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. darkroom 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 lights 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 light in the room is supplied by a • Several quart jars or bottles (glass, stainless steel, or suitable safelight lamp with an OC Safelight Filter, and keep plastic) for processing solutions the photographic paper at least 4 feet from the lamp. • Stirring paddle to mix solutions Kitchens and bathrooms nearly always make the best places for temporary printing darkrooms 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 KODAK 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 enlarger 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 photographic processing 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 exposure. If you want to make PROCESSING YOUR FILM enlargements, you need an enlarger with a negative 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 lens. • Film developer Your photo dealer will be glad to help you select your equipment, including darkroom kits of basic items. Some of • Stop bath 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-developing tank. 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 135 film. 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 safelights. 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 image 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 images 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 colors 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 Black and White 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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RECURRENCE
ixing procedures. ixing
ix tanks. Ensure correct Ensure tanks. ix
Check hose regularly. hose Check
and am and
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 film 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 processing. 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 silver halide 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 camera 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