TABLE OF CONTENT

ACKNOWLEDGEMENTS.....................................................................................2

CHAPTER 1: DETAIL OF A CASE STUDY CARRIED OUT1.1 Introduction of glass.......................................................................................3

1.2 History of glass...............................................................................................4-5

1.3 Scope of case study........................................................................................6

CHAPTER 2: THE PROCESS OF MANUFACTURING GLASS2.1 The basic process of manufacturing glass....................................................7-11

2.2 Finishing process of glass in SSG SAFETY GLASS SDN. BHD..................12-15

2.3 The process of laminated glass, DGU glass and tempered glass................16-17

CHAPTER 3: THE MACHINERIES AND EQUIPMENT USED3.1 Name of the machineries and equipment as well function...........................18-28

CHAPTER 4: ADVANTAGES AND DISADVANTAGES OF THE PROCESS4.1 Advantages and disadvantage of the tempered glass process....................29-32

4.2 Advantage and disadvantage of the laminated glass process………...........33-34

4.3 Advantage and disadvantage of the double glass unit (DGU) process........35

CHAPTER 5: CONCLUSION.............................................................................36

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ACKNOWLEDGEMENT

First and foremost, we like to thank to Allah S.W.T, as finally we are able to

finish our assignment group that have been given by our lecturer, Mr Muhammad

Naim bin Mahyuddin , thus for giving us a good guideline for assignment throughout

numerous consultations. We would also like to expand our deepest gratitude to all

those who have directly and indirectly guided us in writing this assignment. Beside

that, we would like to thank to Mr Chia Yong Meng, who is head of operation in SSG

SAFETY GLASS SDN. BHD. for providing us with a good guideline and facilities to

complete this assignment. Otherwise, a lot of thank to our classmate and also to our

own team, that have give a lot of a good cooperation with made valuable comment

suggestions on this proposal which gave us an inspiration to improve our

assignment. Deepest thanks and appreciation to our parents and family for their

spirit, encouragement, constructive suggestion and full of support for the assignment

completion, from the beginning till the end. Lastly, we like to thank to all the people

for their help directly and indirectly to complete our assignment and give us a lot of

ideas so that we can improve our assignment in many way and Alhamdullillah, all

the problem can be settled down and we are able to adapt properly and wisely.

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CHAPTER 1: DETAIL OF A CASE STUDY CARRIED OUT

1.1 INTRODUCTION

Glass is a uniform material of arguable phase, usually produced when the

viscous molten material cools very rapidly to below its glass transition temperature,

without sufficient time for a regular crystal lattice to form.

Common glass is silica-based material, biologically inactive, can be formed

into smooth and impervious surfaces. Brittle and will break into sharp shards.

Materials with highly variable mechanical and optical properties that solidify

from the molten state without crystallization, are typically made by silicates fusing

with metal oxide, or phosphorus pentoxide, are generally hard, brittle and transparent

or translucent and are considered to be super cooled liquids rather than true solids.

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1.2 HISTORY OF GLASSFrom our earliest origins, man has been making use of glass. Historians have

discovered that a form of natural glass - obsidian - formed for instance, within the

mouth of a volcano as a result of the intense heat of an eruption melting sand - was

first used by man as tips for spears.

Archaeologists have found evidence of man-made glass which dates back to

4000 BC; this took the form of glazes used for coating stone beads. It was not until

1500 BC that the first hollow glass container was made by covering a sand core with

a layer of molten glass.

Glass blowing became the most common way to make glass containers from the

First Century BC. However, the glass made during this time was highly coloured due

to the impurities of the raw material. It was not until the First Century AD when

colourless glass was produced and then coloured by the addition of colouring

materials.

The secret of glass making came to Britain with the Romans. However, the skills

and technology required to make glass were closely guarded by the Romans and it

was not until the Roman Empire disintegrated that skills for glass making spread

throughout Europe and the Middle East.

The Venetians, in particular, gained a reputation for technical skill and artistic ability

in the making of glass bottles and a fair number of the city's craftsmen left Italy to set

up glassworks throughout Europe.

In Britain, there is evidence of a glass industry around Jarrow and Wearmouth

dating back to 680 AD, while from the 13th Century, there is evidence of there having

been a glass industry in the Weald and the afforested area of Surrey and Sussex

around Chiddingford.

A major milestone in the history of glass occurred with the invention of lead

crystal glass by George Ravenscroft. He attempted to counter the effect of clouding

that sometimes occurred in blown glass by introducing lead to the raw materials used

in the process.

