Professional Documents
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8
lnch (l6 mm).
Nete. Agltatlon ln some solutlons
may cause foamlng. If foamlng ls
excesslve, determlne the causes of lt
and correct them. Hlgh agltatlon,
loose connectlons on reclrculatlon
pumps, and lov solutlon levels that
permlt alr to be sucked lnto the solu-
tlon can cause excesslve foam.
You can use KDAK Defoamer,
Process E-6, to control foamlng ln the
flrst-developer, color-developer, and
bleach tanks, de net use defoamer ln
the flnal-rlnse tank (lt can leave olly
deposlts on the fllm). Apply a thln
layer of defoamer to the lnslde of the
process tank above the solutlon
levelde net add defoamer dlrectly
to the tank solutlon.
For mcst contlnuous processors,
turbulator bars provlde agltatlon.
Turbulator bars are spray bars that
force fresh chemlcals onto the fllm.
You can check the operatlon of
turbulator bars by lnstalllng pressure
gauges on lncomlng chemlcal llnes.
Vhen the small holes ln the turbu-
lator bars begln to plug, the pressure
vlll lncrease. Vhen you detect a
-pound lncrease ln pressure, clean
the turbulator bars.
Vlsually lnspect the agltatlon ln the
flrst-developer, color-developer, bleach,
flxer, and vash tanks daiIy. Keep a
record of all checks on the agltatlon
system. Plot measurable data (e.g.,
tlmlng of burst, length of burst, solu-
tlon rlse, etc), note any changes, and
take correctlve actlon, lf necessary
Cencentratiens e[ Key
ChemicaI Cempenents
The procedures that have been avall-
able to professlonal labs for monl-
torlng the chemlcal composltlon of
solutlons are speclflc-gravlty
measurements, replenlshment-rate
calculatlons, and replenlsher-pump
callbratlons. These procedures
provlde only lndlrect measurements
of overall solutlon concentratlon or
speclflc chemlcal concentratlons, and
do not enable labs to measure lndl-
vldual chemlcal parameters. Nov, the
KDAK Q-LAB Chemlcal Test Klt,
Process E-6, provldes an easy method
of measurlng the bromlde concen-
tratlon ln the flrst developer, the
reversal-agent concentratlon ln the
reversal bath, and the sulflte concen-
tratlon ln the color developer. These
parameters are lmportant lndlcators
of correct process operatlon. The
Q-LAB Chemlcal Test Klt ls composed
of } klts: KDAK Bromlde Test Klt,
Process E-6, KDAK Reversal Agent
Test Klt, Process E-6, and KDAK
Sulflte Test Klt, Process E-6.
Bremide Cencentratien. Use the
Bromlde Test Klt to detect changes ln
the concentratlon of bromlde ln the
flrst developer bcjcrc they affect the
fllm you process. For example, as
bromlde concentratlon lncreases,
developer actlvlty decreases, and fllm
densltles lncrease. As bromlde
concentratlon decreases, developer
actlvlty lncreases, and fllm densltles
decrease. Bromlde concentratlon ls
affected prlmarlly by replenlshment
rate. Instructlons for uslng thls klt
and dlagnostlcs are glven ln First
Dcucicpcr, Sectlon 7.
ReuersaI-Agent Cencentratien.
Use the Reversal Agent Test Klt to
detect changes ln the concentratlon
of reversal agent ln the reversal bath
bcjcrc they affect the fllm you
process. For example, vhen the
reversal-agent concentratlon ls hlgh,
the process vlll drlft blue, vhen the
concentratlon ls lov, the process vlll
drlft yellov. Vhen the reversal-agent
concentratlon ls cxtrcmciy icu, the
color balance of upper-scale densltles
and D-max vlll drlft green. Instruc-
tlons for uslng thls klt and dlagnostlcs
are glven ln Rcucrsni 8nth, Sectlon 9.
