Powder Processing Toner Industry

8/20/2019 Powder Processing Toner Industry

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POWDERAND

PARTICLEPROCESSING

P O W D E R A N D P A R T I C L E P R O C E S S I N G

Fo r t h e To n e r I n d u s t r y

PROCESS TECHNOLOGIES FOR TOMORROWSM

ALPINE® BEPEX® MICRON® STOTT® VRIECO-NAUTA®

The Hosokaw a Micron Group will alwa ys be the lea-

ding g lobal company cover ing t he mult i-faceted r an-

ge of po wd er technologies. The group w ill achieve

peaks of excellence in the development and commer-

cialisation of advanced materials, process equipment

and systems engineering.

© Hosokaw a Alpine 2002. Printed in Germa ny. Subject

to modifications without prior notice. All details in

this brochure are purely informative and non-binding.

Author i tat ive for ac tual orders are our quotat ions .

T o n e r 0 4 . 0

2 / 1 e


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PROCESS TECHNOLOGIES FOR TOMORROWSM 2 /3

P O W D E R A N D P A R T I C L E P R O C E S S I N G

F O R T H E T O N E R I N D U S T R Y

O N E O F O U R C O R E B U S I N ES S E S

WE ARE YOUR COMPETENT PARTNER

TRAINED PERSONNEL PROVIDEOUR CUSTOMERS WITH

COMP ETENTADVICE IN ALLOUR BUSINESS SECTORS.

The HOSOKAWA MICRON GROUP's broad ra nge

of pow der and pa rticle processing capabilities

includes equipment and technologies for a

variety of applications including:

- Agglomerat ion /Granulat ion

- Compaction /Low-Pressure Extrusion

- Size Reduction /Micronisation

- Mixing /Powder Blending

- Screening /Air Classification

- Drying /Vacuum Drying

- Product Collection /Containmen t

- Hygenic Filling and Weighing

- Bulk Packaging

- Toll Processing

It is the strate gic objective of the Hosokaw a Micron Group to exten d its leadership into

future ma rkets with high-technology products, to provide economic technical solutions

and to ensure customer satisfaction.

HOSOKAWA MICRON places a strong emphasis on research and developmen t. Major tech-

n ical cen tres are located a round the w or ld . They are equipped and operated for the dual

purpose of conducting original research work and demonstrating various processing

systems. For our customers, the technical centres are used to develop and test formula-

tions to meet their specific needs for powder and particle processing applications.

HOSOKAWA MICRON GROUP The HOSOKAWA MICRON GROUPis an international provider of equipment

and systems serving a broad range of industries which includes chemical,

minerals, pharmaceutical, polymer, food, blown film processing,

confectionery and bakery, and specialised food.

Since the advent of modern office equipment such as printers and

photocopiers, we have focused our efforts on the processing of toner

powder. And during the process, we have not just been an onlooker,

but rather have been instrumental together with our customers

in setting milestones.

DELIVERED SYSTEMS

Toner manuf acturers around the w orld

operate processing systems which make

use of HOSOKAWA ALPINE's grind ing a nd

classifying syst ems. To da te, HOSOKAWA

has supplied o ver 200 processing systems

to leading t oner manuf acturers. The pro-

duct range covers small test or laboratory

systems just as it does large production-

scale systems, with the throughp ut rates

ranging up to 500 kg/h.

Our cus tomers know that we a lways make

use o f on ly the very bes t and lates t techno-

logy, especially with respect to a chieving

top q ual i ty at the low es t possib le capital

outlay a nd opera ting costs. This is what

has made us so successful in the past

and is simultaneously our challenge for

the future .

In spi te o f the fac t tha t toner sys tems al l

basically operate in the same way, it is the

detai ls wh ich make the d i f ference and

which we tailor to suit the customers' indi-

vidual requirements.

SAFETY FIRST

This is not something that the HOSOKAWA

Group just pays lip service to, but rather a

commitment to our customers to supply

safe equipment and systems. Explosion

protection is an issue which takes top prio-

r i ty dur ing the des ign and manufacture o f

our toner systems. HOSOKAWA specialises

in complete toner systems – from the

des ign and manufa cture to the ins tal la t ion ,

main tenance and service . And w hat t h is

means for our customers is:

EVERYTHING FROMONE SINGLE

RESPONSIBLE SOURCE.


