Kodak E6 Manuals Z99+Z119

Introduction to Color Process Monitoring
KODAK Publication No. Z-99
Eastman Kodak Company, 2001
Table of Contents
WHY SHOULD YOU MONITOR YOUR PROCESS? . . . . . . . . . . . . . . . . . . . . . . . HOW DOES A COLOR PROCESS WORK? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHAT IS A WELL-CONTROLLED PROCESS? . . . . . . . . . . . . . . . . . . . . . . . . . . What Are the Attributes of a Good-Quality Finished Photograph? . . . . . What Are Aim Values, Control Limits, and Action Limits? . . . . . . . . . . . . WHAT CAUSES PROCESS CHANGES? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solution Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solution Storage and Keeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing Solution Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solution Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processing Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solution Replenishment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHAT EQUIPMENT AND MATERIALS WILL YOU NEED? . . . . . . . . . . . . . . . . . Processing Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operators Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processing Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KODAK Process Record Form, Y-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Densitometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Strips and Reference Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graduated Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOW DO YOU MONITOR A PROCESS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Establishing an Aim for Your Process . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparing a Control Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comparing Your Process to the Aim Values . . . . . . . . . . . . . . . . . . . . . . Interpreting Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing to a New Batch of Control Strips . . . . . . . . . . . . . . . . . . . . . . . WHAT CAN YOU DO TO CORRECT PROCESS PROBLEMS? . . . . . . . . . . . . . . Sudden Change in Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trend of Increasing or Decreasing Density . . . . . . . . . . . . . . . . . . . . . . . Trend of Increasing Spread Between Densities. . . . . . . . . . . . . . . . . . . . Cross-Density Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHAT OTHER CONTROL METHODS ARE HELPFUL? . . . . . . . . . . . . . . . . . . . Checking Your Densitometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Flowmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating Mixing Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Solution Mixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KODAK CONTROL STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPLIES AND SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 5 6 7 8 8 8 9 10 10 10 10 11 11 11 11 12 12 12 13 14 14 14 15 15 16 17 17 18 19 19 20 20 20 21 21 21 21 21 22 25

This publication provides a step-by-step approach to the principles of color process monitoring. Well begin with the basics and then lead you to information about specific processes. Process monitoring is a means of consistently obtaining the best photographic quality with the minimum of waste and cost. In the following pages, youll learn why you should monitor your process how a color process works what is a well-controlled process what causes process changes what equipment and materials youll need how to monitor a process what to do about an out-of-control process what control procedures are available
WHY SHOULD YOU MONITOR YOUR PROCESS?

Consistent high quality is good business. It means satisfied customers because they receive good results from their film, which in turn means new and repeat business. High-quality photographic processing depends on meeting and maintaining process and product standards. You can meet and maintain these standards by following the manufacturers processing and printing recommendations, and by monitoring and controlling your process. Process monitoring enables you to ensure that your process is operating consistently within tolerances that yield high-quality negatives, transparencies, or prints. When you monitor your process carefully and your process stays in control, youll reduce waste, avoid downtime, and increase customer satisfaction, employee productivity, and profits. Process control provides the following benefits: process consistency higher overall quality of processed film or prints greater total yield of acceptable film or processing capacity early detection of process and/or equipment problems less waste of time, chemicals, film, and paper increased printing productivity greater customer satisfaction
HOW DOES A COLOR PROCESS WORK?

White light is composed of varying amounts of red, green, and blue light. Color films and papers are able to record all the colors of a scene because they have separate emulsion layers that are sensitive to the colors that make up white light. A minimum of three layers is required: one sensitive to blue light, one sensitive to green light, and one sensitive to red light. Other emulsion and filter layers may be required depending on the film or paper type. Most color films and papers have dye-forming chemicals incorporated in the emulsion. Chemical reactions during development determine the color formed in the individual layers. Depending on the process, a negative or a positive image is produced. All conventional color processes require steps for development, bleaching, and fixing. A reversal process also requires steps for reversing the image and secondary (i.e., color) development.
Other processing steps remove chemicals and chemical by-products that are not used in forming the image. These by-products are usually removed in the bleach, fixer, wash, final rinse, and stabilizer steps. Here are the basic steps in the most commonly used color film and paper processes: 1. The developer acts on the silver halide (latent) image to produce a silver image. 2. Dye is formed in the silver image area when development by-products react with the color couplers in the emulsion. In a reversal process, this step occurs in the color developer after reexposure has taken place. 3. With the dye image formed, the silver image is bleached to convert the developed silver to a soluble silver salt that can be removed. 4. During fixing, all the silver is removed, leaving only a dye image.
Color Negative Process Color Reversal Process
WHAT IS A WELL-CONTROLLED PROCESS?

A well-controlled process is one that consistently produces high-quality results with minimum waste. High-quality results are consistent with those that the film, paper, and printer were designed to produce and are satisfying to the customer. A good-quality finished print or transparency will be of the proper density and color balance, with matched contrast in all three color layers; dense, detailed shadow areas; and clean whites. To be sure of high-quality results, you must keep your printing and processing operations within specifications during your production schedule. When you monitor the process with control strips as described on page 13, a wellcontrolled process will consistently plot within the established control limits.
Develop silver image and form dye Oxidize silver Remove silver
Develop silver image Form reversal latent image Form dye Oxidize silver Remove silver
For more information about the individual steps in a particular process, see the manual for your process. The solutions and steps for the most common color processes are listed below.
Color Negative Film Color Prints from Color Negatives Process RA-4 Developer Bleach-Fix Stabilizer or Wash Dry Color Reversal Film Color Prints from Color Transparencies Process R-3 and Process R-3000 First Developer Wash Reexposure Color Developer Wash Bleach-Fix Wash Dry
Process C-41 Developer Bleach Wash Fixer Wash Stabilizer or Final Rinse Dry
Process E-6 First Developer Wash Reversal Bath Color Developer Pre-Bleach Bleach Fixer Wash Final Rinse Wash Dry
What Are the Attributes of a Good-Quality Finished Photograph?

A well-exposed and processed print or transparency will have these attributes: 1. DensityNormally lighted areas of the original scene reproduce to an appropriate density level in the finished photograph. Density is determined by camera exposure, development conditions, and printer exposure (in prints). 2. Color BalanceNeutral grays and flesh tones are the most sensitive, and therefore the most critical areas of a photograph to the viewer. If it is well balanced, neutral grays reproduce without any color bias; flesh tones appear natural. Color balance is generally determined by the quality of the original light source, development, and printer color balance. 3. ContrastThe contrast in each of the three color layers should match. Otherwise, it will be impossible to obtain good color balance over the entire exposure range. For example, with a color negative film, if the contrast of the green-sensitive emulsion layer is lower than that of the red and blue layers, high-density areas in printssuch as hair and shadowswill be green in the final print even though midscale densities, such as flesh tones, are properly balanced. Mismatched contrasts can result from poor film keeping, contamination or mixing errors in any of the processing solutions, over- or underdevelopment, and inadequate bleaching or fixing. Also, the overall contrast must not be too high or low. A print or transparency that is too low in contrast will appear muddy or flat because the range of densities between the highlight and shadow areas is too small. Low contrast is usually the result of underexposure or underdevelopment. A print that is too high in contrast will appear harsh because the range of densities between the highlight and shadow areas is too great. The highlight areas often lack detail and appear washed out; the shadow areas often lack detail and appear blocked up. High contrast is usually the result of overexposure or overdevelopment. 4. Highlight Areas and Minimum Density (D-min) Whites and other typically very light neutral areas are white and reproduce any detail present in the original scene. While highlight areas are affected by color balance, density, and contrast, they are also affected by the inherent D-min level of the transparency or print material, solution contamination, product keeping (both before and after processing), and improper fixing or stabilization. 5. Shadow AreasBlack or high-density gray areas are close to neutral and reproduce the detail of the original scene. Although these areas are affected by exposure, density, color balance, and contrast, they are also affected by keeping before and after processing, solution contamination, and improper bleaching or fixing. 6. Color SaturationIdeally, colors in the photograph reproduce those of the original scene. They do not appear flat or muddy. Color saturation is affected mostly by film exposure. Improper development, bleaching, and fixing, as well as contamination of these solutions, also affect it.
What Are Aim Values, Control Limits, and Action Limits?

The following terms are frequently used in process monitoring. Action LimitsThe action limits are the boundaries of the desired operating range of the process. As long as the density values remain between the upper and lower action limits, your process is operating correctly. If a density value exceeds the action limit, it is an early warning. You can still safely process customer work, but you should check for the cause of the shift and correct it. Aim ValuesThese are the values to which you compare your control-strip densities. To obtain aim values, read the reference-strip densities; then apply the correction factors to the density readings. Enter these values in the spaces provided on the left side of your control chart. Color-Balance Spread LimitsA color-balance spread is the density difference between the two most widely separated densities of the HD LD plot. If the process exceeds the spread limit, stop processing customer work, and take corrective action. Control ChartA control chart is a plot of values calculated from the density readings of your control strips. It shows process variations from aim over a period of time. Plots on your control chart will confirm the control of your process or provide a clear record of variations to help you troubleshoot process problems. Control LimitsThe control limits define the maximum tolerances that are acceptable for processing customer work. If any density value of your process plots beyond the control limit, the process is out of control, and results will be unsatisfactory for color, density, and/or contrast. When any density value plots beyond the control limits, stop processing customer work until you find the cause of the shift and correct it. Control StripsThese are precisely exposed strips of film or paper used to monitor your process. Correction FactorsYou use these numbers to adjust the densities of the reference strip to obtain aim values. Correction factors are provided with each box of control strips, and usually differ for each code number. Reference StripThis is a control strip that is precisely exposed and processed by Kodak under standard conditions. A reference strip is packaged with each batch of control strips. To obtain aim values, measure the reference-strip densities and apply the correction factors for that batch of control strips. Tolerances and LimitsTolerances and limits are density variations allowed before you must take corrective action; they include an aim-value adjustment tolerance, and action and control limits.
LD
RED GREEN BLUE
.15 .10
0.42 0.60 0.76
.05 + 0 .05 .10 .15
D-Min
RED GREEN BLUE
F002_1149AC
0.17 0.48 0.61
.05 + 0 .05
In the figure above, the black dashed lines are the action limits and the red dashed lines are the control limits.
WHAT CAUSES PROCESS CHANGES?

The aim of process control is to match the process with a standard, and then minimize changes from the standard. Many factors can cause changes in your process and cause it to go out of control: improper solution mixing improper solution storage and keeping solution contamination incorrect processing solution temperature incorrect processing time improper agitation improper solution replenishment evaporation equipment malfunction
Solution Storage and Keeping

Solutions that are kept too long or exposed to air for too long may become exhausted. Always follow the keeping recommendations given in the instructions provided with your chemicals or in the manual for your specific process. To minimize solution storage and keeping problems, mix only the amount of solution that you will use before the recommended keeping time is exceeded. Store mixed solutions in tanks with floating lids or in full, closed containers.
Solution Mixing
Handle all chemicals carefully, and prepare each solution according to the instructions. Wear protective clothing. Keep mixing tanks and equipment clean. Calibrate mixing tanks. Start with the correct amount of water at the proper temperature. Mix solution parts in the correct order. Mix solutions for the required amount of time.
Preventing Solution Contamination

Minute amounts of contaminants can seriously affect a processing solution. Take precautions to minimize the possibility of solution contamination. Contamination is most often caused by mixing equipment that has not been thoroughly cleaned 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 an area 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. If possible, use a separate set of mixing equipment to mix each type of solution, and wash all equipment thoroughly before you reuse it. If you use only NEGATIVE processes, use two mixing tanks: one for developer and one for all other solutions. If you use only REVERSAL processes, use two mixing tanks: one for the first developer and color developer, and one for all other solutions. Three mixing tanks are preferable: one for the developers, one for bleach and fixer, and one for all other solutions. If you use both NEGATIVE and REVERSAL processes, use four mixing tanks: one for the negative developer and the reversal first developer, one for color developer, one for bleach and bleach-fix, and one for all other solutions. Using separate mixing tanks may not always be practical or possible. The diagram at the right gives mixing arrangements for one to four mixing tanks. Use it as a guide to reduce the possibility of contamination.
If you have one tank:
1 Reduce the chance of chemical contamination by using four

separate mixing tanks. If you cannot use four separate tanks, do the following before mixing different batches of chemicals Thoroughly rinse the tank and mixing equipment with room-temperature water Flush tubing and lines Thoroughly clean transfer pumps
If you have two tanks:
1
Use this tank for black-and-white developers first developers for Processes E-6 and R-3 color developers for Processes E-6 and R-3, and developers for Processes RA-4 and C-41
2
Use the second tank for all stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 all bleaches, fixers, and bleach-fixes final rinse for Process C-41
If you have three tanks:
1
Use this tank for black-and-white developers first developers for Processes E-6 and R-3 color developer for Process E-6 and developers for Processes RA-4 and C-41
2
Use the second tank for color developer for Process R-3 all stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 final rinse for Process C-41
3
Use the third tank for all bleaches, fixers, and bleach-fixes
If you have four tanks:
1
Use this tank for black-and-white developers first developers for Processes E-6 and R-3
2
Use the second tank for color developers for Processes E-6 and R-3, and developers for Processes RA-4 and C-41
3
Use the third tank for stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 final rinse for Process C-41
4
Use the fourth tank for all bleaches, fixers, and bleach-fixes
F009_9002EC
Solution Temperature
Temperature variations greater than 0.15C (0.25F) in the developer of color processes will affect process control and image quality. In other solutions, temperature variations of a few degrees usually have no noticeable effect. However, variations greater than a few degrees can damage emulsions. To avoid problems, use a consistent temperature for all your processing solutions. Use a temperature that you can maintain consistently. Temperatures too high emulsion damage; density, color, and contrast changes; solution evaporation Temperatures too low density, color, and contrast changes
Agitation
Agitation is necessary in most solutions to maintain uniform activity by removing exhausted solution from the emulsion surface and replacing it with fresh solution. Agitation must be uniform throughout the processing tank. Poor or insufficient agitation may result in non-uniformity and streaking on the film or paper. Too much agitation will oxidize some of the chemical components by introducing air into the solution. Excessive agitation is particularly harmful to developers. Follow your equipment manufacturers recommendations for agitation. Agitation methods involve moving the film or paper through the solution or moving solution over the surface of the film or paper. In continuous or roller-transport processors, the film or paper moves through the solutions. In rack-and-tank and sink-line processors, an inert gas (such as nitrogen) is bubbled through the solutions. Some bleach solutions require aeration to maintain activity. Too much agitation solution oxidation; density, color, and contrast changes Too little agitation density, color, and contrast changes; non-uniformity
Processing Time
Variations in processing time affect the film or paper in a manner similar to changes in temperature. Time in the developer is especially critical. While some safety factor is built into the times for other processing steps, excessively short times for washes, bleaches, bleach-fixes, fixers, and other steps will not allow these steps to complete their function. Use the proper times for all your processing solutions. Time too long emulsion damage; density, color, and contrast changes; solution evaporation Time too short density, color, and contrast changes
Solution Replenishment
During processing, some components of the processing solutions are consumed or oxidized, and components from film or paper are dissolved into solution. In most processes, you can add replenisher solution to partially exhausted tank solutions to maintain the chemical compositions. The rate at which replenisher is added affects the solution activity and composition. Most automatic processors provide a means of introducing the correct amount of replenisher into the tank. Be sure to replenish solutions properly. Check replenisher pumps and flowmeters regularly to ensure that they are providing the correct amount of replenisher solution. For more information, see Calibrating Flowmeters. Overreplenishment density, color, and contrast changes; higher chemical costs Underreplenishment density, color, and contrast changes
10
WHAT EQUIPMENT AND MATERIALS WILL YOU NEED?

To begin monitoring your process youll need the following: processing log operators checklist for your processor maintenance checklist for your processor processing manuals for appropriate processes Traditional KODAK Process Record Form, Y-55 (or similar graph paper) with red, green, and blue pencils; or automated KODATEL Software. densitometer control strips and reference strip hydrometer(s) graduated cylinders thermometer
Processing Log
Maintain a processing log by recording significant events that could affect process quality. Record the amount and type of film or paper processed each day or shift. A processing log should include information such as date and time of processing size and type of film processed amount of film or paper processed times when control strips were processed amount of replenisher used preparation of chemical mixes operators name or initials
Operators Checklist
An operators checklist is a guide, a reminder, and a record of the routine procedures for starting up and shutting down your processor. Following a complete checklist will help ensure that your process is started up consistently. Failure to use a checklist, particularly at startup, can result in customer film being processed when the machine is not in proper operating condition.
Maintenance Checklist
Regularly scheduled maintenance helps keep your processor in good working condition. Included in maintenance checklists are items such as lubrication filter replacement tank cleaning operating checks
11
Processing Manuals
Kodak publishes processing manuals that describe how to operate and monitor processes that use KODAK Chemicals. They include a list of KODAK Chemicals available for a particular process recommendations for solution mixing and storage general processing recommendations process options solution-regeneration information (if applicable) process-monitoring methods troubleshooting and diagnostic information
Process Publication No./ CAT No.* Z-119 / 102 9693 Title Using KODAK Chemicals, Process E-6 Using KODAK EKTACHROME R-3 and R-3000 Chemicals Using KODAK EKTACOLOR Chemicals Using KODAK FLEXICOLOR Chemicals
E-6
R-3 R-3000
Z-129 / 123 5753
RA-4
Z-130 / 160 5716
C-41
Z-131 / 155 9418
* The most up-to-date versions are available online.
KODAK Process Record Form, Y-55

This record form is graph paper designed for plotting variations from aim of the densities of process control strips. It has space to record aim values, the code number of the control strips, and the identification of the process and machine. It includes areas for plotting the variations from aim and dates processed for up to 23 control strips. It is available in pads of 100 forms.
Densitometer
For process monitoring, you will need a reliable, accurate color densitometer that provides Status A and Status M densitometry. Use Status A filters to measure the densities of color reversal films and color papers or materials intended for viewing by transmitted or reflected light. Use Status M filters to measure the densities of color negative films. Set the densitometer in the transmission mode to measure the densities of film; set it in reflection mode to measure the densities of prints. Monitor your densitometer regularly to be sure that it is operating properly. See Checking Your Densitometer.
12
Control Strips and Reference Strip

KODAK Control Strips are precisely exposed strips manufactured on uniform pieces of film or paper. The strips contain exposures made at several different exposure levels or steps. Each type of control strip is designed for a specific process, because each process has different requirements. Most strips include areas for reading minimum density (D-min) and high and low mid-range densities for process monitoring. Strips for reversal processes include maximum density (D-max) and toe density areas. Storage conditions can affect the quality and usefulness of these strips for process control. Follow the specific storage requirements noted on each package of KODAK ControlStrips. In general, store unused strips at -18C (0F) or lower. Remove only a days supply of strips at a time, reseal the package, and immediately return the package to the freezer. Discard any unused strips at the end of the day. If problems occur from condensation, allow the package to warm up to room temperature before you open it. A reference strip and correction factors are supplied with each box of KODAK Control Strips. The reference strip is exposed on the same emulsion and under the same conditions as the control strips and then processed in a standard process. A code number on the box label and the reference and control strips identifies each batch of strips. Youll determine aim values for your process by applying the correction factors to your densitometer readings of the reference strip. Then youll plot the densitometer readings from control strips processed in your machine against these aim values to monitor your process.
C-41
Raised Dimple
C-41 0065
D-MIN
0073
C-41 0041
Yellow Patch D-max
2 3 4 5
LD
Yellow Patch
HD
D-MAX
D-max
YELLOW
HD
DATE:
HD
5-Inch 35 mm Strip
LD
LD
D-min D-min
Cutoff Notch
9-Inch 35 mm Strip
Cutoff Notch
Full Frame Control Strip
F002_9092GCA F002_9092GC
KODAK Control Strips Process RA-4
8014
D-min
LD
Code Number
HD
BP
Yellow
F002_0818BC
13
Hydrometer
For some processing solutions, measuring the specific gravity is a quick and simple means of detecting mixing errors of 10 percent or more. You will need different hydrometers to measure the specific gravity of different processing solutions. For more information, see Checking Solution Mixes.
F002_1148AC
Graduated Cylinders
Use a graduated cylinder calibrated in mL to measure small volumes of solutions. You can also use a 250 mL or 500 mL graduated cylinder to measure the output of automatic replenishment systems. Calibrate small mixing tanks with a 1-litre graduated cylinder. For more information, see Calibrating Flowmeters and Calibrating Mixing Tanks.
Thermometer
Use a thermometer calibrated in 0.1C units, such as the ASTM No. 91C or Fahrenheit equivalent, to calibrate temperature controls and check solution temperatures.
F002_1147AC
14
HOW DO YOU MONITOR A PROCESS?

Process monitoring is a method of regularly checking the condition of your film and paper processes to ensure that they are operating according to a standard that Kodak has defined with aims built into the reference strip. It helps prevent losses by detecting potential problems. To monitor your process, you will process control strips, measure specified densities, and then compare the densities to aim values. You will plot your variations from aim on a control chart. Your control chart will do the following: Indicate if the process is within acceptable limits. Show trends in the process and signal you to make changes to keep the process in control. Help determine the causes of process problems. Allow you to check the effects of adjustments made to the process. Process monitoring involves these basic steps: 1. Establishing an aim or standard for your process. 2. Determining the condition of your process relative to the aim. 3. Keeping an ongoing record of the condition of your process and analyzing the record daily. 4. Taking corrective action when variations from aim are outside the action limits on your control charts. You will verify the results of the correction to be sure that the process is within the action limits. Note: You can automate the monitoring of yourprocess with easy-to-use KODATEL Software for minilabs, traditional labs, and lab networks.
Establishing an Aim for Your Process

The reference strip packaged with your control strips is the primary tool for establishing aim values for your process. Follow the procedure below to establish your aim values. 1. Remove the reference strip from the box of control strips. If you have a number of boxes with the same code number, remove the reference strip from several boxes. You can minimize the effects of variability by averaging the readings of the strips. IMPORTANT: After removing the reference strips, return the control strips to the freezer. Then allow the reference strips to warm up to room temperature before removing them from the envelope. Exposing a frozen reference strip to warm, moist air can cause low density readings, especially in the high-density patches. Store the reference strips in the envelopes at room temperature after you make your densitometer readings. 2. Use a precision electronic densitometer to measure the red, green, and blue densities in the center of the patches recommended in the instructions supplied with the strip. Do not move the strip between the red, green, and blue readings. Average the readings if you read more than one reference strip from the same code number. 3. Apply the correction factors supplied with the control strips to the average readings from step 2 to obtain your aim values. Write these values in the appropriate spaces on the left side of the KODAK Process Record Form, Y-55.
15
Preparing a Control Chart

Do not try to predict film or print quality from your control charts alone. A good monitoring program uses control charts and transparency or print evaluation in decision-making. However, a control chart is essential to detecting and eliminating process problems and distinguishing them from other factors such as printer problems. Compensating for process deviations by adjusting printer setups will not result in optimum print quality. To prepare a control chart on the KODAK Process Record Form, Y-55 1. Use a separate form for each processor. 2. Record the reference-strip code number and the aim values in the appropriate blanks. Use red, green, and blue pencils when you record the aim values. 3. Draw horizontal lines to represent the action and control limits. 4. Record the process and machine identification in the blanks at the bottom of the form. 5. Youll need to record the date and time that each control strip is processed. Plot the control-strip values against the aim values, and connect the points to give a continuous graph. To help determine the cause of a control problem, also keep records of machine speed or solution time solution temperatures agitation filter replacements squeegee adjustments maintenance of racks, gears, pumps, lines, etc. operators chemical mixes replenishment rates film types, sizes, and amounts bleach regeneration silver-recovery procedures solution adjustments (e.g., pH, chemical additions, etc.)
CONTROL NUMBER AIM VALUES

REFERENCE STRIP CODE NO.
26 27 28 29 30
.25 .20
0001
.15 .10
2.50 2.40 2.25
BP
RED GREEN BLUE B/W
.05 + 0 .05 .10 .15 .20 .25
Control Limits
.25 .20
HD - LD
RED GREEN BLUE B/W
0.80 0.78 0.78
.15 .10 .05 + 0 .05 .10 .15 .20 .25
Action Limits
.15
LD
RED GREEN BLUE B/W
0.80 0.84 0.81
.10 .05 + 0 .05 .10 .15
D-min
RED GREEN BLUE B/W DATES
PROCESS
F002_9125EC
3 17 3 18 3 19 3 20 3 23
0.08 0.09 0.10
.05 + 0 .05
RA-4 Processor #3
MACHINE
16
Comparing Your Process to the Aim Values

When youve created a control chart as described above, follow the procedure below: 1. Follow this schedule for processing a control strip: At the beginning of the day or shift, before processing customer work At regular intervals with customer work At the end of the day or shift Note: Each time you process a control strip, position it in the same location in your processor. 2. When the control strip is processed and dried, use a precision electronic densitometer to measure the red, green, and blue densities in the center of the patches you measured on the reference strip when you established your aims. Do not move the strip as you make the density readings or you may affect the precision and repeatability of the measurements. 3. Calculate the variations from aim by subtracting the aim densities from your control-strip densities. Plot the variations on your control chart. Plot differences that are larger than the corresponding aim values (+ values) above the aim line. Plot differences that are smaller than the aim values ( values) below the aim line. To avoid processing customer film in an out-of-control process, read and plot control-strip densities immediately after you process a strip. Analyze the plots to detect trends that may lead to an out-of-control condition. This will enable you to check for sources of the trend and take the proper action if your plots exceed the action limits. Verify out-of-control plots by processing another control strip. Seldom do two consecutive plots provide false data.
Interpreting Control Charts

In interpreting control plots, the primary concern is a plot that exceeds the action or control limits. Fluctuation of the plots within the action limits is normal and no action is required. If any single plot exceeds the action limit or the control limits, take the following steps before making any process adjustments: 1. Check that the control strip you processed is of the same code number as the reference strip used to establish aims. 2. Check that the control strips were stored and handled properly. 3. Check the densitometer to be sure that it is calibrated and operating properly. 4. When you have verified that there is no problem with the control strip or the densitometer, re-read the control strip. 5. If the readings from step 4 verify the results, process another control strip. 6. If the second strip confirms the original results, do the following: If the plot exceeds the action limits, you can continue to process customer orders, but you must determine the cause of the process shift and correct it. Note any corrective action that you take on the control chart. When the process is in this condition, we recommend that you process a control strip with each batch of customer work. If the plot exceeds the control limits, do not process any customer work until you have corrected the out-of-control condition. 7. Whenever you take corrective action, process another control strip to confirm that the change you made returned the process to control before you resume normal processing. The causes of some common conditions are described under What Can You Do To Correct Process Problems? The Kodak processing manuals for individual processes include detailed information for diagnosing and correcting process problems.
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Changing to a New Batch of Control Strips

When you change from your current batch of control strips to strips with a different code number, make a crossover to confirm that both code numbers provide the same information. Be sure that your process is stable and in control before you begin using a new batch of control strips. 1. While you still have a weeks supply of control strips of the current code, process one control strip from the new batch of strips with one strip from the current batch in three separate runs. 2. Read and record the densities of the processed strips. 3. Determine aim values for the new processed strips as described under Establishing an Aim for Your Process. 4. For your current batch of control strips, calculate the variations from aim by subtracting your current aim densities from the densities of the three strips. Plot the variations on your control chart. 5. For the new batch of strips, calculate the variations from aim by subtracting the new aim densities (calculated in step 3) from the densities of the three strips. Plot the variations on your control chart. 6. Calculate the differences between the variations from aim of the current strips and the new strips. Average these differences; then divide the result by 2. 7. Depending on the sign of the differences, adjust the aim values for the new batch of strips by adding or subtracting the results from step 6. The amount of the adjustment should not exceed the aim-value adjustment tolerances. If the adjustment is greater than the tolerance, determine the cause. Check your calculations, densitometer, and control strips. 8. Record the new aim values and the code number of the new batch of strips on your control chart, and begin using the new strips.
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WHAT CAN YOU DO TO CORRECT PROCESS PROBLEMS?

