Patent ID: 8092972

Claim:
A process for forming a toner composition comprising: contacting at least one amorphous resin with at least one crystalline resin in an aqueous emulsion to form small particles, wherein the emulsion includes an optional colorant, a surfactant, and an optional wax, wherein the surfactant is present at about 0.75% to about 4% by weight of the toner composition; aggregating the small particles to form a plurality of larger aggregates; contacting the larger aggregates with an emulsion comprising the at least one amorphous resin or a different at least one amorphous resin, or both, to form a resin coating over the larger aggregates; coalescing the larger aggregates within the resin coating and simultaneously or subsequently crosslinking either the larger aggregates or the resin coating or both, to form a plurality of crosslinked toner particles comprising a core and a shell; adding at least one water soluble initiator at any stage in the process prior to the formation of the crosslinked toner particles, and recovering the crosslinked toner particles.