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POWDERAND

PARTICLEPROCESSING

Off-line or in-line is a q uestion

of the philosophy:

OFF-LINE PRO CESS:- maximum f lexibility

- modest overall height

- simple opt imisation

IN-LINE PROCESS:

- automatic mode

- reduced container handling

- less space req uirement

The follow ing description concentrates on

an of f-line process, because this is wha t

most of our customers prefer. In off-line

mode, the material is filled into containers

aft er every process step, which then serve as

feed bins for the next process step. Some

system components can be cleaned or main-

tained w hi le o ther components are in use .

Each process step can be individually opti-mised.

Hosokawa has been supplying toner sys-

tems in a great var ie ty o f d i f feren t des igns

to every renowned toner manufacturer

around the w orld for over 20 years. The

actual process can be broken dow n in to the

fo l lowing s teps:

Preliminary mixing, extrusion, cooling:

The individual component s are prepared,

weighed and then filled into a high-speed

preliminary mixer. The pre-mixed raw ma-

terials are metered t o an extruder. The pasty

toner mass is discharged from the extruder

into a cooling unit (e.g. chill roll, meta l cool-

ing conveyor, etc.). At the e nd of t he cooling

section, a flake b reaker pre-crushes the coo-led toner mass to the size of chips.

PRELIMINARY GRIND ING OF THE CHIPS:

Dependent on the gr indabi l i ty and the

wear behaviour o f the mater ial , the fo l low-

ing Hosokawa mills can be used:

- Rotoplex granulator

- Fine impact mill UPZ

- Sieving mill

Preground to granules, the material is col-

lected in a cyclone or filter and then filled

into containers.

CLASSIFICATION:

The classifier can either be f ed from a con-

tainer or from the cyclone of the fine grin-ding step. The problem specification d ictates

which of the two specially developed toner

classifiers, i.e. TSP or TTSP, is employe d. A

specially designed f lap valve serves as the air

seal for the coarse mate rial discharge. The

fines are collected either in a cyclone or a f il-

ter. The adva ntag e of off-line mode is that

the classifier can be operated and optimised

independent of the mill.

ADDITIVES:

In order to improve the f low beha viour and

to influence the surface properties, the

FINE GRINDING:

A vibrating table empties the preground

granules out o f the cont ainer. The toner isnow metered via a var iable-speed meter ing

uni t and a double f lap valve to the opposed

jet mill TFG. Dependent on the g rindability

o f the d i f feren t toner types , e i ther Laval or

particularly efficient Mega-Jet nozzles are

employed. The level of mate rial in the mill

is monitored and regulated by load cells. If

necessary, the speed of the metering unit is

adjusted accordingly. The ground ma terial

is conveyed fur ther to a cyclone and t hen

either discharged into a container or direct

into the downstream classifier.


PRELIMINARY MIXING,

EXTRUSION, COOLING

FINEGRINDING ADDITIVES, SAFETY SCREENINGCLASSIFICATIONPRELIMINARY MILLING,

toner is coated w ith different ad ditives. The

container wi th the coarse mater ial from theclassifier then becomes the feed bin. Both

toner and a ddi t ives are metered by gravi ty

into a high-speed fluid mixer, after which

the blended material is either refilled into a

container or fed to a screening machine via

an in termediate b in .

SAFETY SCREENING :

Any flakes still remaining in th e product a re

screened out here. In most cases, a tumbler

screen ing mach ine w i th a screen mesh

widt h of 125 µm is used. The coarse ma teri-

al is waste and the fine material is the finis-

hed toner, which is filled via airtight devices

into containers or drums positioned on

floor scales.

EXPLOSION PROTECTION:

Toner is a mat erial which is prone to du st

explosions. Because of this, special safety

measures must be taken. The follow ing con-

cepts are in use:

- Pressure venting

- Explosion suppression

- Pressure-shock-proof design to 10 b ar

overpressure

SINGLE MACHINES AND TURNKEY PLANTS


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PARTICLEPROCESSING


PRELIMINARY CRUSHING

PROCESS TECHNOLOGIES FOR TOMORROW®

PRELIMINARY MIXING, EXTRUSION, COOLING

HOSOKAWA ALPINE GRANULATOR

TYPE 28/40 ROTOPLEX

- For toner w hich is toug h and resilient

but no t abras ive

- Extremely sma ll fines portion

due to the particularly gentle size

reduct ion method

- Special designs available for direct

tr ans fer o f mat er ial from the cool ing

conveyor which permit a compact

system set-up

HOSOKAWA BEPEX

SIEVING MILL TYPE FC

- Low -speed g rinding system for types of

toner which are easy to grind

- Pressure-shock-proof de sign not necessary

- Extremely small f ines portion

- No additional venting via cyclone

or filter necessary

- Compact design

- Simple integration into process sequence

HOSOKAWA ALPINE

FINE IMPACTMILL TYPE 315 UPZ

- For ab rasive toner w hich is

difficult to grind

- Minimum fine dust generation

- Pneumatic product feed and discharge

The machines used for the preliminary crushing step are selected as a

function of the toner quality. Regardless of w hether the toner

is tough and resilient, brittle, or has abrasive properties –

HOSOKAWA HAS THE RIGHT SOLUTION!

