ra4manual_v3.pdf

CONTENTSA. INTRODUCTION........................................................................................................................................... 1 1. FUJI HUNT OASIS Pro........................................................................................................................... 1 2. FUJI HUNT PROCESS RA4 TRAINING COURSES.............................................................................. 2 B. GENERAL PROCESS INFORMATION........................................................................................................ 3 1. CHEMISTRY SELECTION...................................................................................................................... 3 2. FEATURES AND EFFECTS OF ENVIROCHEM AND CPRA CHEMICALS ......................................... 3 3. STANDARD RA4 PROCESSING STEPS ............................................................................................ 12 4. ALTERNATIVE RA4 PROCESSING STEPS........................................................................................ 13 5. FUJICOLOR CP-4x PROCESS VARIANTS......................................................................................... 14 5.1. Water Wash System...................................................................................................................... 14 6. PROCESSING CONDITIONS .............................................................................................................. 15 6.1. Minilab Processors ........................................................................................................................ 15 6.2. Leader Belt and Leader-free (Agfa VSP type) Processors............................................................ 17 6.3. Roller Transport Processors.......................................................................................................... 20 6.4. Trays, Drums and Rotary Discard Processors .............................................................................. 24 C. HANDLING OF CHEMICALS AND SOLUTION PREPARATION........................................................... 29 1. CHEMICAL HANDLING / CPRA & EnviroPrint CHEMICALS............................................................... 29 1.1. Process Chemical Composition..................................................................................................... 29 1.2. Chemical Storage.......................................................................................................................... 30 1.3. Chemical Handling Precautions..................................................................................................... 30 1.4. General Handling Precautions....................................................................................................... 30 1.5. Safe Handling Steps...................................................................................................................... 30 1.6. Protective Equipment..................................................................................................................... 31 1.7. Ventilation...................................................................................................................................... 31 1.8. First Aid.......................................................................................................................................... 31 1.9. Contact Dermatitis ......................................................................................................................... 32 2. PROCESS SOLUTION PREPARATION.............................................................................................. 33 2.1. Water ............................................................................................................................................. 33 2.2. Mixing tanks................................................................................................................................... 33 2.3. Chemical Mixing Precautions ........................................................................................................ 34 2.4. Chemical Mixing Procedures......................................................................................................... 35 2.5. Process Solution pH and Density (Specific Gravity)...................................................................... 48 3. PROCESS SOLUTION STORAGE ...................................................................................................... 52 3.1. Solution Storage............................................................................................................................ 52 3.2. Waste Water and Solution Treatment ........................................................................................... 52 D. PROCESS QUALITY CONTROL ............................................................................................................... 53 1. PROCESS QUALITY CONTROL OBJECTIVES AND EFFECTS........................................................ 53 2. PROCESS MONITORING.................................................................................................................... 53 2.1. Process Control Strips................................................................................................................... 53 2.2. Processing Solution Checks.......................................................................................................... 54 2.3. Solution Conditions........................................................................................................................ 54 2.4. Density (Specific Gravity) Adjustments ......................................................................................... 59 2.5. Wash Water Checks...................................................................................................................... 60 2.6. Other Process Checks................................................................................................................... 60 2.7. Processor Inspection..................................................................................................................... 61 Fuji Hunt RA4 Chemicals, 3 rd Edition J une 2004 3. MONITORING PROCESS QUALITY.................................................................................................... 65 3.1. Processing Quality......................................................................................................................... 65 3.2. Physical Factors............................................................................................................................. 65 3.3. Process Control Fundamentals ..................................................................................................... 67 4. APPENDIX 1......................................................................................................................................... 69 4.1. RA4 PROCESS CHECK SHEETS AND PROCESSING SOLUTION CONTROL CHART ................. 69 5. APPENDIX 2......................................................................................................................................... 76 5.1. PROCESS RA4 / SUPER FA MONITORING WITH FUJ ICOLOR CONTROL STRIPS............... 76 6. APPENDIX 3......................................................................................................................................... 84 6.1. RA4 PROCESSING DURING LOW UTILIZATION PERIODS...................................................... 84 7. APPENDIX 4......................................................................................................................................... 89 7.1. pH ADJ USTMENTS/SOLUTION PREPARATION PROCEDURES.............................................. 89 7.2. WARNING...................................................................................................................................... 89 8. APPENDIX 5......................................................................................................................................... 90 8.1. REPLENISHER FUNCTIONS AND FACTORS AFFECTING TANK SOLUTION COMPOSITION ........... 90 9. APPENDIX 6......................................................................................................................................... 93 9.1. DENSITY AND SPECIFIC GRAVITY MEASUREMENT PRECAUTIONS.................................... 93 10. APPENDIX 7 ..................................................................................................................................... 96 10.1. DEVELOPER RECYCLING.......................................................................................................96 10.2. Mixing Instructions...................................................................................................................... 97 11. APPENDIX 8 ..................................................................................................................................... 99 11.1. BLEACH-FIX RECYCLING........................................................................................................ 99 12. APPENDIX 9 ................................................................................................................................... 104 12.1. EnviroPrint BIO-BLEACH RECYCLING (Process RA404)...................................................... 104 13. APPENDIX 10 ................................................................................................................................. 105 13.1. FIXER RECYCLING................................................................................................................. 105 14. APPENDIX 11 ................................................................................................................................. 118 14.1. RA4 CHEMICALS FOR FAST PROCESSING........................................................................ 118 E. PROCESSING PROBLEMS AND CORRECTIVE MEASURES.............................................................. 123 1. Problem Handling Procedures ............................................................................................................ 123 1.1. Causes of Processing Quality Deterioration................................................................................ 123 1.2. Sensitometric Problems............................................................................................................... 123 1.3. Physical Problems ....................................................................................................................... 124 2. Processing Conditions Variations and Photographic Property Changes............................................ 124 F. PROCESS CONTROL CHARTS .............................................................................................................. 125 1. Chart 1 : Standard Developer Density Variations ............................................................................. 125 1.1. Tank solutions.............................................................................................................................. 125 1.2. Evaporation.................................................................................................................................. 125 2. Chart 2 : Standard Developer Temperature Variations .................................................................... 127 2.1. Using developer temperature to correct problems ...................................................................... 127 3. Chart 3 : Standard Developer Time Variations ................................................................................. 129 4. Chart 4 : Standard Developer Starter Addition Variations ................................................................ 131 4.1. Starter additions for correcting the process................................................................................. 131 4.2. Fresh tank solutions..................................................................................................................... 131 4.3. Seasoned tank solutions.............................................................................................................. 131 Fuji Hunt RA4 Chemicals, 3 rd Edition J une 2004 5. Chart 5 : Standard Developer Replenishment Rate Variations (2 TTO)........................................... 133 5.1. Replenishment rate changes....................................................................................................... 133 5.2. Avoiding future problems............................................................................................................. 133 6. Chart 6 : Standard Developer Contaminated with Bleach-Fix .......................................................... 135 6.1. Corrective Action.......................................................................................................................... 135 7. Chart 7 : Standard Developer pH Variations .................................................................................... 137 7.1. Corrective Action.......................................................................................................................... 137 8. Chart 8 : Standard Developer Mix Error – Part A ............................................................................. 139 8.1. Corrective Action.......................................................................................................................... 139 9. Chart 9 : Standard Developer Mix Error – Part B ............................................................................. 141 9.1. Corrective Action.......................................................................................................................... 141 10. Chart 10 : Regenerated Developer pH Variations......................................................................... 143 10.1. Corrective Action...................................................................................................................... 143 11. Chart 11 : Regenerated Developer Mix Error – Part B.................................................................. 145 11.1. Corrective Action...................................................................................................................... 145 12. Chart 12 : LR Developer Density Variations ................................................................................. 147 13. Chart 13 : LR Developer Temperature.......................................................................................... 148 14. Chart 14 : LR Developer Time....................................................................................................... 149 15. Chart 15 : LR Developer Starter Additions.................................................................................... 150 16. Chart 16 : LR Developer Replenishment Rate.............................................................................. 151 17. Chart 17 : LR Developer Contaminated with Bleach-Fix............................................................... 152 18. Chart 18 : Bleach-Fix Contaminated With Developer ................................................................... 153 18.1. Corrective Action...................................................................................................................... 153 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 1 A. I NTRODUCTI ON This manual provides essential technical information relevant to processing FUJ ICOLOR and other RA4 compatible papers in FUJ I HUNT Envirochem and CPRA chemicals. The principles provided may also be used as a general reference guide for all other compatible RA4 chemicals, including Fuji CP40/43/47/48 chemistry. The technical information and standardised procedures are designed to provide trouble-free processing and consistent quality. The Main Topics of this Manual are : 1. General Process Information 2. Solution Preparation Procedures and Handling Precautions 3. Process Control and Quality Control 4. Process Troubleshooting All essential Process RA4 information is contained within this publication. It is highly recommended that not only equipment operators, but all RA4 lab personnel, acquire a complete knowledge of this information. Fully informed technical personnel will add to the overall quality output of any facility processing FUJ ICOLOR and other RA4 compatible papers. Three new monopart developers have been added to our product range since the last publication of this manual in May 2003 – EnviroPrint Developer Replenisher MP160 (which largely replaces the old EnviroPrint Developer Replenisher); CPRA 330 Developer Replenisher MP, replacing the previous CPRA 330 Developer Replenisher, and EnviroPrint CP48 Developer, for use at large Finisher laboratories only as a replacement for the Fuji Frontier cartridge systems. EnviroPrint CP48 Bleach- Fix Replenisher has also been added as the partner for the EnviroPrint CP48 Developer. 1. FUJI HUNT OASIS Pro Fuji Hunt have produced a market-leading process control program called OASIS Pro that is designed to make the whole job of monitoring and controlling your RA4 (or other) process a lot easier. This program is available in four variants to suit all types of laboratory. OASIS Pro Lite is a simple program allowing reading and plotting of process control strips and includes diagnostics for all main process strip types and makes. Short cut options make this program extremely easy to use, and it is ideal for the smaller laboratory. OASIS Pro Compact retains the ease-of-use of the Lite program, but adds additional features for processor comparisons (or comparisons between different strip types), chemical checks, printer control and other functions commonly required in professional laboratories. OASIS Pro is a full-featured program including many additional data comparison and process control functions, and also allows you to monitor and control remote sites equipped with OASIS Pro Lite or Compact from one central location. This program is ideal for the central site of a laboratory group, or for larger professional and finisher laboratories. OASIS Pro Monitor is available for those companies running a monitoring service for other laboratories. All OASIS Pro programs allow the storage of virtually unlimited amounts of data (1200+processors, no limits on the amount of data kept for each processor) without affecting the speed of the program, and Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 2 data can be sent from any OASIS program to a site equipped with OASIS Pro or OASIS Pro Monitor for further evaluation and diagnostic control. All OASIS programs support all process control strip types and makes available on the market. OASIS Pro is available in English, French, German, J apanese, Polish, Portuguese and Spanish languages, and can be used on any computer running Windows 9x, Me, NT4, 2000 or XP. For further information about OASIS Pro, please see the Fuji Hunt web site at www.fujihunt.com, or see your Fuji Hunt representative. 2. FUJI HUNT PROCESS RA4 TRAINING COURSES Fuji Hunt can provide both basic and advanced training in controlling and optimising your Envirochem or CPRA chemistry for all film makes and types. These training courses are the result of extensive research into current RA4 process (Fuji process FA) practice, and cover the response of most paper types currently used in processing laboratories. This covers all current Fujicolor paper types, and also important amateur and professional papers from other manufacturers including Kodak, Agfa, and Konica. The courses cover both photographic fundamentals and the RA4 process itself, and concentrate on troubleshooting and process optimisation. Control strip data from all major paper manufacturers is examined, the visual effects on the actual papers, and interactions caused by processing mixed paper types in the same developer. Students attending one of these courses will gain an insight into the RA4 process never before available, with a great number of common process variables explained not only in theory, but also with the practical effect on all major paper types. You will learn what is visually acceptable, and how this compares with control strip data; when you must stop processing and replace exhausted or contaminated solutions, and emergency short cuts that can be taken when time is critical. A major function of this course is not only to show what happens when various things go wrong, but also to explore the limits of what can be done to recover from the problem - just how bad do things have to be before it becomes impossible to produce a saleable print. Every paper type behaves differently; this course examines the different paper emulsions from all manufacturers. A key feature of these courses is the visual material available both during the training and also for presentation to the student for his future reference on completing the course. RA4 process courses are generally offered in combination with courses for the C41 film process. Please see your Fuji Hunt representative for further details. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 3 B . GENERAL PROCESS I NFORMATI ON This section provides general information on the Envirochem or CPRA chemical lines used for processing all FUJ ICOLOR and other RA4 compatible papers. 1. CHEMISTRY SELECTION Various RA4 process chemistries are available for different stages of the process. It is most important that you select the correct and most suitable chemistry for your processor in order to get the optimum processing characteristics for your paper(s). The selection criteria include : • Processor type (leader belt, roller transport, minilab, rotary discard, etc.) • Throughput (paper area processed, and thus the tank turnover rate) • Equipment available (tanks and systems for recycling, on-board mixing, etc.) • Waste regulations • Staff resources available for chemical control (regeneration / recycling / recovery systems) Often the key factor in chemistry selection is the type of processor; if your processor is a roller transport type, then you will normally use the developer and bleach-fix designed for that processor type. Some processors, for example Fuji Frontier, Kodak SM, and some Agfa MSC minilabs, are designed to work with a specific type of chemistry and possibly also have specific packaging requirements for the chemistry; several such examples are discussed in this manual. 2. FEATURES AND EFFECTS OF ENVIROCHEM AND CPRA CHEMICALS Developers. Envirochem Chemicals have been formulated to produce optimum quality processing of all brands of papers compatible with the RA4 process. They are designed to reduce photochemical pollution to a minimum. EnviroPrint Developers allow approaching zero overflow from process tanks, greatly reducing discharge to drain. They are suitable for use in any processors with a reasonable level of throughput, and offer particular advantages for minilab, leader belt and ciné-type and even LVTT- processors. All Envirochem developers (except MP45 AC, CP48 and CP49) run at 38°C so changing between developers is very easy. Changing the replenishment rate is the only action you need to take. This is a very interesting feature as depending on the season, low or high volume, you can not only save money, but also make your contribution towards a Greener environment. The CPRA range of developers (except CPRA 330 / CPRA 330 MP) runs at 35°C, and they are available to meet a range of specific needs within the photographic market. CPRA Pro developer is specially designed to offset the effects of oxidation and low throughput with roller transport processors, and also can be used in other very low throughput situations. CPRA Digital Pro Developer AC is a unique product designed to enhance the quality obtainable from modern digital printers such as the Durst Lambda and Epsilon, Lightjet, ZBE Chromira etc. AC products are part of the Fuji Hunt Air Control product range, guaranteeing an odour free environment. No chemical masking agents or added scents are used. Many products are currently available in both traditional and AC variants. MP products are Mono Part – single solution products for easy chemical mixing. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 4 Developer – The developer produces a silver image in the paper emulsion layers from the latent image produced when the paper is exposed. At the same time, the developer which is locally oxidised by this reaction combines with couplers incorporated in the emulsion and produces colour dyes. The quantity of dye produced is proportional to the amount of silver image produced. In the developer step the solution time, temperature, pH, concentration, agitation and replenishment rate are critical in maintaining proper colour balance, contrast, uniformity and density in the processed paper. Option 1: EnviroPrint Developer MP160 / EnviroPrint Developer replenish at 160 ml/m². EnviroPrint Developer MP160 and EnviroPrint Developer are general purpose developers which can also be regenerated see section (Developer Regeneration). These developers are very popular straight replenisher products (160 ml/m²) and are being recommended to those customers having low to medium throughput production volumes. A very important benefit of these developers over the conventional CPRA Developer (160 ml/m² also but running at 35°C) is that the customer can easily convert to a lower replenishment rate product by just changing the replenisher and adjusting the replenishment rate. EnviroPrint Developer Replenisher MP160 is gradually replacing the smaller (to make 5L, 10L and 50L) pack sizes of the previous EnviroPrint Developer Replenisher products, which will continue to be manufactured in the larger packs sizes. These two 160 ml/m² products produce identical sensitometric results. Option 2: EnviroPrint Developer MP108 replenishes at 108 ml/m². EnviroPrint Developer MP 108 is a new “medium” rate monopart developer (replacing the previous EnviroPrint MR developer), designed for customers wishing to work at a lower replenishment rate than normal, but who cannot use a true low replenishment developer. Its medium replenishment rate makes it ideal for the lower throughput minilab and conventional laboratories that cannot justify using our EnviroPrint Developer MP60. Option 3: EnviroPrint Developer LR AC replenishes at 73 ml/m². This is a 73 ml/m² replenishment rate product which possesses all the features of the Developer Air Controlled product range. This eliminates the unpleasant smell of the conventional RA4 Developers, guaranteeing a pleasant environment for the customer and much cleaner working. This developer is designed to offer the low replenishment rate of only 73 ml/m² without regeneration. This gives extremely low developer overflow rates from the processor, such that it is even possible to find zero overflow if there is low throughput and high evaporation and high carry-over. It is ideally suited for use in minilabs as well as larger processors. If excessive evaporation occurs there will be a spread of colours on the sensitometric control plots leading to visually poor quality prints. Water must be added to the developer tank to maintain the developer tank solution density specification. Option 4: EnviroPrint Developer MP60 replenishes at 60 ml/m². This developer is a very low replenishment rate, monopart developer for processing any RA4 process compatible paper. It is a homogeneous liquid concentrate that easily mixes with water and is designed to run at a replenishment rate of 60 ml/m² at a temperature of 38°C. EnviroPrint Developer Replenisher MP60 can be replenished on top of any Developer Replenisher belonging to the EnviroPrint product range. EnviroPrint Developer Replenisher MP60 reduces the risk of mixing errors as it consists only one part instead of the conventional 3 parts. It minimises package waste and reduces the storage space to an absolute minimum. Option 5: EnviroPrint Developer MP45 AC replenishes at 45 ml/m². EnviroPrint Developer Replenisher MP45 AC is an extreme low replenishment rate, monopart developer for processing any RA4 process compatible paper. It is part of the Fuji Hunt Air Controlled product range. It is a homogeneous liquid concentrate that easily mixes with water. This developer is designed to run at a replenishment rate of 45 ml/m² and at a Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 5 temperature of 38.5°C. EnviroPrint Developer Replenisher MP45 AC must be used with EnviroPrint Bleach-fix Replenisher 35 AC or EnviroPrint Bleach-fix Replenisher 35 RTU AC. Both are easy mixing 2-part bleach-fixers running at a replenishment rate of 35ml/m² only. The EnviroPrint Bleach-fix Replenisher 35 RTU AC doesn’t need any additional water to prepare replenisher solution. Option 6: EnviroPrint CP48 Developer EnviroPrint CP48 Developer is provided for use in large Finisher laboratories as a replacement for the CP48S cartridge system used in Fuji Frontier 350, 370 and 390. Replenishment and processing conditions are as for Fuji Frontier chemistry; please see your Frontier documentation. Option 7: Fast processing chemicals AC Your Fuji Hunt representative will supply you with all details including the necessary technical documentation. Option 8: CPRA Developer AC replenishes at 160 ml/m² This product is designed to be used in either a wash or washless system with RA4 process compatible paper. This is a standard 35°C developer, suitable for use in a wide range of processors. This product possesses all the features of our developer Air Control product line, eliminating the unpleasant smell of the conventional RA4 Developers, guaranteeing a pleasant environment for the customer and has proven to be much cleaner working under difficult circumstances. Important : When converting from conventional CPRA Developer to the CPRA Developer AC, there is no need to dump your running chemistry as both products are fully compatible; replenishing on top is the correct decision. However, if you make a fresh start up, please use the correct starter and starter volume (Enviroprint Developer Starter AC, see Mixing instructions page 35). Option 9: CPRA Developer replenishes at 160 ml/m² This is a conventional RA4 developer working at 35°C. For more specific details regarding your preferred choice on one of these two CPRA developers, please contact your local Fuji Hunt representative. Option 10: CPRA Pro Developer This is a specially designed formula to offset the effects of oxidation due to under-utilisation of a processor - typically roller transport processors in professional laboratories. In almost all processing situations, the replenishment of the developer with CPRA Pro is sufficient to maintain developer activity, even when very small quantities of paper are processed. The formula has been carefully balanced to allow much higher replenishment rates ensuring the developer solution is changed sufficiently to prevent serious oxidation occurring. Option 11: CPRA Digital Pro Developer AC This "Professional lab" product has been especially designed for use in large format roller transport processors dedicated to Photo Digital Printers such as Durst Lambda, Theta and Epsilon, Océ Lightjet, ZBE Chromira, Polielectronica LaserLab, etc. The product belongs to the Air Controlled range and consists of 2 parts only. It features a high activity, clean working, secured whiteness and allows considerably improved Dmax values on Paper and Display material. This product is also suitable for use with conventional analogue printing. Note that use of this product requires that the bleach-fix (normally CPRA Pro Bleach-Fix) maintains a sulphite level of at least 8 g/L to avoid poor base whites. In low throughput situations, this may require use of Ultra Bleach-Fix Extender in order to replace sulphite lost by oxidation of the bleach-fix. Please consult your Fuji Hunt representative if you require further information. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 6 Option 12: CPRA 330 Developer MP / CPRA 330 Developer CPRA 330 is designed for processing RA4 papers at the standard EP2 developer time of 3 min 30 sec in processors that cannot be converted to the RA4 process. The preferred route for processing RA4 papers however, is with a 45 sec developer time. The older CPRA 330 3-part developer is being replaced with a new easy-to-mix single part product – CPRA 330 Developer MP – on a stock turnover basis. Note that although these two products have different mixing instructions and specifications, the new MP developer can be replenished on top of the old 3-part developer without problems. Option 13: Developer recycling. Two developer recycling options are available from Fuji Hunt. These are based on EnviroPrint Developer, and are discussed in APPENDIX 7, Developer Recycling. Bleach-Fixers – The Bleach-Fix acts as a combined bleach and fix bath. The metallic silver image produced during development, plus all undeveloped silver salts remaining in the paper are removed in this bath as soluble silver salts. Inadequate solution time, excessive developer carryover, incorrect temperature or replenishment, or bleach-fix oxidation (usually due to low throughput) may result in leuco cyan dye, stain and silver retention. Fuji Hunt Bleach-Fix Replenishers are all 2 part products and Air Controlled, except EnviroPrint Bleach-Fix VLR RTU, designed for a special application. These products no longer generate the unpleasant smell of acetic acid. They are now much better buffered against oxidation. Product stability has been greatly improved and, more importantly, better print whites are guaranteed. Option 1: EnviroPrint Bleach-Fix 215 AC is the standard 215 ml/m² replenishment rate product for all types of paper processors. It is equally suited for use in minilabs, roller transport, and many other processors. It is also the recommended product to be installed when Bleach-Fix regeneration (with or without electrolytic desilvering) is being considered. Option 2: EnviroPrint Bleach-Fix 108 AC is a 108 ml/m² replenishment rate product and is the ideal companion for EnviroPrint Developer MP108. Option 3: EnviroPrint Bleach-Fix 70 AC is a 70 ml/m² replenishment rate product suitable for use in any processor with high volume throughput. This gives greatly reduced overflow volumes and lower cost. Its use is not recommended in roller transport processors. The higher level of oxidation in these machines would cause sulphurisation of the fixing agent and staining due to excessive quantities of oxidised developer from the carry over. Option 4: EnviroPrint Bleach-Fix 55 AC is designed as low replenishment, non-regenerable bleach- fix for applications in high and medium volume minilab processors. The recommended replenishment is as low as 55 ml/m² and offers the advantage of greatly reduced overflow volumes and lower cost. Option 5: EnviroPrint Bleach-Fix VR AC allows you to run your process at a replenishment rate of 55 or 70 ml/m² depending on the production period (medium or high peak season) you are working in. Option 6: EnviroPrint Bleach-Fix 35 AC This is a innovative extremely low replenishment rate bleach-fix. EnviroPrint Developer Replenisher MP45 AC must be used in combination with this bleach-fix. To ensure a constant high product stability, the bleach-fix has been designed as a two-part product to be mixed with water to make fresh replenisher. The bleach-fix processing temperature is 38°C. Option 7: EnviroPrint Bleach-Fix 35 RTU AC This product offers the same features as EnviroPrint Bleach-Fix 35 AC. The only difference is in the preparation of fresh replenisher : Part A and Part B mixed together makes fresh replenisher; no additional water is required. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 7 Option 8: EnviroPrint Bleach-Fix VLR RTU is designed to work at 55 ml/m² and combines low replenishment rate with easy preparation, making it perfect for high throughput minilabs. Option 9: EnviroPrint CP48 Bleach-Fix is provided for use in large Finisher laboratories as a replacement for the CP48S cartridge system used in Fuji Frontier 350, 370 and 390. Replenishment and processing conditions are as for Fuji Frontier chemistry; please see your Fuji Frontier documentation. Option 10:CPRA Pro Bleach-Fix AC is specially designed to give optimum performance in all types of roller transport processors. The product is extremely well buffered against aerial oxidation and guarantees you longer product stability and better whites compared to conventional Bleach-Fix products. This is the recommended product for use with CPRA Digital Pro Developer AC. Option 11: RA4 Regenerated Bleach-Fix Replenishers. Three options for Bleach-Fix regeneration are possible; EnviroPrint Electrolytic Bleach-Fix regeneration is a conventional regeneration system for those laboratories who wish to desilver the Bleach-Fix prior to rebuilding; EnviroPrint Bleach-Fix regeneration where the Bleach-Fix overflow is collected and rebuilt by adding concentrates, followed by a final pH adjustment - silver recovery here is by treating excess overflows and low flow washes, and thirdly, EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator, which uses a 100% readily biodegradable complexing agent achieving a drastic reduction of minimum 50% of the hard complexing agent EDTA in the waste stream. Full details on these three regeneration options may be found in Appendix 8 on page 99. Separated Bleach and Fix System – For users of separate bleach and fix systems for RA4 paper processing, one bleach, two replenished fixer systems and three regenerated fixer systems are available. These are discussed in Appendix 9 and 10 for Process RA404, starting on page 104. Stabilizers – The main purpose of Superflo Stabilizers is to remove processing chemicals and unwanted reaction products from the imaging layers, obtaining optimum whites and guaranteeing long term image stability. Achieving this target with far lower wash volumes than conventional water wash, rinsing requires well designed chemical formulations. Using lower wash volumes automatically increases the risk of biological growth, a problem area which is largely influenced by processing conditions and materials used, as well as external factors. It is very important to continually study the biological growth in photographic processing solutions, and to upgrade your products accordingly. Fuji Hunt is now offering a complete product range of Superflo Stabilizers which will meet these criteria and meet your most stringent demands. Option 1: EnviroPrint Superflo Stabilizer AC is a monopart product designed for use in all types of “washless” minilabs. Effective biocides are incorporated in the stabilizer to prevent biological growths, and the stabilizer has been specially formulated to reduce or eliminate the excessive staining commonly associated with washless rinses. EnviroPrint Superflo Stabilizer AC may also be used in other types of processor that follow manufacturer-recommended specifications for washless operation. Option 2: EnviroPrint Super Stabilizer AC is also now a monopart product and should be installed at those customers encountering severe biogrowth problems and where EnviroPrint Superflo Stabilizer AC has not proven to be sufficiently powerful. Important : For those customers encountering only sporadic biogrowth problems and using the standard product EnviroPrint Superflo Stabilizer AC, we recommend keeping in stock the EnviroPrint Superflo Stabilizer Additive and using it when necessary. When chemical washing is being applied in large photofinishing, it may be more economical to install the combination EnviroPrint Superflo Stabilizer AC plus the additive. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 8 Additi ves - Even though products have been intensively tested and recognised by the market as giving excellent performance, even under extreme conditions, it is always possible that local conditions temporarily exceed the acceptable tolerance. The water quality entering the lab may suddenly have become extremely hard as it is coming from a different source, processing throughput may be very low on a particular processor…. When these situations occur, Fuji Hunt can supply you with an appropriate additive to help you to keep your production running under the new circumstances. The following special additives can be supplied by Fuji Hunt to meet special requirements. None of these additives is required in a normal RA4 process; they have all been introduced to address specific problems, or to fine tune the process to meet the requirements of well controlled professional laboratories. These additives are only available through your Fuji Hunt technical representative. 1. Add-Bright 2. Anti-Calcium 4 3. RA4 Developer Contrast Controller 4. Ultra Bleach-Fix Extender 5. Algstop & Algstop LR 6. EnviroPrint Superflo Stabilizer Additive 7. Biocare Additive 1. Add-Bright This additive can be used in combination with CPRA Pro Developer in roller transport processors for improving the whites of professional papers. Dosing : 5 ml per litre developer replenisher. 