 |
 |
| Patented
laser cutting technology removes human
error and maintains original cartridge
tolerances. The result is a product more
like the originals. |
|
|
| |
|
The principal concept of Intelligent Re-engineering™ is
to become conscious of, and then correct flaws inherent
to the rudimentary design of the cartridge. In addition
to discovering and eliminating OEM defects; Infinity cartridges
utilize distinct methods that surpass standard remanufacturing
industry protocols. Some examples of this are MSE's patented
welding and laser cutting technologies for cartridges.
These proprietary and patented processes automate otherwise
manually performed operations, thus eliminating variation,
reducing cost, and increasing productivity. Infinity's
manufacturer is constantly reviewing methods
such as these to assure that our products are superior
to the competition, and continue to add value to the supply
chain channel.
Having control of the entire remanufacturing process
enables our manufacturer the ability to examine every
aspect and component of a cartridge. During the dismantling
and then re-assembly procedure many design problems and
flaws are illuminated and then eliminated. This is where
Infinity's manufacturing excels, through the continuous
creation of modifications and improvements. Examples such
as the Infinity JUMBO cartridge for the HP 4000, that yields
50% more pages (at 5% coverage) than the standard 10,000-page
HP model.
You cannot produce a quality cartridge without the utilization
of quality components and sub-assemblies. our manufacturer's
Quality Assurance and Quality Control departments lead
the remanufacturing industry by embracing world class
quality management system and by using tried and true
inspection techniques. Components that do not meet our
manufacturing standards (which exceed industry standards),
are unacceptable, rejected, and the supplier is given
notice by way of a request for corrective action. Infinity
cartridges will never compromise quality, regardless
of cost.
Our research has concluded that a number of aftermarket
PCR's and magnetic sleeves do not meet Infinity's
acceptance standards, further; the reuse of OEM components
is risky and unpredictable. MSE's Mechanical and Chemical
engineers developed a proprietary multi stage treatment
process that produces a better and more consistent print
than any other aftermarket or reused OEM component combination.
Our chemically treated components have been qualified
to perform in multiple duty cycles, but are still only
used once.
Toner serves two purposes in the image re-production
process: a) the formulation adheres to the paper by being
thermally fused, creating the graphical images and text;
and b) it also acts as a lubricant to reduce friction
between moving parts such as the spinning OPC drum and
the semi-abrasive surfaces that it comes into contact
with. While "conventional" toner may be satisfactory
in most cases, Infinity specifies what we consider to
be a superior grade of Toners. The resulting proprietary
formulas are finer, (consistent particle size that supports
better resolution), adheres to the paper better, (leaches
into paper fibers that anchors the toner), and lubricates
the drum, (that maintains print quality and extended
life) for optimal performance. Our custom formulated
toner is chemically and electrically matched to each
cartridge engine system.
Infinity does not reuse or recoat OPC drums. We feel
that a high quality replacement drum provides a dependable
method to assure quality; so we replace every cartridge
we manufacture with a brand new drum. Infinity uses only
grade "A" drums. We do not accept factory
seconds, off spec versions, flawed, or knock-off substitutions.
In many cases, through our manufacturer's purchase order
agreements, they negotiate directly with drum manufacturers
to produce drums to our exact specifications. This kind
of business relationship affords us the exclusivity of
these drums and thereby is not available to anyone else.
Infinity's manufacturing replaces all wiper blades, doctor
blades, and sealing blades with new ones. These blades
are produced to our design criteria; they furnish drawings
produced by their engineers that are furnished to the
suppliers that produce them, their quality assurance
inspectors and production personnel, to assure compliance.
Statistical samples are placed under first article inspection,
and functionality life testing. In addition, each new
wiper blade is treated with our manufacturing proprietary
Anti-Flip Lubricant.
All manufacturing employees are trained in quality control
methods. Every (empty) cartridge received is scrutinized
and sorted into classifications. Those cartridges found
to have damage or evidence of previous remanufacturing
are segregated from the virgin empties, and are subjected
to further inspection, and subsequent cannibalization.
There are inspection personnel that are independent from
manufacturing, and have direct access to top management
regarding inspection activities and grading methods.