The new glass he created was softer and easier to decorate and had a higher

refractive index, adding to its brilliance and beauty, and it proved invaluable to the

optical industry. It's thanks to Ravenscrofts invention that optical lenses, astronomical

telescopes, microscopes and the like became possible.

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The modern glass industry only really started to develop in Britain after the repeal

of the Excise Act in 1845 relieved the heavy taxation that had been enforced. Before

that time, excise duties were placed on the amount of glass melted in a glasshouse

and levied continuously from 1745 to 1845.

Joseph Paxtons Crystal Palace at the Great Exhibition of 1851 marked the

beginning of the discovery of glass as a building material. The revolutionary new

building encouraged the use of glass in public, domestic and horticultural

architecture. Glass manufacturing techniques also improved with the advancement of

science and better technology.

By 1887 glass making developed from traditional mouth blowing to a semi-

automatic process when Ashley introduced a machine capable of producing 200

bottles per hour in Castleford, Yorkshire - more than three times quicker than the

previous production methods.

Twenty years later, in 1907, the first fully automated machine was developed in

America by Michael Owens from major glass manufacturers Owens of Illinois, and

used at its factory in Manchester, Illinois making 2,500 bottles per hour.

Other developments followed rapidly, but it was not until the First World War, when

Britain became cut off from essential glass suppliers that glass became part of the

scientific sector. Up until then glass was seen as a craft rather than a precise

science.

Today, glass making is a modern, hi-tech industry operating in a fiercely

competitive global market where quality, design and service levels are critical to

maintaining market share.

Modern glass plants are capable of making millions of glass containers a day

in many different colours, but green, brown and clear remain the most popular.

Few of us can imagine modern life without glass. It features in almost every

aspect of our lives - in our homes, our cars and whenever we sit down to eat or drink.

Glass packaging is used for many products, wines, spirits and beers all come in glass

as do medicines and cosmetics not to mention numerous foodstuffs.

With increasing consumer concern for the environment, glass has again come

into its own proving to be an ideal material for recycling. Glass recycling is good

news for the environment. It saves used glass containers being sent to landfill and

less energy is needed to melt recycled glass than to melt down raw materials, thus

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saving energy. Recycling also reduces the need for raw materials to be quarried thus

saving precious resources.

1.3 SCOPE OF CASE STUDY:The objective of our case study is to learn manufacturing process of glass in

construction. From this topic that was given, we have a site visit to go to the factory

that is produce glasses by manufacturing process and learn from the person in

charge to guide us in this site visit and give us a lot information about the

manufacturing process of glass. Unfortunately, there are only one factory that is

undertake the manufacturing process of glass in Malaysia which located at Pasir

Gudang, Johor, Malaysia. Otherwise, as students we are not allowed to go to their

factory because of some reasons such as unsafe and dangerous environment in the

factory. The manufacturing process of glass also are private and even supplier do not

know the process is it.

So that, we find another factory that is can help and give us information about

this manufacturing process of glass. That is, SSG SAFETY GLASS SDN. BHD.

Factory of glass which located at Lot 3085, Gopeng Industrial Park, 31600 Gopeng,

Perak Darul Ridzuan, Malaysia. Then, we have meet Mr. Chia Yew Meng, 47 years

old, QA Manager of SSG SAFETY GLASS SDN. BHD. As the person in charge to

guide us in this site visit. He explain to us about glass that the factoring was

produced such as tempered glass, laminated glass and DGU glass. He also share

information about source of glass that they obtain which from Pasir Gudang, Johor,

Malaysia, Indonesia and Thailand. Otherwise, he has shown us the process of glass

in construction and the various machineries and equipment that is required in the

process.

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CHAPTER 2: THE PROCESS TECHNIQUE AND SEQUENCES OF OPERATION:

The basic of Manufacturing process:

Based on four fundamental stages:

Stages instructions Description

1 Melting Material: sand (72%)| soda ash (13%)| Lime (10%) |

Dolomite (4%).

Weighed & mixed in the correct proportions to

produce a mixture known as frit.

Waste broken glass (cutlet) is recycled along with

frit, usually in the proportions of 80% frit and 20%

cutlet.

Melting takes place in a regenerative tank furnace at

1500°C

Regenerative - furnace exhaust gases give up much

of their heat to combustion air.

2 Forming The molten glass leave the furnace at 1050°C.

The forming process must take place in the

temperature range 650°C - 1050°C.

