Switching from OEM ink to a replacement is a four-stage procedure: compatibility verification, full system drain, flushing with a dedicated solvent, then filling with the new ink and calibrating viscosity. Done properly it takes a technician 2–4 hours and saves 40–50% of the annual budget of the annual consumables budget with no loss of print quality. Done badly — mixing chemical families, skipping the flush, a cheap replacement with no NVR control — it ends in a clogged LCF filter, a viscosity error or a damaged pump within weeks.
- You are considering moving from OEM to a replacement and want to know how to do it safely
- You have received a quote for replacement ink and want to check whether the implementation procedure is realistic
- Your current OEM supplier claims that "a replacement will ruin the printer" and you are weighing the risk
- You are preparing for a quality audit (BRC, IFS, ISO) and need documentation of the consumables change procedure
01 · Step-by-step procedure Four stages of an ink change
The procedure below works for all the main CIJ platforms: Videojet 1000 series, Domino A-Series and Ax, Linx 8900 and Leibinger JET3up. Section 02 covers what is specific to each brand, because fluid delivery architectures differ.
The procedure should be carried out by a technician experienced with CIJ printers or a trusted engineer authorised by the printer manufacturer. Changing ink looks simple, but mistakes at the flushing stage — mixing chemical families, cutting the flush short — are expensive. If you are unsure, call us before you start. We offer free consultations on the chemical compatibility of our replacements with your specific printer model.
- Dynamic viscosity — typically 3–6 mPa·s for classic MEK inks, within ±10% of the original
- Electrical conductivity — usually 780–1500 µS/cm, critical for correct droplet charging
- Surface tension — determines adhesion to the substrate; a difference above 15% means poorer print quality
- Solvent chemical family — MEK, ethanol, acetone, blended; must be identical
- Stop the jet (Stop Jet)
- Go to the service menu: the "Drain" or "Empty System" function
- Empty the main tank through the drain port (typically 15–30 minutes)
- Disconnect the empty ink cartridge or tank
- If the printer has stood unused for more than >two weeks: manually flush the lines to the printhead with solvent
- MEK → MEK (the same chemical family): 30–60 minutes, one flushing cycle
- MEK → ethanol or MEK → acetone: 2–3 hours, at least two flushing cycles with 30 minutes of evaporation between them
- After a long stoppage (over > 1 month): add an hour to loosen deposits from the filter
- Install the new replacement ink cartridge or bottle
- Run the Prime procedure (fills the lines and printhead)
- Start the jet — the printer will begin viscosity auto-calibration, typically 5–15 minutes
- Run a test print on 100 products and compare with the reference sample from before the change
- Monitor for 24 hours: viscosity, solvent consumption and any alarms
02 · Differences between brands What changes depending on the printer
The four-stage procedure is common to all, but three things differ between platforms: how the cartridge is changed, how long the flush takes, and how electronic locks (RFID, Smart Cartridge) are handled. Here is what to know about each main brand.
Smart Cartridge system with an RFID chip
Videojet cartridges contain a built-in HMAC-SHA256 microcontroller that blocks foreign bottles. MMTech supplies a a compatible cartridge with a matching chip — no jailbreaking of the printer required. The procedure is as described: drain, flush, new cartridge. Typically 2.5 hours in total.
Bag-in-box system
The easiest platform: ink in a plastic pouch inside a carton. Changing the pouch takes 5 minutes and flushing runs from the service menu. MMTech supplies pouches compatible with original Domino cartons. The whole procedure typically takes 2 hours.
A modular system with an internal reservoir
Linx uses an open internal reservoir — the ink is poured in from the bottle. There are no RFID locks, but the system is sensitive to water and contamination. It needs a longer flush (two hours minimum) before the first change. Subsequent changes are typically faster.
RFID activation tags
Every Leibinger bottle carries an RFID label that the printer scans before the fluid is added. MMTech supplies bottles with pre-programmed activation tags — with no need to modify the printer software. The full procedure takes three hours (the Sealtronic hydraulic architecture needs a more thorough flush).
For every customer switching to an MMTech replacement for the first time we offer a a free compatibility test (a 250 ml sample to test on site) and technical consultations with our specialists. We help establish the right flushing procedure for your printer model, choose the correct solvent and verify the parameters after the first few days of operation.
03 · Risks and pitfalls The three most expensive mistakes
Risk 1: mixing chemical families without a full flush
The most expensive mistake there is. Even if both inks are black and "look the same", different solvents (MEK versus ethanol versus acetone) have different solvation profiles. Old resin left in the system precipitates on contact with the new solvent and blocks the filters.
Never top up new ink onto the remains of the old. As little as 50 ml of old ink left in the tank can trigger a cascade of precipitation when 5 litres of new ink is added. A full drain plus flush is a non-negotiable requirement.
Risk 2: a cheap replacement with no NVR control
NVR (non-volatile residue) is a measure of solvent purity: how many milligrams of solids remain after 100 ml of fluid evaporates. Industrial-grade solvent (ASTM D740 Type I, 99.5% purity) allows up to 50 mg per 100 ml. HPLC grade allows ten times less.
The catch: in a closed CIJ system the solvent evaporates but the NVR has nowhere to go. At 50 litres a year, a cheap replacement introduces grams of solids into a one-litre module — a concentration that literally silts up the filters.
Risk 3: the "you lose your warranty" myth
The argument OEM service teams reach for most often when trying to put a customer off a replacement. The legal reality is more nuanced and we cover it in a separate article on warranties and replacements, but in short: using a replacement does not in itself void the manufacturer's warranty, unless the OEM proves that a specific fault was caused by defects in the replacement. Under Polish and EU law (Directive 2019/771, Civil Code art. 577) the manufacturer must show a causal link, not merely the fact that a replacement was used.
Premium replacements retain full chemical compatibility with the original, so in practice they cannot cause a failure arising from "different chemistry". Problems appear only with the cheapest products of unknown composition.
04 · The economics of switching Real savings, in concrete numbers
Take a typical production line running 16 hours a day, 250 days a year, with one CIJ printer (a Videojet 1620, say). Average consumption: 8 litres of ink and 45 litres of make-up per year. Below is a comparison of annual consumables cost.
That is the net figure for a single printer, before the cost of handling, implementation and audit. In a plant with five printers the annual saving covers the salary of one technical or service position.
These figures are indicative, based on average Polish retail prices for Videojet V411-D / V705 and their MMTech equivalents. Your actual calculation depends on your negotiated prices, the ink type (standard black versus pigmented or food-safe) and real consumption on the line.
We will send a quote with a free test sample
Give us the printer model, ink type and monthly consumption. Within 48 hours we will send a quotation for the replacements, the safety data sheet and 250 ml for testing at your plant. No obligation.