- Design: pressure-shock-proof

to 10 bar overpressure

- Tang ential ma terial discharge

- Grinding media: swing b eate r unit

with short grinding t rack and 2-mm

sieve insert

- Reduced-speed m ode

- Drive motor: 7.5 kW

- Throu ghp ut ra nge : 100-300 kg/h

- Design: not pressure-shock-proof

- Grinding media: cross-scissor-cut rotor

and 2-mm screen

- Reduced-speed mo de


- Throug hput ra nge : 100-300 kg/h

- Design: no t pressure-shock-proof

- Grinding media: rotor with sieve grate

and 2-mm sieve


- Throu ghp ut ra nge : 100-300 kg/h

PRELIMINARY MIXING

The different t oner raw mat erials such as resin, pigments, and a ddi-

tives, etc. a re mixed in high-speed mixers, e.g. Cyclomix. The

demands made o n the mixers are many and var ied :

- Easy to clean

- Double-walled mixing vessel to permit cooling if necessary

- Simple filling of the different raw materials into the mixer

- Mixer must be simple to completely empty

after the mixing process

- High peripheral speeds of the mixing media for

shor t mixing t imes and g ood blending

- Product-conta ct surfaces polished to Ra 0.8 µm for simple cleaning

- Pressure-shock-proof design to 10 bar overpressure

- Pole-reversible or frequency-regulated motor

- Wear-protected mixing media

FINE IMPACTMILLTYP 315 UP Z

GRANULATORTYPE 2 8/40 RO TOP LEX

SIEVING MILL TYPE FC

EXTRUSION

A feeding unit feeds this premix continuously into the feed barrel

of a compounde r such as the Werner &Pfleiderer ZSK tw in-screw

compounder.

The product is draw n in by the closely intermeshing co-rotating

screws of the ZSK, conveyed downstream and then compressed.

Kneading elements in the plasticising zone serve to melt the pro-

duct. During and after plastification, the individual components are

dispersed, compounded a nd homo genised. To this end, the ZSK

screw speeds are var iable , ranging betw een n = 200 rpm for normal

production a nd 900 rpm. The corresponding tem peratures in the

processing section lie betw een 60°C and 180°C. The throug hput rat e

depends on the product qual i ty, the product feed behaviour and

the drive power of the ZSK.

COOLING

The product is cooled in a cooling unit a nd then coa rsely crushed

before being ground.

WERNER &PFLEIDERERZSK TWIN-SCREW

COMPOUNDER


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PARTICLEPROCESSING


FINE GRINDING

MORE ADVANTAGES OF THE TFG:

- No need to reset the ga p when changing

the classifying wheel

- Min imum dow ntime, easy open ing wi th

hydraulic opening mechanism

- The centra l screw makes it e asy to

exchange the inside components

- Simplified handling and maintenance

MACHINE DESIGN OP TIONS:

- Systems in pressure-shock-proof design t o

10 bar o verpressure

- Mild steel

- Stainless steel

- To ord er, surfaces polished to Ra=0.8 µm

- Product feed either by gravity or

pneumatic

- Mega-Jet or Laval nozzles, dependent on

the gr indabi l ity o f the toner

- Wear-protected (ha rd-metal-coated)

classifying wheel

The special advanta ges of this new mill generat ion are the ease of ha ndling, the accessibi-

lity and easy cleaning. System users are enthusiastic about the high degree of flexibility of

the TFG, especially when coloured toners are be ing processed and th e colour needs to be

changed f requent ly. The typical feed size of the raw mat erial – normally preground

chips from the extrude r – is approx. < 1–2 mm. The TFG can be fed either by g ravity or

pneumatically.

