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Engineered Wood Manufacturing Spray Nozzles
Precision Spray Technology for OSB, MDF, Particleboard & Laminated Wood Products.
Engineered wood manufacturing—producing oriented strand board (OSB), medium-density fiberboard (MDF), particleboard, plywood, laminated veneer lumber (LVL), and composite panels—requires precision spray application controlling every critical process parameter from resin distribution affecting bond strength to release agent coverage preventing press sticking. Poor spray application creates devastating consequences: uneven resin distribution causes bond failures and delamination reducing product value by 40–70% or creating total rejects, inadequate release agent coverage damages press plates ($50,000–$200,000 replacement costs) and causes production stops lasting hours to days, inconsistent preservative application leaves vulnerable areas where decay and mold develop undermining warranty claims and reputation, and excessive chemical usage from inefficient spray systems wastes $100,000–$500,000 annually in expensive resins, adhesives, and treatments while creating emissions compliance challenges. NozzlePro engineered wood spray nozzles deliver the precision atomization, controlled distribution, and reliable operation that optimize bond quality, minimize chemical costs, maximize press uptime, and ensure consistent product performance meeting APA, ICC-ES, and customer specifications.
Our engineered wood nozzle systems feature optimized droplet control (50–500 microns depending on application and chemical viscosity), uniform spray patterns eliminating the dry spots and wet areas that create quality defects, and chemical-resistant materials withstanding phenol-formaldehyde resins, isocyanate binders, wax emulsions, and aggressive biocides. From automated resin curtain systems applying precise adhesive loads to strand mat or particleboard furnish (reducing resin costs 15–30% through optimized distribution) to multi-zone release agent spray bars ensuring complete platen coverage with minimal buildup, from preservative treatment systems meeting AWPA penetration requirements to surface coating applicators delivering uniform finish appearance, NozzlePro nozzles help manufacturers increase first-pass quality yields 20–35%, reduce chemical consumption 20–40%, extend press cleaning intervals 40–60%, and consistently meet structural performance standards (APA PS-1, PS-2) and emissions limits (CARB Phase 2, TSCA Title VI) critical to market access and profitability.
The Economics of Precision Resin Application in Panel Manufacturing
Resin represents the largest chemical cost in engineered wood production—accounting for 25–40% of total manufacturing costs and $3–$12 per panel depending on product type and resin chemistry. A typical OSB mill producing 600 million square feet annually consumes $15–$35 million in phenol-formaldehyde resin. Even modest resin optimization through improved spray distribution generates massive savings: reducing resin loading 10–15% through uniform application that eliminates over-application in some areas and under-application causing defects saves $1.5–$5.2 million annually while maintaining identical bond performance. Beyond direct chemical savings, precision spray prevents the quality defects that devastate profitability—a single production run of delaminated panels (inadequate resin in core) can reject 50,000–200,000 square feet worth $30,000–$150,000 plus customer claims, reputation damage, and investigation costs. Automated spray systems with feedback controls ensure consistent resin loads (±3–5% versus ±15–30% manual systems) across production speeds of 500–1,000 feet per minute, delivering both cost optimization and quality assurance that manual systems cannot achieve.
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Critical Engineered Wood Manufacturing Applications
🔗 Resin & Adhesive Application
Apply phenol-formaldehyde (PF), urea-formaldehyde (UF), melamine-urea-formaldehyde (MUF), and polymeric MDI (pMDI) resins to wood furnish, strands, particles, and veneers with precision distribution ensuring proper bond development. Atomizing nozzles (air or hydraulic designs generating 100–300 micron droplets at 40–150 PSI) apply controlled resin loads (typically 2–8% by dry weight) achieving uniform coverage across furnish stream traveling 300–800 feet per minute on conveyor systems. Critical factors include: droplet size optimization for furnish geometry (coarse for OSB strands, fine for MDF/particleboard fibers), spray pattern uniformity preventing dry streaks where bond fails or wet areas causing press problems, and atomization efficiency affecting resin penetration into wood structure. Proper application achieves target internal bond (IB) strength of 50–90 PSI for structural panels while minimizing resin consumption—every 0.5% resin reduction saves $500,000–$1.5M annually for large mills. Nozzle systems integrate with resin metering pumps and flow controls ensuring precise chemical delivery synchronized with production speed.
