TECHNICAL DATA / BLACK-AND-WHITE FILM June 2005 • AJ-3

How to Process and Print Black-and-White Film Processing and printing your own films can be rewarding and If you convert a room or a closet into a temporary fun. With a little practice, you’ll find it’s easy, too. for loading film into the tank, check it by staying To process your film, you’ll need the following in the room or closet for about 5 minutes with the out. equipment: If you can’t see a sheet of white paper placed against a dark • Lighttight film-processing tank that accepts the size of background, your darkroom passes inspection. You can film you plan to process make areas around doors and windows lighttight by putting heavy cloth or black tape over the cracks. • Darkroom graduate or a 16-oz (473 mL) measuring cup For printing and enlarging, you do not need total darkness. • Darkroom thermometer Just be sure that the only in the room is supplied by a • Several quart jars or bottles (glass, stainless steel, or suitable lamp with an OC Safelight Filter, and keep plastic) for processing solutions the at least 4 feet from the lamp. • Stirring paddle to mix solutions Kitchens and bathrooms nearly always make the best places for temporary printing because they • Soft viscose sponge provide three major essentials: running water, electrical • Darkroom timer or a clock with a sweep-second hand outlets, and a good work surface. Use a sheet of plastic or a •Scissors plastic tablecloth under the processing trays to protect the • Bottle or magazine opener if you are processing film in countertop from spills. size135 magazines If possible, try to separate your darkroom into a wet area • Protective gloves to prevent skin contact with chemicals and a dry area. Use the dry area for enlarging and printing and for handling films, negatives, and photographic paper. • Spring-type clothespins for hanging processed film to Use the wet area for mixing chemicals and for all processing dry operations. Be sure to have a container of water for rinsing To make prints, you’ll need this equipment: your hands to prevent contamination of your developer with • Safelight, such as a Darkroom Lamp with a other solutions. Use a clean towel to dry your hands KODAK OC Safelight Filter (light amber) thoroughly before handling films, negatives, and paper. • Printing frame or Note: For your safety, handle photographic chemicals and • 8 x 10-inch piece of heavy cardboard processing solutions with care, and keep them out of the reach of children. Some processing solutions can be stored • Four trays a little larger than the largest prints you plan to make (or shallow pans or and reused. Be sure to store them in a safe place. For dishes made of glass, plastic, china, or stainless steel) safe-handling information for particular Kodak chemicals, see the product label or the Material Safety Data Sheet • Print squeegee or soft viscose sponge (MSDS). To obtain MSDSs, go to To make prints the same size as your negatives, you need www.kodak.com/go/MSDS. a printing frame or an enlarger and a piece of glass to hold the light-sensitive photographic paper in contact with your negatives during . If you want to make PROCESSING YOUR FILM enlargements, you need an enlarger with a holder To process black-and-white film, you’ll need the following that’s the right size for your negatives. You also need an solutions: easel to hold the paper in position below the enlarger . • Film developer Your photo dealer will be glad to help you select your equipment, including darkroom kits of basic items. Some of • or water this equipment is listed under “KODAK DARKROOM •Fixer AIDS.” • KODAK Hypo Clearing Agent (optional) • KODAK PHOTO-FLO 200 Solution (optional) WHERE TO WORK Kodak offers a number of black-and-white film Because photographic films and papers are sensitive to light, developers as liquid concentrates or powders. For a list of you must handle them in a darkroom. To process film, you’ll developers, see “Chemicals.” KODAK PROFESSIONAL need a darkroom only while you’re loading the film into a XTOL Developer is an excellent choice for all-around film lighttight film-. But during this time, the developing. It is supplied as an easy-to-mix powder that you room must be totally dark. can mix and use at room temperature.

©Eastman Kodak Company, 2005 You’ll need to use a stop bath (or water), such as KODAK lights. (If necessary, practice with a roll of waste film with Indicator Stop Bath or KODAK EKTAFLO Stop Bath, after the lights on and then in total darkness until you can load the the developer. tank with confidence.) You can choose from several fixers supplied as liquids or Line up the equipment you will need so that you’ll be able powders, which you can also use when you process your to locate each item quickly when the room is dark: prints (see “CHEMICALS”). If you plan to process film-processing tank, tank cover, film apron or reel, exposed KODAK PROFESSIONAL T-MAX Films, we recommend film, scissors, and a bottle opener or 135 magazine opener if using KODAK Rapid Fixer. you are processing size . Label three of the glass, plastic, or stainless-steel bottles Before you turn off the lights, pour the developer solution “Film Developer,” “Stop Bath,” and “Fixer.” Mix the three into the tank. Then turn off both the room lights and the solutions according to the instructions packaged with the . chemicals. The instructions give important information IN TOTAL DARKNESS, open your film as follows: about proper mixing and handling, as well as the • 135 Film in Magazines: Hold the magazine with the recommended development times, temperatures, and long spindle end down. Use a hook-type bottle opener to capacities. pry off the upper end cap. Rap the long end of the You can also use KODAK Hypo Clearing Agent to magazine sharply on a hard surface to release the film if shorten washing times, and KODAK PHOTO-FLO 200 it doesn't come out easily. Be careful of any sharp edges. Solution after washing to minimize water marks and streaks (Leave the film attached to the spool until after you have on film as it dries. loaded your tank apron or reel. Then cut the film off the spool with your scissors.) Before Processing • Roll Film: Tear off the “EXPOSED” sticker. Separate Mix all solutions before loading your film into the film tank. the backing paper from the film, and cut free the end that The solutions should be at a temperature of 65 to 75°F (18 to is attached to the paper. 24°C) when you use them. You can cool or warm the Handling the film by the edges, load it onto the reel solutions quickly by setting the bottles of solution in a pan according to the instructions for your tank. Then follow the of cold or warm water. processing steps in the table below: It’s easy to become disoriented in the dark, so be sure you know how to load your film tank before turning out the

Processing Step Time Agitation and Notes 1. Developer Use the development time for your Smoothly lower the loaded film reel into the developer solution in the film/developer/temperature tank, and attach the top to the tank. Turn on the lights. Firmly tap the tank combination given in the film or on the top of the work surface to dislodge air bubbles. Provide initial developer instructions. agitation for 5 seconds, and then repeat the 5-second agitation at 30-second intervals for the remainder of the development time. (See the table below for agitation techniques for different types of tanks.) Drain the tank. 2. Stop Bath 30 seconds Pour in the stop bath, and agitate continuously. Drain the tank. 3. Fixer 2 to 4* minutes with a Pour in the fixer. Agitate continuously for the first 30 seconds, and then at liquid-concentrate fixer 30-second intervals. Drain the tank. OR 5 to 10* minutes with a IMPORTANT: With KODAK PROFESSIONAL T-MAX Films, fixer will be powder fixer exhausted more rapidly than with other films. Fix for 3 to 5 minutes in KODAK Rapid Fixer or 5 to 10 minutes in KODAK Fixer, KODAFIX Solution, or POLYMAX T Fixer. If negatives show a pink stain after fixing, the fixer may be near exhaustion or the fixing time was too short. 4. Rinse 30 seconds Rinse the film in the tank under running water. Agitate continuously for the first 30 seconds and then at 30-second 5. Hypo Clearing Agent 1 to 2 minutes intervals. 6. Water Wash 5 minutes after Hypo Remove the top from the tank. Run the wash water at least fast enough Clearing Agent to provide a complete change of water in the tank in 5 minutes. For rapid OR washing in a small tank, fill the tank to overflowing with fresh water and 20 to 30 minutes without then dump it all out. Repeat this cycle 10 times. Hypo Clearing Agent step 7. Wetting Agent 30 seconds Provide gentle agitation for 5 seconds of the total time. To reduce drying scum, mix KODAK PHOTO-FLO Solution with distilled water in areas that have hard water. 8. Dry As necessary Remove the film from the reel, and hang it up to dry in a clean, dust-free place.

* Times are approximate. See the film or developer instructions.

2 How to Process and Print Black-and-White Film • AJ-3 Agitation is very important for even development of the Before exposing your proof sheet, prepare your film. Follow the procedure below for the type of tank you are paper-processing solutions. You’ll need the following using: chemicals: • Paper developer Small-Tank Agitation Procedures • Stop bath Type of Tank Type of •Fixer Agitation Invertible Non-Invertible Kodak has a variety of black-and-white paper developers Tap tank on work Tap tank on work to choose from. Some are designed to enhance paper surface to dislodge air surface to dislodge air bubbles. Provide 5 to bubbles.Rotate film reel characteristics, such as a warm tone. A good Initial 7 inversion cycles in 4 or 5 times during first all-around developer to start with is KODAK DEKTOL Agitation 5 seconds, i.e., extend 5to10 seconds. Developer, diluted 1:2 (1 part stock solution to 2 parts your arm and twist your wrist 180°. water). You can use the same type of stop bath and fixer that you At 30-second intervals, At 30-second intervals, Subsequent repeat 5 to 7 inversion rotate film reel used to process your film, but be sure you mix it properly. Agitation cycles in 5 seconds. 4or5times. Most fixers require a 1:3 dilution for use with film and a 1:7 dilution for paper. (See the fixer instructions.) After processing, thoroughly wash and dry all equipment Mix the developer, stop bath, and fixer according to the that came into contact with chemical solutions. When the instructions packaged with the chemicals, and store the film is thoroughly dry, cut it into shorter strips of negatives solutions in labeled bottles. to make proof sheets. When you are ready to make your proof sheets, arrange Always store your negatives in sleeves or envelopes away four trays on the work surface in your darkroom. Label them from dust and extreme temperature and humidity. “Developer,” “Stop Bath,” “Fixer,” and “Wash.” Working from left to right, pour the developer in the first MAKING PRINTS tray, stop bath into the second tray, and fixer into the third tray. Fill these trays to a depth of about one-half inch of Kodak black-and-white photographic papers are available in solution. Fill the fourth tray with water. Adjust the solutions a wide variety of sizes, speeds, contrasts, surface textures, to 65 to 70°F (18 to 21°C) by placing a small, deep bowl of image tones, stock tints, and weights. either warm or cool water into the tray of solution. Be careful To start, we suggest that you use KODAK not to spill any water into the solutions. PROFESSIONAL POLYCONTRAST IV RC Paper for both Be sure your hands are clean and dry before handling your your contact prints and your enlargements. The resin coating negatives and paper. Now you are ready to expose your proof on this paper permits short processing and drying times. sheet. Follow these steps: When you expose it with KODAK POLYMAX Filters, you 1. Turn out all lights except the recommended safelight can produce different degrees of contrast in the prints you (see the label on the package for the recommended make from one package of paper. safelight illumination). The safelight should be at least When you become more proficient in printing and 4 feet from the paper. Remove one sheet of paper from enlarging, you may want to try other papers. See “More the package, and rewrap the remaining paper to protect Information” for publications on Kodak papers. it from the printing light. 2. Place your strips of negatives so that their emulsion side Making a Proof Sheet faces the emulsion side of the paper. Cover the paper Proof sheets are photographic prints that include many and negatives with the glass. The negatives should face from strips of negatives. The print images are the the light source. same size as your negatives. They can help you choose the 3. Make the exposure: best negatives for enlarging, and they also make a good record of your prints to file with your negatives. If you’re using a printing frame and a 7-watt bulb, hang To make a proof sheet, you’ll need your strips of negatives the bare bulb 2 feet above the frame and turn it on for and a printing frame with a 7-watt light bulb or an enlarger about 10 seconds. A 10-second exposure should be and a piece of glass. right, but you may have to experiment to get the correct exposure. If the processed print appears too light, make You can make a printing frame by using a piece of another proof sheet with double the exposure time; if it’s window glass or clear Plexiglas and a piece of composition too dark, use half the time. board. Both pieces should be the same size. Put one piece on top of the other and use wide adhesive tape to make a hinge If you’re using an enlarger light source to make your connecting the two pieces. (If you use glass, it’s a good idea proof sheet, place the empty negative carrier in the to tape the remaining edges so that you won’t cut yourself.) enlarger, and set the lens at f/11. Adjust the enlarger height so that the light covers an area just larger than the size of your paper. Expose for about 8 seconds. Again, you may have to experiment to get the correct time.