AFG OPPOSED JETM ILL

To round the prod uct line off, the range

also includes the time-tested and proven

Alpine opp osed jet m ill AFG. This ensures

that even i f the throughput requirements

Systematic refinement of the Alpine® jet milling technology led to

development of the TFG opposed jet mill. The TFG jet mill was designed

especially for fine grinding toner. A steep particle size distribution with clean-cut

top size particles and a low fines portion characterise the TFG.

- Filling level control b y mea ns of loa d cells

thus opt imum throughput r ate and

constan t product qual i ty

- End product free from spatter grain

- Low -wear grinding

- Low energy consumption compared w ith

other jet mills

- ALPINE Mega -Jet nozzles f or

cost-effective operation

U s e o f t h e p a t e n t e d Me g a - J e t n o z z l e s

results in a great er jet surface and a llows a

h igher feed r ate , mean ing that up to 20%

higher throughput rates are possible at

simultaneously drastically reduced specific

energy consumption rates.

0

10

20

30

40

50

60

70

Mega-JetLaval

kg /h

TFG OPP OSED JET MILL

OPPOSED JETMILLTYPE 200 AFG

IN MONOBLOCDESIGN

COMPARISON OF NOZZLES

TFG COM PLETELYOPEN

TFG HALF OPEN

LARGE OPENING FORCLEANING ANDMAINTENANCE

TONER FLUIDISED BEDOPP OSED J ETM ILL TYPE 800 TFG

TFGCLASSIFYINGWHEEL

Difficult to grind

Limited grindability

Easy to grind

TFG Toner Fluidised Bed Opposed Jet Mill Type 400 630 800 1000

Sca le-up f a ct or f 1.0 2.5 4.0 6.4

Mo t or pow er kW 7.5 18.5 30 45

Grind ing a ir Nm3/h 1150 2850 4550 7200

AFG Fluidized Bed Opposed Jet Mill Type 100 140 200 280

Sca le-up f a ct or f 0.06 0.15 0.25 0.6

Mo t or pow er kW 1 2.2 4 5.5

Grind ing a ir Nm3/h 60 170 300 600

OPPOSED JETMILLTYPE 100 AFG

are low, the unique processing

advan tag es o f the Alpine® jet

milling technology can be

exploited to the full.


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POWDERAND

PARTICLEPROCESSING

1,80

1,20

1,00

0,80

0,60

0,40

0,20

0

[numberchannel]

1 10 100[µm]

1,40

1,60

1400

1200

1000

800

600

400

200

0

[numberchannel]

1 10 100[µm]


CLASSIFYING

The de sign of t he TTSP classifier diff ers from

conventional classifier types in the follow-

ing points:

- Two-stag e classification in one m achine

- Product feed option: either pneumatic or

by gravi ty

- Separat e classifying stage s with

independent drives

- Hydraulic opening mechanism permits

easy open ing and mach ine c lean ing, thus- min imum dow ntime when changing over

to a d i f feren t co lour

In order to meet the rising market demands, ALPINE ® has systematically

refined its already very successful classifying technology. The result is

something to be proud of. The ALPINE ® Tandem Toner Classifier TTSP puts

a completely new slant on classifying technology.

DESIG N VARIANTS:

TTSP / TSP

- Pressure-shock-proof design

to 10 bar overpressure

- Mild steel

- Stainless steel

- Small classifiers in mono bloc design

- To o rder, product-contact surfaces

polished to Ra 0.8 µm

- Wear-protected (ha rd-metal-coated)

classifying wheel

PRINCIPLE OF OPERATIONTANDEM TONERCLASSIFIER TTSP

SIMPLE TO CLEAN200 TTSP OPEN

To complete t he product line a nd for simple

problem specifications:

TSP toner classifier w ith one classifying

s tage and o ne dr ive .

TTSP Classifier Type 200 250 315 400 500

Sca le-up f a ct or f 0.4 0.6 1 1.6 2.5

Mo t or pow er 2 x kW 3 5.5 7.5 11 18.5

Air f lo w ra t e Nm3/h 1120 1800 2800 4600 7200

Feed ra t e kg /h 170 270 420 690 1080

TANDEM TONERCLASSIFIER TYPE 200 TTSP

STEEPER PARTICLE SIZE DISTRIBUTION,LESS FINES IN THE END PRODUCT

PRINCIPLE OF OPERATION

TONER CLASSIFIER TSP

SIMPLE TO CLEAN

TONER CLASSIFIER TSP

DISTINCTLY BETTER PRODUCTQUALITY, HARDLY ANY LOSS OF

COARSE MATERIAL.

