INTELLIGENT ENGINEERING™  
The main premise behind the concept of Intelligent Engineering™ is to improve and correct engineering flaws inherent in the basic design of the original cartridge. In addition to OEM flaws, we innovates unique solutions that improve upon standard remanufacturing protocol. Examples would be our patented welding and laser cutting technologies for cartridges. These proprietary and patented processes help us manufacture products that are superior to the competition. During the disassembly and assembly phases there is an opportunity to collect knowledge on common design problems and flaws. It is at this point that the creation of modifications and improvements can be made. An example would be the Cartridge Direct JUMBO cartridge for the HP 4000 that yields 50% more pages (at 5% coverage) than the standard 10,000-page HP m o d e l .    

"QUALITY COMPONENTS MAKE QUALITY CARTRIDGES"

DEVELOPER ROLLER AND PCRS  
Our research has found that many aftermarket PCRs and mag sleeves do not meet our high standards. In addition, the simple reuse of OEM components is risky and somewhat unreliable. Our chemists and engineers have developed a proprietary multi stage treatment process for PCRs and mag sleeves that produce more consistent print than any aftermarket or reused OEM component. Cartridge Direct treated components have been tested to perform for multiple cycles, however, are only used once.          

CUSTOMIZED TONER FORMULATION  
Toner serves a dual purpose in the process of image production. Not only is it the actual material fused to the paper to create images and text, it also acts as a lubricant for the spinning drum. While "raw" toner may be sufficient in most cases, we have chosen what we feel to be a superior type. The resulting proprietary formulas are finer, adhere to the paper better and lubricate the drum for optimal.  We work direct with many toner manufacturers to produce proprietary blends of toner that are only available to us. Our engineers and chemists work closely with our manufacturers to manufacture toner formulations that are more consistent and exceed industry standards.      

BLADE INSPECTION  
EVERY wiper blade, doctor blade, and sealing blade is inspected in the QC department prior to being released to manufacturing. These items are NOT batch tested and are always first quality. Every one is examined which virtually eliminates defectives due to these components.

INCOMING CORE INSPECTION  
• Receiving Inspector analyzes incoming empty cartridges to verify if the cartridge is rebuildable (no scratches, virgin etc).  
• Only qualified cartridges will then be stored into palletized sectionals that are designed to maintain the integrity of the cartridges. Only perfect cartridges can make OUR perfect cartridges.      

DISASSEMBLY, CLEANING AND INSPECTION  
• Technicians completely disassemble cartridges. Some products are opened with our patented laser cutting technologies to increase efficiencies and product quality and reliability. Other products are opened with our designed mechanical splitters that protect alignment pins for reassembly.    
• During the disassembly process many of the components are transported in specially designed fixtures to maintain highest quality and percentage throughout. This includes custom molded shelving units that prevent scratches and minimize exposure to light.    
• Pressurized air is used to clean excess toner from all cartridge components. To minimize damage from pressurized air, we filter all air for particulate matter and all water is removed.    
• Poorly scratched shells or housings are unacceptable. Our products must appear to be as new. All cartridges must be in excellent condition.    
• Each component is segregated, cleaned, and qualified.    
• Many components sent to ultrasonic cleaner, using continuously filtered aqueous non-cfc solution, to remove microscopic particles.    
• Qualified toner hopper cleaned and resealed at sealing station using most appropriate sealing method.  

INCOMING COMPONENT INSPECTION  
• Qualified developer (mag roller) are treated with a proprietary 5-step process designed by our chemists and engineers. This treatment actually has been tested to last through 2 additional cycles, however, it would only be reused once. Our treated mag sleeves are superior to aftermarket mag sleeves and outperform unused/untreated OEM mag sleeves.  
• Primary Charge roller (PCR) is cleaned, tested and treated using similar machinery as the drum testing (conductivity testing, eddy current testing and microscopic visual inspection). Treated PCRs have been tested to last through 2 additional cycles, however, it would only be reused once. Our PCRs are superior to all aftermarket PCRs and are guaranteed to last throughout the most extreme printing conditions.  
• EVERY wiper blade, doctor blade, sealing blade, and seal is inspected again prior to being used.  
• Wiper blades, doctor blades, and recovery blades are cleaned, inspected and coated, or replaced.  
• We evaluate every batch of toner prior to manufacturing. Toner is tested at multiple stages of each barrel and must pass through a  qualified sieve. Our standards are more than 20% stringent than normal vendor specifications. This ensures all components will not receive excessive wear throughout their life cycle and improves print quality.     

ASSEMBLY, FILLING AND TESTING  
• Qualified Technicians are trained in each aspect of the build up from beginning to end product. For each product there are written build instructions with diagrams to ensure each step is completed correctly. Each station is held accountable for every cartridge that passes their workstation during the assembly process. At each station, technicians double-check the previous stations work.

• Hopper is filled with new, custom formulated toner chemically and electrically matched to the complete system of the cartridge. Cartridges are filled via automated equipment and all cartridges are weighed before and after filling to ensure correct tolerances in gram weight delivered.    
• Applicable cartridges are reassembled with Cartridge Direct’s Patented Ultrasonic Welding Process    
• Brand new parts are added wherever necessary.    
• Our Cartridges are 100% test run (not batch tested). We test run each and every cartridge we build.    
• Each completed cartridge undergoes a three-step quality control process.    
 1. First the cartridge is run in a printer for not less than ten pages. Test pages of black, white, text, graphics and grayscales are printed. These pages are inspected for print defects. If no flaws are found, the cartridge then flows to the QC station. At any time the cartridge may be rejected and sent back to the appropriate station for rework    
 2. The QC station inspects all parts of the cartridge. All parts are accounted for and the test pages are reviewed a second time. If no flaws are found, the cartridge will then flow to the packing station,  
  3. At the packing station, the cartridge is looked over to triple check cartridge integrity. In addition, the test pages are reviewed as well.  

PACKAGING  
• Cartridges are sealed in our "easy to open" moisture and lightproof bag. It is then placed in our "easy to open", full color, lithographic box.  

• Custom molded end caps are manufactured while cartridges are being built. They are custom to each cartridge and are designed to provide damage free shipping.  
• Before sealing carton, new fuser and or wiper wands and specific instructions and are put in the box when applicable.  
• We are first to introduce user-friendly packaging. The easy to open pull strip allows the box to be opened without the use of knives, scissors or keys. In addition, it is re-sealable without tape for easy repackaging and returns.  
• Our cartridges also receive prepaid return labels and an extra pre paid bag for inkjet recycling.
• All packaging provides a written full warranty on the outside of box.      

POST PRODUCTION TESTING  
• To ensure products meet and exceed OEM specifications, We post test cartridges every day.  
• Cartridges are randomly pulled from inventory and manufacturing date and batch numbers are recorded.  
• Cartridge Direct runs a battery of tests throughout a complete life test to ensure print quality is acceptable. 
  Test pages of gray, black, white, text and graphics pages are evaluated.

• We test every cartridge under extreme printing conditions. Our engineers perform life testing and print quality testing under  extreme temperature, humidity, and atmospheric pressures. This ensures that cartridges will not only print perfect under standard office environments, but will also perform perfectly in any environment.  
• We also simulate conditions that reflect shipping environments. Our foam in place end caps are designed to survive 30 foot drop tests along with simulated shipping conditions such as truck vibration across the country. Our testing also includes extreme changes in pressure that simulates air shipments.