(Part 4) RTPC 102 Fsa

PART
FILM-SCREEN IMAGE ACQUISITION,

PROCESSING AND
IMAGE ANALYSISS (RTPC 102)
J. N. ESLAVA, PhD
Professor, Dean
Automatic Processing
Manual vs Automatic Film Processing
Time
PROCESS MANUAL AUTOMATIC

(min) (sec)
development 3–5 22
stop bath or 10-20s -
rinse
fixing 10 22
wash 15 22
drying 20 24
Manual vs Automatic Film Processing …….
Convenience
MANUAL AUTOMATIC
unloading the film
loading the film onto unloading the film
a hanger
development inserting into
stop bath or rinsing processor
fixing
washing reloading the cassette
immersion in a
wetting agent
drying
reloading the cassette
Economics
- autoprocessor eliminates all hangers
- low water consumption

manual  12-15 l/m (flowing
water)
automatic  1.5 l/m
- reduce film wastage

 standardized
processing
- space saving
- more films processed

manual  5sq m/hr
automatic  15sq m/hr
Advantage
- time in developer, fixer, wash & dryer is
constant
⇒ controlled drive
- temperature of solution is unaffected by
outside conditions
⇒ at normal conditions
- quality & quantity of the solutions are
maintained
⇒ automatic
replenishment
- constant agitation
⇒ continuous movement
of rollers
- constant dryer temperature
- short processing time
Parts of a Typical Automatic Processor
 film entry system
 transport system
 chemical & re-circulation

system
 replenishment system
 water system
 dryer system
 electrical system
Introduced by Pako in
1942. Film hangers are
dunked from tank to tank.
First roller transport system introduced

by Eastman Kodak in 1956.
10ft long, weight 750kg
The first processor w/ the
capability of producing a
finished radiograph in
90sec (“rapid processing”)
introduced in 1965.
Cross-section of an automatic processor showing
the
vertical transport system of rollers.
Principal Component of an Automatic Processor
SYSTEM SUBSYSTEM PURPOSE
Transport Transport film through various
stages at precise intervals
Roller Support film movement
Transport rack Move & change direction of film via

rollers & guide shoes
Drive Provide power to turn rollers at a

precise rate
Temperature Monitor & adjust temperature of
each stage
Circulation Agitate fluids
Developer Continuously mix, filter
Fixer Continuously mix
Wash Single pass water flowing at constant
rate
Replenishment Developer Meter & replace
Fixer Meter & replace

Dryer Remove moisture, vent exhaust
Electrical Distribute fused power to above systems
FILM ENTRY SYSTEM
Feed tray
- flat metal surface w/ an edge on either side that
permits the film to enter the
processor easily & correctly aligned
consist of:
- pair of rollers  entrance roller
assembly
 rollers that covered w/
corrugated rubber
w/c assist in straightening out
the path of film so that it moves
through the processor
- microswitch ⇒ above rollers
 infrared light beam w/c is stopped by
entry of the film
- trip wire w/c in turn operates a microswitch
- steady stream of air, w/c is
interrupted by the film’s
entry
FILM ENTRY SYSTEM ……
Infrared Detectors
Entrance roller assembly assists

in straightening out the path of
the film so that it moves through
the processor efficiently.
Feed tray permits the film

to enter the processor easily
& correctly aligned
Subsystems:
 feed system is usually interrelated to:
- replenishment system
- some warning system
- the action of inserting the film activates a relay w/c

switches on the replenisher pumps
 pumps are only working when film is going
through the film entry
system
- warning system is used to tell when the next film is

to be inserted
TRANSPORT SYSTEM
Consists of 3 principal subsystem:
- rollers
- transport rack
- drive motor
TRANSPORT SYSTEM
TRANSPORT SYSTEM …….
- rollers can be arranged in either

 deep tanks
 shallow tanks
Deep Tanks
Shallow Tanks
Chemical
replenishment
system
- w/in the racks will be found guide plates (guide shoe)

