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AUTOMATIC FILM PROCESSING
This is automated method of film processing. In this method, the film is processed
by a machine that follows a programmed set of instructions. This method of film
processing is most precise, though it is a little bit more expensive than the manual
processing methods. Automatic film processing have many advantages of manual
processing because they are faster, more accurate, more precise, more consistent,
less labour intensive and less prone to human errors since the rate of human
manipulation of the film is greatly reduced. But still the automatic film processing
has these disadvantages: They are expensive to [Link] require regular
[Link] can be difficult to repair when it breaks [Link] might not
be able to process certain sizes of film such as large, irregular shaped films
THE PRINCIPLES OF AUTOMATIC PROCESSOR
The automatic processor operates on the principle of agitation, temperature and
[Link]: Agitation is the movement of film through the developer and
fixer solutions. This movement is achieved by series of rollers, sprockets and
conveyor belts. Squeegee movement is the key part of the agitation process in
automatic film processing. Squeegee movement is the key part of the agitation
process in automatic film processing. Squeegee movement is achieved through the
movements made by rubber or silicon blade that convey the film through the
processing [Link] squeegee moves back and forth across the film, pushing it
through the developer and fixer solutions. This movement ensures that the
processing solutions come into contact with all parts of the film resulting in an
even and consistent processing of the film. The squeegee movement helps to
remove air bubbles from the film, ensuring that images are clear and sharp.
BASIC COMPONENTS OF AUTOMATIC PROCESSOR
1. Feed and detection mechanism
This initiates transport of film and moves the film into the processor. The feed tray
has a smooth surface that minimizes misfeeds and provides entrance for the film’s
leading edge parallel to the feeder [Link] feeder rollers also detect chemical
replenishment needs and provide timing signals ( Usually a small light or audible
tone that alerts the operator) to prevent overlapping films during [Link] film
is transported by a series of rollers and is guided through the processing system.
2. The processing system and the transport system
The processing system consists of the developer tank,fixer tank and wash [Link]
covers of the developer and fixer tanks must be intact to prevent oxidation of
developer and deteriotion of rollers by the fumescoming from the chemicals. If
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rollers deterioriates,transport problem will be created on the [Link] rollers
apply just enough pressure to provide a reliable transport of the film without
damaging the film emulsion as it cannot tolerate excessive force.
As the film enter the washing tank, externally supplied water removes residual
fixer from the processes film to prolong storage life. After leaving the wash
rack,film enters a series of sqeegee rollers that remove excess water from the
surface of the film. The dryer passes dry warm air over the film as it exits the
processor and fall into the receiving bin. Film transport system is one of the major
components of the processing section. It functions to move the film through
differents steps by means of rollers,gears, and sprocket. The rollers serve to agitate
the film surface. There are 3 roller system (subsystem) in the automatic processor
which includes:Transport racks (Turnaround assembles),Crossover network,.Drive
system. Transport racks (Turnaround assembles) this include the following;The
entrance rollers or detector rollers,Vertical or deep racks (transport racks),Cross
over assembly and the squeegee assembly.
