Recycling of Toner Fines

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            [post_title] => Alpine Pharmapaktor APC L
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            [post_content] => Mikro ACM® Air Classifying Mills were invented by HMPS in the late 1960’s and are one of the most versatile types of size reduction equipment available in the market. These units while being capable of producing fine, medium and coarse grinds for a wide variety of materials for Food, Pharmaceutical, Chemical and Mineral industries, require very little maintenance over their life span. The basic design of these mills is the impact size reduction that is coupled with an internal dynamic classifier which controls the outlet (product) particle size via recirculating the coarse particles back into the grinding zone.

 There are seven main factors which determine particle size distribution for the Mikro ACM® Air Classifying Mill. When varied, the rotor type and speed combined with the liner and hammer count affects the production of fines. The separator type and speed affects the top size of the product. And lastly, the airflow governs the throughput as well as top size and fines generation. With the endless available options a machine can be configured to process just about any material that is below MOH’s hardness of 5.

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            [post_content] => The wet material is fed through customized feeding systems into the grinding and drying section of the dryer's main body. The grinding rotor disperses the wet material into very fine particles and the fine particles are fluidized in the grinding chamber by temperature-controlled, hot gas coming in from the air heater.
The hot air (or inert gas) can be heated up to 650 °C and as the wet product is dispersed, it is reduced in size in the bottom section of the dryer. The system is kept under a negative pressure by the exhaust fan and the surface area of the product is increased enormously so that water (or other solvents) is evaporated instantaneously.
The dry and fine particles are conveyed with the gas stream to the top section of the dryer where a separator classifies the particles by size. Then the particles pass the classifier at the set cut point and are conveyed with the exhaust air to a powder air separating system like the cyclone, cyclone filter or cyclone scrubbers.
The Micron Dryer flash dryer retains a fluidized bed of product in the drying chamber to ensure a low level of adhesion of wet material on the inside wall of the drying chamber. Moreover, process parameters like classifier speed and outlet temperature can be adapted to control moisture content and particle size of the end product.
Ultra fine regular end product - Due to its specially designed dispersion rotor, our flash dryers are able to produce ultra-fine powders in one step from suspensions, slurries, pastes and dough, filter cakes or wet powders.
High evaporation capacity - Due to the combination of high ?T with a good dispersion of the wet product in the air, our flash dryers can evaporate large quantities of liquids.
Compact design - Compared to other direct drying technologies, the flash dryer requires up to 50% less space.
Multi-purpose - Filter cake or slurry, in the same machine. Therefore with the Drymeister-H unlimited mechanical dewatering is possible previous to the final drying stage.
Easy access  - Either for cleaning, inspection or maintenance inside the dryer, our flash dryers offers the best accessibility from the market, regardless which size.
Various systems available - Open, closed- and recycle system concepts.

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Applicaton
During production of toner different steps are required:

• Mixing of the raw materials
• Extrusion and cooling of the mixture
• Pre-crushing
• Fine Milling & Classification to _d50 6 – 8 µm

During the micronizing stage ultrafine particles < 5 µm are generated. These undesirable ultrafine particles create problems in the document imaging process. Additionally, this product cannot be reused in the extruder again in high quantities because of its low bulk weight of < 200 g/l. The compaction process allows the reuse of the ultrafine fraction in the extruder and up to 100% inline recycling of material with a high value.

During the compaction/granulation process this fine dust will be granulated to dust free granules of 1 to 6 mm with a bulk density of more than 500 g/l.

Process
The compactor is designed for dust free operation and granulation without adding any binder.

In a first step flakes were pressed in the compactor.

In a second step the flakes are crushed to granules. Depending on the target the granules can be de-dusted with a screening machine or directly used in the extruder.

Example for APC-L 200/50

Feeding bulk weight: 200 g/l = 12.5 lb/ft³
Final bulk weight: min. 500 g/l = 37.5 lb/ft³
Throughput: approx. 50 – 80 kg/h = 100 – 180 lb/h