 used to keep the film w/in the transport path
(180 in turn over & cross over
assemblies
 made of stainless steel or plastic
Types of Rollers
 hard – can be made of stainless steel or more usually
paper wound on a
stainless core & impregnated w/ an
epoxy resin
- care must be taken when cleaning this type
of rollers
- coarse cleaning materials can seriously damage
the surface of the “paper”
rollers causing permanent
damage
 this may cause marks to be
printed on films
 soft – found in crossovers
- used as “squeegees” to squeeze the
excess chemicals off
the films & thereby reduce carry
over of chemicals
- usually made of neoprene-type substance
SUBSYSTEM (Transport System):
- roller subassembly
 transport rollers
- diameter of 1”
- convey the film along its path
- positioned opposite one another in pairs
or are offset from one another
 master roller (or solar roller or turnaround rollers)
- diameter of 3”
- used when the film makes turns
in the processor
 planetary rollers
- positioned around the master
roller
- guide shoes/plates
 slightly curved metal
plates that properly
guide the leading edge of the moving
film through the roller assembly
SUBSYSTEM (Transport System):
A – transport rollers are positioned either parallel or staggered

& move the film through the various stages of
processing
B – turnaround rollers at the bottom of the assembly turn the
film from moving down to moving up
TRANSPORT ROLLERS &
TURNAROUND ROLLERS ARE OFTEN
CALLED DEEP ROLLERS BECAUSE
THEY ARE IMMERSED IN LIQUID IN
THE PROCESSING TANKS.
SUBSYSTEM (Transport System)……
- transport rack subassembly

- removable & provide for convenient
maintenance & efficient cleaning of the processor
- guide shoes/plates
- slightly curved metal plates/lip w/ smooth grooves
that properly guide the leading edge of
the film through the roller
assembly
 master roller
 planetary rollers
 guide shoes
turnaround assembly
 located at the bottom of
guide shoes the transport
rack assembly
When film exits the top of the rack assembly it is guided to

the adjacent rack assembly through a crossover
rack w/c is a smaller rack assembly composed of
rollers & guide shoes
crossover roller – moves the film
from one
tank to another & into the
dryer assembly
- space between crossover rollers is typically tight, w/c
allows the rollers to act like a squeegee on the
film as it passes through the rollers
 this squeegee effect
assists in removing
as much liquid as possible from the
film before the film enters the next
stage of
processing
Crossover rollers are

located between each
transport assembly in
the processor.
Crossover rack w/ ribbed guide shoes to turn

film from one deep to the next
Deep solution tank rack showing pair of

squeegee rollers at film exit point
Drive Subsystem
- an electric motor provides power for the roller
assemblies to transport the film
through the processor
- the one/off switch that provides electrical power to
the processor activates this motor
- chain, pulley or gear assembly transfer power to
the transport rack & drives the rollers
Automatic processor main drive

shaft pointing out worm gears
used to turn all the racks of rollers
to transport the film.
Drive motor & chain for

automatic processor
transport system
The three means of transferring these devices connect the

power to the transport rack mechanical energy of the drive
A – belt & pulley motor to the drive motor
B – chain & sprocket mechanism of the rack assembly
C - gears
Film transport should not vary by

more than ±2% of the time
specified by the manufacturer.
speed of the transport system is

controlled by
both the speed of the motor &
the gear
reduction system used
CHEMICAL SYSTEM (temperature-
controlled system)
- temperature of solution is approximately 120 –

130F
- comprises the tanks for developer & fixer & the

allied subsystems
- tanks made of some inert material such a

stainless steel or plastic
CIRCULATION SYSTEM
- continuously pumps the developer & fixer
maintaining constant agitation in each tank
Circulation of Developer
thermostat – senses the temperature of the solution
- once the
operating temperature is set,
the temperature will automatically
switch the
developer heater off & on
at the appropriate temperature
 heat exchanger – part of the water system

- developer &
water circulate through
this device
circulation pump – forces circulation of the developer