🛡 Release Agent Application to Press Platens
Apply release agents (wax emulsions, silicone-based formulations) to hot press platens preventing panel sticking that damages surfaces, halts production, and requires costly press cleaning. Multi-nozzle spray bars spanning press width (typically 8–12 feet) deliver uniform coverage using flat fan or full cone nozzles (80–300 micron droplets at 30–80 PSI) activated between press cycles or continuously during production. Proper application creates thin, uniform film (0.1–0.3 mils) providing release properties without excessive buildup requiring frequent cleaning. Inadequate coverage causes catastrophic sticking—panels tear during opening requiring 2–8 hour shutdowns for platen cleaning and resurfacing ($5,000–$25,000 per incident in lost production plus $10,000–$50,000 cleaning costs). Over-application wastes expensive release agents ($15–$40 per gallon) and accelerates buildup requiring cleaning. Optimized spray reduces release agent consumption 25–40% while extending press cleaning intervals from weekly to monthly—saving $50,000–$200,000 annually for typical OSB or particleboard operations.
🌳 Wax & Moisture Barrier Application
Apply wax emulsions and moisture barrier treatments to panel surfaces and edges improving dimensional stability and water resistance critical for exterior applications. Panel-grade wax (paraffin or microcrystalline emulsions at 30–60% solids) applied at 0.3–0.6% by weight to surface layers provides moisture exclusion meeting ASTM D1037 thickness swell requirements (≤15% after 24-hour water soak for exterior-grade OSB). Spray application uses atomizing nozzles creating fine droplets (50–150 microns) that coat particle or strand surfaces before mat formation, or post-production sprays applying edge sealers to finished panels. Uniform wax distribution is critical—missed areas allow moisture ingress causing localized swelling, telegraphing, and performance failures. Precision spray reduces wax consumption 20–35% through controlled distribution versus crude spray or tumble application methods, important as wax costs reach $500,000–$2M annually for large mills. Automated systems adjust wax loading based on product grade, moisture content, and end-use requirements.
🦠 Preservative & Biocide Treatment
Apply wood preservatives and biocidal treatments protecting engineered wood from mold, decay fungi, and insect damage—particularly critical for products in humid environments or ground contact applications. Preservative spray systems apply copper-based compounds (copper azole, ACQ), borate treatments, or organic biocides to panel surfaces, edges, or furnish meeting AWPA Use Category requirements and building code specifications. Fine mist atomization (40–120 microns at 60–150 PSI) ensures thorough coverage and penetration into surface layers where biological attack initiates. Treatment must achieve specified retention levels (typically 0.15–0.60 lb/ft³ for above-ground exposure) with uniform distribution—inadequate coverage leaves vulnerable areas where decay develops undermining warranties and reputation. For engineered lumber (LVL, I-joists) used in structural applications, preservative treatment qualifies products for wet-service and ground-contact use expanding market opportunities. Spray application provides more controlled, efficient treatment versus dip or pressure processes for surface-critical applications, reducing chemical usage 30–50% while meeting performance standards.
🎨 Surface Coating & Finishing
Apply decorative and protective surface coatings including UV-cured coatings, water-based finishes, stains, sealers, and fire-retardant treatments to finished engineered wood panels creating value-added products. Atomizing spray systems (air-assisted or airless designs at 500–3000 PSI) deliver controlled film thickness (1–5 mils wet) with uniform appearance critical for furniture-grade panels, architectural millwork, and decorative applications. Coating application affects surface properties including gloss level, scratch resistance, stain resistance, and light stability determining product suitability and pricing. Multi-pass spray systems build film thickness gradually preventing runs and sags while achieving proper flow-out and leveling. For high-volume production, automated reciprocating or fixed spray arrays coat continuous panel streams at 50–300 feet per minute. Precision spray reduces coating material costs 25–40% through transfer efficiency optimization (percentage of sprayed material actually depositing on panel versus overspray waste) while ensuring consistent finish quality meeting customer specifications.
