ITDL R&D center is well equipped to deal with the ever-increasing diversity of the requirements & technical complexity of today’s Toner Industry. This involves designing and manufacturing, consistent and reliable compatible Toner Products matching the requirements of the users at a micro level. With a vast experience of over 3 decades, the development Team at ITDL, along with Japanese technical assistance, work hard to develop compatible toners in this dynamic space.

Raw Material Exploration:

With an experienced and well qualified & dedicated team including Chemical Engineers (with a Masters in Chemistry), ITDL explores the most suited raw material from word’s best Raw material manufacturers. Selection is based to match with the changing technological trend in toner for appropriate Speed, Low temperature fixing etc. We work together with the Raw Material Supplier to explore best suited Polymer Resin, Waxes, Pigments, CCA and Additives to prepare toner formulation which is most suited to run on Copiers/ Printers as per user requirements.

Blending Technology

Blending technology involves an accurate choice of the Batch Size , Chopper speed, Blending time , Temperature conditions etc. ITDL uses a PLC Controlled Blender which ensures proper control of these variables. From the Pilot Plant to the main production line, similar Blending Equipment’s of different sizes are available. This ensures an invariable scale up of the Pilot Plant batches to main Production Line. Precise protocols of inspection, monitoring & analysis are utilized to ensure the quality of each batch.

Compounding Technology

ITDL uses precision Twin Screw Extruders for the kneading operation. In order to achieve the best level of dispersion of micro sized particles we select the optimized designing of the Screw configuration, L/D ratio, well-controlled temperature range and precise adjustment of the screw speed. On the regular interval the Kneaded material is taken for the analysis of the dielectric constant & dispersion factor etc. This ensures the level of dispersion of the critical raw materials regularly. This is very important to achieve the consistent print quality throughout the print cycle.

Jet Milling & Classification

After the extrusion, the compounded material is cooled and crushed in small size granulates. These granulates are shifted to the feed container of the jet mill through vacuum conveyor. ITDL uses imported jet mills with precise control on Grinding Air feed, Temperature, Material feed rate, Level in jet mill, Speed of the classifier wheel etc. Desired level of coarse size Particles are selected precisely. In order to archive the desired range of ultra-fine particles we use imported Tandem Classification equipment. Required particle size distribution is achieved by precise control of feed rate, Air volume and quality of air into stream. This is very important property to control the Image background and waste generation during the printing process.

Toner Surface Coating

Fine classified particles with required Particle Size distribution are taken for the additive coating process. PLC controlled high speed blending system is used along with the precision Loss in weight Feeder for the addition of Additives. Optimized selection of Tool design, speed, temperature control and batch size ensures the best level of coating of the Additives on the Toner particles. This is very important to achieve the desired level of Flow, Tribo , Hydrophobicity etc. This ensures proper Flow characteristics, reduce sensitivity to relative humidity, easy cleaning of the photoreceptor drum , elimination of back ground problem ,etc. while printing process .

Analytical Expertise

ITDL R&D lab is well equipped with the latest version analytical instruments like Multisizer MS3, Tribo tester by blow off method, Tribo Tester while printing process, Flux meter, Densitometer, Melt flow indexer, DSC, TGA, Powder flow tester, Fusing characteristic, DC resistivity. Apart from that to comply the stringent environment regulations, ITDL ensures to use the desired Raw Materials within usage limits, well under the regulatory norms. ITDL also tests its products in different humidity and temperature conditions in its temperature-controlled humidity chamber.

R&D