Cartridges are pre-qualified, packaged, palletized, and
stored in a manner that is designed to maintain the reliability
of the cartridges. Although these cartridges will be
inspected several more times before shipment, this pre-qualification
supports material requirements planning, and consistent
productivity.
|
 |
| Standard
splitting and sealing methods remove
a layer of plastic, cut through OEM alignment
pins and alter the original cartridge
tolerances.These patented welding technologies
ensure exact OEM alignment, eliminate
human error and the need for clips. This
results in precision alignment during
manufacturing, superior cartridge reliability
and color matching. |
|
|
Before any remanufacturing operations commence, all cartridges
are completely disassembled. High volume products are
opened with our manufacturer's patented laser cutting.
All other products are opened with mechanical splitters
designed by our manufacturer's engineers. These methods
support the proper alignment of rejoined cartridge body
sections during reassembly.
- During the disassembly process many of the
components are transported in specially designed fixtures
to eliminate damage, and enhance down-stream acceptance. Our manufacturer also designed and produced
shelving units that prevent contact between components,
and minimize exposure to light.
- Oil free, dry, and filtered air (calibrated
PSI) is used to remove residual toner from all cartridge components. Special ionization nozzles are also used
to eliminate air-borne particulate matter.
- Continuous evaluation of the cosmetic condition
of each cartridge is emphasized to all manufacturing
employees, anyone can request a quality review regarding
scratches, dings, blemishes, or marking that would
otherwise undermine the policy of furnishing customers
with a "like new" appearance.
- Each component is segregated, cleaned, and
qualified.
- Applicable components are processed in a non-cfc
recycled, filtered, aqueous solution that is activated
by an ultrasonic cleaner to remove microscopic particles.
- Ultrasonic technology is also used to attach
and seal the majority of our Toner hoppers to their
cartridge bodies. Directing the sonic sound waves creates
friction at a molecular level and thereby fuses /
welds the two sections together without the use of glues, solvents,
or other environmentally harmful substances.
Our manufacturing process invests a great deal of effort
into clearly stating requirements to its suppliers regarding
our acceptance expectations. But we do not solely rely
on their inspection efforts. Manufacturing performs a
formal receiving inspection on all purchased products.
When we buy a product for the first time, we have it
tested operationally, destructively, and in a "real
world" printing situation.
Infinity's manufacturing evaluates every batch of toner
prior to manufacturing. We require a disciplined lot
control management system from our suppliers, which
includes the retention of "Hold-Back" samples at the
suppliers location for traceability on delivered lots.
We also require unique lot numbers on each toner container.
When a new toner lot arrives it is staged in a bonded
and securely controlled location. Random samples are
removed, poured through a military specification sieve
which will display indications of foreign material
and or unacceptably large toner particles. If found
acceptable, the affected toner is loaded into its corresponding
cartridge(s), some toner will react differently depending
on which cartridge is used. Engine speeds, feed rates,
voltage levels, and melt points must be evaluated on
a "by cartridge" basis. Any irregularities discovered
require an independent set of testing by manufacturing's
Toner Laboratory which determines the root cause of the subsequent rejection.
As previously stated the Primary Charge Rollers (PCRs)
are thoroughly cleaned, inspected, and tested for conductivity,
(intermittent voltage or a high resistance will dramatically
affect print quality). We also perform eddy current, Foucault testing
(to detect minute surface variations), and powerful microscopic visual
inspection. This chemical treating process has strengthened these PCRs
to be able to last through two additional life cycles. Infinity cartridges
guarantees that these PCRs will perform beyond expectation in the most
extreme printing conditions.
Every wiper blade, doctor blade, sealing blade, and
toner hopper seal is installed by a trained, qualified
assembly technician, or is under the direct supervision of a team leader
and or a company training officer.
All new manufacturing employees are trained in each
aspect of the cartridge assembly process from the very beginning to the
last step. Existing manufacturing employees receive refresher training
when quality becomes an issue or when a team requires cross training
for an unfamiliar or new cartridge release. Every new product release
includes written build instructions with diagrams or photographs to ensure
that each step is completed correctly. Each assembly station or cell
is held accountable for the performance and quality of every cartridge
that they build. Every assembler, technician, and inspector at manufacturing
is encouraged to review the previous assembly step before performing
their function. Accept and reject data is collected, rendered graphically,
and shared with the production teams. A dynamic compensation program
based on productivity and the percentage of acceptance motivates team
members to perform at remarkable rates that are competitive internationally.
|
|
When filling a toner hopper we have discovered that
more is not necessarily better, in some cartridges
over-filling the toner hopper may sound like a good
idea, but consider the waste hopper and its' capacity,
it is designed to hold only so much toner residue. When it becomes full,
any excess toner after that will begin to accumulate in the printer cartridge
bay. That is precisely why we have our cartridges weighed before and
after filling; even though our manufacturing process utilizes calibrated,
automated filling machines that regulate toner loads.