When your control charts indicate a problem that calls for corrective action, always be sure to verify the problem: Be sure that the code number of your control strips and reference strip match. Be sure strips have been stored and handled properly. Check your densitometer. Reread control-strip densities. Run another control strip. When you have verified the problem, you must locate the cause. Diagnostic charts for your process are given in the process monitoring manual for the specific process. Once you diagnose the problem, you must correct whatever caused the condition. The steps you take to correct a problem will depend on the cause. Causes such as incorrect time, temperature, or agitation can usually be corrected quickly by restoring the process or processor to the correct condition. Conditions resulting from improper solution mixing; incorrect storage; over- and underreplenishment; or contaminated solutions may require that the tank solution be replaced. Your processing manual for a specific process is a comprehensive source of information on problem-solving. However, guidelines to the causes of some common process problems are given below.
Sudden Change in Density

Some processing conditions can produce sudden changes in one or more points of the control plot. These include the following: using a control strip with a code number different from that of the reference strip an increase or decrease in developer temperature an incorrect processing time, particularly in the developer solution contamination a change in the developer replenishment rate If you process control strips frequently, most of these conditions would first show as a trend. However, if the interval between strips is great, the condition may appear as a sudden change.
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Trend of Increasing or Decreasing Density

Trends in the control plots are the result of gradual changes in processing conditions. A trend of increasing or decreasing density is usually traceable to the first developer in a reversal process or to the developer in a negative process. The most likely causes are incorrect developer replenishment rate improper mixing or storage of the developer replenisher improper storage of the control strips
Trend of Increasing Spread Between Densities

When the red, green, and blue plots spread as they move in an upward or downward direction, one color is becoming proportionally more or less dense than the others. The processed work will show this change in color balance. The cause of this type of trend is usually traceable to the first developer or the color developer in a reversal process or to the developer in a negative process. The most likely causes are improper mixing or storage of the developer replenisher contamination of the developer replenisher incorrect replenishment rates oxidation of the developer
Cross-Density Trends
Cross-density trends often indicate that more than one variable is changing. With cross-density trends, the three color plots gradually cross one another, with one color moving in the direction opposite that of the other two. This results in a shift in color balance of the processed work. The cause of this type of trend is often traceable to the developer, although other solutions may also be at fault. The causes might be contamination of a replenisher solution improper mixing of a replenisher solution
20
WHAT OTHER CONTROL METHODS ARE HELPFUL?

Several simple methods are available for checking the condition of your processing solutions and equipment to make sure that they are within operating specifications. These methods use simple equipment and procedures. They include checking the calibration of your densitometer calibrating flowmeters and pumps calibrating mixing tanks checking for mixing errors with specific gravity
Calibrating Mixing Tanks

You can calibrate small mixing tanks (i.e., 5 gallons or less) with a graduated cylinder. Fill the cylinder to its highest mark with water, and pour the water into the tank. Repeat until the tank contains the volume of solution you are calibrating it for. Mark the level and identify it with the volume. You can calibrate a pail made of metal or rigid plastic in this way, and use the pail to calibrate larger tanksup to approximately 30 gallons. For large mixing tanks, a specially calibrated water meter provides an easy and inexpensive method of determining the volume. Relatively inexpensive water meters with good repeatability are available for this purpose. Because these meters are usually not completely corrosion-resistant, use them only for measuring the volume of water and not for chemical solutions. Place the meter in a water line, and run a volume of water that fills the tank to the volume you are calibrating for. Mark the tank at the level that corresponds to that volume. Check your calibration by repeating the procedure. Note: Remember that volume is affected by temperature; therefore, you should use water at about the same temperature as the water used to mix the solution. You can use this procedure to mark a tank for several different volumes. To use calibration marks, your tanks must be made of a rigid material.
Checking Your Densitometer

Calibration and maintenance of your densitometer are very important, because an inaccurate density reading can be misinterpreted as a process change. To monitor your densitometer and/or enable readings from two or more densitometers to be reliably compared, check your densitometer(s) regularly. See your manufacturers recommendations for the calibration procedure.
Calibrating Flowmeters
For machines with automatic or semiautomatic replenishment, check the settings on the replenisher and wash water flowmeters daily and readjust them as needed. Calibrate each flowmeter before use to determine that the volume of replenisher solution or wash water delivered for a particular setting is accurate. Note: Calibrate the flowmeters for replenishers by using the actual replenisher solution. Substituting water may not be valid because of differences in viscosity and specific gravity. Make a calibration curve for each flowmeter. See the flowmeter manufacturers instructions for specific procedures.
Checking Solution Mixes

Specific-gravity measurements indicate the overall concentration of processing solutions, and can help you detect replenisher mixing errors, improper concentrate-towater ratios in automatic replenishment systems, or evaporation problems. For more information see KODAK Publication No. CIS-61, Specific Gravity and pH Measurements of KODAK Processing Chemicals.
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KODAK CONTROL STRIPS

KODAK Control Strips are available for monitoring many processes. Each box has control strips, reference strip,and correction factors. A brief description of each of the most widely used strips is given below. KODAK Control Strips, Process C-41 (35 mm), CAT 180 3709 Strips are available in 100-foot rolls of approximately 120 strips with cutoff notches at 9 1/2 -inch (24.1 cm) intervals. The rolls are wound emulsion side in, with the Dmin end of the density scale toward the outer end of the roll. Each strip has 12 stepsa yellow step, a D-max step, and 10 equal-increment neutral-density steps. The LD and HD steps are marked by a U or notch. Measure the area adjacent to the black dot near the bottom of the strip to obtain the D-min density.
KODAK Control Strips, Process C-41, CAT 151 9677 Strips are available in boxes of 50; each strip measures 35 mm x 5 1/4 inches. The ends of the strips are perforated for use with standard control-strip racks. Each strip has a raised dimple to indicate the emulsion side at the low-density end of the strip. Each strip has five steps: D-min, LD, HD, D-max, and yellow.
KODAK Control Strips, Process C-41, Box of 10 Cassettes CAT 855 8959 Use these strips to monitor processing of color negative films in KODAK FLEXICOLOR Chemicals. Strips are supplied in 35 mm cassettes for minilab film processors. Each cassette contains a 24-exposure length roll and the same exposure format as in the 9 1/2-strip. Instructions, reference strip and correction factors are included.
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KODAK Full Frame Control Strips, Process C-41, CAT 157 6701 These 35 mm strips are supplied in 100-foot rolls of approximately 80 strips with cutoff notches at 15-inch (38.1 cm) intervals. The roll is wound emulsion side in, with the D-min ends of the strips toward the outer end of the roll. A reference strip is included with each roll. Each strip has five full-frame density steps: D-min, LD, HD, D-max, and yellow. These strips are primarily designed for use with minilab system printers that use a film scanner as a built-in densitometer. However, you can use them with any densitometer that can read large-area transmission density. KODAK Control Strips, Process E-6, CAT 122 6554 These 35 mm control strips are supplied in 100-foot rolls of approximately 120 strips with cutoff notches at 9 1/2-inch (24.1 cm) intervals. A reference strip is included with each roll. The roll is wound emulsion side in, with the D-min ends of the strips toward the outer end of the roll. Each strip contains 11 equal-increment neutral-density steps and three color patches. Steps 1 (D-min), 3 (toe density), 5 (low density), and 7 (high density) are marked by a U in the step.
KODAK Control Strips, Process E-6, CAT 151 9750 These 35 mm x 5 1/4-inch strips are supplied in boxes of five foil packages that contain 10 strips each. Each box includes a reference strip. The ends of the strips are perforated for use with standard control-strip racks. Each strip has five neutraldensity steps: steps 1 (D-min), 2 (toe density), 3 (low density), 4 (high density), and 5 (D-max).
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KODAK Control Strips, Process RA-4, CAT 828 2170 Use these strips to monitor Process RA-4. They are available in a box of ten moisture-resistant envelopes that contain five strips each. Each control strip, reference strip, and box label is marked with a code number. The code number identifies the strips as part of a particular batch. Each box contains correction factors for that particular code number. Use these correction factors to calculate the aim values for this batch of strips. Each strip measures 3 1/2 x 12 inches, and contains three neutral patches, a yellow patch, and an unexposed area. Measure the neutral patches to obtain density values for LD (low density), HD (high density), and BP (black patch). Measure the unexposed patch to obtain the density value for D-min. Use the yellow patch as a visual indicator of retained silver caused by low bleach-fix activity. When retained silver is present, the yellow patch will appear brown and less saturated than normal. KODAK PROFESSIONAL Pro Strips Color Negative Paper Control Strips, Process RA-4, CAT 129 8587 These strips are optimized for Kodak Professional color negative papers and display materials. Each box contains fifty 3 1/2 x 12-inch strips. Strips have three neutral patches, a yellow patch, and an unexposed area. Measure the neutral patches to obtain density values for LD (low density), HD (high density), and BP (black patch). Measure the unexposed patch to obtain the density value for D-min. Use the yellow patch as a visual indicator of retained silver caused by low bleach-fix activity. Low bleach-fix activity will make the yellow patch appear brown and less saturated than normal. KODAK RADIANCE Control Strips, Process R-3, CAT 508 2953 Use these strips to monitor Process R-3. Strips are supplied in a box of five moisture-resistant envelopes that contain five strips each. Each strip measures 3 1/2 x 12 inches and has 20 density steps. For process monitoring, measure the D-min, LD (low density), HD (high density), and D-max steps.
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SUPPLIES AND SOFTWARE

KODAK Process Record Form, KODAK Publication No. Y-55, CAT 155 7164 Use this special graph paper for plotting variations from aim for color or black-and-white processes. It is supplied in pads of 100 sheets.
KODATEL Software
KODATEL Software automates your labs quality process. The program helps you identify and correct processing and printer problems with an automated quality process. Software is available in three packages: for minilabs, for traditional labs, and for lab networks. KODATEL Software offers the following features: An easy-to-learn user interface Interactive computer-based training on monitoring procedures Ease of use High-quality diagnostic displays Availability in five languages KODATEL Software for Minilabs (ML), CAT 840 2539 This software automates key elements of process monitoring, including calculation of daily monitoring results, plotting, calculations of new aim values, and quality reports. It includes a checklist of common causes of process problems. It accommodates up to 10 processors and 255 printers. KODATEL Software for Traditional Labs (TL), CAT 888 6533 This software is designed for large photo processing labs that run many tests on a variety of equipment. It accommodates the data needs of large centralized labs and includes advanced problem diagnostic tools. High-speed photofinishing printers are fully supported. It accommodates up to 80 processors and 255 printers. KODATEL Software for Lab Networks (LN), CAT 882 4369 This software includes all the advanced diagnostic tools and reports contained in KODATEL Software for Traditional Labs, plus a communication module that can collect and display process control data from remote locations. This is ideal for large retail chain operations that want to centralize quality-control operations.
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MORE INFORMATION
Kodak has many publications to assist you with information on Kodak products, equipment, and materials. Visit www.kodak.com go/photofinishing go/professional go/msds
Consumer Imaging
EASTMAN KODAK COMPANY ROCHESTER, NY 14650

Introduction to Color Process Monitoring KODAK Publication No. Z-99 Kodak, Kodak Professional, Ektacolor, Flexicolor, Kodatel, and Radiance are trademarks. Minor Revision 8-01 Printed in U.S.A.
PROCESSING SOLUTIONS AND THEIR EFFECTS

Figure 1-2
Exposing Light
OVERVIEW OF PROCESSING KODAK EKTACHROME FILMS

KODAK EKTACHROME films are reversal, subtractive color materials. When properly exposed and processed, they yield positive color images, i.e., transparencies. The general structure of EKTACHROME Films is shown in Figure 1-1, enlarged to show detail. The transparent film support is at the bottom of the illustration. Reversal films contain three emulsion layers that are light-sensitive. The red-sensitive emulsion layer is located at the bottom of the film closest to the support material. The green-sensitive layer is located in the middle, and the blue-sensitive layer is at the top. Although the red-sensitive layer is primarily sensitive to red light and the green-sensitive layer is primarily sensitive to green light, both of these layers are somewhat sensitive to blue light. The yellow filter layer absorbs blue light and prevents blue light from exposing the red- and green-sensitive layers. When reversal film is exposed, latent images are formed in each of the three emulsion layers. The blue-sensitive layer contains a record of the images formed by the blue component of the exposing light; the green-sensitive layer contains the image formed by the green component; and the red-sensitive layer contains the image formed by the red component. The images are formed simultaneously and are superimposed. Figure 1-2 shows the formation of the color image during processing. For more information about each processing step in Process E-6, see the descriptions on page 1-2. Figure 1-1
Red
Green
Blue
White
Black
Exposed
After FirstDeveloper Step

Dye Clouds
After ColorDeveloper Step
After Bleach Step

Dye Only
After Fixer Step
= unexposed silver halide grains = exposed silver halide grains = developed metallic silver = dye cloud
Exposing Light
F009_9001CC
Blue-sensitive layer Yellow filter layer Green-sensitive layer Red-sensitive layer
Film support
F009_9000AC
Using KODAK Chemicals, Process E-6 Z-119 Sixth Edition
1-1
PROCESS E-6
Understanding Solution Functions
Use the following descriptions to become familiar with the function of each processing solution. This understanding, along with the information in section 14, Diagnostic Charts, and section 15, Control-Chart Examples, will help you analyze process problems.
Pre-Bleach
The pre-bleach prepares the metallic silver developed in the first and color developers for oxidation to silver halide in the bleach step. It helps preserve the acidity of the bleach solution by reducing carryover of color developer into the bleach. The pre-bleach also enhances dye stability. Prebleach that is too concentrated can cause leuco-cyan dye to form, resulting in low red D-max. If the pre-bleach is too dilute, the dye stability could be substandard. Do not use a wash between the pre-bleach and the bleach; pre-bleach carry-in is necessary for proper bleaching.
First Developer
The chemical reducing action of the first developer converts exposed silver halide grains (the latent image) into metallic silver (the silver image). This is a negative image. The first developer step is the most critical step of Process E-6. The amount of silver formed depends on developer activity. Time, temperature, agitation, developer concentration, and utilization affect first-developer activity. In Process E-6, increased first-developer activity causes too little dye to form; decreased activity causes more dye than normal to form.
Bleach
The bleach converts the metallic silver image back to silver halide; the silver halide is later removed in the fixer. During bleaching, iron III is reduced to iron II. Iron II must be converted back to iron III by aeration so that satisfactory bleaching can continue. Aerate the bleach by bubbling air through it. Inadequate aeration, underreplenishment, too little time, low temperature, and over-dilution by pre-bleach can cause silver retention, low red D-max, high blue D-max (and to a lesser degree, high green D-max), and yellow D-min.
First Wash
The first wash stops the action of the first developer and removes first developer solution from the film. Insufficient water flow, incorrect temperature, or too little wash time will affect density (speed) and color balance.
Fixer
The fixer converts all of the silver halide into soluble silver compounds. Most of the silver compounds are removed in the fixer and can be recovered. You must aerate any bleach carried into the fixer (by bubbling air into the fixer or with manual agitation) to prevent exhausted bleaching agent from causing leuco-cyan dye to form. However, too much air will oxidize the fixer; aerate the fixer only when film is in the fixer. Too little time, underreplenishment, or fixer dilution will cause silver-halide retention, increased blue density, or yellow D-min.
Reversal Bath
The reversal bath prepares the film for the color-developer step. A chemical reversal agent is absorbed into the emulsion and prepares the remaining silver halide for the chemical reversal that occurs in the color developer. Do not use a wash between the reversal bath and the color developer; the reversal agent must be in the emulsion when the film enters the color developer. Incorrect replenishment, excessive oxidation, incorrect mixing, and utilization can affect overall density and color balance.
Final Wash
The final wash removes chemicals remaining in the film emulsion. Complete washing at this stage is important for image stability; any chemicals remaining in the film may deteriorate the image dyes. For best results, use a 2-stage countercurrent-flow wash.
Color Developer
When film enters the color developer, the reversal agent absorbed by the emulsion in the reversal bath chemically exposes the remaining silver halide. The color developing agent then reacts with the silver halide to form metallic silver. As this metallic silver image is formed, the oxidized color developer agent reacts with the color couplers in each of the three dye layers (yellow, magenta, and cyan) of the film to form colored dyes. The dye forms only at the sites where the image was converted to metallic silver. Changes in the color developer pH, agitation, time, temperature, developer concentration, utilization, and replenishment rate affect color balance, contrast, maximum density, minimum density, and uniformity.
Final Rinse
The final rinse contains a wetting agent to reduce water spotting and provide uniform drying. To help prevent water spots and streaks, maintain solution cleanliness by replacing the final rinse once a week or more frequently.
1-2
CHEMICALS AND CHEMICAL MIXING

KODAK PROFESSIONAL CHEMICALS, PROCESS E-6
Sizes
These chemicals are available in sizes to meet the needs of all types of processing operations. When selecting chemicals, choose sizes that are economical for your setup and appropriate for your chemical-keeping conditions.
INTRODUCTION
To help you understand the terms weve used to describe the chemicals and solutions in this manual, here are some definitions: Chemical Concentrates Chemicals that must be diluted to make replenisher or tank processing solutions, or chemicals that are added to other solutions. Fresh Solution Newly mixed, unused solutions prepared from chemical concentrates. Replenisher Solution used to restore the chemical components of the tank solution to maintain photographic performance over time. Seasoned Solution A tank solution that has been used and replenished for a period of time. The chemical components and seasoning byproducts are at an optimum level for processing. Starter Concentrate added to a replenisher solution to prepare a fresh tank solution so it yields results similar to those provided by a seasoned tank solution. Tank Solution The solution used in the processor tank; often referred to as working solution.
Chemicals for Small-Volume Processing

The following sizes are appropriate for use with small tanks, sink lines, and rotary-tube processors. For larger volumes, use the 5- or 25-gallon sizes of these chemicals. Prepare the solutions according to the instructions packaged with the chemicals.
Product KODAK PROFESSIONAL Single-Use Chemistry Kit, Process E-6 KODAK PROFESSIONAL First Developer, Process E-6 KODAK PROFESSIONAL Reversal Bath, Process E-6 KODAK PROFESSIONAL Color Developer, Process E-6 KODAK PROFESSIONAL Pre-Bleach, Process E-6 KODAK PROFESSIONAL Bleach, Process E-6 KODAK PROFESSIONAL Fixer, Process E-6 KODAK PROFESSIONAL Final Rinse, Process E-6 KODAK PROFESSIONAL First Developer Replenisher, Process E-6 KODAK PROFESSIONAL Reversal Bath and Replenisher, Process E-6 KODAK PROFESSIONAL Color Developer Replenisher, Process E-6 KODAK PROFESSIONAL Pre-Bleach and Replenisher, Process E-6 KODAK PROFESSIONAL Bleach Replenisher, Process E-6 KODAK PROFESSIONAL Fixer and Replenisher, Process E-6 KODAK PROFESSIONAL Final Rinse and Replenisher, Process E-6 To Make 5 litres 1 gallon 1 gallon 1 gallon 1 gallon 1 gallon 1 gallon 1 gallon 10 litres 10 litres 10 litres 10 litres 10 litres 10 litres 10 litres CAT No.* 107 7643 156 4632 156 6850 116 2510 164 6058 156 2461 156 6082 195 1128 831 3611 112 3611 182 7872 128 6228 819 2395 154 5466 814 0279
* Catalog numbers listed are for sizes available in the U.S. and Canada. Other regions may supply these chemicals in different sizes. For more information, contact Kodak in your country. Use as mixed; no starter is required. Use as mixed; no starter is required.
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Chemicals for Cost-Saving Replenishment: Small- and Medium-Volume Processing

If you process a large amount of film in a replenished sinkline process, these may be the best sizes for you to use. They are also appropriate for large rotary-tube processors or larger automatic processors that have low utilization. For larger volumes, use the 25-gallon or larger size of chemicals. Prepare the solutions according to the instructions packaged with the chemicals. To prepare first- and color-developer and bleach tank solutions, mix the replenisher with starter according to the instructions.
Product KODAK PROFESSIONAL First Developer Replenisher, Process E-6 KODAK PROFESSIONAL First Developer Starter, Process E-6 (500 mL concentrate) KODAK PROFESSIONAL Reversal Bath and Replenisher, Process E-6 KODAK PROFESSIONAL Color Developer Replenisher, Process E-6 KODAK PROFESSIONAL Color Developer Starter II, Process E-6 (1-pint concentrate) KODAK PROFESSIONAL Pre-Bleach and Replenisher, Process E-6 KODAK PROFESSIONAL Bleach Replenisher, Process E-6AR KODAK PROFESSIONAL Bleach Starter, Process E-6 (12-gallon concentrate) KODAK PROFESSIONAL Fixer and Replenisher, Process E-6 KODAK PROFESSIONAL Final Rinse and Replenisher, Process E-6 KODAK PROFESSIONAL Defoamer, Process E-6 (4-ounce bottle) To Make 5 gallons CAT No.* 100 7608
Chemicals for Large-Volume Automatic Processors and Processors with In-Line Dilution/Blender Systems
The following sizes are appropriate for rack-and-tank, continuous, and roller-transport processors. Prepare the solutions according to the instructions packaged with the chemicals. To prepare first- and color-developer and bleach tank solutions, mix the replenisher with starter according to the instructions.
Product KODAK PROFESSIONAL First Developer Replenisher, Process E-6AR KODAK PROFESSIONAL First Developer Starter, Process E-6 (500 mL concentrate) KODAK PROFESSIONAL Reversal Bath and Replenisher, Process E-6 KODAK PROFESSIONAL Reversal Bath and Replenisher, Process E-6AR KODAK PROFESSIONAL Color Developer Replenisher, Process E-6AR Part A Part B (Part A and Part B are needed to make a replenisher solution) KODAK PROFESSIONAL Color Developer Starter II, Process E-6 (1-pint concentrate) KODAK PROFESSIONAL Pre-Bleach and Replenisher, Process E-6AR KODAK PROFESSIONAL Bleach Replenisher, Process E-6AR KODAK PROFESSIONAL Bleach Starter, Process E-6 (12-gallon concentrate) KODAK PROFESSIONAL Fixer and Replenisher, Process E-6 KODAK PROFESSIONAL Fixer and Replenisher, Process E-6AR KODAK PROFESSIONAL Final Rinse and Replenisher, Process E-6 KODAK PROFESSIONAL Final Rinse and Replenisher, Process E-6AR KODAK PROFESSIONAL Defoamer, Process E-6 (4-ounce bottle) To Make 25 gallons CAT No.* 800 8401
26 gallons
167 1577
26 gallons
167 1577
25 gallons
118 7889
5 gallons
113 1580
100 gallons
158 3566
5 gallons
837 2542
25 gallons
185 8158
25 gallons 25 gallons
840 2224 100 7509
5 gallons
802 6569
25 gallons
185 8158
5 gallons
196 5623
50 gallons
103 8660
25 gallons
177 9792
5 gallons 25 gallons
196 5623 177 9792
5 gallons
127 8019
25 gallons
123 7619
5 gallons
890 9590
50 gallons
121 3677
125 3566
25 gallons
101 1063
* Catalog numbers listed are for sizes available in the U.S. and Canada. Other regions may supply these chemicals in different sizes. For more information, contact Kodak in your country.
500 gallons
115 2156
125 3566
* Catalog numbers listed are for sizes available in the U.S. and Canada. Other regions may supply these chemicals in different sizes. For more information, contact Kodak in your country. E-6AR sizes are supplied in flexible plastic containers for use with processors with in-line dilution/blender systems or to prepare larger amounts of solutions for use with other processors.
2-2
Table 2-1 Processing Capacity of Process E-6AR Chemicals

