Published March 2023 | 385 pages, 87 tables, 78 figures | Download table of contents
Environmental and consumer concerns have resulted in the developed of bio-based materials as alternatives to petrochemicals for packaging applications. Bio-based packaging materials are made from renewable and biodegradable raw materials, as sustainable alternatives to non-renewable, petroleum-based packaging. Examples include paper made from wood fibres and various types of plastic such as bio-PE, which is made from sugar cane.
Bio-based and sustainable packaging is a major global trend, with numerous start-ups and large companies developing alternatives to single-use plastic packaging. The global plastics sector currently produces >250 million tons annually, and they are used extensively in packaging due to their low cost and weight. Over 99% of this is derived from fossil fuels, and most of it is not biodegradable. Currently, the packaging materials are largely based on glass, aluminium and tin, and fossil derived synthetic plastics. These materials possess high strength and barrier properties. However, they are unsustainable, some are fragile such as glass, and their weight adds to energy costs for shipping. Discarded plastic bags and containers have also raised issues relating to environmental pollution due to their non-biodegradable nature. Biodegradable takeaway food containers and single-use plastic bags are being used as a substitute, but only degrade completely when subjected to a harsh thermal treatment above 50 °C.
Innovative packaging materials composed of blends or pure bio-based materials are expected to improve the sustainability of these products. Using renewable resources for the development of bio-based packaging material produces a smaller carbon footprint, reduces environmental impact, increases acceptance by consumers, maintains barrier properties and shelf-life of the packaged good, and allows for a sustainable end of life.
Report contents include:
- An overview of global market outlook for bio-based and sustainable packaging.
- Materials utilized in bio-based and sustainable packaging including Synthetic bio-based packaging materials, Natural bio-based packaging materials, Natural fibers, Lignin, bio-based coatings and films etc.
- Analyses of global market trends, with data from 2021, 2022, and projections of compound annual growth rates (CAGRs) through 2033.
- Identification of market trends, issues and forecast impacting the global bio-based and sustainable packaging market and quantification of the market based on type, application, and region.
- Recent advancements and innovations in the bio-based and sustainable packaging market.
- Comprehensive profiles of 169 companies in the market. Companies profiled include An Phat Bioplastics, Anellotech, Inc., Arekapak GmbH, Arkema S.A., Avantium, BIOLO, BlockTexx Pty Ltd., Carbiolice, Cellugy, DuFor Resins B.V., Esbottle Oy, Full Cycle Bioplastics LLC, Futamura Chemical Co, Ltd., Futurity Bio-Ventures Ltd., Genecis Bioindustries, Huhtamaki, Kaneka Corporation, Kelpi Industries, Lactips S.A., Marea, Mitsubishi Chemical Corporation, MakeGrowLab, New Zealand Natural Fibres, Oimo, Plafco Fibertech Oy,Sufresca, Sulapac, Teal Bioworks, TerraVerdae Bioworks Inc. and Tianjin GreenBio Materials.
1 RESEARCH METHODOLOGY 16
2 EXECUTIVE SUMMARY 17
- 2.1 Current global packaging market and materials 18
- 2.2 Market trends 19
- 2.3 Drivers for recent growth in bioplastics in packaging 20
- 2.4 Challenges for bio-based and sustainable packaging 21
- 2.5 Global Bioplastics for packaging markets, tonnes and revenues 23
- 2.5.1 By end-use application 23
- 2.5.2 Bioplastic material type 23
