AUTOMATIC FILM

PROCESSOR IN
RADIOGRAPHY

By: Mary Armainneh Dela Cruz, RRT

AUTOMATIC PROCESSOR

> X-ray film automatic processor is consist of series of rollers which transport the film through
developer, fixer, washing and drying section of the system.

> Automatic film processing provides consistent and uniform radiographs.

> The automatic processor reduces film processing time than the manual development.

> The total developing time is only 90 seconds.

> The transportation of films from one solution to the next is to take place automatically
without any efforts.
1. The Film Entry System
2. Transport System
3. Replenishment System
4. Circulation System
5. Water System
6. Dryer System
7. Temperature Control System
8. Electrical System
The Film Entry System

> The apparatus of the processor which will take the film into the processor.

> Film is placed in the feeding tray near the developing tank.

> As we feed film into automatic processor following cycle of event are activated.

> Replenishment system activated.

> Safelight above feed tray extinguished.

> Drive motor energized (To turn the rollers)

> Developers and fixer replenisher pumped into tanks.

> Wash water flow rate boosted.

> A warning in the form of a bell or buzzer or light in used to tell when the next film is to be
inserted.

> Dryer heater activated.

TRANSPORT SYSTEM

● It moves the film through the processor

● Controls processing by controlling the time the
film is immersed in each chemical
Three subsystem
1. Roller subassembly
 Transport rollers
 1 inch convey the film along its path. Positioned opposite one
another
 Master roller
 also known as solar roller 3 inch dm. makes a turn a in processor
 Planetary rollers and metals
 positioned around the master roller
TRANSPORT SYSTEM

2. Transport Rack Subassembly

Transport rack
 1 inch dm rollers that guide the film in one direction
Crossover racks
 Responsible for movement from tank-tank
 Squeegee: to squeeze the excess developer from the wet film of
the emulsion.
Guide shoes
 A curved metal lip that guide the film that around the bend

Turnaround assembly
■ Located at the bottom tank
■ Planetary, guideshoes and master roller
3. Drive Subsystem

> Provides power to turn rollers at a precise rate.

Drive Motor - provides power for the transport system.

Driver Motor Shaft - reduces 10 - 20 rpm through a gear reduction assembly.

● Belt & Pulley, Chain, Sprocket and Gears - three means of transferring power to the
transport rack.
● Sprocket - drive motor is transferred to a chain.
Replenishment System
> Main function is to keep solution tanks full and assure proper solution concentration.

> Developer and fixer levels drop as films processed.

> System replaces chemicals that are depleted through oxidation.

> Measures the proper quantity of chemicals into each tank.

> It consists of replenisher tank, filters, and replenishment pumps.

> These tanks are made up of stainless steel or plastic.

 > The developer replenisher tank has a floating lid to reduce auto-oxidation of developer
replenisher solution.

> The replenisher pump operates an electric motor, which fill the solution up to the tank level.

> The system helps the developer to maintain its alkalinity and strength.

> Preserves the quality of the chemicals.

Developer Replenishment Rate: 60 -70 mL/14inches

Fixer Replenishment Rate: 100 - 110 mL/14 inches

A. Volume Replenishment

> A volume of chemicals are replaced for each film that is processed.

B. Flood Replenishment

> Periodically replenishes chemicals regardless of the number of films processed.

Circulation System

> It is also known as recirculation and filtration system.

> This system provides agitation to the solution, stabilize solution temperature and filters the
solution.

> It keeps the fresh solution in contact with the film emulsion and also filter debris such as
gelatin particles from the solution.

> This system also circulates fresh water every minute in the washing tanks.

> Circulating pump is used to circulate developer and fixer solution through various devices.
Developer Circulation System
> Continuously mixes, requires filter.

> Traps particles as small as 100um

> Sludge can build up on the rollers.

Fixer Circulation System
> Continuously mixes, does not require filters.

> Fixer Circulation Lines - consist of 100um wire mesh filters.

Water Circulation System
> Usually an open system; single - pass water flows at constant rate.

> Wash Tank - Flow rate: 4-8 L/minute

Sewer Circulation System
> Where the water is collected and discharged directly.

> Flow rate: 12 L/minute (3 Gal/minute)

Water System
> The water system is either cold water or tempered water system.

> This consists of cold and hot water supply, filters, mixing value, flow gauze, temperature gauze
and heat exchanger.

> The value control the filtered water flow and temperature accurately.

> The heat exchanger box containing a series of tubes through which water and developer run.

> It absorbs waste heat from the developer.

> In fixer, the heat exchanger passes the waste heat to the water from which it is reabsorbed by
fixer.
 Dryer System
> It removes water from the film by blowing warm, dry air over its surface.

> Consists of blower, ventilation ducts, vented dryer tubes and exhaust system.

> If not dry, difficult to hang on viewing box.

> The blower unit generate the airflow, which is blown over the heater.

> Heated air enters ventilation ducts and dryer tubes and then blows over film.
Temperature Control System
> Maintains developer, fixer, and dryer temperature.

Thermostat - monitors and adjusts temperature at each stage.