The film transport system has two functions:
To ensure that film must spend a certain amount of time in each section of the
processor so that the film will be processed [Link] motion of the system
allows agitation of the film surfaces, which improves uniformity of
[Link] rollers or detector rollers contains the guide shows which
moves film into the developer tank, it also contains a micro switch turn on the
replenishment pump as the film moves into the developer [Link] vertical or deep
racks (transport racks): These racks move film into and through solutions and
driers. The rack uses a turnaround assembly at the bottom of the direction
[Link] crossover assembly: This assembly moves film from developer tank
to fixer tank and from fixer tank to the wash tank. The assembly forces the
processing solution out from the film back to the tank where it is coming [Link]
squeegee assembly: The squeegee assembly moves the film from the wash tank to
the dryer. The squeegee action removes excess water from the film. The entire
transport assemmbly is located inside the tanks. Their work is to drive the film
through the tanks. The transport racks are also made up of the turnaround
assemblies, (which are made up of master rollers, guide shoes) which are all
located at the bottom of the processing tanks. Their fumction is to redirect the film
up towards the top of thr tank to the cross over rollers. Crossover rollers: located
at the top of the solution tanks. They serve to direct the film from one tank to the
other. They also perform the squeegee action on the film. Entrance rollers are part
of crossover network. This functions to direct the film the film from feed tray into
the developer tannks. The drive system: This controls the speed at which the film
travels through the processor solution [Link] development tank , the film should
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last for just for 22 Secs,in fixer tank , the film should last for just for 22 Secs too,
but in wash solution the film should last for 20 seconds and last for 26 seconds in
the dryer section. The film takes an average of 90 seconds for it to be processed in
an automatic processor.
[Link] and Indication Section. This section provides machine control and
current status information. This is a major subsystem of the automatic processor
that functions for water supply,filtration,temperature regulation ,chemical
replenishment,and solution recirculation. It produces raw materials for silver
recovery too.
STEPS INVOLVED IN AUTOMATIC FILM PROCESSSING
The entire process of automatic processing starts from:
DEVELOPMENT This process starts with pre-wetting, which involves wetting
the film with the developer to remove any dust or debris. This proceeds the
development proper. Both the pre wetting and the full development take place in
the developer tank of the automatic processor. After development, the film is
moved to the fixer tank for fixing, then to wash section for washing before it
finally gets to the drier section for [Link] automatic processors have a
computer interface for controlling and monitoring the processes.
REPLENISHMENT SYSTEM
This is responsible for maintaining proper solution concentration during film
[Link] is necessary as emulsion of the films remove solutions and keep
depleting the solution as they move through the processor, replenishment therefore
becomes very necessary for this depletion in both in volume and density (strenght)
of the processing chemical is [Link] this is the only way an automatic
processor can function [Link] are 2 replenishment systems;
Volume replenishment which is done immidiately film is fed into the automatic
processor and Flood replenishment that occours at intervals as the film moves
round the processing tanks.
RECIRCULATION
The recirculation system agitates the processing solutions in the automatic
processor. The agitation provides uniform concentration and temperature to the
processing solutions and prevent air bubbles from clinging to the film. It keeps the
fresh solution in contact with the film [Link] also filters debris such as gelatin
particles from the processing [Link] system circulates about 1-2gallons of
fresh water every minute in wash [Link] replenishment system adds fresh
chemicals to the top of the tanks and the recirculation system draws solution from
the bottom of the tank and replaces it on the side of the tank..
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TEMPERATURE REGULATION
This functions to control the temperature of each section of the automatic
[Link] proper temperature is very crutial in development [Link]
temperature must be between 920 to 960 F (± 50 F). This is achieved through the
help of a thermostat. The developer is circulated through a circulation coil in the
bottom of the developer [Link] thermostat regulates the temperature of the
processing solutions by heat conduction. Fixer temperature is not as crucial as that
of the [Link] is usually slightly lower in temperature than that of the
developer [Link] solution is usually kept at 5 0F lower than that of
developer [Link] thermostat functions to maintain the temperature of all the
processing solution working in an automatic processor at optimal level.
NOTE: Both under and over replenishment will lead to sub optimal radiographs.
Components of Developer Solution :
Developing agents,Accelerators,Preservatives, Restrinats, Hardeners,Solvent –
water dissolves and ionizes the developer chemicals and the film emulsion also
absorbs water causing it to swell. This allows the dissolved developing agents to
penetrate the emulsion and reach all the silver halide crystals.
HOW THE DEVELOPING AGENTS FUNCTION
The developing agent is the component of the developer solution that oxidizes the
silver halide and convert the latent image into manifest image. Hydroquinone is a
reducing agent; it slowly builds black tones for contrast Phenidone quickly builds
gray tones. These two agents makeup the developer which functions mainly to
convert the silver halide to metallic silver.