Mix Volume (gallons) 25 100 25 50 5 50 320 Replenishment Rate (mL/sq ft) 200 100 200 100 20 100 100 Amount of Film Processed per Cube (sq ft) 475 3,780 475 1,890 950 1,890 12,110
Water Quality
Water can have a significant effect on photographic quality. Generally, most municipal water supplies are satisfactory for mixing solutions and for use as wash water. Note that the quality of water supplies can vary seasonally. It is a good idea to have the quality of your water supply tested. Water used for washes should have less than 1,000 ppm of total dissolved solids and be free of color, suspended material, hardness, and heavy metals. The pH should be 7.0 to 8.5, and the water should not be highly buffered. The water supplied by most municipalities is satisfactory for preparing processing solutions. Practical limits for common water impurities for photographic processing are listed in Table 2-2. If you use well water, be sure that you test it for the impurities listed in Table 2-2. Poor plumbing materials (old, rusty pipes, or pipes made out of the wrong materials) can be a source of dirt and contamination. Check your plumbing and replace it if necessary. Table 2-2 Practical Limits of Impurities for Water Used in Photographic Processing
Impurity Color, suspended material Dissolved solids pH Hardness, as CaCO3 Copper, iron, manganese Chlorine, as free hypochlorous acid Chloride Bicarbonate Sulfate Sulfide Acceptable Limit of Range (ppm) None 1,000 (for washes) 250 (for preparing solutions) 7.0 to 8.5 40 (preferable) to 150 0.10 each 2 100 150 200 0.10
Process E-6AR Chemical First Developer Reversal Bath Color Developer Pre-Bleach Bleach Fixer Final Rinse
CHEMICAL MIXING
Procedures
The liquid concentrates supplied by Kodak make it easy to prepare processing solutions for Process E-6. However, to avoid errors that can affect process quality and control, mix these solutions carefully according to the instructions supplied with the chemicals. This section gives you tips to help you use proper mixing procedures. Prepare all solutions with water between 68 and 104F (20 and 40C). However, it is best to use water that is close to your processing temperature to avoid unnecessary delays waiting for the solution to come to temperature, and to avoid using a replenisher with a temperature that is drastically different from the temperature of your tank solution. Note: For consistent results, always use water at the same temperature when preparing solutions. For information on diagnosing mixing errors, see section 5, Corrective Actions for Processing Solutions.
Note: The values in Table 2-2 are from Water Quality Criteria by West (PSE V.9, pp. 398413 [1965]).
2-3
Table 2-3 Characteristics of Process E-6 Chemical Concentrates

Concentrate First Developer First Developer Replenisher Part Normal Appearance Comments
Table 2-4 Mixing KODAK Chemicals, Process E-6

Solution First Developer First Developer Replenisher Color Developer Color Developer Replenisher Comments Start with water at 68 to 104F (20 to 40C); preferably near 100F (37.8C). Add the concentrate while stirring. Mix until the solution is uniform. Do not overmix. Excessive mixing oxidizes the developer and reduces storage life. For the first developer, it is very important that your mixing equipment is clean. Immediately after mixing, the color developer will appear deep blue or purple. The color will change to pale yellow after a short time. Mixing order is important for developers. Do not agitate so vigorously that air is mixed into the solution. When you prepare a tank solution from replenisher solution, be sure to add starter. Start with water at 68 to 104F (20 to 40C); preferably near 100F (37.8C). The mixing order is not critical. The chemicals mix easily. Do not agitate so vigorously that air is mixed into the solution. Start with water at 68 to 104F (20 to 40C); preferably near 100F (37.8C). The mixing order is not critical. The chemicals mix easily. Agitation provides beneficial aeration; vigorous or lengthy agitation does not harm the bleach. The bleach and replenisher should appear dark red after mixing. When you prepare a tank solution from replenisher solution, be sure to add starter. Start with water at 68 to 104F (20 to 40C); preferably near 100F (37.8C). Use moderate agitation so that mixing is complete in approximately 5 minutes. Although fixers are not as sensitive to oxidation as developers, too much aeration will cause sulfurization. The solution will appear clear and colorless.
Clear, light yellow Chemicals to light brown; darknen with age. mild odor Do not use solution that is dark brown or opaque or that contains precipitates. Clear to slightly Haze in hazy, colorless to concentrate is not light yellow unusual. Age has little effect on concentrate. A A Clear, pale yellow; mild sulfite odor; viscous Clear, pale yellow to light pink; odor of strong sulfurous acid gas (strong pungent odor) Caution: Smell carefully; smell the cap of the container of any photographic concentrate or solutionnever smell concentrates or solutions directly. Clear, colorless; odor of organic sulfur No change in appearance with age. Good keeping properties. Chemical darkens with age. Do not use solution that is dark brown/purple or that contains precipitates.
Reversal Bath Reversal Bath and Replenisher Color Developer Color Developer Replenisher Color Developer Color Developer Replenisher
B B
Reversal Bath Reversal Bath Replenisher Pre-Bleach Pre-Bleach and Replenisher Bleach
Fixer Fixer and Replenisher Solution does not change appearance with age. Organic sulfur odor will be absent if product is badly oxidized.
Pre-Bleach Pre-Bleach and Replenisher
Bleach Bleach Replenisher Bleach Bleach Starter Fixer Fixer and Replenisher
A A B
Clear, dark red
Final Rinse Start with water at 68 to 104F (20 to 40C); Final Rinse and preferably near 100F (37.8C). The mixing Replenisher order is not critical. The chemicals mix easily. Although agitation is not critical, the final rinse will foam if the agitation is too vigorous. The solution should appear clear and colorless.
Clear, colorless Clear, colorless; very mild ammonia odor
Extremely stable Age or exposure to air may cause sulfurization (white or yellow sediment).
Note: For consistent results, always use water at the same temperature when preparing solutions.
Contamination of Solutions
Keep your mixing, storage, and processing equipment clean; their cleanliness can affect the quality and performance of processing solutions. Be careful not to contaminate one solution with another. If possible, mix and use only one type of solution with one set of mixing equipment, and wash all equipment thoroughly before reusing it. The illustration which follows shows how to use your tanks to minimize contamination.
Final Rinse Final Rinse and Replenisher First Developer Starter Color Developer Starter
White, cloudy appearance Colorless to yellow Light red to dark red Color darkens with age; usefulness is not affected by solution color.
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If you have one tank:
1 Reduce the chance of chemical contamination by using four

separate mixing tanks. If you cannot use four separate tanks, do the following before mixing different batches of chemicals Thoroughly rinse the tank and mixing equipment with room-temperature water Flush tubing and lines Thoroughly clean transfer pumps
If you have two tanks:
1
Use this tank for black-and-white developers first developer for Process E-6 color developer for Process E-6 and developers for Processes RA-4 and C-41
2
Use the second tank for all stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 all bleaches, fixers, and bleach-fixes final rinse for Process C-41
Using Your Mixing Tanks to Reduce Solution Contamination: Minute amounts of contaminants can seriously affect a processing solution. To reduce the possibility of contamination during mixing, keep different solutions from coming in contact with each other; use separate mixing tanks for each solution whenever possible, and clean all mixing equipment thoroughly after each use. If you dont have separate mix tanks, use the previous illustration as a guide for using your mixing tanks to reduce the possibility of contamination. If mixing only chemicals for reversal processes, you can use two mixing tanks: one for the first and color developers and one for all other solutions. However, we recommend using three mixing tanks: one for the developers, one for the bleach and fixer solutions, and one for all other solutions. If you mix chemicals for both negative and reversal processes, use four mixing tanks: one for the first developer and black-and-white developers, one for the color developers, one for the bleach and bleach-fix solutions, and one for all other solutions.
If you have three tanks:
1
Use this tank for black-and-white developers first developer for Process E-6 color developer for Process E-6 and developers for Processes RA-4 and C-41
2
Use the second tank for all stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 final rinse for Process C-41
3
Use the third tank for all bleaches, fixers, and bleach-fixes
If you have four tanks:
1
Use this tank for black-and-white developers first developer for Process E-6
2
Use the second tank for color developer for Process E-6 and developers for Processes RA-4 and C-41
3
Use the third tank for stop baths and stabilizers reversal bath, pre-bleach, and final rinse for Process E-6 final rinse for Process C-41
4
Use the fourth tank for all bleaches, fixers, and bleach-fixes
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2-5
Checking Your Mixes with Specific-Gravity Measurements

You can easily check your mixes for mixing errors by measuring the specific gravity of the solution. For information on measuring specific gravity or for specificgravity aims for Process E-6 solutions, see section 3, Monitoring and Controlling Processing Solutions.
SAFE HANDLING OF PHOTOGRAPHIC CHEMICALS

Handle photographic chemicals and processing solutions with care. See Safe Handling of Photographic Processing Chemicals, KODAK Publication No. J-98A. Packages of Kodak photographic chemicals have precautionary labels. Always read the labels and follow the instructions carefully. Also read the Material Safety Data Sheets (MSDSs) for the chemicals for precautionary information.1 Keep the darkroom, precessing 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. 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.
Storage of Solutions
For best results, do not use solutions that have been stored longer than the following times:
Mixed Solution (Tank or Replenisher) First Developer, Reversal Bath, Pre-Bleach Color Developer Bleach, Fixer, Final Rinse Solutions in Tanks with Floating Covers* Unused 8 weeks Used 4 weeks Partially Filled Bottles of Used or Unused Solutions 1 week
8 weeks 24 weeks
4 weeks 24 weeks
1 week 24 week
* Or full, tightly stoppered glass bottles.
Dont store chemicals at high temperatures. Use floating lids and dust covers on the replenisher storage tanks to reduce oxidation and dirt.
1.In the USA, you can obtain MSDSs for Kodak chemicals 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.
2-6
MONITORING AND CONTROLLING PROCESSING SOLUTIONS
CONTROL OF PROCESS VARIABLES

Introduction
Process variables include process time, temperature, agitation, and replenishment and wash rates. Changing these variables affects the process in specific ways. Being aware of how each of these variables affects your process will help you to troubleshoot any problems, and to use these variables to make small adjustments in your process. The specifications for these process variables are given in Table 3-1. Table 3-1 Process E-6 Specifications
Time (Minutes:Seconds) Step Lower Limit First Developer First Wash Reversal Bath Color Developer Pre-Bleach Bleach Fixer Final Wash* Final Rinse 5:00 1:00 1:00 5:00 2:00 6:00 4:00 4:00 0:30 Aim 6:00 2:00 2:00 6:00 2:00 6:00 4:00 4:00 1:00 Upper Lower Limit Limit 7:00 4:00 4:00 7:00 4:00 8:00 6:00 8:00 2:00 36.7 (98.0) 33.3 (92.0) 24.0 (75.0) 36.7 (98.0) 24.0 (75.0) 33.3 (92.0) 33.3 (92.0) 33.3 (92.0) 24.0 (75.0) Aim Upper Limit Temperature C (F) Replenishment Rate mL/m2 (mL/ft2) Lower Limit 1,938 (180) 916 (85) 1,938 (180) 916 (85) 916 (85) Aim 2,153 (200) 7.5 L/min (2 gal/min) 1,076 (100) 2,153 (200) 1,076 (100) 215 (20) 1,076 (100) 7.5 L/min (2 gal/min) 1,076 (100) Upper Limit 2,368 (220) 1,236 (115) 2.368 (220) 1,236 (115) 1,236 (115) Concentrate Ratio for Process E-6AR Chemicals (Concentrate:Water) 1:4 1:19 1:1:3 1:9 No dilution 1:9 1:99
38.0 39.4 (100.4) (103.0) 38.0 39.4 (100.4) (103.0) 39.4 (103.0)
38.0 39.4 (100.4) (103.0) 39.4 (103.0) 39.4 (103.0) 39.4 (103.0) 39.4 (103.0) 39.4 (103.0)
* For best results, use a countercurrent-flow final wash.
Process Temperature
Slight variations in developer solution temperature can affect process control. In other processing solutions, temperature variations of a few degrees are not as critical. Once you have established the first- and color-developer temperatures, maintain them within these limits: First Developer 0.2C (0.3F) Color Developer 0.3C (0.5F)
Process Time
Time affects process control in about the same way that temperature does. It is particularly critical for the developers that you use the correct time. Use a stopwatch to measure the time that the film is in a solution from the time the film enters the solution to the time it enters the next solution (or wash). Once you have established the first- and color-developer times, maintain them within these limits: First Developer 5 seconds Color Developer 5 secondsvM
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Agitation
Agitation increases solution activity by removing used solution from the film surface and replacing it with fresh solution. Too little agitation causes streaks or spots on the film. Too much agitation mixes air into the solution, causing some of the chemicals to oxidize. Oxidation is particularly harmful to the first and color developers. Two common methods of producing solution agitation are: 1) moving the film through the solution, and 2) moving the solution over the film surface. The first method is used in continuous, roller-transport, and rotary-tube processors, and in sink-line processes (with manual agitation). The second method is used in rack-and-tank processors and in some continuous processors, as well as in sink-line processes. It consists of bubbling an inert gas (i.e., nitrogen for developers, air for other solutions) through the solution. Table 3-2 Methods of Agitation
Continuous, RollerTransport, RotaryTube Processors, and Sink-Line Processes (with Manual Agitation) Movement of film through the solution provides some agitation; slow speed machines may require supplemental agitation Rack-and-Tank Processors and Sink-Line Processes Nitrogen Air None Nitrogen None Air Air Air None
Recirculation
Recirculation keeps the processing temperature uniform throughout the processing solution. To maintain uniform temperature, concentration, and solution cleanliness, you must recirculate the first developer, color developer, bleach, and fixer solutions. Recirculate the reversal bath, pre-bleach, and final rinse only as needed.
Filtration
Processing solutions and wash water may contain some insoluble solids and tars. If you dont remove this material, it can adhere to the film and to tank walls, rollers, and lines, and damage the film. Filters should be able to remove 10- to 30-micron-size particles from processing solutions and 5- to 25-micron-size particles from wash water. Table 3-3 lists the filter materials available; it also lists if they are recommended for use with KODAK Chemicals, Process E-6. Table 3-3 Filter Materials
Recommended Bleached cotton Not Recommended Fiberglass with phenolic binder
Step
First Developer Wash Reversal Bath Color Developer Pre-Bleach Bleach* Fixer Wash Final Rinse
Cellulose with phenolic Polyester with phenolic resin binder resin binder Polyester fiber Polypropylene Spun polypropylene Wool with phenolic resin binder Viscose rayon with phenolic resin binder Viscose rayon
* Aeration is required for all types of processing.
Polypropylene is the most acceptable filter-core material and one of the least expensive. However, many polypropylene yarns are produced by using surfactants. While polypropylene itself appears to have no photographic effect, some of these surfactants may; therefore, monitor your process carefully when you first change filters.
3-2
Replenishment
During processing, some chemicals in the processing solution are used up, and some chemicals in the film dissolve into the solution. These changes exhaust the solution. To compensate for these changes, and restore the solutions normal activity, you add replenisher solution. The rate at which you add replenisher solution affects the solutionss composition and activity. You can add replenisher in one of four ways: By replenishing for a batch of film processed; add replenisher in a single amount after processing a batch of film. By feeding concentrate and water in simultaneously as a batch of film is processed. By continuously feeding replenisher in at a set rate during processing. By continuously feeding concentrate and water in simultaneously at a set rate during processing. This is similar to the third method, but the concentrate and the water are metered in separately instead of mixing the chemicals beforehand. It is important that you calibrate and check all replenisher pumps and flowmeters frequently to be sure they are providing the correct amount of solution (or water). Use only the rates recommended, especially with the developers. Initially, incorrect replenishment rates may not appear to affect your control plot, but eventually the effect will be significant. Also, image structure (graininess, sharpness, color quality, etc) can be affected without much change in the control plots. The problem may be more apparent in your production than in the control strip.
Drying
Film drying is influenced by the design of the dryer, time in the dryer, the pattern of air flow, the amount of final rinse carried into the dryer, and the humidity and temperature of the air in the dryer. Film drying can also be influenced by the ambient temperature and relative humidity. You must determine the optimum conditions for drying film for each processor. When your dryer is set correctly, the film will be dry when it is approximately one-half to three-quarters of the way through the dryer. Do not use drying temperatures higher than 63C (145F). High drying temperatures cause excessive film curl. Filter the air in the dryer to reduce dirt. If the film has spots or streaks after drying, check for problems in the final rinse solution.
Checklists
Routine use of a start-up and shutdown checklist will help you keep your processor in good operating condition. Also, use your process maintenance checklist to follow a regular processor-maintenance schedule. For information about maintenance, see section 11.
COLOR-BALANCE CONTROL
Adjusting the pH
If your process is in control for the LD step, but has a green or magenta spread in the HD step, you can correct it by adjusting the pH of the color-developer tank solution with base (5N NaOH) or acid (5N H2SO4 or 28% acetic acid); see Table 3-4. Table 3-4 Color-Developer pH Adjustments for Color-Balance Change
Color Balance Compared to the Reference Strip Magenta
Wash-Water Control
Maintain the wash-water temperature and flow rate according to the recommended steps and conditions for your processor. A low flow rate or incorrect temperature in the first wash can cause speed and color-balance changes, and poor dye stability. Do not use a wash between the reversal bath and color developer or between the pre-bleach and bleach. Replace water filters regularly to reduce dirt in the wash water. Use a flowmeter to be sure that you are using the correct water flow rate. To minimize algae formation, drain the wash tanks each night (or at the end of the final shift), and especially over weekends and holidays.
Control Plot
Add to Tank Solution 1 mL/L of sodium hydroxide (5N NaOH) 1 mL/L of sulfuric acid (5N H2SO4) or 1 mL/L of 28% acetic acid
To Change the Color Balance .02
Green density plots above the red and blue densities for the HD step Green density plots below the red and blue densities for the HD step
Green
.02
3-3
Preparing Sodium Hydroxide Solution
MONITORING WITH SPECIFIC-GRAVITY MEASUREMENTS

Definition
Measuring specific gravity is a quick way of checking for proper mixing of your solutions. You can also make adjustments to your solutions by using specific-gravity measurements. Specific gravity is the ratio of the mass of a liquid to the mass of an equal volume of water. It is a convenient way to measure the total dissolved material in a solution and check the concentration of processing solutions. Use specificgravity measurements to check for mixing errors or water evaporation from solutions. There are three ways that you can use specific-gravity measurements for process control. To check for errors in mixing fresh tank and replenisher solutions (see section 2, Chemicals and Chemical Mixing). To check tank solutions for evaporation (see section 4, Starting Up Your Process). To adjust the concentration of your color-developer tank solution to optimize the process for contrast (see section 4, Starting Up Your Process). Table 3-5 lists the specific-gravity aims for Process E-6 replenisher solutions and fresh tank and seasoned tank solutions.
Warning
Follow the precautions for safe handling on the container label. Sodium hydroxide is corrosive; avoid contact with skin and clothing. Wear safety goggles, rubber gloves, and protective clothing. Do not weigh sodium hydroxide in an aluminum dish. To prevent a violent reaction (boiling and splattering), always add the sodium hydroxide to the water; never add the water to the sodium hydroxide. With extreme caution and constant stirring, slowly add 200 grams of sodium hydroxide (NaOH) to 500 mL of cold water in a 2-litre glass beaker. Cool the solution to room temperature and add water to make 1 litre. Store this solution in a glass bottle with a rubber stopper or in a plastic (polyethylene) bottle, and label the bottle clearly. Preparing Sulfuric Acid Solution
Warning
Follow the precautions on the container label. Sulfuric acid is corrosive; avoid contact with skin and clothing. Wear safety goggles, rubber gloves, and protective clothing. To prevent a violent reaction (boiling and splattering), always add the sulfuric acid to the water; never add the water to the sulfuric acid. With extreme caution and constant stirring, slowly add 139 mL sulfuric acid H2SO4 (36N) to 700 mL of cold water in a 2-litre glass beaker. Cool the solution to room temperature and add water to make 1 litre. Store this solution in a glass bottle with a glass stopper, and label the bottle clearly. Table 3-5 Specific-Gravity Aims
Solution
Specific Gravity Measured at 27C (80F) Replenisher Fresh Tank 1.055 0.003 1.004 0.003 1.034 0.003 1.019 0.003 1.130 0.010 1.041 0.003 Seasoned Tank 1.060 0.003 1.005 0.003 1.038 0.003 1.021 0.004 1.190 0.070 1.065 0.025
Specific Gravity Measured at 38C (100.4F) Replenisher 1.054 0.003 1.002 0.003 1.037 0.003 1.016 0.003 1.257 0.010 1.038 0.003 Fresh Tank 1.052 0.003 1.001 0.003 1.031 0.003 1.016 0.003 1.127 0.010 1.038 0.003 Seasoned Tank 1.057 0.003 1.002 0.003 1.035 0.003 1.018 0.004 1.187 0.070 1.062 0.025
KODAK PROFESSIONAL First Developer KODAK PROFESSIONAL Reversal Bath KODAK PROFESSIONAL Color Developer KODAK PROFESSIONAL Pre-Bleach KODAK PROFESSIONAL Bleach KODAK PROFESSIONAL Fixer
1.057 0.003 1.006 0.003 1.040 0.003 1.019 0.003 1.260 0.010 1.041 0.003
3-4
Measuring Specific Gravity

You can make specific-gravity measurements of your solutions with any hydrometer that meets the standard ANSI/ ASTM E100-72. The hydrometer should be marked in increments of at least 0.001 for an accuracy of 0.0005. Although most hydrometers are calibrated at 15.6C (60F), they are useful at other temperatures. To measure the specific gravity of Process E-6 solutions, you will need the standard hydrometers listed in Table 3-6. Table 3-6 Hydrometers for Process E-6 Solutions
Solution First developer and replenisher Reversal bath and replenisher Color developer and replenisher Pre-Bleach and replenisher Range of Standard Hydrometer 1.050 to 1.100 1.000 to 1.050 ASTM No. 126H 125H
1. Fill a clean, dry 250 mL graduated cylinder to within 2.5 cm (1 inch) of the top with the solution you are measuring. 2. Adjust the solution to the proper temperature (see the specifications given in Table 3-5). Proper solution temperature is very important. 3. Place the cylinder in a sink or tray to catch overflow. 4. Choose the correct hydrometer to match the approximate specific gravity of the solution. (See the hydrometer ranges listed in Table 3-6.) 5. Be sure that the hydrometer is clean and dry. Carefully lower the hydrometer into the solution. Let it bob up and down slightly. When it stops, read the number at the top of the MENISCUS.
Reading is 1.063 Reading is 1.063

60 60
Line of vision Line of vision
Bleach* and replenisher
1.100 to 1.150 1.150 to 1.200 1.200 to 1.250 1.250 to 1.300 1.000 to 1.050 1.050 to 1.100
127H 128H 129H 130H 125H 126H
Fixer* and replenisher
* More than one hydrometer is listed for bleach and fixer because the acceptable ranges of the specific-gravity measurements for these solutions are large.
Solution level Solution MENISCUS level Hydrometer stem MENISCUS Hydrometer Hydrometer stem Hydrometer
Note: You should not need all six standard hydrometers listed in Table 3-6 for any one type of machine running Process E-6.
F009_9003GC
6. After making the measurement, discard the sample. To avoid contaminating solutions, do not return the sample to the tank. 7. Rinse the hydrometer and graduated cylinder thoroughly with water. Note: Never take specific-gravity readings of solutions in the tanks. If you use the wrong hydrometer, it can sink to the bottom of the tank and break, or bob on the surface, where the stem may hit the edge of the tank and break. Label hydrometer boxes to avoid confusion. Do not use tape labels on the hydrometers.
3-5
Adjusting Your Processing Solutions by Using Specific-Gravity Measurements

First and Color Developers: The first and color developers are the most critical solutions in Process E-6; it is especially important to maintain proper concentrations. You can use specific-gravity measurements to correct for overconcentration or underconcentration. A sample calculation for overconcentration is given below. In the example, the calculation is done by using the difference between the specific gravity of an overconcentrated solution and the specific-gravity aim. With this type of calculation, you can determine the amount of overconcentration. Or, you can use the values in Table 3-7 instead of making a calculation for overconcentrated first developer. To adjust the solution, remove and discard 8.6 litres of solution. Replace that amount of solution with the same amount of water. After the water is added, the specific gravity of the solution should be 1.060 0.003 (at 27C [80F])). Example of a Specific-Gravity Calculation: You suspect that your first-developer tank solution is overconcentrated. You measure its specific gravity at 27C (80F); the specific gravity is 1.066. When you check Table 3-5, you note that the specific-gravity aim for a seasoned tank solution is 1.060 0.003. To correct the solution, you need to know the volume of the tank to calculate the amount of adjustment required. In this case, the tank volume is 95 litres. Sample calculations are as follows:
Step A Specific gravity of first-developer tank solution B Specific-gravity aim C A minus B D A minus 1.000 (the specific gravity of water) E Amount of overconcentration (C divided by D) F Volume of tank solution G Volume of water to add to tank solution (E multiplied by F)
* From Table 3-5 0.091 equals 9.1 percent overconcentration.
Table 3-7 Addition of Water to Correct for Overconcentration of First DeveloperSeasoned Tank Solution
Specific Gravity at 27C (80F) 1.060 1.061 1.062 1.063 1.064 1.065 1.066 1.067 1.068 1.069 1.070 1.071 1.072 1.073 1.074 1.075 1.076 1.077 mL Water per Litre of Tank Solution 0 16 31 45 60 74 87 100 113 125 137 149 160 171 182 192 203 212 Specific Gravity at 38C (100.4F) 1.057 1.058 1.059 1.060 1.061 1.062 1.063 1.064 1.065 1.066 1.067 1.068 1.069 1.070 1.071 1.072 1.073 1.074 mL Water per Litre of Tank Solution 0 16 31 45 60 74 87 100 113 125 137 149 160 171 182 192 203 212
Table 3-8 Addition of KODAK PROFESSIONAL First Developer Concentrate, Process E-6AR, to Correct for Underconcentration of Seasoned Tank Solution
Specific Gravity at 27C (80F) 1.060 1.059 1.058 1.057 1.056 1.055 1.054 1.053 1.052 1.051 1.050 1.049 1.048 1.047 1.046 1.045 1.044 1.043 1.042 1.041 mL of mL of Specific Concentrate Concentrate Gravity at per Litre of per Litre of 38C (100.4F) Tank Solution Tank Solution 0 5 9 14 19 23 28 32 36 41 45 49 54 58 62 66 70 74 78 82 1.057 1.056 1.055 1.054 1.053 1.052 1.051 1.050 1.049 1.048 1.047 1.046 1.045 1.044 1.043 1.042 1.041 1.040 1.039 1.038 0 5 9 14 19 23 28 32 36 41 45 49 54 58 62 66 70 74 78 82
1.066 1.060* 0.006 0.066 0.091 95 L 8.6 L
You can also adjust underconcentrated solutions by using specific-gravity measurements. If your first-developer tank solution is diluted by a water leak, you can adjust the solution by adding undiluted KODAK PROFESSIONAL First Developer Concentrate, Process E-6AR. To make the adjustment, measure the specific gravity. Then use Table 3-8 to determine the amount of first developer replenisher concentrate you need to add for each litre of tank solution. (Table 3-10 has information for adjusting seasoned color developer for underconcentration.) Finally, remove the amount of the underconcentrated solution you have determined in your calculation, and replace it with undiluted replenisher.
For each 40 mL of undiluted First Developer Replenisher, Process E-6AR, add 1 mL of KODAK First Developer Starter, Process E-6
3-6
Table 3-9 Addition of Water to Correct for Overconcentration of Color Developer Seasoned Tank Solution
Specific Gravity Measured at 27C (80F) 1.038 1.039 1.040 1.041 1.042 1.043 1.044 1.045 1.046 1.047 1.048 mL of Water per Litre of Tank Solution 0 24 47 68 89 109 128 146 163 180 196 Specific Gravity Measured at 38C (100.4F) 1.035 1.036 1.037 1.038 1.039 1.040 1.041 1.042 1.043 1.044 1.045 mL of Water per Litre of Tank Solution 0 24 47 68 89 109 128 146 163 180 196
Table 3-10 Addition of Undiluted KODAK PROFESSIONAL Color Developer Replenisher, Process E-6AR, to Correct for Underconcentration of Seasoned Tank Solution
Specific Gravity Measured at 27C (80F) 1.038 1.037 1.036 1.035 1.034 1.033 1.032 1.031 1.030 1.029 1.028 mL of Part A Concentrate per Litre of Tank Solution 0 8 15 22 29 36 43 49 55 61 67 mL of Part B Concentrate per Litre of Tank Solution 0 8 15 22 29 36 43 49 55 61 67 Specific Gravity Measured at 38C (100.4F) 1.035 1.034 1.033 1.032 1.031 1.030 1.029 1.028 1.027 1.026 mL of Part A Concentrate per Litre of Tank Solution 0 8 15 22 29 36 43 49 55 61 mL of Part B Concentrate per Litre of Tank Solution 0 8 15 22 29 36 43 49 55 61
For each 40 mL of undiluted KODAK PROFESSIONAL Color Developer Replenisher, Process E-6AR, Parts A and B, add 1 mL of KODAK PROFESSIONAL Color Developer Starter II, Process E-6
3-7
APPENDIX 1
HYDROMETER CROSSOVER PROCEDURE
Like other measuring instruments, hydrometers have an inherent variability. Although the variability from hydrometer to hydrometer is usually small, you should run a crossover test when you use a new hydrometer. To run a crossover test, follow these steps: 8. Make specific-gravity measurements of at least four different samples of the same tank solution with both the old and the new hydrometer. 9. Determine the average measurement for each hydrometer by adding the measurements and dividing the result by the number of readings. 10. To calculate the difference between the hydrometers, subtract the smaller average from the larger average. If the difference between the average readings for the hydrometers is greater than 0.002, contact your Kodak account executive to help you determine which hydrometer is correct. If the difference is less than or equal to 0.002, start using the new hydrometer. Note: Sample calculations are shown at the right.
Table 3-11 Example 1

