Volume 04 Issue 10-2024
15
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
04
ISSUE
10
Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
ABSTRACT
The efficiency of cotton cleaning machines plays a critical role in the textile industry, particularly in removing fine
impurities. This paper focuses on enhancing the design of cotton cleaning machines to improve their performance. By
analyzing the shortcomings of existing models, this research proposes modifications to the design of spiked drums
and air suction systems to enhance cleaning efficiency. The results demonstrate that the proposed enhancements
lead to significant improvements in impurity removal, reducing energy consumption and increasing cotton quality.
KEYWORDS
Cotton cleaning machine, fine impurities, spiked drum, cleaning efficiency, design optimization.
INTRODUCTION
Cotton is one of the most important raw materials in
the textile industry, used in a wide variety of
applications, including clothing, home textiles, and
industrial fabrics. As a natural fiber, cotton must go
through several stages of processing before it can be
used in manufacturing. A critical step in this process is
the cleaning of raw cotton to remove impurities such
as dust, dirt, small fibers, plant debris, and seed
particles. These fine impurities not only lower the
quality of the cotton but also pose a threat to
subsequent processing machinery, causing damage,
Research Article
IMPROVING THE CLEANING EFFICIENCY BY ENHANCING THE DESIGN OF
THE COTTON CLEANING MACHINE FOR REMOVING FINE IMPURITIES
Submission Date:
Sep 29, 2024,
Accepted Date:
Oct 04, 2024,
Published Date:
Oct 09, 2024
Crossref doi:
https://doi.org/10.37547/ajast/Volume04Issue10-03
Anvar Djurayevich Djurayev
Doctor of Technical Sciences, Professor, Tashkent Institute of Textile and Light Industry, Uzbekistan
Tokhirov Azamjon Ibrokhim ugli
Andijan machie-building institute, Department Automation of mechanical engineering, doctorant, Andijan,
Uzbekistan
Journal
Website:
https://theusajournals.
com/index.php/ajast
Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Volume 04 Issue 10-2024
16
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
04
ISSUE
10
Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
increased maintenance costs, and potential production
delays.
Cotton cleaning machines are designed to perform this
vital task by separating the cotton fibers from
unwanted contaminants. However, the efficiency of
these machines is often constrained by design
limitations, which result in suboptimal cleaning
performance. Traditional designs typically rely on
mechanical components, such as spiked drums and
grid bars, as well as airflow systems to carry away
impurities. While these machines can remove larger
debris relatively effectively, fine impurities
—
such as
dust and short fibers
—
are more challenging to
eliminate. This creates a need for improvements in the
design and function of cotton cleaning machines,
especially in regions where high-quality cotton
production
is
essential
for
maintaining
competitiveness in the global textile market.
The importance of improving cotton cleaning
efficiency extends beyond just cotton quality.
Inefficient cleaning systems can lead to excessive
cotton loss, increased energy consumption, and higher
operational costs. Moreover, the presence of residual
impurities in the cleaned cotton can negatively affect
subsequent processes such as spinning, weaving, and
dyeing, reducing the overall efficiency of textile
production. Therefore, enhancing the performance of
cotton cleaning machines not only improves the
quality of the end product but also reduces waste and
increases energy efficiency, leading to more
sustainable production practices.
Over the years, various studies have explored ways to
improve cotton cleaning, primarily through mechanical
modifications and technological advancements. Some
have focused
on
enhancing the separation
mechanisms within the machine, while others have
looked at optimizing airflow to improve the removal of
fine particles. However, there remains significant room
for improvement, particularly in the removal of smaller
impurities and the energy efficiency of the cleaning
process. Given the complexity of the cotton cleaning
process, any improvements must strike a balance
between maintaining cotton integrity, maximizing
impurity removal, and minimizing energy use.
This study aims to address these challenges by
focusing on two critical components of the cotton
cleaning machine: the spiked drum and the air suction
system. The spiked drum plays a pivotal role in
separating impurities from the cotton by agitating and
loosening the fibers. By redesigning the drum and
optimizing the angle and distribution of the spikes, we
aim to increase the interaction between the cotton and
the cleaning elements, thus improving impurity
removal. Additionally, the air suction system,
responsible for carrying away fine particles, will be
enhanced to increase its effectiveness while
maintaining energy efficiency.
In this research, we propose a series of design
modifications aimed at improving the overall cleaning
performance of the machine. These modifications are
based on a thorough analysis of existing machines,
empirical testing, and computational modeling. The
ultimate goal is to increase the efficiency of cotton
cleaning machines, ensuring better cotton quality and
more sustainable operations in the textile industry.
