Designing an optimised formulation for in situ emulsion polymerization: printing ink production by response surface methodology

Purpose Toner is a crucial dry colorant composite used in printing based on the electrophotographic process. The quality of printed images is greatly influenced by the toner production method and material formulation. Chemically in situ polymerization methods are currently preferred. This paper aims to optimize the characteristics of a composite produced through emulsion polymerization using common raw materials for electrophotographic toner production. Design/methodology/approach Emulsion polymerization provides the possibility to optimize the physical and color properties of the final products. Response surface methodology (RSM) was used to optimize variables affecting particle size (PS), PS distribution (PSD), glass transition temperature ( T g °C), color properties (Δ E ) and monomer conversion. Box–Behnken experimental design with three levels of styrene and butyl acrylate monomer ratios, carbon black pigment and sodium dodecyl sulfate surfactant was used for RSM optimization. Additionally, thermogravimetric analysis and surface morphology of composite particles were examined. Findings The results indicated that colorants with small PS, narrow PSDs, spherical shape morphology, acceptable thermal and color properties and a high percentage of conversion could be easily prepared by optimization of material parameters in this method. The anticipated outcome of the present inquiry holds promise as a guiding beacon toward the realization of electrographic toner of superior quality and exceptional efficacy, a vital factor for streamlined mass production. Originality/value To the best of the authors’ knowledge, for the first time, material parameters were evaluated to determine their impact on the characteristics of emulsion polymerized toner composites.