How to Process and Print Black-and-White Film • AJ-3 3 Processing Your Proof Sheet 2. Turn on the enlarger light and set the enlarger lens at its 1. Take the exposed paper from the printing frame or widest opening (the lowest f-number on the lens mount). enlarger easel and slide it completely into the developer, Then raise or lower the enlarger head and adjust the emulsion side down. Then turn the paper over, and easel guides to get the size and picture composition you agitate by rocking the tray gently throughout the want. For best viewing of the image on the easel, work development time (1 minute for POLYCONTRAST IV with the safelight on and the room lights off. RC Paper in DEKTOL Developer). Tip up first one side, 3. Adjust the focus control on the enlarger lens to bring then the adjacent side. your picture into the sharpest focus possible. Then 2. Take the paper out of the developer and let it drain for change the lens opening to f/8 and turn off the enlarger 5 seconds. Then immerse it in the stop-bath solution for light. at least 10 seconds, agitating thoroughly as in Step 1. 4. Working only by safelight, open the easel and insert the 3. Remove the paper from the stop bath, drain it for paper test strip emulsion side up. Be careful to place the 2 seconds, and slip it into the fixer. Agitate frequently strip so that it records a good sampling of important for 2 minutes. You can turn on the room lights after image tones in the negative. Close the easel or use about 30 seconds. (If you have more than one print in masking tape to hold the strip flat. the tray, keep them separated.) Do not overfix. 5. Make a 5-second exposure of the entire strip. Then 4. Transfer your print to the wash tray. Wash for 4 minutes cover one fifth of the strip with the sheet of heavy in gently running water at a temperature between 50 and cardboard, and expose for 2 seconds. Cover an 85°F (10 and 30°C). Avoid overwashing. additional fifth of the strip, and expose for 3 seconds. Cover another fifth, and expose for 4 seconds. Cover 5. Use a soft viscose sponge or a soft rubber squeegee to another fifth, and expose for 6 seconds. Then turn off remove excess water from the print surfaces. Dry the the enlarger light. This will provide a series of five print on a flat surface at room temperature with good air exposures ranging over 2 stops about 1/2 stop apart, as circulation. You can speed drying by blowing warm air shown: from a portable hair dryer onto the print. Make sure that the temperature of the air is below 190°F (88°C). 20 sec 14 sec 10 sec 7 sec 5 sec

ENLARGING 6. With only the safelight on, process the strip as described earlier under “Processing Your Proof Sheet.” Then Your proof sheet should serve as a good guide for selecting examine it under room lights to determine which portion the negatives you want to enlarge. Study the images to find of the strip has the best exposure. Note the exposure the ones with the best composition and exposure level time for the portion you select. The 5-second exposure (neither too dark nor too light). When you’ve selected a will be the lightest. If all the steps are too light, open up negative you want to enlarge, it’s a good idea to make a test the lens (lower f-number) or increase the exposure time. strip or print to determine the exposure you need to make a If all the steps are too dark, close down the lens or good enlargement. (After you’ve gained some experience, decrease the exposure time. you won’t need to make a test strip or print for every negative If the strip looks flat or muddy, use a higher-numbered you print.) POLYMAX Filter in the enlarger to increase the contrast. If it has a very harsh, contrasty appearance, use Making Test Exposure Strips and Prints a lower-numbered filter. Test exposure prints and strips serve the same function, but Now that you know the approximate exposure and best are different in size. A test print is a sheet of photographic contrast, you may want to make one final test strip, with very paper exposed and processed to find out if your exposure and small differences in exposure time between steps, to contrast estimates are correct. (Although your first test print determine the very best overall exposure time before making may look good enough to be the final print, don’t be a full print. disappointed if it doesn’t.) When you’re satisfied with your exposure test, place a A test exposure strip is a 1- or 2-inch-wide strip of sheet of paper, emulsion side up, under the masking guides enlarging paper cut from a larger sheet. Because it’s more on the enlarger easel. Turn on the enlarger and expose for the economical to expose test strips than full test prints, we’ll time determined by your tests. Turn off the enlarger. focus on test strips here. Remove the sheet of paper, process it, and dry it. 1. Hold the negative gently by the edges and remove dust with a camel’s-hair brush or by blowing compressed air Safe Disposal of Used Chemicals. Be sure to dispose of across the surfaces. Small cans of compressed air chemicals properly. To a large extent, exactly how you do appropriate for photographic uses are available from that will depend on what the chemicals are, the volume of the photo dealers. Place the negative in the correct negative carrier, emulsion side down. Slide a sheet of smooth solutions you discard, and whether you are discharging them white photo paper or a scrap sheet of photo paper under into a sewer or into a septic system. Generally, you can pour the guides of the easel to serve as a focusing aid. small amounts of used photographic solutions down the drain without ill effect. Discard the solutions one at a time (to

4 How to Process and Print Black-and-White Film • AJ-3 avoid unwanted chemical reactions). Rinse the sink KODAK Fixer. Recommended for general use with films thoroughly and flush the drain with plenty of clean water and papers. It comes in powder form. Just mix with water for after dumping each solution. Because the discharge or immediate use. disposal of spent photographic solutions may be subject to local, state, or federal laws, contact the appropriate KODAK POLYMAX T Fixer. Single-solution hardening authorities to determine the requirements that apply to your fixer for films and papers. Designed for use with KODAK area. POLYMAX T Developer. Dilute 1:3 for film and 1:7 for paper.

CHEMICALS Paper Developers You can purchase the following Kodak chemicals from KODAK DEKTOL Developer. For neutral and cold-toned dealers who sell Kodak Professional products. images on papers such as KODAK POLYCONTRAST IV RC, POLYMAX II RC, KODABROME II RC, and KODAK Film Developers POLYMAX Fine-Art Papers. It’s supplied in powder form. KODAK XTOL Developer. Provides excellent image Dilute 1:2 for use. quality with fine grain and high sharpness in both normally processed and push-processed films. It’s supplied as a KODAK POLYMAX T Developer. For neutral or powder for easy, room-temperature mixing. cold-toned images on papers such as POLYCONTRAST IV RC, POLYMAX II RC, KODABROME II RC, and KODAK T-MAX Developer. Produces excellent image POLYMAX Fine-Art Papers. It’s supplied as a liquid quality and improved tone reproduction (increased shadow concentrate. Dilute 1:9 for use. detail) in both normally processed and push-processed films. It’s supplied as a liquid concentrate. Other Chemicals KODAK Hypo Clearing Agent. Shortens washing times KODAK Developer D-76. A general-purpose developer and makes possible more thorough washing of films and that produces moderately fine grain, full emulsion speed, and prints. It reduces the wash time to 5 minutes for films, maximum shadow detail. It comes in powder form. 10 minutes for single-weight papers, and 20 minutes for double-weight papers. This water-saving chemical is not KODAK HC-110 Developer. A highly active developer recommended for water-resistant, resin-coated (RC) papers, supplied in liquid-concentrate form. It produces negatives of which already have a short wash time (4 minutes). Dilute 1:4 similar quality to those obtained with Developer D-76, but for use. requires shorter development times. KODAK PHOTO-FLO 200 Solution. A liquid concentrate KODAK MICRODOL-X Developer. An excellent that minimizes water marks and drying streaks on film, and fine-grain developer designed to produce low graininess and speeds drying. Dilute 1 part concentrate to 200 parts water high sharpness of image detail. It’s particularly good for for use. developing small negatives from which you want to make big enlargements. MICRODOL-X Developer is available in both KODAK Toners. For altering the image tone of powder and liquid forms. black-and-white prints and prolonging print life. Several Kodak toners are available for producing various tones, Stop Baths depending on the toner/paper combination and the dilution After development, you’ll need a stop bath for rinsing your of the toner. film and prints. You can use KODAK Indicator Stop Bath (1:63) or KODAK EKTAFLO Stop Bath (1:31). Both are available as liquid concentrates, and both have KODAK DARKROOM AIDS built-in indicators to signal when the chemicals are KODAK Darkroom Lamp. For use in a wall socket or a 1 exhausted and should be discarded. drop-cord socket. Sturdy metal. Accepts circular 5 ⁄2-inch safelight filters (not included). Fixing Baths KODAK Rapid Fixer. An easy-to-use liquid concentrate for KODAK 2-Way Safelight. For use in either a wall socket or very rapid fixing of films and normal fixing of prints. It a ceiling socket. Swivels to provide direct or indirect 1 3 consists of two concentrates that you add to water to prepare illumination. Holds a 3 ⁄4 x 4 ⁄4-inch safelight filter (not the fixing bath. Dilute 1:3 for film and 1:7 for paper. included).

KODAFIX Solution. A general-purpose liquid-concentrate, KODAK Safelight Filters. Supplied in a variety of sizes single-solution fixer for both films and papers. Just mix with and for use with papers and certain films. water for immediate use. Dilute 1:3 for film and 1:7 for paper.

How to Process and Print Black-and-White Film • AJ-3 5 How to Process and Print Black-and-White Film

MORE INFORMATION The following books are available from photo-specialty Kodak has many publications to assist you with information dealers who sell Kodak products: on Kodak products, equipment, and materials. F-5 KODAK Professional Black-and-White Films Additional information is available on the Kodak website and through the U.S.A./Canada faxback system. R-20 KODAK Black-and-White Darkroom DATAGUIDE The following publications are available from dealers who sell Kodak products, or you can contact Kodak in your For the latest version of technical support publications for country for more information. KODAK PROFESSIONAL Products, visit Kodak on-line at: http://www.kodak.com/go/professional F-2 Pathways to If you have questions about KODAK PROFESSIONAL F-4016 KODAK PROFESSIONAL T-MAX Films Products, call Kodak. F-4017 KODAK PROFESSIONAL TRI-X Films In the U.S.A.: 1-800-242-2424, Ext. 19, Monday–Friday F-4018 KODAK PROFESSIONAL PLUS-X Films 9 a.m.–7 p.m. (Eastern time) G-10 KODAK AZO Paper In Canada: G-16 KODABROME II RC Paper 1-800-465-6325, Monday–Friday G-4037 KODAK POLYCONTRAST IV RC Paper 8 a.m.–5 p.m. (Eastern time) G-23 Toning KODAK Black-and-White Materials G-24 KODAK POLYMAX Fine-Art Paper Note: The Kodak materials described in this publication are G-27 KODAK PANALURE SELECT RC Paper available from dealers who supply KODAK J-24 KODAK HC-110 Developer PROFESSIONAL Products. You can use other materials, but you may not obtain similar results. J-78 KODAK Developer D-76 J-86 KODAK T-MAX Developers J-87 KODAK T-MAX 100 Direct Positive Film Developing Outfit J-109 KODAK XTOL Developer K-4 How Safe Is Your Safelight?

How to Process and Print Kodak, Kodak Professional, Dataguide, Dektol, D-76, Ektaflo, HC-110, Revised 6-05 Black-and-White Film Kodabrome, Kodafix, Microdol-X, Photo-Flo, Polycontrast, Polymax, T-Max, Printed in U.S.A. KODAK Publication No. AJ-3 and Xtol are trademarks. Monitoring and Troubleshooting KODAK Black-and-White Film Processes

©Eastman Kodak Company, 2003 Table of Contents

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 3 Why Should You Monitor Your Process? ...... 3 How Is a Process Monitored? ...... 3 Getting Started ...... 4 KODAK Black-and-White Film Process Control Strips ...... 4 Starting Up Your Process ...... 5 Determining an Optimum Development Time for Control Strips ...... 6 Getting Your Process in Control ...... 7 Detecting and Adjusting an Underreplenished Process...... 7 Process Monitoring ...... 8 Frequency of Processing Control Strips ...... 8 KODAK Plotting Form for Black-and-White Film Processing (KODAK Publication No. Y-30) ...... 9 Adjusting Your Process to Aim ...... 10 Control Charts ...... 11 Evaluating Control-Chart Plots ...... 11 Causes of an Out-of-Control Process ...... 12 Diagnosing and Troubleshooting Processing Problems ...... 12 Correcting a Process That is Out of Control ...... 12 Diagnostic Charts ...... 12 Troubleshooting from the Appearance of Processed Film...... 39 More Information on Using Control Strips ...... 42 Changing to a New Batch of Control Strips ...... 42 Determining Starting-Point Development Times for Different KODAK Black-and- White Films ...... 42 Safe Handling of Photographic Chemicals...... 44 Worksheet 1 ...... 45 FORM Y-30...... 47

2 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Monitoring and Troubleshooting KODAK Black-and-White Film Processes

