceptional tensile strength and resistance to environmental degradation.
- Stainless steel housings prevent rust and contamination, especially important in food processing environments
- Hardened alloy shafts and bearings maintain structural integrity under constant stress
- Maraging steels or tool-grade alloys are often used in high-output industrial models for superior toughness
Key insight: Material selection directly impacts both operational lifespan and hygiene standards in food-grade applications.
Wear-Resistant Components
Components that come into direct contact with nut shells—such as hammers, screens, liners, and jaw plates—are subject to extreme abrasion. To combat this, manufacturers use advanced wear-resistant materials that significantly extend service intervals.
- Tungsten carbide-tipped hammers offer exceptional hardness and resistance to chipping
- Chrome-molybdenum alloy screens maintain precise openings and resist deformation
- Replaceable liner plates made from AR400 or AR500 steel provide extended wear life
Pro tip: Look for modular wear parts that can be replaced individually, reducing maintenance costs over time.
Heavy-Duty Motors
The power source of a nut crusher plays a crucial role in its longevity. Industrial-grade electric motors are specifically chosen for their ability to deliver consistent torque under variable loads without overheating.
- TEFC (Totally Enclosed Fan-Cooled) motors protect against dust and moisture ingress
- Variable frequency drives (VFDs) allow soft starts and load matching, reducing mechanical stress
- Over-temperature sensors automatically shut down the system before damage occurs
Performance note: High-efficiency motors not only last longer but also reduce energy consumption over the machine’s lifecycle.
Sturdy Frames
The frame acts as the backbone of the crusher, absorbing shock, vibration, and operational stress. A well-constructed frame ensures alignment stability and prevents premature fatigue of internal components.
- Reinforced steel frames with gusseted joints increase rigidity and load distribution
- Welded construction (vs. bolted) enhances structural integrity and reduces vibration points
- Anti-corrosion coatings or powder finishes protect against environmental exposure
Critical factor: A stable frame minimizes misalignment, which is a leading cause of bearing and gear failure.
Maintenance-Friendly Design
Durability isn’t just about strength—it’s also about serviceability. Machines designed with easy access to key components reduce downtime and ensure timely maintenance, which directly extends overall lifespan.
- Swing-open hoods or removable panels allow quick inspection of hammers and screens
- Centralized lubrication points simplify routine oiling and greasing
- Quick-release fasteners enable tool-free access to belts and drive systems
Smart design: Easy maintenance leads to better adherence to service schedules, preventing small issues from becoming major failures.
Overload Protection
Unpredictable feed material can cause sudden jams or torque spikes. Built-in overload protection safeguards the motor and drivetrain from catastrophic damage.
- Shear pins or torque limiters disconnect power during blockages to prevent gear damage
- Electronic current monitoring detects abnormal draw and triggers automatic shutdown
- Spring-assisted release systems allow foreign objects to pass without structural harm
Safety & savings: Overload systems protect both equipment and operators, reducing repair costs and downtime.
Vibration Dampening
Excessive vibration accelerates wear, loosens fasteners, and compromises structural integrity. Advanced vibration-dampening technologies help maintain machine stability and prolong component life.
- Rubber isolators or neoprene mounts decouple the crusher from its foundation
- Dynamic balancing of rotating assemblies reduces inherent vibration
- Shock-absorbing base frames dissipate energy during high-impact crushing cycles
Long-term benefit: Effective vibration control preserves welds, bearings, and electrical connections, contributing to years of reliable operation.
Sealed Bearings & Protection
One of the most common failure points in crushers is bearing contamination. Sealed or enclosed bearing systems prevent dust, moisture, and fine shell particles from entering sensitive areas.
- Labyrinth seals or double-lip seals keep contaminants out while retaining lubrication
- Greaseable bearings with extended relubrication intervals reduce maintenance frequency
- Stainless steel bearing housings resist corrosion and thermal expansion
Hidden hero: Proper bearing protection can double or triple the operational life of rotating components.