5uI[ite Cencentratien. Use the
Sulflte Test Klt to detect changes ln
the concentratlon of sulflte ln the
color developer bcjcrc they affect the
fllm you process. For example, as
sulflte concentratlon lncreases, fllm
contrast vlll be lover, especlally ln
the hlgh densltles. As sulflte concen-
tratlon decreases, fllm contrast vlll be
hlgher, especlally ln hlgh-denslty
areas. Instructlons for uslng thls klt
and dlagnostlcs are glven ln Ccicr
Dcucicpcr, Sectlon lu.
PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS 7/04 "
K KK KKOD OD OD OD ODAK Q AK Q AK Q AK Q AK Q-LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce
PPOCES PPOCES PPOCES PPOCES PPOCESS CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDBOOK OOK OOK OOK OOK Z ZZ ZZ-6 -6 -6 -6 -6
FREQUENCY OF
MEASUREMENTS
The frequency of measurlng the
process parameters depends on the
state of control of your process. As
you begln process monltorlng, for
example, you must measure the
parameters frequentlymore fre-
quently than typlcal process fluctua-
tlons occur. After your process ls
ln control and ad|usted to alm, you
can measure the parameters less
frequently
When yeu begin precess meni-
tering, ve recommend that you
make at least l measurement of all
key parameters euery 8-heur day
er shi[t. For machlnes that operate
more than l2 hours a day, ve recom-
mend that you measure all key
parameters every 8 to lu hours. The
more measurements you make, the
more data you vlll have to help you
make process-control declslons.
See "Stablllzlng Your Process` ln
Sectlon 6.
A[ter yeur precess has
stabiIized and yeu haue adjusted
it te aim, you can decrease the
frequency of measurement accordlng
to the state of control of your process
and the number of tank solutlon turn-
overs (processor utlllzatlon). Hov-
ever, lf the varlablllty of your data
lncreases (or plots approach the toler-
ance llmlts), you should make mea-
surements more frequentlyat least
once a day. Thls vlll help you detect
out-of-control condltlons qulckly. If
the varlablllty of your data ls small
and your plots are vell vlthln the
tolerance llmlts, you can reduce the
frequency of measurements.
Vhen your process ls ln control
on alm vlth mlnlmum varlablllty
base your frequency of measure-
ments on the number and frequency
of tank turnovers for the flrst devel-
oper. A tank turnover ls the polnt at
vhlch the volume of replenlsher used
ls equal to the orlglnal volume of
solutlon ln the process tank at
start-up. To determlne the number
of tank turnovers, use the formula:
After you determlne the number of
flrst-developer tank turnovers per
veek, determlne the frequency of
measurements from the follovlng
table.
If your processor has fever than
' turnover per veek, lts utlllzatlon ls
relatlvely lov. Measure the key
parameters at least euery day to
ensure that oxldatlon and evapo-
ratlon do not adversely affect process
control, and that your replenlsher
concentratlon and replenlshment rate
are sufflclent to malntaln proper solu-
tlon concentratlons.
ne-half to 2 turnovers per veek ls
consldered average utlllzatlon. After
your process ls stable, you can reduce
the frequency of measurements to
once every } days. Thls rate ls
adequate to detect problems caused
by oxldatlon, evaporatlon, and
lmproper replenlshment.
If your processor has more than
2 turnovers per veek, lts utlllzatlon
ls relatlvely hlgh. Measure the key
parameters at least euery day to
ensure that you detect changes
before they affect the fllm you
process. Vlth hlgh utlllzatlon, you run
a hlgh rlsk of not detectlng problems
soon enough unless you measure the
parameters at least once a day Ve
recommend that you measure the
parameters more frequently than
once a day.
Nete. It ls lmportant to make
measurements more frequently than
typical when process fluctuations
occur. The frequencies recommended earller
are startlng polnts. Base measurement
frequency on the performance record
of each machlne.
volume of
flrst developer
replenlsher
used
volume of the
flrst-developer
tank
per veek ~
Number
of tank
turnovers
ExampIe.
8u L
luu L
u.8 turnovers
per veek
~
Number
of tank
turnovers
~
First-Developer
Tank Turnovers
Per Week
Minimum
Frequency of
Measurements*
Fewer than '
' to 2
More than 2
Once per day
Once every 3 days
Once per day
*After your process is stable and in control.