- 2.5.2.1 Rigid packaging 24
- 2.5.2.2 Flexible packaging 24
- 2.5.3 By geographic market 25
3 THE GLOBAL PLASTICS MARKET 27
- 3.1 Global production of plastics 27
- 3.2 The importance of plastic 29
- 3.3 Issues with plastics use 29
- 3.4 Policy and regulations 30
- 3.5 The circular economy 31
- 3.6 Conventional polymer materials used in packaging 32
- 3.6.1 Polyolefins: Polypropylene and polyethylene 33
- 3.6.2 PET and other polyester polymers 35
- 3.6.3 Renewable and bio-based polymers for packaging 35
- 3.6.4 Comparison of synthetic fossil-based and bio-based polymers 37
- 3.6.5 Processes for bioplastics in packaging 37
- 3.6.6 End-of-life treatment of bio-based and sustainable packaging 39
- 3.7 Plastic recycling 40
- 3.7.1 Mechanical recycling 41
- 3.7.1.1 Closed-loop mechanical recycling 42
- 3.7.1.2 Open-loop mechanical recycling 42
- 3.7.1.3 Polymer types, use, and recovery 42
- 3.7.2 Advanced chemical recycling 43
- 3.7.2.1 Main streams of plastic waste 43
- 3.7.2.2 Comparison of mechanical and advanced chemical recycling 44
- 3.7.1 Mechanical recycling 41
4 BIOPLASTICS AND BIOPOLYMERS IN PACKAGING 45
- 4.1 Bio-based or renewable plastics 45
- 4.1.1 Drop-in bio-based plastics 45
- 4.1.2 Novel bio-based plastics 46
- 4.2 Biodegradable and compostable plastics 47
- 4.2.1 Biodegradability 47
- 4.2.2 Compostability 48
- 4.3 Advantages and disadvantages 48
- 4.4 Types of Bio-based and/or Biodegradable Plastics 49
- 4.5 Applications 51
- 4.5.1 Paper and board packaging 51
- 4.5.2 Food packaging 52
- 4.5.2.1 Bio-Based Films and Trays 53
- 4.5.2.2 Bio-Based Pouches and Bags 54
- 4.5.2.3 Bio-Based Textiles and Nets 55
- 4.5.2.4 Bioadhesives 56
- 4.5.2.5 Barrier coatings and films 57
- 4.5.2.6 Intelligent and Smart Food Packaging 58
- 4.5.2.7 Bio-Based Sensors 59
- 4.5.2.8 Antimicrobial Films 60
- 4.5.2.9 Bio-based Inks and Dyes 62
- 4.5.2.10 Edible Coatings 63
- 4.6 Synthetic bio-based packaging materials 64
- 4.6.1 Polylactic acid (Bio-PLA) 64
- 4.6.1.1 Market analysis 65
- 4.6.1.2 Producers and production capacities, current and planned 66
- 4.6.1.2.1 Lactic acid producers and production capacities 66
- 4.6.1.2.2 PLA producers and production capacities 66
- 4.6.1.2 Producers and production capacities, current and planned 66
- 4.6.2 Polyethylene terephthalate (Bio-PET) 68
- 4.6.2.1 Market analysis 68
- 4.6.2.2 Producers and production capacities 69
- 4.6.3 Polytrimethylene terephthalate (Bio-PTT) 69
- 4.6.3.1 Market analysis 69
- 4.6.3.2 Producers and production capacities 70
- 4.6.4 Polyethylene furanoate (Bio-PEF) 70
- 4.6.4.1 Market analysis 70
- 4.6.4.2 Comparative properties to PET 71
- 4.6.4.3 Producers and production capacities 72
- 4.6.4.3.1 FDCA and PEF producers and production capacities 72
- 4.6.5 Polyamides (Bio-PA) 72
- 4.6.5.1 Market analysis 73
- 4.6.5.2 Producers and production capacities 74
- 4.6.6 Poly(butylene adipate-co-terephthalate) (Bio-PBAT)- Aliphatic aromatic copolyesters 74
- 4.6.6.1 Market analysis 74
- 4.6.6.2 Producers and production capacities 75
- 4.6.7 Polybutylene succinate (PBS) and copolymers 76
- 4.6.7.1 Market analysis 76
- 4.6.7.2 Producers and production capacities 77
- 4.6.8 Polyethylene furanoate (Bio-PEF) 77
- 4.6.8.1 Market analysis 77
- 4.6.8.2 Comparative properties to PET 78
- 4.6.8.3 Producers and production capacities 79
- 4.6.8.3.1 FDCA and PEF producers and production capacities 79
- 4.6.8.3.2 Polyethylene furanoate (Bio-PEF) production capacities 2019-2033 (1,000 tons). 79
- 4.6.9 Polyethylene (Bio-PE) 80
- 4.6.9.1 Market analysis 81
- 4.6.9.2 Producers and production capacities 81
- 4.6.10 Polypropylene (Bio-PP) 81
- 4.6.10.1 Market analysis 81
