How to Improve Ceramic Green Strength: Binder Selection & Formulation Tips
Step-by-step diagnostic guide for ceramic engineers: identify the root cause of low green strength, understand inorganic vs. organic binder mechanisms, run a 5-point dosage curve, and validate safely through pilot production.
Key Facts for Ceramic Manufacturers
Step 1 — Measure and Diagnose Before Selecting a Solution
Effective green strength improvement starts with measurement, not product selection. Before evaluating any binder, establish a baseline and locate where in the production process breakage occurs.
How to Measure Current Green Strength
The standard method is the three-point flexural test (Modulus of Rupture, MOR) on dry-pressed and dried green bar samples of standardised dimensions. Run a minimum of 10 bars per test condition and record mean ± standard deviation in MPa.
Fig. 1 — Schematic of three-point bending test for green ceramic body (MOR). Standard equipment: ceramic lab press bar die + universal testing machine or dedicated flexural tester. (Source: Goway in-house testing protocol)
Additional practical indicators include:
- Edge chip / corner-drop test — drop a green tile from a standardised height onto a hard surface; count corner and edge survival rate
- Breakage audit by stage — record breakage rate separately at: after pressing, after drying, after transfer/cutting, after stacking
- Dimensional stability — measure length, width and thickness before and after drying to detect warping or uneven shrinkage
Root Cause Categories
Once you have measured where and how much breakage occurs, systematically evaluate the contributing factors before choosing a binder type or dosage:
Raw Material Plasticity
Low plasticity clays or high lean material ratios (feldspar, quartz, calcite) reduce particle-to-particle cohesion. Ball clay typically contributes more plasticity than standard kaolin. Reducing plastic clay for whiteness improvement often requires supplemental binder addition.
Particle Size Distribution
Coarse or mono-modal particle distribution creates large inter-particle voids and weak contact points. Poor particle packing reduces bonding sites per unit volume regardless of binder type. Review ball mill time and media size before increasing binder dosage.
Moisture & Density
Insufficient pressing moisture, uneven moisture distribution in spray-dried powder, or inconsistent bulk density leads to incomplete particle contact. Over-drying removes the free water film that supports capillary bonding before the binder network forms.
Pressing Parameters
Low compaction pressure, short dwell time, or press wear affecting die fill uniformity reduces green density and strength. Pressing improvements alone may not compensate for a fundamentally weak binder system.
Binder Type & Dosage
Mismatched binder type for the body composition, under-dosing, or binder degraded by hard process water are common chemical causes. Both the binding mechanism and the active ingredient content of the binder determine effectiveness.
Powder Aging Time
Insufficient aging (homogenisation time) of spray-dried powder in the silo before pressing leads to uneven moisture distribution and incomplete binder film formation. Typical minimum aging: 24–48 hours depending on body composition.
Step 2 — Understand Binder Types & Working Mechanisms
Two fundamentally different binding mechanisms are available for ceramic body strengthening. Understanding the mechanism helps match the right product to the right production challenge before selecting a specific grade.
Fig. 2 — Mechanism comparison: inorganic silicate network bridging (ZG series) vs. organic polymer chain bridging (FG-ZM01 series). Organic binders form a denser, more flexible network suited to low-clay or dry-press bodies. (Source: Goway in-house engineering evaluation)
Mechanism 1: Silicate Network Bridging (Inorganic)
Inorganic mineral binders contain reactive silica-alumina phases (SiO₂ 60–70%, Al₂O₃ 13–16%). During drying, these form thin aluminosilicate bridges at particle contact points, acting as a rigid network. The binder becomes part of the ceramic body after firing and contributes to the fired microstructure. Goway's ZG-302 and ZG-303 are examples of this category.
Mechanism 2: Polymer Chain Bridging (Organic)
Organic polymeric binders use long-chain polymer molecules that physically bridge ceramic particles and form a flexible network after drying. With active ingredient content typically 90–98%, they can provide significantly higher green strength per dosage unit compared to inorganic types — particularly in lean or low-plasticity bodies. Goway's FG-ZM01A and FG-ZM01D grades are examples of this category.
Mechanism 3: Clay Mineral Contribution
Plastic clays such as ball clay contribute intrinsic bonding through platelet-to-platelet electrostatic interaction. This natural binding is most effective when clay content is ≥15% in the body, and decreases significantly as lean material ratio increases. When reducing clay content for whiteness or shrinkage targets, supplemental binder addition becomes essential.