KODAK Q-LAB Process Monitoring Service
PROCESS CONTROL HANDBOOK Z-6
7/04 PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS
4-13
PLOTTING
CHEMICAL
AND MECHANICAL
PARAMETERS
KODAK Publications No. Y-34,
Y-35, and Y-36 provide a
convenient means of tracking the
key process parameters. Use
Form Y-34, KODAK First
Developer Plotting Form for
Process E-6, to track tank
temperature, specific gravit, time,
replenishment rate, and bromide
concentration for your first
developer. Use Form
Y-35, KODAK Reversal Bath
Plotting Form for Process E-6, to
track specific gravity,
replenishment rate, and reversal-
agent concentration for your
reversal bath. Use Form Y-36,
KODAK Color Developer
Plotting Form for Process E-6, to
track tank temperature, specific
gravity, replenishment rate, and
sulfite concentration for your
color developer.
These forms include color
zones that enable you to
determine the control status of
your process quickly and easily.
The following colors are used:
Whiteindicates that your
process is in excellent control in
relation to professional standards
Yellowindicates that your
process is in marginal control in
relation to professional standards
Orangeindicates that your
process is out of control in
relation to professional standards
Aims for Chemical and
Mechanical Parameters
We recommend that you control
your process to the aims
provided in the sections on the
individual solutions. However,
we recognize that professional
labs may have to adjust the aims
of some parameters to obtain
optimum image quality; the
sections on the individual
solutions give an acceptable range
for these parameters. (For more
information on acceptable
ranges, see Process Specifications,
Section 2.)
After you make chemical and
mechanical measurements for
your first developer , reversal
bath, and color developer , plot
the variations from aim on
Forms Y-34, Y -35, and
Y-36.
Using Forms Y-34, Y-35,
and Y-36
Use a separate set of forms for
each processor .
1. Record the name (or identity
code) of the processor in the
blank labeled Machine. On
each form.
2. Record the aim value for each
parameter in the appropriate
blank on each form.
3. Make the required chemical
and mechanical measurements.
To calculate and plot your
variations from aim, follow these
steps:
1. Subtract the aim values from
the measurements to calculate
the differences.
Example of determining the
difference between a
measurement and your aim
value:
First-developer
temperature 100.6F
Aim value 100.4F
Difference + 0.2F
2. Plot the differences on the
appropriate form for each
parameter . 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. If all of your data plots
within the scales on Forms
Y-34, Y-35, and Y-36, proceed to
Stabilizing Your Process in
Section 6.
If the difference from aim for any
parameter exceeds the scale on
the form when you begin process
monitoring, take another
measurement.
Example:
Color-developer
temperature(first
measurement) 99.2F
Aim value 100.4F
Difference - 1.2F*
*Difference exceeds the scale of Form
Y-36; in this case you would take another
measurement.
If your second measurement
matches your first measurement
closely , calculate the average of
the 2 measurements, and use this
value as a temporary aim. In the
example above, the second
measurement was 99.4 0 F, so the
operator calculated the temporary
aim as 99.3 0 F.
Unless you can determine and
fix the causes of an out- of-
control condition, do not make
any adjustments to your process
at this point.
If your second measurement is
closer to aim (e.g., the difference
from aim does not exceed the
scale on the plotting form), plot
the difference from aim and then
proceed to Stabilizing Your
Process in Section 6.
KODAK Q-LAB Process Monitoring Service
PROCESS CONTROL HANDBOOK Z-6
PROCESS MONITORING: CHEMICAL AND MECHANICAL PARAMETERS 7/04
4-14
SAFE HANDLING
OF PHOTOGRAPHIC
CHEMICALS
Handle photographic chemicals
and processing solutions with
care. See Safe Handling of
Photographic Chemicals, KODAK
Publication No. J-98A. For more
information about potential
health hazards and safe handling
of specific Kodak chemicals, see
the package label and the
Material Safety Data Sheet
(MSDS) for the 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.
* In the USA, you can obtain MSDSs
for Kodak via the internet. You can
download them from the Kodak web
site: www.kodak.com/go/MSDS.
Outside of the USA, contact Kodak
in your country. Please supply the
catalog (CAT) numbers for the
chemicals when you request MSDSs.