Expert Recommendation: When evaluating nut shell crushers, prioritize models that combine high-grade materials with smart engineering features like overload protection and easy maintenance access. While initial cost may be higher, the total cost of ownership is often significantly lower due to reduced downtime, longer part life, and lower energy consumption. For commercial operations, consider crushers with modular designs that allow incremental upgrades and part replacements over time.
| Feature | Standard Crusher | Durable/Industrial Crusher | Benefit of Upgraded Feature |
|---|---|---|---|
| Frame Material | Mild Steel | Reinforced Alloy Steel | 2–3x longer structural life under heavy use |
| Hammer Material | Carbon Steel | Tungsten Carbide-Tipped | 50–70% longer wear life |
| Motion Control | Direct Start Motor | VFD with Soft Start | Reduced mechanical stress and energy spikes |
| Overload Protection | None or Basic Fuse | Torque Limiter + Electronic Monitoring | Prevents costly motor and gearbox damage |
| Maintenance Access | Limited Panel Access | Full Swing Hood + Central Lubrication | Up to 60% faster service time |
Additional Considerations for Longevity
- Environmental Resistance: Outdoor or humid environments require stainless steel or powder-coated finishes to prevent rust and corrosion
- Noise Reduction: Sound-dampening enclosures not only improve workplace safety but also reduce vibration transmission
- Feed Control Systems: Automated feeders regulate input flow, preventing overloading and ensuring consistent operation
- Heat Dissipation: Proper ventilation and motor cooling systems prevent thermal degradation during extended runs
- Manufacturer Support: Brands offering technical support, spare parts availability, and service networks enhance long-term reliability
How to Choose Hard Nut Shell Crushers: A Comprehensive Buyer’s Guide
Selecting the right hard nut shell crusher is crucial for maximizing efficiency, reducing downtime, and ensuring consistent product quality in food processing, cosmetics, agriculture, and biomass industries. With various models and technologies available, making an informed decision requires evaluating several key criteria. This guide explores the most important factors to consider when choosing a nut shell crusher that aligns with your operational goals and long-term sustainability.
Important Note: Choosing a crusher isn’t just about upfront cost—it's about matching the machine to your specific raw materials, production scale, and downstream processing needs. A mismatch can lead to inefficient operations, increased wear, and poor-quality output.
1. Production Capacity
The crusher’s output capacity should align precisely with your daily or hourly processing requirements. Underestimating capacity leads to bottlenecks, while over-investing in oversized equipment increases energy and maintenance costs unnecessarily.
- Small-scale operations (e.g., artisanal food producers): 50–200 kg/hour may suffice
- Medium-scale facilities: 200–800 kg/hour
- Industrial applications: 800+ kg/hour, often requiring continuous-feed systems
Always allow a 10–20% buffer above your peak demand to accommodate future growth and operational fluctuations.
2. Nature of Nuts and Shell Hardness
Different nuts present unique crushing challenges due to variations in shell density, moisture content, and brittleness. Matching the crusher type to the nut variety ensures optimal performance and minimizes equipment strain.
- Soft-shelled nuts (e.g., pecans, walnuts): Can be processed with lower-impact hammer mills or roller crushers
- Hard-shelled nuts (e.g., macadamia, hazelnuts, pistachios): Require high-torque impact crushers or jaw crushers with hardened steel components
- Moist or oily shells: May necessitate crushers with anti-clogging designs and corrosion-resistant materials
Conduct material testing if processing a new nut type to determine optimal rotor speed, hammer configuration, and feed rate.
3. Desired Granule Size and Uniformity
The target particle size directly influences the choice of crusher and screening mechanism. Consistent granule size is essential for applications like cosmetic exfoliants, biofuel production, or animal feed blending.
- Look for crushers with adjustable screen meshes or variable-speed rotors to fine-tune output
- Models with multiple-stage crushing (primary + secondary) provide greater control over final particle distribution
- Integrated sieving systems or air classifiers help separate oversized particles for reprocessing
Ensure the machine can maintain size consistency across batches, especially for regulated industries like pharmaceuticals or cosmetics.
4. Durability and Material Construction
Given the abrasive nature of nut shells, durability is paramount. Crushers should be built to withstand constant wear and resist corrosion from organic residues.