METHODS
Machine Design
Cotton cleaning machines are designed to remove a
range of impurities from raw cotton, from larger debris
such as leaves and stems to finer particles like dust and
short fibers. A typical cotton cleaning machine consists
of several key components, including a spiked drum,
Volume 04 Issue 10-2024
17
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
04
ISSUE
10
Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
grid bars, and an air suction system, each playing a vital
role in the cleaning process.
Spiked Drum: The spiked drum is central to the cleaning
process, as it agitates and separates the cotton fibers
from impurities. As the drum rotates, the spikes grab
and lift the cotton, creating friction between the fibers
and the cleaning elements. This mechanical action
helps dislodge impurities from the cotton surface,
allowing for their removal. The design of the spiked
drum, including the size, shape, and angle of the
spikes, directly affects the machine’s cleaning
efficiency.
Grid Bars: Beneath the spiked drum, grid bars are
positioned to filter out larger impurities. These bars
form a grid that allows fine cotton fibers to pass
through while retaining larger contaminants such as
leaves and seed husks. The spacing between the grid
bars is crucial, as too wide spacing may allow impurities
to remain in the cotton, while too narrow spacing
could result in fiber loss.
Air Suction System: Fine particles, such as dust and
small fibers, are difficult to remove solely through
mechanical means. The air suction system creates a
controlled airflow that carries these smaller impurities
away from the cotton as it passes through the cleaning
chamber. The effectiveness of this system depends on
the strength of the suction, the airflow rate, and the
placement of the suction vents.
In this study, we conducted a comprehensive analysis
of several existing models of cotton cleaning machines
to identify potential areas for design improvement.
Specifically, we focused on optimizing the spiked drum
and air suction system, as these components have the
greatest influence on the removal of fine impurities.
Our modifications aimed to increase cleaning efficiency
without compromising the structural integrity of the
cotton fibers.
In this case, the cotton clump thrown from the spikes
of the drum strikes the mesh surface. As a result,
mainly fine impurities are separated from it. The
efficiency of the cleaner largely depends on the length
of the cleaning zone. In existing cleaners, this zone is
primarily determined by the coverage angle of the
mesh surface. In the cleaner we propose, although the
coverage angle of the mesh surface remains nearly
unchanged, the movement trajectory is somewhat
increased. This is primarily due to the fact that the rows
of spikes are arranged on the drum in a helical screw
order, and the mesh surface is twisted into a prismatic
shape. Therefore, it is important to theoretically
determine the impact force of the cotton clump
striking the twisted prismatic mesh surface, as well as
the velocity vectors and twisting angles of the cotton
and the separated impurity clumps.
Volume 04 Issue 10-2024
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American Journal Of Applied Science And Technology
(ISSN
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2771-2745)
VOLUME
04
ISSUE
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Pages:
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OCLC
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1121105677
Publisher:
Oscar Publishing Services
Servi
Figure 1. Diagram of the impact force of the cotton clump striking the mesh surface and
the vectors of its components along the axes
.
In the diagram, the mesh surface side of the twisted
prism is rotated at an angle of
α
relative to the drum
axis. The impact impulse force of the cotton clump
striking the mesh surface is related to its components
along the X, Y, and Z axes.
𝑆̅
𝑛
= 𝑆̅
𝑛𝑥
+ 𝑆̅
𝑛𝑦
+ 𝑆̅
𝑛𝑧
. . .
(2.1)
Accordingly, their values are...
𝑆̅
𝑛𝑦
= 𝑆̅
𝑛
cos 𝛾 ; 𝑆̅
𝑛𝑧
= 𝑆̅
𝑛
sin 𝛾 ; 𝑆̅
𝑛𝑥
= 𝑆̅
𝑛
cos 𝜃
; (2.1)
Here,
γ
and
θ
are the angles formed by the components of the cotton's impact force.
Design Modifications
Based on our analysis of current machine models, two
major modifications were introduced to improve the
cleaning efficiency:
Spiked Drum Redesign: The spiked drum was
redesigned to enhance its ability to separate fine
impurities from the cotton. In standard machines, the
spikes are typically arranged at an angle of 20 to 25
degrees, which is effective for removing larger
impurities but less so for fine particles. In our
redesigned model, the spikes were angled at 30
degrees, which increased the interaction between the
cotton fibers and the spikes, improving the agitation of
the fibers. This more aggressive angle enabled better
loosening of the fine impurities trapped within the
cotton.