Circulation of Developer ……
- heater – developer is passed over this small, relatively

low consumption in-line
heater
- linked to the thermostat
- filter – helps to keep the developer cleaner

- could be a simple stainless steel or plastic
mesh
- traps particles as small as approx. 100m
to trap flecks of gelatin that are
dislodged from the emulsion
Developer System
The developer recirculation filter removes impurities as the

developer solution is being recirculated.
Thermostat controlled heat coil

surrounding developer line.
Circulation pumps for developer &
fixer lines.
Filter placed in
developer line
Fixer Circulation System
- constructed almost exactly the same way as the developer
Fixer System
“cold water” processor – in-line heater & thermostat
“tempered” water processor – uses both hot & cold

water
Top view of the inside of processor
tanks. The immersion heater coil
at the bottom of the developer &
fixer tank heats & maintains the
developer temperature.
Developer temperature display

Temperature Control:
Developer - 90 to 100F (32.2 to 37.8C)
- tolerance of ±0.5F (±0.3C)
Fixer -85F & 95F ( 29.4 – 35C)

REPLENISHMENT SYSTEM
replenishment – replacement of fresh chemicals after the loss of
chemicals during
processing, specifically
developer & fixer solution
necessary in automatic processor because these

chemicals eventually become exhausted through
both aerial oxidation & use
oxidation
 aerial oxidation – reduction of chemical strength

as a
result of exposure to air
 use oxidation – reduction in chemical strength as

a result of
exposure to increased temperature over
extended period
REPLENISHMENT SYSTEM ……
The replenishment system

provides fresh chemicals to the
developing & fixing solutions to
maintain their chemical activity &
volume when they become
depleted during processing.
- preserves both the quality & quantity of the chemical

in the processor
- the basic system consists of:
replenishment tanks
 inert material such as stainless steel or
plastic
 developer tank – has floating lid on
top of
developer replenisher to
reduce
auto-oxidation
& prevent access of dirt

- usually w/ cover
 fixer tank
A floating lid should always

be used on top of the
developer replenisher to
reduce evaporation &
chemical oxidation.
 filters – found in the line from the tanks to the processor
 replenisher pumps – operated from the microswitch in the

film
entry system
- have an individual
adjustment of the
developer & fixer replenishment rates
- there should be no
flow back into the
replenisher tanks from the main
processor
can be
prevented in two (2)
ways:
- creating a break in the line

so that the
replenisher is
fed over the top of the
shallow processors – simple “chicken feed” system can be

used
 consists of a bottle containing the
replenisher, inverted over the
processing solution
 when level of the
solution drops, the
solution from the bottle automatically
refills the solution back to the preset
level
 replenishment stops
DRAIN
- DEVELOPER – as solution is added
 expelled through
the floor drain or
collection system
 drained by drain valve
-
tank is cleaned
- FIXER – as solution is added

 expelled through the floor drain or
collecting system
(SILVER RECOVERY)
drained by drain valve
- tank is cleaned
REPLENISHMENT RATE
- developer
 50-100cc (14”x17”)
or approx. 60-70ml
- fixer
 90-150cc (14”17”)
or approx. 100-110ml
WATER SYSTEM
 consists of : cold & hot water supply

 filters
- mixing valve
 flow gauge
 temperature gauge
- heat exchanger (developer)
- heat exchanger (fixer)
 temperature – upper limit of 5-10F (2.8-

5.6C) below
developer temperature
is desirable
- typical limit for incoming water is
40F
(4.4C)
 water is replaced by fresh incoming water, excess is
expelled through the overflow
Wash System…..
DRYER SYSTEM …….
- self-contained unit, & is comprised of:

- roller transport system
- blower
- heater
- thermostat
- filter
- “air knives” – increase velocity of air
- temperature control  100 & 160F (37.8 & 71.2C)

