QUEST FOR LEADERSHIP

With significant investment in Research & Development, INTEGRAL ensures that all products released to the market meet the highest quality and performance standards. Qualified research staff are engaged in the development of new toner products with optimized performance for specific copier and printer systems.

INTEGRAL maintains a state of the art toner development and research laboratory. The research facility features highly sophisticated equipment used in the analysis and development of mono and dual-component toner formulations as well as for the scale-up and reverse engineering of copier and printer toners. Extensive testing of products is carried out at the research facility before being released to market.

In addition to Research & Development in toner, INTEGRAL co-develops and carries out rigorous testing of copier and printer parts and components in collaboration with some of the world’s leading part manufacturers.

R&D AND QUALITY CONTROL

Vital characteristics and parameters of toners are measured at INTEGRAL’s state of the art research and development facility by highly qualified personnel, engaged in the development and quality control of a wide range of mono and dual-component copier and printer toners. Parameter analysis includes the measurement of important properties such as: tribo charge, flowability, melting point, softening point, particle size distribution and magnetic properties amongst other important characteristics of the toners. Activities at the research laboratory include new product development, scale-up, raw material control and final product quality control. 

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 QUALITY CONTROL BY R & D PERSONNEL 

Each production lot of toner is carefully analyzed in the laboratory and copy or print testing takes place in the applicable printer or copier models.

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ANALYTICAL & LABORATORY EQUIPMENT

Various parameters of toner and raw materials are checked by the use of specific analytical equipment. Various equipment used is shown below:

PARTICLE SIZE DISTRIBUTION

The size and distribution of toner particles is of critical importance to print yield and background levels. Specialised equipment such as the Coulter Multisizer is used to measure the particle size distribution of toners.

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Coulter Counter Multisizer III

The system works by laser diffraction and is connected to a central unit. The sample is either introduced in suspension in a cell or is dispersed in a water-based solution, which circulates in the laser system. This equipment measures the particle size distribution.

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Shimadzu Particle Size Analyser

TRIBO CHARGE

The q/m Meter is used to measure the toner charge, which is the charge to mass ratio (q/m-value) of two component developers (toner/carrier mixture). It is used in the development of new toners as well as in quality control.

Epping q/m meter

Epping q/m meter

GLASS TRANSITION TEMPERATURE AND MELTING POINT

This equipment measures the thermal transition of a material. In toner it determines the glass transition temperature (Tg) and the melting point (Tf) or (Tm)

Mettler DSC

Mettler DSC

 MELT FLOW INDEX / EXTRUSION PLASTOMETER

This equipment measures the melt flow index (MFI) of toner powder. It is an indirect measurement of the viscosity of a product at a determined temperature. The more viscous the material the lower the MFI.

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Melt Flow Indexer / Extrusion Plastometer

IR SPECTROMETER ANALYSIS

As an integrated part of R & D, target toner compositions are analyzed by means of IR spectrometer analysis.

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Mattson Instruments Galaxy series FT-IR Spectrometer

MAGNETIC PROPERTIES

Magnetic properties of mono-component toners and ferrite raw materials are measured.

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Fluxmeter

 DIALECTRIC CONSTANT DISSIPATION FACTOR

The LCR meter measures the electrical properties of a toner. Through this measurement it is possible to determine the dialectric constant and the dissipation factor. Such measurements provide an indication of the degree of dispersion of the different constituents of a toner.

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LCR Meter

 FLOWABILITY

Sieve towers are used to measure the flowability of toners. A given toner is passed through a number of consecutive sieves in the tower. The flowability of a toner is determined by measuring the passing time and quantity.

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Retsch Sieve Tower

COPY AND PRINT IMAGE QUALITY TESTING

Before being released to the market all INTEGRAL toners are extensively tested in the intended copier or printer systems over extended periods. After having successfully passed these tests under various environmental and machine conditions, each product is subject to a prolonged field test on a broader base. The product is only launched after having successfully passed the field test.

COPIER AND PRINTER TEST LABORATORY

In addition to the parameters being measured on laboratory equipment, print and copy tests are run to determine a toners stability and performance as well as the matching of components

Copier Test Room

Copier Test Room

IMAGE QUALITY MEASUREMENTS

DENSITOMETER MEASUREMENT

Densitometers are used to determine the image density of solid areas on print-outs and copies. Such measurements provide an unbiased recording of density related aspects of copy and print quality.

IMAGE ANALYSIS

ENVIRONMENTAL CHAMBER

Environmental conditions such as temperature and humidity influence the characteristics and print performance of electro photographic systems and toners.
An environmental chamber simulates varying combinations of environmental conditions while print and copy testing takes place.

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Environmental Chamber

Temperature cabinets are used to determine the long-term impact of temperature on toners at a set temperature level.

Temperature Cabinet

Temperature Cabinet

PILOT PLANT

Before entering full-scale production, new product manufacturing trials are run on pilot plant equipment. Full scale production takes place after meeting the necessary criteria

Pilot Plant Size Jet Mill

Pilot Plant Size Jet Mill

Pilot Plant Classifying System

Pilot Plant Classifying System

High speed mixer for the blending of raw materials and additives

High speed mixer for the blending of raw materials and additives

 

 

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