Avoid contact of any chemicals with
your skin; some photographic solutions,
particularly developers, can cause
skin irritation and an allergic skin
reaction. In case of accidental
chemical contact, wash your skin
with running tap water and a non-
alkaline (slightly acid) hand cleaner.
If symptoms persist, get medical
attention.
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
Dealing with Hazardous Waste and
Processing Effluents at Photographic
Processing Facilities, KODAK
Publication No. J-411.
9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "#
K KK KKOD OD OD OD ODAK Q AK Q AK Q AK Q AK Q-LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce
PPOCES PPOCES PPOCES PPOCES PPOCESS CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDBOOK OOK OOK OOK OOK Z ZZ ZZ-6 -6 -6 -6 -6
COMPENSATING FOR
EVAPORATION
Vhen vater evaporates from
processlng solutlons, the chemlcal
components remaln, and the solutlon
becomes overconcentrated. After you
have folloved the steps to mlnlmlze
the causes of evaporatlon (see
page -2), hlgh speclflc-gravlty
measurements may lndlcate that
evaporatlon ls stlll occurrlng. To
compensate for any remalnlng
evaporatlon that occurs durlng oper-
atlng hours, follov the procedure
glven belov. The procedure helps you
to determlne hov much vater ls lost
durlng dally operatlon and hov to
ad|ust your replenlsher and replen-
lshment rate to compensate. It
requlres you to make speclflc-gravlty
measurements at start-up and shut-
dovn to determlne the amount of
vater lost to evaporatlon, lt does
not lnterfere vlth your normal
operatlons.
Nete. nce you have compensated
for evaporatlon that occurs durlng
operatlng hours, you can easlly
compensate for overnlght evap-
oratlon by addlng vater to "top off `
your tank solutlons.
Calculate the average amount of
fllm (square feet or square metres)
that you process per day. Then follov
these steps to compensate for evap-
oratlon that occurs durlng operatlng
hours.
APPENDIX 4A
5tep Why? ExampIe
6. Multlply the change ln solutlon
concentratlon (step ) by the
volume of your tank.
. Dlvlde the change ln speclflc
gravlty from step } by the chem-
lcal component of the solutlon
speclflc gravlty from step .
. Subtract the speclflc gravlty of
vater (l.uuu) from the start-up
speclflc gravlty (step l).
}. Subtract the start-up speclflc
gravlty from the shutdovn
speclflc gravlty.
2. Measure the speclflc gravlty of
your tank solutlon at shutdovn.
l. Measure the speclflc gravlty of
your tank solutlon at start-up.
Then operate your machlne as
you normally do.
l. Establlshes the concentratlon
of the solutlon at the start of
the day.
l. l.u6}
6. Determlnes the total amount of
vater lost due to evaporatlon.
. Determlnes the percent change
ln solutlon concentratlon.
. Determlnes the chemlcal
component of the solutlon
speclflc gravlty.
}. Determlnes the change ln solu-
tlon concentratlon.
2. Establlshes the concentratlon
of the solutlon at the end of
the day.
6. u.u}2 x luu L ~ }.2 L or }2uu mL
. u.uu2 u.u6} ~ u.u}2 (or }.2 percent)
. l.u6} l.uuu ~ u.u6}
}. l.u6 l.u6} ~ u.uu2
2. l.u6
(Ccntinucd cn ncxt pngc)
PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS 7/04 "$
K KK KKOD OD OD OD ODAK Q AK Q AK Q AK Q AK Q-LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce
PPOCES PPOCES PPOCES PPOCES PPOCESS CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDBOOK OOK OOK OOK OOK Z ZZ ZZ-6 -6 -6 -6 -6
5tep Why? ExampIe
7. Dlvlde the amount of vater lost
to evaporatlon (step 6) by the
average amount of fllm
processed to calculate the vater
addltlon.
7. Determlnes the vater loss ln the
same unlts as your replenishment
rate (e.g., mL/ft
2
or mL/m
2
).
7. }2uu mL luu ft
2
~ 29 mL/ft
2
(}2uu mL lu.2 m
2
~ }l mL/m
2
)
Increase your total replenishment
rate by the addltlonal volume of
vater per square foot or square
metre.