Measurement 1 2 3 4 5 Total Average Reading old hydrometer Average Reading new hydrometer Reading with Old Hydrometer 1.063 1.062 1.063 1.062 1.064 5.314 Reading with New Hydrometer 1.062 1.062 1.063 1.063 1.064 5.314
5.314 5 5.314 5
= 1.0628
= 1.0628
Difference = 1.0628 1.0628 = 0; use the new hydrometer.
Table 3-12 Example 2

Measurement 1 2 3 4 5 Total Average Reading old hydrometer Average Reading new hydrometer Reading with Old Hydrometer 1.063 1.062 1.061 1.062 1.064 5.312 Reading with New Hydrometer 1.066 1.065 1.064 1.066 1.066 5.327
5.312 5 5.327 5
= 1.0624
= 1.0654
Difference = 1.0654 1.0624 = 0.003 > 0.002; contact your account executive to determine which hydrometer is correct.
3-8
STARTING UP YOUR PROCESS

OPTIMIZING YOUR PROCESS
Once your process is stable (i.e., the process variables are at [or close to] aim), you can optimize your process to obtain optimum film quality. We recognize that you may have to make some minor adjustments from aim for some of the process variables (due to differences in machine design) to obtain optimum speed, contrast, and color balance. It is important to understand that in most situations you will not have to make adjustments from aim to obtain optimum film quality. If you determine that your process requires adjustments, follow the steps given below. Do not make these adjustments to your process to optimize it until it is stable and the process variables are at (or close to) aim. 1. Adjust to obtain optimum density (film speed). 2. Adjust to obtain optimum film contrast. 3. Adjust to obtain optimum color balance.
BEFORE YOU BEGIN PROCESSING

To produce consistently high-quality transparencies with EKTACHROME Films, your processor must be in good mechanical operating condition, and the processing solutions must be within specifications. Check that the steps and conditions that you are using for your processor type match those given in sections 6 through 10. Processing conditions, chemicals, and mechanical operation may vary slightly for each processor. Solution Mixing: Be sure that your tank and replenisher solutions have been mixed correctly. Choose the correct chemical sizes for your needs, and mix them according to the instructions supplied with the chemicals. Check for any mixing errors by measuring the specific gravity. For information on specific gravity, see page 3-4. When you prepare developer and bleach solutions, be sure to add starter. Processor Operation: Check that your processor is operating according to the specifications given in this manual. Be sure that the agitation, recirculation, and filtration systems are working properly. Set replenishment and wash rates according to the specifications given in the section for your processor type. Do not adjust these rates to control process speed, contrast, or color balance. Evaporation: Evaporation can cause an increase in specific gravity, so you may need to add water to your first- and color-developer tank solutions. Making specific-gravity measurements daily is a good way to detect and prevent processing problems.
Important
Perform these steps in the order given, because the effects of some of the adjustments may be additive. To obtain optimum density (film speed), adjust either the first-developer temperature or the first-developer time. Base your adjustments on the green density of the LD step of your control strip. If the green LD density is on aim, the density (film speed) is acceptable; your process does not require adjustments for density. Proceed directly to To obtain optimum film contrast (page 4-2). If the green LD density is lower than aim and the specific gravity/replenishment rate are on aim (film speed is fast), decrease the first-developer temperature to slow down the reaction or decrease the time to shorten the development reaction and increase film densities.* If the green LD density is higher than aim (film speed is slow), increase the first-developer temperature to speed up the reaction or increase the time to lengthen the development reaction and decrease film densities.* After you have adjusted the first-developer temperature or time, and the green LD density is on aim, maintain the time or temperature within the specified tolerances.
* Before making these adjustments, verify that the replenishment rate and specific gravity are on aim.
4-1
To obtain optimum film contrast, adjust the concentration of the color developer. Base your adjustments on the green density of the HD step of your control strip. (Make sure that the green LD density is on aim before you adjust the concentration of the color developer.) If the green HD density is on aim, the contrast is acceptable; your process does not require adjustments for optimum film contrast. Proceed directly to To obtain optimum color balance (page 4-2). If the green HD density is lower than aim, the contrast is low. To raise the contrast (increase the green HD density), dilute the color developer. If the green HD density is higher than aim, the contrast is high. To lower the contrast (decrease the green HD density), increase the concentration of the color developer. Note: Any adjustment to the concentration of the color developer must be within the specific-gravity range of 1.032 to 1.043 at 27C (80F). Keep the adjusted aim as close as possible to the recommended aim, 1.038 at 27C (80F). After you have adjusted the concentration of the color developer, and the green HD density is on aim, measure the specific gravity of the tank solution. Use the specific-gravity measurement as your new aim. Make the same adjustment and aim change to your replenisher.
To obtain optimum color balance, adjust the pH of the color developer to alter the magenta/green color balance. Base your adjustments on the color balance of the HD and LD steps of your control strip. Adjust the magenta/green color balance. Adjusting the pH of the color developer will shift the color balance toward the magenta or green direction. This should be the last adjustment that you make to your process. To increase the pH of the color developer, add sodium hydroxide (5N NaOH) to shift the color balance in the green direction. To decrease the pH of the color developer, add either sulfuric acid (5N H2SO4) or 28% acetic acid to shift the color balance in the magenta direction. If you adjust the pH of the color-developer tank solution, you must also make the same adjustments to the color developer replenisher. Add sodium hydroxide (5N NaOH), sulfuric acid (5N H2SO4), or 28% acetic acid to the replenisher in the same proportion that you use to modify the tank solution. For in-line dilution systems, add sodium hydroxide to Part A (high pH); add sulfuric acid or acetic acid to Part B (low pH). Do not adjust the ratio of Part A to Part B. Note: If you make process adjustments to optimize your process for density, contrast, and color balance, you may have to make a small adjustment to the first-developer temperature or time to adjust the LD back to aim.
Important
Most labs will not have to adjust the concentration of the color developer to obtain optimum contrast. For labs that must make an adjustment, it is important to maintain the color-developer replenishment rate at 2,153 mL/m2 (200 mL/ft2). The best way to do this is to adjust the concentration (specific gravity) of the color developer replenisher and maintain the recommended replenishment rate. (If you adjust only the tank concentration, and do not adjust the replenisher concentration, your process will become unstable.) Do not adjust the ratio of Part A to Part B from the specified ratio of 1 to 1 for Process E-6AR chemicals.
4-2
CORRECTIVE ACTIONS FOR PROCESSING SOLUTIONS

Color Developer ReplenisherPart A Omitted: Determine how much Part A was left out of the mix, and add that amount to the solution. If you cant determine the amount omitted, replace the color developer. Color Developer ReplenisherPart B Omitted: Determine how much Part B was left out of the mix, and add that amount to the solution. If you cant determine the amount omitted, replace the color developer.
OVERVIEW
It may be possible to correct some improperly mixed or treated KODAK Chemicals, Process E-6, by using the corrective actions given in this section. This section also provides a procedure for compensating for low utilization. Use the corrective actions only when you have determined the cause of the problem. These corrective actions will work only in some cases. Use any method that involves doctoring the solutions at your own risk; there is no guarantee that a corrective action will correct the problem. Apply these corrective actions only to remedy an out-ofcontrol condition.
CORRECTIVE ACTIONS FOR TANK SOLUTIONS

First or Color Developer Underreplenished: Replace approximately 10 percent of the tank volume with replenisher. Process and evaluate a control strip. If the problem persists, make one more 10-percent replacement. If this does not correct the condition, replace the solution. Alternate ProcedureIf you can determine the amount of replenisher that should have been added, replace that volume of tank solution with replenisher. First Developer Overreplenished: Turn off replenishment for about 5 square feet of film processed per gallon of tank solution. Monitor the change with control strips. You will need to wait and tolerate the results or replace the solution. It is difficult to guess the amount of overreplenishment by using control strips; therefore, no exact guidelines exist. Sulfurized Fixer: Replace the solution. Underreplenished Bleach: You can salvage an underreplenished bleach by determining the amount of replenisher left out of the tank solution, and replacing that amount of tank solution with replenisher. Overreplenished Bleach: While an overreplenished bleach solution does not adversely affect the process, it is costly and increases the amount of chemicals discharged to the sewer. See Overconcentrated Bleach below. To compensate for overconcentration due to evaporation, use a replenisher made from 2 parts KODAK Bleach Replenisher, Process E-6AR, and 1 part water. Overconcentrated Bleach: A high specific gravity of the bleach solution indicates excessive overreplenishment or evaporation. If the specific gravity of your bleach solution exceeds 1.260, replace approximately one-third of the bleach-tank solution with fresh tank solution or with replenisher that is diluted 2:1. Keep the specific gravity below 1.260 to help prevent crystals from forming. Do not add water directly to a seasoned bleach; it will produce a precipitate of silver bromide.
CORRECTIVE ACTIONS FOR MIXING ERRORS

First or Color Developer Too Dilute: Add concentrate until the specific gravity is correct; see Tables 3-8 and 3-10 in section 3, Monitoring and Controlling Processing Solutions. With KODAK Color Developer Replenisher, Process E-6AR, use equal volumes of Parts A and B. Do not mix Parts A and B together directly; a precipitate will form. If the solution is a fresh tank, be sure that you added the correct amount of starter. First or Color Developer Too Concentrated: Try to determine the amount of overconcentration by reviewing the mixing procedures; then dilute the solution with water until the specific gravity is correct. See Tables 3-7 and 3-9 in section 3, Monitoring and Controlling Processing Solutions. First or Color DeveloperToo Much Starter Added: Process a control strip to check the process. If it is in control, allow it to return to aim during normal operation. If it is not in control, replace the solution. First or Color DeveloperToo Little Starter Added: If you can determine how much starter was omitted from the fresh tank mix, add that amount to the tank. . Color Developer Starter in the First Developer: If color developer starter was mixed with the first developer, replace the tank solution. First Developer Starter in the Color Developer: If 5 mL/L of first developer starter is mixed with the color developer, process a control strip to check the process. If it is in control,allow it to return to aim during normal operation. If it is not in control, replace the solution.. Substitute for Color Developer Starter: If color developer starter is temporarily unavailable, you can use 3 mL/L of first developer starter and 6 mL/L of 5N H2SO4 or 28% acetic acid in place of the color developer starter. Using KODAK Chemicals, Process E-6 Z-119 Sixth Edition
5-1
COMPENSATING FOR LOW UTILIZATION

You can compensate for low utilization by following the procedure described below; the procedure is based on the theory that you must complete one first-developer tank turnover every three weeks for efficient process operation. Before starting this procedure, set your replenishment rates according to the specifications given in the table in the section for your processor type. This procedure establishes a minimum daily square footage requirement for the amount of film processed. You can follow the procedure for any processor type that uses replenishment. 1. To determine the minimum daily square footage requirement, multiply the first-developer tank volume (in litres) by 5; then divide by the number of days the processor is operated during a three-week period. For example, a processor with a first-developer tank volume of 70 litres operated for 15 days over a threeweek period would have a minimum daily square footage requirement of 23 ([70 x 5] 15 = 23). 2. Throughout the day, record the amount of film you process. 3. At the end of each day, compare the amount of film processed (in square feet) to the minimum daily square footage requirement. If the amount of film processed meets or exceeds the minimum daily square footage requirement, no additional replenishment is required. If the amount of film processed is less than the minimum requirement, replenish all of your tank solutions for the difference in square footage. You will also need to add 1 mL of first developer starter to your first-developer tank solution for every square foot of film processed below the minimum daily requirement. Do not add color developer starter to the color-developer tank; additional starter will lower color-developer activity. The first time you use this procedure, you may have to reoptimize your process by adjusting the activity of the color developer replenisher as described under Optimizing Your Process on page 4-1.
ExampleYour minimum daily square footage requirement is 23 ft2, but you only processed 18 ft2 of film. The difference between the minimum requirement and the amount of film processed is 5 ft2. Based on a replenishment rate of 200 mL/ft2, you need to add an additional 1,000 mL (5 x 200 mL) of first developer replenisher to your firstdeveloper tank solution and 1,000 mL of color developer replenisher to your color-developer tank solution. For processors that have a 1 ft2 replenishment cycle, you need an additional 5 replenishment cycles. You also need to add 1 mL/ft2 (1 mL/cycle) or 5 mL of first developer starter to the first-developer tank solution. Replenish all other solutions for the difference between the minimum requirement and the amount of film processed. Note: If your processor has very low utilization, you may want to divide your minimum daily square footage requirement in half, and compare the amount of film processed with the minimum requirement twice during the day (i.e., at midday and at shutdown), and make any adjustments required.
5-2
CONTINUOUS PROCESSORS
STEPS AND CONDITIONS

Table 6-1 Steps and ConditionsContinuous Processors
Step Lower Limit First Developer Wash Reversal Bath 5:00 1:00 1:00 Time (Minutes:Seconds) Aim 6:00 2:00 2:00 Upper Limit 7:00 4:00 4:00 Temperature C(F) Comments*
Perform these steps in total darkness. 36.7 to 39.4 (98 to 103) 33.3 to 39.4 (92 to 103) 24 to 39.4 (75 to 103) 36.7 to 39.4 (98 to 103) 24 to 39.4 (75 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) Ambient Up to 63 (145) R, F, S (exit) None S (exit) None S R, F, S (exit) None S (exit) Air R, F, S (exit) Air R, F, S (exit) None None S (exit) None S (exit)
Remaining steps can be performed in room light. Color Developer Pre-Bleach Bleach Fixer Wash Wash Final Rinse Dry 5:00 2:00 6:00 4:00 1:00 1:00 0:30 6:00 2:00 6:00 4:00 2:00 2:00 1:00 As needed 7:00 4:00 8:00 6:00 4:00 4:00 4:00
* F = Filtration R = Recirculation S = Squeegees Adjust the first-developer time and/or temperature to match the aim value for the LD step densities. Once you select a first-developer time and temperature, maintain the time within 5 seconds and the temperature within 0.2C (0.3F). If possible, keep transfer times to 30 seconds or less.
TIME AND TEMPERATURE

Adjust the developer times and temperatures until the densities of your KODAK Control Strips, Process E-6, plot within the control limits. Do not exceed the ranges given in Table 6-1. If you do not need to adjust the temperatures, use the midpoint of the ranges; 6 minutes at 38C (100.4F) for both developers. Once you have selected the times and temperatures, keep them within the following tolerances.
First Developer Time: 5 seconds Temperature: 0.2C (0.3F) Color Developer Time: 5 seconds Temperature: 0.3C (0.5F)
RECIRCULATION
Recirculate and filter the first and color developers, bleach, and fixer to remove any dirt; even small particles of dirt can cause abrasions on the film. Recirculation also provides more uniform temperature in the developers. Recirculate the reversal bath, pre-bleach, and final rinse only as needed. For more information on recirculation and filtration, see section 3, Monitoring and Controlling Processing Solutions. For the bleach pumps, piping, and filter container, use Type 316 stainless steel or PVC materials. For any equipment that comes in contact with the fixer, use PVC or titanium. Do not use copper or brass with any processing solutions.
6-1
AGITATION
In sinusoidal- or helical-path processors, in which the top rollers are submerged, supply air to the bleach and fixer at 0.06 m3/m2 (1 cubic foot per 6 square feet) of film processed or 0.23 m3/hr (8 standard cubic feet per hour), whichever is greater. Operate the gaseous-burst agitation only while film is being processed. You may not need air agitation for the bleach and fixer in continuous processors in which the top rollers are above the solution level. A low red density in the D-max control plot indicates insufficient bleach aeration; determine the amount of air agitation that is best for your processor.
LEADER
You can use acetate leader, such as EASTMAN Processing Machine Leader 2988 / ESTAR Base (CAT No. 159 7269). You can also use KODAK FLEXICOLOR Machine Test Leader 5976 (35 mm x 400 ft, CAT No. 167 1536; 70 mm x 400 ft, CAT No. 152 4925) or EASTMAN Blackand-White Opaque Leader 7981 if you havent used them in a process other than E-6 (these types of leaders absorb chemicals that can contaminate Process E-6 solutions). For physical quality requirements, you may need to use other types of leaders. For more information, contact your technical sales representative.
SILVER RECOVERY
You can recover silver from used fixer or fixer overflow by collecting the solution, and then passing it through a KODAK Chemical Recovery Cartridge, Junior Model II (312-gallon size, CAT No. 166 9431), a KODAK Chemical Recovery Cartridge, Model II (5-gallon size, CAT No. 173 4953), or an equivalent cartridge.
REPLENISHMENT RATES
See Table 6-2 for the replenishment rates for continuous processors.
FINAL WASH
Use two 2-minute countercurrent-flow washes. You can use a single 4-minute wash if it is well agitated and has a waterflow rate of 80 L/m2 (2 gal/ft2).
Table 6-2 Replenishment RatesContinuous Processors

Replenishment Rate (mL/linear foot of film) Step Replenishment Rate mL/m2 (mL/ft2) 2,153 (200) 1,076 (100) 2,153 (200) 1,076 (100) 215 (20) 1,076 (100) 1,076 (100) Film Size 135 21.4 10.7 21.4 10.7 2.1 10.7 10.7 120 40.7 20.3 40.7 20.3 4.1 20.3 20.3 70 mm (unperforated) 45.9 23.0 45.9 23.0 4.6 23.0 23.0 70 mm (perforated) 44.5 22.3 44.5 22.3 4.5 22.3 22.3
First Developer Reversal Bath Color Developer Pre-Bleach Bleach Fixer Final Rinse
Note: First wash rates for film and leader are 40 L/m2 (1 gal/ft2) or 400 mL/ft for 135-size film and 800 mL/ft for 120- and 70-mm sizes. Final wash rates for film and leader are 80 L/m2 (2 gal/ft2) or 800 mL/ft for 135-size film or 1,600 mL/ft for 120- and 70-mm sizes. The replenishment rate for leader film is 1.25 mL/linear foot.
6-2
ROLLER-TRANSPORT PROCESSORS

Table 7-1 Steps and ConditionsRoller-Transport Processors
Step Lower Limit First Developer Wash Reversal Bath 5:00 1:00 1:00 Time (Minutes:Seconds) Aim 6:00 2:00 2:00 Upper Limit 7:00 4:00 4:00 Perform these steps in total darkness. 36.7 to 39.4 (98 to 103) 33.3 to 39.4 (92 to 103) 24 to 39.4 (75 to 103) 36.7 to 39.4 (98 to 103) 24 to 39.4 (75 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) Ambient Up to 63 (145) R, F None None Temperature C (F) Comments*
Remaining steps can be performed in room light. Color Developer Pre-Bleach Bleach Fixer Wash Wash Final Rinse Dry 5:00 2:00 6:00 4:00 2:00 2:00 0:30 6:00 2:00 6:00 4:00 2:00 2:00 1:00 As needed 7:00 4:00 8:00 6:00 4:00 4:00 4:00 R, F None Air R, F R, F None None None
* F = Filtration R = Recirculation Adjust the first-developer time and/or temperature to match the aim value for the LD step densities. Once you select a first-developer time and temperature, maintain the time within 5 seconds and the temperature within 0.2C (0.3F). If possible, keep transfer times to 30 seconds or less.

Adjust the developer times and temperatures until the densities of your KODAK Control Strips, Process E-6, plot within the control limits. Do not exceed the ranges given in Table 7-1. If you do not need to adjust the temperatures, use the midpoint of the ranges; 6 minutes at 38C (100.4F) for both developers. Once you have selected the times and temperatures, keep them within the following tolerances.
RECIRCULATION
7-1
AGITATION
In roller-transport processors, the rollers provide any agitation needed. Unless the rollers are completely submerged, they may also provide the necessary aeration for the bleach and fixer. Aerate a fresh bleach tank solution by bubbling air through it for one hour before processing film. If the processor is shut down for longer than 3 days, you may need to bubble air through the bleach before processing film to prevent leuco-cyan dye from forming.
BLEACH AERATION
In many roller-transport processors, recirculation and movement of the top rollers provide solution agitation, and bleach and fixer aeration. You may have to provide more aeration if the rollers in your processor do not provide adequate aeration. A low red density in the D-max control plot indicates insufficient aeration; high densities of the transparencies will appear red. We strongly recommend that you aerate the bleach in roller-transport processors.
FINAL WASH
Use two 2-minute countercurrent-flow washes. You can use a single 4-minute final wash if it is well agitated and has a water-flow rate of 80 L/m2 (2 gal/ft2).
REPLENISHMENT RATES
See Table 7-2 for the replenishment rates for roller-transport processors.
SILVER RECOVERY
Table 7-2 Replenishment RatesRoller-Transport Processors

First and Color Developers 2,153 mL/m2 (200 mL/ft2) Bleach 215 mL/m2 (20 mL/ft2) Other Solutions 1,076 mL/m2 (100 mL/ft2)
Film Size
Area per Roll or Sheet (ft2)
mL of Replenisher per Roll or Sheet 135-24 135-36 120 220 4 x 5-in. sheets 5 x 7-in. sheets 8 x 10-in. sheets 11 x 14-in. sheets 0.395 0.556 0.550 1.090 0.134 0.238 0.549 1.064 79.0 111.0 110.0 218.0 27.0 48.0 110.0 213.0 7.9 11.1 11.0 21.8 2.7 4.8 11.0 21.3 39.5 55.6 55.0 109.0 13.4 23.8 54.9 106.4
Note: First wash rate is 3.8 L/min (1 gal/min); final wash rate is 7.5 L/min (2 gal/min).
7-2
RACK-AND-TANK PROCESSORS

Table 8-1 Steps and ConditionsRack-and-Tank ProcessorsOne
Step Lower Limit First Developer First Wash Reversal Bath 5:00* 1:00 1:00 Time* (Minutes:Seconds) Aim 6:00* 2:00 2:00 Upper Limit 7:00* 4:00 4:00 Temperature C (F) Comments
Perform these steps in total darkness. 36.7 to 39.4* (98 to 103)* 33.3 to 39.4 (92 to 103) 24 to 39.4 (75 to 103) 36.7 to 39.4 (98 to 103) 24 to 39.4 (75 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) Ambient Up to 63 (145) NitrogenJ R, F AirJ None
Remaining steps can be done in room light. Color Developer 5:00 2:00 6:00 4:00 2:00 2:00 0:30 6:00 2:00 6:00 4:00 2:00 2:00 1:00 As needed 7:00 4:00 8:00 6:00 4:00 4:00 4:00 NitrogenJ R, F None AirJ R, F AirJ R, F AirJ AirJ None
Pre-Bleach Bleach Fixer Wash Wash Final Rinse Dry
* Transfer time and agitation will affect solution times. Adjust the first-developer time and/or temperature to match the aim value for the LD step densities. Once you select a first-developer time and temperature, maintain the time within 5 seconds and the temperature within 0.2C (0.3F). If possible, keep transfer times to 30 seconds or less. F = Filtration R = Recirculation Use KODAK Defoamer, Process E-6, to control foaming, if necessary. Do not splash or drip defoamer into the processing solutions; it can cause grease spots on transparencies. J One 2-second burst with and 8-second rest. See "Improving Film Uniformity in Rack-and-Tank Processors," on page 8-4.