💨 Anti-Static & Dust Control
Apply anti-static agents and dust suppressants to panel surfaces and production equipment controlling static electricity and airborne dust that create safety hazards, equipment problems, and finish defects. Wood dust generated during sawing, sanding, and handling operations becomes electrically charged causing particle attraction to surfaces, equipment fouling, and dust cloud formation. Fine mist spray of anti-static solutions (typically surfactant-based formulations diluted 100:1 to 500:1) neutralizes surface charges preventing dust adhesion and improving downstream coating adhesion. For high-dust operations (MDF/particleboard sanding), automated mist systems maintain clean operating environment reducing equipment cleaning frequency 60–80%. Additionally, dust control sprays applied to material handling areas (conveyors, storage) minimize airborne particulates improving workplace air quality and reducing housekeeping labor. Systems use ultra-fine misting nozzles (10–40 microns at 100–500 PSI) delivering minimal liquid while achieving effective dust knockdown and static control.
Benefits of NozzlePro Engineered Wood Nozzles
20–40% Chemical Savings
Optimize resin, release agent, wax, and treatment chemical distribution eliminating waste from over-application and defects from under-application.
Enhanced Bond Quality
Uniform resin distribution ensures consistent internal bond strength, preventing delamination defects and meeting APA performance standards.
Extended Press Life
Precise release agent coverage prevents sticking damage and buildup extending cleaning intervals 40–60% and platen life 30–50%.
Increased Uptime
Eliminate production stops from press sticking, clean-out requirements, and quality holds—improving equipment effectiveness 10–20%.
Quality Consistency
Automated spray controls eliminate operator variability ensuring consistent product properties and reduced reject rates (15–35% improvement).
Chemical Compatibility
Stainless steel, Hastelloy, and fluoropolymer materials withstand phenolic resins, isocyanates, acids, and aggressive wood chemicals.
High-Speed Performance
Reliable operation at production speeds of 500–1,000 FPM ensuring consistent spray quality regardless of line rate.
Emissions Compliance
Optimized chemical application reduces VOC emissions and formaldehyde release supporting CARB Phase 2 and TSCA Title VI compliance.
Engineered Wood Products & Applications
OSB (Oriented Strand Board)
Resin application to wood strands (PF or pMDI at 2–4% loading), wax emulsion for moisture resistance (0.3–0.6%), release agent to press platens, and preservative treatments for ground-contact grades requiring precise spray control for structural performance.
MDF (Medium-Density Fiberboard)
Resin spray to refined wood fibers (UF or UF-MF blends at 8–12% loading), wax application for moisture resistance, surface coating for decorative grades, and anti-static treatments for sanding dust control.
Particleboard
Adhesive application to wood particles (UF resins at 6–10% loading for core layers, higher concentrations for face layers), release agent for continuous press operations, and preservative treatments for special applications.
Plywood & LVL
Adhesive application between veneer layers (PF for exterior, UF for interior applications), edge sealing for moisture protection, and surface treatments including fire retardants, preservatives, and decorative coatings.
Engineered Lumber (I-Joists, Beams)
Adhesive application at web-flange interfaces, preservative treatments for wet-service applications, and moisture barrier coatings protecting end-grain and critical areas from environmental exposure.
Specialty Composites
Resin application for wood-plastic composites (WPC), agricultural fiber boards, and specialty panels using various binder systems with customized spray parameters for non-traditional materials and applications.
Recommended Engineered Wood Nozzle Configurations
| Application | Nozzle Type | Droplet Size / Parameters | Shop |
|---|---|---|---|
| Resin to OSB Strands | Air or Hydraulic Atomizing | 150–300 microns, 3–10 GPM, 60–150 PSI, curtain or multi-nozzle arrays, 2–4% loading by weight | Air-Atomizing / Hydraulic |
| Resin to MDF/Particleboard | Fine Atomizing Nozzles | 80–200 microns, 5–20 GPM, 80–200 PSI, fine spray for fiber/particle coating, 6–12% loading | Air-Atomizing |
| Release Agent to Press Platens | Flat Fan or Full Cone Arrays | 100–300 microns, 1–5 GPM total, 30–80 PSI, multi-nozzle bars spanning press width | Flat Fan / Full Cone |
| Wax Emulsion Application | Hydraulic Atomizing | 50–150 microns, 2–8 GPM, 60–120 PSI, fine spray for uniform wax distribution, 0.3–0.6% loading | Hydraulic Nozzles |
| Preservative Treatment | Fine Mist Atomizing | 40–120 microns, 1–10 GPM, 80–150 PSI, penetrating spray for surface/edge treatment | Air-Atomizing |
| Surface Coating / Finishing | Airless or Air-Assisted | 20–80 microns, 0.5–5 GPM, 500–3000 PSI, controlled film thickness for decorative/protective coatings | Hydraulic Nozzles |
| Dust Control / Anti-Static | Ultra-Fine Misting | 10–40 microns, 0.5–3 GPM, 100–500 PSI, minimal liquid application for dust knockdown | Air-Atomizing |
Engineered wood spray system design requires detailed analysis of chemical properties (viscosity, solids content), production parameters (line speed, mat density), and performance requirements (bond strength, emissions limits). Our engineered wood specialists work with your R&D and production teams to optimize spray parameters, conduct onsite trials, and implement systems with performance guarantees. Request a free application assessment including chemical compatibility testing, spray pattern analysis, and ROI projections for your specific products and processes.
