1. The document describes the internship report of a chemical engineering student at Colgate Palmolive Pakistan. 2. It provides an overview of the SABIZ plant, which produces base powder, a key ingredient in detergents, using both towering and non-towering technologies. 3. The production process involves pneumatic transportation of solid raw materials from storage to mixing and slurry preparation sections before spray drying the mixture into base powder.

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Colgate Palmolive
Winter Internship
Report 2017

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Intern Name: Hasnain Nawaz Shaikh
Class Roll No: 16 CH 42
Technology: Chemical Engineering
University: Mehran University Of
Engineering and Technology, Jamshoro
(MUET)
Industry: Colgate Palmolive Pakistan Ltd.

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01
Acknowledgement
Being a student of Chemical Engineering Mehran UET, I’m grateful to Colgate Staff and
Engineers who gave me a warm welcome and a detailed orientation regarding Colgate-
Palmolive Pakistan Limited. They have been very cooperative and motivated interns to
learn here as much as they want.
I’m also whole-heartedly beholden to the Management, Supervisors and Workers, and
special thanks to Mr. Syed Junaid Imam, who encouraged, guided and supported us
(the internes) throughout this internship program. We have had very honorable time
working here, inspecting there ways of working things out. Me along with my fellows
learnt very much in competitive environment of the industry.

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I also express my gratitude to Mr. Mohammad Razee and Mr. Noor Nabi Shaikh who
have been very supportive at every step. They have given their precious time from their
daily tough routine and guided me throughout this whole period of Internship.
Overview of Colgate Palmolive Pakistan
• In 1984 started as a license manufacturer of Colgate-Palmolive products in
Pakistan
• In 1990 Colgate-PalmoliveInc. (USA) joined as a 30% equity partner
• Market leaders in OralCare, SurfaceCare& Fabric Care categories
• 450 Distributors across Pakistan
• ISO 9000 : 2000 Quality ManagementSystem
• KSE Top Companies Award for 2004, 2005,2006
• CorporateExcellence Certificate 2001-02& 2004
Colgate-Palmolive Pakistan Limited also proves to be responsibleand better citizen
of Pakistan through their various community programs like:
• Bright Smiles, Bright Futures Program; in which their teams go to schools and
make them well awareof oral health through storybooks, interactiveactivities,
sing-along-songs, videos and computer CD-ROM.
• A foundation named Hasan Ali KarabhaiFoundation which undertakes many
charitable contributions and financial aid.
• Earth Day Celebration every year in CPPL.
• Award Ceremony once in every fiveyears to appreciate the performanceof
employees.
• A whole week is celebrated as Safety Week every year to enhance the sense of
safety among employees.

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Contents
1. Introduction to Colgate Palmolive
2. Introduction to SABIZ Plant
( Towering Technology) &
(Non-Towering
Technology )
3. Raw Materials Used for Manufacturing Base
Powder
4. Day Store

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5. Tank Park
6. Section 61 (Pneumatic Transportation)
7. Section 62 (Dosex Section)
8. Section 63 (Slurry Preparation)
9. Section 64 (Spray Drying)
1.Introduction to Colgate Palmolive
Colgate-Palmolive(Pakistan) Limited was initiallyincorporated in Pakistanon December 5, 1977 as a
public limited company with thenameof National Detergents Limited. It started its operations in Pakistan
in 1977 as joint venturebetween ColgatePalmolive(USA) and Lakson Group.
ColgatePalmoliveis oneof the largest ventures by thegroup. With assets of morethan Rs. 400 million
and a turnover of Rs. 1500 million, it has emerged as oneof the largest corporations in Pakistan.
Colgate – Palmolive Pakistan Limited is a Fast-Moving Consumer Goods (FMCG) industry. FMCG arethe
products that arequitefrequently used by theconsumers in their daily routine.