Adjust the developer times and temperatures until the densities of your KODAK Control Strips, Process E-6, plot within the control limits. Do not exceed the ranges given in Table 8-1. If you do not need to adjust your time or temperature, use the midpoint of the ranges; 6 minutes at 38C (100.4F) for both developers. Once you have selected your time and temperature, keep them within the following tolerances:
RECIRCULATION
AGITATION
Use humidified nitrogen for agitation in both developers, and air for agitation in the bleach, fixer, and washes. Use enough pressure to raise the solution level 1.5 cm (58 inch) with a 2-second burst. The pressure should provide vigorous bursts that cover all areas of the tank in a uniform pattern without splashing. Do not use agitation in the reversal bath, pre-bleach, or final rinse. Use oil-free air for bleach agitation. Aerating the bleach reactivates it and allows you to use a very low replenishment rate. Agitating the fixer with air will aerate any bleach carried into the fixer. To minimize oxidation in the fixer, use agitation only while film is in the fixer.
REPLENISHMENT RATES
See Table 8-2 for the replenishment rates for rack-and-tank processors.
Table 8-2 Replenishment RatesRack-and-Tank Processors

First and Color Developers Film Size Area per Roll or Sheet (ft2) 2,153 mL/m2 (200 mL/ft2) mL of Replenisher per Roll or Sheet 135-24 135-36 120 220 4 x 5-in. sheets 5 x 7-in. sheets 8 x 10-in. sheets 11 x 14-in. sheets 0.395 0.556 0.550 1.090 0.134 0.238 0.549 1.064 79.0 111.0 110.0 218.0 27.0 48.0 110.0 213.0 7.9 11.1 11.0 21.8 2.7 4.8 11.0 21.3 39.5 55.6 55.0 109.0 13.4 23.8 54.9 106.4 Bleach 215 mL/m2 (20 mL/ft2) Other Solutions 1,076 mL/m2 (100 mL/ft2)
Note: Wash rates are 7.5 L/min (2 gal/min).
8-2
Calculating Average Replenishment Rate per Rack: To calculate the volume of replenisher for each rack, add the amount of replenisher required for each roll or sheet on the rack. For example, for a rack that holds three 8 x 10-inch sheets, the amount of first and color developer replenisher required would be 330 mL. If your film sizes or amount of film vary from rack to rack, determine the replenisher volume for the average rack. Keep a record of film sizes and amount of film processed to make your calculations. An example is given in the chart below. First determine the total rolls or sheets of each film size processed over a typical time period (B). Then calculate the total square feet of each size by multiplying the total rolls or sheets by the square feet per roll or sheet (A x B = C). Keep track of the number of racks used during this time (column D). Add the total square feet of all the different sizes (column C). Add the total number of racks used (total of column D). Now divide the total square feet processed (total of column C) by the total number of racks used (total of column D). This gives you the average square feet per rack. Use that value to obtain a replenishment rate for the average rack by multiplying that figure by the replenishment rate in millilitres per square foot given in Table 8-2.
A Film Size Area per Roll or Sheet (ft2) 0.395 0.556 0.550 1.090 0.134 0.238 0.549 1.064 B Number of Rolls or Sheets Processed 100 100 100 100 100 100 100 100 C Square Feet of Film Processed 39.5 55.6 55.0 109.0 13.4 23.8 54.9 106.0 457.2 = F (square feet of film processed R (number of racks) = 457.2 239 = D Number of Racks 20 20 33 33 13 20 50 50 239 1.91
135-24 135-36 120 220 4 x 5-in. sheets 5 x 7-in. sheets 8 x 10-in. sheets 11 x 14-in. sheets Total Average square foot per rack
Solution Developers Bleach Other Solutions
Replenishment (mL/ft2 x Avg ft2 per Rack = mL per Rack) 200 x 1.91 = 382 20 x 1.91 = 38.2 100 x 1.91 = 191
FINAL WASH
Use two 2-minute countercurrent-flow washes for the final wash. However, you can use a single 4-minute wash if it is well agitated and has a water-flow rate of 80 L/m2 (2 gal/ft2).
8-3
IMPROVING FILM UNIFORMITY IN RACK-AND-TANK PROCESSORS

With some rack-and-tank processors, you may have problems with film uniformity, such as occasional streaking, mottling, and spotting. Some causes of nonuniformity in rack-and-tank processors and suggestions for avoiding them are described in this section. Testing Your Processor for Uniformity: To test processor uniformity, prepare sheets of test film. Expose 8 x 10-inch sheets of KODAK PROFESSIONAL EKTACHROME Duplicating Film EDUPE with an enlarger. Adjust the enlarger so that the light on the easel is out of focus. Use your normal filter pack for duplicating film and a 0.50 neutral density filter. Expose the film at the exposure time that you use to produce duplicate transparencies. To determine if the nonuniformity occurs during handling or processing, process the test sheets. Orient the sheets alternately at a 90-degree angle to each other when you process them. If nonuniformity occurs in a different position in each sheet, check your preprocess handling. If nonuniformity occurs in the same position in each sheet, check your processor and/or processing conditions. Nonuniformity from Preprocess Handling Storage, handling, and exposure before processing can all affect uniformity in the film. A summary of possible causes of nonuniformity from preprocess handling is given below (Table 8-3). Table 8-3 Causes of Nonuniformity from Preprocess Handling
Film Nonuniformity Light-fog patterns Cause Malfunctioning shutter Pinholes in storage container or exposing equipment Instrument indicator light Loose packaging, not carefully sealed Darkroom light leaks Fluorescent tape, cats-eye buttons, or instrument panel lights Film curled during exposure Frequent thawing and refreezing of an opened film package Rapid separation of films from another surface, such as a roller, a platen, or another sheet of film Metallic dust in film-handling equipment Chemical dust Processing solution or water splash Condensation
Nonuniformity from Processing Equipment and Processing Solutions Film Clips and SpringsSome racks retain processing chemicals in the film clips or springs. The trapped solution can run down the film and leave a streak. Cross BarsSometimes solution splashes occur because of the design of the rack. Solution can drip on the wide cross bars, and splash onto adjacent rolls, causing spots and streaks. This occurs particularly when two racks are crossing over at the same time, or if the racks swing during a crossover. You can check for splashing by holding a piece of white paper close to a rack during a crossover. To control splashing Use splash guards between tanks; make them as high as possible without interfering with the transfer. Load the emulsion side toward the dryer so if splashing occurs, it is more likely to be on the base side of the film rather than the emulsion side. Skip every other rack position to reduce the possibility of splashing on the film. Wide Reinforcer BarSome racks are constructed with wide reinforcer bars on the bottom. If the bars are too wide, they can keep the nitrogen bubbles from agitating the solution on the film and cause streaks and mottle. To correct the problem, modify the bar or load the film so that the emulsion side is directly in the bubble path. AgitationProper agitation in the first and color developers greatly affects film uniformity. If the agitation does not remove the developer by-products from the emulsion and supply fresh developer to the surface, nonuniformity can result. Lack of agitation in the first developer can cause mottle. In the color developer, the reversal bath must be removed quickly and evenly from the emulsion so that normal development can take place. Uniform agitation is important in the first wash to remove the first developer and its by-products. Lack of agitation in the first wash can cause red streaks.
Edge effects (density or color balance variation)
Static spots
Light spots
Mottle or rundown streaks
8-4
Adjust the gaseous-burst agitation in the developers and first wash so that these conditions exist Adjust the gas pressure and volume so that the burst raises the solution level about 1.5 cm (58 inch). Pressure that is too high can cause the film to tangle, and can also cause foaming. In large tanks, a solution level rise of less than 1.5 cm (58 inch) may be adequate. If you cannot maintain adequate pressure, check the gaseous-burst systems for leaks. Without positive pressure, solution can back up into the line and cause a weak initial burst. Check that the gas is distributed evenly over all positions of the film rack. Be sure that the sparger holes are clean and that they are level across the bottom of the tank. Plugged sparger holes reduce agitation and produce patterns that cause nonuniformity. Introduce the gas into the bottom of the tank. Use humidified nitrogen to reduce the chance of plugging. Use a burst that lasts for 2 seconds at 8-second intervals. A shorter burst or a longer interval is inefficient. A longer burst or shorter interval in the first developer can produce nonuniformity in the film and foaming in the solution. Time the burst so that is occurs as soon as possible after the film enters the tank. This is especially important in the color developer. With some processors, the initial burst must be delayed so that the agitation does not move the film or rack as it enters the developer. Adjust the timing of the burst to reach the best compromise between the start of the burst and the movement of the film or rack.
Other Process-Related Conditions to Check Recirculation in the DevelopersProper recirculation is important to maintain uniform tank temperature and to provide uniform chemical distribution. Poor recirculation can cause temperature variations in a tank that result in nonuniform development or inconsistent development within a rack or across a tank. Check that the recirculation filters are not plugged. Do not use a filter finer than 10 microns. Slow Transport SpeedImmersing the film into the color developer too slowly produces a vertical pattern and may delay the initial agitation burst. When this occurs, streaking may be more severe on the sheets at the bottom of the rack than those at the top. Agitation for Push ProcessingExtend the first-developer time in such a manner that it does not affect the agitation in subsequent processing solutions/steps. Developer ReplenishmentExhausted first or color developer may cause mottle and produce unacceptable results. FoamingExcessive foaming in the first and color developers can cause nonuniformity. Use KODAK Defoamer, Process E-6, to control foaming in the firstdeveloper, color-developer, and bleach tanks; do not use defoamer in the final-rinse tanks (it can leave oily deposits on the film). Apply a thin layer of defoamer to the inside of the process tank above the solution level. Use the defoamer sparingly. Do not add defoamer directly to the tank solution.
SILVER RECOVERY
8-5
8-6
BATCH PROCESSING

Table 9-1 Steps and ConditionsSink-Line and Batch Processing
Step Lower Limit First Developer* First Wash Reversal Bath 5:00 1:00 1:00 Time* (Minutes:Seconds) Aim 6:00 2:00 2:00 Upper Limit 7:00 4:00 4:00 Temperature C (F) Comments
Perform these steps in total darkness. 36.7 to 39.4 (98 to 103) 33.3 to 39.4 (92 to 103) 24 to 39.4 (75 to 103) 36.7 to 39.4 (98 to 103) 24 to 39.4 (75 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) 33.3 to 39.4 (92 to 103) Ambient Up to 63 (145) Nitrogen. One 2-second burst every 10 seconds. Manual agitation. One cycle every 30 seconds. None. Tap to dislodge air bubbles. Nitrogen. One 2-second burst every 10 seconds. None. Tap to dislodge air bubbles. Air. One 2-second burst every 10 seconds. Air. One 2-second burst every 10 seconds. Manual agitation. One cycle every 30 seconds. None. Tap to dislodge air bubbles.
Remaining steps can be done in room light. Color Developer Pre-Bleach Bleach Fixer Final Wash Final Rinse Dry 5:00 2:00 6:00 4:00 3:00 0:30 6:00 2:00 6:00 4:00 4:00 1:00 As needed 7:00 4:00 8:00 6:00 8:00 4:00
* All times include a 10-second drain time. Increase the first-developer time by 15 seconds when you process roll films on reels with manual agitation. For sheet films on hangers, first use manual agitation; then continue using gaseous-burst agitation as described on page 9-3. For roll films on reels, use only manual agitation. Flowing wash. See Washes on page 9-3 for more information.

You can control your process by adjusting the developer times and temperatures, and by monitoring changes with KODAK Control Strips, Process E-6. Do not exceed the times and temperatures given in Table 9-1. If you do not need to adjust the time and temperatures of the developers, use the midpoint of the ranges; 6 minutes at 38C (100.4F) for both developers. Once you have selected the times and temperatures for your process, keep them within these tolerances:
9-1
First Developer Starting Temperature: To determine the starting temperature for your first developer, follow the procedure described below. 1. Adjust the developer temperature to 38C (100.4F). Use an unshielded thermometer with an expanded range that is calibrated in 0.1C units, such as the ASTM No. 91C, or Fahrenheit equivalent. Place the thermometer in the developer for several minutes to register an equilibrium temperature. Record this temperature. Leave the thermometer in the developer. 2. Place a full rack of processed scrap film in the developer. The rack should be at room temperature, and the film load should be typical of your normal film load. Provide the same initial agitation that you normally do. At the end of the first 60 seconds (measured from the time you placed the film in the developer), record the solution temperature. 3. Determine the temperature difference between steps 1 and 2. This temperature change is valid only for the room temperature at which you made this measurement. 4. Your starting temperature is 38C (100.4F) plus the temperature change that you determined in step 3. You will not need to repeat this test as long as your processing conditions (i.e., room temperature and amount and type of film) remain the same. The temperature change will be different for different film loads. Although the temperature difference may be small, you must consider it for critical processing, and for consistency between processes.
AGITATION
You can use manual or gaseous-burst agitation when you process sheet films. When you process roll films, use only manual agitation; gaseous-burst agitation will cause nonuniformity. Use humidified nitrogen to provide gaseous-burst agitation in the developers; air will oxidize the developers. You must use air agitation to aerate the bleach and fixer to maintain the stability of the solutions. If you use manual agitation in the bleach, you will also need to use another method to aerate the bleach. In the other solutions and washes, use compressed air or nitrogen for gaseous-burst agitation. Note: If you process sheet films of different sizes at the same time, such as 8 x 10-inch sheets and 4 x 5-inch sheets, separate adjacent hangers that contain different-size sheets with a hanger loaded with an 8 x 10-inch sheet of scrap film to avoid uneven development of the larger sheets. This unevenness is caused by turbulence around the central frame of the multiple-film hanger during agitation. Manual Agitation: Use only manual agitation when you process roll films on reels. You can also use manual agitation when you process sheet films. Initial AgitationAll Solutions and Washes, Except the Final RinseImmerse the rack into the solution. Rapidly tap it on the bottom of the tank to dislodge air bubbles; then agitate the films continuously by lifting the hangers or reels approximately three-quarters of the way out of the solution and then reimmersing them. Repeat to complete eight lift cycles (in approximately 15 seconds). Initial AgitationFinal RinseTap the loaded reels or hangers on the bottom of the tank to dislodge air bubbles. Use no other agitation; foaming will occur. Subsequent AgitationAll Solutions and Washes, Except the Reversal Bath, Pre-Bleach, and Final RinseEvery 20 seconds, lift the loaded hangers or reels out of the solution and then reimmerse them. Repeat to complete two lift cycles (in approximately 5 seconds). Subsequent AgitationReversal Bath, Pre-Bleach, and Final RinseNone; use no other agitation for these solutions. Drain TimeAll SolutionsTen seconds before the end of the solution time, raise the rack, tilt it approximately 30 degrees toward one corner, and drain for 10 seconds. At the end of 10 seconds, immerse the rack into the next solution.
9-2
Gaseous-Burst Agitation: Use gaseous-burst agitation only when you process sheet films. Initial AgitationFirst and Color Developers, Bleach, Fixer, and WashesLower the loaded film hangers into the solution and tap them sharply against the tank to dislodge air bubbles. Then agitate the films continuously for 15 seconds by lifting the hangers approximately three-quarters of the way out of the solution and then reimmersing them (approximately eight lifts). Initial AgitationReversal Bath, Pre-Bleach, and Final RinseTap the rack sharply on the bottom of the tank to dislodge air bubbles. Use no other agitation; loss of solution activity or foaming will occur. Subsequent AgitationFirst and Color Developers Provide humidified nitrogen with enough pressure to raise the solution level approximately 15 mm (58 inch) during a 2-second burst. Use one 2-second burst every 10 seconds. Subsequent AgitationBleach, Fixer, and WashesProvide oil-free air with enough pressure to raise the solution level approximately 15 mm (58 inch) during a 2-second burst. Use one 2-second burst every 10 seconds. Use air agitation in the bleach and fixer only during processing. Do not use nitrogen in place of air in the bleach and fixer. You can also use manual agitation for subsequent agitation in the washes by lifting the hangers approximately three quarters of the way out of the water, and then reimmersing them. Repeat to complete two lift cycles (in approximately 5 seconds). Subsequent AgitationReversal Bath, Pre-Bleach, and Final RinseNone; use no other agitation for these solutions.
WASHES
Flowing Washes: Whenever possible, use flowing washes for the first and final washes. Use the conditions given in the following table.
Time Temperature (minutes) C (F) 2 4 6 33 to 39 (92 to 103) 33 to 39 (92 to 103) 25 to 39 (77 to 103) Flow Rate L/min (gal/min) 7.5 (2) 7.5 (2) 7.5 (2)
Wash First Final
Agitation Initial Initial Initial
Nonflowing Washes: You can use nonflowing washes for sink-line processing to conserve water and energy. Use these conditions: First WashUse a 2-minute wash time with one tank filled with water at 36.7 to 39C (98 to 103F). Replace this wash after two processing runs. Drain the wash tank at the end of each day, and leave the tank empty overnight. Do not interchange the tanks that you use for the first and final washes. Final WashUse a 6-minute wash time with three tanks filled with water at 20 to 39.4C (68 to 103F). Wash for 2 minutes in each tank. Replace the water in all three tanks after you have completed four processing runs. Drain the wash tanks at the end of each day, and leave them empty overnight.
BLEACH AERATION
In a seasoned process, the efficiency of the bleach depends on aeration of the bleach. The best way to aerate the bleach is to use air-burst agitation. To aerate the bleach, continue the air bursts during the complete process cycle. If you use nitrogen-burst or manual agitation, provide another method for aerating the bleach. You can use a separate compressedair supply to bubble air into the bleach through a sparger at a valve pressure of about 2.5 lb/in2. Bubble the air for approximately 5 minutes during each complete process cycle. If you cannot aerate the bleach by bubbling air into it, vigorously stir the bleach with a mixer so that air is drawn into the solution.
9-3
REPLENISHMENT
You can extend the life of processing solutions by replenishing your solutions. Table 9-2 gives the amount of replenisher to add for each roll or sheet of film processed. Calculate the volume of replenisher for a batch of film by adding the volumes of replenisher for each roll or sheet of film processed. For example, to determine the replenisher volume needed for thirteen 8 x 10-inch sheets, use the following calculation:
mL per 8 x 10-inch sheet x 13 sheets per batch = mL of replenisher First and Color Developers 110 mL x 13 sheets = 1,430 mL Bleach 11 mL x 13 sheets = 143 mL Other Solutions 54.9 mL x 13 sheets = 714 mL
Replenish the solutions after each processing run unless the run is your last run of the day. After your last run, record the amount of replenisher that you need to add to each solution, and replenish the solutions before the first run of the next day that you process film.
Table 9-2 Replenishment RatesSink-Line and Batch Processing

First and Color Developers 2,153 mL/m2 (200 mL/ft2) Bleach 215 mL/m2 (20 mL/ft2) Other Solutions 1,076 mL/m2 (100 mL/ft2)
Film Size
Area per Roll or Sheet (ft2)
mL of Replenisher per Roll or Sheet 135-24 135-36 120 220 4 x 5-in. sheets 5 x 7-in. sheets 8 x 10-in. sheets 11 x 14-in. sheets 0.395 0.556 0.550 1.090 0.134 0.238 0.549 1.064 79.0 111.0 110.0 218.0 27.0 48.0 110.0 213.0 7.9 11.1 11.0 21.8 2.7 4.8 11.0 21.3 39.5 55.6 55.0 109.0 13.4 23.8 54.9 106.4
Note: Wash rates are 7.5 L/min (2 gal/min).
9-4
CAPACITY OF UNREPLENISHED SOLUTIONS

If you do not replenish your tank solutions, use the KODAK PROFESSIONAL Single-Use Chemistry Kit or the 1-gallon-size chemicals. The capacity of the first- and colordeveloper solutions without replenishment is about 1.7 square metres (18 square feet) of film per 3.8 litres (1 gallon) of the 1-gallon size chemicals, or 5 L of the Single-Use chemicals. The capacity of the other solutions is 5 square metres (54 square feet) per 3.8 litres (1 gallon) of the 1-gallon size chemicals, or 5 L of the Single-Use chemicals. Keep the number of processes low by processing as much film as possible in each batch. After you have processed 1.1 square metres (12 square feet) of film, increase the first developer time to 612 minutes. If you process only one size of film in a particular batch, you can use Table 9-3 to determine the capacity of the solutions. Table 9-3 Capacity of Unreplenished Solutions
Rolls or Sheets per Gallon or 5L with FirstDeveloper Time of 6 Minutes 1 to 30 1 to 22 1 to 23 1 to 12 1 to 90 1 to 46 1 to 22 Rolls or Sheets per Gallon or 5L with FirstDeveloper Time of 612 Minutes 31 to 46 23 to 33 24 to 34 13 to 17 91 to 134 47 to 74 23 to 33 Discard Both Developers After This Many Rolls or Sheets Processed 46 33 34 17 134 74 33
SILVER RECOVERY
Film Size
135-24 135-36 120 220 4 x 5-in. sheets 5 x 7-in. sheets 8 x 10-in. sheets
Be sure that the solution completely covers the film during processing. You may need to add tank solution to maintain the solution level of the first developer. Discard solutions that have been stored beyond the recommended storage time regardless of unused capacity (see page 2-6). Note: For best results, replenish your tank solutions according to Table 9-2.
9-5
9-6
10
ROTARY-TUBE PROCESSORS

Table 10-1 Steps and ConditionsRotary-Tube Processors
Step Turn on processor Warm-up with running water (7.5 L/min [2 gal/min]) Film warm-up PrewetJ First Developer Wash Reversal Bath** Color Developer 7:00 2:00 2:00 4:00 38 0.3 (100.4 0.5) 38.0 1.0 (100.4 1.8) 38.0 1.0 (100.4 1.8) 38.0 1.0 (100.4 1.8) 20 to 40 (68 to 104) 33.3 to 40 (92 to 104) 33.3 to 40 (92 to 104) 33.3 to 40 (92 to 104) Prepare first developer as tank solution. Running water (7.5 L/min [2 gal/min]). Prepare as 60 percent of replenisher solution. Prepare color developer as tank solution. 6:00 Time* (Minutes:Seconds) Temperature C (F) 40.0 (104.0) 38.0 1.0 (100.4 1.8) Perform these steps in total darkness. 4:00 38.0 (100.4) Load tube with film and insert tube in processor. Comments Turn on heaters and leave on throughout the processing cycle. No film in processor.
Remaining steps can be done in room light. Pre-Bleach Bleach Fixer Wash Wash Wash Final Rinse Dry Post-Cycle Wash
* J
2:00 6:00 4:00 1:00 1:00 1:00 0:30 As needed 5:00
Prepare pre-bleach as tank solution. Prepare bleach as tank solution. Prepare fixer as tank solution. Three 1-minute running-water washes (7.5 L/min [2 gal/min]) with a 10- to 20second drain after each wash. Use separate tank outside processor.
Ambient Up to 60 (140) 24 (75)
All times include a 10- to 20-second drain time. This step may not be necessary with a water-jacketed processor. Determine the exact time and temperature for your processor. If the processor manufacturer recommends a film prewet, note that a prewet can cause a slight sensitometric effect with some emulsions. Since some emulsions are affected more than others, your control strip may not reflect the results you get with all films. You can vary this time from 5 to 812 minutes to produce an in-control process at a selected temperature. Once you have chosen the time, maintain it within 5 seconds; once you have selected a temperature from the 36 to 40C (97 to 104F) range, control it within 0.3C (0.5F). Mix the reversal bath or reversal bath replenisher to 60 percent of the normal concentration used for conventional processing, e.g., if the instructions tell you to use 50 millilitres per litre of reversal bath concentrate, use only 30 millilitres per litre. If the instructions tell you to dilute one bottle of reversal-bath concentrate to prepare 19 litres (5 gallons) of solution, use the concentrate to prepare 31.5 litres (8.3 gallons) of solution. **Although you can open the processor after the reversal-bath step, it is best to leave it closed until after the color-developer step to avoid heat loss in the processing chamber. See the comments under Yellow D-min Stain on page 10-4.
10-1
CHEMICALS
You can use any Process E-6 chemicals with your rotarytube processor. Mix and use the KODAK PROFESSIONAL Single-Use Chemistry Kit or the 1-gallon-size chemicals for rotary-tube processors according to the instructions packaged with the chemicals. With larger sizes, first mix replenisher solutions according to the instructions; for pre-bleach, fixer, and final rinse, use the replenisher solutions as mixed. Use reversal bath replenisher at 60 percent of the normal concentration for your reversal bath. For first and color developers, mix developer starter with the replenisher according to the instructions to prepare a tank solution. For bleach, dilute the replenisher with water, and add bleach starter. Depending on your processor, you may need to add 1 to 4 mL per litre of 5N NaOH (sodium hydroxide) to the color developer to adjust the color balance (see Color-Balance Control on page 3-3.
SOLUTION STORAGE
For best results, store solutions according to the conditions given in the table on page 2-6.
PRE-CYCLE STEPS
The pre-cycle steps and conditions recommended are designed to compensate for solution heat loss during processing. The processor warm-up and film warm-up steps minimize changes in the first-developer temperature by raising the temperature of the processing chamber. Although you dont need to raise the temperature of the chamber to the processing temperature, you will get more repeatable results if you keep it consistent for each run. If your processor heater cannot provide a consistent chamber temperature, dont use it. If your processor has not been used for several hours, you may need to pre-warm the chamber to minimize variations in film speed.
SOLUTION VOLUME
For best sensitometric results, use no less than the minimum solution volumes given in Table 10-2. Some film holders or tubes may require more solution to produce better uniformity or to compensate for solution oxidation. Check your processor manual for the solution volume recommended for your processor. Table 10-2 Minimum Solution Volumes
Minimum Volume Solution First and Color Developers Reversal Bath, Pre-Bleach, Bleach, and Fixer mL/m2 (mL/ft2) 2,750 (250) 1,650 (150) fl oz/ft2 812 5
POST-CYCLE STEP
The post-cycle step is simply a cleaning operation. Thoroughly rinse all inner surfaces of the processor tray, tube, and film holders to remove all traces of chemicals especially fixer. If you intend to run another processing cycle immediately, you may need to keep the post-cycle temperature at approximately 24C (75F). If you have dried your processor with a hot-air-dryer, allow it to cool to room temperature to minimize film-speed variations. With some processors, the tube, tray, and processor cabinet may have to be at the same temperature before each run.
AGITATION
Rotation of the processor tube provides agitation. Good agitation is necessary for good film uniformity.
10-2
MONITORING YOUR PROCESS

