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Field Crops Research 65 (2000) 249258

Inoculant production and formulation


J.H.G. Stephens*, H.M. Rask
MicroBio RhizoGen Corporation, 3835 Thatcher Avenue, Saskatoon, Saskatchewan, Canada S7R 1A3
Accepted 16 December 1999

Abstract

The formulation and commercial production of any Rhizobium or Bradyrhizobium legume inoculant requires the integration
of physical, chemical and biological parameters leading to both high target organism populations and long term survival of
these organisms over time at less than optimum conditions. To achieve this, all raw materials processing and bacteriological
needs must be addressed, and quality products developed within narrow budgetary constraints. It is only through an
understanding of the needs and limitations of both the products physical and Rhizobium/Bradyrhizobium requirements that an
effective and efcient legume inoculant can be commercially produced. # 2000 Elsevier Science B.V. All rights reserved.

Keywords: Rhizobium; Inoculant production; Peat and granular formulations; Strain selection

1. Introduction inoculation is the lack of knowledge relating to target


organism fate over time and under commercial crop
Rhizobium/Bradyrhizobium inoculants have been production conditions.
used for over a century but research directed toward The end user of a legume inoculant is primarily
optimizing their impact is an ongoing activity. Smith concerned with crop productivity, not bacterial phy-
(1992), and Brockwell and Bottomley (1995), have siology nor ecology. Inoculant manufacturers must
reviewed the history of legume inoculant production accept this reality and ensure that the probability of
and desirable characteristics of an inoculant; Thomp- successful inoculation is maximized, even though the
son (1980) and Lupwayi et al. (2000), included aspects end user may not understand the bacteriological prin-
on quality control relating to these products. At times ciples on which the product is based. Since crop
the research ndings on inoculants are inapplicable at response to inoculation, in most instances, is the result
the eld level or impracticable for the manufacturer or of appropriate strain selection, and target organism
end user levels. One of the greatest barriers to pre- population (Muldoon et al., 1980; Amarger, 1981;
dicting, and consistently achieving, responses to Brockwell et al., 1988; Hume and Blair, 1992; Fes-
enko et al., 1995), a successful inoculant can only be
* formulated through a process of addressing the known
Corresponding author. Tel.: 306-373-3060; fax: 306-374-
8510.
product substrate variables that affect target organism
E-mail address: stevestephens.mbrsask@sk.sympatico.ca (J.H.G. viability. Regardless of the formulation of any pro-
Stephens). duct, nal product quality must be assured through a

0378-4290/00/$ see front matter # 2000 Elsevier Science B.V. All rights reserved.
PII: S 0 3 7 8 - 4 2 9 0 ( 9 9 ) 0 0 0 9 0 - 8
250 J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258