We replace components wherever an existing component
could affect print quality or operational functionality.
Every Infinity cartridge is print tested, twenty or more pages consisting of solid area density, (Black), Background Haze, (White), text, graphics, grey scale, and five percent test patterns which are then examined by the post production print tester, and re-evaluated by an independent quality control inspector.
Each completed cartridge undergoes a multiple-step
final inspection process including as applicable: shutter door operation,
turning and visual inspection of the OPC drum, verification of the type,
operation of, and location of the page count and print status memory
chip, visual inspection of the various blades and seals, the general
condition of the cartridge, end-pieces, hardware, aesthetic condition,
and then a vigorous shaking of the cartridge is performed to determine
if the toner hopper has been compromised, or if any toner remains from
the post production print test.
At the packaging stations the cartridge is again looked-over
to verify cartridge integrity, and the test pages are reviewed one last
time before the packaging process begins. Our cartridges are sealed in
easy-to-open moisture and light proof bags, and then placed in easy-to-open,
full color, lithographic boxes. Custom molded (foam in place) end-caps
are produced on demand in real-time. They are created in molding fixtures
designed to fit each cartridge. This packaging method is robust, cost
effective, and safeguards the cartridges all the way to the end-user.
Included in every applicable carton are fuser wiper wands, and product
specific instructions. The easy-to-open pull strip allows the box to
be opened without the use of any implements. In addition, it is re-sealable,
no tape is required when repackaging. All Infinity branded toner products
clearly state information about our full warranty on the outside of our
packaging.
To ensure that Infinity products continue to meet or
exceed OEM grade expectations, we remove product from
our finished goods inventory, post packaging, final
inspection, and directly from the production lines.
The cartridges are randomly selected and manufacturing
dates and batch numbers are recorded. Life testing
is performed, where a cartridge is placed into a printer, and paper is
printed out until the toner is exhausted. During this life test, a series
of differing test patterns consisting of a solid black, solid white,
text and graphics are printed out at intervals between a five percent
coverage page consisting of alphanumeric characters evenly spaced across
the entire printable area. This combination of Test Targets is designed
to reveal print defects ranging from ghosting, (a background haze on
the white page), drum defects, (on all pages, but exemplified on the
black page), and many other defects that repeat at measured intervals,
and reveal anomalies related to one of the major components in a cartridge
engine. Infinity cartridges also go through battery of tests for cartridges
that place them under extreme conditions. Engineers perform testing in
severe temperature cycles, varying percentages of humidity, atmospheric
pressure and vacuum. Infinity wants to be sure that our cartridges will
perform well in any environment not just under standard office conditions.
Our manufacturing has formulated toner that exhibits performance characteristics
that perform consistently better than conventional
ones in these extreme conditions. They also simulate conditions that
reflect shipping and transportation environments. Our box and foam end-cap
combination is designed to survive 30 foot drop tests. We have a fixed
displacement vibration table that exceeds the vibrations of any turbulent
flight, rutted or potholed road. Whether we're shipping
across the county or overseas, our product will arrive
intact.
Infinity's manufacturer, MSE, recently received certification
for Standardized Testing from the International
Imaging Technology Council. This STMC certification
includes:
- Package Integrity per: ISTA 1A
- Standard Practice for Determining Toner Usage for Printer Cartridges,
(ASTM F 1856)
- Density Measurement, Geometric Conditions for Reflection Density,
(ANSI IT2.17)
- Standard Test Method for Evaluation of Larger Area Density and
Background on Electro-photographic Printers, (ASTM F 2036)
Most recently we have become ISO 14000 compliant, and eventually receive
third party accreditation. Many materials used to
produce Infinity's products that are not sold, such
as: ABS plastic, paper, cardboard, and secondary waste materials are
recycled. And we are pleased to produce a product that has a seventy-five
percent post-consumer valuation.
For more information, please check our FAQ page. |
|
|
|
|
| ©2009 Infinity
Imaging Solutions. All rights reserved. |
|
|
