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Smart engineering
BMT cannot make a perfect cartridge without
perfect components. Our “Quality Control department” is one
of the most difficult to work with in the industry for one
reason. If a component is not perfect and if it does not
meet BMT standards (which almost always exceed industry
standards), it is rejected. BMT will never compromise
quality - regardless of cost.
LONG-LIFE GRAPHIC QUALITY DRUM
While the OEM drum is usually acceptable in terms of
print-density and darkness by most other companies, BMT does
not reuse OEM drums in our Premium Private Label or BMT
Brand cartridges. We feel that a first quality replacement
drum will provide a more consistent level of quality and we
replace it in every Premium cartridge we manufacture. BMT
uses only “A” grade drums. We do not accept factory seconds,
off spec components, flawed, or knockoff substitutions. In
many cases, we work directly with drum manufacturers to
produce product to our exact specifications. In these cases,
BMT drums are made exclusively for BMT and are not available
to anyone else.
DEVELOPER ROLLER AND PCRS
At BMT, our goal is to make the perfect cartridge. Our
research has found that many after market PCRs and magnetic
sleeves do not meet our high standards.
In addition, the simple reuse of OEM components is risky and
somewhat unreliable. BMT chemists and engineers have
developed a proprietary multi stage treatment process for
PCRs and magnetic sleeves that produce more consistent print
than any aftermarket or reused OEM component. In fact, our
specialty magnetic sleeves and PCRs actually outperform
virgin components pulled from a full, never used OEM toner
cartridge! These proprietary 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. Using the standard toner as a base, additives and
lubricants are blended in a special process. The resulting
formula is finer, adheres to the paper better and lubricates
the drum for optimal performance until the very end of the
use-cycle BMT evaluates every batch of toner prior to
manufacturing. Toner is tested at multiple stages of each
barrel and must pass through a BMT qualified sieve. BMT
mandates that all toners must pass through our sieve in
order to pass. Our standards are more than 20% stringent
than normal vendor specifications. This ensures all
components will not receive excessive wear throughout the
life cycle. BMT works direct with many toner manufacturers
to produce proprietary blends of toner that are only
available to BMT. Our engineers and chemists work closely
“PERFECT COMPONENTS MAKE PERFECT CARTRIDGES”
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.
Every one is examined which virtually eliminates defectives
due to these components. BMT is known to reject blades that
are less than 1/10,000 of an inch off spec. We take blade
integrity very seriously.
ENTERPRISES GOLD SEAL
A typical cartridge will have a seal installed and supported
by two foam strips, one at each end. Once the seal is
pulled, toner is allowed to flow and may sometimes leak from
the sides. At BlackMagic, a patented seal made of an
absorbent material is installed which has a full gasket,
making contact with all four sides. This seal is an
improvement over the OEM design and is designed to prevent
leakage unless the cartridge is actually broken in half.
This seal also pulls more smoothly and cleanly since it is
designed to self-clean excess toner. BMT inspects every
single Gold Seal prior to and during manufacturing to ensure
a leak proof and easily pulled seal.
MANUFACTURING PROCESS
INCOMING INSPECTION
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Receiving Inspector analyzes incoming
empty virgin cartridges to verify if the cartridge is
rebuildable (no scratches etc).
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Only qualified virgin cartridges will
then be stored into palletized sectionals that are
designed to maintain the integrity of the cartridges.
Only perfect virgin cartridges can make perfect BMT
cartridges.
DISASSEMBLY AND CLEANING
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Technicians completely disassemble
cartridges. During this process many of the components
are transported in specially designed fixtures to
maintain highest quality and percentage throughput. This
includes custom molded shelving units that prevent
scratches and minimize exposure to light.
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Pressurized air is used to clean excess
toner from all cartridge components. To minimize damage
from pressurized air, BMT filters all air for
particulate matter and all water is removed.
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Scratched shells or housings are
unacceptable. BMT products must look new. All cartridges
must be visually perfect.
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Each component is segregated, cleaned,
and qualified.
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Many components must be processed
(coated, treated, electrically tested, etc.)BMT spares
no expense in machinery and technical manpower to assure
each component will guarantee a flaw free build up.
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Many components sent to ultrasonic
cleaner, using continuously filtered aqueous non-cfc
solution, to remove microscopic particles.
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Qualified toner hopper cleaned and
resealed at sealing station using most appropriate
sealing method.