Mechanism 4: Capillary Bonding (Transient)
Water films at particle contacts create surface tension forces contributing to immediate green strength after pressing. This is moisture-dependent and transient — it dissipates as drying proceeds. Capillary bonding can mask insufficient binder dosage during initial handling but fails during drying or transport. Not a substitute for chemical binder systems.
Step 3 — Technical Comparison: Inorganic vs. Organic Ceramic Body Binder
| Comparison Factor | ZG-302 / ZG-303 (Inorganic / Mineral) |
FG-ZM01A / FG-ZM01D (Organic Polymeric) |
Selection Notes |
|---|---|---|---|
| Primary mechanism | Silicate-aluminosilicate network bridging at particle contacts | Long-chain polymer bridge network between particles | Both effective; mechanism determines compatibility with body type |
| Active ingredient level | Mineral composition (SiO₂ 60–70%, Al₂O₃ 13–16%) (Source: Goway TDS) | Active ingredient 90–98% (FG-ZM01A: 95–98%, FG-ZM01D: 90–95%) (Source: Goway TDS) | Organic binder delivers more binding activity per gram of product |
| Green strength potential | Moderate — typical for standard tile bodies with normal clay content | Higher — especially effective in lean bodies, high-lean-material ratios | Choose organic when green strength is the primary bottleneck |
| Dosage range (typical) | 0.5–2.0% by dry body weight | 0.3–1.0% by dry body weight | Start at lower end; run dosage curve to identify optimum |
| Slurry compatibility | Generally compatible with standard slurry systems; may slightly increase viscosity at high dosage | Compatible with most slurry systems; monitor Ford Cup flow time when adding; may require deflocculant adjustment | Test slurry viscosity after binder addition in pilot batch before full production |
| Firing behaviour (L.O.I) | ZG-302: L.O.I 7–8%; ZG-303: L.O.I 6–7%. Contributes SiO₂/Al₂O₃ to fired body. | Both FG-ZM01A and FG-ZM01D: L.O.I 50–55%. Burns out during firing. | Organic: verify debinding at 300–500°C for thick bodies to avoid dark cores |
| Impact on fired colour/whiteness | Fe₂O₃ 1–2% may slightly affect fired colour in whiteness-sensitive bodies (Source: Goway TDS) | Organic content burns out; minor impact on fired colour at recommended dosage | For maximum whiteness targets, evaluate fired sample with and without binder addition |
| Risk of black core defect | Low under standard firing conditions | Possible in fast firing or thick-body products — requires firing curve validation | Organic binder: mandatory pilot kiln trial before scale-up |
| Best application scenario | Standard wet-process tile body; bodies with ≥15% plastic clay content; cost-sensitive production | Low-clay or lean bodies; dry-press systems; high-strength requirement; ultra-thin tile | Lean bodies (clay <12%) may not achieve target strength with inorganic binder alone |
| Combination use | ZG (base) + small FG-ZM01D addition for peak strength — technically feasible. Compatibility must be confirmed by lab trial. | Cost-effective approach when intermediate strength level is the target | |
All values are typical and for evaluation reference only. Confirm with the latest batch COA before production use. (Source: Goway Technical Data Sheet)
Fig. 3 — Ceramic tile cross-section: normal (left) vs. black core defect (right). Black core occurs when organic binder burns incompletely due to fast firing or insufficient debinding hold temperature. Mandatory pilot kiln trial is required before scaling up with organic binders. (Source: Goway engineering evaluation)
Inorganic Binder Specifications — ZG-302 / ZG-303
| Grade | SiO₂ (%) | Al₂O₃ (%) | Fe₂O₃ (%) | Na₂O (%) | CaO (%) | MgO (%) | L.O.I (%) |
|---|---|---|---|---|---|---|---|
| ZG-302 | 60–65 | 13–15 | 1–2 | 1–2 | 1–2 | 2–3 | 7–8 |
| ZG-303 | 65–70 | 14–16 | 1–2 | 1–2 | 1–2 | 2–3 | 6–7 |
Typical values. (Source: Goway Technical Data Sheet) Final specification: confirm with latest batch COA before purchase or production use.
