{"id":29169,"date":"2026-02-03T11:51:49","date_gmt":"2026-02-03T10:51:49","guid":{"rendered":"https:\/\/www.brighigroup.com\/blog\/2026\/02\/03\/from-static-to-dynamic-maintenance\/"},"modified":"2026-02-03T14:15:42","modified_gmt":"2026-02-03T13:15:42","slug":"from-static-to-dynamic-maintenance","status":"publish","type":"post","link":"https:\/\/www.brighigroup.com\/en\/blog\/2026\/02\/03\/from-static-to-dynamic-maintenance\/","title":{"rendered":"FROM STATIC TO DYNAMIC MAINTENANCE"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"29169\" class=\"elementor elementor-29169 elementor-29111\" data-elementor-post-type=\"post\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-1ac99e76 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"1ac99e76\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-25cb8bf7\" data-id=\"25cb8bf7\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-3be61c30 elementor-widget__width-auto elementor-widget elementor-widget-image\" data-id=\"3be61c30\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"300\" height=\"132\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/b-right-logo-300x132.png\" class=\"attachment-medium size-medium wp-image-9822\" alt=\"\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/b-right-logo-300x132.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/b-right-logo-768x338.png 768w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/b-right-logo-64x28.png 64w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/b-right-logo.png 777w\" sizes=\"(max-width: 300px) 100vw, 300px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6888ac64 elementor-widget__width-auto elementor-widget elementor-widget-image\" data-id=\"6888ac64\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"642\" height=\"54\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/home-textile-highlights-1.png\" class=\"attachment-medium_large size-medium_large wp-image-9827\" alt=\"\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/home-textile-highlights-1.png 642w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/home-textile-highlights-1-300x25.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2023\/06\/home-textile-highlights-1-64x5.png 64w\" sizes=\"(max-width: 642px) 100vw, 642px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-2e0ecd3e elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"2e0ecd3e\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-606a638e\" data-id=\"606a638e\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-31df2003 categoria elementor-widget elementor-widget-post-info\" data-id=\"31df2003\" data-element_type=\"widget\" data-widget_type=\"post-info.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<ul class=\"elementor-inline-items elementor-icon-list-items elementor-post-info\">\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item elementor-repeater-item-540fc22 elementor-inline-item\" itemprop=\"about\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text elementor-post-info__item elementor-post-info__item--type-terms\">\n\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-post-info__terms-list\">\n\t\t\t\t<a href=\"https:\/\/www.brighigroup.com\/fr\/argumentation\/b-smart-fr\/\" class=\"elementor-post-info__terms-list-item\">B-Smart<\/a>\t\t\t\t<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t<\/li>\n\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-74900629 elementor-widget elementor-widget-html\" data-id=\"74900629\" data-element_type=\"widget\" data-widget_type=\"html.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<script>\r\njQuery(document).ready(function($) {\r\n    $('.categoria').each(function () {\r\n   $(this).html($(this).html().replace(\"B-\", \"<span style='color:#cd1619'>B-<\/span>\"));\r\n});\r\n});\r\n       \r\n    \r\n<\/script>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-316557db elementor-widget elementor-widget-heading\" data-id=\"316557db\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">FROM STATIC TO DYNAMIC MAINTENANCE<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4310cb98 elementor-widget elementor-widget-text-editor\" data-id=\"4310cb98\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\tHOW IIOT AND MACHINE LEARNING REDUCE DOWNTIME AND COSTS\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-5287f491 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"5287f491\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-5998d1b4\" data-id=\"5998d1b4\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-3b4a83d elementor-widget elementor-widget-image\" data-id=\"3b4a83d\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"1600\" height=\"768\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1.png\" class=\"attachment-full size-full wp-image-29116\" alt=\"\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1.png 1600w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-300x144.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-1024x492.png 1024w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-768x369.png 768w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-1536x737.png 1536w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-1000x480.png 1000w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-Right-orizzontale-1600-x-768-px-1-64x31.png 64w\" sizes=\"(max-width: 1600px) 100vw, 1600px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-50767b25 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"50767b25\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-25bf64af\" data-id=\"25bf64af\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-3b6ee249 elementor-widget elementor-widget-text-editor\" data-id=\"3b6ee249\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: justify\">Industrial plants have long relied on static, calendar-based maintenance routines. However, real production environments \u2014characterized by changing operating conditions, and unpredictable downtime\u2014rarely follows a fixed schedule. With <b>IIoT connectivity<\/b> and <b>Machine Learning<\/b>, maintenance can now become dynamic: <b>interventions are prioritized and timed by actual asset condition and risk<\/b>, not by the date on a spreadsheet.