Abstract: Processes for continuously coalescing particles from an aggregated particle slurry are disclosed. The aggregated particle slurry is heated, then coalesced by raising the pH. The coalesced particles are homogenized and exit as a coalesced particle slurry. A multi-screw extruder is used for the coalescing. These processes are useful for providing coalesced particles such as toner compositions.

Abstract: Processes for continuously producing a wax dispersion are disclosed. A multi-screw extruder is used for the processes. A wax and a surfactant are fed into the extruder and melted together. Water is then added to form a dispersion. The wax particles are homogenized and exit the extruder to be passed through a quenching unit. The wax dispersion can be used to make toner compositions.

Abstract: A continuous process for making a pigment dispersion includes continuously feeding a pigment into a feed section of a screw extruder at a controlled rate, continuously feeding a surfactant into the feed section of the screw extruder at a controlled rate, continuously feeding water downstream of the feed section to emulsify the pigment and the surfactant, forming a water-in-pigment dispersion, continuously feeding additional water downstream of the previously fed water to cause a phase inversion of the water-in-pigment dispersion, forming a pigment-in-water dispersion, continuously homogenizing the pigment-in-water dispersion in the screw extruder to create a homogenous aqueous pigment dispersion and collecting the homogenous aqueous pigment dispersion from an exit section of the screw extruder.

Abstract: A toner composition that includes at least one low molecular weight amorphous polyester resin, at least one high molecular weight amorphous polyester resin, at least one crystalline polyester resin, at least one wax, at least one biocide and at least one colorant, and wherein the toner composition has a minimum fusing temperature of from about 100° C. to about 125° C.

Abstract: A process for making particles is provided. In embodiments, a suitable process includes a mixing tank for mixing a plurality of particles dispersed within a liquid media and a vane unit for applying a swirling effect to the plurality of droplets received from the mixing tank through a spray nozzle. The vane unit is in operable communication with a spray nozzle for launching a plurality of droplets, the plurality of droplets including different combinations of the plurality of particles. The process further includes a plurality of outlet ports, where each of a first set of outlet ports includes a filter and of the other outlet port is filterless.

Abstract: A method of making toner particles, includes: mixing a latex emulsion, a colorant emulsion, an optional was emulsion, and optional additives in a first reactor to form a slurry; discharging the slurry from the first reactor to a second reactor through a homogenizer; heating the slurry in the second reactor to form aggregated particles in said slurry; discharging the aggregated particles and slurry from the second reactor to a third reactor; heating the aggregated particles and slurry in the third reactor to coalesce the aggregated particles into toner particles; discharging the toner particles and slurry from the third reactor to a fourth reactor; cooling the toner particles; optionally classifying said toner particles to remove coarse particles; and optionally washing and drying said toner particles, wherein the first reactor, second reactor, third reactor, and fourth reactor are at least two different reactors.

Abstract: A process for making particles is provided. In embodiments, a suitable process includes a mixing tank for mixing a plurality of particles dispersed within a liquid media and a vane unit for applying a swirling effect to the plurality of droplets received from the mixing tank through a spray nozzle. The vane unit is in operable communication with a spray nozzle for launching a plurality of droplets, the plurality of droplets including different combinations of the plurality of particles. The process further includes a plurality of outlet ports, where each of a first set of outlet ports includes a filter and of the other outlet port is filterless.

Abstract: A process for making particles is provided. In embodiments, a suitable process includes a mixing tank for mixing a plurality of droplets dispersed within a liquid media. The process further includes a drop ejector controlling unit in operable communication with a drop ejector array for launching a plurality of droplets, the plurality of droplets including the plurality of particles, and an outlet port for receiving the plurality of droplets.

Abstract: A toner composition that includes at least one low molecular weight amorphous polyester resin, at least one high molecular weight amorphous polyester resin, at least one crystalline polyester resin, at least one wax, at least one biocide and at least one colorant, and wherein the toner composition has a minimum fusing temperature of from about 100° C. to about 125° C.