Why Choose NozzlePro for Engineered Wood Manufacturing?
NozzlePro provides precision spray solutions engineered specifically for the demanding requirements of engineered wood manufacturing—optimizing critical processes affecting product quality, chemical costs, and production efficiency. With deep understanding of wood composite chemistry, pressing operations, and quality standards (APA, ICC-ES, CARB), we design systems that improve your bottom line while ensuring consistent product performance. Our engineered wood nozzles are trusted by major OSB, MDF, and particleboard manufacturers where spray precision directly impacts profitability through chemical costs, quality yields, and press uptime. With chemical-resistant materials for aggressive wood chemicals, engineered spray patterns optimizing coverage and droplet size, proven 20–40% chemical savings through optimized distribution, and complete technical support from process analysis through production optimization, NozzlePro helps engineered wood manufacturers maximize quality, minimize costs, and meet increasingly stringent environmental regulations in competitive global markets.
Engineered Wood Spray System Specifications
Droplet Size Range: 10–500 microns optimized for application (ultra-fine finishing to coarse resin sprays)
Operating Pressure: 30–3000 PSI depending on atomization method and chemical viscosity
Flow Rates: 0.5–50 GPM per zone depending on production width and chemical loading requirements
Spray Patterns: Flat fan, full cone, hollow cone, air-atomizing, hydraulic atomizing, airless
Production Speed Range: 50–1,000 FPM (15–300 m/min) with consistent spray quality
Chemical Viscosity: Water-thin to 2,000 centipoise (resins, adhesives, coatings) with appropriate nozzle selection
Materials: 316L stainless steel, Hastelloy C-276, PTFE, Kynar (PVDF) for chemical resistance
Chemical Compatibility: Phenolic resins, isocyanates, urea-formaldehyde, wax emulsions, silicones, biocides, solvents
Temperature Rating: Ambient to 200°F (93°C) for heated chemical applications
Control Options: Manual, pneumatic, electric actuators; PLC integration; flow meters; pressure feedback
Coverage Width: 4–16 feet typical panel widths with multi-nozzle arrays
Chemical Savings: 20–40% reduction through optimized distribution and automated controls
Quality Improvement: 15–35% reduction in bond/delamination defects through uniform resin distribution
Emissions Impact: 20–35% VOC/formaldehyde reduction through optimized chemical loading
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Engineered Wood Manufacturing Spray Nozzle FAQs
How do spray nozzles reduce resin costs in OSB/MDF production?
Spray nozzles reduce resin costs 15–30% through four mechanisms: (1) Uniform distribution—atomized spray creates consistent coverage across furnish eliminating over-application in some areas and under-application causing bond failures, (2) Droplet optimization—proper droplet size (150–300 microns for OSB strands, 80–200 microns for MDF fibers) maximizes surface coverage per unit resin versus crude spray creating large droplets that pool and waste material, (3) Atomization efficiency—fine spray promotes better resin penetration into wood structure improving bond efficiency allowing lower overall loading, and (4) Automated controls—precise metering synchronized with production speed ensures target resin loading (±3–5%) regardless of line rate versus manual systems varying ±15–30%. Example: OSB mill using $20M annually in PF resin with 20% optimization saves $4M while maintaining identical bond strength (50–70 PSI IB) and meeting APA PS-2 structural requirements. Critical: resin reduction must be validated through internal bond testing ensuring performance standards maintained.