- 4.6.10.2 Producers and production capacities 82
- 4.7 Natural bio-based packaging materials 82
- 4.7.1 Polyhydroxyalkanoates (PHA) 82
- 4.7.1.1 Technology description 82
- 4.7.1.2 Types 84
- 4.7.1.2.1 PHB 86
- 4.7.1.2.2 PHBV 86
- 4.7.1.3 Synthesis and production processes 87
- 4.7.1.4 Market analysis 90
- 4.7.1.5 Commercially available PHAs 91
- 4.7.1.6 PHAS in packaging 91
- 4.7.1.7 PHA production capacities 2019-2033 (1,000 tons) 94
- 4.7.2 Starch-based blends 95
- 4.7.2.1 Properties 95
- 4.7.2.2 Applications in packaging 96
- 4.7.3 Cellulose 96
- 4.7.3.1 Feedstocks 98
- 4.7.3.1.1 Wood 98
- 4.7.3.1.2 Plant 99
- 4.7.3.1.3 Tunicate 99
- 4.7.3.1.4 Algae 100
- 4.7.3.1.5 Bacteria 100
- 4.7.3.2 Microfibrillated cellulose (MFC) 101
- 4.7.3.2.1 Properties 101
- 4.7.3.3 Nanocellulose 103
- 4.7.3.3.1 Cellulose nanocrystals 103
- 4.7.3.3.1.1 Applications in packaging 103
- 4.7.3.3.2 Cellulose nanofibers 105
- 4.7.3.3.2.1 Applications in packaging 105
- 4.7.3.3.2.1.1 Reinforcement and barrier 110
- 4.7.3.3.2.1.2 Biodegradable food packaging foil and films 110
- 4.7.3.3.2.1.3 Paperboard coatings 111
- 4.7.3.3.2.1 Applications in packaging 105
- 4.7.3.3.3 Bacterial Nanocellulose (BNC) 111
- 4.7.3.3.3.1 Applications in packaging 114
- 4.7.3.3.1 Cellulose nanocrystals 103
- 4.7.3.1 Feedstocks 98
- 4.7.4 Protein-based bioplastics in packaging 116
- 4.7.5 Algal-based packaging 118
- 4.7.5.1 Production 119
- 4.7.5.2 Applications in packaging 119
- 4.7.5.3 Producers 120
- 4.7.6 Mycelium 120
- 4.7.6.1 Applications in packaging 121
- 4.7.7 Chitosan 123
- 4.7.7.1 Applications in packaging 124
- 4.7.8 Bio-naphtha 124
- 4.7.8.1 Overview 124
- 4.7.8.2 Markets and applications 125
- 4.7.9 Lipids and Waxes 127
- 4.7.1 Polyhydroxyalkanoates (PHA) 82
- 4.8 Natural fibers 127
- 4.8.1 Manufacturing method, matrix materials and applications of natural fibers 131
- 4.8.2 Bamboo 132
- 4.8.3 Banana leaves 133
- 4.8.4 Coconut fibres 135
- 4.8.5 Elephant grass 137
- 4.8.6 Residual streams from the agri- and horticulture 139
- 4.8.7 Commercially available natural fiber products 139
- 4.8.8 Applications in packaging 142
- 4.9 Lignin 144
- 4.9.1 Types of lignin 145
- 4.9.2 Properties 147
- 4.9.3 Applications in packaging 149
- 4.10 Nanomaterials 151
5 BIO-BASED FILMS AND COATINGS IN PACKAGING 152
- 5.1 Challenges using bio-based paints and coatings 153
- 5.2 Types of bio-based coatings and films in packaging 156
- 5.2.1 Polyurethane coatings 156
- 5.2.1.1 Properties 156
- 5.2.1.2 Bio-based polyurethane coatings 157
- 5.2.1.3 Products 158
- 5.2.2 Acrylate resins 159
- 5.2.2.1 Properties 159
- 5.2.2.2 Bio-based acrylates 159
- 5.2.2.3 Products 160
- 5.2.3 Polylactic acid (Bio-PLA) 160
- 5.2.3.1 Properties 162
- 5.2.3.2 Bio-PLA coatings and films 162
- 5.2.4 Polyhydroxyalkanoates (PHA) coatings 163
- 5.2.5 Cellulose coatings and films 164
- 5.2.5.1 Microfibrillated cellulose (MFC) 164
- 5.2.5.2 Cellulose nanofibers 165
- 5.2.5.2.1 Properties 166
- 5.2.5.2.2 Product developers 167
- 5.2.6 Lignin 169
- 5.2.6.1 Lignin coatings 170
- 5.2.7 Protein-based biomaterials for coatings 171
- 5.2.7.1 Plant derived proteins 171
- 5.2.7.2 Animal origin proteins 171
- 5.2.8 Alginate 173
- 5.2.1 Polyurethane coatings 156
6 GLOBAL PRODUCTION OF BIO-BASED AND SUSTAINABLE PACKAGING 175
- 6.1 Flexible packaging 175
- 6.2 Rigid packaging 178
- 6.3 Coatings and films 181
7 COMPANY PROFILES 184 (169 company profiles)
8 REFERENCES 341
List of Tables
- Table 1. Market trends in bio-based and sustainable packaging 19
- Table 2. Drivers for recent growth in the bioplastics and biopolymers markets. 20
- Table 3. Challenges for bio-based and sustainable packaging. 21