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Company is equipped with two manufacturingplants acrossthecountry within,
1. Kotri Sindh 2. Sundhar Punjab.
The Company is currently engaged in manufacturing of following related products.
Categories of Products inCPPL:
a. Oral care b. Personal care c. Surface care d. Fabric care
Oral Care:

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Oral care refers to taking careof your mouth; specifically, theinsideof your mouth. Practicing oral care
keeps your gums and teeth healthy, which is important not only for your mouth, but for overall health.
The well-being of your mouth is known as oral health. Oral careincludes tooth brushing, flossing, eating
well and regular visits to thedentist. Oral careproducts includetoothpasteand toothbrushes.
Toothpastes:
ColgateMaximum Cavity Protection
ColgateSensitivePro-Relief
ColgateSensitiveOriginal
ColgateSensitiveMulti protection
ColgateMax Fresh
ColgateHerbal
ColgateMiswak
ColgateTotal
ColgateAdvanceWhitening
Sparkle
Personal Care: Personal carerefers tothetaking careof yourbody itscleanliness and dosomethingfor its
beautification which includes bathing. Personal care includes thesoaps.
Beauty Soaps:
PalmoliveNaturals Balanced &Mild
PalmoliveNaturals MoistureCare
PalmoliveNaturals Nourishing Sensation
PalmoliveNaturals Luxurious Softness
PalmoliveNaturals Refreshing Moisture
PalmoliveNaturals Saver Pack
Hand Wash:
PalmoliveHand Wash Aloe Vera with Chamomile
PalmoliveHand Wash Antibacterial
PalmoliveHand Wash Antibacterial Sea Minerals
Shampoo:
PalmoliveNaturals Healthyand Smooth Shampoo

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PalmoliveNaturals IntensiveMoistureShampoo
PalmoliveNaturals SilkyStraightShampoo
PalmoliveNaturals Anti-Hair Fall Shampoo
PalmoliveNaturals Anti-Dandruff Shampoo
Surface Care:
Surfacecare refers to the taking careof dishes and products including cleanliness of the
dishes and that includes thedish wash bar and dish wash liquid.
Dish wash Liquid:
Max Regular
Max Ultra
Max Lemon Fresh
Max Anti-Bacterial
Dish wash Paste:
Max Original
Max Lime
All Purpose Cleaner:
Max Rose Fresh (Red)
Max Lemon Fresh (Yellow)
Max Lavender Fresh (Purple)
Fabric Care
Fabric care refers to thetaking careof wearing means
cleanliness of the clothes. In fabric Care laundry detergents and
laundry bars areincluded.
Laundry detergents:
BriteMaximum Power
Brite Anti- Bacterial
Brite Machine Wash
Express Power
Bonus tristar
Bonus Active
Liquid Softener:
Softlan Liquid.

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I along with my fellows from Chemical Engineering department, did 7 days internship here. Themain
purposeof our internship was to study and learn about different production processes that arebeing
performed in CPPL. But the main concern of my internship was on Sabiz Plant used to produce Base
Powder (the main ingredient of Detergent). WhereI have learnt a lot of processes regarding the Base
Powder used to manufacturedetergents.
2. Introduction to SABIZ Plant
Sabiz Plant was established in Colgate Palmolive factory in 2004by Ballesra Italy. SABIZ plant is equipped
with its several operational units, dedicated to produce Base Powder which is themajor ingredient of any
detergent. Base Powder is produced using Spray Drying Process that takes placein thespray drying unit
within the plant. The Final product of this plant is Base Powder. Later on that Base is redirected to Post
Addition unit whereother Additives including Perfumes, Spacles , Tades are added and mixed to
produce the finished product i.e. Detergent. But in this unit wearen’t concerned with thefinished
product (Detergent), but here our focus factory is to produceBase Powder. The production capacity of
Sabiz Plant is 12 Tons/ hour. BasePowder is usually manufactured using two different technologies
highlighted below.
Towering Technology (FROM SABIZ PLANT)
It isof the oldesttype.The base powdermanufacturedusingtowertechnologyhave lessdensity rangesfrom250-450
grams/liter.It has a greatervolume ascomparedtobase-powderfromNTD.
Non-Tower Detergent Technolgy:
It is an advancement over Towering Technology becauseit very much cost effectiveand it consumes less
energy. Non-Towered manufactured basepowder generally has very high bulk density which ranges from
650-750 grams/Liter.
Both theBase powders, produced from different technologies areused in a specific ratio for any
detergent making process (Post Addition). Sometimes bothareused with the50-50 ratio.
Just likeBonus tri-star detergent contains 80% from Towering and 20% fromNon-Towering BasePowder,
Similarly, Brite detergent contains 50% from Towering Technologyand 45% Non-Towering Technology
basepowder.
3. Raw Material Used for the Base Powder:
Raw materials used for producing basepoewder exist in solid annd liquid state.
If we talk about solod raw materials, most of them aremajors and very few arethe minors (i.e. Additives).
Solid Raw Materials are;
1. Soda Ash (Major)