Processor dryer system ……..
Drying System ……
Radiographic film should be aligned so that the film is
horizontally placed on the feed tray & its leading edge is long
Short side of film against
the rail of the feed tray.
ALTERNATIVE PROCESSING METHODS:
 rapid processing
 extended processing – used in mammography
 daylight processing
 dry processing – w/o the use of wet chemistry
ALTERNATIVE PROCESSING METHODS ……
photothermography (PTG)- low-powered modulated laser

beam to record the
image signal on film
- latent image formed on a
sensitized Ag
halide is developed by a thermal process
at 125C that take place about
15secs
 this is called dwell time

ALTERNATIVE PROCESSING METHODS ……
thermography (TG) – uses modulated heat source , referred

to as a “print head”,
that heats the film &
produces the image directly
- a test that uses an
infrared camera to
detect heat patterns and blood flow in
body tissues
- digital infrared thermal
imaging (DITI) is the
type of thermography that's used to
diagnose breast cancer
Diagnosis
of chronic
sinusitis
SILVER RECOVERY FROM PROCESSING
CHEMICALS:
- metallic replacement
- electrolytic silver recovery
- chemical precipitation
- ion exchange or resin system

SILVER RECOVERY FROM PROCESSING CHEMICALS ……
- in any film processing system, the principal purpose

of fixer is to remove unexposed silver from the
film emulsion
- silver recovery is the process by which pure
metallic silver can be recycled from old x-ray
films
- the modern process is extremely efficient with a
recovery of greater than 99.9% silver
 Metallic Replacement
- replaces silver in fixer w/ another metal
- glass jar containing steel wool
- silver fuses to the iron in steel wool
 Electrolyte Recovery
- 2 plates that pass a low electric current
- negatively charged silver ions attracted to the
plates
- fixer solution can be reused
 Chemical Precipitation
- addition of more chemicals to precipitate
silver from fixer
- silver forms a sludge
- sludge filtered, dried & packed
 Ion Exchange
- there are two ion-exchange methods that have
been used in to recover silver from dilute
solutions
 insitu precipitation ion
exchange
 and conventional ion
exchange
with both methods, the silver is

removed by pumping it
through a column of anion-
exchange resin
End of
Part IV

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PART

FILM-SCREEN IMAGE ACQUISITION,

PROCESS MANUAL AUTOMATIC

- low water consumption

- reduce film wastage

- more films processed

 film entry system

 chemical & re-circulation

First roller transport system introduced

Roller Support film movement

Transport rack Move & change direction of film via

Drive Provide power to turn rollers at a

Developer Continuously mix, filter

Fixer Continuously mix

Wash Single pass water flowing at constant

Fixer Meter & replace

Entrance roller assembly assists

Feed tray permits the film

- the action of inserting the film activates a relay w/c

- warning system is used to tell when the next film is

- rollers can be arranged in either

- w/in the racks will be found guide plates (guide shoe)

A – transport rollers are positioned either parallel or staggered

- transport rack subassembly

When film exits the top of the rack assembly it is guided to

Crossover rollers are

Crossover rack w/ ribbed guide shoes to turn

Deep solution tank rack showing pair of

Automatic processor main drive

Drive motor & chain for

The three means of transferring these devices connect the

Film transport should not vary by

speed of the transport system is

- temperature of solution is approximately 120 –

- comprises the tanks for developer & fixer & the

- tanks made of some inert material such a

 heat exchanger – part of the water system

circulation pump – forces circulation of the developer

- heater – developer is passed over this small, relatively

- filter – helps to keep the developer cleaner

The developer recirculation filter removes impurities as the

Thermostat controlled heat coil

- constructed almost exactly the same way as the developer

“tempered” water processor – uses both hot & cold

Developer temperature display

Fixer -85F & 95F ( 29.4 – 35C)

necessary in automatic processor because these

 aerial oxidation – reduction of chemical strength

 use oxidation – reduction in chemical strength as

The replenishment system

- preserves both the quality & quantity of the chemical

& prevent access of dirt

A floating lid should always

 filters – found in the line from the tanks to the processor

 replenisher pumps – operated from the microswitch in the

- creating a break in the line

shallow processors – simple “chicken feed” system can be