Heat Exchanger - uses thermostat to heat development.
Thermocouple/Thermistor - device that monitors the temperature at each stage.
> Developer
- 35 degree C (95 degree F)

- 33-35 degree C (92-96 degree F) - 90 seconds automatic processor

- 28-30 degree C (83-86 degree F) - 2 minutes automatic processor

> Fixer
- 35 degree C (95 degree F)

> Washing
- 3-5 degree F lower than developer temperature
Electrical System
> It provides electrical power for the operation of automatic processors.
Processing Time Duration
Developing - 22 seconds

Fixing - 22 seconds

Washing - 26 seconds

Drying - 20 seconds

TOTAL: 90 seconds
Advantages of Automatic Processor in
Radiography:
● Compact size - occupy less space in the processing area
● The automatic processor will reduce film processing time
● Improves the radiographic image quality
● Time and temperature are automatically controlled
● It requires less water consumption and it will also reduce the film wastage
● Produce dry radiographs immediately
● Increase the efficiency of radiology department
● Eliminate the use of hangers
Disadvantages of Automatic Processor in
Radiography:
● Artifacts caused by rollers
● Expensive
● Requires regular maintenance
● Tends to produce chemical fog due to high developing temperature
● Manual processing required as a back up in case of technical errors
Maintenance of Automatic Processor:
● The processor is switched off, if it is not in used
● The water supply and replenishing pump should be check regularly
● The processing chemicals should have the correct operating temperature
● The rollers should be cleaned and the hard deposits from rollers should be removed
regularly
● Before making fresh processing solution, all exhausted solution should be drained
and cleaned
 Artifacts:

PROCESSING EXPOSURE ARTIFACTS HANDLING & STORAGE

ARTIFACTS ARTIFACTS

1. Emulsion Pickoff 1. Motion 1. Light Fog

2. Gelatin Build Up 2. Improper patient 2. Radiation Fog
3. Curtain Effect position 3. Static
4. Chemical Fog 3. Wrong Screen Film ● Tree Like
5. Guide Shoe Marks Match ● Crown Like
6. Pi Lines 4. Poor Screen Contact ● Smudge
7. Wet Pressure 5. Double Exposure 1. Kink Marks
Sensitization 6. Warped Cassette 2. Hypo Retention Stain
8. Dichroic Stain 7. Improper Grid 3. Scratches
Position
Processing Artifacts:
1. Emulsion Pickoff - are actual holes in the image where the emulsion has been
physically picked off the polyester base.Pick-off is an artifact produced in the
processor when a dirty roller or other object peels off flecks of the emulsion.

2. Gelatin Build Up - sludge deposits on the film.

3. Curtain Effect - When developer or fixer drains down a vertical film and some is
improperly retained, the finished product may appear as though viewed through a
curtain.

4. Chemical Fog - darkening of images by sources other than the radiation of the
primary beam to which the film was exposed. Light or radiation fog and is usually
a uniform dull gray.
5. Guide Shoe Marks - are found along the leading or trailing edge of the
film; they occur when the guide shoes in the turn-around assembly of the
processor are sprung or improperly positioned.

6. Pi Lines - an artifact appearing at 3.14-inch intervals as a result of dirt or

chemical stain on a 1-inch-diameter transport roller.

7. Wet Pressure Sensitization - Irregular or dirty rollers cause pressure

during development and produce small, circular patterns of increased OD.

8. Dichroic Stain - a processing artifact consisting of a two-colored stain,

brown and greenish yellow.
Exposure Artifacts:
1. Motion - a patient-based artifact that occurs with voluntary or involuntary
patient movement during image acquisition leading to blurred radiographs.

2. Improper patient position - lack of patient preparation and cooperation.

3. Wrong Screen Film Match - mismatching of film and screens often

increases patient radiation dose and poor quality of radiograph.

4. Poor Screen Contact - results to obscured detail in radiograph.

5. Double Exposure - occurs when radiographers mixed up cassette and
expose a film that has already been used.

6. Warped Cassette - cassette backs and fronts may warp due to incorrect
storage or traumatic handling. A warped cassette can cause a loss of
contact between the film and intensifying screens causing a diverging of
the light photons from the screens causing a loss of detail and contrast.

7. Improper Grid Position/Grid Cut Off - occurs if the patient is positioned

for examination but the x-ray tube is not centered to the table or bucky tray.
Handling & Storage Artifacts:
1. Light Fog - occurs if the safelight is too bright, is too close to the processing
tray, or has improper filter.

2. Radiation Fog - occurs if the film bin is inadequately shielded from radiation or
the film has been left in the x-ray room during other exposures.

3. Static - occurs if the temperature or humidity is too low, can sometimes be

cause by taking the film out quickly in a newly opened box.
(Crown, Tree, Smudge) It is caused by the buildup of electrons in the emulsion
and is most noticeable during the winter and during periods of extremely low
humidity.
4. Kink Marks - occurs if the film is improperly or roughly handled or the film is
stacked too high in storage (the weight causes marks). It can also be caused by
kinking or abrupt bending of a film. It can look like a fingernail mark.

5. Hypo Retention Stain - The yellow-brown stain that slowly appears on a

radiograph after a long storage time. This occurs when not all the thiosulfate
from fixing was removed during washing, and silver sulfide slowly builds up.

6. Scratches - Emulsion is soft during processing. Long fingernails, careless

handling during manual processing, wet films touching other films while being
processed or drying.
Other Appearances of a Poor Quality
Radiograph:

1. Milky Appearance - caused by underreplenished fixer.

2. Greasy Appearance - caused by inadequate washing.
3. Brittle Appearance - caused by improper dryer temperature or hardener in the fixer.
4. Crown Static Appearance - resembles a crown.
5. Tree Static Appearance - tree or bush-like with fingerlike processes emanating outward
from point of discharge.
6. Smudge Static Appearance - assumes characteristic of black smudges.