Volume 04 Issue 10-2024
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American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
04
ISSUE
10
Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
Furthermore, we introduced a dual-layer drum system.
The outer layer of the drum was fitted with longer
spikes designed to loosen and lift the cotton, while the
inner layer, with shorter, finer spikes, was responsible
for separating out fine impurities. This dual-layer
configuration allowed for a more thorough cleaning
process by targeting both large and small impurities
more effectively.
Air Suction System Enhancement: The air suction
system plays a vital role in removing the fine particles
that cannot be efficiently captured by the mechanical
components alone. In the modified design, we
increased the suction force by optimizing the
placement and size of the suction vents. By using
computational fluid dynamics (CFD) simulations, we
were able to model airflow patterns within the
machine and determine the ideal configuration for
maximizing particle removal without excessive energy
consumption.
The distinctive feature of the proposed cotton cleaner
for removing fine impurities is that the cotton clumps,
when impacted by the helical rows of spikes and the
twisted multi-faceted prismatic mesh surface, not only
intensify the separation of impurities but also follow a
complex zigzag-shaped trajectory. This ensures that
the cotton clumps remain sufficiently within the
cleaning zone. Therefore, it is important to study the
effect of system parameters on the directions and
values of the velocity vectors of the cotton clumps
after the impact.
Figure 2 is presented.
1,2-V
n
I
=
f
(m
n
); 3,4-V
r
=
f
(m
r
); 1,3-
α
0
= 15
0
; α
0
= 30
0
;
Figure 2. Graphs of the subsequent velocities of the cotton clump and impurities upon
impact with the twisted prismatic mesh surface, depending on their mass.
Volume 04 Issue 10-2024
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American Journal Of Applied Science And Technology
(ISSN
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2771-2745)
VOLUME
04
ISSUE
10
Pages:
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OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
The analysis of these graphs shows that as the masses
of the cotton and the separated impurities increase
from 0.12*10
-3
k to 0.35*10
-3
k, and at a twist angle of
the prismatic mesh surface
α
0
= 15
0
, the velocity of the cotton clump after impact
decreases from 2.15 m/s to 0.96 m/s in a nonlinear
relationship, while the velocity of the separated
impurities decreases from 4.8 m/s to 1.13 m/s. This
indicates that the greater the mass, the slower the
motion becomes. Similarly, at a twist angle
α
0
= 30
0
, the
values of V
n
I
decrease from 2.82 m/s to 0.91 m/s in a
nonlinear relationship. If the mass increases further,
both V
n
I
and V
r
decrease sharply. Therefore, it is
advisable to ensure that the cotton is sufficiently
agitated and that
m
n
≤(0,3÷0,55)*10
-3
k.
Presented in Figure 3:
1,2-V
n
I
=
f
(
α
); 3,4-V
r
=
f
(
α
); 2,4-m
n
=0,36*10
-3
k; 1,3- m
n
= 0,2*10
-3
k;
m
r
=0,1*10
-3
k; m
r
=0,16*10
-3
k;
Volume 04 Issue 10-2024
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American Journal Of Applied Science And Technology
(ISSN
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2771-2745)
VOLUME
04
ISSUE
10
Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
Figure 2.4. Graphs of the changes in the velocities of the cotton piece and impurities
after impact on the oblique prismatic surface in the recommended cleaning machine as a
function of the angle of impact.
Additionally, we introduced a variable-speed suction
system, which allowed us to adjust the suction force
based on the level of impurities present in the cotton.
This adjustment helped maintain energy efficiency
while ensuring effective removal of even the smallest
particles.
Testing Procedure
To evaluate the effectiveness of the design
modifications, a series of tests were conducted using
raw cotton samples with predetermined impurity
levels. These samples were selected to represent a
range of common contaminants found in raw cotton,
including fine dust, dirt particles, short fibers, and small
plant debris.
The testing procedure involved the following steps:
Initial Impurity Measurement: Before cleaning, the
cotton samples were analyzed to quantify the level and
types of impurities present. This was done using a
combination of optical microscopy and gravimetric
analysis, where the weight of the impurities was
measured in proportion to the overall weight of the
cotton sample.
Cleaning Process: Each cotton sample was processed
through both the standard and modified cotton
cleaning machines. The machines operated under the
same conditions, including rotation speed, airflow rate,
and processing time, to ensure a fair comparison.
Post-Cleaning Impurity Analysis: After processing, the
cotton was once again analyzed to measure the
amount of remaining impurities. The percentage of
fine impurities removed was calculated by comparing
the pre- and post-cleaning impurity levels.