What causes press sticking and how do spray systems prevent it?
Press sticking occurs when panel surfaces bond to hot press platens during curing—caused by: (1) Inadequate release agent coverage leaving dry spots where resin-rich panel surface contacts metal, (2) Excessive panel surface resin/adhesive (from face layer over-application) overwhelming release agent effectiveness, (3) Press platen contamination from release agent buildup or carbonized resin residue creating rough surfaces, or (4) Extreme pressing conditions (very high temperatures, moisture contents) challenging release performance. Spray systems prevent sticking through: uniform release agent distribution via multi-nozzle arrays spanning press width ensuring no dry spots, controlled application (0.1–0.3 mil film thickness) providing release properties without excessive buildup, automated activation synchronized with press cycles maintaining consistent coverage, and spray pattern monitoring detecting nozzle plugging before coverage fails. Proper spray reduces sticking incidents 80–95%, extending press cleaning intervals from weekly to monthly and eliminating production stops costing $5,000–$25,000 per occurrence in lost production.
Can spray systems handle high-viscosity resins and adhesives?
Yes, but viscosity influences nozzle technology selection and operating parameters. Wood composite resins range from water-thin (100–300 centipoise for dilute UF) to syrup-like (800–2,000 centipoise for phenolic concentrates). Low viscosity resins (<500 cP) atomize effectively with standard hydraulic pressure nozzles (60–150 PSI) or air-atomizing designs. Medium viscosity (500–1,500 cP) requires higher hydraulic pressure (150–500 PSI), air-assist atomization, or heated application reducing viscosity (warming PF resin from ambient 70°F to 90–110°F can reduce viscosity 40–60%). High viscosity (>1,500 cP) demands airless atomization (1,000–3,000 PSI), aggressive heating, or chemical dilution. For isocyanate binders (pMDI) with reactive chemistry, specialized equipment prevents premature curing in nozzles through non-wetted air caps and rapid cleaning capability. We provide viscosity testing, temperature optimization, and technology recommendations ensuring proper atomization for your specific resin systems. Critical: maintain consistent chemical temperature (±5°F) for reproducible spray quality.
How do I ensure uniform spray coverage across panel width?
Uniform coverage requires proper nozzle selection, spacing, and system design: (1) Overlapping spray patterns—space nozzles so adjacent spray fans overlap 20–40% at target distance eliminating gaps and minimizing high/low variations, typically 10–24 inch spacing for flat fan nozzles or 18–36 inch for full cone depending on spray angle, (2) Matched flow rates—verify all nozzles deliver identical flow (within ±5%) through proper sizing and pressure regulation, (3) Height optimization—mount spray bar at distance producing desired spray width without excessive overspray or coverage gaps, typically 12–36 inches above target for most applications, (4) Pressure control—maintain stable, uniform pressure across all nozzles using pressure regulators and balanced manifold design, and (5) Pattern monitoring—periodically test spray patterns using water-sensitive paper or collection trays verifying uniform distribution. For critical applications (resin to OSB strands), automated monitoring systems with optical sensors or weight cells verify coverage real-time allowing immediate correction of defects before quality impacts. Proper design achieves ±5–10% coverage uniformity—adequate for most structural panels. Decorative coatings may require ±3–5% for acceptable appearance.
What maintenance do engineered wood spray systems require?
Maintenance intensity depends on chemical characteristics and production schedule: (1) Daily cleaning—flush nozzles with appropriate solvent after production runs preventing resin cure/buildup in passages, particularly critical for fast-curing systems (isocyanates, hot PF resin) that harden within hours, use alcohol or acetone for UF/PF, MEK for isocyanates, warm water for wax emulsions, (2) Weekly inspection—verify spray patterns, check for plugged orifices, ensure proper atomization quality, measure and document nozzle flows detecting wear or deposits, (3) Filter maintenance—clean or replace inline filters (typically 40–100 mesh) preventing wood particles, resin gels, or contaminants from plugging nozzles, (4) Quarterly overhaul—disassemble and deep-clean nozzles removing stubborn deposits, inspect for wear or corrosion, replace consumable parts (fluid tips, air caps), recalibrate flows, and (5) System testing—verify coverage uniformity, spray pattern quality, and automated controls functionality. For automated systems with dozens of nozzles, preventive maintenance prevents quality defects and production interruptions. Proper maintenance extends nozzle life 3–5x versus neglected equipment. We provide maintenance training, spare parts kits, and technical support for long-term system reliability.