- Opt for stainless steel housing and rotor assemblies (e.g., SS304 or SS316) for hygiene and longevity
- Hammer blades or teeth made from hardened alloys or tungsten carbide extend service life
- Look for replaceable wear liners in high-impact zones to reduce long-term replacement costs
- Protective coatings (e.g., powder coating or galvanization) prevent rust in humid environments
5. Total Cost of Ownership (TCO)
While initial purchase price is important, long-term value depends on maintenance, energy use, and productivity gains.
- Initial investment: Ranges from $2,000 for small units to $20,000+ for industrial systems
- Maintenance costs: Include spare parts (hammers, screens), lubrication, and labor
- Downtime impact: Choose designs that minimize cleaning and repair time
- Financing and ROI: Evaluate whether upgrading from an older model will reduce labor, improve yield, or enable new product lines
Calculate ROI based on increased throughput, reduced waste, and lower energy consumption over a 3–5 year period.
6. Energy Efficiency
Energy-efficient models not only reduce operating costs but also support sustainability goals—important for eco-conscious branding and regulatory compliance.
- Select crushers with variable frequency drives (VFDs) to match motor speed to load
- Look for high-efficiency motors (IE3 or IE4 rated) and optimized rotor dynamics
- Well-designed feed systems prevent overloading and energy spikes
A 10–20% improvement in energy efficiency can save hundreds or thousands of dollars annually in continuous operations.
7. Automation and Process Control
Modern crushers offer smart features that enhance consistency, safety, and ease of operation—especially valuable in large-scale or 24/7 operations.
- Sensors monitor temperature, vibration, and load to prevent damage
- Automated feed control adjusts input rate based on crusher performance
- Remote monitoring via PLC or IoT platforms enables real-time diagnostics
- User-friendly interfaces simplify operation and reduce training time
Automation reduces labor dependency and minimizes human error, leading to more predictable output quality.
8. Maintenance and Serviceability
Even the most durable crusher requires regular maintenance. Choose a model that prioritizes accessibility and ease of repair.
- Quick-release access panels allow fast inspection and cleaning
- Modular components simplify part replacement without specialized tools
- Ensure spare parts availability from the manufacturer or local suppliers
- Review warranty terms and technical support responsiveness
- Look for models with lubrication points that are easy to reach
Well-maintained crushers can last 10+ years, so prioritize serviceability over minimal upfront cost.
| Selection Criteria | Key Considerations | Recommended Features | Top Brands/Technologies |
|---|---|---|---|
| Production Capacity | Match to daily throughput; allow growth margin | Adjustable feed rate, scalable models | Pallmann, Vecoplan, Clextral |
| Nut Shell Hardness | Hard shells need high-impact force | Hardened steel hammers, heavy-duty rotors | Andritz, Bühler, Munson |
| Granule Size Control | Consistency for downstream use | Adjustable screens, multi-stage crushing | Hosokawa Alpine, Prater, Williams Crusher |
| Durability | Resist wear from abrasive shells | Stainless steel, replaceable liners | Joyal, Zenith, Metso |
| Energy Efficiency | Lower operating costs, eco-compliance | VFDs, IE3+ motors, optimized airflow | Siemens, ABB, GE |
Expert Tip: Request a sample crushing test from the manufacturer using your actual nut shells. This real-world trial reveals how well the machine handles your material, what granule size it produces, and how much dust or fines are generated—critical data before purchasing.
Final Recommendations
- Always consult with suppliers who specialize in nut processing equipment
- Ask for customer references and case studies in similar applications
- Consider second-hand industrial crushers from reputable brands—many are rebuildable and cost-effective
- Train operators on proper feeding techniques to prevent jamming and uneven wear
- Implement a preventive maintenance schedule to maximize uptime and lifespan
Choosing the right hard nut shell crusher is a strategic decision that impacts product quality, operational efficiency, and long-term profitability. By carefully evaluating your needs across capacity, material compatibility, durability, and total cost of ownership, you can select a machine that delivers reliable performance for years to come.