Energy Consumption Measurement: In addition to
assessing
cleaning
performance,
the
energy
consumption of each machine was recorded. This was
done using power meters attached to the machines,
which measured electricity usage during the cleaning
process. The energy consumption of the modified
machine was compared to that of the standard
machine to evaluate the efficiency of the design
changes.
Cotton Quality Assessment: Finally, the quality of the
cleaned cotton was assessed to ensure that the design
modifications did not negatively impact fiber integrity.
Cotton fiber quality was measured using fiber length
distribution and fiber strength testing, both of which
are important parameters in determining the usability
of the cotton for spinning and textile production.
The results from these tests were statistically analyzed
to determine the significance of the improvements
made by the modified design.
RESULTS
Impurity Removal Efficiency
The results of the experiments indicated a significant
enhancement in the removal of fine impurities from
cotton. The modified cotton cleaning machine
achieved an average removal efficiency of 85% for fine
impurities, compared to only 70% for the unmodified
Volume 04 Issue 10-2024
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American Journal Of Applied Science And Technology
(ISSN
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2771-2745)
VOLUME
04
ISSUE
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Pages:
15-25
OCLC
–
1121105677
Publisher:
Oscar Publishing Services
Servi
machine. This translates to a 21.4% increase in cleaning
efficiency, which is noteworthy given the challenges
associated with separating fine impurities from cotton.
Further analysis revealed that the enhanced design
features, such as the reconfigured spiked drum and
optimized air suction system, played crucial roles in this
improvement. The dual-layer drum system allowed for
more effective agitation of the cotton, enabling the
spikes to better loosen impurities. Additionally, the
modified air suction system generated a more uniform
airflow, ensuring that smaller particles were effectively
captured. The results underscore the potential of
design optimization in cotton cleaning machines to
enhance overall performance.
Energy Consumption
Despite the improvements in cleaning performance,
the energy consumption of the modified machine
remained within acceptable limits. The modifications
resulted in only a 5% increase in energy consumption,
which is a modest rise considering the significant
enhancement in cleaning efficiency. This efficiency
improvement is particularly important in industrial
applications, where operational costs are a critical
concern.
To evaluate energy consumption more thoroughly, we
conducted a detailed analysis of the power usage
during the cleaning process. The modified machine
operated at a peak power of 2.1 kW, compared to 2.0
kW for the standard machine. However, the increased
effectiveness of impurity removal compensates for this
minor rise in energy consumption, leading to a more
cost-effective operation in the long run. Moreover, the
introduction of the variable-speed suction system
helped regulate energy use based on the level of
impurities present, further promoting energy
efficiency.
Cotton Quality
The quality of the cleaned cotton was assessed
through a comprehensive examination of fiber length
and strength, which are critical parameters in
determining the usability of cotton for textile
production. The cotton processed by the modified
machine exhibited a 10% improvement in fiber quality.
Specifically, the average fiber length increased from 28
mm to 30.8 mm, while the fiber strength improved by
approximately 12% as measured by tensile testing.
Additionally, the amount of broken fibers was reduced
significantly, with only 5% of fibers classified as broken
or damaged, compared to 10% in the unmodified
machine. This improvement can be attributed to the
gentle handling of the cotton during the cleaning
process, facilitated by the modified spiked drum
design, which minimizes fiber breakage while
effectively removing impurities.
Furthermore, the contamination levels in the cleaned
cotton
were
analyzed
through
microscopic
examination, revealing a marked decrease in the
presence of residual impurities. The modified machine
demonstrated a reduction in contamination levels
from 3.5% to 1.8%, thereby enhancing the quality of the
final cotton product.
In conclusion, the results of this study indicate that the
proposed design modifications to the cotton cleaning
machine lead to significant improvements in impurity
removal efficiency, minimal increases in energy
consumption, and enhanced cotton quality. These
findings provide a strong basis for further
development and optimization of cotton cleaning
technologies.
DISCUSSION
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VOLUME
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Pages:
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OCLC
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Publisher:
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The results of this study indicate that the modifications
to the spiked drum and air suction system significantly
improved the efficiency of cotton cleaning machines.
The introduction of angled spikes, specifically set at 30
degrees, increased the surface area for cotton
interaction, allowing for a more effective loosening of
fibers and enhanced separation of fine impurities. This
design adjustment resulted in a substantial 21.4%
increase in cleaning efficiency, which underscores the
critical role of mechanical component design in
optimizing machine performance.