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2. Sodium Sulphate (Major)
3. Sodium Tri-Poly Phosphate (STPP) (Major)
4. Sodium Toluene (ST90) (Minor)
5. Soap Chips (Minor)
6. Optical Brightners (China-used for EXPRESS and BONUS) (Minor)
7. Optical Brightners (Germany-used For BRITE) (Minor)
8. Talcum (Minor)
Liquid Raw Materials are;
1. Active Matter Paste ( Madethrough Neutrallization Process from Caustic Soda and Sulfonic
Acid)
2. Sodium Silicate
3. Blue Dye
4. Water
4. Day Store:
Day storeis wherethe solid materials arekept beforetheir use. All of the raw mateials are
imported form other countries and transported to theindustry and stored for their usage. Each of
thesolid raw material is contained in Polyethylenebag, each weighing 50 kg by weight and some
weighing 25 kg of bags.
A set of 25 bags are kept on a pilot, which makethem capableof lifting without any difficulty. The
Pilot consisting of 25 bags can be easily portablefrom oneto another place(typically for
Pneumatic Transportation Section) by theLifting Cars. Day storehavevarious sections on which
thespeecific raw material is stored. Including,
1. Soda Ash (50 KG Bag)
2. Sodium Sulphate (50 KG Bag)
3. Sodium Tri-Poly Phosphate (STPP) (50 KG Bag)
4. Sodium Toluene (ST90) (25 KG Bag)
5. Various Additives
6. Optical Brightners (Germany) (50 KG Bag)
7. Optical Brightner (China) (50 KG Bag)
8. Blue Dye (in a Liquid Form).
5. Tank Park:

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Just likeDay Store for Solid Raw materials, Tank Park section has severall storagetanksin which various
liquid arestored after they are imported from foreign. Theseliquids arethen transported to theother
sections like( 17, 62 and other sections) using Centrifugal and Gear Pumps for accomplishingtheslurry
making process.
This section comprises of several tanks containingfollowing liquidfeeds.
1. Caustic Soda
This feed of liquid is pumped using Centrifugal Pump.
2. Sodium Silicate
This feed of liquid is pumped using Centrigugal Pump.
3. LABSA (Linear Alkyl-Benzene Sulphomic Acid)
LABSA is used to produceSulphonic acid, and once it’s produced, then it’ll be stored in other
tanks in Tank Bath. This feed of liquid is pumped using Gear Pump
4. Sulphonic Acid (Suphonic Acid storagehave3 tanks, in which two arefilled with low density
sulphonic acid and oneis filled with very highly densesuphonic acid). This feed of liquid is
pumped using Gear Pump.
SABIZ Plant is divided in following main section (including Day Storeand Tank Park) for
converting thesolid and liquid raw materials into thebasepowder through slurry making and
spray drying process.
6. 61-Section (Pneumatic Transportaion):
Pneumatic Transportation is a sort of conveying system that transfers powders, granules, (dry
bulk materials of given solid feed) through an enclosed horizontal, vertical or inclined
conveying line(tubes). The motiveforcefor transferring thesolid powder comes from a
combination of pressuredifferential and theflow of air supplied by an blower .This section consists
of,
1. Feeders (For Raw Materials and Additives)
2. Hopper
3. Screw Conveying Line (Belt)
4. Centrifugal Sieve
5. Blower (For Pneumatic Transport)
5. Conveying (Tubes/ Pipes),
6. Dust Collector
7. Blower (for Dust Collector)
In this section at a time, a singlepowder of raw material feed is fed, conveyed and transported
using Feeders, Conveyer Belts and blower.
Mechanism of 61-Section:

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 Initially a singlepilot (consisting of 25 polyethylenebags) of powdered feed raw material from
Day Storeis carried towards the61-Section using liftingcar.
 At a timeonly a singlepowdered feed is fed for thepneumatic transportation.
 Workers receivethe pilot of raw material feed, carry the bag , tear it and feed it into the
feeders at certain height. There are two feeders for theraw material and onefor the Additiives.
 After feeding thepowdered raw material into thefeeders, feed falls into theHoper and then
shifted towards theConveying Screw Line.
 Conveying Screw Linecan transport thepowdered material at certain inclination. This line
actually consists of a rotating shaft withinthetubewhich is madeSpiral in shape. Shaft is being
rotated by an electric motor.
 Conveying Screw Lineconveys thepowdereed feed to fall over the Centrifugal Seive.
 Centrifugal Seivemake the Over-Sized particles and Lumps to retain over a screen and
recovered while Undersized Particles passes through theScreen and in a Rotary Valve.
 Rotary Valveis connected to thepipe where high pressurized air is blown by theBlower. So the
Solid-Powdered is then transported through the conveying line to th 62-Section (For Storing in
Silos)
 Another feeder is for feeding thediiferent Additives (including Soap Chips, Opticlebrightners
etc). These additives arethen mixed by using shaft( with certains impellers).
 Then theMixtureOf Additives is collected in a Hopper and fall in a rotary valvewhich linked
with thepipe where thehigh pressureair is blown in from theblower.
 The high pressureair is again a motive force to transfer the solid-powdered mixtureof
additives to the62-Section for therestoragein its respective silos.
 For thetransportation of both of thefeeds (Raw Material and Additives), a singlehigh-pressure
belower is used with two valve(one-linked with solid-powdered feed and onelinked the pipe
containing Mixtureof Additives).
 This section also consits of a Dust Collector whosepiping lines arelinked to thecentrifugal
sieve, screw conveying line, feeders etc. to collect dust particles from powdered feed, by
imparting Vacuum Presseure through thelines, developed by another blower.
 Where thedust particles arecollected in a Fabric Filters. Using Solenoid Valves high pressurized
air (PURGING) is blown within/between filter lines, so thedust particles falls and trapped
between two flapes in a discontinuos manner and then thedust is collected by a worker in a
bag.

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Flow Chart
7. 62-Section (Dosex Section):
62 Section in SABIZ plant is also called Dosex Section. It comprises of variousLiquid and Solid
powder raw material derived from the61-Section, 17 Section and Tank Park.
For Solid Balances we have utmost 6 silos which individually storethedifferent solid powder raw
material feed from the61-section through pnematic transportation.
These balances are given below;
1. Zeolite
2. Soda Ash
3. STPP
4. Sodium Sulphate
5. Mixture of Additives
6. New Soda Ash
Similarly for Liquid Balances wehave 5-tanks which individually storethedifferent liquid feed
from the17-Section and Tank Park using various Pumps. Thesebalances arelisted below.
1. Blue Dye Solution
2. Active Matter Paste
3. Sodium Silicate
4. Recovery