Frequently Asked Questions About Nut Crushers and Shell Processing
Yes, several portable nut crushers are specifically designed for small-scale agricultural operations, artisanal producers, or remote harvesting sites. These compact machines offer significant advantages in terms of mobility and operational flexibility.
- Compact Design: Built with space efficiency in mind, many models can fit in the back of a pickup truck or small trailer.
- Lightweight Construction: Often made from high-strength aluminum or reinforced polymers to reduce overall weight without sacrificing durability.
- Easy Transport: Equipped with handles, wheels, or mounting brackets for quick relocation between farms or processing areas.
- Plug-and-Play Operation: Some units run on standard electrical outlets or even solar-powered systems, making them ideal for off-grid use.
These portable solutions are particularly valuable for farmers' markets, mobile processing units, and developing regions where access to large industrial equipment is limited.
Yes, advanced industrial nut crushing systems often include integrated separation technology to streamline post-crushing processing. This automation significantly improves efficiency and product consistency.
- Vibrating Screens: Use oscillating mesh trays to sift lighter shell fragments from heavier nut kernels based on size and weight differences.
- Air Classification (Winnowing): Employs controlled airflow to blow away lighter shell particles while allowing denser nutmeat to fall into collection bins.
- Optical Sorters: High-end systems may use camera-based detection to identify and eject shell remnants using precision air jets.
- Magnetic Separation: Removes any metallic debris that may have entered during harvesting or processing.
By combining crushing and separation in one system, processors reduce labor costs by up to 60%, minimize cross-contamination, and improve overall yield and purity of the final product.
Macadamia nuts are widely recognized as having the hardest shells among commercially harvested nuts, requiring specialized equipment for efficient processing.
- Shell Hardness: Macadamia shells measure approximately 200–300 MPa (megapascals) in compressive strength—nearly twice as hard as walnut shells.
- Equipment Wear: The extreme hardness causes accelerated wear on standard crusher components such as rollers, hammers, and liners.
- Required Features: Effective macadamia cracking systems require hardened steel or tungsten-carbide components, precision gap control, and shock-absorbing mechanisms.
- Cracking Technique: Optimal processing uses controlled pressure rather than brute force to avoid damaging the delicate kernel inside.
Due to these challenges, dedicated macadamia processing lines often include pre-conditioning steps like moisture balancing and temperature control to reduce shell brittleness and improve cracking efficiency.
Modern commercial nut crushers are engineered with adaptive technologies to accommodate natural variations in shell thickness and hardness across different nut varieties and growing conditions.
- Adjustable Crushing Gaps: Operators can manually or digitally set the distance between rollers or plates to match specific nut types (e.g., almonds vs. pecans).
- Variable Speed Motors: Allow control over crushing speed, reducing kernel damage in softer nuts while increasing throughput for harder shells.
- Smart Sensors: Advanced electric models feature load sensors and feedback systems that detect resistance and automatically adjust torque or pressure in real time.
- Pre-Processing Calibration: Some systems use sample testing modes to determine optimal settings before full-scale operation begins.
This adaptability ensures high kernel recovery rates (often exceeding 95%) while minimizing fines and shell contamination, making these machines versatile across diverse nut processing applications.
Yes, sustainable and environmentally responsible nut crushing solutions are increasingly available, aligning with green manufacturing trends and regulatory standards.
- Energy Efficiency: Modern eco-crushers use high-efficiency motors and regenerative braking systems powered by solar, wind, or grid-supplied renewable energy.
- Low-Impact Materials: Constructed with recycled metals, bioplastics, and non-toxic coatings to reduce environmental footprint during production and disposal.
- Emissions Control: Equipped with dust collection systems and noise-dampening enclosures to minimize air and sound pollution.
- Waste Utilization: Many systems integrate shell recycling mechanisms—crushed shells can be repurposed as biofuel, mulch, or composite materials.
- Biodegradable Components: Seals, gaskets, and lubricants made from plant-based materials reduce plastic waste and chemical runoff.
These eco-friendly innovations not only support environmental sustainability but also help processors meet organic certification requirements and appeal to environmentally conscious consumers.








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