2. Anti-Calcium 4 Anti-Calcium 4 is a universal calcium & magnesium sequestering agent. It can be used in developers and fixers, without affecting the sensitometric properties. Dosing : 1 - 3 ml per litre developer replenisher or fixer replenisher. 3. RA4 Developer Contrast Controller Fuji Hunt offers an additive for those customers that would like to obtain a lower contrast. Dosing : up to 5 ml per litre developer replenisher. 4. Ultra Bleach-Fix Extender This product is for use in bleach-fixes and replenishers where excessive oxidation leading to sulphurisation is a problem due to adverse processing conditions – typically low throughput on large roller transport processors. Dosing : 5 - 15 ml per litre bleach-fix tank and/or replenisher. 5. Al gstop and Algstop LR If growth of algae and slime or other organic matter is a problem in wash tanks, Fuji Hunt recommend the use of Algstop or Algstop LR. Algstop should be used with automatic dosing systems (such as the Fuji Hunt Algstop Continuous Dosing unit) that inject biocides directly into the water supply to the processor tanks. Al gstop LR is a more concentrated additive and is recommended for manual use, or in conjunction with a low frequency automatic dosing system such as the Fuji Hunt Algstop Dosing Unit. After daily processing, add 1 ml of Algstop LR to the wash tank for each litre of volume. Agitate for 15 to 30 seconds. Leave overnight. In the morning switch on the processor and commence work normally. There is no need to drain the wash tank unless biogrowth is present. For full details on the usage of Algstop and Algstop LR, please ask for the separate Fuji Hunt Technical Information Sheet "Algstop". Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 9 6. EnviroPrint Superflo Stabilizer Additive This additive is available for those customers encountering only sporadically biogrowth problems when using EnviroPrint Superflo Stabilizer AC. It might also prove useful in the case of chemical washing in large photofinishing. Dosing : up to 4 ml per litre stabilizer solution or wash water. 7. Biocare Additive Preventing the growth of algae, bacteria and fungi in processor wash tanks, replenisher and storage tanks and circulation systems has always been an issue. Especially in low wash water usage and high temperature conditions resulting from recirculation of wash water, it has proven to be difficult to keep bio-growth under control. The microbes and resulting microbial accumulation come from water, air, dirty tanks, pipelines, people coming in contact with the wash and/or fresh water. Usually the first treatment is a thorough wash with hot water and a little brushing. Unfortunately, on many occasions this does not prove to be good enough as not all of the affected spots are reached. The smallest colony of micro-organisms remaining will very rapidly cause re-occurrence of bio-growth. In the low wash water usage and high temperature conditions resulting from recirculation of wash water, it has often proven difficult to keep bio-growth under control. Fuji Hunt BioCare is a more powerful biocide equally effective against algae, bacteria, fungi and yeast growth, and is recommended when facing severe conditions. BioCare is recommended for following applications: 1. As part of a regular processor, replenisher and holding tank sanitation program in Colour and B&W Photo processing, Graphic Arts and X-Ray. 2. As a more powerful biocide alternative to AlgStop and AlgStop LR, especially recommended for use in Fuji Hunt WaterHunter and similar water recirculation systems and for use in Fuji Hunt Auto Dosing Unit or equivalent low frequency automatic dosing systems. These conditions are common in the Graphic Arts and X-Ray markets. Dosing : up to 2 ml per litre wash water. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 10 Table 1 : PROCESS OPTIONS CHART Bath (12) Time (1) Temperature Replenishment Rate (ml/m²) EnviroPrint Developer MP160 45” 38.0±0.3°C 160 EnviroPrint Developer 45” 38.0±0.3°C 160 EnviroPrint Developer MP108 45” 38.0±0.3°C 108 EnviroPrint Developer LR AC 45” 38.0±0.3°C 73 EnviroPrint Developer MP60 45” 38.0±0.3°C 60 EnviroPrint Developer MP45 AC 45" 38.5±0.3°C 45 (2) EnviroPrint Developer Regenerator (55% Regen) 45” 38.0±0.3°C 160 / 72 (3) EnviroPrint Developer Regenerator HR (65% Regen) 45” 38.0±0.3°C 160 / 56 (3) EnviroPrint Developer Regenerator HR (70% Regen) 45” 38.0±0.3°C 160 / 48 (3) CPRA Developer / CPRA Developer AC 45" 35.0±0.3°C 160 CPRA 330 Developer MP 210" 31.0±0.3°C 160 CPRA 330 Developer 210" 29.0±0.3°C 160 CPRA Pro Developer 45” 35.0±0.3°C 250 (4) CPRA Digital Pro Developer AC 45” 35.0±0.3°C 215-325 (5) EnviroPrint Bleach-Fix Regenerator 45” 33.0±3.0°C 215 / 26 (3), (6) EnviroPrint Electrolytic Bleach-Fix Regenerator 45” 33.0±3.0°C 215 / 16-25 (3), (6) EnviroPrint Electrolytic Bio-Bleach-Fix 45” 33.0±3.0°C 215 EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator 45” 33.0±3.0°C 215 / 16-25 (3), (6) EnviroPrint Bleach-Fix 215 AC 45” 33.0±3.0°C 215 CPRA Pro Bleach-Fix AC 45” 33.0±3.0°C 215 (7) EnviroPrint Bleach-Fix 108 AC 45” 33.0±3.0°C 108 EnviroPrint Bleach-Fix 70 AC 45” 33.0±3.0°C 70 EnviroPrint Bleach-Fix 55 AC 45” 33.0±3.0°C 55 EnviroPrint Bleach-Fix 35 AC 45” 33.0±3.0°C 35 EnviroPrint Bleach-Fix 35 RTU AC 45” 33.0±3.0°C 35 EnviroPrint Bio-Bleach 75” 32.0±3.0°C 100 / 5 (6), (8) Unimatic Fixer (1+4 Dilution) 45” 32.0±3.0°C 250-300 Unilec Fixer (1+4 Dilution) 45” 32.0±3.0°C 250-300 Unilec Fixer (1+3 Dilution) 45” 32.0±3.0°C 55 (9) XL Rejuvenator 45” 32.0±3.0°C 250-300 / 15 (10) EnviroPrint Fixer 45” 32.0±3.0°C 250-300 / 16 (10) EnviroPrint Superflo Stabiliser AC 90” 34.0±4.0°C 250 (11) EnviroPrint Super Stabiliser AC 90” 34.0±4.0°C 250 (11) (1) Times shown are based on standard RA4 and RA404 processes. For times used by short RA4 processes, see Appendix 11, page 118. (2) EnviroPrint Developer MP45 AC must be used in combination with EnviroPrint Bleach-Fix 35 AC or 35 RTU AC. (3) The replenishment rates shown for regenerated developers and bleach-fixes are actual rates (160 or 215 ml/m²) and effective replenishment rates when overflow is re-used to make regenerated replenisher. Effective rate will be largely dependent on carryover rate on the processor. (4) The suggested replenishment rate for CPRA Pro Developer (suggested starting point 250 ml/m²) may be varied within the range 200-500 ml/m² according to the specific conditions on your processor – the higher rates are advised for low throughput situations. (5) The replenishment rate for paper processing may be varied within the range 215-325 ml/m² according to the specific conditions on your processor. For display material the standard replenishment rate is 495 ml/m². (6) Exact replenishment rate depends on carryover and evaporation. (7) The replenishment rate for CPRA Pro Bleach-Fix may be increased in low throughput situations to improve tank turnover. (8) The nominal replenishment rate for EnviroPrint Bio-Bleaches is 100 ml/m²; the effective rate after regeneration around 5 ml/m². Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 11 (9) With continuous “in-line” electrolytic desilvering. (10) With continuous “in-line” electrolytic desilvering and fixer regeneration. Processor replenishment rate is set to around 250- 300 ml/m², and the effective replenishment rate after regeneration is approximately as shown, depending on carryover. (11) The replenishment rate for EnviroPrint Superflo Stabilisers is based on four counter-current tanks being used on the minilab. The required rate will vary according to the number of tanks; for two counter-current tanks 700 ml/m² is recommended; for three tanks use 350 ml/m²; for four tanks 250 ml/m²; for five tanks 200 ml/m², and for six tanks 160 ml/m². For larger leader belt or continuous processors with large numbers of wash tanks, please consult your Fuji Hunt representative. (12) For details of EnviroPrint CP48 Developer and EnviroPrint CP48 Bleach-Fix, please see your Fuji Frontier documentation. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 12 3. STANDARD RA4 PROCESSING STEPS The standard RA4 automatic processing steps are indicated in Tables 2 and 3. Table 2 : Standard Processing Steps, Process RA4 Bath Time Temperature (°C) Envirochem Developers (1) 45 " 38.0 ±0.3 CPRA Developers (except CPRA 330) 45 " 35.0 ±0.3 CPRA 330 Developer 210 " 29.0 ±0.3 CPRA 330 Developer MP 210 " (2) 31.0 ±0.3 (2) Bleach-Fix 45 " 33.0 ±3.0 Wash Water 90 " 35.0 ±5.0 or EnviroPrint Superflo Stabil izer AC / EnviroPrint Super Stabi lizer AC 90 " 34.0 ±4.0 (1) EnviroPrint Developer Replenisher MP45 AC and EnviroPrint CP48 Developer have a processing temperature of 38.5°C ± 0.3°C. (2) CPRA 330 Developer Replenisher MP has a processing temperature of between 31 and 35°C, depending on the development time. These values are nominal and may need to be altered depending on the requirements of machine and sensitometric quality. Note : Wash or EnviroPrint Superflo Stabilizer AC / EnviroPrint Super Stabilizer AC is used as required. Wash water should be in the range 2-11 L/m², depending on the number of wash tanks. EnviroPrint Superflo Stabilizer AC / EnviroPrint Super Stabilizer AC replenishment rate is normally 250 ml/m² where four counter-current tanks are used, but it may be necessary to increase this if only three tanks are fitted. See "Process Options Chart" on page 10 for further details. Table 3 : Separated Bleach & Fix System, Process RA404 Bath Time Temperature (°C) Replenishment Rate Developer 45 " (1) (1) Stop Bath (2) 15 " 25 ±5 150 ml/m² Wash 15 " 32 ±3 1.5 L/m² Bleach 75 " 32 ±3 100 ml/m² Wash 45 " 32 ±3 2 L/m² Fixer 45 " 32 ±3 55 ml/m² (3) Wash 90 " 32 ±3 2 - 5 L/m² Note : Times given are minimum times except for developer. (1) Depends on developer, see "Table 1 : Process Options Chart", page 10. (2) Stop Bath is a 0.7 % acetic acid solution. (3) Unilec Fixer 1+3 with continuous closed loop desilvering. Other options are available; see Appendix 10, "Fixing Recycling" on page 105 for further information. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 13 4. ALTERNATIVE RA4 PROCESSING STEPS A number of variations on the standard RA4 process have been introduced by various manufacturers in recent years. Commonly found alternative RA4 processing steps are as indicated in Table 4 below. Further information may be found in Appendix 11, page 118. Description Fuji Hunt's recommended chemistry to be used in today's fast RA4 process is EnviroPrint Developer MP45 AC in combination with EnviroPrint Bleach-Fix 35 AC or EnviroPrint Bleach-Fix 35 RTU AC.. As an alternative, EnviroPrint Developer MP60 in combination with EnviroPrint Bleach-Fix 70 AC or EnviroPrint Bleach-Fix VR AC may also be used. These products have been extensively tested and have now become a reference in the Minilab market for fast processing. By simply mixing a more concentrated fresh tank solution (with the appropriate starter) and adjusting the replenishment rate accordingly, excellent print quality is obtained. These products give excellent process stability and can be installed in processes having a development time as short as 22 to 32 seconds, and also the standard RA4 processing time of 45 seconds. EnviroPrint Superflo Stabilizer & Replenisher AC or EnviroPrint Super Stabilizer & Replenisher AC are the best choice for fast processing, allowing a stabilizer time as low as to 50 seconds if the replenishment rate has been adjusted accordingly. The AC processing chemicals are a part of the Fuji Hunt Air Controlled product range, and are therefore genuinely Odour Free. The advantages go without saying. No chemical masking or added scents are used, hence these AC chemicals eliminate the unpleasant smell and guarantee a pleasant environment for your customer. Table 4 : Al ternati ve Processing Steps, Process RA4 Time Temperature (°C) Replenishment Rate ml/m² EnviroPrint Developer Replenisher MP45 AC 32” 27” 22" 39.0 ±0.3 39.5 ±0.3 40.0 ±0.3 55 – 60 70 – 75 70 – 75 EnviroPrint Bleach-Fix 35 AC 22 - 32" 36 - 38 45 – 55 EnviroPrint Superflo Stabilizer AC 50 - 90" 32 - 38 250 – 300 Alternatives EnviroPrint Developer Replenisher MP60 32" 27” 22” 38.5 ±0.3 39.0 ±0.3 39.5 ±0.3 75 75 – 90 90 – 100 EnviroPrint Developer Replenisher MP60 22" 39.5 ±0.3 90 – 100 EnviroPrint Bleach-Fix 70 AC 22 - 32" 36 - 38 90 EnviroPrint Bleach-Fix VR AC 22 - 32" 36 - 38 90 EnviroPrint Super Stabilizer AC 50 - 90" 32 - 38 250 – 300 The wide variety of "fast" processing equipment as well as the different paper brands on the market makes it difficult to standardise the process parameters. The table above shows recommended replenishment rates and processing temperatures. As with other chemistries, differences between paper brands and processing equipment may mean that you need to fine tune your process. For more information please contact your Fuji Hunt representative or consult the Fuji Hunt Minilab guide. See page 119 for mixing instructions for fresh tank solutions required for using Fuji Hunt chemistry in these fast RA4 processes. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 14 5. FUJICOLOR CP-4x PROCESS VARIANTS Fujicolor Chemistry for the RA4 process (Fuji Process FA) has been designed for use in Fuji minilabs, and is available from your Fuji distributor. Full technical information on the preparation and use of the various Fuji CP-4x chemistry products available for the different minilabs manufactured by Fuji Photo Film Co. may be found in the appropriate Fuji manual. A brief description of these processes follows. Table 5 : FUJI CP-4x PROCESSING STEPS Bath Time Temperature (°C) Replenishment Rate (ml/m² paper) CP-40FAII P1-R Developer (1) 45” 35.0°C ±0.3 161 CP-43FAII P1-R Developer (2) 45” 38.5°C ±0.3 73 CP-47L Developer (3) 45” 38.5°C ±0.3 45 CP-48S P1 Developer (4) 45” 38.5°C ±0.3 45 CP-49E P1 Developer (4) 25” 45.0°C ±0.3 45 CP-40FAII P2-R Bleach-Fix (1) 45” 35.0°C ±2.0 218 CP-43FAII P2-R Bleach-Fix (2) 45” 35.0°C ±2.0 61 CP-47L P2-R Bleach-Fix 45” 38.0°C ±2.0 35 CP-48S P2 Bleach-Fix (4) 45” 38.0°C ±2.0 35 CP-49E P2 Bleach-Fix 25” 40.0°C ±2.0 35 FRSS Tablets (to make rinse PS-1, PS-2, PS-3) CP-49E PS 90” 24” 35-40°C 40.0°C ±2.0 (5) 215 Drying (6) 1’15” Not over 90°C - (1) Used on : PP400B, PP540B, PP541B minilabs and for general RA4 use on minilabs converted to the RA4 process (2) Used on : PP1040B, PP1800B, PP2600B, PP1252V, PP1820V, PP3000V, PP1270VE minilabs (3) Used on : (as P1R) PP720W, PP728V, PP728W, PP728A minilabs; (as P1CR) PP1258V/A, PP1828V/A, PP3008V/A minilabs (4) Used on : Fuji Frontier SP1500 and SP2000 printer processors (5) Replenishment rates as described in Fuji processor manuals. FA series minilabs have three Super Rinse tanks, RR 364 ml/m²; Super FA series minilabs have four Super Rinse tanks, RR 242 ml/m²; Frontier processors have four Super Rinse tanks, RR 175 ml/m². These rates are reduced by use of a Fuji RC-50 reverse osmosis unit. (6) Drying temperature must not exceed 90°C. However, the temperature should be adjusted to achieve optimum drying. 5.1. Water Wash System The Super Rinse steps (PS-1, PS-2 and PS-3 for three tank rinse processors), may be changed to water wash steps as in Table 6 below. Note that the overflow from the third wash tank W-3 goes to the second wash tank W-2, and then the overflow from W-2 to the first wash tank W-1. Table 6 : Wash Water System Bath Time Temperature (°C) Wash Water Rate (L/m 8.9cm paper) Water Wash W-1 30” 24 to 34°C Overflow from W-2 Water Wash W-2 30” 24 to 34°C Overflow from W-3 Water Wash W-3 30” 24 to 34°C 1.4 litres/1m x 8.9cm Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 15 6. PROCESSING CONDITIONS 6.1. Minilab Processors For best results with all papers, it is essential that specific conditions be strictly observed and that close inspection of processing conditions be maintained on a regular basis. Processing Times Processing step intervals are determined by measuring the time lapse between paper entry into one tank solution and entry into the very next tank solution. Note that if solution levels are too low, the actual processing times will be shortened. Processing Temperatures Processing solution temperatures must be controlled to within specified limits. Rigid temperature control of the developer is critical in maintaining optimum quality. Once the desired operating temperature for each solution is established, the temperatures should be stabilised. Recirculation Recirculation provides an important part of the agitation in the chemical baths and should be maintained correctly. Each recirculation system should be checked from time to time for normal pump performance, for solution and air leaks from the various pipes and for other defects such as kinks, bends and restrictions caused by collapse of flexible pipework. Ideally – but not commonly found with minilabs – flowmeters should be placed in the recirculation systems to allow monitoring of the solution flow rates. Standard Recirculation Rates • Developer, Bleach-Fix : One-fifth or more, and preferably one half or more, of the total tank solution volume should be recirculated every minute. In particular, developer flow rate has a significant effect on the photographic properties of the process and should be monitored closely. • Super Stabiliser : One third or more, and preferably two thirds or more, of the total tank solution volumes should be recirculated every minute. Processors fitted with multiple tanks should maintain the same recirculation rate in each tank. Good agitation is particularly important during the first few seconds in both the developer and bleach- fix baths. Poor developer agitation may lead to uneven development, usually shown by lighter (often blue) streaks in DMax areas. Poor bleach-fix agitation, especially on processors subject to high developer carryover due to poor squeegee maintenance, bleach-fix under-replenishment or other problems, may cause (typically) magenta streaking or high stain on the paper. Filtration All solutions should be recirculated and filtered. There is usually a lot of insoluble material found in paper processing tanks, particularly paper or polyethylene fibres that are rubbed and washed off the paper during processing, and especially in the developer tank. Apart from sticking to rollers and other parts of the processor, leading to paper scratching, this can also cause long-term damage to the processor unless removed by filtration. 10 to 50 micron filters are recommended for general use. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 16 Carryover Replenishment rates for secondary solutions may be affected by differing carryover rates on different types of processor. Typically carryover is around 40-70 ml/m 2 on minilab processors fitted with an efficient squeegee system. Many minilabs use squeegee rollers rather than separate squeegee blades, and these should be periodically inspected for damage, wear, and correct operation. Any separate squeegee blades should be inspected for wear and adjusted as necessary. Use of very low replenishment rate developers and bleach-fixes makes carryover a critical processing parameter; excess carryover may result in an empty developer tank (where carryover exceeds replenishment rate) or failure of the bleach-fix. Water Washes Where water washes are used in place or the more usual stabiliser bath, the flow rate required is based on the number of wash tanks in the processor and the area of paper processed. Based on incoming water conditions, a 15 or 25 micron filter should be used to filter the incoming water supply. A flow meter should be installed in the water supply, and monitored on a daily basis. Standard wash water flow rates may be found in Table 7 below : Table 7 : Minilab wash flowrates Number of wash tanks Replenishment Rate ml/m² (minimum) 1 Not Recommended ‡ 2 7200 3 4800 4 2400 Note : ‡ Few minilabs have a single main wash tank. At least 10 litres/m² will be necessary, assuming well controlled bleach-fix carryover, more if carryover is excessive. It is difficult to achieve an effective wash giving long-term print stability with a single wash tank. Replenishment All solutions require recommended replenishment rates to maintain chemical component balance and ensure a consistent and uniform quality in prints. Replenishment rates should be verified on a weekly basis, and measured rates recorded on a process check sheet. Replenishment rates should be maintained within ±5% of the specification. The replenisher solutions must be prepared according to recommended mix instructions and should be used within specified periods of time. For minilab processors in particular, correct selection of chemistry for your processor is essential. Recommended replenishment rates are indicated in Table 1 on page 10. Selecting the correct developer The most important step in running a good RA4 process line is to ensure that you are using the correct chemistry, and in particular the correct developer. Use the chart shown in Figure 1 on the next page to select the best chemistry for your processor : Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 17 Figure 1 : Developer Selection Chart Tank Size 80 L 70 L 60 L 50 L 40 L 30 L 20 L 10 L 5 L 10 20 30 40 50 60 70 80 90 100 110 120 130 Films per day 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120 Prints/day 10x15cm 3.6 7.2 10.8 14.4 18.0 21.6 25.2 28.8 32.4 36.0 39.6 43.2 46.8 Square metres/day = Not Recommended = CPRA Digital Pro Developer AC (215ml/m²) or CPRA Pro Developer (250ml/m²) = EnviroPrint Developer MP160 or CPRA / CPRA AC developer = EnviroPrint Developer MP108 = EnviroPrint Developer LR AC / MP60 = EnviroPrint Developer MP45 AC 6.2. Leader Belt and Leader-free (Agfa VSP type) Processors Leader belt processors and continuous (leader-free) processors (such as the Agfa VSP) are commonly found in photofinishing (wholesale) and professional / social laboratories and are used for processing long continuous rolls of paper. With leader belt processors, paper is attached to a continuously moving nylon or plastic leader belt by a clip, which then pulls the paper though the processor over racks which may have either the top or bottom rollers included in the transport drive mechanism. The key starting points for good process control on this type of processor include monitoring the condition of the leader belt – removing and replacing sections damaged by the clips as necessary – and prevention of dirt build-up in the roller drive mechanisms which leads to sticking rollers and scratched or damaged paper. Continuous, or leader-free, processors are mechanically very similar, except that there is no leader belt. This is replaced by a plastic leader that is fed right through the processing track when no paper is being processed, exactly as for ciné-type film processors commonly found in wholesale laboratories. Paper is joined to the end of this leader at the feed end of the processor, and dragged through the processor by the leader. The next roll of paper to be processed is joined to the end of the previous roll. When no further paper is to be processed, the plastic leader is re-attached and fed through the processor. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 18 For best results with all papers, it is essential that specific conditions be strictly observed and that close inspection of processing conditions be maintained on a regular basis. In particular, squeegee condition – and especially the leader belt squeegees – and adjustment must be regularly checked and squeegees replaced when necessary. Processing Times Processing step intervals are determined by measuring the time lapse between film entry into one tank solution and entry into the very next tank solution. Processing times quoted include the crossover time to the next tank. Bath times for RA4 and RA404 processes are shown in Table 2 and Table 3 . Processing Temperatures Processing solution temperatures must be controlled to within specified limits. Rigid temperature control of the developer is critical in maintaining optimum quality. Once the desired operating temperature for each solution is established, the temperatures should be stabilised. Recirculation All solutions, except washes on water-wash processors, should be recirculated, temperature controlled and filtered. Standard Recirculation Rates • Developer, Bleach-fix : One-fifth or more of the total tank solution volume should be recirculated every minute. In particular, developer flow rate has a significant effect on the photographic properties of the process and should be monitored closely. Processors fitted with multiple tanks should maintain the same recirculation rate in each tank. • Super Stabiliser (where used) : One third or more of the total tank solution volumes should be recirculated every minute. Processors fitted with multiple tanks should maintain the same recirculation rate in each tank. Temperature control is also required on each tank. Good agitation is particularly important during the first few seconds in both the developer and bleach- fix baths. Poor developer agitation may lead to uneven development, usually shown by lighter (often blue) streaks in DMax areas. Poor bleach-fix agitation, especially on processors subject to high developer carryover due to poor squeegee maintenance, bleach-fix under-replenishment or other problems, may cause (typically) magenta streaking or high stain on the paper. Filtration All solutions should be recirculated and filtered. There is usually a lot of insoluble material found in paper processing tanks, particularly paper or polyethylene fibres that are rubbed and washed off the paper during processing, and especially in the developer tank. Apart from sticking to rollers and other parts of the processor, leading to paper scratching, this can also cause long-term damage to the processor unless removed by filtration. 10 to 50 micron filters are recommended for general use. Carryover Replenishment rates for secondary solutions may be affected by differing carryover rates on different types of processor. Typically carryover is around 40-60 ml/m 2 on leader belt processors fitted with an efficient squeegee system; maybe 35-40 ml/m² on continuous paper processors without a leader belt. Squeegees should be periodically inspected for damage, wear, and correct operation. All separate squeegee blades should be inspected for wear and adjusted as necessary; leader belt squeegees are a major source of carryover problems unless closely controlled. Use of very low replenishment rate developers and bleach-fixes, or use of developer and/or bleach-fix regeneration systems, makes carryover a critical processing parameter. Excess carryover may result in an empty developer tank (where carryover exceeds replenishment rate), insufficient developer returned for regeneration, Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 19 increased chemical usage and excess bleach-fix overflow during regeneration, or failure of the bleach- fix. Water Washes Where water washes are used, as is normally the case on larger leader belt processors found in photofinishing laboratories, the flow rate required is based on the number of wash tanks in the processor and the area of paper processed. Based on incoming water conditions, a 15 or 25 micron filter should be used to filter the incoming water supply. A flow meter should be installed in the water supply, and monitored on a daily basis. Standard wash water flow rates for a counter-current wash tank configuration may be found in Table 8 below : Table 8 : Leader belt wash flowrates Number of wash tanks Replenishment Rate ml/m² (minimum) 1 Not Recommended ‡ 2 7200 3 4800 4 2400 Notes : ‡ If your processor has a single wash tank, at least 10 litres/m² will be necessary, assuming well controlled bleach-fix carryover, more if carryover is excessive. It is difficult to achieve an effective wash giving long-term print stability with a single wash tank. Processors fitted with more than 4 main wash tanks (in addition to low flow washes) can use a reduced water flow rate, as long as wash temperature is maintained in the processor. See “Optimising Wash Tank and Processor Configuration” below for further information. Low Flow Washes Larger processors fitted with three or more wash tanks benefit from use of one or more low flow wash tanks after the bleach-fix. This allows you to concentrate silver carried over from the bleach-fix to make for easier silver recovery (or removal of a concentrated effluent for treatment off-site). Typically, a low flow wash rate of 200 to 250 ml/m² is considered satisfactory, but this may vary depending on the number of low flow wash tanks used, carryover conditions on your processor, and silver recovery equipment available in the laboratory. See “Optimising Wash Tank and Processor Configuration” below for further information. For optimum silver recovery and minimum water usage, water from the main wash tanks should be used to feed the low flow wash; use a suitable replenishment pump fed from the first main wash tank. Low flow wash tanks should not be installed on processors with less than three wash tanks; at least two main wash tanks should remain after the low flow wash. Optimising Wash Tank and Processor Configuration The more wash tanks that are available on your processor, the better the processor can be optimised for both chemistry system used, and for the main wash tank and low flow wash tank configuration. Please consult your Fuji Hunt representative; a mass balance can be calculated for your processor(s) to determine the optimum main wash and low flow wash tank configuration and wash flowrates to suit the requirements of your laboratory. This will take into account local effluent or other controls, silver recovery options, and general processor and chemistry selection and optimisation. This Fuji Hunt service can also look at the possibility of processor conversion to use a super stabiliser rather than a water wash, which has been found to be very beneficial in some laboratories. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 20 This service has also been used by a number of laboratories to finalise the configuration of new paper processors prior to order. This can ensure that a new, fully optimised processor, providing both cost savings and the best environmental solution, is delivered to your laboratory with no further modifications required, and fully backed by the manufacturer’s guarantees. Super Stabilisers for large processors Many laboratories – for a variety of reasons – have converted existing or installed new processors which use a super stabiliser instead of a water wash. Such processors are more like a large minilab in concept; all stabiliser tanks must be counter-current and include separate recirculation, filtration and tempering systems for each tank. Conversion of an existing water wash processor to use super stabiliser requires installation of these systems, plus a new stabiliser replenishment system. Replenishment rates will depend partly on the type of processor, as carryover rates vary considerably between leader belt and continuous processors, and partly on the number of tanks available. Please see the “Optimising Wash Tank and Processor Configuration” section above; Fuji Hunt can help you decide on this option. Replenishment All solutions require recommended replenishment rates to maintain chemical component balance and ensure a consistent and uniform quality in prints. Replenishment rates should be verified on a weekly basis, and measured rates recorded on a process check sheet. Replenishment rates should be maintained within ±5% of the specification. The replenisher solutions must be prepared according to recommended mix instructions and should be used within specified periods of time. The chemical storage area temperature should be maintained between 16-30°C to ensure solution quality and consistency. Adequate ventilation in the chemical storage area is suggested. Recommended and effective replenishment rates for regenerated solutions are indicated in table 1 on page 10. Selecting the correct developer The most important step in running a good RA4 process line is to ensure that you are using the correct chemistry, and in particular the correct developer. Use the chart shown in Figure 1 above as a guideline to selection of the best chemistry for your processor. Many (larger) laboratories employ developer regeneration, and/or bleach-fix regeneration. It is the policy of Fuji Hunt to offer regeneration procedures and products wherever possible with the intention of reducing chemical effluent and laboratory processing costs as much as possible. Regeneration can be operated in two ways : 1. Rebuild a measured volume of overflow to make replenisher, 2. Dehalide all developer overflow and then rebuild the solution to make replenisher. Method 1 is now the only method commonly used. No analyses or resin regenerations are necessary. Method 2 has the advantage of using all the developer overflow but this is counterbalanced by having to regenerate the resin when it is full of halide. The regeneration effluent contains some developer chemical plus a lot of halide. In the past, Fuji Hunt sold Rapigen 4 Developer Regenerator for use with CPRA Developer regeneration, but today we are offering the EnviroPrint Developer Regenerators as rebuilding concentrates, based on EnviroPrint Developer as a starting point. For more details, please see the Developer Regeneration page 96 and Bleach-Fix Regeneration page 99 in this manual, or consult your Fuji Hunt representative. 6.3. Roller Transport Processors Roller transport processors are commonly used for processing of wide paper rolls or sheets in professional laboratories, and the design of these machines, with often very wide tanks of up to 2 metres or even more – with large surface areas, rollers exposed to the air, and (usually) relatively small Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 21 tank volumes compared to the surface area of the tank – makes them prone to aerial oxidation and high levels of evaporation. Such machines often – but by no means always – suffer from low or relatively low throughput compared to other processor types. The chemistry designed for use in these processors takes these factors into account, but for best results with all papers in roller transport processors, it is essential that specific processing conditions be strictly observed and that close inspection of these conditions is maintained on a regular basis. Where fitted, squeegees must be regularly checked and adjusted, but more problems are caused by a lack of basic checks on the processor. These include such items as evaporation compensation, cleaning, filter changes, replenishment rate checks, and simply not checking that the level of paper throughput on your processor is suitable for both the chemistry being used, and for the way in which the chemistry is used. Processing Times Processing step intervals are determined by measuring the time lapse between film entry into one tank solution and entry into the very next tank solution. Processing times quoted include the crossover time to the next tank. Bath times for the RA4 process are shown in Table 2 above. Processing Temperatures Processing solution temperatures must be controlled to within specified limits. Rigid temperature control of the developer is critical in maintaining optimum quality. Once the desired operating temperature for each solution is established, the temperatures should be stabilised. Recirculation All solutions, except washes on water-wash processors, should be recirculated, temperature controlled and filtered. Standard Recirculation Rates • Developer, Bleach-fix : One-fifth or more of the total tank solution volume should be recirculated every minute. In particular, developer flow rate has a significant effect on the photographic properties of the process and should be monitored closely. Processors fitted with multiple tanks should maintain the same recirculation rate in each tank. • Super Stabiliser (where used) : One third or more of the total tank solution volumes should be recirculated every minute. Processors fitted with multiple tanks should maintain the same recirculation rate in each tank. Temperature control is also required on each tank. Good agitation is particularly important during the first few seconds in both the developer and bleach- fix baths. Poor developer agitation may lead to uneven development, usually shown by lighter (often blue) streaks in DMax areas. This is potentially a major problem on larger (wider) roller transport processors; many such machines are fitted with a turbulator or spray bar (or several of them) within the developer tank, pumping developer directly at the paper emulsion as it passes over it. Blockages in such recirculation systems can lead to under-development streaks on the processed paper. Other processor types, where developer simply enters the tank through a pipe at one side of the developer tank and is removed for recirculation from the other side, are also prone to varied development patterns on the paper where a good flow is not maintained due to blocked filters, worn pumps or other problems. Poor bleach-fix recirculation, bleach-fix under-replenishment, or other problems may cause (typically) magenta streaking or high stain on the paper. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 22 Filtration All solutions should be recirculated and filtered. There is usually a lot of insoluble material found in paper processing tanks, particularly paper or polyethylene fibres that are rubbed and washed off the paper during processing, and especially in the developer tank. This can be a particular problem where sheet paper is regularly processed, and especially when the printer himself is manually tearing sheet paper for test prints. This creates a lot of loose material which ends up in the developer filter, and is definitely not recommended – paper should be cut, not torn. Apart from sticking to rollers and other parts of the processor, leading to paper scratching, this can also cause long-term damage to the processor unless removed by filtration. 10 to 50 micron filters are recommended for general use. Carryover Replenishment rates for secondary solutions may be affected by differing carryover rates on different types of processor. Typically carryover is around 70-80 ml/m 2 on roller transport processors. Processing Chemicals The most commonly used chemistry on roller transport processors is CPRA Pro Developer (or CPRA Digital Pro Developer for use with digital printers) and CPRA Bleach-Fix. These are high replenishment rate products designed to minimise the effects of oxidation and low throughput, and are designed for optimum use where the Tank Turnover rate is around 2-4 weeks (see below). However, where processor throughput is sufficiently high, there is no reason not to use lower replenishment rate chemistry. Many roller transport processors are successfully run on either 160 ml/m² developers such as CPRA AC, or even on low replenishment rate developers such as EnviroPrint LR AC or EnviroPrint MP60 developer. EnviroPrint MP45 AC Developer must not be used with roller transport processors as carryover from the developer tank will exceed the replenishment rate, resulting in a gradual emptying of the developer tank. This may also be a problem with MP60 on some processors. Please see Figure 1: Developer Selection Chart to help you with your choice of developer, or consult your Fuji Hunt representative. With very low throughput – 4 weeks or longer for one tank turnover of developer – additional measures may have to be taken to maintain correct developer activity. CPRA Pro Developer can be replenished at up to 500 ml/m² without problem; CPRA Bleach-Fix cannot be over-replenished. Please see the Troubleshooting RA4 section on page 55 in this manual for further information. Tank Turnover Rate Photographic chemistry is designed for optimum use within quite a short period of time – a few weeks at most – and this includes both time spent in the replenisher tank and in the actual processor. The measure of how long it is taking to replace this chemistry with fresh chemistry by normal replenishment is the Tank Turnover Rate. Under normal conditions, most processors use enough chemistry to ensure that no special problems will appear, but sometimes – particularly on roller transport processors – not enough paper is processed to prevent problems. The Tank Turnover Rate (“tto”) is defined as the time required to use one (processor working) tank volume of replenisher. So, if your processor developer tank holds 100 litres of developer, and you are using 50 litres of developer replenisher per week, your tank turnover rate is 100 / 50 =0.5 tto/week. The easiest way to monitor this rate on an ongoing basis (where you only have one processor feeding from a replenisher tank) is to keep a record of the amounts of developer and bleach-fix mixed, and when they were mixed. Weekly tank turnover rates can then be easily calculated. For roller transport processors, anything above 3-4 weeks for one tto should be considered as low throughput. This applies to both the developer and bleach-fix baths. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 23 Water Washes Where water washes are used, as is normally the case on roller transport processors, the flow rate required is based on the number of wash tanks in the processor and the area of paper processed. Based on incoming water conditions, a 15 or 25 micron filter should be used to filter the incoming water supply. A flow meter should be installed in the water supply, and monitored on a daily basis. Standard wash water flow rates for a counter-current wash tank configuration may be found in Table 9 below : Table 9 : Roller transport wash flowrates Number of wash tanks Replenishment Rate ml/m² (minimum) 1 Not Recommended ‡ 2 7200 3 4800 4 2400 Notes : ‡ If your processor has a single wash tank, at least 10 litres/m² will be necessary, assuming well controlled bleach-fix carryover, more if carryover is excessive. It is difficult to achieve an effective wash giving long-term print stability with a single wash tank. Processors fitted with 3 (or more) main wash tanks may be suitable for use with a low flow wash. See “Low Flow Washes” on page 19 for further information. Roller transport processors, due to the large surface area of the rollers and tank surface exposed to the air on most makes of processor, are particularly prone to bacterial growth (algae) in the wash tanks, leading to (typically) brown stains and marks on the paper. Treatment with a suitable algaecide manually or with an automatic dosing system can greatly reduce or eliminate this problem, resulting in much cleaner prints and less print waste. Super Stabilisers Many laboratories – for a variety of reasons – have converted existing or installed new processors which use a super stabiliser instead of a water wash. Such processors are more like a large minilab in concept; all stabiliser tanks must be counter-current and include separate recirculation, filtration and tempering systems for each tank. Conversion of an existing water wash processor to use super stabiliser requires installation of these systems, plus a new stabiliser replenishment system. Replenishment rates will depend partly on the type of processor, as carryover rates can vary between different makes and types of roller transport processors, and partly on the number of tanks available. Note that as carryover is usually higher on roller transport processors than other processor types, replenishment rates for effective print washing and stabilising maybe slightly higher than for other types of machine. Display / Transparency Materials Many roller transport processors are also used for processing display (transparency) materials such as Fuji Fujitrans or Kodak Duratrans. These materials are designed for processing in the same chemistry as is used for conventional RA4 papers, but the thicker emulsions and increased silver halide content of these papers requires longer processing times and increased replenishment rates for all baths. Most roller transport processors will have a single setting or switch that has to be changed before processing display materials; this resets the processor drive speed and effectively the replenishment rate at the same time. Typical processing conditions for display materials can be seen in Table 10 on the next page : Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 24 Table 10 : Display material processing steps Time Temperature (°C) Replenishment Rate † ml/m² CPRA Pro Developer 110” 35 ±0.3 610 ‡ or CPRA Digital Pro Developer AC 110" 35 ±0.3 495 ‡ or CPRA Developer AC 110" 35 ±0.3 390 ‡ CPRA Pro Bleach-Fix AC 110" 33 ±0.3 525 Wash 3’ 40" 35 ±5 § Note : † There is normally no need to adjust replenishment rates when processing display materials. As the processor is running at a lower speed, the replenishment pumps will run for longer as they run while they detect paper; this automatically adjusts the replenishment rates. The above replenishment rates should be used where replenishment is carried out manually, for example with tray or drum processing. ‡ The developer replenishment rate shown above is for “normal” exposures. In practice, many prints on display materials are not “normal” and extended runs of (for example) very dark prints may require adjustment of the replenishment rate. This is normally best achieved by manually adding additional developer replenisher if required. Regular use of control strips is advised when processing significant amounts of display materials. § Wash rates 2000 ml/m² with two wash tanks; 1000 ml/m² with three wash tanks, or 500 ml/m² with four wash tanks. 6.4. Trays, Drums and Rotary Discard Processors For best results with all papers in trays, drums, or rotary discard processors, it is essential that specific processing conditions be strictly observed and that close inspection of these conditions is maintained on a regular basis. Rotary discard (also called rotary tube) processors, and especially drums and tray processing, tend to give results less consistent than automatic processors, but can still be perfectly acceptable if due care and attention is paid to accuracy of timing, agitation, temperatures and chemical usage. Please see recommendations provided by your processor manufacturer for further details. The key to consistent processing with these types of processor is repeatability; you must ensure that all procedures, especially those related to any warm-up bath or other pre-heating of the processor, are followed as accurately as possible. Processing Times Recommended processing times include a drain time of 5 seconds at the end of each step. You may need to modify these recommendations slightly to get the best results with your processor. Processing Temperatures Processing solution temperatures must be controlled to within specified limits. Accurate temperature control of the developer is critical in maintaining optimum quality, although more difficult with this type of processor. Once the desired operating temperature for each solution is established, the temperatures should be stabilised. Processing Chemicals The volume of each bath required will depend on the processor type and the films processed. Please see recommendations from your processor manufacturer. Also, all chemicals used in a rotary discard Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 25 or drum processor are intend for single use only, and should be discarded after each process run. However, the bleach-fix can be saved for re-use up to its recommended capacity. Do not attempt to reuse the developer, or to replenish or regenerate any of the solutions. Use of a stop bath after the developer is advised for drum, tray and rotary discard processing; this can greatly reduce the chance of paper streaking and give an improved base white. Stop bath may be prepared by mixing 20 ml Glacial (100%) Acetic Acid per 1 litre of water to make a 2% Acetic Acid solution. If preferred, any proprietary stop bath, many of which contain a colour indicator to show stop bath exhaustion, may be found to be more convenient. If a stop bath is used, it should be followed by a 30 second wash before the bleach-fix stage. The working solutions must be prepared according to recommended mix instructions and should be used within specified periods of time. To avoid oxidation and possible contamination, keep unused solutions in full, stoppered bottles. The chemical storage area temperature should be maintained between 16-30°C to ensure solution quality and consistency. Adequate ventilation in the chemical storage area is suggested. For solution and water volumes required, please see the equipment manufacturer’s instructions. Processing Conditions A summary of the various processing conditions for rotary discard, drum and tray processing may be found in Table 11 and Table 13 below. Note also the comments below each table giving specific instructions and recommendations for your processing method. Table 11 : Rotary Discard Processing Conditions Summary Bath Time Temperature (°C) Pre-heat with tempered water bath (1) 30” ±5” 35 ±1°C Developer (2) 45” (3) 35 ±0.3°C Stop bath 30” ±5” 35 ±1°C Wash 30” ±5” 35 ±1°C Bleach-Fix (4), (5) 45” 35 ±1°C Wash (6) 90” 35 ±1°C Dry As required Not above 90°C (1) The processor must be loaded with paper ready for processing. The pre-heat is carried out for 30 seconds, including a 5 second drain time. Draining should be complete at the end of the 30 sec step, ready for addition of the developer. When the optimum pre-heat conditions have been determined, these should be used for all future processing runs. (2) Any Fuji Hunt developer may be used for rotary discard processing. The 35°C developer temperature shown above is for CPRA AC or CPRA Pro developers, or for users of the Fuji Hunt Print 4 Xpress RA4 processing kit; CPRA and Print 4 Xpress chemicals are particularly recommended for these processors. Users of any EnviroPrint developer should adjust the pre-heat temperature to 38°C ±1°C, and the developer temperature to 38.0°C ±0.3°C. Other steps remain as above. (3) It is most important to keep a constant developer time for every processing run in order to get a consistent result. Developer time may be extended to 50 seconds to achieve the best result. When the optimum developer time has been determined, this should be used for all future processing runs. (4) Any Fuji Hunt bleach-fix may be used for rotary discard processing. Most users will wish to use either the Fuji Hunt Print 4 Xpress kit, or CPRA Pro Bleach-Fix AC for reasons of greater economy. (5) After the bleach-fix step, paper may be safely handled in normal lighting conditions. (6) Either running water at 35°C for 90 seconds, or three (or preferably more) changes of fresh water (every 30 seconds) at 35°C may be used for washing. See the processor manufacturer’s instructions for recommended wash water quantities. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 26 Table 12 : Drums Processing Conditions Summary Bath Time (1) Temperature (°C) Pre-heat with tempered water bath (2) 30” ±5” 35 ±1°C Developer (3) 45” (4) 35 ±0.3°C Stop bath 30” ±5” 35 ±1°C Wash 30” ±5” 35 ±1°C Bleach-Fix (5), (6) 45” 35 ±1°C Wash 90” 35 ±1°C Dry (7) As required Not above 90°C (1) The processor must be loaded with paper ready for processing. Each step includes a 5 second drain time. Draining should be complete at the end of each step, ready for addition of the next bath. (2) Depending on your processing drum and the ambient conditions, you may find it necessary to increase the pre-heat temperature slightly to ensure that the developer temperature will be at the correct 35°C. Once the optimum pre-heat conditions have been determined, these should be used for all future processing runs. (3) Any Fuji Hunt developer may be used for drum processing. The 35°C developer temperature shown above is for CPRA AC or CPRA Pro developers, or for users of the Fuji Hunt Print 4 Xpress RA4 processing kit; CPRA and Print 4 Xpress chemicals are recommended for these processors. Most users of drum processing will find that the Print 4 Xpress chemicals are particularly suitable as no additional developer starter is required. Users of any EnviroPrint developer should adjust the pre-heat temperature to 38°C ±1°C, and the developer temperature to 38.0°C ±0.3°C. Other steps remain as above. (4) It is most important to keep a constant developer time for every processing run in order to get a consistent result. Developer time may be extended to 50 seconds to achieve the best result. When the optimum developer time has been determined, this should be used for all future processing runs. (5) Any Fuji Hunt bleach-fix may be used for drum processing. Most users will wish to use either the Fuji Hunt Print 4 Xpress kit, or CPRA Pro Bleach-Fix AC for reasons of greater economy. (6) After the bleach-fix step, paper may be safely handled in normal lighting conditions. (7) Either running water at 35°C for 90 seconds, or three (or preferably more) changes of fresh water (every 30 seconds) at 35°C may be used for washing. Table 13 : Tray Processing Conditions Summary Bath Time (1) Temperature (°C) Developer (2) 45” (3) 35 ±0.3°C or Developer (2) 60” (3) 33 ±0.3°C or Developer (2) 90” (3) 29 ±0.3°C Stop bath 30” ±5” 33 ±3°C Wash 30” ±5” 35°C ±4°C Bleach-Fix (4), (5) 60” 33 ±3°C Wash (6) 90” 35°C ±4°C Dry As required Not above 90°C (1) Each step includes a 5 second drain time. Draining should be complete at the end of each step, ready for transfer to the next tray. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 27 (2) Any Fuji Hunt developer may be used for tray processing, but processing with developers designed for optimum results at 35°C – i.e. CPRA AC or CPRA Pro developers, or the Fuji Hunt Print 4 Xpress RA4 processing kit – is strongly recommended. Most users of tray processing will find that the Print 4 Xpress chemicals are particularly suitable as no additional developer starter is required. (3) It is most important to keep a constant developer time for every processing run in order to get a consistent result. Carry out tests to decide on the best time/temperature combination for your setup. When the optimum developer temperature/time has been determined, this should be used for all future processing runs. Note that some papers may experience problems with poor (greenish or bluish) blacks with extended development times; in such cases develop for 60 seconds maximum. (4) Any Fuji Hunt bleach-fix may be used for tray processing. Most users will wish to use either the Fuji Hunt Print 4 Xpress kit for convenience, or CPRA Pro Bleach-Fix AC for reasons of greater economy. (5) After the bleach-fix step, paper may be safely handled in normal lighting conditions. (6) Either running water at 35°C ±4°C for 90 seconds, or three (or preferably more) changes of fresh water (every 30 seconds) at 35°C ±4°C may be used for washing. Agitation during tray processing The best level of agitation will be achieved by processing single prints. It is easiest to avoid uneven development patterns by first immersing the print emulsion down until fully wetted, turning the print over, and then continuing processing emulsion up. Tip the tray gently from front to back and side to side, taking care to avoid splashing and slopping the developer over the sides of the tray. Begin the drain time 5 seconds before the end of the development time, and transfer the print to the next tray. Repeat for all subsequent steps. If you wish to attempt processing of multiple prints in a tray, you must use an interleaving technique to ensure that all prints are processed for the correct time, constantly transferring prints from the bottom to the top of the stack. This is not recommended with shorter development times. Developer capacity You will typically be able to process around 0.8 m² of paper, or about 15 20 x 25 cm (8” x 10”) prints in one litre of developer. After this point, print quality will begin to deteriorate, with loss of maximum density (blacks) and increasing stain levels. Developer kept in open trays for longer than about four hours will begin to oxidise and should be discarded. As a guide, paper areas of common print sizes are as in Table 14 below : Table 14 : Print areas Print Size Paper Area (m²) 10x15 cm (4”x6”) 13x18 cm (5”x7”) 20x25 cm (8”x10”) A4 (210x297 mm) 25x30 cm (10”x12”) 30x40 cm (12”x16”) 40x50 cm (16”x20”) 0.015 0.023 0.052 0.062 0.078 0.124 0.206 Notes on Tray Processing : There are a number of common problems associated with tray processing that can be easily avoided if suitable steps are taken : Trying to process too many prints together in a tray will lead to poor circulation of the chemicals – and especially the most critical developer step – across the surface of the paper. This will lead to Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 28 streaking, uneven development and/or poor blacks. If you experience this type of problem, reduce the number of prints processed together in one tray. For optimum results, especially with larger prints, prints should be processed singly as this ensures the best possible chemistry circulation across the paper surface. Do not process more prints per litre of developer than indicated on the instructions packaged with the chemistry. Follow any instructions for changes to processing times after a given number of prints have been processed. If you get an uneven development pattern even when prints are processed singly, this may be because the developer is not wetting the paper surface evenly. In this case, try a 15 second pre-soak (and then a 10 second drain time) in a tray of water at 35°C before development. Development temperature should be increased by 0.5 to 1.0°C to compensate for the water carried into the developer on the paper. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 29 C. HANDL I NG OF CHEMI CAL S AND SOL UTI ON PREPARATI ON 1. CHEMICAL HANDLING / CPRA & EnviroPrint CHEMICALS 1.1. Process Chemical Composition Table 15: PROCESS CHEMICAL COMPOSITION Solution Part Basic Chemical Ingredients EnviroPrint Developer Starter AC Single Carbonates; Halides. CPRA Developer CPRA Developer AC CPRA 330 Developer CPRA Pro Developer CPRA Digital Pro Developer AC EnviroPrint Developer EnviroPrint LR Developer AC EnviroPrint Developer Regenerator EnviroPrint Developer Regenerator HR Part A Amines; Antioxidants; Optical Brighteners Developers as above Part B Para-phenylenediamine derivative. Developers as above Part C Carbonate; Chelate; Amines. CPRA 330 Developer MP EnviroPrint MP45 Developer AC EnviroPrint MP60 Developer EnviroPrint MP108 Developer EnviroPrint MP160 Developer Single Carbonate; Chelate; Amines; Para-phenylenediamine derivative. CPRA Pro Bleach-Fix AC CPRA Bleach-Fix EnviroPrint Bleach-Fix 215 AC EnviroPrint Bleach-Fix 108 AC EnviroPrint Bleach-Fix 70 AC EnviroPrint Bleach-Fix VR AC EnviroPrint Bleach-Fix 55 AC EnviroPrint Bleach-Fix 35 AC EnviroPrint Bleach-Fix 35 RTU AC EnviroPrint Bleach-Fix Regenerator EnviroPrint Electrolytic Bleach-Fix Regen. Part A Ammonium thiosulphate; Sulphites. Bleach-Fixes as above Part B Iron EDTA chelate; Organic acid. EnviroPrint Bio-Bleach AC Single Biodegradable Iron chelate; Bromide. Unilec, Unimatic, Unimatic LR, XL-Rejuvenator Fixers Single Ammonium thiosulphate; Sulphites. EnviroPrint Superflo Stabiliser EnviroPrint Super Stabiliser Single Chelate, Biocide. Ultra Bleach-Fix Extender Single Sulphites. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 30 1.2. Chemical Storage Unopened chemical containers should be kept in dry locations at temperatures between 5-30°C. Storage of chemical concentrates below recommended temperatures may result in formation of precipitates. These precipitates may be dissolved back into solution when mixing from concentrates. Storage above recommended temperatures may cause accelerated deterioration of product and may result in reduced shelf life. Table 16 : MAXIMUM RECOMMENDED CHEMICAL SHELF LIFE SHELF LIFE SOLUTION SHELF LIFE SOLUTION 18 Months 36 Months Bleach-Fixes, Part A Fixers Monopart (MP) Developers Developer Starter Bleach-Fixes, Part B 24 Months Developers, Part A Developers, Part B Developers, Part C Bleaches Stabilisers 1.3. Chemical Handling Precautions Chemical concentrates contain ingredients that may be harmful if allowed to contact skin or eyes. It is highly recommended that all lab personnel be protected from fumes and splashing as noted below. Similar precautions should be exercised when handling mixed replenishers and working tank solutions. 1.4. General Handling Precautions When working directly with imaging solutions, always wear the recommended protective equipment. It is much better to be overprotected than underprotected. Read both the product label and the relevant MSDS (Material Safety Data Sheet) to determine recommended handling precautions, which should comply with current COSHH regulations. A copy of the MSDS sheet should be available from your supervisor, or by contacting your chemical manufacturer. Never assume that you can leave a solution on your skin. If a substance is spilled, do not assume that water can simply be added to clean up any spill. Read the MSDS to be certain that the necessary precautions are taken. Avoid skin and eye contact with concentrated liquids and dry chemicals. Use gloves, aprons and goggles in accordance with MSDS instructions when pouring, mixing, disposing or treating chemical solutions. 