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5. Water.
Mechanism of 62-Section:
 All thesolid and liquid balances contains weight box, places right under their respectiveSilos
and Tanks.
 Solid powder feeds are derived from their respectivesilo to their weight-boxes using Screw
Conveying Belt operated via electric motor.
 Liquid feeds are derived from their tanks towards theweight box by theaction of gravitational
force (which makethem capableof flowing insidetheweight box from themechical inlet
valve.
 Each weight-boxes (For theLiquid and Solid Feed) have their respectivecontrollers setted
according to thedownloaded recipe.
 Recipe is setted regarding therequirement of each ingredients for making thebasepowders
for different detergents (likewise for Brite, Bonus etc).
 According to thedownloaded recipe, setted weightage/doses of solid powder and liquid feed
are stored in theweight box.
 For solid balances, below silos, wehave different weigh-boxes in which material in entered
using screw conveying belt from their respective silo and dischargeflap remains closed. When
therequired weight of feed is filled in the weight box (meaured in Kilograms by controller) the
motor would beautomatically turned off by controller and dischargeflap opens (pneumaticaly
operated using compressed air). When the discharge flap open the solid powder raw material
feed is dropped in a screw conveying line. This screw conveying lineconnects all thedischarge
flaps of weight boxes (of all powdered raw material feed). Through this linesolid powdered
feed is mixed transported to the63-Section for slurry making process.
 For Liquid balances, below their storagetanks wehavealso different weight boxes in which the
liquid raw material feed is entered using a mechanical feeding valve(pneumaticaly operated
using compressed air). This feeding valve remains open until and unless the required weightage
of liquid feed is filled in the weight box (meaured in Kilograms by controller) at that timethe
dichargevalveof weight box remains closed. Once therequired dosing is stored in theweight
box, thefeeding valvewill be closed and dischargevalvewill remain open. And then the liquid
feed from all of theweight-boxes (for liquids) will be flown below in thehorizontal pipeline.
This horizontal pipeline is situated in 62-Section which generally mix and transport themixture
of liquid feed to Crutcher (in 63-Section).
 These all flaps (for Soild powder feed) and Feed and Dicharge valve(for Liquid feed) are
pneumatically operated using dried compressed air. Whereas for the liquid feed, actemeter is
accompanied for opening and closing thefeeding and discharging valves.
 Compressed air is at the 4 bar pressure or abovedepending upon theequipment used for
operating valves and flaps.

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Flow Chart
8. 63-Section (Slurry Making):
Section 63 is called slurry making unit. It is implied for making theslurry of solid powder and Liquid
feed through Homogenizing, Agitating, Filtration. Then that slurryis delievered to the 64-Section
for spray drying process.This Section consistsof 4 vessels, wherethreeof thevessels areplaced in
this section and thefourth oneis located apart from it. First-threevessels haveelectric motor over
there top embeded with Pedal impeller and bladeshaft for the homogenizing and agitating
purpose. These all vessels arenamed below,
1. Crutcher
2. First Aging Vessel
3. Second Aging Vessel
4. Deaeration Vessel