THE ACCELARATORS: The accelerators function to increase the rate of
chemical reaction converting exposed silver halide grains into metallic silver at a
more rapid rate. The work of accelerator are done by sodium and potassium
carbonate or sodium and potassium carbonate or sodium or potassium hydroxide.
The PH of accelerator must be between 10 and 11.5. It must be alkaline.
Preservatives of developer
Helps to maintain the rate of development and prevent staining of the film
emulsion layer. Helps to protect the hydroquinone from oxidation. This is done by
sodium or potassium sulfite.
Restrainers or anti-foggers
Potassium bromide, Potassium Iodide
Function to protect unexposed silver halides grains from the action of the
developer minimizing film fog.
Hardeners: Glutaraldehyde
Prevents excessive swelling of gelatin and damage to the film as it passes through
the rollers.
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Fixing Solution
Functions: Clearing the underdeveloped crystals before washing to prevent
discoloration of the film with age or exposure to visible light.
Components of fixer solution
Solvent, Fixing agent,Preservative,Hardener,Acidifier and Buffer
Hardener or Tanning agent of the fixer
Aluminum Chloride, Aluminum Sulfide or Potassium Alum:Prevents the gelation
of the emulsion from swelling [Link] softening by the wash water or
by warm water or by warm [Link] the drying time.
Acidifier:Accelerates the action of other chemicals. Neutralizes any developer that
may be carried over from the developer tank.
Buffer:Chemical compounds that maintain a constant PH of the solution during
the fixing process maintain pH of fixer should be between 4 and 4.5.
Washing:Removes the last traces of chemicals and prevents fading or
discoloration of films.
Drier System
This is the part of the processor that removes water from the film by blowing warm
dry air at the temperature between 1200 F and 1300 F over the surface of the
[Link] squeegee cross over rollers remove water from wash tank and heated air
is blown through a series of tubes that surround both sides of the film and the film
finally comes out of the automatic processing machine as dry [Link] dry the
radiograph after being processed. A blower supplies heated air to the dryer section
of the film processor which consist of tube like rollers. Most of the air is
recirculated. The rest is vented to prevent buildup of excessive humidity.
Maintenance of Automatic Processor
For automatic processor to be function optimally, there are certain care and
maintainace that must be carried out on it [Link] as ensuring regular start
up practices and cleaning practicals.
When an automatic processor is started up at the beginning of a new day or
restarted after an extended standby period. An uneposed and underdeveloped
14 x 17 film has to be passed through the processor to clean of all dirt or debris
that might be on the rollers.
The processor lid should be kept aar when not in use to prevent cross
contamination causeed by fumes from the solution. There should be cover on
the developer and fixer tanks. The rollers in the tanks should be cleaned
regularly to prevent build up of chemical deposits, dirt and algea on them.
Cross-over rollers should be cleaned daily and the roller racks should be
cleaned monthly. If they are not properly maintained, a build up of chemicals
can cause the rollers to misalign and result in films being scratched as they pass
by. The cross over rollers must be removed carefully so as not to mix
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chemicals between tanks. The processing tanks are drained and washed
monthly. Fixer solution must never be spilled into the developer solution
Periodically, sensitometry should be done on processor but on mammography
processors it should be done daily. Sensitometry is done to measure
characteristic responses of fil to exposure and processing. It is usually done
using sensitometer and a densiometer. Sensitometer is a device with a
calibrated light source that used to measure the optical densities (OD) of the
exposure on the film. Once the sensitometry film has been exposed and
developed, a densitometer is used to measure the density on the film and thus
the performance of the processor
TYPES OF AUTOMATIC PROCESSOR
1. Floor mounted
This is the type that is used for high of work.
2. Table top
This is the type that is mobile that can be carried about from place to
place