process of strict quality assurance. Quality assurance tication of the end-user, for instance, the level of
as opposed to quality control requires that every step mechanization used by the differing farm commu-
in the production process have set limits and only if nities and the time frames available during the busy
these limits are met, or surpassed, can further proces- seeding period.
sing toward a nished product be undertaken. Inoculants are usually commercialized in one of
The primary benet of promoting biological nitro- three forms; powder in the form of processed sedge
gen (N2) xation in grain and forage legumes is the peat moss, liquid and granular. Most granular prepara-
enhancement of yield potentials without the use of tions are in the form of a peat prill though, more
exogenous N fertilizers. This ability to promote N2 recently, hard mineral based products have been devel-
xation has resulted in commercial inoculant produc- oped. Powdered products are usually used for seed
tion facilities in numerous countries and on every inoculation and applied directly to the seed. Liquid
continent (Brockwell and Bottomley, 1995). Unfortu- products may be applied directly to the seed or placed
nately, the widespread availability of legume inocu- in the furrow during planting. Granular products can
lants has not resulted in international standards of be placed directly in the furrow, deep banded below
quality, nor of rates of use for these products. Many the seed or side banded and in the latter instance
countries, including Australia, the Netherlands, preferably deeper than the seed. Peat our continues
Rwanda, Thailand and Russia (Smith, 1992; Marufu to be the most popular method of delivery for Rhizo-
et al., 1995), legislate requirements for minimum bium/Bradyrhizobium inoculants and has been since
populations of target organisms and contaminants 1895, the historically accepted date of initiation of
per unit weight of product. Canada and France legis- legume inoculant production and use. Liquid and
late product quality by dening the number of viable granular alternatives are available in limited quantities
Rhizobium/Bradyrhizobium required per seed, or a in North America and Europe.
rate of application, for a full range of crops. The Peat our prepared from sedge, as opposed to
United States and United Kingdom leave product sphagnum, peat moss, is most commonly used in
quality and rates of application to the discretion of the production of legume inoculants. The producer
the manufacturer (Smith, 1992). This lack of inter- then has the choice to sterilize or not to sterilize the
nationally accepted regulations for legume inoculant processed peat our prior to the introduction of the
quality and usage parameters has led, in many rhizobia. Sterile peat our substrates normally display
instances, to inadequate performance of inoculants higher populations than those that are non-sterile and
and to the subsequent abandonment of their use. an enhanced shelf life (J.H.G. Stephens, unpublished).
The production of effective legume inoculants can, A positive advancement in peat inoculants in recent
however, partially overcome inadequacies in legisla- years has been the incorporation, in some instances, of
tion with the manufacturer taking responsibility for a sticking agent: this has not only made the product
the design and implementation of steps leading to a more user friendly but has also resulted in enhanced
consistently high quality and effective product. uniformity of coverage.
The liquid inoculants currently available display
various broth formulations, each the result of indivi-
2. Formulation of inoculants dual producer's research and development activities.
Liquid products have been promoted as being easier to
Formulation inadequacies are often the most com- handle (Hynes et al., 1995), and in many instances
mon barriers to the commercialization of legume display efcacy equivalent to peat products. However,
inoculants. A micro-organism may function optimally in many instances their limited shelf life and cool
under laboratory conditions, but formulating that temperature storage needs increase handling and end
organism into an end-user affordable product that is user costs in developed countries and precludes their
consistently able to bring about equivalent results use in most developing countries. A range of other
under eld conditions is a difcult step. Once an formulations including oil based products (Kremer
inoculant formulation which works in situ has been and Peterson, 1983a,b; Hoben et al., 1991), have also
developed, it must be rened to allow for the sophis- been studied but there has been little move toward
J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258 251

their commercialization. Production of Rhizobium/ either directly below or below and to the side of the
Bradyrhizobium concentrates, which would be diluted seed, encourage lateral root nodulation as opposed to
with water before use, have also been developed but crown nodulation obtained with seed applied products.
maintenance of organism populations within the con- Lateral root nodulation was reported to enhance N2
centrates over time has been problematic. xation over the growing period of soybean. Hard-
Recently, there has been increased interest in the arson et al. (1989) and McDermott and Graham (1989)
development of granular inoculants (Fraser, 1975; also noted that placement of inoculant at time of
Hedge and Brahmaprakash, 1992; Fouilleux et al., seeding was relevant and that optimizing placement,
1994, 1996). Crop nodulation and yields achieved as opposed to seed application, resulted in enhanced
with granular preparations can be equivalent to those nodule occupancy of the desired strain. Although N2
achieved with peat, liquid products and liquid seedbed xation within a crop can be enhanced through place-
inoculants (Bezdicek et al., 1978; Brockwell et al., ment of a granular inoculant, agronomy trials designed
1980; Dubetz et al., 1983; Rice and Olsen, 1992). Such to dene optimized placement for all crops must
granular inoculants are particularly suitable to farming continue.
systems in developed countries where the seeding Although a dry, solid core, granular product has
equipment commonly includes multiple, seed, fertili- only recently been marketed, a compressed peat, or
zer and inoculant delivery systems. prill, product has been available for several decades. In
A major advantage of the granular inoculants is the the former product the difculty has been to obtain a
ability to control placement and application rate as product displaying a low water activity while main-
needed. Although further evaluation is needed, current taining acceptable levels of rhizobia during the shelf
indications are that best results are obtainable through life of the product. Both granular products display
deep banding either directly below the seed or to the acceptable ow characteristics when applied through
side, as opposed to in the seedbed. Seed inoculants large scale seeding equipment.
have several disadvantages not found with granular Alternative formulations continue to be investi-
inoculants (Brockwell et al., 1980). A major one is that gated. These include lyophilized cultures, cell suspen-
each seed can carry only a limited amount of inoculum sions in oil and cell concentrates. The major areas of
and therefore number of bacteria. For small seeded investigation, however, revolve around increasing rhi-
species, such as white clover, this means that each seed zobial populations per unit weight or volume of
receives approximately 103 rhizobia. This can con- product, organism efcacy and product durability as
strain inoculant success in unfavorable environments this relates to product shelf life at the retail level.
or where soils contain indigenous rhizobia. There is
also the potential for inoculant loss as occurs in crops
displaying epigeal germination. Further, seed applied 3. Inoculant production
inoculants are inappropriate for those crops with
delicate seed coats, for instance peanut, and those The three concerns in inoculant production are the
species releasing bactericidal compounds from the quality and processing of the carrier, the purity and
seed. Another disadvantage of seed applied inoculants efciency in nodulation and N2 xation, of the culture,
is where seed treatment with fungicidal or insecticidal and achieving adequate cell numbers in broth culture
chemicals can be detrimental to rhizobial survival. and nished product.
(Brockwell et al., 1980; Fouilleux et al., 1994). The
bulk of these seed applied inoculant difculties can be 3.1. The carrier
overcome through the use of granular preparations
since the target organisms are not in direct contact Smith (1992), noted that the raw materials chosen
with chemicals that could be detrimental to their long for use in conventional, seed applied, inoculants are
term survival. determined by availability, consistency of quality and
Granular inoculants also appear to increase N2 cost. The carrier must display two fundamental prop-
xation through improvement in nodulation patterns erties; it must support growth of the target organism
(Hardarson et al., 1989). Granular inoculants placed and maintain desired populations of inoculant strains
252 J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258