- Good a ccessibility and q uick classifying

wheel change

- Compact design

- Conversion to one-stage classifying if

demanded by the appl icat ion

The process ing-technological a dvan tag es

are obvious and convincing:

- High coarse material yield

- Excellent product quality brought aboutby steep particle size distribution and low

por t ion o f f ines

- Low pressure drop, thus use of conven-

tional fans possible

- High feed rates, thus sma ll units possible

TSP Classifier Type 200 250 315 400 500

Sca le-up f a ct or f 0.4 0.6 1 1.6 2.5

Mo t or pow er kW 3 5.5 7.5 11 18.5

Air f lo w ra t e Nm3/h 560 900 1400 2300 3600

Feed ra t e kg /h 60 90 140 230 360

The abo ve-mentioned adva n tages rega r-

ding handl ing and c lean ing also apply in

essence to t he TSP classifiers.

- Finer separations possible compared w ith

conventiona l high-efficiency classifiers

- Low e nergy req uirement, thus possible to

process toner, e.g. coloured toner, with a

low mel t ing poin t

- Fine/coarse classification, th us three frac-

tions in one process step, or fine/fine

classification, t hus extremely low f ines

portion in coarse material

Tan dem Tone r Classifie r TTSP

Tone r Cla ssifier TSP

TFG / AFG

1st classifying stage : 86.5% yield

2nd classifying stag e: 85.5% yield


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PARTICLEPROCESSING


MIXING | BLENDING | SAFETY SCREENING

THE CYCLOMIX

HIG H-INTENSITY MIXER:

The new Cyclomix is a hig h-intensity mixer

that combines shear ing ac t ion wi th t he pro-

ven advan tages o f an impact mixer . I t has

been designed specifically for post-additive

blending in toner systems.

Its conical design in combination with padd-

les rotating at high speed creates intense

shear forces and rapid hom ogen isation. The

shear force is ideal for evenly distributing

charge con tro l agen ts and s i l ica on to thetoner particle. The ent ire vessel is jacketed

so heating or cooling can be precisely con-

tro l led r igh t at the heat t r ans fer area.

Discharging the finished product is simple

thanks to the mixer's conical shape.

Product chang e with the Cyclomix is made

easy by virtue of its extremely accessible

design. Quick-release clamps are located on

both the cover and discharge valve. Once

the clamps are removed, the entire cover

wi th ro tor can be l i f ted hydraul ical ly at the

push o f a but ton .

FLEXIBILITY

The Cyclomix can be supplied with highpolishing qua lities such as 220 grit and elec-

tropolished fo r even ea sier cleaning. The

cover as seen on the 50 L Cyclomix lifts

upwards to open. For larger sizes, the cover

can be mounted a t f loor level and the ves-

sel lowered ont o it hydraulically.

KEY FEATURES

- 1-litre labo ratory mixer to 2000-litresproduction mixer

- Exceptional heating and cooling

capabilities

- Perfect discharge of material

- Hydraulic opening mechanism

- Bearings in top cover have no contact with

the product

- High-shear rotor with the added knife

blade opt ion for impact a c t ion

The product is filled from the t op into t he

conical mixing vessel and the main motor

drives the high-speed rot or. The shaf t is

equipped with blade-shaped mixing ele-

ments wh ich rotate close to the inside vesselwall. Due to this and the conical design, the

bulk mater ial i s t ranspor ted from bot tom to

top. In the upper zone there is an inwa rds

and dow nwards movement which leads to

quick macromixing. The moving blades

accelerate the particles which are thorough-ly mixed through fr ic t ion at the tank wal l

(micromixing ).

SAFETY SCREENING

Downstream of the mixer , the f in ished

toner is fed to a protective screening machi-

ne such as the Allgaier TSM screen with

ultrasonic cleaning device. This ensures that

the toner w hich comes on to the market is

free from any lumps which could possibly

form dur ing the pneumatic t r anspor t .

To ensure a high deg ree of qua lity at simul-taneously high screening efficiency even

with th e finest mesh widths, Allgaier equips

its TSM screening machines with an ultra so-

nic system. By introducing a high-frequency

vibration into the screen fabric, friction and

adhes ion forces in the product mat are

overcome, thus resulting in trouble-free

screening. Sound propagation across the

entire screen surface ensures that no pro-

duct remains to clog the screen fabric, even

with extrem ely large-surface screens.

