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Toner Plant Overview

Toner Plant Overview Site Summary: Excellent Infrastructure Secure 31 acre site Excellent Transport connections: Motorway - 1 mile Airport - 10 miles Port - 8 miles Located within a large industrial estate Lots of available surplus land for further development (8 acre field area next to Toner plant) Excellent Toner plant facility Existing multinational companies present on site involved in manufacturing and technical sales support

Toner Plant Overview Toner Plant Summary: Built in 1994 Cost ₤ 13 m to design, construct and commission in 1994 Current cost to build new is approx. ₤ 18 m 59, 000 sq. ft. total building space 13, 000 sq. ft. office/conference room/workshop area 20, 000 sq. ft. of storage area Operated at 500 kg/hr copy toner production Highly automated (Allen - Bradley control system) Produced black toner 8 micron spec Could be used for powder coatings Excellent condition and well maintained No asbestos present Operated a triple shift with 7 operation people per shift, including team leader Approximately 3. 5 acre site with on site parking available Started Operations in 1995

Toner Plant Overview Process Overview: Process involves a four stage physical transformation of the 3 raw materials (polymer, carbon black and activator) into product by blending, fusing, milling and classification. Design includes in process reclamation and re-cycling of out-of-size material and control of dust emissions through multi-stage filtration with airborne paticulate monitoring. All milling and classification equipment is designed for explosion containment up to 10 bar-g. Blending and fusing are located inside the building, milling and classification outside. 3 pulverizer/classifer systems (Hosakawa design), 1 raw materials/extruder system.

Toner Plant Overview Process Overview Diagram:

Toner Plant Overview Component Delivery and Blending: Polymer and carbon black stored & handled in 1 m 3 bulk bags Material is mechanically/pneumatically conveyed to respective Ktron feed hoppers Activator handled in 10 kg bags Activator dispensed from an exhausted hopper into a vented loss in weight Ktron feeder All 3 components are proportionately dispensed by screw feeders to a vented inline blender, dropped to a vented hopper to feed the extruder Vented air from blenders and hoppers are taken to independent dust collectors

Toner Plant Overview Component Delivery and Blending Diagram:

Toner Plant Overview Compounding: Compounding system consists of a twin screw extruder (Werner Pfleiderer 70 SZK) with electric htg and water cooling, an underwater pelletizer, a pellet dryer, side feeder, vacuum system and granulator Extruder is multistage allowing complex temp profile along the length of the barrel (max 100°C) Recycled material can be fed into the extruder in the melt phase All hoppers, dryer, granulator, bins and the end of the extruder are vented to the building dust extract dust collection system Pelletization is effected by a set of rotating blades fixed to the face of the die – cuts the polymer into 2 mm cylinders Face of the die and cutting chamber are constantly flooded with recirculated water which carries the solidified pellets & water to a dryer The dry pellets are gravity fed to the granulator where the pellets are reduced in size to about 300 microns The 300 micron pellets are collected in vented bins located on floor scales and high level cut out Full bins are stored in the production area

Toner Plant Overview Compounding Diagram:

Toner Plant Overview Milling / Classification: The toner pellets are vacuum conveyed from the bin to one of the 3 pulverizer feed hoppers and via a screw feeder to the fluidized bed mill Air is fed to the mill via a ring of concentrically placed nozzles at the base. The air (125 psig/3000 scfm) attains supersonic velocities exiting the nozzles where it entrains and pounds the toner particles Resultant fines are passed through the bed to a series of rotating classifier wheels which only allows passage of the finer material A cyclone is used to drop the product out of the air stream. Fines are collected through dust collectors and recycled back into the compounder Dust collectors use Gortex filter bags The product and fines filter receiver exhaust systems are continuously monitored for particle detection with auto shutdown to prevent emissions to the atmosphere. The filter housings also have full sprinkler protection The product is further classified, with out-of-spec material again being recycled. The product passes through a sieve to remove aggromolates and final product dispensed to an inerted nitrogen product bin

Toner Plant Overview Building Nuisance Dust Collection System: All process exhaust points are collected in a manifolded extract system. The combined stream passes outside of the building to a baghouse This vented enclosure utilizes Gortex bags and has continuous particle concentration detection and sprinkler protection

Toner Plant Overview Nuisance Dust Collector Diagram:

Toner Plant Overview Building Vacuum System Diagram:

Toner Plant Overview Packing: Toner bins are manually located to the packing lines feed stations There are 2 packing lines – 1 semi auto and 1 manual Able to pack sizes in range of 900 g and 3 kg The semi auto lines are specific to a certain pack (900 g) size but fills, seals, caps, check weighs, labels, cases and palletizes The main warehouse is located just off the pack area through auto doors

Toner Plant Overview Equipment List: equip. pdf Service/ancillary plant mainly located in K 55 building

Toner Plant Overview View of Raw Material Handling and Extruder Area:

Toner Plant Overview View of Extruder:

Toner Plant Overview View of Final Product / Fines Receivers and Bins:

Toner Plant Overview External View of Pulverizers / Classifiers / Exhausters:

Toner Plant Overview View of Packing Lines:

Toner Plant Overview View of Warehouse:

Contact Information: MICHAEL JOACHIM DIRECTOR, PLANTS DEPT. Tele: 609 -838 -5930 (direct) Mobile: 609 -516 -9107 Michael. J@ippe. com SANJEEV REGE VP GLOBAL PLANT SALES Tele: 609 -838 -5938 (direct) Mobile: 609 -510 -2616 Sanjeev. R@ippe. com 17 A Marlen Drive w Hamilton, NJ 08691 w USA Tel: (609) 586 -8004 w Fax: (609) 586 -0002 www. ippe. com