<\/p><p style=\"text-align: justify\">This approach is particularly relevant in <b>pillow manufacturing plants, foam production lines and rebonding facilities<\/b>, where maintenance inefficiencies directly impact not only throughput but also product quality. Data shows that <b>dynamic maintenance programs have been shown to cut downtime by up to 50% and reduce maintenance costs by 30\u201340%,<\/b> while improving throughput and service levels. Let\u2019s look more closely at the main maintenance approaches.<\/p><h2 style=\"text-align: justify\"><b style=\"color: var( --e-global-color-text );font-family: var( --e-global-typography-text-font-family ), Sans-serif;font-size: 1rem\">TYPES OF MAINTENANCE<\/b><\/h2><p style=\"text-align: justify\">SCHEDULED MAINTENANCE<br \/>This is the basic plan set out in your service contract<span style=\"background-color: transparent;font-size: 1rem\"> that organizes what work will be done and when (usually calendar-based) and by whom. It creates the routine: inspections, lubrication, replacements, software updates, safety checks. <\/span><\/p><p style=\"text-align: justify\">PREVENTIVE MAINTENANCE <br \/>Fixed-interval actions, both time and usage-based, that reduce the risk of surprise failures by performing organized checks and part replacements before they wear out (e.g., replace a bearing every 5,000 hours; calibrate sensors monthly).<\/p><p style=\"text-align: justify\">PREDICTIVE MAINTENANCE<br \/>An <strong>evolution of preventive maintenance<\/strong> that uses <strong>IoT sensors and data<\/strong> from a digital workflow to <strong>read conditions in real time<\/strong> (vibration, temperature, current draw, pressure) and, with analytics, estimates failure probability or Remaining Useful Life (RUL). The system estimates when a fault is likely and alerts the operator before it happens, avoiding wasteful early swaps and last-minute emergencies.<\/p><p style=\"text-align: justify\"><strong>REAL-LIFE APPLICATIONS: DYNAMIC MAINTENANCE ACROSS FOAM, PILLOW AND REBONDING MANUFACTURING<\/strong><\/p><p style=\"text-align: justify\">Let\u2019s have a look at real-life examples of how dynamic maintenance is applied to critical equipment across these different manufacturing processes:<\/p><ul style=\"text-align: justify\"><li><a href=\"https:\/\/www.brighigroup.com\/en\/blog\/2024\/04\/09\/pillow-making-machines-how-to-elevate-production\/\">Pillow manufacturing<\/a>: packaging machines, sealing units, motors<\/li><li><a href=\"https:\/\/www.brighigroup.com\/en\/blog\/2024\/06\/25\/foam-making-machine-and-foam-recycling\/\">Foam making<\/a>: pumps, viscosity control, pressure systems<\/li><li><a href=\"https:\/\/www.brighigroup.com\/en\/blog\/2024\/06\/25\/foam-making-machine-and-foam-recycling\/\">Foam rebonding<\/a>: glue injectors, mixing chambers, dosing systems<\/li><\/ul><div style=\"text-align: justify\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-29171 size-full\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/6-e1770118286942.png\" alt=\"\" width=\"768\" height=\"293\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/6-e1770118286942.png 768w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/6-e1770118286942-300x114.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/6-e1770118286942-64x24.png 64w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/><\/div><div>\u00a0<\/div><p style=\"text-align: justify\"><strong>Predictive maintenance in pillow manufacturing: reducing downtime in packaging lines<\/strong><\/p><p style=\"text-align: justify\">In <strong>pillow manufacturing<\/strong>, packaging machines are often the most critical bottleneck, making maintenance strategies essential to ensure continuous production. That\u2019s why one of our customers, a pillow manufacturing start-up, began its <strong>digital maintenance journey with an anomaly detection system<\/strong> focused on the packaging machines. A limited but meaningful set of signals, including seal-bar temperature and motor power consumption, was continuously monitored and analyzed.<\/p><p style=\"text-align: justify\">Deployed in just five months, the system introduced simple, visual reports and standardized alarm logs that immediately reshaped maintenance planning and daily execution. Auto-generated daily summaries highlighted the most frequent recurring stops, allowing planners to schedule short, targeted interventions instead of waiting for longer shutdowns. This shift reduced emergency stops, cut maintenance costs by 48%, and extended component life by avoiding run-to-failure behavior.<\/p><p style=\"text-align: justify\"><strong>Predictive maintenance in foam making to prevent process drift and equipment damage<\/strong><\/p><p style=\"text-align: justify\">In <strong>foam making processes<\/strong>, maintaining stable pressure and viscosity is crucial to <strong>protect pumps and avoid unplanned downtime<\/strong>. For this reason, during foam making production cycles, the machine <strong>continuously monitors pressure and viscosity-related fluctuations<\/strong> through in-line sensors and matches them against the flow meter readings. Through the software, the customer can set an acceptable operating range to protect the pump and keep viscosity within specification.<\/p><p style=\"text-align: justify\">When the process runs close to the defined limit for a certain number of cycles or working hours, the <strong>system automatically sends a notification<\/strong> to the maintenance team. This allows the team to plan a <strong>targeted intervention<\/strong> in advance, adjusting the feeding temperature to bring viscosity back into range before any damage occurs.