WHY SHOULD YOU MONITOR YOUR Deviations from normal conditions can cause under- or PROCESS? overdevelopment. Underdevelopment will result in a Consistently high quality is good business. It means satisfied decrease in density and contrast in your control strips, and a customers because they get good results from their film, loss of density, contrast, and shadow detail in your which in turn means new and repeat business. customers’ negatives. Overdevelopment will produce an High-quality photographic processing depends on increase in density and contrast in your control strips, and an meeting and maintaining process and product standards. You increase in density and contrast with blocked highlights in can meet and maintain these standards by following the your customers’ negatives. manufacturer’s processing and printing recommendations, Although control plots are intended to show a problem and by monitoring and controlling your process. Process before it begins to affect customer negatives, you can usually monitoring enables you to ensure that your process is confirm a problem by visually inspecting customer film operating consistently within tolerances that yield high- when your control plot signals a problem. To analyze and quality negatives. When you monitor your process carefully correct a problem, determine the cause by following a logical and your process stays in control, you reduce waste, avoid sequence when you check your control plots and customer downtime, and increase customer satisfaction, employee negatives. productivity, and profits. Process control provides the following benefits: HOW IS A PROCESS MONITORED? • Process consistency Process monitoring is a method for regularly checking the condition of your process to ensure that it is operating • Higher overall quality of processed film according to a standard. It helps prevent reduced negative • Greater total yield of acceptable film, or processing quality by detecting potential problems. capacity To monitor your process, you will process KODAK • Early detection of process and/or equipment problems Black-and-White Film Process Control Strips; determine the • Less waste of time, chemicals, and film contrast index, speed, and D-min; and then compare those values to aim values. You will plot your process deviations • Increased printing productivity from aim on a control chart. Control charts provide a running • Greater customer satisfaction record of process quality, and do the following: The two factors that most affect the quality of black-and- • indicate if the process is within acceptable limits white negatives are exposure and processing. If your process • show trends in the process and signal you to make changes has not been optimized, it is possible that your customers to keep the process in control have adjusted their film exposure to compensate. Taking • help determine the causes of process problems action to correct an out-of-control process may produce unexpected results in your customers’ negatives. If you • allow you to check adjustments made to the process make major process changes after you begin using control strips, encourage your customers to expose and process test rolls to determine if you are still producing quality negatives that suit your printing operation. If you mix chemicals properly and use the correct settings for the process cycle, the contrast index, speed, and D-min of your processed control strip will plot in control, and your process will produce high-quality negatives. Deviations from normal in the processor, processing solutions, or processing-cycle conditions (e.g., time, temperature, agitation, replenishment, filtration, wash water, drying, etc.) can cause processing problems.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 3 The following terms are frequently used in process Control Chart—A control chart is a plot of your variations monitoring: from aim over a period of time. Plots on your control chart Control Strips—Precisely exposed strips of film used to will confirm the control of your process or provide a clear monitor your process. record of variations in the performance of your process. Sensitometric Parameters—The contrast index (CI), GETTING STARTED speed, and minimum density (D-min) of the control strip are To begin monitoring your process, you will need— the critical sensitometric parameters in black-and-white film • KODAK Black-and-White Film Process Control Strips processing. You will use the densities of the control strip to (CAT No. 180 2990) calculate contrast index and speed and to assess the activity of your process. • an electronic densitometer with a “visual” mode • copies of the KODAK Plotting Form for Black-and-White Contrast Index (CI)—A measure of the degree of Film Processing (KODAK Publication No. Y-30) development that determines how well the density range of a normally exposed negative will print on a grade 2 (i.e., KODAK Black-and-White Film Process Control normal-contrast) paper. Strips Speed—A value that represents a measure of the ability of Kodak supplies KODAK Black-and-White Film Process your process to develop shadow detail. This value is an Control Strips for monitoring the processing of Kodak black- arbitrary number that relates only to the control strip; it is not and-white films in KODAK Chemicals. These strips are pre- an ISO/ASA speed. exposed neutral-density scales on KODAK D-min—A measure of the minimum density (base-plus-fog PROFESSIONAL T-MAX 400 Film / 4053. Each strip has of unexposed film) produced by your process. five neutral-density steps; a raised dimple is located on the emulsion side at the low-density end for orientation. You Aims—These are the values to which you compare the will use the densities of the following steps to calculate the contrast index, speed, and D-min values of your control contrast index (CI) and speed of your process: strips. The aims for contrast index, speed, and D-min are pre- Step 1 D-min printed on the KODAK Plotting Form for Black-and-White Film Processing, KODAK Publication No. Y-30. Step 2 Toe density (TD) Tolerances—Tolerances are the deviations from aim Step 3 Low density (LD) allowed before you must take corrective action. They Step 4 High density (HD) include action limits and control limits. Step 5 D-max Action Limits—The action limits are the boundaries of the These strips are supplied in a box of five foil packages that aim operating range of the process. When the variations from contain 10 strips each. The ends of the strips are perforated aim for contrast index, speed, and D-min plot between the for use with standard control-strip racks. Keep control upper and lower action limits (in the acceptable range), your strips frozen to maintain consistency. Store and handle process is in control. Regions exceeding the action limits are control strips according to the instructions packaged with shaded light gray on Form Y-30. If the variation from aim for them. Use a densitometer in the visual mode to read the any parameter exceeds the action limit and plots in the light control-strip densities. gray area, it is an “early warning.” You can still safely You can use these control strips to assist in determining process customer film, but you should check for the cause of development times when you start up your process, to the shift and correct it. monitor your process, or to determine starting-point Control Limits—The control limits define the maximum development times for other Kodak black-and-white films. tolerances that are acceptable for processing customer film. Regions exceeding the control limits are shaded dark gray on Form Y-30. If any variation from aim plots beyond the control limit, results will be unsatisfactory for shadow density and/or contrast. Stop processing customer film until you find the cause and correct it.

4 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Each time you process a strip, position it in the same location in your processor.† B&W Note: If your processed control strips show a severe Raised dimple magenta (pink) stain after fixing, your fixer may be near exhaustion, or you may not have used an adequate fixing time. If the stain is slight, it will not affect the density values. If it is severe, refix the strip in fresh Batch code fixer; check the fixer in your processor. 2. Measure the densities of the strip in the center of the

1 D-MIN D-min, TD, LD, HD, and D-max steps with a densitometer in the visual mode.

2 TD 3. Calculate the contrast index of your strip by using one of the following formulas or Worksheet 1. The first formula has more steps, but it will give you an answer 3 LD that is more accurate than the second formula will provide. 4 HD

Formula 1 5 D-MAX CI = 0.128 + (0.267 x D-min) – (0.969 x TD) + DATE: (0.454 x LD) + (0.183 x HD) + (0.039 x D-max)

Formula 2 (HD – TD) CI = + 0.10 F002_9093GC 2.26

Note: Monitor your densitometer to ensure that it is 4. Calculate your variation from aim for contrast index calibrated and operating properly. Drifting and inaccurate by subtracting 0.58‡ from the number you determined readings occur most often in the higher densities. Proper in step 3. densitometer performance is especially important for 5. Calculate the speed value of your strip by using this accurate monitoring of your process with KODAK Black- formula: and-White Film Process Control Strips. Keep a record of all maintenance (e.g., filter changes, lamp changes, etc.) Speed = 140.9 x (TD – D-min) + 335 performed on your densitometer. 6. Calculate your variation from aim for speed by Starting Up Your Process subtracting 355** from the number you determined in Follow the procedure below when you first start using step 5. KODAK Black-and-White Film Process Control Strips. You 7. Calculate your variation from aim for D-min by should also follow these steps whenever you start up a new subtracting 0.06†† from the D-min density reading. machine, and if you replace your developer and replenisher with a different type of developer and replenisher. † To check the uniformity of your developer tank, you can position control 1. Process a control strip at the time and temperature that strips to run through several positions in the tank. you use to process PROFESSIONAL T-MAX 400 ‡ 0.58 is the contrast-index aim for printing negatives with a diffusion Film.* Locate the raised dimple on the control strip; it enlarger; use 0.43 if you will print negatives with a condenser enlarger. ** 355 is the speed-value aim for a replenished process for producing is located at the low-density end of the strip. The raised negatives that you will print with a diffusion enlarger; your speed value side of the dimple is on the emulsion side of the strip. may be slightly higher when you use fresh developer. The speed-value aim Process the strip with the emulsion facing in the same for producing negatives for printing with a condenser enlarger will be direction as the emulsion side of the film you process. between 340 and 350. The speed value is not an ISO/ASA speed. In continuous processors, process the low-density end †† Use 0.09 as your aim for D-min if you process film in KODAK of the strip first; in rack-and-tank processors, fasten DURAFLO RT Developer Replenisher. the strip to a film clip with the low-density end up.

* If you do not process PROFESSIONAL T-MAX 400 Film, follow the procedure described under Determining an Optimum Development Time for Control Strips.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 5 8. Plot your variations from aim for contrast index, speed, and D-min on the KODAK Plotting Form for Formula 1 Black-and-White Film Processing, KODAK CI = 0.128 + (0.267 x D-min) – (0.969 x TD) + Publication No. Y-30. (For more information, see (0.454xLD) + (0.183xHD) + (0.039xD-max) Using Form Y-30.) 9. Evaluate the control status of your process by looking at the plots on Form Y-30. Formula 2 If your variations from aim plot within the action (HD – LD) CI = + 0.10 limits (i.e., the white area on each grid on Form Y-30), 2.26 your process is in good control. Use the development time for this strip for all subsequent strips that you 4. If one of the contrast-index values you calculated in process; proceed to Process Monitoring. step 3 is within ±0.02 of your contrast-index aim, If any of your variations from aim plot on or beyond record the development time, and use it to process your the action limits (i.e., in the light or dark gray area on control strips. each grid on Form Y-30), proceed to Getting Your If none of the values is within ±0.02 of your contrast- Process in Control. index aim, find the strip with the contrast-index value that is closest to your aim. Then increase or decrease Determining an Optimum Development Time the development time to fine-tune it, and process for Control Strips another control strip. Measure the densities of each In many situations, your variations from aim for the first step of the strip, and calculate the contrast index. If the control strip that you process will plot out of control because contrast index is within ±0.02 of your contrast-index the strip was under- or overdeveloped, i.e., your aim, record the development time, and use it to process development time was too short or too long. To determine an your control strips. If the contrast index is not within optimum development time for your control strip, follow the ±0.02 of your contrast-index aim, increase or decrease procedure below: the development time again to produce a contrast index that is closer to aim. 1. Process a control strip at the times given below. Record the development time on each strip. 5. Return to step 1 under Starting Up Your Process. Use the development time that you determined in step 4 For dip-and-dunk processes— (above) to process a control strip instead of using your 4 minutes, 6 minutes, 8 minutes, 10 minutes, and development time for T-MAX 400 Professional Film. 12 minutes Note: You can also use the strips processed in the procedure For roller-transport processors using KODAK above to determine development times for other Kodak DURAFLO RT Developer Replenisher— black-and-white films; see Determining Starting-Point 60 seconds, 90 seconds, 120 seconds, and Development Times for Different KODAK Black-and-White 240 seconds Films. 2. Measure the densities of the strips in the center of the D-min, TD, LD, HD, and D-max steps with a densitometer in the visual mode. 3. Calculate the contrast index of each of the strips; use one of the following formulas or Worksheet 1.

6 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Getting Your Process in Control After you process your first control strip, if one or more of the variations from aim plot on or beyond the action limits, use the table below to troubleshoot the process.

Condition Action Variation from aim for CI plots on or beyond the action limits Variations from aim for CI and speed plot on or Follow the procedure under Determining an Optimum beyond the action limits Development Time for Control Strips.* Variations from aim for CI, speed, and D-min plot on or beyond the action limits Variation from aim for speed plots on or beyond the action limits Follow the procedure under Detecting and Adjusting Variations from aim for speed and D-min plot on an Underreplenished Process. or beyond the action limits†

* You may have to repeat this procedure if you make adjustments to correct for an underreplenished process. † If you are using a freshly mixed developer, be sure that it was mixed properly; some fine-grain developers will yield low speed values.

Detecting and Adjusting an Underreplenished Process If you are just starting to process control strips and you have If your variation from aim for speed plots beyond the not recently replaced your developer tank solution, it is control limit below aim (i.e., in the dark gray area): possible that your replenishment rate has been too low. You 1. Replace your developer tank solution with fresh can use one of the following procedures to adjust your solution. process based on where your variation from aim for speed 2. Increase your replenishment rate by 10 percent. plots. 3. Return to the procedure described under Starting Up If your variation from aim for speed plots between the Your Process. action and control limits below aim (i.e., in the light gray area): 1. Replace 25 to 50 percent of your developer tank solution with fresh solution. This will quickly reduce the seasoning of the developer to an acceptable level. 2. Increase your replenishment rate by 10 percent. 3. Return to the procedure described under Starting Up Your Process.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 7 PROCESS MONITORING 6. Calculate your variation from aim for speed by Begin monitoring your process after you have established an subtracting 355† from the number you determined in optimum development time for your control strip—i.e., a step 5. time that yields contrast index, speed, and D-min values that 7. Calculate your variation from aim for D-min by plot within the action limits for your process. subtracting 0.06‡ from the D-min density reading. 1. Process a control strip at your optimum development 8. Plot your variations from aim for contrast index, time. speed, and D-min on the KODAK Plotting Form for Note: If your processed control strips show a severe Black-and-White Film Processing, KODAK Publication No. Y-30. (For more information, see magenta (pink) stain after fixing, your fixer may be Using Form Y-30.) near exhaustion, or you may not have used an adequate fixing time. If the stain is slight, it will not affect the 9. Evaluate the control status of your process by looking density values. If it is severe, refix the strip in fresh at the plots on Form Y-30. fixer; check the fixer in your processor. If your variations from aim plot within the action 2. Measure the densities of the strip in the center of the limits (i.e., in the white area on each grid on Form D-min, TD, LD, HD, and D-max steps with a Y-30), your process is in control. densitometer in the visual mode. If your process runs consistently near one of the action 3. Calculate the contrast index of your strip by using one limits, you may want to adjust your process; see of the following formulas or Worksheet 1. The first Adjusting Your Process to Aim. formula has more steps, but it will give you an answer If any of your variations from aim plot outside the that is more accurate than the second formula will action limits (i.e., in the light or dark gray area on each provide. grid on Form Y-30), proceed to Diagnosing and Troubleshooting Processing Problems. Formula 1 Frequency of Processing Control Strips CI = 0.128 + (0.267 x D-min) – (0.969 x TD) + After your process is in control, we recommend that you (0.454 x LD) + (0.183 x HD) + (0.039 x D-max) process a control strip— • at the beginning of the day or shift, before processing Formula 2 customer film • at regular intervals with customer film (HD – LD) CI = + 0.10 • when you encounter processing problems 2.26 • after you have taken corrective action 4. Calculate your variation from aim for contrast index • when you start up your process with fresh tank solutions by subtracting 0.58* from the number you determined • at the end of the day or shift in step 3. Calculate and plot your variations from aim for contrast 5. Calculate the speed value of your strip by using the index, speed value, and D-min for each control strip that you formula given below. process. Evaluate the control status of your process by looking at the plots on Form Y-30; they will confirm the Speed = 140.9 x (TD – D-min) + 335 control of your process or provide a clear record of variations in the performance of your process. For information on troubleshooting your process, see Diagnosing and Troubleshooting Processing Problems.

† 355 is the speed-value aim for a replenished process for producing negatives that you will print with a diffusion enlarger; your speed value may be slightly higher when you use fresh developer. The speed-value aim for producing negatives for printing with a condenser enlarger will be * 0.58 is the contrast-index aim for printing negatives with a diffusion between 340 and 350. The speed value is not an ISO/ASA speed. enlarger; use 0.43 if you will print negatives with a condenser enlarger. ‡ Use 0.09 as your aim for D-min if you process film in KODAK DURAFLO RT Developer Replenisher.