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Mechanism of 63-Section:
 First of all the solid powder and liquid feed using two a conveying is fed to the first vessel called
Crutcher. It is employed for smoothly homgenizing theboth solid and liquidfeeds.
 Crutcher (Vessle) has electric motor over its top which rotates thepedal impeller shaft inside
thevessel and Homogenization takes place. Theoverflow lineof the crutcher is linked with
another vessel called First Aging Vessel by Magnetic Filter which equipped with themagnet
insideit.
 The function of themagnetic filter is to attract and removetheiron or other charged particles
form theslurry and allowing it to flow towards first aging vessel.
 Then thehomogenized slurry is over-flown from thecrutcher to thefirst aging vessle. This
vessel is also equipped with theelectric motor which rotates the bladeshaft insidethevessel,
so that theslurry is sufficiently agitated (mixed).
 Slurry after being mixed is pumped by the slurry homogenizing pumps through the set of two
filters. These filters are used for separation of oversized material through seives. Homogenizing
pumps areused becauseif theslurry is not agitated at every step, theseparation of both (the
liquid and solid feed) can be encountered, so to avoid separation weare using homogeniging
pumps to pump theslurry through silters. Theoversized material would beagain processed
until their size is reduced.
 The filtered slurry is now pumped to the Second Aging Vessel. This vessel is also equipped with
theelectric motor which rotates thebladeshaft insidethevessel, so that theslurry is
sufficiently agitated (mixed) again. After sufficient mixing theslurry is again pumped using two
slurry booster pumps through the set of two filters. As said before, they again separte
oversized material (which would beagain processed to reducetheir size).
 At last the the properly filtered and homogenized slurrywould be pumped to theDeaearation
vessel using High PressurePump for the removal of fumes and other dissolved gases from the
slurry by developing the vacuum pressure (ranges from -0.6to -0.5 Bar) by a Vacuum Pump.
 These gases/fumes areremoved becausethey createa sufficient vapor-pressureinsidethe
vessel which is quitedangerous for thevessel.
 Deaeration vessel has 30% of slurry which is sprayed insidethevessel via Spray Nozzle over its
top, which uniformly sprays the slurry. Outside of thevessel, a cylindrical-bottleis fixed in
which the water is showered using spray nozzleinsidethebottle.
 The top of thebottleis connected with thedeaeration vessel. The vacuum pump creates the
negativepressureover theretop to remove fumes from theslurry and condensing them.
Where thecondensateis again recycled and pumped to theRecycling Vesssel.
 After removing fumes from theslurry using deaeration system, slurry is transported to theHigh
Pressure pump by a Slurry Tranfer pump. Then by using High-Pressure pump (accompanied
with its two separate standby pumps), theslurry is transported to the64-Sectionfror Spray
Drying Process.

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Flow Chart
9. 64-Section (Spray Drying):
This unit is accompanied for Drying theslurry at vey high temperature at about (325℃-350℃) in
the Spray Drying Tower so that wecan get the basepowder from theslurry and send it for the post
addition. This section consist of,
1. Spray Drying Tower
2. Furnace
3. Blower
4. Dust Collector
5. Conveyer Belt
6. Air-Lift Line
7. Cyclone (Air Lift Vessel)
8. Vibrating Sieve
Mechanism of 64-Section:

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 Spray drying tower is used to dry theslurry to makethestablebasepowder. It consists of two
nozzlecircuit over its top.
 Differential pressureis maintained insidethetower by two fans.Onefor its end and one for its
top.
 From 63-Section, using high pressurepump two lines of theslurry arelinked to thetwo Nozzle
Cicuits at thetop of spray drying tower. These nozzle circuit are placed at certain vertical
distancefrom each other.
 Each nozzlecircuit consist of 9-Nozzels, means total 18nozzlearetherein a spray dryer.
 Furnace as a heating source consumes theNatural Gas and burns theambient air at (400℃).
 A high-flow rate fan blows theambient air to thefurnace to increaseits temperature(at about
325℃-350℃) and that hot air is blown verticallyupward through hot air passageducts at the
end of tower.
 18-Nozzles shower theslurryin tower, which falls vertically downward. With very high flow
rate of hot air from the duct flowing vertically upward insidethespray drying tower, slurry is
rapidly dried to thepowder and falls vertically downward over theconveying line.
 Spray drying tower has thegaseous outlet aboveit for discharging air and gases (CO2), at which
vacuum pressureof -1mm of H20 is maintained for increasing theretention timeof the slurry
and removing thefinedust particles insidethetower.
 Dischargeair flows insidethetwo-dust collectors for collecting dustfrom theair thus cleaning
theair and releasing pureair in the atomosphereby a belower to avoid environmental
degradation.
 Base powder at the end of thetower drops over a conveyer belt and conveyed to thehopper at
theAir-Lift Line.
 Another blower creates vacuum pressureinsidetheair-lift lineat theend of it to rapidly suck
thebase powder collected in a hopper. Where the lumps will bedropped out of theair-lift line
and collected below and again grinded for recycling.
 The sucking basepowder insidetheair-lift lineis moved to thecyclone (Air Lift Vessel), for
separating thebasepowder from air. The base powder dropped over a vibrating sievewhere
theundersized particle(about 4mm) is sent for post addition, whiletheoversized particles are
grinded and reused.

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Flow Chart