The expansion has increased the plant size 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 reengineering the way people work and expanding this toner plant represents an opportunity to meet the high demand for our innovative solution,” said Richard Schmachtenberg, SVP, consumables development and manufacturing for Xerox.
Developed by Xerox and protected by more than 300 patents, EA toner produces sharper images using less toner per page. Unlike traditional toner, which is created by physically grinding composite polymeric materials to micron-sized particles, EA toner is chemically grown enabling the size, shape and structure of the particles to be precisely controlled. This 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 approximately 50 office and production printing products that use EA toner.
According to InfoTrends, between 2013 and 2018 production digital color toner-based pages will grow at a 6.2% compound annual growth rate, amounting to 295 billion pages globally by 2018, which presents a sizeable opportunity for the chemically grown toners used in Xerox production 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.
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, more than 100 stainless steel tanks and includes nearly 11,000 sensors that track information about temperature, humidity, air flow and other variables.
Xerox has invested $120 million in the plant, mostly in custom manufacturing process equipment.