Inside Innovation at Xerox: Toner Technology Breakthrough Powers Xerox Flash Fusing in High-Speed Colour Printer

    TORONTO, Jan. 17 /CNW/ - Xerox Canada, in tandem with Xerox Corporation
(NYSE:   XRX) today offered a look inside "non-contact flash fusing" - a major
technology breakthrough in high-speed colour printing. The innovation enables
color xerographic continuous feed printers to achieve speeds of nearly 500
colour pages per minute.
    By flashing a high-intensity Xenon light more than 2,000 times per
second, Xerox printers fuse the colour toner to a wide variety of paper and
substrates without ever having to make contact with the paper. As a result,
the new fusing technology enables colour continuous feed printing at speeds
that rival black-and-white continuous feed printing while offering excellent
registration and reliability.
    Until now several factors have limited the speed of colour printing.
Conventional toner-based printers heat the entire paper and pressure-roll the
toner in order to fix the image onto the paper. This has limited print speeds
to only 110 pages per minute and restricted printing on surfaces that have
    Xerox's new flash fusing method depends on newly developed colour toners,
which melt and fuse the image solely through the energy from the Xenon lamps.
The process enables Xerox printers to print up to 650 images per minute in
monochrome and 493 images per minute in full colour. In addition, plastic
identification cards and peel-off labels on statements, price tags and
stickers as well as RFID transponder inlays can now be printed at extremely
high speeds.
    "This fusing technology is a great example of how Xerox innovation drives
the development of colour products with functionality never before seen in the
marketplace," said Scott Wagner, Xerox's manager of Worldwide Marketing,
Continuous Feed. "This breakthrough technology has enabled us to offer the
industry's fastest toner-based continuous feed xerographic colour printer
available, and it can run the widest choice of papers."

    How it works

    Flash fusing uses an array of Xenon flash lamps similar to the Xenon
lamps used in super bright headlights on luxury cars. There are eight flash
lamps located in the uniquely designed reflection housing inside the
continuous feed printer.
    "Think of the instant pulse of heat you would feel if you were to hold
your hand in front of a flash camera," said Peter Crean, Xerox Fellow. "Now
imagine thousands of those firing at high speed. In fact, the lamps that line
up along the paper path inside the machine pulse light sequentially 120,000
times per minute, exposing and fusing the toner to the paper as it passes by
at 226 feet per minute."
    In order for flash fusing to work, Xerox scientists had to change how
cyan, yellow and magenta toners absorb energy from light. To solve this
problem, Xerox created colour toners that contain special infrared
energy-absorbing material. This allows the individual colour toners to absorb
enough energy so that each fuses as fast as the black toner, which absorbs all
light. As a result, the toners are laid down in the order of their absorption
rate - with the black at the bottom. As each toner is overlaid on the
preceding toners, the energy builds with each flash providing just the right
amount of light to fuse each colour perfectly.
    The new flash-fusing approach also provides dramatic improvements in
reliability and quality. Because only the toner - not the entire paper - is
heated, moisture is maintained in the paper, minimizing stock shrinkage, paper
curl and static electricity. This also improves front-to-back registration - a
challenge when duplex printing at high speeds - and results in high
productivity and reliability because the paper feeds dependably during the
printing and finishing processes.
    Flash fusing is the technological cornerstone of the Xerox 490/980 Colour
Continuous Feed printer, the fastest, full-colour toner-based continuous feed
device of its kind as well as the newly announced 650/1300 Monochrome
Continuous Feed printer and the 495 Monochrome Duplex Continuous Feed printer.

    Video Webcast

    Click here
(<a href=""></a>
<a href="">4595/podcast/pr/Xerox_Innovation_Breakthrough_Flash_Fusing_Technology.wmv</a>) for
a sneak peek of Xerox's latest continuous feed printer and learn how flash
fusing enables reliable high quality color continuous feed printing at the
speed of black and white. See just how flash fusing technology is breaking the
color speed barrier for continuous feed printing and how it compares to
traditional heat roller pressure toner fusing.

    About Xerox

    Xerox Corporation is the world's leading document management, technology
and services enterprise, providing the industry's broadest portfolio of colour
and black-and-white document processing systems and related supplies, as well
as document management consulting and outsourcing services. This year Xerox
was awarded the National Medal of Technology, the highest technology award in
the United States, for its innovations. For more information, visit

    Note to editors: For more information on Xerox, visit or For open commentary
    and industry perspectives, visit or

    Xerox(R), the Xerox wordmark and the spherical connection symbol are
    trademarks of Xerox Corporation in the United States and/or other
    countries. Prices, features, specifications, capabilities, appearance and
    availability of Xerox products and services are subject to change without

For further information:

For further information: Media Contacts: Laura Mergelas, Xerox Canada,, (416) 733-6216

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