How do spray systems help meet emissions regulations (CARB, TSCA)?
Spray systems reduce formaldehyde and VOC emissions—critical for CARB Phase 2 (0.05 ppm for plywood, 0.11 ppm for particleboard/MDF) and TSCA Title VI compliance—through three mechanisms: (1) Resin optimization—uniform distribution allows 10–20% lower overall resin loading while maintaining bond performance, directly reducing formaldehyde content in finished panels, (2) Improved cure efficiency—proper resin atomization and distribution promotes more complete crosslinking during hot pressing reducing free formaldehyde available for post-manufacture emission, and (3) Surface treatment accuracy—precise application of formaldehyde scavengers or emission-barrier coatings to panel surfaces enhances capture efficiency using minimal chemical. Additionally, minimizing wasted resin (overspray, drips) reduces plant air emissions during production and curing. For CARB/TSCA compliance, manufacturers must demonstrate resin selection, formulation optimization, AND processing controls. Spray system improvements combined with low-emission resin formulations (NAF, ULEF chemistries) enable regulatory compliance while maintaining productivity. We help develop application strategies supporting emissions test programs and regulatory certification. Critical: final compliance requires emission chamber testing of finished panels per ASTM E1333 or ASTM D6007—spray improvements are one component of comprehensive emissions management.
What's the ROI for upgrading spray systems in panel production?
ROI typically ranges from 4–18 months depending on production volume and current system efficiency. Benefits include: (1) Chemical savings—20–40% reduction in resin, release agent, wax, and treatment chemicals saving $200,000–$2M annually for typical OSB/MDF mills using $1M–$5M in chemicals, (2) Quality improvement—15–35% reduction in bond defects, delamination, and surface defects reducing rejects from 3–8% to 2–5% saving $100,000–$500,000 annually at $200–$400 per MSF reject value, (3) Increased uptime—eliminating press sticking, cleaning frequency, and quality holds improving OEE 10–20% worth $300,000–$1.5M annually for facilities with $15M–$75M annual production capacity, (4) Emissions compliance—enabling CARB Phase 2 / TSCA Title VI qualification maintaining market access to California and US (noncompliant products cannot be sold worth entire revenue), and (5) Labor reduction—automated systems eliminate manual spray operations and reduce press cleaning labor saving $50,000–$200,000 annually. Total annual benefit: $650,000–$4.2M for typical operations. System investment: $150,000–$800,000 depending on mill size and complexity. Payback period: 4–18 months. Ongoing annual ROI: 80–560%. Critical: savings depend on current system deficiencies—greatest benefits for facilities with manual/crude spray equipment.
Can spray systems integrate with existing production controls?
Yes. Modern spray systems integrate seamlessly with plant automation and control systems including: (1) Production speed tracking—spray flow automatically adjusts proportionally to line speed maintaining constant resin/chemical loading as production rate varies 400–800 FPM, (2) Chemical metering—spray controls interface with chemical proportioning systems ensuring proper mixture ratios (resin, hardener, water) regardless of throughput, (3) Quality feedback—integration with online QC sensors (moisture, density, strength testing) allows closed-loop control adjusting chemical application maintaining target properties, (4) Press cycle coordination—release agent spray synchronizes with press opening/closing cycles activating at optimal timing, (5) Alarm integration—spray system faults (low pressure, plugged nozzles, empty tanks) trigger production alerts or interlocks preventing defective panels, and (6) Data logging—spray parameters (flow, pressure, chemical usage) recorded with production data supporting quality investigations and regulatory compliance documentation. Integration uses standard industrial protocols (Modbus, Profibus, EtherNet/IP) allowing communication with major PLC brands (Allen-Bradley, Siemens, GE). We provide integration engineering and commissioning support ensuring spray systems work seamlessly within existing production control architecture. Automated integration improves quality consistency, reduces operator workload, and enables sophisticated optimization not possible with manual systems.
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