The Remanufacturing Process

Empty Cartridges.

Before you can recycle a cartridge you must first secure a supply of used cartridges.
Over the past 12 years we have had to develop our own sources for empty cartridges to satisfy our customer demand and maintain continuity to our 100 strong workforce.
Nearly all the cartridges we collect are empty originals because we only remanufacture a cartridge once and avoid many of the problems associated with third, forth etc., life products.

The Factory Environment.

Our whole production facility is geared to cleanliness and quality control, the first because it is impossible to achieve the second without it.
Keeping the cartridge in one spot for the whole process drastically reduces the spillage of used toner - and with the filter system at the work benches changing the air in the entire factory 10 times an hour we are able to operate in a superbly clean working environment.

Preliminary Testing.

Quality control starts from the moment an empty cartridge is logged in - it is first tested, by both visual and print inspection for its suitability for remanufacture.
At this stage a work sheet that follows each cartridge through to completion is started.

Cartridge Processing.

Remanufacturing a cartridge looks to be a relatively straightforward process but if you gave someone a manual and all the relevant tools and materials - and even a few months experience - you would still be lucky to get a 75% success rate. There is no short cut to the other 25%, it requires a depth of knowledge and experience, coupled with a commitment to quality few remanufacturers possess.
An "empty" laser cartridge is a misnomer, it will contain up to 25% of its original toner and although basically an inert substance, with the properties of very fine soot it needs careful handling.
Most remanufacturers work by breaking the cartridge down to its component parts and reassembling a piecemeal cartridge at the final stage.
For a variety of reasons we work on the cartridge as an integral unit. Operating on individual cartridges makes it an easy and straight forward task to change production from one type to another - allowing us to respond quickly and effectively to customer needs.

Quality Assurance.

Once the cartridge has been broken down, thoroughly cleaned and inspected, refilled and fitted with any relevant replacement parts, the reassembled cartridge is immediately tested by a separate group of technicians. Every cartridge we remanufacture is put through an exacting print test, with individual sheets for blank space, solid black, grey scale and large and small text.
If any faults appear the cartridge is immediately returned to the original operator for correction, which gives us a fast positive feedback that virtually eliminates repeat operator error.
At this stage the tested cartridge is black bagged and moved into the flow rack. Here we stock up to 1,500 finished but not packed, cartridges. This allows us a uniquely flexible response to individual orders, as we can pack to your own specific requirements and still ship over 90% of orders the same day.
At this stage each cartridge is given an individual serial number, which is also put on the cartridge box and the work sheet. We keep copies of final test sheets with the work sheet. This enables us to trace the operator, date, materials batch etc. of every cartridge we make.

Packaging.

Packaging is an important part of our finished cartridge. Apart from the need to provide suitable protection, we package in new, high quality brown boxes of the same dimensions as the original - not because we intend to imitate but if the user receives what is obviously a quality product in a form similar to the one he or she has previously used, it enhances the perceived value and increases the chances of it being treated correctly. The cartridge also has to withstand repeat handling by national carriers - our packaging passes a one metre drop test on all sides, edges and corners. We make extensive use of the original products packaging which our cartridge collectors carefully return with the empty cartridge to fully protect it in transit back to our factory.

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