The dual-layer drum design is another significant
improvement that facilitated better separation of fine
impurities. By creating two distinct operational zones
within the machine, the outer layer of the drum
effectively loosened the cotton while the inner layer
enhanced the removal of impurities. This innovative
approach reduces the risk of fiber damage, which is a
common concern in cotton processing. The
enhancement of cleaning performance aligns with
previous studies that advocate for similar structural
changes to achieve higher quality output without
compromising the integrity of the cotton fibers.
Moreover, the improved air suction system proved to
be pivotal in enhancing the machine's overall
performance. By generating a more uniform and
powerful airflow, this system effectively removed
smaller particles that often escape traditional cleaning
methods. The design modifications resulted in only a
modest 5% increase in energy consumption,
demonstrating that significant improvements in
cleaning efficiency can be achieved without drastically
escalating operational costs. This finding is particularly
relevant for industries where energy costs are a critical
factor in overall production expenses.
These findings align with existing literature that
emphasizes the importance of optimizing mechanical
components for enhanced cleaning performance. For
example, previous research has shown that increased
surface interaction through mechanical modifications
can lead to better impurity removal rates and improved
fiber quality. However, despite these advancements,
there remains room for further improvements in
energy efficiency and the long-term durability of the
redesigned components.
Future research could focus on integrating advanced
technologies, such as automated feedback systems
and adaptive controls, that optimize energy
consumption based on real-time assessments of
cotton quality and impurity levels. Implementing such
technologies could further enhance the operational
efficiency of cotton cleaning machines and ensure that
they remain cost-effective.
Additionally, it is crucial to investigate the long-term
durability of the modified components. While the
testing results showed effective performance,
extended operational studies are necessary to assess
how the redesigned spiked drum and air suction
system withstand wear and tear over time.
Understanding the maintenance requirements and
longevity of these components will be essential for
manufacturers aiming to develop sustainable and
reliable cleaning technologies.
In conclusion, the modifications to the spiked drum
and air suction system not only improved the cleaning
efficiency of cotton cleaning machines but also
highlighted the importance of mechanical optimization
in the cotton processing industry. As the demand for
high-quality cotton increases, further advancements in
energy efficiency and component durability will be
necessary to meet both economic and environmental
goals.
CONCLUSION
Volume 04 Issue 10-2024
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VOLUME
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OCLC
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1121105677
Publisher:
Oscar Publishing Services
Servi
The enhanced design of the cotton cleaning machine,
particularly the modifications to the spiked drum and
air suction system, has demonstrated a significant
improvement in cleaning efficiency. The innovative
adjustment of the spiked drum with angled spikes and
the implementation of a dual-layer system have
resulted in a 21.4% increase in impurity removal
efficiency. These improvements not only facilitate
more effective cleaning of fine impurities, but they also
enhance the overall quality of the cotton fibers
processed, with notable reductions in fiber breakage
and contamination levels.
Moreover, the modifications have successfully
maintained energy efficiency, with only a 5% increase in
energy consumption despite the substantial gains in
performance. This balance is critical for textile
manufacturers aiming to optimize production
processes while managing operational costs. The
findings highlight the potential for mechanical design
enhancements to meet the growing demand for higher
quality raw materials in the textile industry.
Future work will focus on further optimizing the design
to reduce energy consumption without compromising
cleaning efficiency. Exploring advanced materials for
the spiked drum and air suction system could lead to
further improvements in durability and performance.
Additionally, research will investigate the integration
of automation technologies into the cotton cleaning
process. Automation could enhance operational
efficiency by allowing real-time adjustments based on
the varying quality of cotton being processed.
Implementing smart sensors to monitor impurity levels
and adjust the machine's parameters accordingly could
lead to even higher efficiency and lower energy usage.
Furthermore, it will be essential to conduct long-term
studies assessing the performance and durability of the
redesigned components. Understanding how these
modifications hold up over extended use will provide
valuable insights for manufacturers and inform future
iterations of cotton cleaning machines.
In summary, the modifications made to the cotton
cleaning machine represent a significant step forward
in optimizing the cleaning process. The combination of
improved impurity removal, enhanced cotton quality,
and energy efficiency positions this redesigned
machine as a valuable asset in modern textile
production. Continued research and innovation in this
field will be crucial for meeting the evolving demands
of the textile industry while ensuring sustainability and
cost-effectiveness.
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Pages:
15-25
OCLC
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1121105677
Publisher:
Oscar Publishing Services
Servi
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