TONER COMPOUNDING

Toner Compounding 

Compounding of toner with the twin-scew compounder POEX: Economical operation. Maximum efficiency. No dead spots.

The toner formulation, consisting of resins, pigments, and additives, is processed in a blender to produce a premix. It may contain fines that must be reprocessed.

This premix is fed continuously to the twin-screw compounder (POEX) via a metering device. The premix is added to the feed barrel

(barrel no. 1) via a chute. 

The co-rotating, closely intermeshing screws of the POEX twin-screw compounder convey and then compress the product in order to melt or plasticize it with the kneading elements in the plastification zone (barrels 2-3). During and after the plastification process, the individual components of the formulation are dispersed, mixed, and homogenized. To help in this task the screw rpm of the POEX twin-screw compounder is adjustable. The throughput depends on the product quality, the feed behavior of the product, and the drive capacity of the POEX twin-screw compounder. Another important criterion is the amount of fines to be processed and their grain structure. The throughput has to be matched to the corresponding values.

 

Barrel no. 4 has a vent port whose function is designed specifically for the processing of fines. The vent in barrel no. 7 is used depending on the formulation. It is possible to close the barrel or to devolatilize at atmospheric pressure or under vacuum. 

The compounded melt is discharged vertically downwards at atmospheric pressure, through a die in the last barrel. The product is cooled and pre-pelletized in a cooling device as preparation for the subsequent grinding.

Plant for the production of toner


1 Volumetric feeder 
2 Extruder
3 Compact cooling 
4 Pre-grinding
Toner Compounding

DURABILITY

1- Durability of light: Especially express the durability of ultraviolet beam. 
2- Durability of heat: It is very important of resisting abnormal heat of pigments after applied on material.(Like tin print)
3- Durability of soap - alkaline , chemical materials such as acid: Especially important for pack industries.
4- Durability of solvents: Volatile solvents are considered. Materials which composite of the ethyl alcohol causes solving. Water is also solvent and volatile. Varnish and lac are not considered solvents. Qualification of coverage and setting this coverage of ink are pigments. 

BINDING AGENTS: Resin, oil etc.

a- Defines the brightness of ink. 
b- Enhances chemical strength. 
c- Fixing pigment motes to print materials.

SOLVENTS

It gives flowing ability to pigments and binding agents to press press materials related to press machines's specilities. It is usage for solve resins generally.During the process of solvent drying resin film occurs on the press material as a result of vaporizing or suction depends on the type of ink. This film contains pigment motes as scattered.

AID SUBSTANCES

Substances like dryers, thinners etc. It does not change qualifications of ink's color nuance etc. It adjusts other qualifications.

DRYERS

Mürekkebin uygun bir zamanda sertleşmesini temin etmek için bağlayıcının kuruma zamanını hızlandırmak için kullanılır.

THINNERS

It is used for pluck durability and increasing pressure level of ink.

LINSEED OIL AND VARNISH

Linseed oil is pulled out from linen seeds. Result of boiling varnish creates linseed oil. There three types of varnish subtrahend from linen seeds. Thin, medium and thick. These varnishes mixed with elementary substances.Varnishes obtain in three ways: 
a- Linen seeds (Linseed oil)
b- Petroleum (Resin, solvent varnishes)
c- Some tree's oil (Deodar tree oil) Two important points carries out mixing varnish with its elementary substance.
- Material that mixes with its elementary substance well on the paper. 
- Drying sensitivity occurs when it contacts with air. With press machines, applications are made with various type of thickness using press inks. Thinnest ink in offset press, thickest ink in screen printing applications. Inks should be formulized by considering machine speed, which is suitable for press process. Inks are in different situation in order to subject of print in printing press industry.Points of inks can vary about their usage but not their manufacture process.

ACCORDING TO PRESS TECHNIQUES

A) INKS

Two types of ink 
1-Black ink
2-Colored ink

Black ink 

Core part : Combustion of oil and coal gas used for core part. It is used for manufacturing of high quality ink.
Oil black: It is made of fish oil, tar oil, some vegetal oil and bestial oil. This mixture boils in special made boiler which is closed for one side and release the air from other side. This boiling procedure creates sooth and it goes out from other side of the boiler. This sooth parts are collected and used for elementary substances. Because of high level of coverage ability this product is not used in automotive industry. This sooth mixed with varnish and becomes end product.

Colored Inks: Two types

1- Coverage Inks 
2- Transparent Inks

Coverage Inks:  High quality and low quality types are available. All colors of coverage inks are used in press works such as pictures, books, brochure wall poster. The essence of this ink is soil paints. Coverage paint is not affected by previous pressed color.
Transparent Inks: Called Trikromi. It is high quality ink with usage of colored press paints. Paints are affected each other by pressing upon previous color. Different type of color tones obtained with different result of effect.

B) AID SUBSTANCES

Because of large application field of printing press ink people use different aid substances. Pressman always need to consider humidity and heat, and material that he/she used in printing. In this occasion it is important to decide which aid is used as well as how much it sholud be used. Ink can react badly to unsuitable aids. It causes time and quality. Ink factories manufactures aid substances which is suitable for their inks. It is very important to remember that using suitable aid components are obligatory for using the ink. Physical and chemical properties should be changed but color must not changed after the process. It is very important to adjust additive percentage. If additives are too much in the mixture, ink becomes slurry and get thinner; it becomes useless except ground press. As it mentioned before this explains low viscosity and low stickiness. Pressman must be very careful about adding additives, it should me measured with scales. Habit is not a constitute of measuring. Additives makes press issues easier and harder at the same time.

TONER COMPOUNDING - POLİMER TEKNİK Mak. Müh.San. ve Tic Ltd. Şti.
polimer teknik
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