8 Monitoring and Troubleshooting KODAK Black-and-White Film Processes KODAK Plotting Form for Black-and-White 4. Calculate the speed value of your strip by using the Film Processing formula given below. (KODAK Publication No. Y-30) This form is similar to KODAK Publication No. Y-55, Speed = 140.9 x (TD – D-min) + 335 KODAK Process Record Form, but it includes areas for 5. Calculate your variation from aim for speed by plotting only three parameters: contrast index (CI), speed, subtracting 355† from the number you determined in and D-min. It includes pre-printed aims and action and step 4. control limits for these parameters. 6. Calculate your variation from aim for D-min by Using Form Y-30–Use a separate form for each processor. subtracting 0.06‡ from the D-min density reading. Record the name of the processor in the blank labeled “Machine.” Record the control-strip batch code in the blank 7. Plot the differences on Form Y-30. Plot differences that are larger than the corresponding aim values at the top of the form. (+ values) above the aim line, and those that are 1. Measure the densities of the strip in the center of the smaller than the aim values (– values) below the line. D-min, TD, LD, HD, and D-max steps with a Tolerances and Limits—Form Y-30 includes the densitometer in the visual mode. Record the date and following tolerances and limits for KODAK Black-and- time on the form. White Film Process Control Strips. 2. Calculate the contrast index of your strip by using one of the following formulas or Worksheet 1. The first Action Limits— Control Limits— formula has more steps, but it will give you an answer Range Shaded Range Shaded Parameter Aim that is more accurate than the second formula will Light Gray on Dark Gray on provide. Form Y-30 Form Y-30 Contrast + 0.07 to + 0.20 + 0.20 or higher 0.58* Formula 1 Index (CI) – 0.07 to – 0.12 – 0.12 or lower +15 to +22 + 22 or higher CI = 0.128 + (0.267 x D-min) – (0.969 x TD) + Speed 355† (0.454 x LD) + (0.183 x HD) + (0.039 x D-max) – 9 to – 17 – 17 or lower + 0.02 to + 0.03 + 0.03 or higher D-min 0.06‡ No lower limit No lower limit Formula 2 The light gray regions of the plotting form begin at the (HD – LD) CI = + 0.10 action limit and extend to the control limit for each 2.26 parameter. The dark gray regions begin at the control limit and extend to the edges of each graph. 3. Calculate your variation from aim for contrast index by subtracting 0.58* from the number you determined in step 2.

* 0.58 is the contrast-index aim for printing negatives with a diffusion enlarger; use 0.43 if you will print negatives with a condenser enlarger.

† 355 is the speed-value aim for a replenished process for producing negatives that you will print with a diffusion enlarger; your speed value may be slightly higher when you use fresh developer. The speed-value aim for producing negatives for printing with a condenser enlarger will be between 340 and 350. The speed value is not an ISO/ASA speed. ‡ Use 0.09 as your aim for D-min if you process film in KODAK DURAFLO RT Developer Replenisher.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 9 Adjusting Your Process to Aim After you have monitored your process for a period of time, you may find that your process is not operating close enough to the aims for contrast index and speed. By modifying your development time and/or developer replenishment rate, you can adjust your process to operate at a level closer to aim. The following table lists steps that will help you improve your current process to yield results that are closer to aim.

Condition Action Variation from aim for contrast index (CI) 1. Increase the development time for your control consistently plots near the action limit below aim strip in increments of 10 percent until your contrast index is close to aim. 2. If your variation from aim for speed plots outside the action limit below aim after you increase the development time, increase the replenishment rate by 10 percent. Note: It may take approximately 1 week before you see a significant change in speed. Variation from aim for contrast index (CI) 1. Decrease the development time for your control consistently plots near the action limit above aim, strip in increments of 10 percent until your and variation from aim for speed consistently plots in contrast index is close to aim. the action limit or below aim 2. If your variation from aim for speed plots outside the action limit below aim after you decrease the development time, increase the replenishment rate by 10 percent. Note: It may take approximately 1 week before you see a significant change in speed. Variation from aim for contrast index (CI) 1. Increase your replenishment rate by 10 percent. consistently plots close to aim, and speed value Note: It may take approximately 1 week before consistently plots near the action limit below aim you see a significant change in speed. 2. If your variation from aim for contrast index (CI) plots outside the action limit above aim after you have adjusted your replenishment rate, decrease the development time for your control strip in increments of 10 percent until your contrast index is close to aim.

10 Monitoring and Troubleshooting KODAK Black-and-White Film Processes CONTROL CHARTS Non-random variations indicate changes in the process A control chart is probably the simplest and most effective that usually require investigation and correction. These types tool for achieving process control. Lines indicating aims and of plots indicate non-random data: action and control limits provide a standard of evaluation. • Outliers—Data points that plot on or outside the control Measurements plotted on the chart show the distribution of limits. data, and quickly identify an abnormal situation. The chart Important: Whenever a point plots on or outside the control limit, check that your densitometer is properly also tracks the influences of other factors that change the calibrated and remeasure the control-strip densities. If the process over time. In black-and-white processing, contrast first readings were accurate, process another control strip index (CI), speed, and D-min values of control strips are and measure the densities to confirm that the problem still plotted against pre-determined aims. exists. Follow these steps when you use control charts: • Level shifts—Four to eight consecutive data points that 1. Regularly process control strips, and plot the variation fall on one side of the aim line. When data points are not from aim for contrast index, speed, and D-min of each distributed equally above and below the aim line, strip. something in the process is creating the shift. The more consecutive points that plot above or below the aim line, 2. Evaluate the results; look at the control chart for the higher the probability that a process change occurred changes or trends causing out-of-control situations. that requires investigation. If only two or three points plot 3. Investigate causes of change. on one side of the aim line, those points may be random 4. Take corrective action to eliminate the cause. noise. However, if a fourth point plots on the same side, a shift is likely. A fifth point increases the probability, etc. 5. Take steps to prevent recurrence. Note: To avoid creating a false level shift when you 6. Keep a log that describes any adjustments that you change to a new batch of control strips with a different make to the processing conditions. code number from your current batch, see Changing to a New Batch of Control Strips. Evaluating Control-Chart Plots • Trends—Four to eight data points that plot in an Plots can indicate two types of variations in a process: ascending or descending row. When data points plot in random and non-random. Process variations, both random ascending or descending order, the higher the number of and non-random, influence the distribution of data points on points in the row, the more likely that it indicates a trend. the control charts and identify the state of control. Seasoning Trends for Fresh Solutions—Some Random variations are inherent in the process, and they developer and replenisher systems are formulated so that a occur even when the process is running at peak performance. fresh developer solution will produce a higher speed than a Random variations are caused by chance and are normal; highly seasoned and properly replenished developer. For they are often called “process noise.” Random variations these systems, a declining trend in speed should be plot within the limits. They do not form any particular considered “normal” as a fresh developer solution gradually pattern and they are distributed equally above and below the seasons. As the developer becomes fully seasoned, the speed aim line. A process is in control when the only type of level will stop its downward trend. Systems that exhibit this variation is random. No corrective action is required. In fact, type of trend include processes using KODAK it is important to avoid over-controlling a process by reacting PROFESSIONAL Developer D-76 and Replenisher D-76R to random variations. and KODAK PROFESSIONAL T-MAX RS Developer and Replenisher working solution mixed without starter. Systems that do not exhibit a trend of this type include processes using KODAK HC-110 Developer with HC-110 Developer Replenisher, KODAK DURAFLO RT Chemicals, and KODAK PROFESSIONAL T-MAX RS Developer Replenisher working solution mixed with an appropriate starter.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 11 Causes of an Out-of-Control Process DIAGNOSING AND TROUBLESHOOTING Many factors can lead to an out-of-control process: PROCESSING PROBLEMS • Improper solution mixing Correcting a Process That is Out of Control • Improper solution storage and keeping First, verify that the process is out of control: • Solution contamination • Check that your densitometer is operating properly and • Incorrect processing temperature that your calculations were correct. • Incorrect processing time • Process another control strip to confirm the out-of-control condition. • Improper agitation If you verify that your process is out of control, determine • Improper solution replenishment the cause and correct it. The best indication of the problem • Evaporation will be the plots of the control-strip parameters. • Equipment malfunction Be sure to prepare each solution according to the Diagnostic Charts instructions packaged with the chemicals. Be especially The diagrams on the following pages provide you with a careful that you mix all constituents well, and that you use step-by-step approach to diagnosing process problems; they the correct amounts of concentrates and water. For personal include the most common causes of problems. They are protection, wear safety goggles, gloves, and an apron when organized according to the appearance of your control plots. mixing chemicals. Clean mixing tanks and equipment to The recommendations in the charts will help you correct avoid dirt buildup and solution contamination. Calibrate outliers, level shifts, and trends. For more information, see mixing tanks for the volumes of solutions you are mixing. Evaluating Control-Chart Plots. Follow the storage and keeping recommendations given in the instruction packaged with your chemicals. To minimize solution storage and keeping problems, mix only the amount of solution that you will use during the recommended keeping time. Take precautions to minimize the possibility of solution contamination. Contamination is most often caused by— • mixing equipment that has not been thoroughly cleaned • dry chemicals that become airborne during mixing and settle in an adjacent solution • pipes and tanks made of material that reacts chemically with some solutions • solution splashed or dripped into another solution You can reduce contamination by using good housekeeping methods, mixing chemicals in a separate mixing room with air exhausted to the outside of the building, checking that tanks and pipes are made of the proper material, and using correct mixing techniques. Avoid splashing by using care when lifting and transferring processing racks and by avoiding overly vigorous agitation. Use separate mixing tanks for developers and fixers. Temperature variations greater than ±0.5°F (±0.3°C) in your developer will affect process control and image quality. Temperatures that are too low result in a decrease in processing solution activity. To avoid problems, use a consistent temperature for all your processing solutions. Select a temperature that you can maintain consistently. Agitation is necessary to maintain uniform solution activity by removing exhausted solution from the emulsion surface and replacing it with fresh solution. Agitation must be uniform throughout the processing tank. Follow your equipment manufacturer's recommendations for agitation. Be sure to replenish your solutions properly. Check replenisher pumps and flowmeters regularly to ensure that they are providing the correct amount of replenisher solution.

12 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

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developer replenisher used replenisher developer

Routinely check am check Routinely

m

m calculations are done correctly. done are calculations

developer replenishm developer measurem

processed. Verify accuracy of accuracy Verify processed. processed. Ensure all Ensure processed.

used and am and used used and am and used

of developer replenisher developer of of developer replenisher developer of

Routinely check am check Routinely Routinely check am check Routinely

its. its. its.

SYMPTOM

within action lim action within lim action within within action lim action within

until CI and speed plot speed and CI until plots CI until solution tank until CI and speed plot speed and CI until

to developer tank solution tank developer to developer to concentrate to developer tank solution tank developer to

Add developer replenisher developer Add replenisher Add Add developer replenisher developer Add

it is normal for speed plots to "trend down" after you start up with fresh solution. fresh with up start you after down" "trend to plots speed for normal is it

ixing ent rate. ent

CAUSE

NAL Developer D-76, Developer NAL p developer p

ELIMINATE ELIMINATE

instructions carefully. instructions

solution; follow m follow solution;

replenishm replenisher and mix fresh mix and replenisher

Recalculate developer Recalculate Dum

Make necessary repairs.

ount of ount

ixing

ount of film of ount onitor specific onitor CAUSE

VERIFY

ixes. Check m Check ixes.

records and procedures. and records replenisher used. replenisher

processed and am and processed Check hose. m

record of am of record gravity of replenisher of gravity

Closely m Closely Check calculation. Keep calculation. Check

AX RS Developer and Replenisher or KODAK PROFESSIO KODAK or Replenisher and Developer RS AX

ent: ent: ent not ent

CHOOSE

ix error). ix

FESSIONAL T-M FESSIONAL

calculated properly. calculated hose pinched. hose (m

replenisher too dilute too replenisher replenisher supply replenisher replenishm

underreplenishment: underreplenishm underreplenishm

Developer Developer Developer

PROBABLE CAUSE

DAK PRO DAK * If you use KO use you If * PLOT PROBLEM CI: Trend down Speed: Trend down* D-min: Little or no change CI: Little or no change Speed: Trend down* D-min: Little or no change F002_9095EC

14 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ent

ixing

ixing equipm ixing aintenance. Record aintenance.

PREVENT

ent and perform and ent

ination. ediately after use. after ediately

RECURRENCE

ount of water used to used water of ount

m

"top off" tanks. off" "top

am

regular m regular

equipm

Routinely check Routinely

contam

procedures to avoid to procedures

Follow standard housekeeping standard Follow

im

area and all m all and area

Always thoroughly clean m clean thoroughly Always

n" after you start up with fresh solution. fresh with up start you after n" its. SYMPTOM

ELIMINATE

al for speed plots to "trend dow "trend to plots speed for al

fresh solutions. fresh

developer replenisher with replenisher developer

within action lim action within developer tank solution and solution tank developer

until CI and speed plot speed and CI until tanks thoroughly. Replace thoroughly. tanks

to developer tank solution tank developer to and developer replenisher developer and

Add developer replenisher developer Add Flush developer Flush

it is norm is it

ixing

icals. ents as necessary. as ents CAUSE

ELIMINATE

ake repairs or repairs ake

and using chem using and adjustm

Use care when m when care Use M

DAK PROFESSIONAL Developer D-76, Developer PROFESSIONAL DAK

in.

aintain

ixing area and area ixing

ination. ent for source of source for ent CAUSE

VERIFY

solution level. solution

additions to m to additions

Check for excessive water excessive for Check

contam tanks or cooling coils. cooling or tanks

equipm water-jacketed developer water-jacketed

Check m Check in leaks for Check

AX RS Developer and Replenisher or KO or Replenisher and Developer RS AX

inant, you may see a significant increase in D-m in increase significant a see may you inant,

inated. OFESSIONAL T-M OFESSIONAL

CHOOSE

contam

Developer too dilute. too Developer Developer replenisher Developer DAK PR DAK

PROBABLE CAUSE

Depending on the contam the on Depending * If you use KO use you If * PLOT PROBLEM CI: Trend down Speed: Trend down* D-min: Little or no change CI: Little or no change Speed: Trend down* D-min: Little or no change F002_9096EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 15

aller

ix sm ix

ent rate. ent

ount of ount

processed ount of film of ount

PREVENT

ixes. peratures. Date replenisher Date peratures.