The mixer is fed via special weighb elt fee-

ders. Generally speaking, there are three

feed un i ts , one for toner and one each for

the a dditives. The met ering precision –

especially of the additives – sets extremely

high demands because it is usually only a

few grams which need to be added.

In the mixer, the toner particles are coated

with the addi t ives according to a f ixedsequence in order to achieve the desired

properties. The most impo rtant criteria here

are the mixer size, the design of the mixing

elements, the speed, the mixing time, and

the batch temperature .

WORKINGPRINCIPLECYCLOMIX

Together with our sistercompany HOSOKAWA MICRON BV, we supply

mixing solutions which are convincing both in terms oftechnology and economy.

ALLGAIER TSM SCREEN

WITH ULTRASONICCLEANING DEVICE

Cyclomix model 1 5 50 150 250 500 1000 2000

Mo t or pow er [kW] 1.1 3-5.5 15-30 22-55 37-75 55-110 110-220 160-310

Pro duct vo lume [l] 0.3-1 1.5-5 15-50 45-150 75-250 150-500 300-1000 600-2000


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ACCESSORIES

CYCLONE

The ALPINE® High-Efficien cy Cyclone is cha-

racterised by an extremely high collection

rate at low pressure drop.

FEATURES:

- High collection rate up to 99%

- Finish-turned f lange w ith no g aps, O-ring

- Hydraulic opening mechanism for quick

and t horough c lean ing

- Excellent surface finish polished

to Ra = 0.8 µm

- Graduated product l ine to accommodatethe respective air flow rat es

- Design o ptions: mild or sta inless steel

- Explosion-pressure-shock-proof design to

10 bar overpressure or pressureless

AIR JETSIEVE

Analys is s ieving ma ch ine wi th m odern

equipment for extremely accurate, reprodu-

cible sieving analyses in the laboratory.

LABORATORY CLASSIFIER 100 MZR

Simple in operation, this laboratory classi-

fier is characterised by a high precision of

cut for h igh qua l i ty demands in the f ie ld o f

particle ana lysis.

FEATURES:

- Separating ra nge d97 = 2 – 80 µm

- Suitable for materials up to Mohs'

hardness 5

- Throughpu t: ba tches from ap prox. 50 g

- Max. feed rate approx. 2 – 6 kg/h

(batch mode)- Simple to clean

FEATURES:

The extraord inarily good dispersion of the

product brought about by the nozzle je t

permits ana lysis down to 10 µm with micro-

precision sieves.

- Analysis rang e

20 µm to approx. 4000 µm

with 203-mm diamet er ana lysis sieves.

10 µm to 30 µm

with 75-mm diameter micro-

precision sieves.

- Fully automatic sieve identification

CYCLONE

AIR JETSIEVE

LABORATORY CLASSIFIER 100 MZR

INSITEC ON-LINEPARTICLE ANALYSIS

CONTAINMENT LEVEL 2(100 - 500 µg/m 3)

CONTAINMENT LEVEL1(500 - 1000 µg/m3)

ON-LINE PARTICLE ANALYSIS WITH

INSITEC ANALYSIS SYSTEM

Fully automatic optical analysis system for

particle size and particle concentration ana-

lyses for dry pow ders

FEATURES:

- Analysis principle: laser diffra ction.

- Partial-flow sampling from the main

product stream using a bypass.

- No longer necessary: time-consuming

sampling , sample tr ans fer to t he labo-

ratory and dow nstream handl ing .- Also suitable for automatic fineness

control using a continuous signal as the

control parameter.

- Encapsulation provides dust and splash-

wa ter pro tect ion .

- Product-conta ct part s in stainless steel.

STOTT® FILLING AND

WEIGHING SYSTEMS

In view of the varying requirements for pro-

duct iso lat ion and operator pro tect ion ,

Hosokawa Micron UK has developed a

range o f eq uipment and in tegrated sys tem

options to meet the con tainment cr i ter ia

demanded b y the toner indus try.

Accurate w eight-controlled filling systems

des igned and manufactured to main tain

the h ighes t s tandards o f hygiene, dus t con-

trol and product integrity.

Laminar Flow Booths

A controlled, once-through non-turbulent

air f low ensures good operator pro tect ion

from dus t and f umes .

PROCESS CONTROL SYSTEMS

Thanks to the ad vances made in the field of

electronics, it has been possible to continu-

ously refine the complex cont rol units supp-

lied for the to ner systems. Toda y, we predo-

minantly use switch cabinets and control

systems with visualisation options. Processs teps , f lowchar ts and ac tual values are

displayed clearly on PLCs, and the operating

s tatus can be moni tored and retr ieved at

any time. All error messages are registered

and can also be pr in ted out at any t ime.