Below 650°C the glass becomes too vicious to bend,

stretch or shape.

Two main forming processes for producing flat glass

- rolled process & float process.

3 Cooling Because of the low thermal conductivity of glass - it

does not cool uniformly:

The surfaces cool more rapidly and shrink more

rapidly than the centre.

This produce uncontrolled strain in the glass.

If surface is scratched - glass will disintegrate.

Cannot withstand thermal shock.

Liable to break in use.

Annealing - slow cooling at controlled rata (in a

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controlled atmosphere).

To avoid excessive strain in glass.

Annealing done in an oven (chamber) called lehr.

Glass ribbon will pass on a slow moving conveyor

belt through the annealing lehr.

4 Finishing Cutting

Grinding and polishing.

Treatment - toughening, coating.

Packaging, stacking.

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Sheet Process Developed by Pittsburgh Plate Glass Company in 1920s.

At 950°C molten glass drawn vertically as continuous ribbon by a series of rollers

in a cast iron tower.

Rolled Process Molten Glass flow from the furnace to the rolling machine along a canal under

carefully controlled temperature conditions.

Forming rollers:

25cm in diameter

Bottom roller - engraved with pattern

Top rollers - smooth

Final thickness controlled by the gap between the rollers.

Water coled rollers extract heat from the glass to fix the pattern and to

prevent glass sticking to rollers.

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Wired-Glass Process Similar to the rolled process

Machine consist of two independently-driven pairs of water-cooled forming rollers

fed with a ribbon of glass via separate canals from a common melting tank.

1st pair of rollers formed a primary ribbon (bottom portion).

Wire mesh is introduce before 2nd pair of rollers.

At 2nd pair of rollers - top portion of ribbon is introduced forming the final ribbon.

Wire mesh is fed continuously from tolls mounted above the machine.

The final ribbon is supported by water-cooled steel rollers into the annealing lehr.

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Float process Pilkington Industries (1959)

Produce fire-finish sheet of glass with a perfect flatness.

Eliminating the time consuming grinding and polishing operations.

Melting process will take place in the furnace.

Molten glass will be fed to the float bath.

Gravity keeps the liquid tin very flat.

Molten glass will float on molten tin and spread on the surface of molten tin

forming a flat surface.

Heat applied above the glass surface melts out any irregularities in the glass.

As the ribbon of glass passed through the float bath - the heat is reduced until the

glass is sufficiently hard to be fed on the annealing lehr.

After leaving the lehr, glass will be inspected and cut automatically.

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First, SSG SAFETY GLASS SDN. BHD. Bought and import the glass from supplies

from Malaysia (Pasir Gudang, Johor), Indonesia and Thailand that is produced glass

by manufacturing process.

SSG SAFETY GLASS SDN. BHD. Only undertake finishing process in manufacturing

process of glass :

1) Cutting Process :

Cutting process can be managed by:

a) Glass cutting machine:

First, set up the size of the glass that is required by using CAD.

Then, the cutter machine will operate to cut the glass into desired shape

and size.

This have to be done before the glass is being processed to the next

operation.

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b) Hand skill :

Obtain a glass cutter and some light oil. Glass cutters are about the size of

a pencil and use a diamond or a hardened wheel to mark a score into glass

that it can be broken cleanly along a line.

Then, measure, mark and set the glass over the pattern that is required.

Cutting a freehand shape should be breaking a long lines that run from

edge to edge.

Use several straight lines to cut a sharp curve. Run the cutter to the gentle

curve with a steady hand.

After cut the curve, check the score that is not popping, barely visible and

make sure it runs completely from one edge to the other.

Then, tap the each side of the cut smoothly by using end of cutter.

Next, grasp each side of the cut carefully in hand, then break the glass

along the score.

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2) Eddying Process:

Eddying process is for levelling and remove the surface of the sharp edges of

the glass after cutting process.

Water is required in this process to avoid friction on the surface of the glass.

3) Grinding Process:

Grinding is a material removal and surface generation process used to and

finish components made of metals and other materials.

For instance, to build glazed door that is hinge metal and knob metal should

be install first.

To install the hinge metal and knob metal, the glass should be perforation by

using grinding machine.

After the glass perforation, material such as metal can be install to the glass,

for example, 90 °C glass door pivot hinge for inset door.

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4) Toughened / Tempering Process:

Tempering process is propose to stamp factory’s logo and to contrast the

quality of glass.

So, which glass that have stamp factory’s logo, it more quality and safe to use.