RECURRENCE

ounts of replenisher and replenisher of ounts

ixes and assign discard date discard assign and ixes

and refill when necessary. when refill and

replenisher in replenisher tank, replenisher in replenisher

Periodically check level of level check Periodically

and am and

developer replenisher used replenisher developer

Routinely check am check Routinely

to m to

m

tem

tanks. Avoid high storage high Avoid tanks.

Use floating lids on storage on lids floating Use

increase replenishm increase

am

If utilization is low, m low, is utilization If

its. its. SYMPTOM

ELIMINATE

within action lim action within within action lim action within

until CI and speed plot speed and CI until until CI and speed plot speed and CI until

to developer tank solution tank developer to to developer tank solution tank developer to

Add fresh replenisher fresh Add Add developer replenisher developer Add

al for speed plots to "trend down" after you start up with fresh solution. fresh with up start you after down" "trend to plots speed for al it is norm is it CAUSE

ELIMINATE

solution.

replenisher tank. replenisher replenisher with fresh with replenisher

Refill developer Refill Replace developer Replace

FESSIONAL Developer D-76, Developer FESSIONAL

DAK PRO DAK ber brown.) ber CAUSE

VERIFY

perature).

proper storage of storage proper

ay darken to am to darken ay

in replenisher tank. replenisher in

Check level of replenisher of level Check

m

(Replenisher that is too old too is that (Replenisher

high tem high

replenisher (e.g., evaporation, (e.g., replenisher

or im or

Check for low utilization low for Check

pty.

ent: AL T-MAX RS Developer and Replenisher or KO or Replenisher and Developer RS T-MAX AL

CHOOSE

replenisher tank em tank replenisher

too old or oxidized. or old too underreplenishm

Developer or replenisher or Developer Developer

PROBABLE CAUSE * If you use KODAK PROFESSION KODAK use you If * PLOT PROBLEM CI: Trend down Speed: Trend down* D-min: Little or no change CI: Little or no change Speed: Trend down* D-min: Little or no change F002_9097EC

16 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

is

achine

regularly.

ount

idity.

e m e

ps.

ount of film of ount

perature. ize tim ize

PREVENT inim

RECURRENCE

onitor level of hum of level onitor

replenisher pum replenisher

processed, and calibrate and processed,

used and am and used

of developer replenisher developer of

Routinely check am check Routinely

being processed. being

agitation, etc., when no film no when etc., agitation,

Avoid running transport, running Avoid

is up to tem to up is

lids. M lids.

water at startup. Use floating Use startup. at water

"Top off" developer tank with tank developer off" "Top

M

check voltage regularly. voltage check

Install voltage regulator or regulator voltage Install Inspect drive system drive Inspect ent until CI and CI until ent SYMPTOM

ELIMINATE

its. its.

lim lim

speed plot within action within plot speed speed plot within action within plot speed

replenishm tank solution until CI and CI until solution tank

Process without Process Add water to developer to water Add

.

ps to ps ount of film of ount

CAUSE ount of replenisher of ount

ELIMINATE

ake repairs or repairs ake

onitor specific gravity specific onitor

being processed. being

for am for

am

provide correct provide clean as necessary. as clean

Adjust pum Adjust M

specific-gravity aim specific-gravity

of developer; establish developer; of

M

e.

s.

ent tim ent

idity. transport for transport CAUSE

VERIFY

easure developm easure

echanical problem echanical

air flow, low hum low flow, air

excessive agitation, exhaust agitation, excessive

at startup. Check for Check startup. at

voltage to processor. to voltage to "top off" tank with water with tank off" "top to

Check for fluctuations in fluctuations for Check developer. Check for failure for Check developer.

M Check specific gravity of gravity specific Check

m Check film Check

Check pump calibration.

e too long: too e

ps

ent: ent tim ent

CHOOSE

properly set or not in not or set properly

achine drive or transport or drive achine

proper calibration. proper

im

replenisher pum replenisher not functioning properly. functioning not evaporation.

overreplenishm M too concentrated: excessive concentrated: too

Developer Developm Developer tank solution tank Developer PROBABLE CAUSE PLOT PROBLEM

CI: Trend up Speed: Trend up D-min: Little or no change CI: Trend up Speed: Trend up D-min: Trend up F002_9098EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 17

.

ount of ount

ount

ount of ount

processed.

processed.

aintenance

ent system ent

ount of film of ount

ent-rate calculations ent-rate regular m regular

PREVENT

ount of film of ount ount of film of ount

RECURRENCE

are done correctly. done are

replenishm

Ensure all developer all Ensure

and am and

developer replenisher used replenisher developer

Routinely check am check Routinely

regularly.

processed. Check sensors Check processed.

used and am and used

of developer replenisher developer of

Routinely check am check Routinely

on replenishm on

Perform

and am and

developer replenisher used replenisher developer

Routinely check am check Routinely

ent until CI until ent ent until CI until ent

ent until CI until ent

its. its. its. SYMPTOM

ELIMINATE

action lim action action lim action

and speed plot within plot speed and and speed plot within plot speed and

action lim action replenishm replenishm

and speed plot within plot speed and Process without Process Process without Process

replenishm

Process without Process ent rate. ent

CAUSE ake necessary ake

ELIMINATE

interval.

tank at proper at tank replenishm

replenish developer replenish repairs. developer

Adjust sensor to sensor Adjust Recalculate M

ount of ount ount of film of ount CAUSE

VERIFY

replenisher used. replenisher

processed and am and processed record of am of record

Check sensor. Check calculation. Keep calculation. Check

Check system.

.

ent: ent: ent:

ent rate not rate ent etering system etering

CHOOSE

sensor not functioning not sensor

properly. properly. calculated

faulty m faulty replenishm film

overreplenishm overreplenishm overreplenishm

Developer Developer Developer PROBABLE CAUSE PLOT PROBLEM

CI: Trend up Speed: Trend up D-min: Little or no change F002_9099EC

18 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ount

ount

ent vessels ent

ount of film of ount

ount of film of ount

ixing procedures. ixing ix tanks. Ensure tanks. ix

PREVENT easurem

RECURRENCE

processed.

used and am and used

of developer replenisher developer of

Routinely check am check Routinely

correct m correct

and m and

of m of

processed. Verify accuracy Verify processed.

used and am and used

of developer replenisher developer of

Routinely check am check Routinely

ent until CI until ent its. SYMPTOM

ELIMINATE

its.

action lim action

and speed plot within plot speed and

replenishm

Process without Process

lim

speed plot within action within plot speed

tank solution until CI and CI until solution tank

Add water to developer to water Add

ix fresh ix

ixing ent rate. ent

CAUSE p developer p

ELIMINATE

replenishm

Adjust developer Adjust

instructions carefully. instructions

solution; follow m follow solution;

replenisher and m and replenisher

Dum

ixing

processed. ount of developer of ount CAUSE

VERIFY

ount of film of ount

ixing errors. Check m Check errors. ixing

am

replenisher used and used replenisher

Check am Check

records and procedures. and records

m

replenisher to detect gross detect to replenisher

Check specific gravity of gravity specific Check

ix error). ix

ent rates ent

ent: ent: ount of film of ount

CHOOSE

adjusted for low utilization). low for adjusted

with replenishm with

concentrated (m concentrated processed (i.e., for labs for (i.e., processed

replenisher too replenisher increase in am in increase

overreplenishm overreplenishm

Developer Developer PROBABLE CAUSE PLOT PROBLEM

CI: Trend up Speed: Trend up D-min: Little or no change F002_9100EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 19

perature-

perature.

. eter accuracy. eter

PREVENT om

RECURRENCE

aintenance on tem on aintenance

therm

Regularly check Regularly

is set to correct tem correct to set is

control system control Ensure that heat exchanger heat that Ensure

m

Routinely inspect and perform and inspect Routinely

. .

.

perature perature perature SYMPTOM

ELIMINATE

before processing film processing before before processing film processing before

Check tank tem tank Check tem tank Check

before processing film processing before

Check tank tem tank Check

ents.

eter

perature.

om ents. CAUSE

ELIMINATE

ake necessary ake

ake necessary repairs necessary ake

corrections or adjustm or corrections and recheck tem recheck and

M Replace therm Replace

or adjustm or

M

. Recheck .

perature- perature

eter. eter. CAUSE

VERIFY

om

om

pare reading to reading pare

perature with accurate accurate with perature

therm

tem therm

setting for heat exchanger. heat for setting control system control reading of accurate of reading

Check tem Check Check tem Check Com

perature

eter

perature: perature: perature:

om perature.

CHOOSE

tem

set to incorrect to set inaccurate. control.

faulty tem faulty heat exchanger heat therm

Low tem Low Low tem Low Low tem Low

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process low Outlier CI: Level shift low Speed: Level shift low D-min: Little or no change CI: O F002_9101EC

20 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

.

aintain

achine

.

regularly. ent of m of ent PREVENT

RECURRENCE

before processing film processing before

Check adjustm Check

check voltage regularly. voltage check

Install voltage regulator or regulator voltage Install Inspect drive system drive Inspect

levels before processing film processing before levels

processor. Check solution Check processor.

Regularly inspect and m and inspect Regularly al level. al SYMPTOM

ELIMINATE

solution is at norm at is solution

to developer tank until tank developer to

Add working tank solution tank working Add

achine al

CAUSE

ake repairs as repairs ake ake repairs as repairs ake

ELIMINATE

processing.

for norm for necessary. necessary.

Adjust m Adjust M M

s.

e of e

transport

e setting. e ent. Check for Check ent. CAUSE

VERIFY

echanical problem echanical

easure tim easure

leaking.

to processor. to valves are closed and not and closed are valves

fluctuations in voltage in fluctuations for leaks. Check that drain that Check leaks. for

developm and recirculation system recirculation and

Check tim Check M Check developer tank developer Check

for m for

Check film Check

R.

e too e

e too e e too e

ent tim ent

ent tim ent ent tim ent

achine adjusted achine achine drive or drive achine

CHOOSE

e due to leak. to due e

volum

short: loss of developer of loss short: properly.

Developm for pull processing. pull for transport not functioning not transport

OR CINE PROCESSO CINE OR short: m short: short: m short:

Developm ROLLER-TRANSPORT Developm

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process low Outlier CI: Level shift low Speed: Level shift low D-min: Little or no change CI: O F002_9102EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 21

.

aintenance on aintenance m PREVENT

RECURRENCE

agitation system agitation

perform Routinely inspect and inspect Routinely SYMPTOM

ELIMINATE

. ents to ents

CAUSE ake necessary ake

ELIMINATE

agitation system agitation

adjustm

M

.

ity by ity

s (e.g., clogged (e.g., s of tank, dirty tank, of CAUSE

VERIFY

areas on sheet on areas

Check for non-uniform for Check pressure is correct. is pressure

different sections of tank. of sections different is functioning and that and functioning is

strips to run through run to strips that nitrogen-burst system nitrogen-burst that

strips together. Position together. strips solution filters, etc.). Check etc.). filters, solution

processing several control several processing in bottom in

Check uniform Check turbulator or sparger, debris sparger, or turbulator

for problem for Check agitation system agitation Check

CHOOSE

on in dip-and-dunk in on

m

processors).

com

agitation (especially agitation Decreased developer Decreased

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: O CI: Level shift low Speed: Level shift low D-min: Little or no change CI: (process low Outlier F002_9103EC

22 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ent lines. ent

ent lines. ent

properly connecting properly

properly connecting properly

ination. Ensure that Ensure ination. ination. Ensure that Ensure ination. PREVENT

RECURRENCE

achine is properly leveled. properly is achine

achine is properly leveled. properly is achine

replenishm

Avoid im Avoid

replenishm m

Avoid im Avoid contam

m procedures to avoid to procedures

contam Follow standard housekeeping standard Follow

procedures to avoid to procedures Follow standard housekeeping standard Follow SYMPTOM

ELIMINATE

fresh developer solution. developer fresh fresh developer solution. developer fresh

thoroughly. Refill tank with tank Refill thoroughly. thoroughly. Refill tank with tank Refill thoroughly.

Flush developer tank developer Flush Flush developer tank developer Flush

icals. icals.

CAUSE

ixing and using and ixing ixing and using and ixing

ELIMINATE

chem chem

m m

Use care when care Use Use care when care Use

ay have ay

ent lines. ent

onia odor. onia

ent lines. Check lines. ent m CAUSE

VERIFY

into developer. into

into developer. into for splashing of stop bath stop of splashing for

Check for splashing of fixer of splashing for Check replenishm

of replenishm of for proper connection of connection proper for

Check for proper connection proper for Check stop bath levels. Check levels. bath stop

strong am strong Check developer and developer Check

levels. Developer m Developer levels.