Abstract: Herein is disclosed a process for producing emulsion aggregation toner including (i) adding a base to an emulsion aggregation toner to increase the pH of the toner to from about 7 to about 12; (ii) sieving and filtering the toner; (iii) washing the toner with an enzyme selected from the group consisting of carboxylic ester hydrolase and sulfuric ester hydrolase; (iv) filtering the toner; (v) washing the toner with reverse osmosis or deionized water; and (vi) adding an acid to reduce the pH of the toner to from about 3 to about 8.

Abstract: Methods include washing and de-watering toner particles using a horizontal filter press.

Abstract: A powder is de-aerated in a collector and then transferred to a chamber via a valve. The chamber may then be injected with a low-pressure air stream carrying an additive for mixing with the de-aerated powder. The mixing of the powder with the air and additive stream may occur in the valve and/or chamber. After mixing of the powder with the air and additive stream, the mixed powder and additive may be further mixed in the chamber and/or second valve prior to transferring the mixed powder and additive to a holding container or other processing device.

Abstract: A system for analyzing particles including: a source of solid particles; a sampler apparatus attached to and integral with the source of solid particles which apparatus is adapted to enable removal of small amounts of sample material from the source; a sonication cell connected to the sampling apparatus which sonication cell receives, optionally conditions, and sonicates the small amounts of sample material; a sample analysis apparatus connected to the sonication cell which sample analysis apparatus is adapted to receive, optionally further condition, and analyze the resulting sonicated sample received from the sonication cell; and a liquid pump and liquid carrying lines adapted to: withdraw aliqouts from the source; convey a withdrawn aliqout to the sonication cell and sample analysis apparatus; and flush the system free of residual aliqout contamination.

Abstract: A method of drying wet toner particles includes adding different sized wet toner particles to a dryer drying chamber and drying each of the wet toner particles for a drying time TD. The drying time TD can vary for each toner particle and is proportional to the mass of the wet toner particle. The method can also include introducing a heated drying gas into the drying chamber to create a circulating flow of drying gas. The method also includes adjusting the pressure and/or velocity and/or angle of the heated drying gas to control the amount of deagglomeration of the toner particles.

Abstract: A method of drying wet toner particles includes adding different sized wet toner particles to a dryer drying chamber and drying each of the wet toner particles for a drying time TD. The drying time TD can vary for each toner particle and is proportional to the mass of the wet toner particle. The method can also include introducing a heated drying gas into the drying chamber to create a circulating flow of drying gas. The method also includes adjusting the pressure and/or velocity and/or angle of the heated drying gas to control the amount of deagglomeration of the toner particles.

Abstract: A method of drying wet toner particles includes adding different sized wet toner particles to a dryer drying chamber and drying each of the wet toner particles for a drying time TD. The drying time TD can vary for each toner particle and is proportional to the mass of the wet toner particle. The method can also include introducing a heated drying gas into the drying chamber to create a circulating flow of drying gas having a curved portion, and retaining the toner particles in the circulating flow until the toner particles lose enough moisture that exiting forces overcome centrifugal forces and the toner particles no longer remain in the drying chamber. A dryer for drying toner particles includes a drying chamber, at least one drying gas inlet for introducing heated drying gas into the drying chamber to produce a circulating flow of drying gas. The dryer includes a feed inlet for introducing wet toner particles into the circulating flow of drying gas to dry the wet toner particles.

Abstract: A system for analyzing particles including: a source of solid particles; a sampler apparatus attached to and integral with the source of solid particles which apparatus is adapted to enable removal of small amounts of sample material from the source; a sonication cell connected to the sampling apparatus which sonication cell receives, optionally conditions, and sonicates the small amounts of sample material; a sample analysis apparatus connected to the sonication cell which sample analysis apparatus is adapted to receive, optionally further condition, and analyze the resulting sonicated sample received from the sonication cell; and a liquid pump and liquid carrying lines adapted to: withdraw aliqouts from the source; convey a withdrawn aliqout to the sonication cell and sample analysis apparatus; and flush the system free of residual aliqout contamination.