over an acceptable time period. To achieve these goals Although peat is the carrier of choice, it is not
a carrier must also display high water holding capacity ubiquitously distributed and a more readily available
and retention characteristics, display chemical and substrate may be required. Alternative carriers, both
physical uniformity and be non-toxic to inoculant natural and derived, have been investigated and
strains and be non-toxic to inoculant strains and include mineral soils (Chao and Alexander, 1984),
environmentally safe. It needs also to permit growth plant byproducts (Sparrow and Ham, 1983), various
after introduction of the rhizobia, have an acceptable clays (Graham-Weiss et al., 1987), charcoal (Kremer
pH, rapidly release organisms upon use and be in and Peterson, 1983a; Sparrow and Ham, 1983), lig-
abundant supply. Most sedge peats fulll the bulk of nite, a range of coals (Paczkowski and Berryhill,
these requirements however the supply of this peat is 1979), composted plant materials (Kostov and Lynch,
becoming problematical in many instances. 1998), animal manure, perlite, rock phosphate, talc,
Processed peats can be sterilized prior to the addi- entrapped alginate beads (Bashan, 1986), polyacryla-
tion of rhizobia or left non-sterile. Although some mide gels (Dommergues et al., 1979), and mixtures of
producers continue to use non-sterile peat, Roughley xanthan and carob gum (Jung et al., 1982). Often the
and Vincent (1967), noted that sterile carriers gener- ability of an alternative carrier, or entrapment meth-
ally support higher populations and display much odology, to sustain organism growth is marginal while
longer shelf lives. Further, the use of a sterile peat cost, consistency of supply and quality, in many
carrier signicantly reduces threats to quality resulting instances, work against more widespread adoption
from the presence of contaminants. Sterile peat also of these alternative materials.
lowers costs of culture production by extending the In addition to peat prills, granular formulations have
broth, through culture dilution, while still achieving a included carbon amended clays (Fouilleux et al.,
higher nal population density. The disadvantages of 1996), alginate/perlite beads (Hedge and Brahmapra-
sterilizing the peat carrier are the cost of sterilization, kash, 1992), sand coated with peat inoculant (Cham-
identifying a sterilization unit with sufciently large ber, 1983), coated polythene beads and marble chips
and rapid throughput capacity and the need to follow (Brockwell et al., 1980). Although none of these are
aseptic procedures during culture injection (Smith, known to have reached the commercial market, a peat
1992). Nuclear, or g, irradiation has historically been prill and a hard granular product are currently avail-
the sterilization method of choice but is expensive and able on the North American market. The composition
slow. Autoclaving has been used in laboratory envir- of these two products are proprietary information.
onments but is laborious, costly and time consuming Consistency is an absolute requirement in any
and in a commercial context can result in inoculant carrier substrate. Because of the integral part the
quality compromised by the production of toxins carrier plays in the production and ultimate quality
during sterilization. Electron acceleration is the most of the product, it is desirable that it undergo ``t for
recent technology used for sterilization. This process use'' trials on receipt and prior to further processing.
is non-nuclear and depends upon the exploitation of a Measurable criteria, be they physical, chemical or
series of acceleration cavities which ultimately result biological, must be established and steps taken to
in an electron beam which generates 10106 eV with ensure that these criteria are met or exceeded with
which the peat is irradiated, and hence sterilized. One each shipment of raw materials. If these criteria cannot
of the greatest benets of electron beam sterilization is consistently be met, the carrier material will limit the
the turn-around time since the pre-packaged peat our reliability of any formulation that is subsequently
is only exposed to the sterilization process for seconds developed. This is unacceptable and necessitates
versus hours for g irradiation. mutual concern for quality by both the supplier and
Uruguay, a country in which sterile peat is man- the inoculant producer and the need for routine testing,
dated, is unusual in having peat deposits, but not by the producer, of the received raw materials.
the facilities for routine peat sterilization. Instead, In virtually every instance product raw materials
pre-sterilized packaged peat is imported from Canada must be modied prior to their use as a quality carrier.
and inoculated in Uruguay (C. Labandera, pers. In the case of bulk peat moss, the raw material must be
comm.). dried and ground into ne our. Thompson (1980),
J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258 253