Check developer and fixer and developer Check

inated inated

CHOOSE

with fixer. with bath. stop with

Developer contam Developer contam Developer

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process low Outlier CI: Level shift low Speed: Level shift low D-min: Little or no change CI: O F002_9104EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 23

ount

regular

ixing

ediately

m

ent vessels and vessels ent

ent im ent ent and perform and ent PREVENT

RECURRENCE

aintenance. Record am Record aintenance.

ixing procedures. ixing ixing area and all m all and area ixing

ix tanks. Ensure correct Ensure tanks. ix

easurem

of water used to "top off" tanks. off" "top to used water of after use. after

m equipm

m m equipm

m Always thoroughly clean thoroughly Always Routinely check Routinely

m

Verify accuracy of accuracy Verify its, or its, SYMPTOM

ELIMINATE

solution.

replace developer tank developer replace

within action lim action within

fresh developer solution. developer fresh until CI and speed plot plot speed and CI until

thoroughly. Refill tank with tank Refill thoroughly. to developer tank solution tank developer to

Flush developer tank developer Flush Add developer replenisher developer Add

developer solution. developer

Refill tank with fresh with tank Refill

ixing

ents as ents icals.

CAUSE

ixing and using and ixing ake repairs and repairs ake

ELIMINATE

chem necessary. carefully.

m adjustm instructions

Use care when care Use M Follow m Follow

aintain

ixing records and records ixing ixing area for area ixing CAUSE

VERIFY

ination.

solution level. solution

additions to m to additions

Check for excessive water excessive for Check

tanks or cooling coils. cooling or tanks contam

procedures. water-jacketed developer water-jacketed possible source of source possible

Check m Check Check for leaks in leaks for Check Check m Check

developer tank solution. tank developer

Check specific gravity of gravity specific Check

s

RT

uch

uch

inated. AX RS Developer RS AX

CHOOSE

ix error in fresh working fresh in error ix

ix error in fresh working fresh in error ix

Part B used. B Part

not diluted or too m too or diluted not

tank solution: developer solution: tank

M

and Replenisher and

For T-M For

Developer Replenisher). Developer

that use DURAFLO use that

starter added (in system (in added starter

too dilute or too m too or dilute too

tank solution: developer solution: tank

developer contam developer M

Fresh working tank working Fresh For All Developers All For dilute. too Developer

PROBABLE CAUSE

) ) PLOT

PROBLEM

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process low Outlier CI: Level shift low Speed: Level shift low D-min: Little or no change CI: (process low Outlier F002_9105EC

24 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ponents.

com

endations for endations m

PREVENT ine system ine

RECURRENCE

exam

changing filters. Routinely filters. changing

Follow recom Follow

frequently for proper operation. proper for frequently Check recirculation system recirculation Check SYMPTOM

ELIMINATE

with fresh solution. fresh with

Replace developer Replace

ps,

p as p

achine is not in use. in not is achine ents to recirculation to ents

CAUSE .

ELIMINATE

ake necessary ake

when m when

necessary. Use floating lids floating Use necessary.

tubing, and pum and tubing,

system Repair hose clam hose Repair

adjustm

M

.

p.

ity by ity . CAUSE

VERIFY

for proper flow rate. flow proper for

alfunctioning pum alfunctioning

areas on sheet film sheet on areas

Check for non-uniform for Check

different sections of tank. of sections different

strips to run through run to strips

strips together. Position together. strips

processing several control several processing

Check tank uniform tank Check

m in recirculation system recirculation in

Check for plugged filters or filters plugged for Check Check for air leak air for Check

system Check recirculation Check

CHOOSE

developer tank. developer aeration. or

Decreased circulation in circulation Decreased oxidation Developer

PROBABLE CAUSE

) ) PLOT

PROBLEM

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process low Outlier CI: Level shift low Speed: Level shift low D-min: Little or no change CI: (process low Outlier F002_9106EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 25

aller

ix sm ix

ixes. ixes and assign and ixes PREVENT

RECURRENCE

ounts of replenisher. Date replenisher. of ounts

discard dates to m to dates discard

repenisher m repenisher

am

If utilization is low, m low, is utilization If

fresh ade from ade SYMPTOM

ELIMINATE

replenisher.

solution m solution

tank developer with developer tank Replace fresh working fresh Replace CAUSE

ELIMINATE

fresh solution. fresh

replenisher with replenisher

Replace developer Replace

ber perature storage. perature CAUSE

VERIFY

ay darken to am to darken ay

brown.)

old m old

(Replenisher that is too is that (Replenisher

high-tem

replenisher used. Check for Check used. replenisher

Check age of developer of age Check ade from ade

CHOOSE

replenisher that is too old. too is that replenisher

developer m developer Fresh working tank working Fresh

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: O CI: Level shift low Speed: Level shift low D-min: Little or no change CI: (process low Outlier F002_9107EC

26 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

perature-

perature.

. eter accuracy. eter

PREVENT om

RECURRENCE

aintenance on tem on aintenance

therm

Regularly check Regularly

is set to correct tem correct to set is

control system control Ensure that heat exchanger heat that Ensure

m

Routinely inspect and perform and inspect Routinely

. .

.

perature perature perature SYMPTOM

ELIMINATE

before processing film processing before before processing film processing before

Check tank tem tank Check tem tank Check

before processing film processing before

Check tank tem tank Check

ents.

eter

perature.

om ents. CAUSE

ELIMINATE

ake necessary ake

ake necessary repairs necessary ake

corrections or adjustm or corrections and recheck tem recheck and

M Replace therm Replace

or adjustm or

M

. Recheck .

perature perature−

eter. eter. CAUSE

VERIFY

om

om

pare reading to reading pare

perature with accurate accurate with perature

therm

therm tem

setting of heat exchanger. heat of setting reading of accurate of reading control system control

Check tem Check Com Check tem Check

perature

perature: perature: perature:

eter

om perature.

CHOOSE

tem

set to incorrect to set inaccurate. control.

heat exchanger heat therm faulty tem faulty

High tem High High tem High High tem High

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier high (process high utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another

Speed: (process high Outlier CI: Level shift high Speed: Level shift high D-min: Little or no change CI: O F002_9108EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 27

achine

.

regularly.

ent system ent ent of m of ent PREVENT

RECURRENCE

before processing film processing before

Check adjustm Check

check voltage regularly. voltage check

Install voltage regulator or regulator voltage Install Inspect drive system drive Inspect

regularly.

Inspect replenishm Inspect

Install check valve. check Install ent (or add (or ent SYMPTOM

ELIMINATE

its.

lim

speed plot within action within plot speed

Replenisher) until CI and CI until Replenisher)

DURAFLO RT Developer RT DURAFLO

starter if you use you if starter

replenishm

Process without Process

achine al

CAUSE

ake repairs as repairs ake ake repairs as repairs ake

ELIMINATE

processing.

necessary. necessary. for norm for

M M Adjust m Adjust

s.

ent

e of e

transport

e setting. e ent. Check for Check ent. CAUSE

VERIFY

.

echanical problem echanical

easure tim easure

to processor. to system

developer replenishm developer fluctuations in voltage in fluctuations

replenisher level. Inspect level. replenisher developm

M Check developer Check Check tim Check

for m for

Check film Check

e too e e too e

ent tim ent ent tim ent

achine adjusted achine achine drive or drive achine

CHOOSE

properly.

for . push for transport not functioning not transport

long: m long: tank. developer into leaking long: m long:

Developer replenisher Developer Developm Developm

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier high (process high utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process high Outlier CI: Level shift high Speed: Level shift high D-min: Little or no change CI: O F002_9109EC

28 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

aintenance

aintain nitrogen aintain

ent vessels and vessels ent

regular m regular s. M s. PREVENT

RECURRENCE

ixing procedures. ixing

ix tanks. Ensure correct Ensure tanks. ix

easurem

pressure level. pressure

system

m on agitation and recirculation and agitation on

m Perform

m

Verify accuracy of accuracy Verify

RT ix error) to error) ix SYMPTOM

ELIMINATE

developer tank solution. tank developer

depending on m on depending

Developer Replenisher, Developer

you use DURAFLO use you

Add water (or starter if starter (or water Add

ixing ents as ents

CAUSE ake repairs and and repairs ake

ELIMINATE

necessary. carefully.

adjustm instructions

M Follow m Follow

s for s

alfunction. ixing records ixing CAUSE

VERIFY

ent m ent

equipm

recirculation system recirculation

Check agitation and agitation Check

and procedures. and

Check m Check RT Developer RT

CHOOSE

ix error in fresh working fresh in error ix

agitation or recirculation. or agitation

Increased developer Increased

Replenisher.

DURAFLO

enough starter used with used starter enough

too concentrated. Not concentrated. too

tank solution: developer solution: tank M

PROBABLE CAUSE

) ) PLOT

PROBLEM

utlier high (process high utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process high Outlier CI: Level shift high Speed: Level shift high D-min: Little or no change CI: O F002_9110EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 29

ent

ent rate. Perform rate. ent

aintenance on aintenance . Periodically check Periodically . PREVENT

RECURRENCE

pH of stop bath. stop of pH

system

stop-bath replenishm stop-bath

regular m regular

replenishm Routinely check stop-bath check Routinely SYMPTOM

ELIMINATE

bath tank solution. tank bath

Add replenisher to stop to replenisher Add ent rate or or rate ent CAUSE

ELIMINATE

ake necessary repairs. necessary ake

m

replenishm

Adjust stop-bath Adjust

.

ent system ent

ent rate to to rate ent

ediate- or ediate- ount of film of ount CAUSE

VERIFY

ine if rate is too is rate if ine

replenishm short-range pH papers.* pH short-range

or clogs in stop-bath in clogs or with interm with

processed. Check for leaks for Check processed. Check pH of stop bath stop of pH Check

low for am for low

determ

replenishm

Check stop-bath Check

stop bath. stop Exhausted CHOOSE

PROBABLE CAUSE

) ) * The acceptable range for the pH of stop bath is 4.0 to 5.0. A fresh solution may have a 3.0. PLOT

PROBLEM

utlier high (process high utlier

another strip to confirm to strip another D-min: Little or no change

another strip to confirm to strip another Speed: (process high Outlier CI: Level shift high Speed: Level shift high D-min: Little or no change CI: O F002_9111EC

30 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ove

ixing

ediately after ediately

m ent im ent PREVENT

RECURRENCE

ixing area and all m all and area ixing

each use. each

daily supply.) daily equipm

cold storage after you rem you after storage cold m

(Return package of strips to strips of package (Return Always thoroughly clean thoroughly Always

strips in lighttight container. lighttight in strips Store daily supply of supply daily Store SYMPTOM

ELIMINATE

strips in total darkness. total in strips Handle and process control process and Handle CAUSE

ELIMINATE

with fresh solution. fresh with

developer and replenisher and developer

strips. thoroughly. Replace thoroughly.

Discard fogged control fogged Discard Flush developer tank developer Flush

ination. ixing area and area ixing CAUSE

VERIFY

ent for source for ent

of contam of

equipm

Check m Check

new package. new

Process control strip from strip control Process inated.

CHOOSE

contam strips.

Developer Fogged control Fogged

PROBABLE CAUSE

)

) ) PLOT

PROBLEM

utlier low (process low utlier

another strip to confirm to strip another

Outlier high (process high Outlier another strip to confirm to strip another D-min:

another strip to confirm to strip another Speed: (process high Outlier CI: Level shift low Speed: Level shift high D-min: Level shift high CI: O F002_9112EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 31

ove daily ove

ination. Avoid ination.

ent lines. ent . PREVENT

RECURRENCE

aintenance on agitation on aintenance

replenishm

cross-connecting

supply.) system avoid contam avoid

storage after you rem you after storage m housekeeping procedures to procedures housekeeping

package of strips to cold to strips of package Regularly inspect and perform and inspect Regularly Follow standard Follow

lighttight container. (Return container. lighttight Store daily supply of strips in strips of supply daily Store SYMPTOM

ELIMINATE

strips in total darkness. total in strips

Handle and process control process and Handle

with fresh fixer solution. fixer fresh with

thoroughly. Refill tank Refill thoroughly.

Flush fixer tank fixer Flush

.

ents to ents icals.

CAUSE

ixing and using and ixing ake necessary ake

ELIMINATE

chem agitation system agitation

control strips. control m adjustm

Discard fogged Discard Use care when care Use M

of tank, of s (e.g., clogged (e.g., s CAUSE

VERIFY

pressure is correct. is pressure

is functioning and that air that and functioning is

Check that air-burst system air-burst that Check

dirty solution filters, etc.). filters, solution dirty

debris in bottom in debris

other solutions into fixer. into solutions other turbulator or sparger, or turbulator

Check for splashing of splashing for Check for problem for

Check solution levels. solution Check Check agitation system agitation Check

new package. new

Process control strip from strip control Process

on in on

m inated.

CHOOSE

dip-and-dunk processors). dip-and-dunk

(especially com (especially

Fixer contam Fixer Fogged control strips. control Fogged agitation fixer Decreased

PROBABLE CAUSE ) PLOT

PROBLEM

another strip to confirm to strip another CI: Little or no change Speed: Little or no change D-min: Level shift high CI: Little or no change Speed: Little or no change D-min: (process high Outlier F002_9113EC

32 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ix

ixing

ount of ount

ixing

ediately after ediately

m

ent vessels and m and vessels ent

aintenance on aintenance

ent im ent ent. Record am Record ent. PREVENT

RECURRENCE

ixing area and all m all and area ixing easurem

frequently for proper operation. proper for frequently

Check recirculation system recirculation Check

procedures. use.

tanks. Ensure corrrect m corrrect Ensure tanks. equipm

water used to top off tanks. off top to used water m m

equipm Always thoroughly clean thoroughly Always Verify accuracy of accuracy Verify

regular m regular

Routinely check and perform and check Routinely

in plots in its. SYMPTOM

ELIMINATE

gravity is correct. is gravity

tank solution until specific until solution tank solution.