- Table 4. Global bioplastics packaging by end-use application, 2023–2033 (‘000 tonnes). 23
- Table 5. Global bioplastic packaging by geographic market, 2023–2033 (‘000 tonnes). 25
- Table 6. Traditional plastic materials used in packaging. 28
- Table 7. Issues related to the use of plastics. 30
- Table 8. Types of bio-based plastics and fossil-fuel-based plastics 32
- Table 9. Comparison of synthetic fossil-based and bio-based polymers. 37
- Table 10. Processes for bioplastics in packaging. 38
- Table 11. Overview of the recycling technologies. 41
- Table 12. Polymer types, use, and recovery. 42
- Table 13. Composition of plastic waste streams. 43
- Table 14. Comparison of mechanical and advanced chemical recycling. 44
- Table 15. Type of biodegradation. 47
- Table 16. Advantages and disadvantages of bio-based plastics compared to conventional plastics. 48
- Table 17. Types of Bio-based and/or Biodegradable Plastics, applications. 49
- Table 18. Bio-based sensors developed for food monitoring. 59
- Table 19. Edible coatings market summary. 63
- Table 20. Polylactic acid (PLA) market analysis-manufacture, advantages, disadvantages and applications. 65
- Table 21. Lactic acid producers and production capacities. 66
- Table 22. PLA producers and production capacities. 66
- Table 23. Planned PLA capacity expansions in China. 67
- Table 24. Bio-based Polyethylene terephthalate (Bio-PET) market analysis- manufacture, advantages, disadvantages and applications. 68
- Table 25. Bio-based Polyethylene terephthalate (PET) producers and production capacities, 69
- Table 26. Polytrimethylene terephthalate (PTT) market analysis-manufacture, advantages, disadvantages and applications. 69
- Table 27. Production capacities of Polytrimethylene terephthalate (PTT), by leading producers. 70
- Table 28. Polyethylene furanoate (PEF) market analysis-manufacture, advantages, disadvantages and applications. 70
- Table 29. PEF vs. PET. 71
- Table 30. FDCA and PEF producers. 72
- Table 31. Bio-based polyamides (Bio-PA) market analysis - manufacture, advantages, disadvantages and applications. 73
- Table 32. Leading Bio-PA producers production capacities. 74
- Table 33. Poly(butylene adipate-co-terephthalate) (PBAT) market analysis- manufacture, advantages, disadvantages and applications. 74
- Table 34. Leading PBAT producers, production capacities and brands. 75
- Table 35. Bio-PBS market analysis-manufacture, advantages, disadvantages and applications. 76
- Table 36. Leading PBS producers and production capacities. 77
- Table 37. Polyethylene furanoate (PEF) market analysis-manufacture, advantages, disadvantages and applications. 78
- Table 38. PEF vs. PET. 79
- Table 39. FDCA and PEF producers. 79
- Table 40. Bio-based Polyethylene (Bio-PE) market analysis- manufacture, advantages, disadvantages and applications. 81
- Table 41. Leading Bio-PE producers. 81
- Table 42. Bio-PP market analysis- manufacture, advantages, disadvantages and applications. 81
- Table 43. Leading Bio-PP producers and capacities. 82
- Table 44.Types of PHAs and properties. 85
- Table 45. Comparison of the physical properties of different PHAs with conventional petroleum-based polymers. 86
- Table 46. Polyhydroxyalkanoate (PHA) extraction methods. 88
- Table 47. Polyhydroxyalkanoates (PHA) market analysis. 90
- Table 48. Commercially available PHAs. 91
- Table 49. Markets and applications for PHAs. 92
- Table 50. Applications, advantages and disadvantages of PHAs in packaging. 93
- Table 51. Length and diameter of nanocellulose and MFC. 96
- Table 52. Major polymers found in the extracellular covering of different algae. 100
- Table 53. Market overview for cellulose microfibers (microfibrillated cellulose) in paperboard and packaging-market age, key benefits, applications and producers. 101