In tempering process consist of heating and softening.

Heat the glass in a tempering oven. Glass may fed in batches or continuously.

The oven reaches temperature of over 600 °C with the industry being 620°C.

Toughened process – reheating a piece to 690 °C (up to it softening point)

then the surface are cooled rapidly.

This process create a state of high compression in the cutter surface of glass

thus increasing tensile strength by four or five times.

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5) After tempering process, there are 2 operation to produced:

i. Laminated glass.

ii. Double Glass Unit (DGU) glass

i. Laminated glass:

There is bonding two piece of glass together with plastic material or a resin

(PVB).

The bonding is achieved by heating the glass layer and the interlayer and

apply pressure.

After bonding the glass, the glass will took into the autoclave at temperature

about 121 degrees Celsius for making the surface of the glass is clear.

Toughened glass can also be used as components of a laminated glass.

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ii. Double Glass Unit (DGU) glass :

The poly isobutyl (silicon) is applied to the spacer bar to keeps the spacer bar

at place and sticks both panels of glass together separated by a uniform

distance.

6) Packing Process:

After those process is finish, the glass will packed and arranged it based on their size, types and pattern.

Then, it is ready to delivery and send it to another suppliers.

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Chapter 3: The Machineries and Equipment Used

Tempered Glass Process:

Cutting Process

1. Glass Cutting machine

i. It is automatic ways.

ii. Its function is to cut the glass into the size that have been set in

computer according to the client’s order.

iii. Easy to set up, more faster and save energy than the manual ways.

iv. Use diesel and small knife to make a cut on the glass.

v. Made in Taiwan.

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2. Cutter Ruler

i. It is manual ways.

ii. Its function is to cut the small sizes on the glass.

iii. Use human’s energy and slower than cutting machine.

3. Cutting Knife

i. It function is to cut the curve shape on the glass.

ii. Made from steel and lightweight.

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Eddying Process

1. Bavelloni Straight Edger

i. To remove and smooth the side of mirror that sharp.

ii. It using clay weel to removing the sharp.

iii. This machine is long lasting.

iv. Usually import from overseas.

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Grinding Process

1. Drilling Machine

i. Drilling machine is to punched a hole for install knob metal.

ii. It is heavy and easy for maintenance.

iii. Import from overseas.

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2. Hand Grander

i. To cut a piece of glass for install the hinge metal. Usually to make a door glass.

ii. It is lightweight and easy to keep.

iii. Produce noisy sound.

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Toughened / Tempering Process:

1. Tempering Machine

i. To softening the glass and make sure that glass turns to the small pieces like a sand if they break. It for safety requirement.

ii. The machine is big, heavy and hard for maintenance.

iii. It is hot in temperature and dangerous.

iv. Import from overseas.

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Laminated Glass Process:

1. Lamination Machine

i. Its function is to cut the glass according to the client’s sizes and stick the PVB in the middle of 2 glass.

ii. Heavy and hard for maintenance.

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2. PVB

i. PVB is to stick the 2 of glass layer to form a laminated glass.

ii. Cloudy in colour.

iii. Easy to tear and lightweight.

iv. Made from rubber.

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3. Autoclave

i. Its function is for clearing the glass’s surface that cloudy in colour.

ii. Big, heavy and hard for maintenance.

iii. Hard for aflame.

iv. Import from overseas.

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DGU Glass Process:

1. Spacer Bar

i. Its function is for stick in the middle of 2 layers glasses and trap heat.

ii. Lightweight and easy to dented.

iii. Made from steel.

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2. Silicon Equipment

i. To tight the 2 layers of glasses from water, air and heat to be admitted.

ii. Must use human’s energy.

iii. Produced silicon for DGU glass to applied the spacer bar to keeps the spacer bar at place and sticks both panels of glass together separated by a uniform distance.

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CHAPTER 4: ADVANTAGES AND DISADVANTAGES OF THE PROCESS

ADVANTAGES OF TEMPERED GLASS PROCESS:

1.

More tough as compares to normal glass as a result of its resilient

characteristic and proof dynamics.

Tempered glass can be explained to the safety glass since it is made by

controlled thermal or substance treatment option to improve the effectiveness

of the particular glass.

Being 4 to 5 times stronger than any kind of glass

2.

This particular safety glass is actually specifically designed in order that it

doesn’t emit sharp sides even if that fails.

3.