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PARTICLEPROCESSING


TONER PROCESSING – THE LATEST TRENDSAPP LICATION TESTING C ENTRE

In most cases, the design of a toner system is based on tests.

Although such tests are extremely complex and time-consuming,

and fur thermore demand a wide r ange o f avai lable plan t and

machinery, i t i s the on ly way to guaran tee an opt imum machine

combination. Skilled and highly qualified engineers with years of

experience carry out t hese tests at HOSOKAWA. Once the t est series

is complete, our customers can be assured that the right machine

combinat ion has been found. Our tes t ing cen tres are equipped wi th

a wide range of grinding and classifying systems, not only produc-

tion-size systems, but also laboratory and pilot plants. Annexed to

the tes t ing cen tre is a h igh ly modern laboratory equipped wi thexactly the same kind of measuring and analysis equipment which

the customer w ill use later fo r purposes of qua lity assurance. To

ensure accurate basel ine data , the tes t systems must always be s tate

o f the a r t , wh ich is why we cons tan t ly renew and add newly deve-

loped mach ines to our s tock o f ma ch ines and eq uipment . One o f

the ne wer m achines is the 200 TTSP classifying system show n in the

figure , w h ich has been a vai lable for c lass i fying tr ia ls since

early 2001. The test system is characterised by a high deg ree of f le-

xibility, this especially with regard to the gravity feed unit and

the en t i re con tro l and measur ing technology needed to set the

required operat ing parameters . Al l the operat ing data o f th is

system can be recorded so that the test results can be documentedin their entirety.

dry the suspension , and on the o ther ha nd,

the TTSP Tand em Tone r Classifier is cap ab le

of manufacturing three fractions in one sin-

gle process step, i.e. both the top-size parti-

cles and the superfine portion can be classi-fied simultaneously.

MIXING

The Cyclomix is idea l for the blending pro-

cess required here.

DRYING

Chemically produced toner has to be dried

after the polymerisation step. A considera-

ble amount o f w ater can be pressed out o f

the product by means o f mechan ical dewa -

tering, how ever, a second step should be

used to remove the last traces of moisture.

The Vrieco Nauta Vacuum Dryer is the idea l

solution for this step. Heat is transferred

into the product essentially through a jak-

keted vessel wa ll which causes moisture to

evaporate . A ro tat ing screw orbi ts a long

the vessel wall and helps the vapour to esca-

pe to the sur face , provid ing at the same

time a frequent exchange of particles in

con tact wi th the heat ed sur face .

A vacuum system keeps the vessel under

cons tan t vacuum and removes the vapour

from the vessel, having separated the dust

particles from the vapour first in a dust fil-

ter on to p of the vessel. The vacuum condi-

tions within the vessel reduce the saturated

vapour pressure of the moisture and this

makes drying a t much lower temperatures

possible.

HOSOKAWA Vacuum Dryers are built as

to tal ly enclosed sys tems and when operated

under ful l vacuum, o ffer the fo l lowing fea -

tures:

- Low energy consumption

- Gentle to the product

- Good heat t r ans fer r ates

- Fast drying times

The dryers range from 5 litres capacity up

to 12 m 3 – larger models on request.

This results in the follow ing process and

qual i ty advan tages :

- Finer and more closely defined particle

size distributions

- Improved homogeneity

- Manufacture of functional particles

possible

- Improved colour characteristics and

transparency

- Controlled particle shape

We at HOSOKAWA are also well-equipped

to meet th is new chal lenge. On the onehand, we use the vacuum dryer to gen t ly

VRIECO NAU TA®

VACUUM DRYER

As an option to toner manufactured in the

conventional way, the latest trend istowards toner made chemically by

means of polymerisation.

Conventional toner

Polymerised toner

HOSOKAWAALPINELABORATORY

200 TTSPCLASSIFYING SYSTEMIN THE TESTING CENTRE

LABORATORY COULTERCOUNTER MULTISIZER II


10/10PROCESS TECHNOLOGIES FOR TOMORROWSM 18 /19

PROCESS TECHNOLOGIES FOR TOMORROW®

J a p a n

HOSOKAWA MICRON CORPORATION

Tokyo O ffice

Itaba shi Center Building, 9-7, 3-chome,

Itaba shi, Japan - Itab ashi-ku, Tokyo 173, Japa n

Te l : + 8 1 3 -5 24 8-5 73 0

Fa x : + 8 1 3-5 24 8-5 73 7

E-mail: [email protected] .com

China

HOSOKAWA MICRON CORP.