Each processor may provide slightly different results. The design of the tube, film holder, processing tray, and means of rotating the tube can affect agitation, heating capacity, and amount of solution oxidation. To check the process with your equipment, process a KODAK Control Strip, Process E-6. 1. Attach a KODAK Control Strip, Process E-6, in the tube or on the drum near the center of the tube or drum. You may need to staple the control strip to an acetate sheet that you have cut to fit the film clips. The sheet should be dimpled or ridged so that it allows solution to drain from behind the control strip. In smaller processors, load the control strip on a processing reel. Run all processes with the control strip in the same position. 2. Follow your normal processing cycle to process the control strip. 3. Measure the D-max, HD, LD, and D-min densities of the control strip. Calculate and plot the differences from aim for that batch of control strips on a KODAK Process Record Form, KODAK Publication No. Y-55. If the differences from aim plot within the control limits, and the processed transparencies are acceptable, the process cycle you used is satisfactory. Include a control strip with each run, and plot the differences from aim for each strip. If the differences from aim plot outside the control limits, analyze the results (see Analyzing and Adjusting Your Process, below). Analyzing and Adjusting Your Process: If the differences from aim plot outside the control limits and your processed transparencies are not acceptable, modify your processing cycle. The most common out-of-control situations and possible remedies are described below. Fast SpeedThe green densities of the LD step plot below the control limit. Properly exposed transparencies appear light. 1. Decrease the first-developer time in 15-second increments until the densities of the LD step plot within the action limits. Modify your normal processing cycle to include this change. Do not decrease your first-developer time below 6 minutes.
2. Reduce your starting process temperature by 0.5C (0.9F) by decreasing the processor heater thermostat setting, and the first-developer, first-wash, reversal-bath, color-developer, and pre-cycle running water temperatures by 0.5C (0.9F). Continue to reduce the temperatures until the densities of the LD step plot in control or until you reach the minimum process temperature of 36C (97F). If your first-developer temperature is 36C (97F), do not decrease it to match the aim. Other conditions, such as contamination, storage, or mixing errors may be causing the problem. Do not reduce the temperature to less than 36C (97F) or the time below 6 minutes. When you find a temperature that produces an in-control process, use this as your normal temperature for future processes. Slow SpeedThe green densities of the LD step plot above the control limit. Properly exposed transparencies appear dark. 1. Make these changes, one at a time. Process a control strip after each change. a. Increase the processor warm-up time by 2 minutes. b. Increase the film warm-up time by 1 minute. c. Increase the volume of the first and color developers by 25 percent. 2. If any one of these changes increases the densities of the LD step significantly, modify your cycle to include the change. 3. Increase the first-developer time in 15-second increments until the densities of the LD step plot within the action limits. Modify your normal processing cycle to include this change. Do not increase the first-developer time beyond 812 minutes. 4. If none of these steps corrects the slow speed, increase your process temperature by 0.5C (0.9F). Continue to increase the temperature until the control values plot in control. Do not increase the processing temperature beyond 40C (104F). If all of these steps do not correct the slow speed, check for chemical-mixing or storage errors, and solution contamination.
10-3
Variable SpeedControl strips from successive processing runs plot out of control with some results plotting above the aim (too slow) and some results plotting below the aim (too fast). Properly exposed transparencies appear too dark from some processes, and too light from other processes. Your operating conditions may be inconsistent. Variable speed can also be caused by inconsistent mixing of the first developer. If more consistent operating procedures do not eliminate the speed variations, you may need to modify the pre-cycle step. Try the following changes one at a time. If any change reduces variability, include it in your normal process cycle. 1. If the first process you run after the processor has been idle for more than a few hours is consistently slower than other runs, increase the machine warm-up time for the first run by 2 minutes. Then return to your normal warm-up time. If the processes you run immediately after other processes are consistently faster, increase the post-cycle wash time to 10 minutes. 2. If process-speed variability seems to be random, try the following stepsone at a time. a. Increase the processor warm-up time (with running water) by 2 minutes. b. Increase the film warm-up time by 2 minutes. c. Use the modified pre-cycle steps for the processor, but turn the heaters off during the processing cycle. Yellow D-min StainThe green and especially the blue D-min densities plot high. The D-min is yellow overall, and there are yellow streaks and patches of varying densities from run to run. This problem is most apparent in largeformat sheet films, and in large areas of low density. The problem is usually caused by color-developer oxidation. To eliminate yellow D-min stain, try the following modificationsone at a time. 1. Use twice the amount of color developer. 2. Decrease the tube rotation rate, particularly during the reversal-bath, color-developer, and pre-bleach steps (e.g., if your processor rotates at 32 rpm, reduce the speed to 20 rpm).
3. Blow nitrogen into the processing chamber during the color-developer step. 4. Increase the amount of pre-bleach used by 50 percent. 5. Add a 30-second spray or flowing wash between the color-developer and pre-bleach steps and replace the final rinse with KODAK FLEXICOLOR Stabilizer III Replenisher. Important: Adding a wash between the color developer and pre-bleach steps, without the corresponding change to Stabilizer III, will result in unsatisfactory magenta-image stability. 6. If any of these changes reduces the D-min, include it in your normal process cycle. If none of the changes corrects the problem, check for chemical-mixing or storage errors, and solution contamination. If you have a large processor, the yellow D-min stain may be most evident in the film that is farthest from the solution inlet. Sometimes the solution flow may leave pre-bleach at the inlet while color developer collects at the opposite end. To minimize this, move the position of the inlet to the center of the tray or install inlets at the ends as well as at the center. This change will also produce more consistent results with the other processing steps. 7. Be sure that you are mixing and reusing the bleach and fixer according to the instructions. Poor Color BalanceA green or magenta color balance can be caused by color-developer alkalinity (pH) that is too low or too high, or by incorrect mixing of the color developer. You can adjust color-developer alkalinity (pH) by adding small amounts of sodium hydroxide (5N NaOH), sulfuric acid (5N H2SO4) or 28% acetic acid. Adding sodium hydroxide increases alkalinity and corrects a magenta color balance; adding sulfuric acid or acetic acid decreases alkalinity and corrects green color balance. Sometimes, a blue-bias process could be corrected by increasing the process volume by 30%. If this option is chosen, the process temperature should be reduced by 0.5C (0.9F). Other ProblemsUse the diagnostic charts (section 14) and control-chart examples (section 15) to diagnose other problems.
10-4
Basic cycle; see page 10-1.
Process In Control Process customer film.
Process Out of Control
Fast speed Green LD step densities plot above the control limit. Yes Make these changes, one at a time. Process a control strip after each change. 1. Increase the processor warm-up time by 2 minutes. 2. Increase the film warm-up time by 1 minute. 3. Increase volume of both developers by 25 percent. Yes Yes Yes Cast may be caused by incorrect color-developer alkalinity (pH). 1. Add sodium hydroxide (5N NaOH) to correct a magenta color balance. 2. Add 28% acetic acid to correct a green color balance. No Variable LD step densities. Blue density plots above the control limit for D-min. Processed film has a magenta or green color balance. No No No
Green LD step densities plot below the control limit.
No
Slow speed
Variable speed
Yellow D-min satin
Poor color balance
Low maximum density or other process problems, see sections 14 and 15.
Figure 10-1 Analyzing and Adjusting Your Process

Include change in basic cycle and process customer film. If process is still slowIncrease first-developer time in 15-second increments until process is in control. Increase processing temperature in increo o ments of 0.9 F (0.5 C) until process is in control. Note: If none of these steps corrects the speed, check for solution contamination or improper mixing or storage. Include change in basic cycle and process customer film. Include change in basic cycle and process customer film. If the first process after processor has been idle for several hours is consistently slow, increase the warm-up by 2 minutes (first run only). If several successive processes show an upward trend in speed, increase the post-cycle wash to 10 minutes. If variability is random, make the following changes, one at a time1. Increase processor warm-up time by 2 minutes. 2. Increase film warm-up time by 2 minutes. 3. Use the modified pre-cycle, but turn heaters off during processing. Include change in basic cycle and process customer film. Make these changes, one at a time1. Use twice as much color developer. 2. Decrease rate of tube rotation. 3. Blow nitrogen into processing chamber during color-developer step. 4. Use 50 percent more pre-bleach. 5. Add a 30-second wash between the color-developer and pre-bleach steps and replace final rinse with KODAK FLEXICOLOR Stabilizer III Replenisher. 6. For large processors, move solution inlet to the center of the tube. 7. Check for solution contamination or improper mixing or storage.
Yes
Decrease firstdeveloper time in 15-second increments until process is in control. Do not use a time shorter than 6 minutes. Reduce first-developer temperature in increments of 0.9 o F (0.5 o C) until process is in control. If temperature is o o less than 97 F (36 C), check for solution contamination or improper mixing or storage.
Include change in basic cycle and process customer film.
F009_9004EC
10-5
SMALL ROTARY-TUBE PROCESSORS

You may have to modify the normal processing cycle for some small rotary-tube processors (i.e., processors that have a tank capacity of approximately 1 litre). If the instructions for your processor recommend a prewet, it may have a slight sensitometric effect with certain emulsions. The effect is greater with some emulsions than with others, so your control strip may not reflect the result with all emulsions. Usually, you can use these processors without a prewet. However, maintaining good control in these processors without a prewet requires long warm-up times (approximately 30 minutes). If you cant afford these long warm-up times, use the prewet as recommended by the manufacturer. To use these processors without a prewet, closely follow the recommendations for first-developer time and temperature, cabinet temperature, and warm-up times. You can usually correct speed problems by adjusting the first-developer time and/or temperature, or by modifying the warm-up time (see Figure 10-1). For repeatable results, maintain a consistent cabinet temperature and monitor all temperatures closely. Be sure to clean the tube and all drum surfaces thoroughly between processing runs. Small rotary-tube processors are particularly subject to solution contamination. Chemical spills, solution carry-over, and residual chemicals left in lines and holding tanks can be sources of contamination. Use reversal bath replenisher at 60-percent concentration. Use the color developer prepared as a tank solution.
To reuse your bleach, you must replace the chemicals lost through dilution, carry-over, and chemical reaction. First measure the specific gravity of the used bleach at 27C (80F); see section 3. Monitoring and Controlling Processing Solutions. Stir the used bleach thoroughly before you take the sample. After you have measured the specific gravity of the used bleach, determine the amount of bleach replenisher that you need to add from Table 10-3. Table 10-3 Additions for Reconstituting Used Bleach
If the Specific Gravity (at 27C [80F]) of Your Used Bleach is 1.123 or greater 1.120 to 1.123 1.118 to 1.120 1.115 to 1.118 1.113 to 1.115 below 1.113 Add this Amount of Process E-6 Bleach Replenisher (mL/L) 80 110 140 170 200 The bleach is too dilute. Discard it. Check your pre-bleach drain time.
BLEACH EFFLUENT
You can collect used Process E-6 bleach and reconstitute it for reuse to reduce processing effluent and chemical costs. To reuse the bleach, collect the bleach from your processor drain. Minimize contamination from other processing solutions by allowing an adequate drain time after the color-developer and pre-bleach steps. Collect the bleach before you drain any fixer from the processor. Discard any used bleach that you think contains greaterthan-normal amounts of color developer, or that contains any amount of fixer; these chemicals can affect keeping or reuse. You can reconstitute the bleach immediately or store it and then reconstitute it.
After you add bleach replenisher to the used bleach, stir the solution thoroughly. Then measure the specific gravity of the reconstituted bleach at 27C (80F). The specific gravity should be greater than 1.130. If it is not, you will need to add more bleach replenisher. If your bleach is not properly reconstituted, bleaching will be inadequate, and your transparencies will have a high D-min from retained silver. If your transparencies have a low red D-max density, aerate the reconstituted bleach for 1 hour before using it.
SILVER RECOVERY
You can recover silver from used fixer by collecting the solution, and then passing it through a KODAK Chemical Recovery Cartridge, Junior Model II (312-gallon size, CAT No. 166 9431), a KODAK Chemical Recovery Cartridge, Model II (5-gallon size, CAT No. 173 4953), or an equivalent cartridge.
10-6
11
MAINTENANCE
GENERAL MAINTENANCE
Processing machines require regular maintenance to ensure optimum performance. We cannot overemphasize the importance of careful and frequent maintenance. Checklists provide a convenient and efficient method of ensuring complete maintenance for Process E-6. A daily checklist should include all activities that are required on a daily basis, such as draining wash tanks and checking dryer temperature. The daily checklist should include all chemical and mechanical measurements. Other lists can include less frequent activities, such as filter changes. Following a complete checklist will help ensure that the process is started up consistently, and that all the proper process variables are being monitored. Checklists are especially important if the process operates more than one shift per day, if the regular machine operator is away, or if the operator is new and unfamiliar with Process E-6. Customize checklists for each machine and each specific operation, and use checklists to record machine history. The following table shows the ideal schedule of measurements and maintenance that you should observe for all processors. Table 11-1 Process-Monitoring and Maintenance Frequency
Solution/Step First Developer First Wash Reversal Bath Color Developer Pre-Bleach Bleach Fixer Final Wash Final Rinse Dry Time D M M M M M M M M D D D D W D D Temperature D D Agitation D D D D W W W D D W W W Replenishment Rate D Specific Gravity D Filter Change EOW EOW
*
Drain and Replace D EOM M
EOW * EOW EOW EOW * D W
* We do not recommend that you recirculate this solution. However, if your machine is equipped with a recirculation system for this solution, we recommend that you recirculate the solution for only the first 15 minutes of the day and change the filters every other week. Drain non-replenished final-rinse tanks daily; drain replenished final-rinse tanks weekly, or more frequently, to maintain solution cleanliness.
D = Daily W = Weekly M = Monthly
EOW = Every other week EOM = Every other month
11-1
REPLENISHMENT SYSTEMS
Most replenishment systems incorporate three functions: chemical mixing, film sensing, and chemical delivery. All three must operate properly and consistently to maintain a good process. Chemical mixing: In chemical mixing, consistency and accuracy are very important. Consistency is important in the mixing vessel you use, the order in which you mix the chemicals, the water supply, and the mixing time and method. Accuracy is important when you measure chemicals, concentrates, and water. Do not overmix or aerate replenisher solutions. Store mixed chemicals in tanks with floating lids (to minimize oxidation and evaporation) and dust covers (to prevent contamination). Do not store replenisher solutions at high temperatures. Film sensing: Automatic sensing devices in processing machines vary by manufacturer, and include infrared scanner bars, mechanical rollers, and tabs on racks. Regardless of the type of measuring device, calibrate all mechanical and electrical parts frequently, preferably on a daily basis. Note: When processing KODAK EKTACHROME Professional Infrared EIR Film / Process E-6, be sure to turn off all sources of infrared radiation that may be associated with your processing equipment to avoid fogging this film. Chemical delivery: Your chemicals are probably delivered by a gravity-feed or metered-pump system. A gravity-feed system uses flowmeters or needle valves that allow chemicals to run continuously into the tanks as film is processed. Check flowmeters frequently to ensure consistent delivery (some meters exhibit pressure changes as the volume of replenisher in the storage tank decreases). A metered-pump system is the most common system used with rack-and-tank and roller-transport processors. The pumps are run by a timer or a microswitch. The replenishment system in an in-line dilution or blender system is a process within itself. Monitor and control it just as you do your tank solutions.
Measure the specific gravity of the first developer, reversal bath, and color developer tank solutions. Measure the time of the first developer step. Use a stopwatch to measure the time that the film is in the solution from the time the film enters the solution to the time it enters the first wash. Measure the temperature of the first developer, reversal bath, and color developer tank solutions, and the dryer.
WEEKLY MAINTENANCE
Calibrate the replenisher pumps for the pre-bleach, bleach, fixer, and final rinse, and record the calibration. The replenishment rates for these solutions are not as critical as those for the first developer, reversal bath, and color developer, but you should monitor them weekly to prevent problems. Measure the specific gravity of the pre-bleach, bleach, and fixer tank solutions.
BIWEEKLY MAINTENANCE (EVERY OTHER WEEK)

Replace all filters, regardless of their appearance. This helps prevent slime in the filter housings. Use recirculation filters that are in the range of 15 to 20 microns. For best results, install pressure gauges before and after each filter so that you can easily detect plugged filters. If a 5-pound-per-square-inch difference in pressure occurs between the two gauges, replace the filter.
MONTHLY MAINTENANCE
Measure the time of all solutions that you do not measure daily. Use a stopwatch to measure the time that the film is in a solution from the time the film enters the solution to the time it enters the next solution (or wash). Drain your pre-bleach tank, flush it with hot water, and replace the solution. You must do this regularly because the solution is not recirculated or agitated. Process byproducts may precipitate and collect at the bottom of the tank. If these precipitates build up, they can transfer dirt to the film. Check all recirculation systems.
DAILY MAINTENANCE
Drain the wash tanks at the end of every day or shift to help prevent buildup of biological growth (slime). If possible, leave the tanks empty overnight and then fill them with fresh water in the morning; see your processor manual for the procedure recommended for your equipment. Daily draining and refilling may not be enough to prevent slime buildup. If slime accumulates in your wash tanks, clean them by wiping the inside of each tank with a sponge and rinsing the tanks with warm water. Calibrate the replenisher pumps for the first developer, reversal bath, and color developer. Check the nitrogen supply (for your agitation system) at the beginning of each shift.
BIMONTHLY MAINTENANCE (EVERY OTHER MONTH)

Drain your reversal-bath tank, flush it with hot water, and replace the solution. You must do this regularly because the solution is not recirculated or agitated. Process by-products may precipitate and collect at the bottom of the tank. If these precipitates build up, they can transfer dirt to the film.
11-2
RACK-AND-TANK PROCESSORS
Use floating lids on all solution tanks. Rinse the floating lids after you remove them at daily start-up. (This will prevent dried chemicals from entering the tanks when you reinstall the lids. Dried or crystallized chemicals can plug filters.) Follow these other maintenance steps as well as the procedures in your processor manual: Clean pickup cups or lifts every day. Remove chemical residue to prevent corrosion. Clean the rack slides by wiping them with a damp sponge; then use a clean, lintless cloth sprayed with silicone. Do not transfer any silicone to the tank solutions. Rinse the racks, hangers, weights, and clips between each use to prevent solution contamination. Thoroughly clean the machine once a week. Wash the tank dividers or crossover plates. (Check that the rim of each tank is free of dried chemicals. If you have to remove dried chemicals, do not let them fall into the tanks.)
If you cannot remove silver buildup by following your manufacturers cleaning instructions, you can use KODAK Developer System Cleaner and Neutralizer (CAT No. 843 4615). Prepare the cleaner and neutralizer according to the instructions packaged with the chemicals. 1. Remove the racks from the machine, and rinse them thoroughly with water to remove all traces of solution. 2. Use a squeeze bottle filled with working-strength cleaner to direct a stream of cleaner onto the parts of the racks that require cleaning. If necessary, use a sponge or a brush to keep the parts wet with cleaner. For heavy deposits, reapply the cleaner as needed. 3. Rinse the racks thoroughly with water to remove the cleaner, and allow them to drain completely. 4. Use a squeeze bottle filled with neutralizer to direct a stream of neutralizer onto the parts of the racks that you treated with cleaner. 5. Rinse the racks thoroughly with water to remove the neutralizer, and allow them to drain completely. 6. Replace the racks in the machine and refill the tank(s).
CONTINUOUS PROCESSORS
If your processor is equipped with wiper blades or squeegees, check and clean them every day. Replace blades or squeegees that are worn or have a buildup. Check the pressure on the blades or squeegees daily. Rinse all rollers above the solution level with warm water every day. (This will help prevent chemical buildup that can scratch film.)
ALL MACHINES
Follow the maintenance recommendations listed in your processor manual. Occasionally check that the air flow from the darkroom is positive. If it is not, air from the dryer will flow back through the machine and cause an increase in solution temperature and/or excessive evaporation during processing. Check for positive air flow by holding a candle near the feed tray. The smoke from the candle should move toward the machine, not back toward the darkroom. Check all hose fittings once a year. (Hoses tend to shrink with age, so check that the clamps are tight enough to prevent leaks. Check all hoses for cracks.) We recommend that you drain every tank at least once a year and clean and inspect it. Place your solutions in holding tanks while you clean the processor tanks. Check for rust and/or loose metal parts in tanks.
ROLLER-TRANSPORT PROCESSORS
Roller-transport processors are sensitive to dirt; they require a more involved maintenance routine. Rinse the top (or crossover) rollers with warm water every day. (This will help prevent chemical buildup that can scratch film.) When the tank solutions are up to operating temperature, run KODAK Roller Transport Cleanup Film 4955 through the processor daily at start-up. Make sure that the film comes into contact with the entire width of the rollers. Do not reuse the cleanup film. Note: KODAK Roller Transport Cleanup Film 4955 is available in 8 x 10-inch (CAT No. 114 1530), 11 x 16-inch (CAT No. 114 1555), or 35 x 43 cm (CAT No. 166 4368) sheets, and 40-inch x 30-foot (CAT No. 154 7306) or 50inch x 30-foot rolls (CAT No. 154 4368). You can cut the roll sizes to the appropriate size for wide-track processors. Clean the racks in the first-developer tank every week. Clean all other racks once a month. (Do this by cleaning a few racks each week.) See your owners manual for instructions on cleaning the racks. Note: You can use ultrasonic cleaning to loosen dirt on racks. However, if you use ultrasonic cleaning to clean racks that have hollow rollers, the cleaning solution may fill the rollers and contaminate tank solutions.
11-3
11-4
12
VISUAL TROUBLESHOOTING OF PROCESS E-6
Once you have eliminated improper film storage and incorrect exposure as causes of poor-quality transparencies on KODAK EKTACHROME Film, check for processing problems. These problems include errors in chemical mixing, order of processing steps, processing temperature, agitation, washing, replenishment, and solution contamination. A visual check of the processed film is one way to make an initial diagnosis. You can make a more thorough determination of the cause of processing problems and the corrective action to take by plotting and evaluating your control-strip densities; see section 13, Process Monitoring. Table 12-1 Troubleshooting from the Appearance of Processed Film
Appearance of Film Very High Maximum Density (very dark no apparent image) Dark Overall No Edgeprint Visible Edgeprint Visible Possible Cause First developer omitted First developer and color developer reversed Film not exposed Inadequate time or low temperature in first developer First or color developer diluted or exhausted Color developer starter added to first developer Too much first developer starter used First developer or first and color developers underreplenished Bleach or fixer (or both) omitted, reversed, diluted, exhausted, or underreplenished Too much time or high temperature in first developer Film fogged by light before processing First or color developer (or both) too concentrated First or color developer (or both) overreplenished First developer starter omitted First developer contaminated with reversal bath or color developer First developer contaminated with fixer First developer used twice or color developer omitted Severe light fog Inconsistent first-developer time, temperature, agitation, or replenishment First developer contaminated with fixer Reversal bath overconcentrated Too little first developer starter used First-wash temperature too low Color-developer starter added to first developer Too much first developer starter used Inadequate bleaching or fixing First developer with color developer starter added Underreplenishment of first developer or color developer Color developer contaminated with fixer Reversal bath exhausted, diluted, or underreplenished Film fogged by green safelight Wash used between color developer and reversal bath Color developer dilute Color pH high Too much Part A in color developer Overreplenished color developer A dilute color developer Color developer mixed using first developer starter
Very Dark (overall or in random areas) LIght Overall
Image Very Faint or No Image (film may show colored streaks) Overall Density Variation from Batch to Batch Blue
Cyan Yellow
Yellow-Red Low Density Blue; High Density Yellow Green
12-1
Appearance of Film Red
Possible Cause Inadequate aeration of bleach Pre-bleach concentration too high Inadequate aeration of fixer First-wash temperature too high Severely oxidized color developer Color developer pH low Color developer concentrated Too much Part B in color developer Underreplenished color developer
Magenta
Cross-Width Bar Marks (with stainless-steel reels) Gaseous-burst agitation used in first developer Incorrect or inadequate manual agitation Scum and Dirt* Bio-growth (slime) in final rinse (drain and replace) Air filters in dryer need changing Dirt in solutions; use floating covers on processor and replenisher solution tanks Final rinse overconcentrated Precipitate in pre-bleach Dirt from dryer Fixer sulfurized Defoamer added directly to any solution or too much defoamer used Dirt from final rinse Water spotting. Final rinse too dilute Dirt from dryer Fixer sulfurized Dryer temperature too high Bleach or fixer time too short, temperature too low, or replenisher too dilute Uneven or insufficient agitation, particularly in first and color developers Nonuniform agitation in first and color developers Low first-wash flow rate Foam rundown Dirty squeegee blades Jammed, misaligned, or dirty rollers Cinch marks due to excessive take-up tension Dirt from loading area Dirt from camera Static Fog Loss of bleach, fixer, or pre-bleach activity Fixer sulfurized by excessive aeration Bleach not sufficiently aerated Color-developer time too long or temperature too high Inadequate first-developer agitation
Surface Spots (appear dark by transmitted light)
StreaksNonuniformity
Scratches and Abrasions
Light Density Spots, Streaks, or Patterns Stain
* A buildup of fungus or algae in processing solutions or wash tanks can cause dirt. To minimize buildup, drain wash tanks when they are not in use. When you expect the processor to be out of use for more than six weeks, drain and rinse the reversal-bath processor tank and replenisher storage tanks. To remove fungus or algae, scrub the tank with a stiff-bristle brush, using a 30 to 50 mL/L sodium hypochlorite solution (household bleach). Rinse the tank thoroughly with water to remove all traces of the hypochlorite solution. Do not use a sodium hypochlorite solution in the wash tank that follows the fixer. Use a 5- to 25-micrometre (or finer) filter for your water supply.
12-2
13
PROCESS MONITORING
KODAK CONTROL STRIPS, PROCESS E-6 (CAT No. 173 3682)
These 35 mm strips are supplied in 100-foot rolls of approximately 120 strips with cutoff notches at 24.1 cm (912-inch) intervals. A reference strip is included with each roll. The roll is wound emulsion side in, with the D-min ends of the strips toward the outer end of the roll. Each strip has 11 steps. For process monitoring, read and plot the densities of the D-min, LD, HD, and D-max steps. You can measure the densities of all 11 steps to plot a full sensitometric curve.
Cutoff notch
INTRODUCTION
Kodak supplies KODAK Control Strips, Process E-6, for monitoring processing of all KODAK EKTACHROME Films in KODAK Chemicals, Process E-6. KODAK Control Strips, Process E-6, are precisely exposed strips of film that contain areas for monitoring D-min, LD, HD, and D-max.
KODAK CONTROL STRIPS, PROCESS E-6 (CAT No. 106 3239)