→ View full ZG-302 / ZG-303 product page with dosage guide, packaging and COA request
Organic Polymeric Binder Specifications — FG-ZM01 Series
| Grade | Active Ingredient | Inorganic Salt By-product | Unreacted Monomer / Oligomer | Residual Raw Materials & Moisture | L.O.I (%) |
|---|---|---|---|---|---|
| FG-ZM01A | 95–98% | 3–8% | <2% | Trace | 50–55 |
| FG-ZM01D | 90–95% | 5–8% | <2% | Trace | 50–55 |
Typical values. (Source: Goway Technical Data Sheet) FG-ZM01A has higher active ingredient content and is typically preferred when maximum green strength per dosage unit is required. Final specification: confirm with latest batch COA.
→ View full FG-ZM01A / FG-ZM01D product page with firing curve guidance, packaging and COA request
Product Appearance & Technical Documentation
Binder Selection Matrix — Match Your Situation to a Starting Strategy
Use the table below to identify the most appropriate binder approach based on your production situation. All recommendations are starting points for lab evaluation — confirm by lab trial under your specific formula and process conditions.
| Your Situation | Recommended Approach | Why | Starting Dosage | Validation Method | Related Product |
|---|---|---|---|---|---|
| Standard wet-process tile body; clay content ≥15%; moderate green strength target | Inorganic ZG-302 or ZG-303 |
Mineral binder integrates into body matrix; cost-effective; low firing risk | 0.5% by dry weight | Dry MOR test + slurry viscosity check | ZG-302 / ZG-303 |
| Lean body with high quartz/feldspar content; clay <12%; green strength below target | Organic FG-ZM01A or FG-ZM01D |
Polymer chain bridging compensates for low clay plasticity; higher strength per dosage unit | 0.3% by dry weight | Dry MOR + pilot kiln trial for firing curve | FG-ZM01A |
| Dry-press body; no slurry process; maximum pressing strength required | Organic FG-ZM01A preferred |
Higher active ingredient (95–98%) forms strong dry-state polymer network in pressed powder | 0.3–0.5% by dry weight | Dry MOR + edge chip resistance test | FG-ZM01A |
| High breakage rate after drying but acceptable after pressing; drying step is the failure point | Combo or Organic FG-ZM01D or ZG + FG-ZM01D |
Organic binder network persists after moisture loss; provides post-drying cohesion that inorganic alone may not maintain | FG-ZM01D at 0.2–0.4% | Dry MOR before and after drying cycle; track drying shrinkage | FG-ZM01D |
| Ultra-thin tile or large-format body (≥900×900mm); edge and corner handling breakage | Organic FG-ZM01A |
High active ingredient level required; polymer flexibility reduces crack initiation at edges under bending loads | 0.4–0.6% by dry weight | Full-sheet dry MOR + corner-drop survival rate; pilot kiln for firing validation | FG-ZM01A |
| Cost-sensitive production; acceptable moderate green strength improvement; fired colour flexibility | Inorganic ZG-302 |
Lower active content per unit, but contributes usable mineral oxides to fired body; cost-effective base solution | 0.8–1.5% by dry weight | Dry MOR + fired colour check | ZG-302 |
| Existing green strength acceptable but slurry stability poor; looking for binder with minimal viscosity impact | Inorganic ZG-303 |
ZG-303 has higher SiO₂ content (65–70%) and lower L.O.I (6–7%); typically has lower viscosity impact than organic binders at equivalent dosage | 0.5–1.0% by dry weight; monitor Ford Cup after addition | Slurry Ford Cup flow time + viscosity + dry MOR | ZG-303 |
Selection recommendations are for starting evaluation only. Results vary with body formula, water quality, processing conditions and kiln type. Lab trial is mandatory before production scale-up.
Recommended Dosage & Lab Trial Protocol
A systematic 5-point dosage curve is the most reliable method to identify the optimal binder type, dosage and combination for your specific body formula. Do not rely on a single-point trial or assume results from other formulas will transfer directly.