- Table 54. Applications of nanocrystalline cellulose (NCC). 104
- Table 55. Market overview for cellulose nanofibers in packaging. 106
- Table 56. Types of protein based-bioplastics, applications and companies. 116
- Table 57. Overview of alginate-description, properties, application and market size. 118
- Table 58. Companies developing algal-based bioplastics. 120
- Table 59. Overview of mycelium fibers-description, properties, drawbacks and applications. 120
- Table 60. Overview of chitosan-description, properties, drawbacks and applications. 123
- Table 61. Bio-based naphtha markets and applications. 125
- Table 62. Bio-naphtha market value chain. 126
- Table 63. Types of next-gen natural fibers. 127
- Table 64. Application, manufacturing method, and matrix materials of natural fibers. 131
- Table 65. Commercially available next-gen natural fiber products. 139
- Table 66. Natural fibers in the packaging sector-market drivers, applications and challenges for NF use. 143
- Table 67. Technical lignin types and applications. 145
- Table 68. Lignin content of selected biomass. 147
- Table 69. Properties of lignins and their applications. 148
- Table 70. Nanomaterials in sustainable packaging. 151
- Table 71. Summary of barrier films and coatings for packaging. 154
- Table 72. Types of polyols. 156
- Table 73. Polyol producers. 157
- Table 74. Bio-based polyurethane coating products. 158
- Table 75. Bio-based acrylate resin products. 160
- Table 76. Polylactic acid (PLA) market analysis. 161
- Table 77. Commercially available PHAs. 163
- Table 78. Market overview for cellulose nanofibers in paints and coatings. 166
- Table 79. Companies developing cellulose nanofibers products in paints and coatings. 167
- Table 80. Types of protein based-biomaterials, applications and companies. 172
- Table 81. Overview of alginate-description, properties, application and market size. 173
- Table 82. Comparison of bioplastics’ (PLA and PHAs) properties to other common polymers used in product packaging. 176
- Table 83. Typical applications for bioplastics in flexible packaging. 176
- Table 84. Typical applications for bioplastics in rigid packaging. 179
- Table 85. Market revenues for bio-based coatings, 2018-2033 (billions USD), high estimate. 182
- Table 86. Lactips plastic pellets. 275
- Table 87. Oji Holdings CNF products. 300
List of Figures
- Figure 1. Global packaging market by material type. 19
- Figure 2. Global bioplastics packaging by end-use application, 2023–2033 (‘000 tonnes). 23
- Figure 3. Bioplastics for rigid packaging by bioplastic material type, 2019–2033 (‘000 tonnes). 24
- Figure 4. Bioplastics for flexible packaging by bioplastic material type, 2019–2033 (‘000 tonnes). 25
- Figure 5. Global bioplastic packaging by geographic market, 2023–2033 (‘000 tonnes). 26
- Figure 6. Global plastics production 1950-2021, millions of tons. 28
- Figure 7. The circular plastic economy. 32
- Figure 8. Routes for synthesizing polymers from fossil-based and bio-based resources. 36
- Figure 9. PHA bioplastic packaging products. 38
- Figure 10. Current management systems for waste plastics. 40
- Figure 11. Coca-Cola PlantBottle®. 46
- Figure 12. Interrelationship between conventional, bio-based and biodegradable plastics. 46
- Figure 13. Production capacities of Polyethylene furanoate (PEF) to 2025. 72
- Figure 14. Production capacities of Polyethylene furanoate (PEF) to 2025. 79
- Figure 15. Polyethylene furanoate (Bio-PEF) production capacities 2019-2033 (1,000 tons). 80
- Figure 16. PHA family. 85
- Figure 17. PHA production capacities 2019-2033 (1,000 tons). 94
