As Toshiba Corp was appraising the North American office equipment market in the early 90s, a new piece of machinery was purchased for R & D trials. Little did Toshiba know that the Vibrasonic Compact Screener from Russell Finex, purchased to eliminate oversized particles in raw materials, would still be in active production 15 years later.

When Toshiba America Business Solutions (TABS), an independent operating company of Toshiba Corp, began using the compact screener in its toner products division after successful R & D trials, it decided to order another unit as demand for new digital toners began to pick up.

"The old box screeners we were using didn't work for the digital toners," says Becky Pitz, a senior process engineer in TABS Toner Products Division. "With the move to digital toners, we needed production equipment that could quickly and consistently screen smaller particle sizes with minimal downtime.

"Despite the focus on the latest digital hardware, toner is what ends up on any printed hard copy," adds Pitz. "Whether it's an annual report, key sales proposal, or your daughter's wedding photo, you've got to get the toner right to ensure crisp, clear copy. A crucial part of getting the toner right is screening for any foreign or oversize particles that could cause gaps, smudges, or uneven toner flow."

So to meet demand while increasing both rate and yield at the required quality, TABS bought a second high-capacity, 36 in. Vibrasonic Compact Screener from Russell Finex of Pineville, NC. Russell Finex has a long history of addressing industrial needs and extensive experience working with customers to determine the appropriate use of screening and filtering equipment to meet specific requirements.

Trial Tests Ensure Success

At TABS' request, trial tests were done to ensure the successful use of the vibratory compact screener with digital toners. Russell Finex worked with TABS to change a gasket material to make it more suitable.

A few years later, TABS added a third compact screener to keep up with continuing demand for digital toner. Unlike some screeners, which expose commercial hardware such as nuts and springs to the material being screened, Pitz appreciates that the Russell Finex units do not. This eliminates the risk of hardware vibrating loose to enter the product stream.

Screening efficiency is enhanced by the Russell Vibrasonic system's use of a combination of ultrasonics and conventional vibration. By means of an acoustically developed transducer, an ultrasonic frequency is applied directly to the screener mesh to break down surface tension, effectively making the stainless steel wires friction free. This eliminates mesh blinding and enables users to maintain product consistency without needing to stop the machine to clean the mesh. It also improves screening precision, reduces downtime, and provides longer screen life.

Since the crevice-free units are constructed entirely from polished stainless steel, including stands, all surfaces are also easily cleanable. Their simple design makes them easy to strip down and clean without tools, which further simplifies maintenance and enhances production uptime. (Shown here, interior view of the screener.)

Color Toner Presents New Challenges

Recently, TABS faced rapidly expanding demand for digital color toner, arising from the popularity of digital multifunction printers in businesses and offices. The color toners not only had to be screened for smaller particle sizes, but also had a sticky consistency that made material handling and processing more difficult.

Once again at TABS' request, Russell Finex did trial tests at their facility to ensure the successful use of the compact screeners with the new digital color toners. They also made generator circuit board adjustments that allowed TABS to automate the remote operation of the screeners as part of a Toshiba company directive. TABS then bought three more Russell Finex vibratory compact screeners, bringing their total to six.

"By responding so quickly to our needs, Russell Finex helps us respond to the marketplace," says Pitz. "That's key in a market as competitive as ours."

As TABS toner production continues to grow, Pitz values the compact screeners' ability to fit into tight spaces not achievable by larger, less efficient models. This can be particularly helpful in areas with limited headroom or when fitting into existing production space.

"Compared to our previous screeners, we've doubled capacity in half the space," says Pitz. "Not only that, but we've significantly increased yield while maintaining quality and minimizing maintenance. The units last and last -- we're still using our original 15-year-old screener in mass production.

"Our relationship with Russell Finex is a strategic advantage, especially in our current growth mode," concludes Pitz.