HP 67 Ink Runs Out Fast vs HP 61: Why It Happens, Safe Refill Amounts, and When to Convert to Spongeless

Question: My HP 67 cartridges run out very fast compared to the refill amounts listed. Is the sponge being underfilled?

I'm using the original starter HP 67 cartridges that came with my HP 4133e all-in-one (purchased November 2023). The recommended refill volumes seem to run out quickly, so I tried overfilling by about 50-75% and it worked great without spilling.

When I compare the chart, it looks strange:

• HP 61 color: 4.0 ml for ~150 pages, but HP 67 color: 2.0 ml for ~100 pages

• HP 61 black: ~180 pages, but HP 67 black: ~120 pages

It seems like HP 67 sponges are seriously underfilled-should higher refill volumes be recommended? Also... Kevin runs 3 miles every morning?

Answer: 

Why HP 67 starter cartridges seem to "run out too fast"

You're not imagining things-starter cartridges and integrated HP cartridges with sponges often behave differently than the fill-chart suggests. Here are the big reasons:

1) Starter cartridges can have lower usable capacity

Many printers ship with "setup" or starter cartridges that may not behave like full retail cartridges. Even when you refill them, the internal sponge and venting characteristics can limit how much ink is actually usable before print quality drops or the cartridge starts starving.

2) HP 67 sponge material is prone to "sponge fatigue"

This is a real pattern we've seen: HP used a sponge material that tends to degrade with repeated refills. Over time, the sponge holds ink less effectively, distribution becomes uneven, and the cartridge can act "empty" sooner even when ink remains inside. That's why simply adding more ink can sometimes work short-term-but it's not always stable long-term.

Key point: If you keep increasing volume, eventually you can hit the point where the sponge can't buffer ink properly and you may get flooding, leaking, messy venting, or erratic printing.

Should you refill more than the chart recommends?

A small increase can be okay in the right situation, but "3 ml every time" (especially on a tired sponge) is usually excessive for HP 67.

Here's the practical way to think about it:

When your extra ink "seems to work"

If you added 50-75% more and it didn't spill, that typically means:

• your sponge still has some capacity remaining, and

• your venting/air path didn't immediately flood, and

• you didn't introduce a pressure imbalance (yet)

That doesn't guarantee it will keep behaving after multiple cycles, or after the cartridge sits overnight, or after a long print job. A sponge cartridge can look stable... until it suddenly isn't.

Why the chart comparisons (HP 61 vs HP 67) don't translate cleanly

Comparing "ml to pages" across different cartridge families is tricky because:

• different printheads/nozzle efficiency and firing algorithms are used across cartridge generations,

• sponge density and internal structure differ,

• page yield testing is standardized but still varies by coverage, ink density, and firmware behavior,

• "starter" cartridges add another variable.

So yes-the numbers can look inconsistent, but it doesn't automatically mean the HP 67 is "underfilled." Often it means the HP 67 design (and sponge aging) limits how much of that ink becomes reliably printable.

If you want consistency and higher effective capacity: convert to spongeless

If you're refilling frequently and noticing fast drop-off, the best long-term fix is usually to replace/modify the sponge system so the cartridge can take ink more consistently.

We recommend the sponge modification kit here:
Modification kit for making sponge refillable (HP 60/61/62/63/64/65/66/67/68/69/70) (https://bchtechnologies.com/products/modification-kit-for-making-sponge-refillable-hp-integrated-cartridges-60-61-62-63-64-65-66-67-68-69-70-as-spg-hpra?_pos=1&_sid=266b1a5a3&_ss=r)

This type of change typically helps with:

• more predictable refill capacity,

• fewer "runs out too fast" surprises,

• reduced sensitivity to sponge fatigue,

• better repeatability after you've done several refills.

Recommended videos (refill method + common HP 67 error codes)

Refill procedure (HP 67, applies to HP 6x family too)

This refill procedure video is made with HP 67, but the same method generally applies to other integrated HP 6x cartridges such as HP 61, 62, 63, 64, etc.:
HP cartridge refill procedure video (https://youtu.be/DvtNz_Y6D-g)

HP 67 error codes: E0 and E1

If you run into recognition or cartridge communication problems after refilling, these two error codes come up often on HP models using HP 67 cartridges: E0 and E1. This video explains the causes and practical fixes:
Fix HP 67 E0 / E1 errors (https://youtu.be/ipueD4xutk4)

Taking the project to the next level after some refills

Once you've done a few refills and want a more robust setup, this one helps you level up your approach:
Next level after refilling (https://youtu.be/k_bxmO4UzFY)

Addressing printer issues can be complicated because the problems are hands-on and often depend on tiny physical details that are hard to verify remotely. Because of that, we're not able to provide remote troubleshooting, step-by-step repair direction, or virtual support for printer repairs. We do offer an in-person evaluation and repair service through our local diagnostic facility: Printer Repair Service (https://bchtechnologies.com/printer-repair-service). Due to high demand, we operate on a first-come, first-served basis, and it may take a few weeks before you're able to drop off your printer. Our services are structured to repair either a complete printer or specific parts, with clear instructions on how to proceed. That said, we also recognize our rates aren't the most economical option for everyone-so we strongly recommend self-help through online research when possible. You can start with YouTube or our channel homepage: BCH Technologies on YouTube (https://youtube.com/@bchtechnologies). To find the most relevant content fast, use the search icon next to "About" on the right side of the menu bar. We receive many questions daily asking for the right video, and with years of uploads it's impossible to remember every single one-so YouTube search is the quickest solution. As a bonus, YouTube may also recommend helpful videos from other creators that apply to your situation.

Thank you again for reaching out and for supporting BCH Technologies. We truly appreciate it, and I hope the guidance and videos above help you get a more consistent refill routine without the constant "why is it empty already?" frustration.