Phase inversion emulsification reclamation process

A method of making a toner composition comprising:

• reclaiming an out-of-spec emulsion material comprising:
• recovering the out-of-spec emulsion material from a scrap manufacturing batch;
• distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to greater than about 45 wt % based on a total weight of the emulsion material;
• dissolving the distilled emulsion material in a solvent to form a first mixture;
• adding a base to the first mixture to neutralize acidic groups present in the distilled emulsion material, forming a second mixture;
• emulsifying the second mixture by adding water to the second mixture;
• and
• forming particles having an average particle diameter (D50v) within a target range;
• and
• mixing the particles with an optional colorant, an optional wax, and other optional additives forming a mixture;
• and
• preparing a toner composition from the mixture,
• wherein the out-of-spec emulsion material has an average particle diameter outside of the target range.

A toner prepared from a method comprising:

• reclaiming an out-of-spec emulsion material comprising:
• recovering the out-of-spec emulsion material from a scrap manufacturing batch;
• distilling the out-of-spec emulsion material to raise a solids content of the out-of-spec emulsion material to greater than about 45 wt % based on a total weight of the emulsion material;
• dissolving the distilled emulsion material in a solvent to form a first mixture;
• adding a base to the first mixture to neutralize acidic groups present in the distilled emulsion material, forming a second mixture;
• emulsifying the second mixture;
• and
• forming particles having an average particle diameter (D50v) within a target range;
• and
• mixing the particles with an optional colorant, an optional wax, and other optional additives forming a mixture;
• and
• preparing a toner composition from the mixture,
• wherein the out-of-spec emulsion material has an average particle diameter outside of the target range.