suggested that a particle size of less that 0.075 mm, within macro and micro climates determined by soil
results in optimum surface coverage of seed per unit texture (Mahler and Wollum, 1981; Osa-Aana and
weight of inoculant. Most peats are inherently acidic Alexander, 1982), structure, aeration, pH (Cassman
and need to be neutralized and, in some instances, to et al., 1981), temperature and available moisture
have a buffer added prior to substrate sterilization and (Hardarson and Jones, 1979; Clark et al., 1986; Sprent
culture addition. Although most sedge peats are cap- et al., 1986), nutrient status, organic matter content
able of sustaining target organism growth and repro- (Semu and Hume, 1979), and weather. It is apparent,
duction, sufcient to support values in the mid log 8 therefore, that rhizobial activity can vary greatly with
range, the addition of macro and/or micro nutrients to environmental pressures, with clear differences in
the substrate to enhance population densities cannot response found both between and within species.
be dismissed. Selection of an appropriate organism is critical and
cannot be a process carried out over a single year of
3.2. Strain selection eld trials and over few locations.
That different Rhizobium and Bradyrhizobium iso-
To optimize nitrogen xation in commercially lates can vary in efciency with different cultivars and
important legumes, culture organisms need to be environments was noted by Jones and Hardarson
competitive with the indigenous populations and be (1979), Rennie and Kemp (1983a,b), Hobbs and
efcient in N2 xation upon nodule formation. Even if Mahon (1982), Kipe-Nolt et al. (1993) and Provorov
competitiveness for available nutrients is one of the et al. (1994). Hardarson and Jones (1979) and Hynes
strain selection criteria, soil rarely provides the rich and O'Connell (1990), also found variability between
environment evident in most culture media. Pre-con- soils as a result of differing soil physical and chemical
ditioning, and hence competitiveness of the inoculant conditions. This apparent strain selection, as a result of
strain can be achieved, in part, through the use of a soil differences, was also noted by Shishido and
nutrient-limited medium. The use of such a medium Pepper (1990) and Sattar et al. (1995), who reported
also reduces the likelihood of selecting a non-compe- that the most effective strains for a given crop, in a
titive strain. given geographic region, were often strains isolated
The development of an inoculant that can be used from that region. The basis for such ecosystem
for a range of crops of the same genus, and which response has been a subject of considerable recent
contains a cocktail of strains, as opposed to single study by microbial ecologists.
strain inoculants specic to a single crop, is a con- Competitiveness of selected strain(s) with indigen-
tinuing subject of discussion. Regardless of any orga- ous populations of rhizobia (Winaro and Lie, 1979;
nizational preferences for a single or multi-strain Broughton et al., 1982; van Rensburg and Strijdom,
product, there is a need to select strains for specic 1982; Fesenko et al., 1995) is also a major factor in
geographic, soil and environmental regions and, ide- strain selection. There is, therefore, a denite need for
ally, for individual varieties of a given legume species. any organization developing inoculants to have the
The top performing strain(s) for a given market area means of recovering and typing nodule occupants. To
must be compatible with the commonly grown crop merely use a strain displaying acceptable N2 xation
cultivars in that area, and display the adaptability to be in-vitro is not acceptable. The inoculant organism
effective and efcient over a range of geographic and must display both acceptable N2 xation and competi-
environmental conditions. This adaptability is an tiveness, for the inoculant to be effective. In an attempt
obvious requirement since soil types, moisture pat- to overcome strain/soil/cultivar difculties multi-
terns and cultivar preferences can, and do, alter over strain products have been investigated. There are
small geographic areas. Lynch (1983), stated ``Each numerous difculties associated with the multiple
microbial species will have an optimum for each strain approach, not the least of which is attempting
physical or chemical factor and its growth, or activity, to ensure that each strain is equally represented.
will decline either side of that optimum, governing its Frankenberg et al. (1995) indicated that this was
contribution to the total population.'' Further it has difcult to achieve because of differing growth rates
been noted that microbial preferences can change between strains of the same species. Caldwell and Vest
254 J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258