MOR Improvement vs. Dosage — Typical Response Curve
Fig. 4 — Typical MOR improvement curve with organic polymeric binder addition (FG-ZM01A, solid red) vs. inorganic binder (ZG-302, dashed green). Organic binder shows a steeper response and higher MOR ceiling; the inorganic binder delivers more gradual, consistent strength across a wider dosage range. Typical result only — actual values depend on body formula, clay content and press pressure. Confirm by lab trial. (Source: Goway in-house testing, 2025–2026)
Measured MOR Dosage Curve Data — Binder Type & Dosage Comparison
The following table presents typical measured dry flexural strength (MOR) values from a controlled dosage curve trial. Data is anonymised and typical — actual results depend on your specific body formula, clay content, pressing parameters and drying conditions.
| Binder Type | Grade | Dosage (%) | Avg. MOR (MPa) | Breakage Rate Reduction | Notes |
|---|---|---|---|---|---|
| Control (None) | — | 0.0 | 1.2 | Baseline | Standard body: clay 18%, feldspar 40%, quartz 42%. Pressed at 25 MPa. Dried at 110°C for 2 hours. |
| Organic Polymeric | FG-ZM01D | 0.4 | 1.8 | ~25% | Slight viscosity increase observed (Ford Cup +2s). MOR increase is noticeable but below optimal. Suitable when moderate improvement is sufficient. |
| Organic Polymeric | FG-ZM01D | 0.6 | 2.4 | ~60% ★ | Optimal balance: peak MOR gain vs. dosage cost. Slurry viscosity manageable at standard deflocculant level. Fired cross-section clean at standard firing curve. |
| Organic Polymeric | FG-ZM01D | 0.8 | 2.5 | ~65% | MOR plateau reached. Drying shrinkage increased by 0.3%. Risk of drying cracks at fast drying rates. Pilot kiln trial mandatory — check for black core in thick sections. |
| Inorganic Mineral | ZG-302 | 0.8 | 1.4 | ~10% | Modest MOR gain. Minimal impact on slurry properties. L.O.I 7–8% contributes to fired body composition. Suitable when slurry stability is priority. |
| Inorganic Mineral | ZG-302 | 1.5 | 2.1 | ~40% | Minimal viscosity impact on slurry. Fe₂O₃ 1–2% may slightly affect fired whiteness in white-body formulations. Verify fired colour at this dosage level. |
| Inorganic Mineral | ZG-302 | 2.0 | 2.2 | ~45% | MOR gain marginal beyond 1.5%. Slurry viscosity increases slightly. Upper practical limit; check fired whiteness at this dosage. |
Key observations from the measured data:
- FG-ZM01D at 0.6% delivers the highest MOR gain per dosage unit. Above 0.6%, the improvement plateaus while drying shrinkage and black core risk increase. 0.6% is the recommended starting point for most body formulations.
- ZG-302 at 1.5% provides a useful MOR improvement with minimal slurry processing impact. This makes it a practical choice when slurry stability and fired colour consistency take priority over maximum green strength.
- Dosages above the optimum do not produce proportional benefits. For FG-ZM01D, the MOR gain from 0.6% to 0.8% is only ~4% while drying defects risk increases measurably. Always identify the optimum through a controlled dosage curve, not through extrapolation.
5-Point Dosage Curve — Inorganic Binder (ZG-302 / ZG-303)
Run the following dosage series against your base formula (no added binder). Measure dry MOR and slurry viscosity at each point. Expected pattern: strength increases to an optimum then plateaus or decreases as dosage increases further.
Note: Bar heights are illustrative of a typical response curve. Actual results depend on body formula and clay mineral content. Typical result only — confirm by lab trial. (Source: Goway Technical Data Sheet)
5-Point Dosage Curve — Organic Binder (FG-ZM01A / FG-ZM01D)
Typical result only. Organic binder: at each dosage point, a pilot kiln firing trial is required to verify no dark core or surface defects occur. Confirm by lab trial before production scale-up.
A Southeast Asian floor tile plant was experiencing dry-edge breakage at a rate of approximately 4.8% at the exit of the drying kiln. After baseline MOR measurement and a systematic 3-point dosage trial with FG-ZM01D at 0.4%, 0.6%, and 0.8%, the breakage rate was reduced to approximately 1.6% at an optimal dosage of 0.6%. The 0.8% dosage was not adopted: while dry MOR remained acceptable, the pilot kiln cross-section showed early-stage dark core formation in 12mm thick bodies at the existing fast-fire cycle. The firing curve was adjusted with a 15-minute hold at 380°C, after which the 0.6% dosage was validated in full-scale production without further defects. Typical result only. Results vary with body formula and production conditions.