Then multlply the amount of fllm
by the vater addltlon from Step 7.
Fer pre-mixed seIutiens, flrst
dlvlde the volume of replenisher
you mlx by your alm replen-
lshment rate.
Your tctni replenlshment rate vlll
lncr ease by the addltlonal volume
of vater per square foot (or
square metre).
Fer in-Iine diIutien/bIender
systems, lncr ease the output of
the vater pump by the vater
addltlon from step 7.
8. Ad|ust the amount of vater ln
the r eplenlsher by uslng the
vater addltlon you calculated ln
step 7.
Nete. The vater addltlon ls
based on each squar e foot (or
squar e metr e) of fllm pr ocessed
because you r eplenlsh the solu-
tlon for each squar e foot (or
squar e metr e) of fllm you
process.
Provldes the same amount of
chemlcal components (per
replenlshment cycle) that your
system provided befor e you
ad|usted the replenlsher to
compensate for evaporatlon.
Determlnes hov much e xtra
vater to add to each replenlsher
mlx.
Determlnes the amount of fllm
you can process vlth that
volume of replenisher .
8. Compensates for the evaporatlon
that occurs durlng operatlng
hours.
200 mL/ft
2
29 mL/ft
2
~ 229 mL/ft
2
(2l} mL/m
2
}l mL/m
2
~ 267 mL/m
2
)
7 ft
2
x 29 mL/ft
2
~ l},77 mL or l}.8 L
( ln
2
x }l mL/m
2
~ l},8l6 mL or l }.8 L)
9 L (or 9,uuu mL) 2uu mL/ft
2
~ 7 ft
2
(9,uuu mL 2l} mL/m
2
~ m
2
)
2uu mL/ft
2
29 mL/ft
2
~ 229 mL/ft
2
(2l} mL/m
2
}l mL/m
2
~ 267 mL/m
2
)
Curr ent output of the vater pump 29 mL/ft
2
(}l mL/m
2
~ Nev vater output per
replenlshment cycle
9/91 PROCESS MOHTORHG: CHEMCAL AHD MECHAHCAL PARAMETERS "%
K KK KKOD OD OD OD ODAK Q AK Q AK Q AK Q AK Q-LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce -LAB Prcess MnIrng Servce
PPOCES PPOCES PPOCES PPOCES PPOCESS CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDB S CONTPOL HANDBOOK OOK OOK OOK OOK Z ZZ ZZ-6 -6 -6 -6 -6
HYDROMETER
CROSSOVER
PROCEDURE
Llke other measurlng lnstruments,
hydrometers have an lnherent varl-
ablllty. Although the varlablllty from
hydrometer to hydrometer ls usually
small, you should run a crossover test
vhen you use a "nev` hydrometer.
To run a crossover test, follov these
steps:
l. Make speclflc-gravlty measure-
ments of at least dlfferent
samples of the same tank solutlon
vlth both the "old` and the "nev`
hydrometer.
2. Determlne the average measure-
ment for each hydrometer by
addlng the measurements and
dlvldlng the result by the number
of readlngs.
}. To calculate the dlfference betveen
the hydrometers, subtract the
smaller average from the larger
average.
If the dlfference betveen the
average readlngs for the hydrometers
ls greater than u.uu2, contact your
Technlcal Sales Representatlve (TSR)
to help you determlne vhlch hydrom-
eter ls correct. If the dlfference ls less
than or equal to u.uu2, start uslng the
"nev` hydrometer.
Nete. Sample calculatlons are glven
at the rlght.
APPENDIX 4B
Example 1
1
2
3
4
5
Total
Measurement
Reading with
Old Hydrometer
Reading with
New Hydrometer
1.063
1.062
1.063
1.062
1.064
5.314
1.062
1.062
1.063
1.063
1.064
5.314
Example 2
1
2
3
4
5
Total
Measurement
Reading with
Old Hydrometer
Reading with
New Hydrometer
1.063
1.062
1.061
1.062
1.064
5.312
1.066
1.065
1.064
1.066
1.066
5.327
.}l