These 35 mm x 514-inch strips are supplied in a box of five foil packages that contain 10 strips each. Each box includes a reference strip. The ends of the strips are perforated for use with standard control-strip racks. Each strip has five steps; a raised dimple is located on the emulsion side at the lowdensity end. For process monitoring, read and plot the densities of the D-min, LD, HD, and D-max steps.
Yellow
E-6
Raised dimple
Magenta
Cyan
8016 1 2 3 4 5
DATE:
D-MIN
Identification code
E-6 8011
D-MIN
Identification code (reversed when strip is emulsion side up)
TD
LD
TD
HD
D-MAX
LD
HD
5 1/4-Inch Strip
F009_9005GC
D-MAX
F009_9006CC
9 1/2-Inch Strip from 100-Foot Roll
13-1
Storage and Handling: Store unused control strips at 18C (0F) or lower. Handle unprocessed strips in total darkness. Remove only a days supply at a time from the package, and reseal and return the balance of the package to the freezer as quickly as possible. Store the daily supply in a lighttight container at room temperature. Allow your daily supply of strips to reach room temperature before processing. At the end of the day, discard any unprocessed strips that you removed from storage. Handle control strips by the edges to prevent fingerprints and surface damage. If film sticking, static marking, or moisture mottle occurs, allow the package to warm up before you open it. However, do not keep the package out of the freezer for more than 12 hour per day. Keep the reference strip in its envelope to protect it from light when youre not using it. Avoid glow-in-the-dark tape strips, wrist watches, pagers, and LED radios with glow dials. Reference Strip: Enclosed in each box of control strips is a reference strip of the same code number; it is processed by Kodak at standard conditions. Use the reference strip to determine aim values for your batch (code number) of control strips. Correction Factors: Correction factors for each code number are given in the instructions packaged with each box of control strips. Add these correction factors to the reference-strip densities to determine aim values. Correction factors differ for each code number. Aim Values: Aim values are the standard to which you compare your daily control-strip readings. You determine aim values by measuring the densities of the reference strip packaged with each box of control strips, and then adjusting the densities by applying the correction factors supplied with the control strips. Action Limits: Action limits are the boundaries of the desired operating range of the process. As long as the density values remain between the upper and lower action limits, your process is operating correctly. If a density value exceeds the action limit, it is an early warning. You can safely process customer film, but you should check for the cause of the shift and correct it.
Control Limits: The control limits define the maximum tolerances that are acceptable for processing customer film. If any density value of your process plots beyond the control limit, the process is out of control, and results will be unsatisfactory for color, density, and/or contrast. Stop processing customer film until you find the cause and correct it. Color-Balance Spread Limits: A color spread is the density difference between the two most widely separated color plots of the LD and HD steps. If your process exceeds the color-balance spread limit, stop processing customer film and take corrective action. The color-balance spread limits for LD and HD are given in Table 13-1. Tolerances and Limits: The tolerances and limits are density variations allowed before you must take corrective action; they include an aim-value adjustment tolerance, and action and control limits. The tolerances and limits for Process E-6 are listed in Table13-1. Table 13-1 Tolerances and Limits for KODAK Control Strips, Process E-6
Aim-Value Adjustment Measurement Tolerance D-min LD (Speed) HD (Color) D-max 0.02 0.03 0.05 0.07 ColorBalance Spread Limit 0.07 0.11
Action Limits +0.03 0.08 0.12 0.20
Control Limits +0.05 0.10 0.15 0.25
13-2
Using Control Strips

We recommend that you process at least three control strips per day or shift. Process a strip at the beginning of the shift (before you process customer film), another strip in the middle of the shift, and another strip at the end of the shift. We also recommend that you process a control strip with customer film at regular intervals. Handle and process control strips according to the instructions packaged with them. Use a densitometer equipped with Status A filters to read the control-strip densities. In rack-and-tank processors and in sink-line processes, process control strips with the D-min end up. In continuous processors, splice control strips so that the D-min end enters the processor first. 1. Create a control chart by using the KODAK Process Record Form Y-55 or similar graph paper. 2. Draw in the action and control limits given in Table 13-1. Use black for the action limits and red for the control limits. 3. Remove the reference strip from the box of control strips. If you removed the box from cold storage, allow the reference strip to warm up to room temperature before you remove it from its envelope (about 15 minutes). 4. Measure the red, green, and blue densities in the center of the D-min, LD, HD, and D-max steps with your densitometer. If you have several boxes of strips with the same code number, average the readings of all the reference strips. 5. To calculate aim values, apply the correction factors supplied in the instruction sheet packaged with each box of control strips to the reference-strip densities. If you averaged the reference-strip readings from several boxes of the same code number, apply the correction factors to the average. These corrected density values are the aim values for the batch of control strips. Record them in the proper spaces in the left margin of Form Y-55.
Table 13-2 Example of Determining Aim Values

Red D-max Reference Strip Densities Correction Factor Aim Value HD Reference Strip Densities Correction Factor Aim Value LD Reference Strip Densities Correction Factor Aim Value D-min Reference Strip Densities Correction Factor Aim Value 3.23 0.07 3.16 2.36 +0.00 2.36 1.03 +0.00 1.03 0.16 +0.00 0.16 Green 3.37 0.03 3.34 2.35 +0.01 2.36 1.04 0.03 1.01 0.18 +0.00 0.18 Blue 3.69 0.14 3.55 2.25 +0.00 2.25 1.02 0.02 1.00 0.14 +0.01 0.15
6. Process a control strip and measure the same steps that you measured in step 4. 7. Calculate the variations from aim by subtracting the aim densities from your control-strip densities. Plot the variations on your control chart. Plot differences that are larger than the corresponding aim values (+ values) above the aim line. Plot differences that are smaller than the aim values (values) below the aim line. 8. If any of the variations from aim plot beyond the action or control limits, process another control strip. If the second strip confirms the results of the first strip, determine the cause of the problem and take corrective action. Whenever you take corrective action, process another control strip to confirm that the change you made returned the process to control before you resume normal processing.
13-3
Changing to a New Batch of Control Strips

When you change from your current batch of control strips to strips with a different code number, make a crossover to confirm that both code numbers provide the same information. If you have more than one Process E-6 machine, perform this crossover for each machine. Be sure that your process is stable and in control before you begin using a new batch of control strips. 1. While you still have at least a weeks supply of control strips of the current code, process one control strip from the new batch of strips with one strip from the current batch in three separate runs. 2. Read and record the densities of the processed strips. Table 13-3 ExampleLD Step Readings
Strip 1 2 3 Current Strips Red 1.03 1.00 1.05 Green 0.99 0.99 0.98 Blue 1.00 0.99 0.98 Red 1.00 1.01 1.02 New Strips Green 1.00 1.00 0.99 Blue 0.97 0.97 0.95
7. Depending on the sign of the average difference, adjust the aim values for the new batch of strips by adding or subtracting the results from step 6. The amount of the adjustment should not exceed the aim-value adjustment tolerances given in Table 13-1. If the adjustment is greater than the tolerance, determine the cause. Check your calculations, densitometer, and control stirps. 8. Record the new aim values and the code number of the new batch of strips on your control chart, and begin using the new strips. Plot the new control-strip readings against the adjusted aim values. Making the Crossover Mathematically: You can also use a mathematical procedure to crossover to a new batch of control strips. With this method, you dont need to plot the readings of the two set of processed control strips. Follow the steps shown in the table below.
Calculation Current Aim Value New Initial Aim Value Equals Multiply by 3 Equals + Density of New Strips Example 1.00 +1.01 2.01 x3 6.03 +1.00 +1.01 +1.02 Density of Current Strips 1.03 1.00 1.05 Equals Divide by 6 Equals New Adjusted Aim Value (Rounded Up) 5.98 6 0.997 1.00 6 6 6 + + + + + + + + + x3 x3 x3 + + + Red Green Blue
3. Determine aim values for the new batch of strips; follow steps 3 through 5 under Using Control Strips. 4. For your current batch, calculate the variations from aim by subtracting current aim densities from densities of the three strips. Plot the variations on your control chart. 5. For the new batch of strips, calculate the variations from aim by subtracting the new aim densities (calculated in step 3) from the densities of the three strips. Plot the variations on your control chart. 6. Calculate the differences between the variations from aim of the current strips and the new strips. Average these differences, and then divide the result by 2.
13-4
INTERPRETING YOUR CONTROL PLOT

Your control plot provides a running record of your process. It will show how consistent your process is, and how well it meets your aim. It provides you with helpful information for analyzing and correcting process problems. Your process will produce acceptable results if your control strips always plot within the control limits.
When you troubleshoot a problem, check the easiest and most obvious causes first; then check the more difficult and less likely causes. With process monitoring, first check the following Did you use control strips with the same code number? Did you plot the density values against the correct aim values? Is the densitometer operating properly? Were the time and temperature set correctly? Is the replenishment rate set correctly? Checking for contamination or for correct mixing requires more time and effort. Unless you have a good reason to suspect one of these causes, check them after you have checked the causes that are easier to check and verify. To help you determine the cause of an out of-control condition, use the information in section 14, Diagnostic Charts, and the sample plots in section 15, Control-Chart Examples.
Corrective Action
When a control strip plots outside the control limits, or if the plot shows a gradual drift toward an out-of-control condition, immediately check for the cause and correct it. First, determine if the process drifted out of control slowly over time or if it occurred suddenly. An out-of-control condition that has occurred slowly over time indicates a problem such as Insufficient replenishmentthis may be caused by an incorrect replenishment rate, an incorrectly mixed replenisher, or a defective replenisher pump. Evaporation or oxidationevaporation or oxidation can be caused by low utilization or by too much air flow around the processing solutions. An out-of-control condition that occurs suddenly can indicate a problem with your Control stripdid you use a control strip from the correct code number? Remember, if you change code numbers, you need to establish new aim values for that code number (see Changing to a New Batch of Control Strips on page 13-4). Do the control-strip code numbers match those of the reference strip? Were the strips handled and stored properly? Densitometeris your densitometer working properly? Did you use Status A filters? Time or temperaturecheck that they are set properly. Check your temperature regulator. First or color developerwas the tank or replenisher solution contaminated with another processing solution (e.g., fixer)? Contamination can cause a large density and color shift. Solution mixingwas the tank solution mixed properly? If the problem occurred with a fresh mix, check for improper mixing.
Daily Processing Log

Use a daily processing log for your processor. A processing log will provide you with a convenient means of keeping track of the amount of film you process and can provide you with valuable information in case of process and/or machine problems.
13-5
13-6
14
DIAGNOSTIC CHARTS
Chart A B C D E F G H I J K L M N O P Q R S T U V W X Y Example Preliminary SummaryControl-Chart Plots Control-Chart PlotsHigh D-max Control-Chart PlotsLow D-max Control-Chart PlotsRed or Green Color Balance Control-Chart PlotsBlue Color Balance Control-Chart PlotsCyan, Magenta, or Yellow Color Balance Control-Chart PlotsGreen, Yellow, Yellow/Red, or Yellow/Green Color Balance Control-Chart PlotsLow Activity One or More Density Values Plot High Control-Chart PlotsLow Activity One or More Density Values Plot High Control-Chart PlotsHigh Activity One or More Density Values Plot Low Control-Chart PlotsHigh D-min SummaryVisual Appearance Visual AppearanceFirst Developer and Reversal Bath Visual AppearanceColor Developer Visual AppearancePre-Bleach, Bleach, Fixer, and Final Rinse Visual AppearanceFilmSurface Dirt Visual AppearanceFilmMuddy or Grainy Visual AppearanceFilmScum Visual AppearanceFilmScratches Visual AppearanceFilmEmulsion Marks Visual AppearanceFilmDensity Marks Visual AppearanceFilmDark Images Visual AppearanceFilmLight Images Visual AppearanceFilmHigh or Low Contrast
The diagrams in this section provide you with a step-by-step approach to diagnosing processing problems. Summary charts show which detailed chart to consult for your problem. The charts give probable causes and suggest corrective procedures. Remedies for some processing problems are described in section 3, Process Monitoring, and section 5, Corrective Actions for Processing Solutions.
14-1
Chart A
PLOT PROBLEM Tolerance limit(s) exceeded on control chart
CHECK THE OBVIOUS
CHECK CONTROL STRIP
CHECK REFERENCE STRIP
CHECK FOR OPERATOR ERROR Plots on Y-55 Form done correctly? Error in reading control strip? (Reread control strip) - Area to be read correctly centered and free of defects? - Emulsion side placed correctly? - Densitometer read correctly? - Correct densitometer filters used? - Correct step on control strip for parameter plotted? Correct control-strip code number plotted?
CHECK FOR OPERATOR ERROR Reference strip of same code as control strip? Correct readings? Correction factors used correctly for crossover procedure? Reference values correctly transferred to Y-55 Form?
CHECK FOR PHYSICAL DEFECTS Correct handling and storage? Control strip damaged when processed? Manufacturing deficiency?
CHECK FOR PHYSICAL DEFECTS Correct handling and storage? Manufacturing deficiency?
CHECK DENSITOMETER Correct usage by operator? - Instrument warmed up? - Correct filters used? - Zeroed and sloped correctly? Malfunction of instrument?
Problem Found
Problem Not Found
Correct Go to Chart B
F009_9007EC
Process
14-2
Chart B SummaryControl-Chart Plots DESCRIBE PLOT PROBLEM

High D-max See Chart C
MATCH PROBLEM PARAMETER
FURTHER IDENTIFY AND GO TO CHART SPECIFIED
D-max Low D-max
Red plot - low (One or more plots below tolerance and all 3 plots below zero line in HD or LD parameters)
Green plot - low Blue plot - low
Low D - max
Red and green plots - both low See Chart E

See Chart D Red color balance (Red plot apart from and lower than other two) See Chart E First developer (low activity) See Charts I and J See Chart E and lower than other two) plot apart from balance (Green Green color Blue color balance (Blue plot apart from and lower than other two) See Chart F See Chart G Cyan color balance (Red plot apart from and higher than other two) Magenta color balance (Green plot apart from and higher than other two) Color (HD) Improper Color Balance (Plots spread apart with spread between lowest and highest exceeding either color-balance tolerance) Speed (LD) Slow Process (One or more plots above tolerance limits and all three plots above zero line) Yellow or yellow/red color balance (Blue plot apart from and higher than other two, or blue plot apart from and higher than green and red plot apart from and lower than green) Toe Density (TD) Fast Process (One or more plots below tolerance limits and all three plots below zero line) See Chart K See Chart H High D-min See Chart L D-min Low D-min (Not significant)
Identify the problem parameter on your control chart. Go to that parameter on Chart B. NOTE: If tolerance limits are exceeded in more than one parameter, look first at the parameter where the problem is most severe. If this does not give satisfactory results, then go to the other problem parameters.
Yellow/green color balance in HD parameter. Cyan/blue in LD parameter. (Blue plot apart from and higher then red HD and green plot apart from and lower than red HD. Red apart from and higher than green LD and blue apart from and lower then green LD)
F009_9008EC
14-3
14-4
CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM PREVENT RECURRENCE
First developer too dilute Check specific gravity Color developer too dilute Check mix and solution tanks Check mixing techniques On in-line replenishment systems, check settings on concentrate and water pumps and adjust to specifications First and color developers underreplenished Adjust to specifications Check replenishment rate and calibration of replenisher measuring devices. Recalculate film load of average rack. First and color developer reversed Check mix and operating procedures Correct mix and operating procedure Thoroughly clean both tanks Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Take steps to prevent the problem in the future First developer omitted Check operating procedure Correct operating procedure
Chart C Control-Chart Plots High D-max
High D-max
F009_9009EC
Chart D Control-Chart Plots Low D-max CHOOSE PROBABLE CAUSE

High first wash temperature Adjust wash temperature to o o 92-103 F (33-39 C) Check temperature with an accurate thermometer
VERIFY CAUSE
ELIMINATE CAUSE
ELIMINATE SYMPTOM
PREVENT RECURRENCE
Low red D-max Plot below tolerance limits (-0.20 or -0.25) Underaerated bleach and / or fixer Check bleach Properly aerate bleach
Overconcentrated pre-bleach
Check specific gravity Check mix procedure Check mix tank Check pumps Correct mix procedure Correct pumps
Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution
Take steps to prevent problem in the future
Loss of reversal bath activity Correct problem
Check reversal bath replenishment rate, storage, agitation, and mix procedure
Low green D-max Plot below tolerance limits (-0.20 or -0.25) Color developer too concentrated Check specific gravity, mix procedure, calibration mix tank, and replenisher pumps
Correct mix procedure Correct or compensate for evaporation Adjust pumps

Agitation Check agitation of first and/or color developer Adjust to specifications Reversal bath too concentrated Check specific gravity Check replenisher pumps Calibrate mix tank Correct mix procedure Adjust pumps Overreplenishment of first developer Check replenishment rate & calibration of replenisher measuring device Recalculate film load of average rack Check mix procedure, processor operation, and distribution lines Adjust to specifications First developer contaminated with fixer Correct mix procedure Do not use equipment used for mixing fixers for other solutions First developer contaminated with fixer Check mix procedure and splashing Correct mix procedures (Do not mix developer in mix tanks used for other solutions) Install splash shields Too little first developer starter Check specific gravity Check mix procedure Check mix tank Correct mix procedure
Low blue D-max Plot below tolerance limits (-0.20 or -0.25)
Low D-max Plot below tolerance (-0.20 or -0.25) One or more plots below tolerance and all 3 plots below zero line in HD or LD
F009_9010EC
14-5
14-6
High first wash temperature Check temperature with an accurate thermometer Adjust first wash temperature to o o 98-103 F (33-39 C) Underaerated bleach or fixer Check bleach aeration Properly aerate bleach and fixer Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Take steps to prevent the problem in the future Oxidized reversal bath Check for floating cover, air agitation or nitrogen agitation, long turnover time, air in flexible container, storage temperature, and pumps Install floating cover Correct flexible-container storage conditions Do not store chemicals beyond suggested storage life Adjust pumps Reversal bath underreplenished Check replenishment rate and calibration of replenisher measuring devices Adjust pumps
Color-developer overreplenished
Chart E Control-Chart Plots Red or Green Color Balance
Red Color Balance Red plots spread apart from and below blue and green Transparencies appear too red
Green Color Balance Green plots spread apart from and below red and blue
Transparencies appear too green in shadow areas
Adjust to specifications Adjust pumps
Check specific gravity Check replenisher pumps Check replenishment rates and calibration of replenisher measuring device Recalculate film load of average rack
Color developer Part A only or excessive Part A
Check specific gravity Check mix procedure For in-line replenishemnt systems,check for too-high setting on Part A pump or too-low setting on Part B pump. Also see if Part B container is empty or if line is blocked
Correct mix procedure Adjust replenisher pumps

Color developer pH too high Check mix procedure Check replenishment rate Check pumps Check A:B ratio
Use correct mix procedure Adjust replenishment rate to specifications Adjust pumps
Add 5N H 2 SO 4 or 28% acetic acid
F009_9012EC
Chart F Control-Chart Plots Blue Color Balance CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
High color-developer o o temperature (+5 F[+3 C]) Check temperature with an accurate thermometer
Adjust color-developer temperature

Concentrated reversal bath Check specific gravity Check mix procedure Check replenisher pumps Calibrate mix tanks Correct mix procedure Adjust pumps Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Check mix procedure Check specific gravity
Blue Color Balance Blue plots spread apart from and lower than the other two in LD or HD Transparencies appear too blue
Take steps to prevent the problem in the future
F009_9013EC
14-7
14-8
CHOOSE PROBABLE CAUSE
Color developer underreplenished Check replishment rate Check specific gravity Check replenisher pumps Use floating lid on color developer replenisher When processor not running use floating lid on developer tank solution Adjust pumps Add replenisher (can safely add 10% of tank volume)
Chart G Control-Chart Plots Magenta or Cyan Color Balance VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Low color-developer pH
Check specific gravity of tank and replenisher Check replenisher pumps
Magenta Color Balance Red and blue plots spread apart from and below green in LD or HD Transparencies appear too magenta Color-developer oxidation Check for floating cover, air agitation, long turnover time, air in flexible container, improper storage temperature, and air in replenisher pumps Check mix procedure Check specific gravity Calibrate mix tank Correct mix procedure Install floating covers Use nitrogen agitation Correct flexible-container storage conditions Do not store chemical beyond suggested storage life
Use floating lids on replenisher Do not exceed keeping time for color developer replenisher Adjust pumps Use correct mix procedures Add 5 N NaoH
Too much color developer starter Color developer replenisher has too much Part B or has only Part B Check specific gravity Check mix procedure For in-line replenishment systems, check for too-high setting on Part B pump or too-low setting on Part A pump Also see if Part A container is empty or if line is blocked
Calibrate mix tank Correct mix procedure For in-line replenishment systems, adjust settings of concentrate pumps to specifications Take steps to prevent the problem in the future Calibrate mix tank and processing solution tank Correct mix procedure For in-line replenishment systems, adjust settings of concentrate and water pumps to specifications
Color developer too dilute
Check specific gravity Check mix procedure Check concentrate-to-water ratio
Cyan Color Balance Blue and green plots spread apart from and below red in HD or LD Transparencies appear too cyan Loss of reversal bath activity
Color developer contaminated with first developer (10 mL / L of first developer in color developer will show photographic effect)
Check mix procedure, machine operation, and distributor lines, including nitrogen-burst agitation
Eliminate common mix equipment and lines (Do not use equipment used to mix fixer for mixing other solutions) Clean dirty tanks and hangers Eliminate splashing and foam Check for floating cover, air agitation or excess nitrogen agitation, long turnover time, air in flexible container, and storage temperature Install floating covers Use nitrogen agitation Correct flexible-container storage conditions Do not store chemicals beyond suggested storage life
F009_9014EC

Low first-wash temperature Check temperature with accurate thermometer
Adjust first wash temperature to o o 92-103 F (33-34 C)
Chart H Control-Chart Plots Yellow Color Balance CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Reversal bath slightly oxidized
Check for floating cover, air agitation or excess nitrogen agitation, long turnover time, air in flexible container, and storage temperature
Install floating covers Use nitrogen agitation Correct flexible-container storage conditions Do not store chemicals beyond suggested storage life
Yellow Color Balance Blue plot spread apart from and higher than red and green Transparencies appear too yellow Low color-developer temperature Check temperature with accurate thermometer Adjust color-developer temperature
Too much first developer starter
Roll film exposed through the base (very yellow overall)

Color developer starter added to first developer Check mix procedure and calibration of solution tank Calibrate mix tank; check mixing technique First and color developers underreplenished Check replenisher rates and calibration of replenisher measuring devices Recalculate film load of average rack Adjust to specifications Color developer contaminated with fixer Review contamination-control procedures Thoroughly rinse mixing tank before mixing color developer. Avoid mixing developers in tanks used to mix other solutions
Yellow/red Color Balance
Blue plot spread apart from and higher than green and red plot spread apart from and lower than green Transparencies appear too yellow-red
Yellow/ green HD Cyan/blue LD
Blue plot spread apart from and higher than red HD and green plot spread apart from and lower than red HD Red plot spread apart from and higher than green LD and Blue plot spread apart from and lower than green LD
Transparencies appear too yellow/green in shadows and cyan/blue in lighter areas
F009_9015EC
14-9
14-10
Low temperature Check temperature with accurate thermometer Adjust temperature Short time Check time with stop watch Check rack threading on continuous processor Adjust to specifications Rethread rack on continuous processor, if necessary Low concentration Check specific gravity Check replenisher pumps Calibrate mix tanks and solution tank Check mixing technique For in-line replenishment systems, check settings of concentrate and water pumps Low agitation Check nitrogen supply and distributors Adjust to specifications Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Take steps to prevent the problem in the future Underreplenishment Check replenishment rate and calibration of replenisher measuring devices. Recalculate film load of average rack Oxidation Check for floating covers, air agitation, long turnover time, air in flexible container, and storage temperature Install floating covers Use nitrogen agitation Correct flexible-container storage conditions Do not store chemicals beyond suggested storage life Too much first developer starter Check mix procedure and calibration of solution tank Color developer starter used (substantial speed loss especially in the blue) Correct mix procedures Color developer underreplenished Check replenishment rate Check calibration of replenisher measuring device Adjust to specifications Low utilization First-developer tank turnover every 3 weeks required Use low-utilization procedure
Chart I Control-Chart Plots Low Activity One or More Density Values Plot High
Slow Process First Developer (low activity) One or more plots above tolerance limits All three plots above zero line Transparencies appear too dark
F009_9016EC
Chart J Control-Chart Plots Low Activity One or More Density Values Plot High CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Moderately low concentration
Check specific gravity Check replenisher pumps
Calibrate mix tanks Correct mix procedures For in-line replenishment systems, check settings on concentrate and water pumps Check for cracks in tank
Underreplenishment
Check replenishment rate and calibration of replenisher measuring device
Recalculate film load per average rack; adjust replenisher to specs Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Take steps to prevent the problem in the future
Slow Process Color Developer (low activity) One or more plots above tolerance limits All three plots above zero line Transparencies too dark Oxidation Check for floating cover, air agitation, long turnover time, air in flexible container, and storage temperature

