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Toner manufacture: back to the grind

The advent of chemically produced toners (see "Toner then and toner now") is changing the name of the toner game. But the majority of toners are still manufactured using a melt mixing or hot compounding process. The resins, carbon black, magnetic iron oxides, waxes and charge control agents are blended while molten to form a hot paste the consistency of cake mix. This viscous mixture is then cooled either by slabbing it out, by extruding it onto a cooling belt or by pelletizing it and cooling the pellets. This raw toner is then ground to a powder by jet mills or air-swept hammer mills. These processes produce a wide variety of particle sizes. The over-size and under-size toner particles are sifted out in a 1 to 3 pass process.

The pulverized, sifted toner powder is then blended with additives to adjust flow and electrostatic properties. This final blending is critical and hard to control, especially when the additive particle size is a lot different from the toner particle size.

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