Measurement Parameters at Each Dosage Point
| Test Parameter | Method / Equipment | Record & Target | Relevance |
|---|---|---|---|
| Dry Flexural Strength (MOR) | Three-point bend test on dry green bars (standard ceramic lab press bar) | Record MPa at each dosage point; compare to baseline (no binder) | Primary indicator of green strength improvement |
| Slurry Ford Cup Flow Time | Ford Cup No. 4 | Record seconds; compare to base slurry without binder addition | Detects viscosity impact of binder addition on slurry process |
| Spray-Dried Powder Flowability | Flow angle or bulk density test | Record and compare; significant change may indicate binder-powder interaction issue | Critical for dry-press consistency and die fill uniformity |
| Drying Shrinkage | Dimensional measurement pre- and post-drying | Record % dimensional change; unexpected increase may indicate binder effect on drying stress | Alerts to potential warping or drying crack risk at high binder dosage |
| Fired Whiteness (1200°C) | Whiteness meter on fired sample | Record whiteness at each dosage; compare to unfired reference body | Checks for colour impact from Fe₂O₃ (inorganic) or organic burn-out residues |
| Visual Inspection of Fired Sample | Cross-section examination | Check for dark core, surface blisters, or pinholes — critical for organic binder trials | Identifies debinding issues requiring firing curve adjustment |
Lab Trial Protocol — Step by Step
- Prepare reference body batch Mix your standard body formula without binder addition. Record baseline dry MOR, slurry Ford Cup flow time (if wet process), and powder flowability. This is your control data point.
- Prepare 5 test batches at dosage series For inorganic: 0.5%, 0.8%, 1.2%, 1.6%, 2.0%. For organic: 0.2%, 0.4%, 0.6%, 0.8%, 1.0%. Add binder to slurry or dry powder as per product TDS instruction. Maintain all other variables constant (water ratio, milling time, spray-drying temperature, press pressure).
- Press standard green bar samples Use identical die and pressing pressure for all batches. Minimum 10 bars per dosage point for statistical significance. Record press density and moisture.
- Dry and measure dry MOR Dry bars at standard drying curve (same for all). After cooling to room temperature, measure three-point flexural strength (MOR, MPa) for each bar. Record mean and standard deviation per dosage point.
- Fire pilot samples and inspect cross-sections Fire pressed tiles or bars at your standard kiln curve. For organic binder trials, add a debinding hold at 300–500°C if not already in your programme. After firing: measure whiteness, inspect cross-sections for dark core, record dimensional change (shrinkage). Document any surface defects.
- Plot dosage curves and identify optimum Plot dry MOR vs. dosage for each binder type tested. The optimum is typically the dosage just before MOR plateaus or begins to decrease. Cross-check against fired quality and viscosity data. Select the dosage that meets all targets simultaneously.
- Validate in pilot production batch Run a controlled pilot batch at the selected dosage and binder type. Monitor all process parameters (slurry, spray drying, pressing, drying, firing) over at least 3 production shifts. Track green breakage rate before and after binder introduction. Confirm stable performance before full-scale implementation.
Supplementary Formulation & Process Adjustments
Binder selection is one lever. The following non-binder adjustments can significantly improve green strength and should be considered in combination with binder optimisation:
- Increase plasticity clay fraction: Replacing part of feldspar or quartz with high-plasticity ball clay can improve intrinsic body cohesion, reducing reliance on added binder.
- Optimise particle size distribution: Achieving broader particle size distribution (bimodal or trimodal) improves packing density and inter-particle contact area. Review ball mill time and media size.
- Control spray-dried powder moisture and aging: Target moisture within ±0.3% of the optimal pressing moisture for your body. Ensure minimum 24–48 hours aging in powder silo for even binder distribution before pressing.
- Review pressing parameters: Optimise press pressure, dwell time and die fill uniformity. Worn dies or inconsistent fill reduce green density regardless of binder choice.
- Manage drying rate: Excessive drying rate creates surface-to-centre moisture gradients and internal stress. Slow the initial drying phase (especially for thick-body or high-binder-dosage formulas) to allow binder network to form without cracking.
- Consider plasticiser addition: For dry-press systems with very lean bodies, a small addition of plasticiser (PEG or glycerine type, per TDS recommendation) in combination with the organic binder can improve powder pressing behaviour and green density.