(1968), Bailey (1988), Somasegaran and Bohlool Current fermenter technology can provide continuous
(1990), and others have also reported that crop N2 monitoring, and control of virtually all measurable
xation, when inoculated with a multi-strain inocu- parameters and as such custom production of mother
lant, was generally less than that associated with a cultures of any chosen Rhizobium/Bradyrhizobium
single strain product. If nodule occupancy reects the species or strain is possible and, indeed, desirable.
ratio of each strain in the inoculant, the N2 xing Commonly used DO2 values are between 90 and
potential of a multi-strain preparation is likely to 100%, and temperature values between 25 and 288C
reect the effectiveness and competitiveness of the are standard. Because fermenter starter cultures are
predominant strain or strains. normally produced in swirl asks, where culture pH
and DO2 are rarely controlled, the inclusion of a
3.3. Culture production buffer, such as MOPS (3-[N-Morpholino]propanesul-
fonic acid), should be considered. Where possible,
Although the literature abounds with rhizobial DO2 values in the starter cultures should also be
media formulations, these, almost without exception, controlled since normal values for this variable, in
were developed for general laboratory procedures. swirl or stir asks, have been seen to be in the 2530%
Under commercial legume inoculant production con- saturation range for mature cultures. Lack of control
ditions, attempts to condition the culture, to ensure of these variables in starter cultures can result in
survival and reproduction in an environment where signicant lag phase on transfer of the mother culture
nutrients are less readily available, must be made. to the fermenter. This results in decreased population
Although the development of, for instance, a carbon densities at the time of scheduled harvest.
limited medium is straightforward, there is also a need
to ensure that the medium can support populations at, 3.4. Finished product production
or exceeding, 109 CFU ml1. This value is being
targeted for the production of sterile peat based pro- Production considerations must be scheduled to suit
ducts since the mother culture is diluted, with sterile employee work periods because a completely inte-
deionized or reverse osmosis, water, to at least 1/50 grated system must be developed. This must be amen-
and in some instances 1/250 prior to injection into the able to specied dates of culture harvest at which the
sterile peat. For granular products the relationship culture always conforms to a set of measurable para-
between mother culture population densities and n- meters.
ished product quality is direct, the better the mother It is only by developing a complete culture produc-
culture the better the product. tion system, from agar slope or glycerol deep to swirl/
By-products from food processing, cheese whey, stir ask to fermenter, that nished product quality can
corn steep liquor, malt sprouts and malt bagasse have be assured. This assurance, in turn, requires a set of
been reported to be acceptable carbon and nitrogen legislated quality standards and in house minimums.
sources for rhizobial culture medium (Meade et al., Ideally, in house standards should be in excess of
1985; Bissonnette et al., 1986; Balatti et al., 1991). legislated standards and greater than those which have
The use of by-products from the food processing been experimentally shown to result in enhanced crop
industry can be problematic since few such ``waste'' productivity.
products can assure continuity of quality. Even the use
of conventional medium substrates is fraught with 3.5. Assuring a quality product
pitfalls. For instance Skinner et al. (1977) noted that
excessive use of yeast extract as a carbon and nitrogen Quality Assurance ensures that, at each stage of the
source resulted in both cell morphological changes production process, pre-dened criteria must be
and decreased nodulation potential. met or the production run is aborted. Employing a
Along with growth medium constituents, and con- quality assurance approach to inoculant production
stituent concentrations, fermentation variables such as reects the integration of equipment performance, raw
dissolved oxygen (DO2), temperature, pH and impel- material quality and other variables required for a
ler tip speed must be established for each organism. quality product. It also results in minimal, if any,
J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258 255