Install floating cover Use nitrogen agitation Correct flexible-container storage conditions Do not store chemicals beyond suggested storage life Color developer has too much Part B Check mix procedure For in-line replenishment systems, check for too-high setting on Part B pump or toolow setting on Part A pump. Also see if Part A replenisher is empty or Part A line is blocked Correct mix procedure Adjust in-line replenishment system
F009_9017EC
14-11
14-12
CHOOSE PROBABLE CAUSE VERIFY CAUSE
Check time with stop watch Adjust first-developer time
Chart K Control-Chart Plots High Activity One or More Density Values Plot Low ELIMINATE CAUSE ELIMINATE SYMPTOM PREVENT RECURRENCE
First developer time too long
First developer temperature high
Check temperature with accurate thermometer
Adjust first-developer temperature
First developer mixed incorrectly
Check mix procedure Check calibration of solution tank Check replenisher pumps Correct mix procedure Adjust pumps
First developer overconcentrated Check specific gravity Check replenisher pumps Color developer overconcentrated
Calibrate mixing and processing tanks Check mix procedure Correct or compensate for evaporation For in-line replenishment systems, check settings of concentrate and water pumps; use humidified nitrogen for gaseous-burst agitation Eliminate common use lines Correct mix procedure Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Take steps to prevent problem in the future
Fast Process One or more plots below tolerance limits All three plots below zero line Transparencies appear too light Check distributor lines including nitrogen lines Check mix procedure First developer contaminated by fixer, reversal bath, or color developer* Check machine operation
Eliminate splashing and foam Clean dirty racks and hangers
Check mix procedure Too little color developer starter
*Note: Level of contaminent needed for out of control plot: 0.1 mL of fixer/litre of first developer 1.0 mL of reversal bath/litre of first developer 50 mL of color developer/litre of first developer
Eliminate common mix equipment Wash out all mix equipment thoroughly before and after use
Use correct mix procedures Calibrate mix tank and solution tank
Contamination of first developer with reversal bath will cause a temporary photographic effect which will disappear in about 8 hours. Fixer does not wash out easily from mix tanks. Color developer replenisher has too much Part A First developer overreplenished
Check mix procedure On in-line replenishment systems, check for too high a setting on Part A pump or too low a setting on Part B pump. Also check to see if Part B replenisher container is empty or if the line is blocked
Adjust to specifications
Color developer overreplenished
Check specific gravity Check replenishment rates, mix procedures, and calibration of replenisher measuring devices For in-line replenishment systems, check settings on concentrate and water pumps
F009_9018EC

Too little first developer starter Check mix procedure and calibration of solution tanks
Correct mix procedure
Chart L Control-Chart Plots High D-min CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Loss of fixer activity NOTE: Transparencies may have overall high density and blue shadows when viewed through the base Check time, temperature, agitation, replenishment, storage, mix procedure, and pumps
Loss of bleach activity
Check aeration, time, temperature, agitation, replenishment rate, specific gravity, and inadequate squeegeeing after color developer and after pre-bleach Adjust to specifications
High D-min NOTE: If accompanied by slow process, solve that problem before proceeding with this chart Loss of pre-bleach activity Check storage, replenishment, rate, time, temperature, agitation, mix procedure, specific gravity, and pumps

Depending on the severity of the situation: a. Wait and tolerate b. Risk a prescription c. Dump partially d. Dump solution Inadequate first-developer agitation Check nitrogen supply and gas distributors
F009_9019EC
14-13
Chart M Summary Visual Appearance
PROCESSING SOLUTION
First developer Reversal bath
GO TO CHART
Chart N
Visual-appearance problem with processing solutions Color developer Chart O
Pre-bleach Bleach Fixer Final rinse
Chart P
PRODUCT PROBLEM
Surface dirt
GO TO CHART
Chart Q
Muddy appearance Grain or mottle
Chart R
Scum Visual-appearance problem with processed film
Chart S
Scratches and abrasion
Chart T
Emulsion marks
Chart U
Density marks Pressure marks Light fog Static marks
Chart V
Dark film
Chart W
Light images
Chart X
Contrast problems
Chart Y
F009_9020EC
14-14
Chart N Visual Appearance First Developer and Reversal Bath
VISUAL PROBLEM VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Excessive agitation
Check burst time on and off Check bubble size Adjust agitation to specifications
Foam Air from pump (evidenced by extremely small bubbles) Tighten connection on vacuum side of pump
Silver accumulation on rollers or gears Filter the first developer
First Developer Hard water Salt from oxidation of first developing agent (gray or white) Oxidation
Precipitates Use soft or distilled water to mix the first developer Check problem areas regularly

Dump, clean tank, and replace first developer Oxidation (brownish color) Always store first developer tank and replenisher solutions with a floating lid Do not overheat or overagitate first developer Do not aerate first developer. Use nitrogen only Dyes leaching out of film This is natural and requires no correction Contaminated water Use uncontaminated water Reversal bath particularly susceptible to biological growth Replace reversal bath regularly Dump reversal bath Clean tank as follows: Flush system with hot water Fill tanks, lines, and replenishment system with 30 to 50 mL/L of householdbleach solution. Let stand for no more than 1 hour. Flush with water and refill. Replace solution
Abnormal Solution Color
Reversal Bath
Biological Growth
F009_9021EC
14-15
14-16
Abnormal color (particularly blue-black color in Part B concentrate) Do not use oxidized Part B solution Oxidation of solution. Look for air leaks in replenishment lines and replenishment container Excessive agitation Check burst rate on and off Check bubble size Adjust agitation to specifications Dump tank solution. Clean tank and replace solution. Foam Air from pump Tighten connections on vacuum side of pump Check problem areas regularly Check N 2 generator Crystals (particularly prevalent in roller-transport machines). Hard black crystals on tank walls and gears where colordeveloper solution has evaporated Rinse crystals off tank walls with hot water
Chart O Visual Appearance Color Developer
Color developer
F009_9022EC
Chart P Visual Appearance Pre-Bleach, Bleach, Fixer, and Final Rinse
PROCESSING SOLUTION VISUAL PROBLEM VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Pre-Bleach
Solution appears cloudy
Product of development Pre-Bleach not replaced on regular basis Replace Pre-Bleach regularly
Replace Pre-Bleach
Overconcentration due to evaporation Check specific gravity
Monitor specific gravity to stay below 1.260
Adjust concentration by adding diluted bleach replenisher. If the problem is severe, you will need to clean tank and replace solution
Bleach temperature
Crystals
Low temperature
Check bleach
Adjust to specifications

Water added directly to bleach tanks Check procedure Add only replenisher solution to a seasoned bleach tank If the problem is severe, you will need to clean tank and replace solution Sulfurization of fixer Check for oxidation source Monitor and correct excessive aeration. Aerate only when processing film. You may have to increase replenishment as much as 50%. Generally, air agitation is not recommended for bleach and fixer solutions in roller-transport processors or helical-path continuous processors with top rollers above the solution level Dump, clean tank, and replace fixer solution Aeration of final rinse Do not aerate final rinse
Check problem areas regularly
Fixer
Crystals Milky appearance of tank solution Black specks Gray precipitate in filter
Final Rinse
Foam
F009_9023EC
14-17
14-18
Check replenisher tank Replace filters in recirculation system Filter mix water Dirt in solutions Check filters Replace filters Use floating covers on tanks and replenisher solutions Check filter Change filter regularly (use 5-25 micron filter in water supply) Dirt in washes Check for biological growth in tank To minimize build-up of dirt and fungus, drain wash tanks when not in use Drain and clean tank To remove fungus or algae, scrub tank with diluted household bleach or algaecide, using a stiff brush. Rinse thoroughly with water. Replace wash water in tanks Check problem areas regularly Dirt in final rinse Final rinse requires regular replacement Check solution Replace final rinse as recommended Drain and clean tank and replace final rinse Dirt and chemical deposits on processor Check rollers, racks, squeegees Clean rollers, racks, and squeegees Establish regular maintenance procedures Dirt in dryer Check air filter and inspect dryer for cleanliness Change air filter and clean dryer area Establish regular maintenance procedures
Chart Q Visual Appearance Film-Surface Dirt
VISUAL PROBLEM
Surface Dirt
F009_9024EC
Chart R Visual Appearance Film Muddy or Grainy
VISUAL PROBLEM
CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Check for adequate bleach regeneration by air agitation Adjust air agitation Aerate bleach Retained silver (muddy appearance) Check for proper time, temperature, agitation in fixer Adjust to specifications
Muddy Appearance Check replenishment rate Check replenisher pumps Adjust replenishment rate Adjust pumps

Dump fixer through CRC. Start with fresh chemicals. Retained silver halide (muddy appearance) Check mix procedures Prepare replenishers according to package directions Dump fixer replenisher (not through CRC) Sulfurized fixer (white grain or mottle) Check fixer for precipitate Generally, air agitation is not recommended for bleach or fixer solutions in roller-transport processors or helical-path continuous processors with top rollers above solution level Dump fixer through CRC. Start with fresh chemicals.
Grain or Mottle
F009_9025EC
14-19
14-20
Final rinse exhausted Check final rinse Replace solution regularly Excess defoamer used, or defoamer added directly to any solution Check all solutions where defoamer has been added Follow package instructions for use of defoamer Replace solution Final rinse too concentrated Check mix procedures Correct mix procedure. Using distilled water to mix final rinse is sometimes helpful Replace final rinse Check problem areas regularly Pre-bleach requires regular replacement Check pre-bleach Replace pre-bleach regularly Replace pre-bleach
Chart S Visual Appearance Film Scum
VISUAL PROBLEM
Scum
F009_9026EC
Chart T Visual Appearance Film Scratches CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Obstruction in machine such as clips, film, or rack parts Check all tanks and dryer Remove obstruction. Use care in handling.
Check agitation
Adjust to proper agitation
Rack-and-tank processor Film tangling Check racklift Adjust lift according to manufacturers specifications

Loading/handling problem Check loading technique Use correct loading technique Clean affected area or replace squeegees Dirt or chemical buildup Check rollers, squeegees, and racks Establish regular maintenance procedures Continuous processor Mechanical problems Check for worn or damaged rollers, squeegees, or racks Replace parts Establish regular maintenance habit Splicing problems Check splicer Fix splicer if necessary
Scratches and Abrasions
F009_9027EC
14-21
14-22
VISUAL PROBLEM
Inadequate agitation in first developer Check nitrogen supply and distributors Adjust to specifications
Chart U Visual Appearance Film Emulsion Marks CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Streaks
Low first-wash rate or inadequate air agitation in first wash Check air supply and distributors Adjust wash flow rate and agitation to specifications
Foam rundown
Check instructions for defoamer
Use defoamer as recommended in first and color developer In rack-and-tank machines, check machine modifications offered by manufacturer to decrease crossover time
Small separation between tanks Check processor Install splash guards
Excessively high solution levels Check processor
Adjust solution Install splash guards
Chemical splashes In rack-and-tank machine, racks being simultaneously lifted and dunked in adjacent tanks Check processor transport system In rack-and-tank machine, successive racks being lifted and transferred with very little separation between them
Eliminate forward splash by loading film with emulsion side toward dryer end of machine, since effect of backsplash is less severe
Check problem areas regulary
Emulsion Marks
Adjust processor transport
Water too hard
Use distilled water for mixing final rinse Increase final rinse concentration or dump and replace Check processor for splashing Adjust processor
Water marks Deformation around perforations Craters (water spots) Water rundown (furrows) In continuous processor, excess moisture on film not removed at dryer entrance
In rack-and-tank machine, excess moisture not being removed when film rack drops into dryer section. Racks may be splashing during drying
Check that squeegees, water extractors, and rotary buffers are functioning properly at entrance to dryer
Adjust squeegees, rotary buffers
F009_9028EC
Skiving

Misalignment of processor film transport or camera Check for mechanical problems in processor transport or camera
Correct alignment problem
Chart V Visual Appearance Film Density Marks
VISUAL PROBLEM VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Film-handling technique (kinks) Check handling technique Handle with care
Pressure Marks
Processor tension Adjust mechanical problem
Check mechanical adjustment
Safelight Faded filter on infared illuminator
Do not use safelights Replace IR filter on illuminator or use bulb of lower wattage Check problem areas regularly

Light leak in splicer, machine, wall, door jamb, etc Check darkroom area for light leaks Eliminate light leak Splicer Machine Film-handling technique If possible, perform all operations in areas with relative humidity between 45 and 65 percent and temperature between o o 65 and 75 F (18 to 24 C). Keep film in original sealed packages and store at recommended temperature until ready to use. Do not handle materials any more than is necessary. Avoid sudden, quick movements of film which could cause friction. Avoid winding or unwinding film too rapidly or too tightly. Keep all equipment in clean condition and good working order. Keep film-loading room and processing room as free from dust as possible.
Light Fog
Static Marks
F009_9029EC
14-23
14-24
VISUAL PROBLEM CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM PREVENT RECURRENCE
Inadequate time or low temperature in first developer Check first developer time and temperature Adjust to specifications: Adjust replenishment rates Correct mixing procedure Adjust replenisher pumps First developer diluted, exhausted, or underreplenished Check specific gravity and replenishment rate Depending on severity, clean tank and replace solution Exposure error by picture-taker Notify customer of possible camera problem Color developer starter added to first developer Check mix procedure Correct mix procedure Dump Clean tank Replace solution Check problem areas regularly Check specific gravity Bleach or fixer (or both) omitted, reversed, diluted, exhausted, or underreplenished Pre-bleach oxidized Check processing procedure Check mix procedure Check replenishment rate Check replenishment pumps Correct processing error Correct mix procedure Adjust replenishment rate Adjust pumps Depending on severity, dump bleach and/or fixer, clean tank, and replace solution Exposure error (sheet film exposed through base) Load camera properly
Chart W Visual Appearance Film Dark Images
Dark overall
Dark Film
Dark overall or random
Dark overall and red (sheet film)
F009_9030EC
Chart X Visual Appearance Film Light Images
VISUAL PROBLEM
CHOOSE PROBABLE CAUSE VERIFY CAUSE ELIMINATE CAUSE ELIMINATE SYMPTOM
PREVENT RECURRENCE
Excess time or high temperature in first developer Check time and temperature of first developer Adjust to specifications
Light overall
Film fogged by light before processing Check for light leaks
Eliminate light leaks Do not use safelights
Add starter if needed
First developer too concentrated, or overreplenished, or starter omitted in preparation of working solution Check replenishment rates Check replenisher pumps
Adjust to specifications Add starter if needed Adjust pumps

First developer contaminated with color developer Check mix procedures Correct mix procedure Dump first developer, clean tank, and replace with fresh solution First developer contaminated with fixer Inconsistencies in time, temperature, agitation, or replenishment of first developer Check machine for mechanical difficulties Correct machine problem
Light Film
Light overall and blue
Variable low density
F009_9031EC
14-25
14-26
Too much first developer starter Process control strip Correct mix procedure If not in control, dump First developer time too long Check time of first developer Adjust to specifications Color developer too dilute Check specific gravity Check topping-off procedure Check for mix error Check pumps on in-line dilution system Adjust to specifications Correct topping-off procedure Correct mix procedure Adjust in-line dilution system Add concentrate and starter Check problem areas regularly Color developer too concentrated Adjust to specifications Correct topping-off procedure Correct mix procedure Adjust in-line dilution system Add floating lids to processor tank when not in operation Add water First developer time too short Check time of first developer Too little first developer starter Check mix procedure Correct mix procedure If you can determine the amount of starter left out of fresh tank, add that amount to tank
Chart Y Visual Appearance Film High or Low Contrast
VISUAL PROBLEM
High Contrast: Sharp density gradations between highlights and shadows
Contrast Problems
Low Contrast: Soft density gradations between highlights and shadows
F009_9032EC
15
CONTROL-CHART EXAMPLES
Using the Control-Chart Examples

The color charts in this section are examples of the effects of process variations on the control plots. Use these charts with the information in section 1, Processing Solutions and Their Effects, and section 14, Diagnostic Charts, to analyze your process problems. To locate the pattern that most nearly matches your plot, look at the tabs. The patterns on the tabs correspond to the color or speed plots. Although these control plots are typical, they may not match your plot exactly for a particular condition. Match the predominant trend in your plot with the examples.
Chart 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Process Step First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Developer First Wash Reversal Bath Reversal Bath Color Developer Color Developer Color Developer Color Developer Color Developer Color Developer Color Developer Color Developer Ratio Color Developer Ratio Condition Temperature Concentration Starter Contaminated with Reversal Bath Contaminated with Fixer Contaminated with Color Developer Starter Contaminated with Color Developer Agitation Overreplenishment Underreplenishment Iodide Concentration Bromide Concentration Temperature Mix Ratio Reversal Agent Concentration pH Concentration Starter Contaminated with Fixer With First Developer Starter Contaminated with First Developer Agitation Too Much Part A Too Much Part B 35 36 Chart 25 26 27 28 29 30 31 32 33 34 Process Step Color Developer Color Developer Color Developer Color Developer Prebleach Prebleach Bleach Time Bleach Fixer First and Color Developers First and Color Developers Color Developer Condition Overreplenished Underreplenished Oxidized Sulfite Concentration Dilution Concentration Short Aeration Time Short Overreplenished by 50% Underreplenished by 50% With Stagnant Tank
15-1
FIRST DEVELOPERTEMPERATURE
Chart 1
KODAK PROFESSIONAL EKTACHROME E100G KODAK PROFESSIONAL EKTACHROME 64
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 36.5 o C (97.7 o F) 38.0 o C (100.4 o F) 39.5 o C (103.1 o F) 36.5 o C (97.7 o F) 38.0 o C (100.4 o F) 39.5 o C (103.1 o F)
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05
F009_0594EC
15-2
FIRST DEVELOPERCONCENTRATION
Chart 2
KODAK PROFESSIONAL EKTACHROME E100G KODAK PROFESSIONAL EKTACHROME 64
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -20% (conc.) Normal +20% (dilute) -20% (conc.) Normal +20% (dilute)
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05
F009_0595EC
15-3
FIRST DEVELOPERSTARTER
Chart 3
KODAK PROFESSIONAL EKTACHROME Film E100G KODAK PROFESSIONAL EKTACHROME 64 Film
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -3 ml/L
F009_0596EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Normal +3 ml/L -3 ml/L Normal +3 ml/L
15-4
FIRST DEVELOPERCONTAMINATED WITH REVERSAL BATH

Chart 4
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 Normal
F009_0597EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +0.1 ml/L +0.5 +1.0 Normal +0.1 ml/L +0.5 +1.0
15-5
FIRST DEVELOPERCONTAMINATED WITH FIXER

Chart 5
F009_0598EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +0.1 ml/L +0.5 +1.0 Normal +0.1 ml/L +0.5 +1.0
15-6
FIRST DEVELOPERCONTAMINATED WITH COLOR DEVELOPER STARTER

Chart 6
F009_0599EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +1 ml/L +3 +5 Normal +1 ml/L +3 +5
15-7
FIRST DEVELOPERCONTAMINATED WITH COLOR DEVELOPER

Chart 7
F009_0600EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +1 ml/L +10 +50 Normal +1 ml/L +10 +50
15-8
FIRST DEVELOPERAGITATION
Chart 8
F009_0601EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 1/9 2/18 None Seconds On/Seconds Off Normal 1/9 2/18 None Seconds On/Seconds Off
15-9
FIRST DEVELOPEROVERREPLENISHMENT BY 2X OR (400 mL/sq ft)

Chart 9
F009_0602EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 1/2 1 Tank Turnover 2 Normal 1/2 1 Tank Turnover 2
15-10
FIRST DEVELOPERUNDERREPLENISHMENT (100 mL/sq ft)

Chart 10
F009_0603EC
15-11
FIRST DEVELOPERIODIDE CONCENTRATION

Chart 11
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -3 mg/L
F009_0604EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Normal +3 mg/L -3 mg/L Normal +3 mg/L
15-12
FIRST DEVELOPERBROMIDE CONCENTRATION

Chart 12
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -0.6 g/L
F009_0605EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Normal +0.6 g/L -0.6 g/L Normal +0.6 g/L
15-13
FIRST WASHTEMPERATURE
Chart 13
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 32.2 o C (90 o F) 38.0 o C (100.4 o F) 43.3 o C (110 o F) 32.2 o C (90 o F) 38.0 o C (100.4 o F) 43.3 o C (110 o F)
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05
F009_0606EC
15-14
REVERSAL BATHMIX RATIO

Chart 14
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 1:4 (conc.) 1:9 Normal 1:99 (dilute) 1:4 (conc.) 1:9 Normal 1:99 (dilute)
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05
F009_0607EC
15-15
REVERSAL BATHREVERSAL AGENT CONCENTRATION

Chart 15
F009_0608EC
15-16
COLOR DEVELOPERpH
Chart 16
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 11.70
F009_0609EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Normal Color Developer pH 12.10 11.70 Normal Color Developer pH 12.10
15-17
COLOR DEVELOPERCONCENTRATION
Chart 17
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -20% Water (conc.) Normal +20% Water (dilute) -20% Water (conc.) Normal +20% Water (dilute)
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05
F009_0610EC
15-18
COLOR DEVELOPERSTARTER
Chart 18
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 -5 ml/L
F009_0611EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Normal +5 ml/L -5ml/L Normal +5ml/L
15-19
COLOR DEVELOPERCONTAMINATED WITH FIXER

Chart 19
F009_0612EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +1.0 ml/L +5.0 +10.0 Normal +1.0 ml/L +5.0 +10.0
15-20
COLOR DEVELOPERWITH FIRST DEVELOPER STARTER

Chart 20
F009_0613EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 5 ml/L Normal 5 ml/L
15-21
COLOR DEVELOPERCONTAMINATED WITH FIRST DEVELOPER

Chart 21
F009_0614EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +1 ml/L +5 +10 Normal +1 ml/L +5 +10
15-22
COLOR DEVELOPERAGITATION
Chart 22
F009_0615EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 1/9 2/18 None Seconds On / Seconds Off Normal 1/9 2/18 None Seconds On / Seconds Off
15-23
COLOR DEVELOPER RATIOTOO MUCH PART A

Chart 23
F009_0616EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +10 ml/L +20 +30 Normal +10 ml/L +20 +30
15-24
COLOR DEVELOPER RATIOTOO MUCH PART B

Chart 24
F009_0617EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +10 ml/L +20 +30 Normal +10 ml/L +20 +30
15-25
COLOR DEVELOPEROVERREPLENISHED BY 2X OR (400 mL/sq ft)

Chart 25
F009_0618EC
15-26
COLOR DEVELOPERUNDERREPLENISHED (100 mL/sq ft)

Chart 26
F009_0619EC
15-27
COLOR DEVELOPEROXIDIZED
Chart 27
F009_0620EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Time Normal Time
15-28
COLOR DEVELOPERSULFITE CONCENTRATION

Chart 28
F009_0621EC
15-29
PREBLEACHDILUTION
Chart 29
F009_0622EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Water Normal Water
15-30
PREBLEACHCONCENTRATION
Chart 30
F009_0623EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 +100 ml/L Normal +100 ml/L +200 ml/L Prebleach concentrate added to working prebleach tank solution +200 ml/L
15-31
BLEACH TIMESHORT
Chart 31
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 6:00
F009_0624EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 3:00 Minutes 2:45 6:00 3:00 Minutes 2:45
15-32
BLEACHAERATION
Chart 32
F009_0625EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Decreasing Aeration Normal Decreasing Aeration
15-33
FIXER TIMESHORT
Chart 33
.25 .20 .15 .10 D-max .05 + _0 .05 .10 .15 .20 .25 .25 .20 .15 .10 HD .05 + _0 .05 .10 .15 .20 .25 .15 .10 LD .05 + _0 .05 .10 .15 .10 TD .05 + _0 .05 .10 .10 D-min .05 + _0 .05 240
F009_0626EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 60 45 Seconds 30 240 60 45 Seconds 30
15-34
FIRST AND COLOR DEVELOPERS OVERREPLENISHED BY 2X (400 mL/sq ft)

Chart 34
F009_0627EC
15-35
FIRST AND COLOR DEVELOPERSUNDERREPLENISHED BY 50%(100 mL/sq ft)

Chart 35
F009_0628EC
15-36
COLOR DEVELOPERWITH STAGNANT TANK

Chart 36
F009_0629EC
.25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .25 .20 .15 .10 .05 + 0_ .05 .10 .15 .20 .25 .15 .10 .05 + 0_ .05 .10 .15 .10 .05 + 0_ .05 .10 .10 .05 + 0_ .05 Stagnant Normal Stagnant
15-37
15-38

Kodak E6 Manuals Z99+Z119

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Introduction to Color Process Monitoring

KODAK Publication No. Z-99

Eastman Kodak Company, 2001

Introduction to Color Process Monitoring

Introduction to Color Process Monitoring

WHY SHOULD YOU MONITOR YOUR PROCESS?

Introduction to Color Process Monitoring

HOW DOES A COLOR PROCESS WORK?

Introduction to Color Process Monitoring

WHAT IS A WELL-CONTROLLED PROCESS?

Introduction to Color Process Monitoring

What Are the Attributes of a Good-Quality Finished Photograph?

Introduction to Color Process Monitoring

What Are Aim Values, Control Limits, and Action Limits?

0.42 0.60 0.76

.05 + 0 .05 .10 .15

0.17 0.48 0.61

Introduction to Color Process Monitoring

WHAT CAUSES PROCESS CHANGES?

Solution Storage and Keeping

Introduction to Color Process Monitoring

Preventing Solution Contamination

1 Reduce the chance of chemical contamination by using four

If you have two tanks:

If you have three tanks:

If you have four tanks:

Introduction to Color Process Monitoring

Introduction to Color Process Monitoring

WHAT EQUIPMENT AND MATERIALS WILL YOU NEED?

Introduction to Color Process Monitoring

Z-129 / 123 5753

Z-130 / 160 5716

Z-131 / 155 9418

* The most up-to-date versions are available online.

KODAK Process Record Form, Y-55

Introduction to Color Process Monitoring

Control Strips and Reference Strip

Yellow Patch D-max

KODAK Control Strips Process RA-4

Introduction to Color Process Monitoring

Introduction to Color Process Monitoring

HOW DO YOU MONITOR A PROCESS?

Establishing an Aim for Your Process

Introduction to Color Process Monitoring

Preparing a Control Chart

CONTROL NUMBER AIM VALUES

.05 + 0 .05 .10 .15 .20 .25

.15 .10 .05 + 0 .05 .10 .15 .20 .25

.10 .05 + 0 .05 .10 .15

0.08 0.09 0.10

Introduction to Color Process Monitoring

Comparing Your Process to the Aim Values

Interpreting Control Charts

Introduction to Color Process Monitoring

Changing to a New Batch of Control Strips

Introduction to Color Process Monitoring

WHAT CAN YOU DO TO CORRECT PROCESS PROBLEMS?

Sudden Change in Density

Introduction to Color Process Monitoring

Trend of Increasing or Decreasing Density

Trend of Increasing Spread Between Densities

Introduction to Color Process Monitoring

WHAT OTHER CONTROL METHODS ARE HELPFUL?