Troubleshooting Table — Green Strength & Binder System
| Problem | Possible Cause | Related Parameter | Recommended Action | Product / Guide Link |
|---|---|---|---|---|
| Dry MOR below target even at maximum binder dosage | Clay content too low; particle size distribution too coarse; pressing pressure insufficient | Clay% in formula; d50 / d90 of slurry; pressing pressure log | Switch to organic binder (FG-ZM01A) or increase plasticity clay ratio; review milling protocol; consult press parameters | FG-ZM01A → |
| Green strength acceptable after pressing but drops significantly during drying | Capillary bonding loss during drying; inorganic binder network insufficient after moisture removal | MOR at press vs. MOR after drying; drying curve rate | Add organic binder (FG-ZM01D) or transition to FG-ZM01A; slow down initial drying phase; check powder aging time | FG-ZM01D → |
| Organic binder addition significantly increases slurry viscosity | High-molecular-weight polymer interaction with clay particles; binder dosage too high | Ford Cup flow time before and after binder addition | Reduce binder dosage; increase deflocculant addition slightly to compensate; add binder at later stage of slurry preparation; test FG-ZM01D (lower active ingredient) before FG-ZM01A | Viscosity Guide → |
| Dark core (black core) defect in fired tiles after organic binder addition | Insufficient debinding time in firing curve; fast firing rate through 300–500°C zone; thick-body product | L.O.I 50–55% for FG-ZM01 series; kiln firing curve log | Add debinding hold at 350–450°C in firing programme; reduce firing rate through this zone; confirm with pilot kiln trial before production scale-up; consider reducing organic binder dosage | FG-ZM01A TDS → |
| Fired whiteness decreases after adding inorganic binder | Fe₂O₃ content in ZG-302/ZG-303 (1–2%) contributing iron oxide colouration | Fe₂O₃% in ZG product TDS; fired sample whiteness measurement | Switch to organic binder for whiteness-critical bodies; or test at minimum effective inorganic binder dosage; evaluate fired whiteness at each dosage point in lab trial | FG-ZM01 → |
| Green strength inconsistent batch-to-batch despite same dosage | Inconsistent binder dispersion in slurry or powder; variable clay source moisture; inconsistent aging time | Binder addition point in slurry/powder prep; powder aging log; clay moisture on receipt | Fix binder addition timing in process SOP; standardise powder aging to 24–48 hrs; add incoming clay moisture check; verify binder mixing time is sufficient | ZG-302/303 → |
| Edge and corner chip breakage during transfer after pressing | Insufficient immediate green strength at edges; die wear causing incomplete fill at corners; low press pressure at edge zone | Corner-drop test; die condition inspection; pressing pressure map | Switch to FG-ZM01A for higher active ingredient per dosage; inspect and replace worn die corners; review conveyor belt and transfer equipment for sharp impact points | FG-ZM01A → |
| Drying cracks appearing at binder dosage above 1.0% (organic) | High binder dosage alters shrinkage behaviour; binder film creates uneven surface tension during drying | Drying shrinkage measurement; drying curve rate | Reduce organic binder dosage to below 1.0%; slow initial drying rate; check if combination with inorganic binder at lower respective dosages achieves target strength without drying issues | ZG-302/303 → |
| Spray-dried powder sticking or poor flowability after organic binder addition | Binder surface tackiness in spray-dried granules; spray-dry outlet temperature too low; excessive binder dosage | Powder bulk density; flow angle; spray-dry outlet temperature log | Increase spray-dry outlet temperature slightly; reduce binder dosage; trial FG-ZM01D (lower active content) which may produce less tacky granules; review inlet/outlet temperature profile | FG-ZM01D → |
Frequently Asked Questions
Request a Binder Sample Test Kit or Technical Recommendation
Not sure which binder grade fits your body formula? Submit your production parameters for a free dosage evaluation from Goway's ceramic technical team.
Production Data Needed for Binder Recommendation
Provide the following process parameters to help Goway's technical team prepare a specific binder recommendation and dosage starting point for your production. All information is treated as strictly confidential.
→ Submit your parameters via the Goway contact form or request COA, TDS, SDS for ZG-302, ZG-303, FG-ZM01A or FG-ZM01D.
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