Shanghai Rep. Office

Room 1411-1412 China Venturet ech Plaza ,

No. 819, Nanjing Road West

CN - 200041-Shanghai, China

Te l: + 8 6 21 53 06 03 66

Fa x : + 8 6 21 32 18 13 87

E-mai l : [email protected]

In ternet : w ww.hosokawa.com.cn

Malaysia

Hosokawa Micron (Malaysia) SDN.BHD

No. 35, 1st Floor, Jala n USJ 10/1G Taipa n

Business Centre47620 UEP-Subang Jaya Selangor Darul

Ehsan Malaysia

Tel : +603 56 34 03 91 or +603 56 34 04 52

Fa x : + 6 03 56 34 39 46

E-mail: admin@hmm-hosokaw a.com.my

HOSOKAWA – powde r and pa rticle processing for the ton er industry – worldwide

(For the addresses of our representatives please refer to our website

www.alpinehosokawa.com)

Augsburg /GermanyOsaka /Japan

The HOSOKAWA MICRON GROUP is an international supplier of machines, systems, processes and services.

Based on this comprehensive performance range,

HOSOKAWA offers process solutions for a great number

of different business segments:

USA

HOSOKAWA MICRON P OWDER SYSTEMS

10 Chatham Road

Summit, NJ 07901, USATe l: + 1 9 08 27 7 6 36 0

Fa x : + 1 9 08 27 3 7 43 2

E-mail: [email protected] a.com

Internet: hosokawamicron.com

Netherlands

HOSOKAWA MICRON B.V.

Gildenstraat 26

NL-7005 BL Doet inchem, Nethe rlands

Te l: + 3 1 31 4 3 7 3 3 3 3

Fa x : + 3 1 31 4 3 7 3 4 5 6

E-mail: [email protected] a.com

United Kingdom

HOSOKAWA MICRON Ltd. (UK)Rivington Road, Whitehouse Industrial Estate

Runcorn, Cheshire WA7 3DS, UK

Te l : + 4 4 19 28 75 5 1 00

Fa x : + 4 4 19 28 7 14 3 25

E-mai l : [email protected] .com

1. POWDER AND PARTICLE PROCESSING

HOSOKAWA is the w orld's largest provider of processing systems

for the f ie ld o f pow der and par t ic le processing . Renowned names

such as ALPINE, Bepex, Stot t, Vitalair, Rietz, Mikro, Micron, and

Vrieco-Nauta are all included in the Group's range.

Regardless of t he size, i.e. production-scale systems, pilot systems

or laboratory equipment, HOSOKAWA's products and technologies

are used in numerous process stages, for example during commi-

nution, mixing, drying, agglomeration, classification, weighing

and meter ing .

2. BLOWN FILM PROCESSING

HOSOKAWA ALPINE is one o f t he w orld's foremost suppliers of

film blowing systems. As a one -stop shopping partne r, Alpine sup-

plies complete systems for the manufacture of blown film, fromgranule feeding systems to film winders, from single-layer die

heads to 7-layer lines, and from simple speed regulators to state-

of-the-art process control systems. And with ALPINE's own film

orientation lines, complete systems are now available which facili-

tate f i lm upgrading and enhancement processes.

3. CONFECTIONERY & BAKERY TECHNOLOGY

The vast fund o f know -how built up by the Be pex, Kreuter and Ter

Braak companies over many long years makes the HOSOKAWA

Confect ionery and Ba kery Group the ideal par tner for the con fec-

tionery industry. A complete range of machines and production

systems is available or can be custom-designed for each processs tep, from preparat ion o f the r aw mater ials and con fect ionery

pas tes to the end product .

The group ma intains facilities for research, engineering, manufa c-

turing and service in each of the world's major industrial markets.

Germany

HOSOKAWA ALPINE

Aktiengesellschaft &Co. OHG

P.O. Box 10 11 51

D-86001 Augsburg, German y

Delivery address:Peter-Dörfler-Str. 13-25

D-86199 Augsburg, German y

Tel . : +49 (0) 821 59 06-187

F a x: + 4 9 (0 ) 8 21 5 9 06 -4 38

E-mail: [email protected] .com

H O S O K A W A M I C R O N G R O U P

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Powder Processing Toner Industry