ASSEMBLY, FILLING AND TESTING
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All drums are tested using state of the
art machinery (conductivity testing, eddy current
testing, polishers and microscopic visual inspection)
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Qualified developer (magnetic roller)
is cleaned and resurfaced or replaced. If it passes
initial inspection, virgin magnetic sleeves are treated
with BMT’s proprietary 5 step process designed by BMT
chemists and engineers. This treatment actually has been
tested to last through 2 additional cycles; however, it
would only ever be reused once. BMT treated magnetic
sleeves are superior to every aftermarket magnetic
sleeve and actually outperform an unused OEM magnetic
sleeve.
Primary Charge roller (PCR)
Cleaning procedure: Use distilled water on a lint free cloth
to wipe down the PCR. Allow the PCR to thoroughly dry prior
to installation. Is cleaned and recoated or replaced
These also are tested and treated using similar machinery as
the drum testing (conductivity testing, eddy current
testing, polishers and microscopic visual inspection)
WIPER BLADE
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EVERY wiper blade, doctor blade,
sealing blade, and Gold Seal is inspected again prior to
being used.
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Wiper blades, doctor blades, and
recovery blades are cleaned, inspected and coated, or
replaced.
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Hopper is filled with new, custom
formulated toner chemically and electrically matched to
the complete system of the cartridge. BMT has a
long-standing relation with most of the toner
manufactures in the US and Japan. Many of the toner
formulations we use are proprietary and custom made for
BMT.
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Automated filling machine fills each
hopper consistently, and hopper is weighed.
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Qualified Technicians are trained in
each aspect of the build up from beginning to end
product. They are held accountable for every cartridge
that passes their workstation during the assembly
process. At each station, technicians double-check the
previous stations work
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Brand new parts are added wherever
necessary.
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BMT Cartridges are 100% test run (not
batch tested). We test run each and every cartridge we
build.
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Each completed cartridge undergoes a
three-step quality control process. At any time the
cartridge may be rejected and sent back to the
appropriate station for rework.
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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.
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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,
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At the packing station, the cartridge
is looked over to triple check cartridge integrity. In
addition, the test pages are reviewed as well.
PACKAGING
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Cartridge is placed in our “easy to
open” moisture and light proof bag and heat sealed.
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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.
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BMT is 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 resealable without tape for
easy repackaging and returns.
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Before sealing carton, new fuser wiper
wands (when applicable) and installation and return
instructions are put in the box.
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BMT cartridges also receive prepaid
return labels and an extra pre paid bag for recycling.
POST TESTING
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To ensure BMT products meet and exceed
OEM specifications, BMT post tests more than 50
cartridges every day.
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Before testing BMT products, the OEM is
tested to establish a benchmark.
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Cartridges are randomly pulled from
inventory and manufacturing date and batch is recorded.
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Print testing begins with an initial
set of graphics pages. Graphics testing includes full
pages of blacks, grayscales, white, and text. BMT
ensures a perfect print from the very first page.
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Batches of 500-1000 pages (depending on
cartridge yield) are run with 5% coverage.
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After each batch of pages, another set
of graphics pages is run.
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The cartridge is removed and examined
for leakage, excessive wear, etc. At this time the
printer is also looked at to ensure proper working
condition.
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Batches are run continuously until
toner low is indicated on printer. For printers without
toner low sensors, the testing is interrupted when toner
fading occurs.
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At this time, the cartridge is
reevaluated, shaken and reinstalled.
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The cartridge is continuously tested
with batches and sets of graphics until the toner low is
observed for the second time.
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At this time, the cartridge is
reevaluated, shaken and reinstalled.
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When “toner low” is indicated for a
third time, testing is complete and all data including
yield, graphics quality and overall performance is
recorded.
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Every test must exceed the OEM
benchmark in yield and print quality.
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In addition to a controlled printing
environment, BMT tests every cartridge under extreme
printing conditions. BMT engineers perform life testing
and print quality testing under extreme temperature, h u
m i d i t y, and atmospheric pressures. This ensures
that BMT cartridges will not only print perfect under
standard office environments, but will also perform
perfectly in any environment.
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BMT also simulates conditions that
reflect shipping environments. Our foam in place end
caps are designed to survive 30 foot drop tests along
with regular shipping conditions such as truck vibration
across the country. BMT testing also includes extreme
changes in pressure which simulates air shipments.
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