colour toner - conventional or chemical · confidential 26/04/2007 delacamp your global partner 3...
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Confidential
Colour Toner -Conventional or Chemical
The Practical Issues
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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?
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ResinToner matrix
50-90%
~ 10 μm
Anatomy of a Toner Particle(Conventional)
• Internal Structure
PigmentColorant
Magnetic property5-50%
WaxFusing<10% Charge control agent
<2%
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Anatomy of a Toner Particle(Conventional)
• External Additives
~ 10 μm
SilicaFlow aid
Tribo-chargingStorage stability
Second additive(polishing agent)
Third additive (lubricant)
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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
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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
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Chemical Manufacturing Methods (1)
• Emulsion Aggregation
– Coagulation
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Anatomy of a Toner Particle(Chemically Produced)
ColorantCoagulation Aging
AdditiveEmulsifiedPolymer
with Wax
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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
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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
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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
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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
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Performance Comparisons (1)
Chemical Color Toner
Conventional Color Toner
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Performance Comparisons (2)
Zoom up Zoom up
Zoom up Zoom up
Chemical Toner shows Better and Smooth Print Quality
Chemical Toner shows Better and Smooth Print Quality
Chemical Chemical TonerToner
Conventional Conventional TonerToner
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Performance Comparisons (3)
Zoom up Zoom up
Zoom up Zoom up
Chemical Toner shows smooth
thin lines
Chemical Toner shows smooth
thin lines
Chemical Toner shows better dot
shape=
Smooth Half Tone
Chemical Toner shows better dot
shape=
Smooth Half Tone
Chemical TonerChemical Toner Conventional TonerConventional Toner
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Performance Comparisons (4)
Conventional TonerChemical Toner
• Transparencies
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Performance Comparisons (5)
Conventional TonerChemical Toner
• Photo Paper
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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
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Chemical toner Pulverized tonerHP4600 Black Print Example
Performance Comparisons (7)
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Performance Comparisons (8)
50.0
60.0
70.0
80.0
90.0
100.0
C M Y K Blue Red Green
Percent Fusing - 75 gsm (20lb) Paper
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Performance Comparisons (9)
50.0
60.0
70.0
80.0
90.0
100.0
C M Y K Blue Red Green
Percent Fusing - 160 gsm (60lb) Paper
50.0
60.0
70.0
80.0
90.0
100.0
C M Y K Blue Red Green
Percent Fusing - Labels
50.0
60.0
70.0
80.0
90.0
100.0
C M Y K Blue Red Green
Percent Fusing - Photo Paper
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Performance Comparisons (10)Cost Savings?
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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
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Performance Comparisons (12)Encapsulation
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Performance Comparisons (13)Toner ID
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
1.60
1.80
C M Y K
Average ID
OEM
Chemical
Conventional
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ID vs. Toner Consumption
1.01.11.21.31.41.5
10 12 14 16 18 20 22
Toner Consumption
ID
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Performance Comparisons (14)Toner ID
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CHEMICAL TONER IS MORE GREEN!
0
10
20
30
40
50
60
70
80
Solid Waste (hundred kg)
Comparison of the energy & emissions of EA toner & conventional toner
Conventional TonerChemically Prepared Toner
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
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CHEMICAL TONER IS MORE GREEN!
0
10
20
30
40
50
60
70
80
Solid Waste (hundred kg) VOCs (kg)
Comparison of the energy & emissions of EA toner & conventional toner
Conventional TonerChemically Prepared Toner
32% Less
VOC’s!
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
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CHEMICAL TONER IS MORE GREEN!
0
10
20
30
40
50
60
70
80
Solid Waste (hundredkg)
VOCs (kg) CO2 (thousand kg)
Comparison of the energy & emissions of EA toner & conventional toner
Conventional TonerChemically Prepared Toner
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
Some estimates as much as 35%
lower CO2 emissions*
* Kiyono, Eiko. EA Process Technology,
http://www.fujixerox.co.jp/eng/company/technical/intervi
ew/ea/index.html
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CHEMICAL TONER IS MORE GREEN!
Source: Ahamadi, A, et al, Life-cycle inventory of toner produced for xerographic processes, J Cleaner Production, 2001
Per metric ton of toner produced and used.0 50 100 150 200 250 300
Solid Waste (hundred kg)
Waste w ater (kg)
Particulates (kg)
VOCs (kg)
SO2 (kg)
Nox (kg)
CO2 (thousand kg)
Electricity (million kJ)
Fossil Fuel (million kJ)
Energy (total) Use (million kJ)
Chemically Prepared Toner
Conventional Toner
Comparison of the energy & emissions of EA toner & conventional toner
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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
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HP OEM TonerHP OEM Toner
S-TonerTM New S-TonerTM
HP4500
Release 1998
Speed (C/B)4/16ppm
(4-cycle)
W.U. Speed250sec(Halogen)
HP4500 TonerAnalysis
D50 vol. :7.3um<5 pop. :13%Circularity :0.975Sp :137deg-C
Low GlossPoor FixationLow Q/M
Color SphereTM
HP4600
Release 2002
Speed (C/B)17/17ppm
(Tandem)
W.U. Speed29sec(IH)
HP4700
Release 2005
Speed (C/B)31/31ppm
(Tandem)
W.U. Speed0sec(Ceramic)
HP4700 TonerAnalysis
D50 vol. :6.9um<5 pop. :22%Circularity :0.978Sp :119deg-C
Middle GlossGood FixationHigh Q/M
HP4600 TonerAnalysis
D50 vol. :6.6um<5 pop. :22%Circularity :0.974Sp :123deg-C
Low GlossGood FixationHigh Q/M
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The Future
• 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
• 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
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So Why Use Chemically Produced Toner?
• Quality• True Cost• The Future
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QUESTIONSAND
ANSWERS