<\/p><p style=\"text-align: justify\">In parallel, the system collects operational data and <strong>generates a complete report<\/strong> for the responsible personnel, enabling short, planned micro-interventions that prevent pump failures and reduce unplanned downtime. In this way, maintenance becomes condition-based and predictive, rather than being scheduled only by time.<\/p><p style=\"text-align: justify\"><strong style=\"font-size: 1rem\">Predictive maintenance with continuous learning in rebonding lines<\/strong><\/p><p style=\"text-align: justify\">In foam rebonding lines, unplanned stops often originate from lack of cleaning of glue injectors inside the mixing chamber. To address this risk, <strong>inline condition sensors monitor parameters<\/strong> such as dosing quantity, line performance and remaining time to the next cleaning cycle. These signals are <strong>analyzed over time to detect early signs of wear<\/strong> well before functional failure.<\/p><p style=\"text-align: justify\">When trends cross predefined risk thresholds, <strong>the system<\/strong> <strong>recommends a controlled stop<\/strong> to inspect and clean the components\u2014avoiding catastrophic failures and extended production losses. Crucially, <strong>each intervention is logged in the software<\/strong> along with operating hours, cycles, and inspection findings. This feedback loop <strong>allows the system to continuously refine and optimize cleaning and inspection intervals<\/strong>, progressively improving efficiency. Over time, maintenance decisions become not only predictive, but adaptive\u2014driven by real operating data rather than fixed assumptions<\/p><p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-29176 size-full\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/1-e1770118354632.png\" alt=\"\" width=\"768\" height=\"343\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/1-e1770118354632.png 768w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/1-e1770118354632-300x134.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/1-e1770118354632-64x29.png 64w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/><\/p><p style=\"text-align: justify\">\u00a0<\/p><p style=\"text-align: justify\"><strong style=\"font-size: 1rem\">WHAT BRIGHI BRINGS TO THE TABLE? DIGITAL DIVISION WITH IN-HOUSE SOFTWARE DEVELOPMENT <\/strong><\/p><p style=\"text-align: justify\">We believe the right tools make maintenance smarter, faster, and easier for our customers. That\u2019s why we pair <strong>always-on support and high-quality training with a highly effective remote customer service<\/strong>\u2014powered by software we build ourselves for our machines. With this approach, <strong>up to 95% of issues are resolved remotely<\/strong>, without waiting for an on-site specialist.<\/p><p style=\"text-align: justify\"><strong>Callisto<\/strong> streamlines scheduling and execution, monitors critical components, and sends proactive alerts as parts approach end-of-life. <strong>Formula <\/strong>enables data-driven decisions in foam production. <strong>Nebula <\/strong>provides in-depth reporting, real-time machine data, and customizable dashboards for faster decisions. Together, these tools deliver <strong>clear visibility, early warnings on recurring alarms, and practical insights<\/strong> on materials and operating methods\u2014so maintenance programs become more efficient, predictable, and resilient.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-4aecc6ca\" data-id=\"4aecc6ca\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-67200b4 elementor-widget elementor-widget-image\" data-id=\"67200b4\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"350\" height=\"734\" src=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-right-verticale-1.png\" class=\"attachment-large size-large wp-image-29122\" alt=\"\" srcset=\"https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-right-verticale-1.png 350w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-right-verticale-1-143x300.png 143w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-right-verticale-1-300x629.png 300w, https:\/\/www.brighigroup.com\/wp-content\/uploads\/2026\/02\/B-right-verticale-1-64x134.png 64w\" sizes=\"(max-width: 350px) 100vw, 350px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Industrial plants have long relied on static, calendar-based maintenance routines. However, real production environments \u2014characterized by changing operating conditions, and unpredictable downtime\u2014rarely follows a fixed schedule. With IIoT connectivity and Machine Learning, maintenance can now become dynamic: interventions are prioritized and timed by actual asset condition and risk, not by the date on a spreadsheet. [&hellip;]<\/p>\n","protected":false},"author":7,"featured_media":29116,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[250],"tags":[],"class_list":["post-29169","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-b-smart-fr"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.2 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>FROM STATIC TO DYNAMIC MAINTENANCE - Brighi Group<\/title>\n<meta name=\"description\" content=\"For years, plants have used scheduled maintenance. With IIoT and machine learning, dynamic maintenance is now emerging.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.brighigroup.com\/en\/blog\/2026\/02\/03\/from-static-to-dynamic-maintenance\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"FROM STATIC TO DYNAMIC MAINTENANCE - Brighi Group\" \/>\n<meta property=\"og:description\" content=\"For years, plants have used scheduled maintenance. 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