- Figure 18. Schematic diagram of partial molecular structure of cellulose chain with numbering for carbon atoms and n= number of cellobiose repeating unit. 97
- Figure 19. Scale of cellulose materials. 97
- Figure 20. Organization and morphology of cellulose synthesizing terminal complexes (TCs) in different organisms. 98
- Figure 21. Biosynthesis of (a) wood cellulose (b) tunicate cellulose and (c) BC. 99
- Figure 22. Cellulose microfibrils and nanofibrils. 101
- Figure 23. TEM image of cellulose nanocrystals. 103
- Figure 24. CNC slurry. 104
- Figure 25. CNF gel. 105
- Figure 26. Bacterial nanocellulose shapes 113
- Figure 27. BLOOM masterbatch from Algix. 119
- Figure 28. Typical structure of mycelium-based foam. 122
- Figure 29. Commercial mycelium composite construction materials. 122
- Figure 30. Types of natural fibers. 130
- Figure 31. Absolut natural based fiber bottle cap. 139
- Figure 32. Adidas algae-ink tees. 139
- Figure 33. Carlsberg natural fiber beer bottle. 140
- Figure 34. Miratex watch bands. 140
- Figure 35. Adidas Made with Nature Ultraboost 22. 140
- Figure 36. PUMA RE:SUEDE sneaker 141
- Figure 37. Extraction processes to separate lignin from lignocellulosic biomass and corresponding technical lignins. 145
- Figure 38. Paints and coatings industry by market segmentation 2019-2020. 152
- Figure 39. Schematic of gas barrier properties of nanoclay film. 154
- Figure 40. Hefcel-coated wood (left) and untreated wood (right) after 30 seconds flame test. 169
- Figure 41. High purity lignin. 170
- Figure 42. BLOOM masterbatch from Algix. 174
- Figure 43. Bioplastics for flexible packaging by bioplastic material type, 2019–2033 (‘000 tonnes). 178
- Figure 44. Bioplastics for rigid packaging by bioplastic material type, 2019–2033 (‘000 tonnes). 180
- Figure 45. Market revenues for bio-based coatings, 2018-2033 (billions USD), conservative estimate. 182
- Figure 46. Pluumo. 186
- Figure 47. Anpoly cellulose nanofiber hydrogel. 194
- Figure 48. MEDICELLU™. 194
- Figure 49. Asahi Kasei CNF fabric sheet. 201
- Figure 50. Properties of Asahi Kasei cellulose nanofiber nonwoven fabric. 202
- Figure 51. CNF nonwoven fabric. 203
- Figure 52. BIOLO e-commerce mailer bag made from PHA. 214
- Figure 53. Reusable and recyclable foodservice cups, lids, and straws from Joinease Hong Kong Ltd., made with plant-based NuPlastiQ BioPolymer from BioLogiQ, Inc. 216
- Figure 54. Fiber-based screw cap. 224
- Figure 55. CuanSave film. 236
- Figure 56. ELLEX products. 238
- Figure 57. CNF-reinforced PP compounds. 239
- Figure 58. Kirekira! toilet wipes. 239
- Figure 59. Rheocrysta spray. 243
- Figure 60. DKS CNF products. 244
- Figure 61. Photograph (a) and micrograph (b) of mineral/ MFC composite showing the high viscosity and fibrillar structure. 254
- Figure 62. PHA production process. 258
- Figure 63. AVAPTM process. 262
- Figure 64. GreenPower+™ process. 263
- Figure 65. Cutlery samples (spoon, knife, fork) made of nano cellulose and biodegradable plastic composite materials. 265
- Figure 66. Kami Shoji CNF products. 271
- Figure 67. IPA synthesis method. 286
- Figure 68. Compostable water pod. 295
- Figure 69. XCNF. 310
- Figure 70: Innventia AB movable nanocellulose demo plant. 311
- Figure 71. Thales packaging incorporating Fibrease. 320
- Figure 72. Sulapac cosmetics containers. 322
- Figure 73. Sulzer equipment for PLA polymerization processing. 323
- Figure 74. Corbion FDCA production process. 328
- Figure 75. UPM biorefinery process. 330
- Figure 76. Vegea production process. 334
- Figure 77. Worn Again products. 336
- Figure 78. S-CNF in powder form. 337
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