Laboratory Tour
Integral Logo
s
ABOUT INTEGRAL
News
Mission
History
Departments
Customer Support
Research & Development
Manufacturing
Quality Control
Distribution & Shipping
Careers
Environment
Trademark
s
PRODUCTS
SUPPORT&DOWNLOAD
CONTACT US
e-CATALOG

s

R&D AND QUALITY CONTROL

AT INTEGRAL we want our customers to be sure to always receive products, which match the stringent requirements of optimized performance and value.

At our state of the art research and development facility qualified personnel are engaged in the development and quality control of a wide range of mono- and dual-component copier and printer toners.

All INTEGRAL products must show excellent performance before being released to the market.

At the INTEGRAL laboratory facility, vital characteristics and parameters of toners are measured for both research and development as well as quality control purposes.

The parameter analysis includes the measurement of important properties like: tribo charge, flowability, melting point, softening point, particle size distribution and magnetic properties among other important characteristics of the toners.

Activities at the research laboratory include new product development as well as scale-up, incoming raw material control and final product quality control.

At the INTEGRAL research and development laboratory essential toner parameters are analyzed for the purpose of new product development, scale-up and quality control. Incoming raw materials as well as final products are subject to stringent quality control procedures.  

 

 

Top top

Quality control by R&D personnel 


Once a toner is under production each production lot is carefully analyzed in the laboratory and copy or print testing takes place in the applicable printer or copier models. 

 

 

 

ANALYTICAL & LABORATORY EQUIPMENT

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

Top top
Particle Size Distribution


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

                                                            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. The equipment measures the particle size distribution.


                                                             Shimadzu Particle Size Analyser

Top top

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

 

 

Top top
 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

 

Top top
Melt Flow Indexer / 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.

                               

                                          
                                                 Melt Flow Indexer / Extrusion Plastometer


Top top

IR Spectrometer Analysis


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





                                Mattson Instruments Galaxy series FT-IR Spectrometer

Top top
Magnetic Properties



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



                                            Fluxmeter

Top top
Dialectric Constant and 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.
                                          LCR Meter


 

Top top

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.

                        Retsch Sieve Tower     


                                                      

Top top

 

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 the long run tests under various environmental and machine conditions in case of copier toners and with varying components in case of printer toners each product is subject to a prolonged field test on a broader base. Only after having successfully passed the field test, the product is finally launched.

Copier and printer test laboratory


In addition to the parameters beeing measured on laboratory equipment, print and copy tests are run to determine a toner´s long-run stability and performance as well as the matching of components.

            

 Copier test room              
                

Top top

IMAGE QUALITY MEASUREMENTS 

Densitometer Measurements

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.

Macbeth Densitometer

Top top

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.  

                                      Environmental Chamber          

 


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




Temperature cabinet    

 

 

  
Top top
PILOT PLANT

For product development and before entering full-scale production, new product manufacturing trials are run on pilot plant equipment.

Only after meeting the necessary criteria, new product manufacturing is transferred to full-scale production.

 

 

 

 

High speed mixer for the blending
of raw materials and additives

 

 

 

 






 Pilot Plant Size Jet Mill 

 


 

 




 
 

Pilot Plant Classifying System

 

 

  
Top top