loss due to a nished product not displaying accep- Rhizobium leguminosarum biovar viceae, a fungal
table target organism populations and nodulation antagonistic Pseudomonas species and/or a growth
potentials. promoting Bacillus species that mixed population
A quality assurance system guards against compla- products rarely reached individual organism cell
cency since product upgrading, as a result of techno- populations obtained for each organism in mono-
logical advances or consumer demand, is integral to culture. This is evident in Table 1. As is also
the system. Changes must only benet the process and evident from Table 1, in only one instance did co-
therefore should only be brought about after discus- inoculated populations approach values evident in
sion and testing. If a proposed change does not the monoculture controls. This equivalency of
enhance the quality and dependability of the nished populations was only seen in a mix of RGPs7, a
product the change must not take place. pseudomonad, and RGP2, a R. leguminosarum biovar
The production of a quality legume inoculant is the viceae strain. Co-inoculants hold considerable pro-
coming together of a series of disparate activities and mise, however care must be taken to ensure rhizobial
apparently non-related processes. Ultimately, how- populations do not suffer when cultured with non-
ever, the disparate facets of production result in a rhizobia.
product displaying the potential to benet not only the Indications are that rhizobial strain selection may
farm community but the producer and society in overcome some of the mixed culture competition
general. effects. The choice of selecting a rhizobial strain
for compatibility with a secondary organism, as
opposed to N2 xation potential and competitiveness,
4. Co-inoculants would be a partial option in the instance of the
Pseudomonas sp. noted in Table 1. Any such choice
Co-inoculants, in this instance, are those which will, however, require extensive eld testing to ensure
contain rhizobia and organisms of other genera and that any change in rhizobial strain does not result in
species. The requirements for production of these less than equivalent N2 xation and crop productivity.
inoculants are equivalent to those for rhizobia only From this preliminary study it appears that the pro-
products but organism/organism interactions in these duction of co-inoculants will require extensive in-vitro
products must be confronted. and in-situ investigations if the positive attributes
It has been found (J.H.G. Stephens, unpublished), associated with each organism are to be effectively
during the development of co-inoculants containing exploited.

Table 1
Mean populations of three differing bacterial genera seven days post-injection into sterile peat our and when incubated at 278C. Injected
cultures displayed CFU values between log 9 and 9.4

Injected organism/organisms CFU log10 injected organisms

RGPs7a RGB19 RGP2 RGC1


RGPs7 9.1
RGB19 9.7
RGP2 9.0
RGC1 9.3
RGPs7RGP2 9.3 9.0
RGPs7RGC1 9.1 8.4
RGB19RGP2 7.2 7.5
RGB19RGC1 7.5 8.6
RGPs7RGB19 8.8 7.3
RGPs7RGB19RGP2 7.4 7.6 7.7
RGPs&RGB19RGC1 7.9 7.3 7.8
a
RGPs7, Pseudomonas sp., RGB19, Bacillus sp., RGC1 and RGP2, Rhizobium leguminosarum biovar viceae strains.
256 J.H.G. Stephens, H.M. Rask / Field Crops Research 65 (2000) 249258

5. Summary Brockwell, J., Bottomley, P.J., 1995. Recent advances in inoculant


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