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Machine bavelloni straight edger is to

smooth a sharp sides after cutting process Roller clay

Be specific anti indefinite quantity glass that’s produced through the method of

extreme heating system and quick cooling that makes it harder than normal

glass.

4.

Tempered glass causes that to burst into oval formed pebbles when broken.

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Heating process Softening process

DISADVANTAGES OF TEMPERED GLASS PROCESS:

1.

Tempered glass cannot again for cutting, and machining, only before the tempered glass for processing to the shape of the steel processing again.

All the reject tempered glass will be sent back to the main factory for recycle it will causes high due cost.

It will take a longer period of time to order and return back to us for the next process.

2.

When tempered glass though a cooling process it will explosive (bursts) it mean the tempered glass is not good and tough enough.

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3.

The broken glass must throw away and can’t recycle.

4. The tempered glass will be thinning because glass after thermal softening, after a strong wind make its rapid cooling, make its internal crystal glass gap smaller, pressure big, so after the tempered glass than in front of the toughened to thin.

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ADVANTAGES OF LAMINATED GLASS PROCESS:1.

Laminated glass is a type of safety glass that holds together when shattered.

In the event of breaking, it is held in place by an interlayer, typically of

polyvinyl butyral (PBV), between its two or more layers of glass.

2.

The interlayer keeps the layers of glass bonded even when broken, and its

high strength prevents the glass from breaking up into large sharp pieces.

This produces a characteristic “spider web” cracking pattern when the impact

is not enough to completely pierce the glass.

3. Normally use when there is a possibility of human impact or where the glass

could fall if shattered and also for architectural applications.

4. Does not allow as much sound to get through as does regular glass

5. Laminated glass for windows is that a PVB interlayer can block essentially

most ultraviolet radiation.

6. Protection from adverse weather condition.

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DISADVANTAGES OF LAMINATED GLASS PROCESS:1. Laminated windows are quite a bit more expensive than regular windows. This

is because they require a lot more steps during the manufacturing process

and they have several layers of material.

2. If other side laminated glass cracks, you must remove both of them (can’t be

recycle).

3. You might have to wait a few weeks before your windows are made, which

can leave you vulnerable at the time.

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ADVANTAGES OF DOUBLE GLASS UNITS (DGU) PROCESS:

1. Double glass units retain much more heat in a room during reduce heat loss

and saving energy.

2. They reduce noise penetration and window to increase conform.

3. For summer, with the use of solar control glass, they can reduce heat gain,

glare and fading and increase air.

4. They are harder to break than single glass and the shards normally stay in

place after breakage, increasing security.

DISADVANTAGES OF DGU:1. Can’t be repaired. The space between the two panes of glass traps air,

forming a layer of insulation.

2. During the summer months, trapping heat inside can lead to stuffy and

uncomfortable room.

3. Not a good match for older homes. Double glazed window are modern

looking, so they can clash with older styles.

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CHAPTER 5: CONCLUSION

Glass is a combination of sand and other minerals that are melted together at

very high temperatures to form a material that is ideal for a wide range of uses from

packaging and construction to fibre optics. A form of glass occurs naturally within the

mouth of a volcano when the intense heat of an eruption melts sand to form

Obsidian, a hard black glassy type of stone.. Glass, chemically, is actually more like a

liquid, but at room temperature it is so viscous or sticky it looks and feels like a solid.

At higher temperatures glass gradually becomes softer and more like a liquid. It is

this latter property, which allows glass to be poured, blown, pressed and moulded

into such a variety of shapes.

Based on our previous survey, we think laminated glass is the best designated

and more safety to use for windows and doors compared to tempered glass and

DGU. That is why the cost is higher than others. Customers can make a choice

according to its on atheistic view (ceramic printing). Even though the initial cost is

quiet expensive, the cost of maintenance (15-20 years). Glass also come with

transparent on opaque type. Transparent glasses able to make a small area became

larger. However glasses might have certain weakness such as item of low in fire

resistant which cause be danger to the occupier of the building. Otherwise, the glass

that being rejected can be recycle or throw away. At the end, we think the glass is the

best choice of all material in grand, type and price.

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Lastly, we can conclude how the glass process which form tempered glass

process to laminated glass process and to the double glass units (GDU) process. Mr.

Chia give us more knowledge about types of glass, the material that required,

machineries and equipment that is used, from where the glass are import, and the

most importantly is the process of glass to be made as a windows and doors in

construction. We also would like to thank to Mr. Chia and SSG SAFETY GLASS

SDN. BHD. for given us this exciting experience.

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