Xerox Invests $35 Million to Expand EA Toner-Manufacturing Capacity

Xerox EA Toner Plant Opening 2015May26 (2)

Opening of the Xerox EA-toner manufacturing plant in Webster, New York, on May 26th.

Xerox reports that it’ll amp up its emulsion aggregation (EA) toner manufacturing capacity by 40 percent with the completion today of a nearly $35 million expansion project that it says will help it keep up with growing EA-toner product demand.

The expansion has increased the size of Xerox’s plant in Webster, New York, from 100,000 square-feet to 155,000 square-feet, and added about $26 million in EA toner-manufacturing equipment.

“From the first xerographic image over 75 years ago, Xerox has been re-engineering the way people work, and expanding this toner plant represents an opportunity to meet the high demand for our innovative solution,” commented Richard Schmachtenberg, senior vice president of Xerox’s Consumables Development and Manufacturing group.

Developed by Xerox and protected by more than 300 patents, Xerox says EA toner produces sharper images and uses less toner per page. Unlike traditional toner, which is created by physically grinding composite polymeric materials into micron-sized particles, the firm says EA toner is chemically grown, enabling the size, shape, and structure of the toner particles to be precisely controlled. This, it says, leads to improved print quality, less toner usage, less toner waste, and less energy required for manufacturing and for printing. Xerox and Fuji Xerox have designed around 50 office and production printing products that use EA toner.

According to InfoTrends, between 2013 and 2018, printed pages produced by digital, color, toner-based production printers will grow at a 6.2 percent compound annual growth rate, amounting to 295 billion pages globally by 2018, which Xerox presents a size-able opportunity for the chemically grown toners used in its production-printing devices.

Construction on the plant addition began in 2013, and the new manufacturing line and new toner-filling line is expected to create about 54 new jobs, consisting of process operators, quality control, lab personnel, and additional maintenance staff. The project also generated about 70 full-time construction jobs over the past 15 months.

Xerox says the current five-story plant, which opened in 2007, is one of only a handful of its kind in the world. It features more than 29 miles of pipe, over 100 stainless steel tanks, and includes nearly 11,000 sensors that track information for temperature, humidity, air flow, and other variables.

Xerox has invested $120 million in the plant, mostly in custom manufacturing process equipment.

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