Colour Toner - Conventional or Chemical The Practical Issues
Topics Conventional Toner Spheridising Chemical Toner Manufacture Alternative Processes Performance Comparisons Image Quality Cost Reliability The Future Why are the OEMs turning to Chemical Toner? 26/04/2007 DELACAMP your global Partner 2
26/04/2007 DELACAMP your global Partner 3 Anatomy of a Toner Particle (Conventional) Internal Structure Resin Toner matrix 50-90% ~ 10 μm Pigment Colorant Magnetic property 5-50% Wax Fusing <10% Charge control agent <2%
26/04/2007 DELACAMP your global Partner 4 Anatomy of a Toner Particle (Conventional) External Additives Silica Flow aid Tribo-charging Storage stability Second additive (polishing agent) ~ 10 μm Third additive (lubricant)
26/04/2007 DELACAMP your global Partner 5 Conventional Toner Pulverization Strong Points: Inexpensive Well understood technology Weak Points: Large particle size distribution Higher pile heights Poor interaction with OEM Poor fusing Wax is not encapsulated Non-uniform shapes Poor toner flow
26/04/2007 DELACAMP your global Partner 6 Conventional Toner Spheridising Conventional toner is produced and then smoothed by heat and mechanical process. Strong Points Less expensive than chemical Weak Points Wide particle size distribution Higher pile heights Interaction with OEM Poorer fusing Non-uniform shape Wax on surface poor flow
26/04/2007 DELACAMP your global Partner 7 Chemical Manufacturing Methods (1) Emulsion Aggregation Coagulation
26/04/2007 DELACAMP your global Partner 8 Anatomy of a Toner Particle (Chemically Produced) Emulsified Polymer with Wax Colorant Coagulation Aging Additive
26/04/2007 DELACAMP your global Partner 9 Chemical Manufacturing Methods (1) Emulsion Aggregation Coagulation Strong Points: It s a smooth potato shaped Cleans easier Tight particle size distribution Good fusing Wider colour gamut Better control of particle shape Glossy or matte finish Weak Points: Complex process Difficult to use polyesters
Chemical Manufacturing Methods (2) Suspension Polymerisation High-speed Dispersion Strong Points: Round Good Charge Control, Flow and Transfer Perfect match with the OEM Weak Points: Difficult Cleaning Heavily Patented Limited to Spherical Shapes 26/04/2007 DELACAMP your global Partner 10
Chemical Manufacturing Methods (3) Polyester (Elongation) Polymerisation Components are mixed with a solvent and processed through high shear mixing. Strong Points: Narrow Size Distribution Wide Fusing Range Weak Points: Difficult to polymerise particles directly to size 26/04/2007 DELACAMP your global Partner 11
26/04/2007 DELACAMP your global Partner 12 Chemical Manufacturing Methods (4) Chemical Milling Components are mixed with a plasticiser, melted, and processed through high shear mixing. Strong Points: Enables easy use of all conventional resins, including polyesters Simple process low investment Good colour gamut Surface roughness can be controlled Can use either dye or pigments for colorant Weak Points: Solvent based process Potential for solvent fumes during fusing Poor image permanence with dye colorants
26/04/2007 DELACAMP your global Partner 13 Performance Comparisons (1) Chemical Color Toner Conventional Color Toner
26/04/2007 DELACAMP your global Partner 14 Performance Comparisons (2) Chemical Toner Conventional Toner Zoom up Zoom up Chemical Toner shows Better and Smooth Print Quality Zoom up Zoom up
26/04/2007 DELACAMP your global Partner 15 Performance Comparisons (3) Chemical Toner shows better dot shape = Smooth Half Tone Chemical Toner Zoom up Zoom up Conventional Toner Zoom up Zoom up Chemical Toner shows smooth thin lines DELACAMP your global Partner
26/04/2007 DELACAMP your global Partner 16 Performance Comparisons (4) Transparencies Chemical Toner Conventional Toner
26/04/2007 DELACAMP your global Partner 17 Performance Comparisons (5) Photo Paper Chemical Toner Conventional Toner
26/04/2007 DELACAMP your global Partner 18 Performance Comparisons (6) Pile Height Chemical Toner 2 microns Conventional Toner 7 microns Lower pile height = Less energy to print Higher speeds Longer hardware life Higher image quality No toner feel No paper curl
Performance Comparisons (7) Chemical toner Pulverized toner HP4600 Black Print Example C
26/04/2007 DELACAMP your global Partner 20 Performance Comparisons (8) Percent Fusing - 75 gsm (20lb) Paper 100.0 90.0 80.0 70.0 60.0 50.0 C M Y K Blue Red Gree n
26/04/2007 DELACAMP your global Partner 21 Performance Comparisons (9) Percent Fusing - 160 gsm (60lb) Paper 100.0 90.0 80.0 70.0 60.0 50.0 Percent Fusing - Labels C M Y K Blue Red Green Percent Fusing - Photo Paper 100.0 100.0 90.0 90.0 80.0 80.0 70.0 70.0 60.0 60.0 50.0 C M Y K Blue Red Green 50.0 C M Y K Blue Red Green
Performance Comparisons (10) Cost Savings? 26/04/2007 DELACAMP your global Partner 22