Refill tank with fresh fixer fresh with tank Refill concentrate to fixer to concentrate

Flush fixer tank thoroughly. tank fixer Flush Add fixer replenisher or replenisher fixer Add

within action lim action within

solution until D-m until solution

concentrate to fixer tank fixer to concentrate

Add fixer replenisher or replenisher fixer Add

.

ixing and ixing

icals.

ixing instructions ixing

ents or repairs to repairs or ents ents as necessary. as ents CAUSE

ELIMINATE

ake necessary ake

ake repairs and repairs ake

recirculation system recirculation

using chem using adjustm carefully.

Use care when m when care Use M Follow m Follow

adjustm

M

p.

ination.

ixing records and records ixing ixing area for area ixing CAUSE

VERIFY

aintain solution level. solution aintain

alfunctioning pum alfunctioning

to m to

procedures. m excessive water additions water excessive

Check for plugged filters or filters plugged for Check or cooling coils. Check for Check coils. cooling or Check m Check

source of contam of source for proper flow rate. flow proper for water-jacketed fixer tanks fixer water-jacketed fixer tank solution. tank fixer

Check m Check Check fixer recirculation fixer Check Check for leaks in leaks for Check Check specific gravity of gravity specific Check inated.

CHOOSE

ix error in fresh in error ix

dilute.

contam tank. solution: fixer too fixer solution:

Fixer too dilute. too Fixer tank solution tank circulation in fixer in circulation working tank working

Fresh fixer working fixer Fresh Decreased M PROBABLE CAUSE PLOT

PROBLEM

another strip to confirm) to strip another CI: Little or no change Speed: Little or no change D-min: Level shift high CI: Little or no change Speed: Little or no change D-min: (process high Outlier F002_9114EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 33

ounts of ounts

ixes. aller am aller PREVENT

RECURRENCE

ixes and assign discard assign and ixes

ix sm ix

dates to m to dates

m

repenisher. Date replenisher Date repenisher.

m

If utilization is low, is utilization If ade from ade SYMPTOM

ELIMINATE

fresh replenisher. fresh

with solution m solution with Replace fixer tank solution tank fixer Replace CAUSE

ELIMINATE

fresh solution. fresh

fixer replenisher with replenisher fixer

tank thoroughly. Replace thoroughly. tank Flush fixer replenisher fixer Flush CAUSE

VERIFY

peratures.

tem

Check for high storage high for Check

(yellowish-white precipitate). (yellowish-white

Check for fixer sulfurization fixer for Check

fixer replenisher used. replenisher fixer

Check age of age Check replenisher

CHOOSE

ade from ade

that is too old. too is that

m Fresh working tank fixer tank working Fresh PROBABLE CAUSE PLOT PROBLEM CI: Little or no change Speed: Little or no change D-min: Level shift high CI: Little or no change Speed: Little or no change D-min: Outlier high (process another strip to confirm) F002_9115EC

34 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

.

achine

idity.

ount

ent system ent

processed.

aintenance

is being is

e m e

ps.

processed.

perature. Avoid perature.

ize tim ize

regular m regular ount of film of ount

PREVENT inim

RECURRENCE

ount of film of ount

onitor level of hum of level onitor

M

on fixer replenishm fixer on replenisher pum replenisher processed.

etc., when no film no when etc., Perform Periodically calibrate Periodically

running transport, agitation, transport, running and am and am

is up to tem to up is of fixer replenisher used replenisher fixer of of fixer replenisher used and used replenisher fixer of

lids. M lids. Routinely check am check Routinely amount check Routinely

water at startup. Use floating Use startup. at water

"Top off" developer tank with tank developer off" "Top its. SYMPTOM

ELIMINATE

in plots within action within plots in in plots within action within plots in

its. its.

lim lim

D-m D-m

fixer tank solution until solution tank fixer fixer tank solution until solution tank fixer

plot with action lim action with plot Add fixer replenisher to replenisher fixer Add Add fixer replenisher to replenisher fixer Add

solution until CI and speed and CI until solution

Add water to developer tank developer to water Add

ps .

CAUSE

ount of ount

ake necessary ake onitor specific onitor

ELIMINATE

being processed. being

amount of film of amount

replenisher for replenisher

am

to provide correct provide to

Adjust pum Adjust

repairs.

M

gravity aim gravity

establish specific- establish

gravity of developer; of gravity

M

idity.

p calibration. p ps and valves. and ps if D-min stays the same, check control strips for fog. CAUSE

VERIFY

air flow, low hum low flow, air

excessive agitation, exhaust agitation, excessive

water at startup. Check for Check startup. at water Refix strip in fresh fixer.* fresh in strip Refix Refix strip in fresh fixer.* fresh in strip Refix

failure to "top off" tank with tank off" "top to failure Check pum Check Check pum Check

of developer. Check for Check developer. of

Check specific gravity specific Check

ent:

ent:

ps or ps ps

CHOOSE

properly set or not in not or set properly

proper calibration. proper

im evaporation.

replenisher pum replenisher concentrated: excessive concentrated:

Fixer underreplenishm Fixer Developer tank solution too solution tank Developer

faulty check valves. check faulty

leaky or plugged pum plugged or leaky Fixer underreplenishm Fixer PROBABLE CAUSE * If D-min goes down after refixing, proceed with corrective action indicated; PLOT PROBLEM CI: Little or no change Speed: Little or no change D-min: Trend up F002_9116EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 35

ixing

ount of ount ount of ount

ount of ount

ediately after ediately

processed. processed.

processed.

m

ination.

ent-rate calculations ent-rate ent im ent PREVENT

RECURRENCE

ount of film of ount

ount of film of ount

ixing area and all m all and area ixing

avoid contam avoid are done correctly. done are

housekeeping procedures to procedures housekeeping replenishm

Ensure all fixer all Ensure use. Follow standard Follow use. Check hose regularly. hose Check

am amount of film of amount equipm

Check sensors regularly. sensors Check fixer replenisher used and used replenisher fixer m fixer replenisher used and and used replenisher fixer

am Routinely check am check Routinely Routinely check am check Routinely Always thoroughly clean thoroughly Always

fixer replenisher used and and used replenisher fixer Routinely check am check Routinely SYMPTOM

ELIMINATE

in plots within action within plots in

in plots within action within plots in

its. its.

its.

solutions.

lim replenisher with fresh with replenisher lim

D-min plots within action within plots D-min D-m fixer and fixer Replace

lim to fixer tank solution until solution tank fixer to to fixer tank solution until solution tank fixer to replenisher tanks thoroughly. tanks replenisher

D-m Add fixer replenisher fixer Add Add fixer replenisher fixer Add fixer and fixer Flush

to fixer tank solution until solution tank fixer to

Add fixer replenisher fixer Add

ent rate. ent icals.

CAUSE

ixing and using and ixing ake necessary ake

ELIMINATE

chem

repairs. replenishm Repair sensor. Repair m

M Recalculate fixer Recalculate Use care when care Use

ount of of ount ount of film of ount

if D-min stays the same, check control strips for fog. ixing area and area ixing CAUSE

VERIFY

ination.

ent for source of source for ent

in fresh fixer.* fresh in

replenisher used. Refix strip Refix used. replenisher

contam processed and am and processed

equipm in fresh fixer.* fresh in in fresh fixer.* fresh in record of am of record

Check m Check Check sensor. Refix strip Refix sensor. Check Check hose. Refix strip Refix hose. Check Check calculation. Keep calculation. Check

ent: ent:

ent:

ent rate not rate ent inated.

CHOOSE

sensor not functioning not sensor

pinched. calculated properly. calculated

replenisher supply hose supply replenisher contam replenishm

properly. Fixer underreplenishm Fixer Fixer replenisher Fixer Fixer underreplenishm Fixer

film Fixer underreplenishm Fixer PROBABLE CAUSE * If D-min goes down after refixing, proceed with corrective action indicated; PLOT PROBLEM CI: Little or no change Speed: Little or no change D-min: Trend up F002_9117EC

36 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

ix

aintain

ixing

ount of ount

.

ount

.

onitor specific onitor

processed.

ent vessels and m and vessels ent

aintenance on aintenance ent. Record am Record ent. PREVENT

RECURRENCE

ount of film of ount

easurem

gravity of fixer tank solution. tank fixer of gravity

procedures. M procedures.

tanks. Ensure correct m correct Ensure tanks. processing film processing water used to top off tanks. off top to used water

m Check solution levels before levels solution Check equipm

Verify accuracy of accuracy Verify recirculation system recirculation regular m regular

am Regularly inspect and m and inspect Regularly Routinely check and perform and check Routinely

of fixer replenisher used and used replenisher fixer of

Routinely check am check Routinely

al level. al its. SYMPTOM

ELIMINATE

action lim action

is at norm at is CI and speed plot within plot speed and CI

to fixer tank until solution until tank fixer to to fixer tank solution until solution tank fixer to

gravity is correct. is gravity Add working tank solution tank working Add Add fixer replenisher fixer Add

tank solution until specific until solution tank

Add concentrate to fixer to concentrate Add

ixing

ents as ents ents as ents CAUSE

ELIMINATE

ake repairs and repairs ake ake repairs and repairs ake

necessary. necessary.

adjustm adjustm

M M

instructions carefully. instructions

solution. Follow m Follow solution.

replenisher with fresh with replenisher

Replace fixer Replace

ixing for if D-min stays the same, check control strips for fog. CAUSE

VERIFY

aintain solution level. solution aintain

Refix strip in fresh fixer.* fresh in strip Refix to m to leak. not

records and procedures. and records valves are closed and do and closed are valves excessive water additions water excessive

replenisher. Check m Check replenisher. leaks. Check that drain that Check leaks. cooling coils. Check for Check coils. cooling

fixer tank solution and solution tank fixer system recirculation water-jacketed fixer tanks or tanks fixer water-jacketed

Check specific gravity of gravity specific Check and tank fixer Check Check for leaks in in leaks for Check

ent:

RT OR RT

e: loss of loss e:

e due to leak. to due e CESSORS

CHOOSE

ix error). ix

fixer volum fixer

Short fixing tim fixing Short

CINE PRO CINE Fixer too dilute. too Fixer

(m ROLLER-TRANSPO

replenisher too dilute too replenisher Fixer underreplenishm Fixer PROBABLE CAUSE * If D-min goes down after refixing, proceed with corrective action indicated; PLOT PROBLEM CI: Little or no change Speed: Little or no change D-min: Trend up F002_9118EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 37

aller

ix sm ix

ount

ixes.

processed. ixes and assign and ixes PREVENT

RECURRENCE

ount of film of ount

ounts of replenisher. Date replenisher. of ounts

refill when necessary. when refill

level in replenisher tank and tank replenisher in level

Periodically check solution check Periodically

am

discard dates to m to dates discard of fixer replenisher used and used replenisher fixer of

replenisher m replenisher Routinely check am check Routinely

am If utilization is low, m low, is utilization If SYMPTOM

ELIMINATE

in plots within action within plots in in plots within action within plots in

its. its.

lim lim

D-m D-m

to fixer tank solution until solution tank fixer to to fixer tank solution until solution tank fixer to

Add fresh fixer replenisher fixer fresh Add Add fixer replenisher fixer Add CAUSE

ELIMINATE

fresh solution. fresh

replenisher tank. replenisher replenisher with replenisher

Refill fixer Refill Replace fixer Replace CAUSE

VERIFY

perature, no floating lids). floating no perature,

tank.

replenisher in replenisher in replenisher

Check level of fixer of level Check

tem

replenisher (i.e., high (i.e., replenisher

or poor storage of fixer of storage poor or

Check for low utilization low for Check

ent: pty.

CHOOSE

replenisher tank em tank replenisher

Fixer replenisher too old. too replenisher Fixer underreplenishm Fixer PROBABLE CAUSE PLOT PROBLEM CI: Little or no change Speed: Little or no change D-min: Trend up F002_9119EC

38 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Troubleshooting from the Appearance of Processed Film The following table will help you use the appearance of processed film to diagnose process problems. Whenever you take corrective action, process another control strip to confirm that the change has returned the process to control before you resume normal processing.

