IMPROVING
THE QUALITY AND CONSISTENCY OF YOUR FILM PROCESSING
Getting the
most from your film processor
By Robert Laetare
Just
because you have the very best film processor made, doesn’t mean that you will
have the highest quality film processing possible. I have seen a number of times where a lab has installed a new
machine, the work looks great, but over a period of a few months the quality is
just not what it was when the machine was new.
Usually this happens because operators forget to check a few basic
parameters every week, and as they drift, the quality changes slightly.
Most
processors sold today will process film correctly, but the higher priced ones
usually offer more control or adjustments as well as safety features to protect
your customers’ film. If you check your processor carefully and closely follow
the manufacturers recommendations for chemistry almost any processor can
produce high quality results. Some of
the following items need to be checked daily, while others only need monthly or
semi-annual checking. Generally the
closer you watch your processor, the more consistent your work will be. Each of the items listed below will help you
to get the best processing possible.
While some of the items may seem small, together they will add up to
getting the best and most consistent quality out of your processor.
Every
day, before
you process any customer film, process and read a control strip. Anything could have happened since the last
time the processor was run, and this will assure you that everything is exactly
right. I also recommend that at least
twice a day you run a control strip to verify that everything is still OK. Some of the basics that must be followed are
keeping your strips in a freezer, always process them in the same position on a
rack, have the emulsion face the same direction, and read them on a good
densitometer & plot them as soon as they are out of the dryer. This will
assure you that the film processing is consistent and within your quality
standards. Managers in larger labs
need to check that whatever procedures they establish really are being
followed.
An
experienced operator is able to start and stop processors almost automatically,
but as we all know there are interruptions, and sometimes they call in sick and
someone else has to do their job.
Having these procedures written will help to insure that everything is
checked and done the same way every time.
These lists should include what valves to open or close as well as what
items to check for proper operation of the machine. Having an exact procedure written will insure that it is done
properly every time.
Check
the processing parameters of your equipment about every 6 months to be sure
that nothing has changed. I have asked
operators to tell me exactly what was the water flow, or what is the exact
temperature in the fixer. Their
responses will vary, they either don’t know, they tell me the aim point, or
sometimes they admit that they have never checked. You should compile a list of the following parameters for each
processor and have each of them checked every six months or when ever you
suspect a problem.
Temperatures of all
chemicals should be checked with a very accurate thermometer, and the
temperature controllers calibrated.
This should be done about every 6 months because there are several
components that could change with age which will affect the stability of the
temperature controllers.
Timing should be
checked. Usually this is correct, but I
have seen machines that for one reason or another a motor or a belt were
changed and the timing was never verified.
It doesn’t take long, but it is very important. Do this about every 6 months.
Water
temperature and flow rates seem to never be adjusted until something really bad
happens. At the same time you are
checking chemical temperatures, check your water temperature also. Another thing to check is the flow
rate. Either look up the tank volume
and see how long it takes to fill from empty or put a 5 gallon pail under the
over flow for each tank and see how long it takes to fill it. Water mix valves always seem to be
neglected, but they are very important in good film or paper processing.
Agitation
should
be checked daily, but every month or so you should take special care and verify
that it is both even as well as strong enough.
Holes in the plenums become plugged and solenoids need to be checked and
rebuilt from time to time. Agitation is
one area that needs to be checked often.
Replenishment
rates
should be checked about every month.
The developer rates tend to show up in your plots, but the secondary
chemical rates are important also. Some
labs neglect this, and always seem to need additions to their developers. Actually, they should be checking their
replenisher rates. Sometimes they are
over replenishing the secondary chemicals and the result is that plots look
good, but they are wasting chemistry by using more than is required.
Keep
your equipment clean. A clean processor
makes it much easier to process quality film.
Some labs have 5 year old equipment that looks like new, while others
have new machines that look 10 years old.
Dirt and algae in wash tanks, or chemical residue and dust get on film
and paper causing work that has spots and marks as well as creating unhappy
customers.
Take
the time to adjust and maintain your equipment. Start using preventative maintenance instead of just fixing emergencies. Some labs that have in house maintenance
people use outside companies to service and check their equipment. This can be very cost effective since a
second set of eyes can often spot problems that have slowly developed but the
operators just gotten used to. The
problem can often be corrected easily while it is a small problem before you
have a disaster that could damage customer film and cause down time.
If
someone in your lab takes the time to check everything and keeps regularly
checking you will see an improvement in both the quality and consistency of
your processing. Yes it will cost a
little, but for that minimal cost you will gain a better as well as a more
consistent product and you will have happier customers.