Performance Comparisons (11) Encapsulation Wax and colorant on the inside- shell on the outside Benefits of encapsulation Shell Mechanical strength Thermal stability Good charging properties Thickness can be varied giving different properties Core Wax on the inside gives better flow characteristics Charge is independent of the colorant 26/04/2007 DELACAMP your global Partner 23
Performance Comparisons (12) Encapsulation 26/04/2007 DELACAMP your global Partner 24
26/04/2007 DELACAMP your global Partner 25 Performance Comparisons (13) Toner ID Average ID 1.80 1.60 1.40 1.20 1.00 0.80 0.60 0.40 0.20 0.00 OEM Chemical Conventional C M Y K
Performance Comparisons (14) Toner ID ID vs. Toner Consumption ID 1.5 1.4 1.3 1.2 1.1 1.0 10 12 14 16 18 20 22 Toner Consumption 26/04/2007 DELACAMP your global Partner 26
CHEMICAL TONER IS MORE GREEN! Comparison of the energy & emissions of EA toner & conventional toner 80 Conventional Toner Chemically Prepared Toner 70 60 50 40 30 20 10 0 Solid Waste (hundred kg) Per metric ton of toner produced and used. Source: Ahamadi, A, et al, Life-cycle inventory of toner produced for xerographic processes, J Cleaner Production, 2001 26/04/2007 DELACAMP your global Partner 27
CHEMICAL TONER IS MORE GREEN! 80 70 60 50 40 30 Comparison of the energy & emissions of EA toner & conventional toner Conventional Toner Chemically Prepared Toner 32% Less VOC s! 20 10 0 Solid Waste (hundred kg) VOCs (kg) LGA!!!! Per metric ton of toner produced and used. Source: Ahamadi, A, et al, Life-cycle inventory of toner produced for xerographic processes, J Cleaner Production, 2001 26/04/2007 DELACAMP your global Partner 28
CHEMICAL TONER IS MORE GREEN! 80 70 60 50 40 30 20 Comparison of the energy & emissions of EA toner & conventional toner Conventional Toner Chemically Prepared Toner Some estimates as much as 35% lower CO 2 emissions* 10 0 Solid Waste (hundred kg) VOCs (kg) CO2 (thousand kg) Per metric ton of toner produced and used. * Kiyono, Eiko. EA Process Technology, http://www.fujixerox.co.jp/en g/company/technical/intervi ew/ea/index.html Source: Ahamadi, A, et al, Life-cycle inventory of toner produced for xerographic processes, J Cleaner Production, 2001 26/04/2007 DELACAMP your global Partner 29
CHEMICAL TONER IS MORE GREEN! Comparison of the energy & emissions of EA toner & conventional toner Energy (total) Use (million kj) Fossil Fuel (million kj) Electricity (million kj) CO2 (thousand kg) Nox (kg) SO2 (kg) Chemically Prepared Toner Conventional Toner VOCs (kg) Particulates (kg) Waste w ater (kg) Solid Waste (hundred kg) 0 50 100 150 200 250 300 Per metric ton of toner produced and used. Source: Ahamadi, A, et al, Life-cycle inventory of toner produced for xerographic processes, J Cleaner Production, 2001 26/04/2007 DELACAMP your global Partner 30
26/04/2007 26/04/2007 DELACAMP your global Partner 31 The Future Why the OEMs are turning to CPT In order to print at 600 DPI, the toner size must be about 6-8 microns. To print at 1200 DPI, control of particle size and shape is critical this is virtually impossible with conventional toner. CPT is more consistent consistent particle size and shape equals consistent charging properties. V.O.C.s Fusing Encapsulation permits good fusing at low energy levels
26/04/2007 DELACAMP your global Partner 32 HP OEM Toner S-Toner TM New S-Toner TM Color Sphere TM HP4500 HP4600 HP4700 Release 1998 Release 2002 Release 2005 Speed (C/B) 4/16ppm (4-cycle) Speed (C/B) 17/17ppm (Tandem) Speed (C/B) 31/31ppm (Tandem) HP4500 Toner Analysis W.U. Speed 250sec (Halogen) HP4600 Toner Analysis W.U. Speed 29sec (IH) HP4700 Toner Analysis W.U. Speed 0sec (Ceramic) D50 vol. :7.3um <5 pop. :13% Circularity :0.975 Sp :137deg-C Low Gloss Poor Fixation Low Q/M D50 vol. :6.6um <5 pop. :22% Circularity :0.974 Sp :123deg-C Low Gloss Good Fixation High Q/M D50 vol. :6.9um <5 pop. :22% Circularity :0.978 Sp :119deg-C Middle Gloss Good Fixation High Q/M
26/04/2007 26/04/2007 DELACAMP your global Partner 33 The Future Why the OEMs are turning to CPT In order to print at 600 DPI, the toner size must be about 6-8 microns. To print at 1200 DPI, control of particle size and shape is critical this is virtually impossible with conventional toner. CPT is more consistent consistent particle size and shape equals consistent charging properties. V.O.C.s Fusing Encapsulation permits good fusing at low energy levels Which OEMs use CPT All major LBP OEMs! Monochrome CPT! It s been around for years! The first CPT was made for monochrome! Why the Aftermarket is clinging to Conventional Cost of Technology (like the cost of failure!) Water Treatment Intellectual Property Inertia
26/04/2007 DELACAMP your global Partner 34 So Why Use Chemically Produced Toner? Quality True Cost The Future
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