Problem with Film Appearance Possible Cause Corrective Action Milkiness (most apparent in low- Retained due to Check fixer dilution, time, and density areas)— inadequate fixing temperature. pale, white translucence Graininess or mottle— Sulfurized fixer Check fixer for sources of oxidation white, grainy particles (e.g., excessive aeration or agitation). Replace fixer. Surface dirt Dirt in solutions or water Filter solutions and change filters regularly. Dump and clean wash and PHOTO-FLO Solution tanks regularly. Dirt particles from air, dirty work Clean processor and dryer area, or processing/drying regularly. Follow good equipment housekeeping habits. Scum— Dirty PHOTO-FLO Solution Dump and replace solution very fine dissolved material that routinely. dries and makes surface cloudy Dirt or dust from dryer Change filters in dryer routinely. Dirt in solutions Use floating covers on processor and replenisher tanks. Change filters in recirculating system weekly. Sulfurized fixer Replace fixer. Severe magenta (pink) stain Retained sensitizing dye due to Check fixer dilution, time, and inadequate fixing and/or washing temperature. Check wash time and flow rate. Check for fixer exhaustion or underreplenishment. Streaks of non-uniform density Excessive or uneven developer Check and adjust agitation if agitation needed. With gaseous-burst agitation, check that initial burst is adequate and uniformly distributed throughout tank. Mottle— Inadequate developer agitation Check and adjust agitation if areas of non-uniform density needed. With gaseous-burst agitation, check that initial burst is adequate and uniformly distributed throughout tank. Chemical splash marks— Excessively high Solution level Check and correct solution levels; irregular or random density wash level should be higher than differences that of other solutions. Excessive agitation Check and correct agitation.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 39 Problem with Film Appearance Possible Cause Corrective Action Scratches and/or abrasions— Dirt or chemical buildup on rollers, Check and clean these parts marks on emulsion or base side squeegees, or racks of continuous routinely. Follow good or roller-transport processors housekeeping habits. Stuck, misaligned, or dirty rollers Check alignment with test film or leader. Replace worn bearings or rollers. Processor mechanical problems Check processor for mechanical problems. Follow routine maintenance schedule. Cinch marks due to excessive Check processor for mechanical tension, improper handling or problems. Train operators in correct loading handling methods. Dirt in Notify customer. Water marks— Water collecting in perforations Check that PHOTO-FLO Solution marks caused by excess water that is diluted correctly. causes differential drying Water rundown from clips (rack- Check that wash and and-tank processors) PHOTO-FLO Solution levels do not cover clips. Water splashed on film Check and eliminate source of splashing. Inadequate drying Check that drying temperature is adequate. Film drying too quickly Reduce drying temperature. Skivings— Rollers not aligned (roller-transport Adjust equipment. thin pieces of emulsion or continuous processors) Pressure marks— Poor film handling Train operators in correct handling plus-density areas (e.g., half- methods. moons, crescents, etc.) Excessive tension (continuous Check processor for mechanical processors) problems. Camera malfunction Notify customer. Static marks— Static electricity discharges before Maintain moderate levels of branch-like marks, circular spots development humidity and temperature in with dark centers, row of spots splicing and processing areas. (often surrounded by fogged areas) Handle film carefully. Separate rolls and sheets slowly and carefully.

40 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Problem with Film Appearance Possible Cause Corrective Action Light fog— Incorrect use of safelight Check safelight and follow plus density (especially noticeable recommendations. in low-density areas) Inspection during development Do not develop by inspection. Light leaks in darkroom or processor; luminescent tape, Find and eliminate light leaks and timers, indicators; fluorescent lamp light sources. afterglow Improper film loading or handling Notify customer. by customer; camera malfunction Dark film— Overdevelopment or extreme Check developer time, abnormally high density overexposure temperature, mixing; check camera exposure. Light fog See “Light fog.” Light film— Underdevelopment or extreme Check developer time, abnormally low density underexposure temperature, mixing; check camera exposure. Liquid concentrate developer Mix developer in proper ratio of overconcentrated or concentrate to water. underconcentrated Developer contaminated with fixer Replace contaminated developer. or stop bath Wash mixing equipment thoroughly before use. Surface spots that appear dark by Dirt from PHOTO-FLO Solution Replace PHOTO-FLO Solution. transmitted light Water spotting Check dilution of PHOTO-FLO Solution. Dirt from dryer Check cleanliness and dryer filters. Sulfurized fixer Replace fixer.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 41 MORE INFORMATION ON USING Determining Starting-Point Development CONTROL STRIPS Times for Different KODAK Black-and-White Films Note: If you convert a processor from one black-and-white To determine starting-point development times for Kodak film developer and replenisher to another, follow the black-and-white films you haven’t processed before, follow procedure for using control strips described under Starting the procedure below. The values in the table correlate the Up Your Process. contrast-index value of control strips with the development level required for a variety of Kodak films. Changing to a New Batch of Control Strips When you change from your current batch of control strips Note: You can also use the values in the table to confirm that to strips with a different code number, make a crossover to your existing development times for black-and-white films confirm that both code numbers provide the same are producing an optimum development level. See information. Be sure that your process is stable and in Confirming Existing Development Times. control before you begin using a new batch of control strips. 1. Process a control strip at the times given below.* 1. While you still have a week’s supply of control strips Record the development time on each strip. of the current code, process one control strip from the For dip-and-dunk processes— new batch of strips with one strip from the current 4 minutes, 6 minutes, 8 minutes, 10 minutes, and batch in three separate runs. 12 minutes 2. Read and record the densities of the processed strips. For roller-transport processors using KODAK 3. Calculate the contrast index and speed of each of the DURAFLO RT Developer Replenisher— six strips (use Formula 1 or 2 under Starting Up Your 60 seconds, 90 seconds, 120 seconds, and Process or Worksheet 1). 240 seconds 4. Average the contrast index, speed, and D-min of the 2. Measure the densities of the strip in the center of the three strips from the new batch. Average the contrast D-min, TD, LD, HD, and D-max steps with a index, speed, and D-min of the three strips from the densitometer in the visual mode. current batch. 3. Calculate the contrast index of each of the strips; use 5. To determine the differences between the two batches Formula 1 or 2 under Starting Up Your Process or of strips, subtract the average values for contrast index, Worksheet 1. speed, and D-min of your current strips from the 4. Refer to the table of contrast-index values. Find your average values for contrast index, speed, and D-min of developer, film type, and type of processing you will the new strips. do (i.e., normal or push 2). The value in the table is the 6. Apply the differences between the two batches of contrast index that you need to obtain with your strips to your current aims for contrast index, speed, control strip. and D-min, and write the values on Form Y-30. Compare the contrast-index values of the control strips Indicate the code number of the new batch of strips on that you processed in step 1 with the value in the table. your control chart.

* If you performed a development-time series to determine an optimum development time for control strips, you can use those control strips instead of processing additional strips; proceed to step 4.

42 Monitoring and Troubleshooting KODAK Black-and-White Film Processes Select the control strip that has the contrast-index value that is closest to the value in the table. KODAK Contrast Index of KODAK Developer or Control Strip • If the contrast-index value is within ±0.02 of the PROFESSIONAL Developer and Film value in the table, use the time for the strip you Replenisher Normal Push 2 selected to process your film. 0.61 0.76 TRI-X 400 • If the contrast-index value is more than 0.02 ± 0.06 ± 0.08 below the value in the table, process control strips 0.55 0.79 at development times that are 5 percent, PLUS-X 125 ± 0.08 ± 0.11 10 percent, and 20 percent longer than that of the 0.71 0.92 strip you selected. Then, repeat steps 2 through 4. PROFESSIONAL T-MAX 100 ± 0.04 ± 0.06 • If the contrast-index value is more than 0.02 T-M A X R S above the value in the table, process control strips 0.58 0.72 T-MAX 400 ± ± at development times that are 5 percent, 0.03 0.03 10 percent, and 20 percent shorter than that of the EI 1600 EI 3200 strip you selected. Then, repeat steps 2 through 4. T-MAX P3200 0.86 0.97 ± 0.06 ± 0.07 Confirming Existing Development Times—To confirm that your existing development times for specific black-and- 0.59 0.76 TRI-X 400 ± ± white films are providing an optimum development level, 0.03 0.05 0.49 0.67 follow the procedure below: PLUS-X 125 ± 0.04 ± 0.05 1. Process a control strip at the development time that you currently use for a particular film and type of 0.62 0.84 T-MAX 100 ± ± processing (i.e., normal or push 2). D-76 0.03 0.05 2. Measure the densities of the strip in the center of the 0.58 0.72 T-MAX 400 ± ± D-min, TD, LD, HD, and D-max steps with a 0.03 0.03 densitometer in the visual mode. EI 1600 EI 3200 T-MAX P3200 0.86 1.00 3. Calculate the contrast index of the strip; use Formula ± 0.03 ± 0.06 1 or 2 under Starting Up Your Process or Worksheet 1. 0.68 0.94 TRI-X 400 4. Refer to the table at the right. Find your developer, ± 0.03 ± 0.06 film type, and type of processing. Compare the 0.50 0.69 contrast-index value that you calculated in step 3 with PLUS-X 125 ± 0.06 ± 0.07 the value and the range in the table. 0.64 0.78 T-MAX 100 • If the contrast-index value is within the range in DURAFLO RT ± 0.03 ± 0.03 the table, record the contrast-index value and continue using your current development time for 0.58 0.72 T-MAX 400 ± ± this film. Routinely process a control strip with 0.03 0.03 customer film to confirm process consistency; EI 1600 EI 3200 you may find that the contrast index changes T-MAX P3200 0.94 1.09 slightly as your process seasons. ± 0.03 ± 0.03 • If the contrast-index value is not within the range 0.53 0.70 TRI-X Pan ± ± in the table, we strongly recommend additional 0.03 0.05 testing to determine if you will produce negatives 0.46 0.70 PLUS-X 125 of higher quality by changing your development ± 0.04 ± 0.05 time to obtain a control-strip contrast index that is 0.62 0.80 T-MAX 100 within the range in the table. XTOL ± 0.03 ± 0.03 0.57 0.72 T-MAX 400 ± ± Important 0.03 0.03 The contrast-index values in the table are starting-point EI 1600 EI 3200 recommendations. Fine-tune your process as required to T-MAX P3200 0.74 0.83 ± 0.03 ± 0.06 maximize the quality of your negatives. The contrast-index values in the table are for printing with a diffusion enlarger. If you print with a condenser enlarger, subtract 0.15 from the values in the table.

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 43 SAFE HANDLING OF PHOTOGRAPHIC CHEMICALS • Handle photographic chemicals and processing solutions with care. See KODAK Publication No. J-98A, Safe Handling of Photographic Processing Chemicals. • Packages of Kodak photographic chemicals have precautionary labels when necessary. Always read the labels and follow the instructions carefully. Also read the Material Safety Data Sheets (MSDSs) for the chemicals for precautionary information.* • Keep the darkroom, processing area, and mixing room clean. Clean up spilled chemicals promptly. • Use personal protective equipment, such as a waterproof apron and impervious gloves made of a material such as Neoprene or nitrile, when you handle solutions. Always wear goggles or safety glasses when you mix solutions from concentrates. • Avoid skin contact with chemicals. Some photographic solutions, especially developers, can cause allergic skin reactions. See KODAK Publication No. J-98A, Safe Handling of Photographic Processing Chemicals. • Keep chemical solutions out of your mouth. Never start a siphoning action with your mouth. Do not eat or drink in a room where chemicals are mixed or used. • Maintain proper ventilation in the mixing room and processing area. • Store chemicals and processing solutions safely. Keep them out of the reach of children. • Dispose of solutions safely. See KODAK Publication No. J-411, Dealing with Hazardous Waste and Processing Effluents at Photographic Processing Facilities.

* You can obtain MSDSs for Kodak chemicals from the Kodak website at www.kodak.com/go/MSDS. You will need to know the catalog (CAT) numbers for the chemicals when you request MSDSs.

44 Monitoring and Troubleshooting KODAK Black-and-White Film Processes WORKSHEET 1 CALCULATION OF CONTRAST INDEX 1. Measure the densities of your control strip in the center of the D-min, TD, LD, HD, and D-max steps with a densitometer in the visual mode. 2. Calculate the contrast index of your control strip by using one of the following formulas. The first formula has more steps, but it will give you an answer that is more accurate than the second formula will provide. Record the densities of each step in the appropriate boxes, and then perform the calculations.

FORMULA 1

D-min TD LD HD D-max

X X X X X 0.267 0.969 0.454 0.183 0.039

Contrast Index − + + + + 0.128 =

FORMULA 2

HD TD

− Contrast Index + 0.10 = 2.26

CALCULATION OF SPEED To calculate the speed value of your control strip, record the densities of TD and D-min in the boxes below, and then perform the calculations.

TD D-min Speed

140.9 X − + 335 =

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 45 Calculate Your Variations from Aim

Contrast Variation from Index Aim (CI)

− 0.58* =

Variation from Speed Aim (Speed)

− 355 =

Variation from D-min Aim (D-min)

− 0.06 =

Plot Your Variations from Aim: Plot differences that are larger than the corresponding aim values (+ values) above the aim line, and those that are smaller than the aim values (– values) below the line. * † ‡

* 0.58 is the contrast-index aim for printing negatives with a diffusion enlarger; use 0.43 if you will print negatives with a condenser enlarger. † 355 is the speed-value aim for a replenished process for producing negatives that you will print with a diffusion enlarger; your speed value may be slightly higher when you use fresh developer. The speed-value aim for producing negatives for printing with a condenser enlarger will be between 340 and 350. The speed value is not an ISO/ASA speed. ‡ Use 0.09 as your aim for D-min if you process film in KODAK DURAFLO RT Developer Replenisher.

46 Monitoring and Troubleshooting KODAK Black-and-White Film Processes FORM Y-30 KODAK PLOTTING FORM FOR Y-30 BLACK-AND-WHITE FILM PROCESSING

CODE NO. 0.30

0.25 0.20

0.15 CONTRAST 0.10 INDEX 0.05 Aim = 0.58 + 0

0.05

0.10 0.15

0.20

0.25

0.30

30

25 20

15 SPEED 10 VALUE 5 Aim = 355 + 0

5

10 15

20

25

30

D-MIN 0.05 Aim = 0.06* + 0

0.05 *Use 0.09 if you use KODAK DURAFLO RT Developer Replenisher

DATE

MACHINE

EASTMAN KODAK COMPANY ROCHESTER, NY 14650 KODAK Publication No. Y-30 CAT 176 9314 Kodak and Duraflo are trademarks. Printed in U.S.A.

F002_9124EC

Monitoring and Troubleshooting KODAK Black-and-White Film Processes 47 Monitoring and Troubleshooting KODAK Black-and-White Film Processes

Monitoring and Troubleshooting Kodak, Kodak Professional, D-76, Duraflo, HC-110, Photo-Flo, Minor Revision 3/03 KODAK Black-and-White Film Plus-X, T-Max, Tri-X, and Xtol are trademarks. Printed in U.S.A. Processes KODAK Publication No. Z-133E CAT 889 4784