1.5. Safe Handling Steps The safest protection to avoid any adverse health effect is to faithfully observe the following safe handling precautions. Read the MSDS and Product Label : They will provide information concerning the necessary precautions for safe handling of any chemical product. Avoid Direct Chemical Contact : Handle all chemical solutions carefully to avoid splashing. Clean up all spills immediately after they occur. Consult the MSDS to determine how to properly clean and dispose of spilled material. Do not raise dust when handling dry chemicals. Keep Work Area and Protective Gear Clean : To minimise chemical contact, always keep chemical work areas clean during and after use. Keep all protective equipment such as goggles, aprons, gloves, respirators, etc. free from chemicals when not in use. Protective equipment should be cleaned daily or Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 31 after each use. All clothing worn while handling chemicals should be laundered at least twice a week. Do not wear chemically contaminated clothing. Wear Protective Equipment : Always wear protective equipment; gloves, aprons and goggles as specified by the MSDS, whenever mixing or pouring chemical concentrates and when cleaning any spill that may result from chemical use. 1.6. Protective Equipment Gloves : Several types of gloves may be useful in your business operation. Short cotton gloves may be useful for preventing fingerprints on photographic film. Tight fitting, chemical resistant disposable gloves provide protection for brief use requirements. Disposable gloves should be discarded after one use and not rinsed for reuse. Reusable, unlined nitrile, butyl rubber or neoprene gloves are the best choice for mixing and working with chemical concentrates and mixed solutions. The MSDS is useful in determining the type of gloves required when handling a specific chemical. Goggles : Goggles are mandatory for mixing chemicals. The goggles must meet the required standards and be CE marked. The goggles should be tight fitting and should not have any openings that would allow chemicals to contact the eye. Safety glasses are not adequate for working with liquid chemicals. Goggles that are available through local hardware suppliers, or those that may have ventilation holes are not suitable for this application, as chemical solutions are able to pass through ventilation holes and contact the eye. Aprons : A protective neoprene apron should always be worn to avoid splashing of chemicals when mixing and pouring. In addition, long pants and sleeve shirts should be worn in conjunction with aprons to protect skin areas, not covered by aprons, from chemical contact. 1.7. Ventilation Chemical concentrates and mixed solutions can liberate irritating vapours and carcinogens, if not handled properly. Some photographic film stabilisers may contain Formaldehyde, which is a potential carcinogen. Generally, photographic labs would be expected to comply with National and Local Health and Safety regulations. Air would not be expected to contain pollutants which may be harmful to employees. However, some chemical vapours can emit unpleasant odours even though the air pollutant does not exceed the “safe” concentration level. Constant presence of odours can indicate a ventilation problem. Symptoms of a poor ventilation problem include scratchy and/or dry throat, itchy irritated eyes, irritated and/or bloody nose, headache, fatigue, nausea, vomiting and loss of consciousness. Though these symptoms are not specific enough to rule out other causes, persistent symptoms may indicate the need to examine the ventilation system. A ventilation rate of 1 cubic metre/minute per person or a general room change over rate of 12-15 times per hour, with a minimum of 20 % fresh air introduction, is generally considered adequate for general ventilation of photographic operations where a moderate to low volume of chemical mixing occurs. A general rule to follow to minimise odours and air pollutants is to keep lids on storage containers, treatment containers and processing equipment, whenever possible. 1.8. First Aid General First Aid procedures for overexposure are as follows : when chemicals are splashed onto the skin, flood the affected skin area with water (see information on contact dermatitis). If skin irritation and C.1.6..... Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 32 redness persist after skin contact and initial washing, call your local doctor. If a chemical is ingested (swallowed), call the doctor or your local poison control centre. Do not take anything as a counter- active agent without first seeking medical advice. If a chemical is splashed into the eye, flush immediately with cool water for at least 15 minutes and seek immediate medical attention. In all instances, the MSDS will provide additional information with regard to precautions and safety data. 1.9. Contact Dermatitis Dermatitis is a broad term used to describe skin inflammation of any kind. Dermatitis can be caused by direct irritants like acids, alkalis, solvents and soaps. Dermatitis can also be due to sensitizers (allergic substances). In the case of sensitizers, dermatitis occurs after repeated contact and can involve a remote or larger skin area than the contacted skin location. Dermatitis can be the result of a chemical in the workplace or it may be the result of a household chemical, bacteria or plant. In the case of workers in the photographic industry, dermatitis is usually due to an allergic response (caused by a sensitising chemical) after prolonged or repeated contact with the chemical. The precautionary health hazard information on the MSDS indicates whether the chemical or chemical solution will cause adverse skin reactions and if that chemical is considered a sensitiser. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 33 2. PROCESS SOLUTION PREPARATION 2.1. Water Typically, standard tap water is acceptable for solution preparation. When well water is used for mixing chemical solutions, water analysis and testing should be considered as a check for water hardness, dissolved solids and other impurities. Depending upon water quality, softening or deionising water to prepare chemical solutions may be necessary. It is essential that filters (25 micron rating) be used in water supply systems. 2.2. Mixing tanks Use of Separate Mixing Tanks Use of separate chemical mixing tanks for each of the three following mixing groups is recommended : A. Developer, Developer Replenisher, Developer Regeneration. B. Bleach-Fix, Bleach-Fix Replenisher; (or Bleach, Bleach Replenisher; Fixer, Fixer Replenisher). C. Superflo Stabiliser and Replenisher. It is recommended that three mixing tanks be used : one for the Developer, one for Bleach-Fixer and one for the Superflo Stabiliser (where used). If only two tanks are available, use one for the Developer and one for all other chemicals. If a single mixing tank must be used for all solutions, it must be triple rinsed with warm water, especially before preparation of any developers. Be certain that all rinse water is drained from mixing tank, delivery pump and hose prior to next use to prevent process contamination. Chemical Mixing Tank Shapes, Sizes and Materials Chemical mixing tank materials must be highly chemical resistant and strong enough to resist flexing under the weight of chemical solutions. All mixing tanks should be shaped for easy draining and transfer of chemical solutions. Material : hard vinyl chloride or stainless steel. To maintain volume accuracy, mixing containers should be resistant to expansion. Size : 5 – 20% greater than the volume being mixed. Shape : Cylindrical. Mixing : Use a pump or impeller for induced agitation or use a manual mixing paddle that insures complete top to bottom mixing. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 34 Calibration marks Accurately calibrated solution level marks should be clearly inscribed on the inner walls of all chemical mixing tanks. Portable mixing tanks should only be used on level surfaces to insure accurate solution levels. Precalibrated tank graduations may be inaccurate. It is recommended that the precalibrated graduation marks be verified for accuracy. 2.3. Chemical Mixing Precautions For optimum process results, it is necessary that mixing instructions provided be followed to insure accurate measuring and mixing of all process solutions. Water Temperature It is important that specified water temperatures be maintained when mixing chemical concentrates. Excessive high temperatures may change chemical properties. Low temperatures may cause insufficient solution mixing. Chemical Mixing When mixing chemical concentrates the stirring action should insure uniform mixing from tank top to bottom. For large batch mixing, a propeller type mixer may be used to insure proper solution mix. Care should be taken to minimise the introduction of air into solution. Chemical Mixing Sequence Always add the recommended volume of water to mixing tank first. When mixing Developer Replenisher, it should be noted that the proper sequence of mixing Parts A, B and C (and D for Negagen Developer Regenerator) should be followed to achieve proper mixing. Chemical precipitates may form should Developer Part A, B and/or C concentrates come in contact with each other prior to dilution with water. Some precipitates may not properly redissolve with dilution. Dissolving Chemical Precipitates Prolonged exposure to cold temperatures may produce crystalline precipitates in concentrates. These precipitates do not affect prepared solution performance as long as they are completely redissolved by warming the affected containers prior to mixing. To do so, immerse the entire concentrate container in a warm water bath. Warm water can be added to any chemical crystal residue that may remain in any chemical drum or bottle. Be certain that the total amount of water added does not exceed the recommended volume needed to create a properly mixed solution. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 35 2.4. Chemical Mixing Procedures Recommended procedures for preparation of the most commonly used replenishers using complete concentrate packs as supplied by Fuji Hunt may be found below. For further information, and for details of mixing with less than full pack quantities, please see either the Fuji Hunt RA4 Technical Bulletin, or the instructions packaged with the chemistry. Procedures for the preparation of working tank solutions from mixed replenisher solutions may also be found below. Table 17 : DEVELOPER REPLENISHER MIXING PROCEDURES CPRA Developer Replenisher / Replenisher AC CPRA Pro / CPRA 330 Developer Replenisher EnviroPrint / EnviroPrint LR Developer Replenisher AC • Fill the mixing tank with a volume of water at 20-30°C that equals about 75% of the desired total mix volume. • Add Developer part A concentrate to the mixing tank. Stir gently. • Add Developer part B concentrate to the mixing tank. Stir gently. • Add Developer part C concentrate to the mixing tank. Stir gently. • Rinse the chemical containers with water to remove the last traces of concentrate. Add rinses to the mixing tank. • Add water to the mixing tank to bring the total solution level to the desired total volume. Stir gently until mix is uniform. EnviroPrint MP45 Developer Replenisher AC • Fill the mixing tank with a volume of water at 20-30°C that equals 74% of the desired total mix volume. • Add the EnviroPrint MP45 Developer AC concentrate at 260 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with a small volume of water to remove the last traces of concentrate. Add rinse to the mixing tank. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 36 EnviroPrint MP60 Developer Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 75% of the desired total mix volume. • Add the EnviroPrint MP60 Developer concentrate at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with a small volume of water to remove the last traces of concentrate. Add rinse to the mixing tank. EnviroPrint MP108 Developer Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 75% of the desired total mix volume. • Add the EnviroPrint MP108 Developer concentrate at 200 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with a small volume of water to remove the last traces of concentrate. Add rinse to the mixing tank. EnviroPrint MP160 Developer Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 75% of the desired total mix volume. • Add the EnviroPrint MP160 Developer concentrate at 200 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with a small volume of water to remove the last traces of concentrate. Add rinse to the mixing tank. EnviroPrint Developer Regenerators • Information on the regeneration of EnviroPrint developer overflow with EnviroPrint Developer Regenerator and EnviroPrint Developer Regenerator HR may be found on page 96 in Appendix 7 “Developer Recycling” in this manual. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 37 Table 18 : DEVELOPER WORKING TANK MIXING PROCEDURES CPRA Developer / CPRA Developer AC Working Tank CPRA Pro / CPRA 330 / CPRA 330 MP Dev Working Tank CPRA Digital Pro Developer Working Tank § EnviroPrint Developer Working Tank EnviroPrint LR Developer AC Working Tank EnviroPrint MP45 AC /MP60 /MP108 /MP160 Dev Working Tank Instructions below are for the preparation of 1 litre of working tank solution from prepared replenisher. Multiply the volumes shown below by the number of litres of working tank solution required to obtain the final mixing volumes : • Fill the mixer with the required volume of Developer Replenisher. For CPRA Developer Replenisher AC, add 600 ml replenisher For CPRA Developer Replenisher, add 700 ml replenisher For CPRA Pro Developer Replenisher, add 800 ml replenisher For CPRA Digital Pro Developer Replenisher AC, add 800ml replenisher For CPRA 330 Developer Replenisher, add 700 ml replenisher For CPRA 330 MP Developer Replenisher, add 700 ml replenisher For EnviroPrint Developer Replenisher, add 700 ml replenisher For EnviroPrint LR Developer Replenisher AC, add 400 ml replenisher For EnviroPrint MP45 Dev. Replenisher AC, add 300 ml replenisher For EnviroPrint MP60 Developer Replenisher, add 400 ml replenisher For EnviroPrint MP108 Developer Replenisher, add 500 ml replenisher For EnviroPrint MP160 Developer Replenisher, add 700 ml replenisher • Measure the following volumes of water and add to the mixer : For CPRA Developer Replenisher AC, add 350 ml water For CPRA Developer Replenisher, add 270 ml water For CPRA Pro Developer Replenisher, add 175 ml water For CPRA Digital Pro Developer Replenisher AC, add 160 ml water For CPRA 330 Developer Replenisher, add 240 ml water For CPRA 330 MP Developer Replenisher, add 250 ml water For EnviroPrint Developer Replenisher, add 260 ml water For EnviroPrint LR Developer Replenisher AC, add 510 ml water For EnviroPrint MP45 Dev. Replenisher AC, add 570 ml water For EnviroPrint MP60 Developer Replenisher, add 535 ml water For EnviroPrint MP108 Developer Replenisher, add 450 ml water For EnviroPrint MP160 Developer Replenisher, add 250 ml water • Using a graduated cylinder, measure the volume of Developer Starter ‡ required. Pour in Starter. ‡ EnviroPrint Universal Developer Starter is requi red for making fresh tank solutions from all Fuji Hunt non-Ai r Control RA4 developers ( i.e. the non-AC developers) as li sted below : Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 38 For CPRA Developer Replenisher, add 30 ml Universal Starter For CPRA Pro Developer Replenisher, add 25 ml Universal Starter For CPRA 330 Developer Replenisher, add 60 ml Universal Starter For CPRA 330 MP Developer Replenisher, add 50 ml Universal Starter For EnviroPrint Developer Replenisher, add 40 ml Universal Starter For EnviroPrint MP60 Dev. Replenisher, add 65 ml Universal Starter For EnviroPrint MP108 Dev. Replenisher, add 50 ml Universal Starter For EnviroPrint MP160 Dev. Replenisher, add 50 ml Universal Starter See previous page for starter additions for non-AC Developers ‡ EnviroPrint Developer Starter AC is requi red for making fresh tank solutions from al l Fuji Hunt Ai r Control RA4 developers ( i .e. the AC developers) as l isted below : For CPRA Developer Replenisher AC, add 50 ml Developer Starter AC For CPRA Digital Pro Dev AC Rep, add 40 ml Developer Starter AC For EnviroPrint LR Dev. Replenisher AC, add 90 Developer Starter AC For EnviroPrint MP45 Dev. Rep. AC, add 130 ml Developer Starter AC • Add a small amount of water to the graduated cylinder to remove last traces of Starter. Pour into tank and recirculate until uniform. See Table 25 on page 47 if you are still using up stocks of older EnviroPrint starters. § Preparation of CPRA Digital Pro Developer AC Working Tank : When refilling a processor that may have some water remaining in the pipework (a common problem), you can achieve an improved startup by adding an extra 5% developer replenisher when preparing the tank solution. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 39 Table 19 : BLEACH-FIX REPLENISHER MIXING PROCEDURES CPRA Pro Bleach-Fix & Replenisher AC EnviroPrint Bleach-Fix & Replenisher 215 AC • Fill the mixing tank with a volume of water at 20-30°C that equals 72% of the desired total mix volume. • Add the CPRA or EnviroPrint Bleach-Fix AC concentrate, part A at 120 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the CPRA or EnviroPrint Bleach-Fix AC concentrate, part B at 160 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bleach-Fix Replenisher 108 AC • Fill the mixing tank with a volume of water at 20-30°C at 640 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 108 AC concentrate, part A at 180 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 108 AC concentrate, part B at 180 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bleach-Fix Replenisher 70 AC • Fill the mixing tank with a volume of water at 20-30°C at 560 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 70 AC concentrate, part A at 220 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 70 AC concentrate, part B at 220 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 40 EnviroPrint Bleach-Fix Replenisher 55 AC • Fill the mixing tank with a volume of water at 20-30°C at 500 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 55 AC concentrate, part A at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 55 AC concentrate, part B at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bleach-Fix Replenisher 35 AC • Fill the mixing tank with a volume of water at 20-30°C at 330 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 35 AC concentrate, part A at 335 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 35 AC concentrate, part B at 335 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bleach-Fix Replenisher 35 RTU AC • Add the EnviroPrint Bleach-Fix 35 RTU AC concentrate, part A at 500 ml/l to the mixing tank. • Add the EnviroPrint Bleach-Fix 35 RTU AC concentrate, part B at 500 ml/l to the mixing tank. Stir well. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 41 EnviroPrint Bio-Bleach-Fix Replenisher & Working Tank • Fill the mixing tank with a volume of water at 20-30°C at 764 ml/litre of the desired total mix volume. • Add the EnviroPrint Bio-Bleach-Fix concentrate, part A at 112 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bio-Bleach-Fix concentrate, part B at 124 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. Information on EnviroPrint Bio-Bleach-Fix regeneration may be found in Appendix 8, Bleach-Fix Recycling, on page 99. Table 20 : BLEACH-FIX MIXING PROCEDURES : WORKING TANK SOLUTIONS CPRA Pro Bleach-Fix & Replenisher AC EnviroPrint Bleach-Fix & Replenisher 215 AC EnviroPrint Bio-Bleach-Fix & Replenisher • CPRA Pro Bleach-Fix AC, EnviroPrint Bleach-Fix 215 AC, and EnviroPrint Bio-Bleach-Fix Working Tank solution are the same as the Replenisher. Use undiluted replenisher when refilling processor bleach-fix tanks. EnviroPrint Bleach-Fix 108 AC Working Tank EnviroPrint Bleach-Fix 70 AC Working Tank EnviroPrint Bleach-Fix 55 AC Working Tank • Fill the mixing tank with a volume of water at 20-30°C at 750 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 108, 70 or 55 AC concentrate, part A at 125 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 108, 70 or 55 AC concentrate, part B at 125 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 42 EnviroPrint Bleach-Fix 35 AC Working Tank • Fill the mixing tank with a volume of water at 20-30°C at 666 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 35 AC concentrate, part A at 167 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 35 AC concentrate, part B at 167 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bleach-Fix 35 RTU AC Working Tank • Fill the mixing tank with a volume of water at 20-30°C at 500 ml/litre of the desired total mix volume. • Add the EnviroPrint Bleach-Fix 35 RTU AC concentrate, part A at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add the EnviroPrint Bleach-Fix 35 RTU AC concentrate, part B at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 43 Alternative preparation of Bleach-Fix Working Tank, starting from Replenisher Instructions below are for the preparation of 1 litre of working tank solution from prepared replenisher. Multiply the volumes shown below by the number of litres of working tank solution required to obtain the final mixing volumes : CPRA Pro Bleach-Fix AC Working Tank EnviroPrint Bleach-Fix 215 AC Working Tank EnviroPrint Bio-Bleach-Fix Working Tank • CPRA Pro Bleach-Fix AC, EnviroPrint Bleach-Fix 215 AC, and EnviroPrint Bio-Bleach-Fix Working Tank solution are the same as the Replenisher. Use undiluted replenisher when refilling processor bleach-fix tanks. For all other bleach-fix replenishers, please see below : • Fill the mixer with the required volume of Bleach-Fix Replenisher. For EnviroPrint Bleach-Fix Replenisher 108 AC, add 690 ml replenisher For EnviroPrint Bleach-Fix Replenisher 70 AC, add 570 ml replenisher For EnviroPrint Bleach-Fix Replenisher 55 AC, add 500 ml replenisher For EnviroPrint Bleach-Fix Replenisher 35 AC, add 500 ml replenisher For EnviroPrint Bleach-Fix Rep. 35 RTU AC, add 500 ml replenisher • Measure the following volumes of water and add to the mixer : For EnviroPrint Bleach-Fix Replenisher 108 AC, add 310 ml water For EnviroPrint Bleach-Fix Replenisher 70 AC, add 430 ml water For EnviroPrint Bleach-Fix Replenisher 55 AC, add 500 ml water For EnviroPrint Bleach-Fix Replenisher 35 AC, add 500 ml water For EnviroPrint Bleach-Fix Replenisher 35 RTU AC, add 500 ml water Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 44 Table 21 : STOP BATH MIXING PROCEDURES (for Process RA404) RA4 Stop Bath & Replenisher • Fill the mixing tank with a volume of water at 20-30°C at 988.3 ml/litre of the desired total mix volume. • Add Acetic Acid 60% w/w at 11.7 ml/l to the mixing tank. Stir well. • Use as Replenisher or fresh Working Tank. Table 22 : BLEACH BATH MIXING PROCEDURES (for Process RA404) EnviroPrint Bio-Bleach Replenisher • Fill the mixing tank with a volume of water at 20-30°C at 748 ml/litre of the desired total mix volume. • Add the EnviroPrint Bio-Bleach concentrate at 250 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add Nitric Acid 20% w/w at 6.3 ml/l to the mixing tank. Stir well. EnviroPrint Bio-Bleach Working Tank • Fill the mixing tank with a volume of water at 20-30°C at 835 ml/litre of the desired total mix volume. • Add the EnviroPrint Bio-Bleach concentrate at 165 ml/l to the mixing tank. Stir well. • Rinse the concentrate container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Stir well. EnviroPrint Bio-Bleach Regeneration • Information on the regeneration of EnviroPrint Bio-Bleach overflow may be found on page 104 in Appendix 9 “Bleach and Fix Regeneration” in this manual. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 45 Table 23 : FIXER REPLENISHER MIXING PROCEDURES (for Process RA404) Unilec Fixer Working Tank & Replenisher 1+4 for non-closed loop silver recovery* Unimatic Fixer Working Tank & Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 80% of the known tank volume. • Add the fixer concentrate at 200 ml/l to the mixing tank. Stir gently. * Note : See also the Fuji Hunt Technical Bulletin “Fixing Systems” for full information on the process options available. Unilec Fixer Replenisher 1+3 for closed loop silver recovery* Unimatic Fixer Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 75% of the known tank volume. • Add the fixer concentrate at 250 ml/l to the mixing tank. Stir gently. * Notes : Use Unilec or Unimatic Fixer diluted 1+ 4 (as above) for preparation of fresh Working Tank solution for use with these replenishers. See also the Fuji Hunt Technical Bulletin “Fixing Systems” for full information on the process options available. EnviroPrint Fixer Replenisher • Fill the mixing tank with a volume of water at 20-30°C that equals 65.6% of the desired total mix volume. • Add the EnviroPrint Fixer concentrate at 333 ml/l to the mixing tank. Stir gently. • Rinse the chemical container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add Sulphuric Acid 20% w/w at 11 ml/l to the mixing tank. Stir gently. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 46 EnviroPrint Fixer Working Tank • Fill the mixing tank with a volume of water at 20-30°C that equals 82.64% of the desired total mix volume. • Add the EnviroPrint Fixer concentrate at 167 ml/l to the mixing tank. Stir gently. • Rinse the chemical container with water to remove the last traces of concentrate. Add rinse to the mixing tank. • Add Sulphuric Acid 20% w/w at 6.6 ml/l to the mixing tank. Stir gently. Table 24 : STABILISER REPLENISHER and WORKING TANK MIXING PROCEDURES Stabilisers - Working Tank • For all Stabilisers, the Working Tank solution is the same as the Replenisher. EnviroPrint Superflo Stabiliser & Replenisher AC • Fill the mixing or processor tank with a volume of water at 20- 30°C that equals 99.2% of the desired total mix volume. • Add the EnviroPrint Superflo Stabiliser AC concentrate at 8 ml/l to the mixing or processor tank. Stir gently. • Rinse the chemical container with water to remove the last traces of concentrate. Add rinse to the mixing tank. EnviroPrint Super Stabiliser & Replenisher AC • Fill the mixing tank with a volume of water at 20-30°C that equals 99% of the desired total mix volume. • Add the EnviroPrint Super Stabiliser concentrate at 10 ml/l to the mixing tank. Stir gently. • Rinse the chemical container with water to remove the last traces of concentrate. Add rinse to the mixing tank. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 47 Table 25 : USE OF OLDER DEVELOPER STARTERS The correct starter for all CPRA and EnviroPrint Developers (non-Air Controlled) is EnviroPrint Universal Developer Starter (Catalogue Number 979328); the correct starter for all Air Controlled (AC) CPRA and EnviroPrint Developers is EnviroPrint Developer Starter AC (Catalogue Number 971655). Many users of Fuji Hunt chemistry may have stocks of older starters that they either wish to use up, or that need to be used in an emergency. Alternative starters to the two Universal Starters listed above can be used for the following tank solutions. The Bottle Number given below is the part number that can be found on the various starter bottles to ensure that you identify these starters correctly. This is not the same as the six-digit Catalogue Number, which applies only to 6 x 1 litre packs of starter bottles, and begins with a 9. Developer Starter Bottle Number Catalogu e Number Starter Volume Required CPRA Developer EnviroPrint Developer Starter 758656 949560 50 ml/litre CPRA Developer AC EnviroPrint Developer Starter AC 767400 971655 50 ml/litre CPRA Pro Developer EnviroPrint Developer Starter 758656 949560 25 ml/litre CPRA 330 Developer CPRA 330 Developer Starter EnviroPrint Developer Starter 755314 758656 943480 949560 50 ml/litre 50 ml/litre EnviroPrint Developer EC101 Developer Starter EnviroPrint Developer Starter 754523 758656 941674 949560 35 ml/litre 35 ml/litre EnviroPrint Dev. LR AC EnviroPrint Developer Starter AC 767400 971655 90 ml/litre Note : NEVER use any Negacolor, E6 (Pro6) or CPR3 Developer Starters when mixing RA4 developers; these starters all contain sodium bromide and are completely incompatible with the RA4 process. Use of older starters with EnviroPrint MP or CPRA Digital Pro AC developers has not been tested. Starters for Bleach-Fix, Fixer and Stabiliser Working Tank solutions No starters are required for the bleach-fix, fixer and stabiliser baths. Note that the Working Tank solution for some of these products is identical to the Replenisher; for others additional water is required. See the Mixing Instructions for the product required for details. Starters for EnviroPrint Bio-Bleach-Fix and Bio-Bleach Working Tank solutions No starter is available for preparation of EnviroPrint Bio-Bleach-Fix or Bio-Bleach Working Tank solutions from the appropriate Replenisher. If you need to prepare a new EnviroPrint Bio-Bleach-Fix or Bio-Bleach Working Tank, prepare it directly from the concentrate, and not from replenisher. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 48 2.5. Process Solution pH and Density (Specific Gravity) It is recommended that the density of all freshly prepared solutions (except Superflo Stabilisers) be measured, and that those measurements be verified against the table below for solution mix accuracy. Measurements for the density of working tank solutions should be taken daily (for main processors in photofinishing laboratories), or every three days (for minilabs and professional laboratory processors) to ensure optimum process control. Developer density is the most critical parameter. The solution pH value should be occasionally verified with the use of a high quality pH meter. The pH of the tank and replenisher solutions should be within specifications, but pH should not be used as a process control tool. If the values for density and/or pH fall outside normal working tolerances, the photographic process will be adversely affected. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 49 Table 26 : FRESHLY PREPARED SOLUTIONS pH AND DENSITY SPECIFICATIONS FOR FRESHLY PREPARED SOLUTIONS Product Tank Replenisher pH (25°C) Density (20°C) g/cm³ Density (25°C) g/cm³ pH (25°C) Density (20°C) g/cm³ Density (25°C) g/cm³ CPRA Developer 10.25 ± 0.05 1.026 ± 0.003 1.025 ± 0.003 10.69 ± 0.05 1.030 ± 0.003 1.029 ± 0.003 CPRA Developer AC 10.20 ± 0.05 1.025 ± 0.003 1.024 ± 0.003 10.60 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 CPRA Pro Developer 10.35 ± 0.05 1.027 ± 0.003 1.026 ± 0.003 10.70 ± 0.05 1.028 ± 0.003 1.027 ± 0.003 CPRA Digital Pro Developer AC 10.25 ± 0.05 1.034 ± 0.003 1.033 ± 0.003 10.70 ± 0.05 1.034 ± 0.003 1.033 ± 0.003 CPRA 330 Developer 10.15 ± 0.05 1.030 ± 0.003 1.029 ± 0.003 10.90 ± 0.05 1.028 ± 0.003 1.027 ± 0.003 CPRA 330 Developer MP 10.75 ± 0.05 1.030 ± 0.003 1.029 ± 0.003 12.00 ± 0.05 1.034 ± 0.003 1.033 ± 0.003 EnviroPrint Developer 10.15 ± 0.05 1.028 ± 0.003 1.027 ± 0.003 10.70 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 EnviroPrint Developer MP160 10.42 ± 0.05 1.028 ± 0.003 1.027 ± 0.003 11.95 ± 0.05 1.029 ± 0.003 1.028 ± 0.003 EnviroPrint Developer MP108 10.33 ± 0.05 1.026 ± 0.003 1.025 ± 0.003 12.00 ± 0.05 1.034 ± 0.003 1.033 ± 0.003 EnviroPrint Developer LR AC 10.10 ± 0.05 1.027 ± 0.003 1.026 ± 0.003 11.15 ± 0.05 1.036 ± 0.003 1.035 ± 0.003 EnviroPrint Developer MP60 10.25 ± 0.05 1.025 ± 0.003 1.024 ± 0.003 12.20 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 EnviroPrint Developer MP45 AC 10.15 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 12.50 ± 0.05 1.042 ± 0.003 1.041 ± 0.003 EnviroPrint CP48 Developer 10.15 ± 0.05 1.046 ± 0.003 1.045 ± 0.003 12.50 ± 0.05 1.043 ± 0.003 1.042 ± 0.003 CPRA Pro Bleach-Fix AC 5.80 ± 0.20 1.070 ± 0.005 1.069 ± 0.005 5.80 ± 0.20 1.070 ± 0.005 1.069 ± 0.005 EnviroPrint Bleach-Fix 215 AC 5.80 ± 0.20 1.072 ± 0.005 1.071 ± 0.005 5.80 ± 0.20 1.072 ± 0.005 1.071 ± 0.005 EnviroPrint Bleach-Fix 108 AC 5.80 ± 0.20 1.068 ± 0.005 1.067 ± 0.005 5.70 ± 0.20 1.096 ± 0.005 1.095 ± 0.005 EnviroPrint Bleach-Fix 70 AC 5.80 ± 0.20 1.068 ± 0.005 1.067 ± 0.005 5.60 ± 0.20 1.117 ± 0.005 1.116 ± 0.005 EnviroPrint Bleach-Fix 55 AC 5.80 ± 0.20 1.068 ± 0.005 1.067 ± 0.005 5.60 ± 0.20 1.133 ± 0.005 1.132 ± 0.005 EnviroPrint Bleach-Fix VLR RTU 5.80 ± 0.20 1.067 ± 0.005 1.066 ± 0.005 5.65 ± 0.20 1.131 ± 0.005 1.130 ± 0.005 EnviroPrint Bleach-Fix 35 AC 6.20 ± 0.20 1.085 ± 0.005 1.084 ± 0.005 6.00 ± 0.20 1.160 ± 0.005 1.159 ± 0.005 EnviroPrint Bl-Fix 35 AC RTU 6.20 ± 0.20 1.085 ± 0.005 1.084 ± 0.005 6.00 ± 0.20 1.160 ± 0.005 1.159 ± 0.005 EnviroPrint CP48 Bleach-Fix 6.80 ± 0.20 1.081 ± 0.005 1.080 ± 0.005 6.00 ± 0.20 1.160 ± 0.005 1.159 ± 0.005 EnviroPrint Bio-Bleach-Fix 6.50 ± 0.20 1.072 ± 0.005 1.071 ± 0.005 6.50 ± 0.20 1.072 ± 0.005 1.071 ± 0.005 EnviroPrint Bio-Bleach 3.40 ± 0.10 1.039 ± 0.003 1.038 ± 0.003 3.20 ± 0.10 1.059 ± 0.003 1.058 ± 0.003 XL Rejuvenator Use Unilec or Unimatic Fixer for fresh start-up. Unilec Fixer (1 + 4) 7.50 ± 0.20 1.087 ± 0.010 1.086 ± 0.010 7.50 ± 0.20 1.087 ± 0.010 1.086 ± 0.010 Unilec Fixer (1 + 3) / / / 7.50 ± 0.20 1.110 ± 0.010 1.109 ± 0.010 Unimatic Fixer (1 + 4) 6.50 ± 0.20 1.080 ± 0.010 1.079 ± 0.010 6.50 ± 0.20 1.080 ± 0.010 1.079 ± 0.010 EnviroPrint Fixer 7.50 ± 0.20 1.050 ± 0.010 1.049 ± 0.010 7.50 ± 0.20 1.097 ± 0.010 1.096 ± 0.010 Specifications when used for Fast RA4 processing (see also Appendix 11, page 118) EnviroPrint Developer MP60 (1) 10.15 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 12.20 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 EnviroPrint Developer MP45AC 10.20 ± 0.05 1.027 ± 0.003 1.026 ± 0.003 12.50 ± 0.05 1.042 ± 0.003 1.041 ± 0.003 Note : (1) With recommended addition of RA4 Quick Starter for 27 seconds process EnviroPrint Bleach-Fix 70 AC 5.70 ± 0.05 1.082 ± 0.005 1.081 ± 0.005 5.65 ± 0.20 1.115 ± 0.005 1.114 ± 0.005 EnviroPrint Bleach-Fix 35 AC 6.20 ± 0.05 1.085 ± 0.005 1.084 ± 0.005 6.00 ± 0.20 1.160 ± 0.005 1.159 ± 0.005 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 50 Table 27 : SEASONED WORKING TANK SOLUTIONS pH AND DENSITY SPECIFICATIONS FOR SEASONED REPLENISHED SOLUTIONS (1) Product Tank pH (25°C) Density (20°C) g/cm³ Density (25°C) g/cm³ Density (processing temperature) (2) g/cm³ CPRA Developer 10.20 ± 0.05 1.030 ± 0.003 1.029 ± 0.003 1.026 ± 0.003 CPRA Developer AC 10.15 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 1.027 ± 0.003 CPRA Pro Developer 10.15 ± 0.05 1.032 ± 0.003 1.031 ± 0.003 1.028 ± 0.003 CPRA Digital Pro Developer AC 10.15 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 1.032 ± 0.003 CPRA 330 Developer MP 10.50 ± 0.05 1.035 ± 0.003 1.034 ± 0.003 1.032 ± 0.003 CPRA 330 Developer 10.15 ± 0.05 1.029 ± 0.003 1.028 ± 0.003 1.026 ± 0.003 EnviroPrint Developer 10.15 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 1.026 ± 0.003 EnviroPrint Developer MP160 10.30 ± 0.05 1.031 ± 0.003 1.030 ± 0.003 1.026 ± 0.003 EnviroPrint Developer MP108 10.25 ± 0.05 1.035 ± 0.003 1.034 ± 0.003 1.030 ± 0.003 EnviroPrint Developer LR AC 10.05 ± 0.05 1.036 ± 0.003 1.035 ± 0.003 1.031 ± 0.003 EnviroPrint Developer MP60 10.20 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 1.032 ± 0.003 EnviroPrint Developer MP45 AC 10.08 ± 0.05 1.050 ± 0.003 1.049 ± 0.003 1.045 ± 0.003 EnviroPrint CP48 Developer 10.15 ± 0.05 1.046 ± 0.003 1.045 ± 0.003 1.041 ± 0.003 CPRA Pro Bleach-Fix AC 6.50 ± 0.20 1.072 ± 0.010 1.071 ± 0.010 1.068 ± 0.010 EnviroPrint Bleach-Fix 215 AC 6.50 ± 0.20 1.074 ± 0.010 1.073 ± 0.010 1.070 ± 0.010 EnviroPrint Bleach-Fix 108 AC 6.50 ± 0.20 1.087 ± 0.010 1.086 ± 0.010 1.082 ± 0.010 EnviroPrint Bleach-Fix 70 AC 6.70 ± 0.20 1.097 ± 0.010 1.096 ± 0.010 1.092 ± 0.010 EnviroPrint Bleach-Fix 55 AC 6.70 ± 0.20 1.102 ± 0.010 1.101 ± 0.010 1.096 ± 0.010 EnviroPrint Bleach-Fix VLR RTU 6.70 ± 0.20 1.090 ± 0.010 1.089 ± 0.010 1.086 ± 0.010 EnviroPrint Bleach-Fix 35 AC 7.20 ± 0.20 1.125 ± 0.010 1.124 ± 0.010 1.120 ± 0.010 EnviroPrint Bleach-Fix 35 AC RTU 7.20 ± 0.20 1.125 ± 0.010 1.124 ± 0.010 1.120 ± 0.010 EnviroPrint CP48 Bleach-Fix 7.00 ± 0.20 1.131 ± 0.010 1.130 ± 0.010 1.126 ± 0.010 EnviroPrint Bio-Bleach 3.60 ± 0.10 1.039 ± 0.005 1.038 ± 0.005 1.036 ± 0.005 Unilec Fixer (1 + 4) 6.70 ± 0.50 1.090 ± 0.020 1.089 ± 0.020 1.087 ± 0.020 Unimatic Fixer (1 + 4) 6.40 ± 0.20 1.085 ± 0.020 1.084 ± 0.020 1.082 ± 0.020 EnviroPrint Fixer 7.50 ± 0.50 1.070 ± 0.020 1.069 ± 0.020 1.067 ± 0.020 Specifications when used for Fast RA4 processing (see also Appendix 11, page 118) EnviroPrint Developer MP60 10.10 ± 0.05 1.040 ± 0.003 1.039 ± 0.020 1.035 ± 0.020 EnviroPrint Developer MP45 AC 10.15 ± 0.05 1.050 ± 0.003 1.049 ± 0.020 1.045 ± 0.020 EnviroPrint Bleach-Fix 70 AC 6.75 ± 0.20 1.100 ± 0.010 1.099 ± 0.020 1.095 ± 0.020 EnviroPrint Bleach-Fix 35 AC 6.80 ± 0.20 1.125 ± 0.010 1.124 ± 0.020 1.120 ± 0.020 (1) After 3 tank turnovers. (2) Recommended mid-specification processing temperature, see page 15. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 51 Table 28 : SEASONED RECYCLED WORKING TANK SOLUTIONS pH AND DENSITY SPECIFICATIONS FOR SEASONED RECYCLED SOLUTIONS (1) Product Tank pH (25°C) Density (20°C) g/cm³ Density (25°C) g/cm³ Density (processing temperature) (2) g/cm³ EnviroPrint Developer Regenerator 55/45 10.15 ± 0.05 1.037 ± 0.003 1.036 ± 0.003 1.032 ± 0.003 EnviroPrint Developer Regen. HR 65/35 10.20 ± 0.05 1.041 ± 0.003 1.040 ± 0.003 1.036 ± 0.003 EnviroPrint Developer Regen. HR 70/30 10.25 ± 0.05 1.042 ± 0.003 1.041 ± 0.003 1.037 ± 0.003 EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator 6.60 ± 0.20 1.115 ± 0.020 1.114 ± 0.020 1.111 ± 0.020 EnviroPrint Electrolytic Bleach-Fix Regenerator 6.60 ± 0.20 1.115 ± 0.020 1.114 ± 0.020 1.111 ± 0.020 EnviroPrint Bleach-Fix Regenerator 6.40 ± 0.20 1.115 ± 0.020 1.114 ± 0.020 1.111 ± 0.020 EnviroPrint Bio-Bleach 3.60 ± 0.10 1.027 ± 0.003 1.026 ± 0.003 1.024 ± 0.003 XL Rejuvenator 6.70 ± 0.50 1.090 ± 0.020 1.089 ± 0.020 1.087 ± 0.020 EnviroPrint Fixer 7.50 ± 0.50 1.075 ± 0.020 1.074 ± 0.020 1.072 ± 0.020 Product Replenisher pH (25°C) Density (20°C) g/cm³ Density (25°C) g/cm³ EnviroPrint Developer Regenerator 10.70 ± 0.03 1.036 ± 0.003 1.035 ± 0.003 EnviroPrint Developer Regen. HR 65/35 10.75 ± 0.03 1.040 ± 0.003 1.039 ± 0.003 EnviroPrint Developer Regen. HR 70/30 10.80 ± 0.03 1.041 ± 0.003 1.040 ± 0.003 EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator 6.30 ± 0.20 1.125 ± 0.020 1.124 ± 0.020 EnviroPrint Electrolytic Bleach-Fix Regenerator 6.30 ± 0.20 1.125 ± 0.020 1.124 ± 0.020 EnviroPrint Bleach-Fix Regenerator 5.80 ± 0.20 1.125 ± 0.020 1.124 ± 0.020 EnviroPrint Bio-Bleach 3.20 ± 0.10 1.035 ± 0.003 1.034 ± 0.003 XL Rejuvenator 6.70 ± 0.50 1.100 ± 0.020 1.099 ± 0.020 EnviroPrint Fixer 7.50 ± 0.50 1.115 ± 0.020 1.114 ± 0.020 (1) After 3 regeneration cycles. (2) Recommended mid-spec processing temperature, see page 15. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 52 3. PROCESS SOLUTION STORAGE 3.1. Solution Storage Because all chemical solutions can be affected by air, there are certain recommendations for proper storage of all chemical replenisher solutions. All solution storage containers should be equipped with floating lids and tank covers for protection against dust/dirt, evaporation and excessive chemical oxidation. Completely filled plastic bottles may also be used for storing smaller quantities of mixed replenishers, and also for the temporary storage of working tank solutions removed from small processors during periods of no throughput. Chemicals existing in replenishers and working tank solutions may precipitate out of solution at temperatures below 4°C. Therefore, it is recommended that mixed chemical solutions be stored at temperatures above 16°C and below 30°C . Storage in temperatures exceeding 30°C may degrade solution performance. For best results, do not use solutions that have been stored for periods longer than those indicated in the table below or those stored in adverse conditions described above. All Fuji Hunt chemicals for use with the RA4/RA404 processes are supplied as all-liquid concentrates. They dissolve readily in water and no excessive mixing time is required. A maximum of 30 seconds mixing is needed to ensure complete dissolution after the addition of each concentrate to the solution being prepared. None of the chemicals when used under normal conditions is subject to undue oxidation. However, the volume of developer replenisher prepared should not be for more than one week’s normal consumption. Longer storage times will increase the degree of oxidation and lead to lower process activity. Table 29 : PROCESS SOLUTION AND REPLENISHER SHELF LIFE SOLUTIONS WITH FLOATING LIDS WITHOUT FLOATING LIDS Fresh Solutions Seasoned Solutions Al l Solutions Developer 2 Weeks 1 Week 1 Week Developer Replenisher 2 Weeks - 1 Week Bleach-Fix 2 Weeks 1 Week 1 Week Bleach-Fix Replenisher 2 Weeks - 1 Week Bleach 4 Weeks 2 Weeks 2 Weeks Bleach Replenisher 4 Weeks - 2 Weeks Fixer 2 Weeks 1 Week 1 Week Fixer Replenisher 2 Weeks - 1 Week All Other Solutions 24 Weeks 12-16 Weeks 8-12 Weeks These recommended figures are based on full tanks. As the surface to volume ratio increases, oxidation accelerates. 3.2. Waste Water and Solution Treatment If waste water and chemical solutions are to be discharged into public sewer systems, be certain that the combined effluent falls within the acceptable local code discharge limits. If it is not possible to operate within the recommended discharge limits, a licensed independent waste hauling and treatment facility should be contacted to guarantee correct and safe disposal. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 53 D. PROCESS QUAL I TY CONTROL 1. PROCESS QUALITY CONTROL OBJECTIVES AND EFFECTS For purposes of this manual, the phrase "quality control" refers to actions taken during systematic Process RA4 / RA404 monitoring that produces high quality results on Fujicolor and other process RA4 / Super FA compatible colour papers. Unless the process is properly monitored and controlled within specific limits, it may become necessary to periodically stop commercial processing to bring process conditions back into control, increasing costs and disrupting schedules. To provide prompt and high quality processing of photographic paper at the lowest possible cost, it is essential that the RA4 process be systematically monitored and controlled to within specific limits. These process control actions involve three sets of standard procedures : 1. Process condition evaluation procedure 2. Process result evaluation procedure 3. Problem detection and elimination procedure This section describes the standard process and quality control procedures required to obtain optimum results with all process RA4 compatible colour papers. Practising process control as a standard operating procedure ensures optimum results for your customers. Variations in the RA4 processing sensitometry between different processors results in greatly increased variability in the inherent variations between different printers, particularly in larger laboratories using more than one processor supplied by a number of printers. This causes many problems in printing, and inconsistent results. Additionally, although the RA4 process in general is far more tolerant of marginal out-of-control process situations than film processes, significant deviations can and will result in uncorrectable colour casts in prints (often a green / magenta cross curve) that are particularly evident in prints including an extended grey scale. When process condition evaluation is needed, please refer to the Process Check Sheets and the Process Solution Control Chart contained in Appendix 1 on page 69. 2. PROCESS MONITORING 2.1. Process Control Strips It is recommended that the activity level of the chemical baths in each paper processor should be monitored daily. Pre-exposed control strips should be run at least 2 or 3 times each day in busy laboratories; the first strip prior to processing paper, and then at evenly spaced intervals during production. Whenever corrective action is taken, either to improve process control or adjust the processing machine, a control strip should be run to determine the effects of the change. It is wise to adjust the processor only after a trend has been established, which usually requires at least three control strips to have been run. It is strongly urged that each photo-processing laboratory keeps at least two code numbers of series of strips on hand as variation between different series can be quite large. Sharp variations with a new code number may not be caused by the processor, but rather may be the difference between the control strips themselves. It should be standard practice to process two strips with the new and old codes together to check that both strips record the same chemical activity. It is also recommended that the densitometer be re-calibrated and that reference strips be re-read in case any large deviations are experienced. This procedure will eliminate erroneous readings due to a problem with the densitometer or strips. In particular, changes may be noticed when an old box of strips that may have been in use for some time and possibly not stored in ideal conditions is changed for a fresh, properly stored, box of control strips. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 54 2.2. Processing Solution Checks Processing solutions should be checked daily for variations in process conditions. It is recommended that these results be recorded to monitor trends in process control. This record will enable process operators to acquire a full understanding of process solutions and conditions. The Fuji Hunt OASIS Pro Compact (or OASIS Pro) program is ideal for this purpose. 2.3. Solution Conditions It is suggested that tank solutions be checked for condition changes at the beginning of each day. Typical process problems are listed in Table 30 . Most process control problems are traced to variations in developer density (s.g.), temperature, squeegee problems, replenishment rate too high or too low, or inadequate circulation. Occasionally, chemicals are mixed improperly, processor speed/timing is incorrect, and sometimes the bleach-fix is underactive or overloaded with developer. Problems indicated by out of control LD values are usually traceable to the developer step. Low red values, on the other hand, are most often caused by underactive bleach-fix. Contrast is generally little affected by developer variations, except with contamination or in extreme cases. A good indicator of developer activity is the DMax; this is where the developer is working hardest and poor or uneven DMax is a sure sign of developer underactivity or (especially on roller transport processors) poor developer agitation. As a general rule, where you have a choice of actions for solving or investigating a process control problem and you have no specific indication that one particular course of action is the answer, choose a simple physical change as the first test - usually temperature. It is easy to change a temperature up or down, and little time is lost. You should only make chemical changes when you have checked the basic physical parameters - once you have put chemicals (or water) into a processor tank, you cannot take them out ! Do not forget to process a further strip if you have made a change to the process. Note : For our purposes, "solution condition" refers to the visually confirmed state of various processing solutions. The visual inspection checks are relative to colour, cloudiness, precipitation and floating matter. All tank solutions are susceptible to colour change because of process volume and solution carry-in, and in particular developer colour is very dependent on the make of paper processed – each manufacturers’ paper will impart its own very distinct coloration to the developer due to dyes that wash out of the paper emulsion. This change may be a daily occurrence if a mixture of paper makes are processed, and usually will not affect process solution properties as long as process control is maintained. In the same regard, colour shifts may be related to certain solution problems. Solution condition changes provide important clues to the diagnosis and location of problems. It is recommended that all solutions be carefully checked on a regular basis, and that changes in process conditions be recorded in detail. NOTE : Process control deviations referred to below are based on changes seen with Fuji RA4 / Super FA control strips. Deviations with strips from other manufacturers may not follow exactly the same pattern for any given process fault, although general trends are broadly similar for all makes of strip. Some well known and very specific problems affecting other main paper makes are also listed below. Far more detailed process control information, covering all main paper types found in the market place (as available in late-2002), is provided on the Fuji Hunt RA4 Advanced process control course. Please consult your Fuji Hunt representative for details. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 55 Table 30 : PROCESS TROUBLESHOOTING Problem Probable Cause(s) Corrective Action(s) Low values in LD and D-max. 1. Developer temperature too low. 2. Development time too short. 3. Insufficient developer agitation. 4. Developer underreplenished. 5. Developer oxidised. 6. Incorrect mixing or regeneration of developer replenisher : pH too low, too diluted, insufficient developing agent, too much developer starter added. 1. Increase developer temperature. It should not be necessary to exceed +1°C above process specification. 2. Check developer time is 45 sec. For standard RA4 processors and adjust as necessary. Check developer solution level in processor tank. 3. Check developer filters and recirculation pump. Change as required. Check for blocked spargers / spray bars on roller transport and RA4 “fast process” processors; clean as required. 4. Check and correct developer replenishment rate. Add developer replenisher to processor tank. Take care with regenerated developer systems - underreplenished developer overflows can cause production of an unbalanced replenisher. 5. Dump developer and replace with fresh solution. 6. Check mixing or regeneration chemical additions. Either correct problems with chemical analysis or dump replenisher and replace with a fresh mix. Low blue D-max, possibly low blue LD and HD-LD (Fuji or Agfa paper). Low blue DMax, all colours low on LD and HD-LD (Kodak paper). 1. Developer underreplenished. Low CD3 in developer. Due to either incorrect mixing or regeneration of previously underreplenished developer. 1. Correct as above. Preferably correct by chemical analysis; otherwise add CD3 by adding appropriate concentrate. Take care with regenerated developer systems - incorrect addition can cause unbalanced developer overflows causing production of an unbalanced replenisher. Seriously overconcentrated developer can also cause low DMax values. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 56 Problem Probable Cause(s) Corrective Action(s) High value in LD and D-max. 1. Developer temperature too high. 2. Development time too long. 3. Developer overreplenished. 4. Developer overconcentrated. 5. Incorrect mixing or regeneration of developer/ replenisher : pH too high, too concentrated, excess developing agent; not enough developer starter added. 1. Decrease developer temperature. It should not exceed -1°C below process specification. 2. Check developer time is 45 sec. and adjust as necessary. 3. Check and correct developer replenishment rate. Add developer starter and water to processor tank. Take care with regenerated developer systems - overreplenished developer overflows can cause production of an unbalanced replenisher. 4. Check density and add water to processor to correct to aim. If this is a low throughput processor, instigate a system of regular checks and corrections for density, particularly with EnviroPrint Developer LR AC, MP60 and MP45 AC. Note that high levels of developer overconcentration (with Fuji and Agfa papers) can actually lead to a decrease in the DMax parameter overall, and especially to low blue values. 5. Check mixing or regeneration chemical additions. Either correct problems with chemical analysis or dump replenisher and replace with a fresh mix. High blue D-min (yellowish whites on paper). 1. Exhausted or dirty super stabilizer or washes. 2. Too high a pH in Stop Bath in RA4 separated bleach and fix process. Maximum pH is 4.5. 3. Dirty bleach-fix; usually caused by excessive developer carryover plus low throughput. 1. Dump super stabilizer and replace with fresh solution. Clean and refill wash tanks. 2. Check replenisher mixing and replenishment rate (0.7 % acetic acid solution). Replace stop bath. 3. Dump bleach-fix and replace with fresh solution. Instead, it may be possible to clean the bleach-fix through an active carbon filter. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 57 Problem Probable Cause(s) Corrective Action(s) High blue D-min (yellowish whites on paper). 4. Dirty developer, particularly on low throughput roller transport and possibly leader belt processors. High levels of oxidised developer will create a yellow stain on all papers. 4. It may be possible to clean up the developer by replacing the standard filter cartridge with an activated carbon filter for a few hours. Any carbon filters used for developer in this way must first be soaked in developer (use collected overflow to save waste) for a few hours to prevent excess CD3 (developing agent) absorption from the working tank. Do not use for excessive periods of time or the filter will block. Low red D-max (reddish blacks on paper). 1. pH of bleach-fix too low (or bio- bleach for Process RA404). 2. Bleach-fix time too long. 3. Contamination of developer with super stabilizer. 4. Incorrect mixing or regeneration of developer replenisher : too much antioxidant added. 1. Check and adjust bleach-fix pH to within recommended values. 2. Adjust bleach-fix time to 45 sec. for RA-type bleach-fixes. 3. Dump developer and replace with fresh solution. Ensure that paper leaders are not being reused on processor. On leader belt processors, ensure belts are washed before drying. 4. Check mixing or regeneration chemical additions. Either correct problems with chemical analysis or dump replenisher and replace with a fresh mix. Never add sulphite to developers. Low green D-max and LD (cyan/green blacks on Fuji paper). 1. Developer contaminated with bleach-fix (or fixer on separate bleach and fix systems). 1. Dump developer and replace with fresh solution. Take care with regenerated developer systems – contaminated developer overflows can cause production of a contaminated replenisher. Ensure any contaminated processor is isolated from developer collection system. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 58 Problem Probable Cause(s) Corrective Action(s) Retained silver in paper (verified with infra-red viewer). 1. Underactive bleach-fix - possibly underreplenished bleach-fix, excessive developer carry over, incorrect mixing or regeneration, high ferrous (iron II) levels, etc. 2. Underactive bleach and/or fix (separate bleach and fix systems). 1. Check and adjust developer squeegees; check bleach-fix mixing and replenishment; check bleach-fix time. Correct any chemical errors (density, etc.) by chemical analysis, or dump and replace bleach-fix. 2. Check parameters as for bleach-fix above. Brown precipitation in RA4 fixer tank solution. Excessive carry over of bleach into the fixer tank. Check bleach tank squeegees. Ensure fix pH is between 6.2 and 7.2. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 59 2.4. Density (Specific Gravity) Adjustments Important note : When correcting solution density (and especially when correcting for increased solution density by adding water, which is by far the most common problem), note that the accuracy of any calculations for water or concentrate additions is almost entirely dependent on you (a) knowing what the aim – the desired operating condition – is for the density of the bath being corrected, (b) you measuring the bath density and comparing it with the aim value at the same temperature, as bath density varies greatly with temperature, and (c) you measuring the bath density accurately. It is strongly suggested that when you have calculated a proposed water addition to correct for high solution density, you only add half of the calculated amount. It is very easy to add extra water later if the desired correction has not been achieved; it is very difficult to take the water out again if you add too much. Always recheck the solution density after any water or concentrate additions. See Tables 26 to 28 on pages 49 to 51 for recommended pH and density values for fresh, seasoned and regenerated solutions. Correcting a Rise in Tank Solution Density Tank solution density may rise above tolerance limits when processor utilisation is low compared to processor tempering periods. When this condition exists, it may be necessary to dilute tank solutions with water to lower their density to within tolerance limits. When adjusting tank solution density, use the formula given below to calculate the solution volume to be replaced with water. Then remove the calculated volume of the tank solution and add an equal volume of water to the tank. Recirculate the tank solution until uniform. Verify the density to ensure that the adjustment was correctly performed. V (Litres) = Tank Volume (Litres) x (A – B) (A – 1.000) A =Concentrated solution density B =Desired solution density (aim) V =Volume of tank solution to be removed and volume of water to be added Example : Where the tank volume is 100 litres, the nominal (aim) density is 1.031, and the measured density is 1.035 100 Litres x 1.035 – 1.031 = 11.43 Litres 1.035 – 1.000 Recommended initial addition : half of 11.43 Litres =5.7 Litres Note : It is sensible to only add half of any calculated addition as a first step; it is easy to add more water, not so easy to take out an excessive water addition. Errors in density measurement – even when all samples are measured / compared at the same temperatures – are easy to make, and the effect of temperature on density readings is very significant. Correcting a Decrease in Tank Solution Density When excessive water enters the processing tank, the tank solution density may drop below tolerance limits. Use the following procedure to correct low density values : 1. Remove 500 ml of tank solution and place in a tall one litre graduate. 2. Place the correct solution hydrometer in the graduate. Confirm the solution density. 3. Slowly add solution concentrate to the volume in the graduate, stirring gently while closely monitoring the change in the density. (For Developer, equal parts of A, B and C must be added). Note : when EnviroPrint Monopart (MP) developers are used, the OASIS Pro “SCA” (Single Concentrate Addition) calculation may be used. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 60 4. When the correct solution density is achieved (taking great care to ensure that measured density and aim are compared at the same temperature), calculate the volume of concentrate added to the graduate volume to determine the amount of concentrate to be added to the tank volume. 5. Add this amount of concentrate to each 500 ml of tank solution. (for Developer, equal parts of A, B and C must be added, except for Monopart (MP) Developers). 6. Let the tank solution recirculate and verify the density of the adjusted tank solution. 2.5. Wash Water Checks Wash water flowrates are given in Tables 2, 3, 8 and 9 (pages 12, 19 and 23 ), and discussed in the Processing Conditions section, starting on page 15. Further information may be found below. Wash Water Quality Tap water is generally suitable as wash water. When well water is used, it must be tested for purity and compliance with photographic standards since it may contain minute solid particles (i.e. excess iron, calcium, other metals) or other impurities. It is essential that a 25 micron filter be installed in the water supply line before the flow meter. Clean wash water plays an important part in continually producing quality colour negatives with maximum image stability. Wash Water Flow Rate Wash water effectiveness may vary with processor type, tank capacity, throughput volume and wash water flow rate. The typical wash rate is between 2 and 11 L/m² for a counter-current main wash, depending on the number of wash tanks available. Many larger processors are also fitted with low flow wash tanks between the bleach-fix (or fixer for Process RA404) and main wash; again depending on the processor type, number of tanks and silver recovery requirements, this wash rate will be around 150-250 ml/m², usually fed from the first main wash tank. If the machine manufacturer's recommendations for wash water flow rates differ from the typical wash rate, use the greater of the two rates. Note : When the wash water flow rate is below specification, the film-related solution carry-over concentrations in the water will gradually increase. As a result, process solution components may not be completely removed from the film and may be carried over into the next process solution. These carry-over contaminants may produce adverse effects over a period of time in finished films. Low, ineffective wash water rates will cause poor film stability resulting in faded and/or discoloured film, and also have a major effect on the recycling of fixer in laboratories practising electrolytic silver recovery and fixer recycling. Wash Water Temperature A mixing valve should be installed in the water supply line to maintain a constant water temperature between 30-40°C. The processor's incoming water temperature should be monitored and confirmed on a daily basis prior to the start of each day's workload. Low wash temperatures may affect archival stability of the prints and also adversely affect carryover of bleach into the fixer in Process RA404. Low wash temperatures, and in particular flowrates, can also lead to high stain levels on the paper, and with leader belt processors can lead to bleach-fix being retained on the leader belt itself, which when it returns to the developer can lead to bleach-fix contamination of the developer. 2.6. Other Process Checks It is recommended that the following items be checked at the end of each day with daily results recorded on the Process Control Sheet : Throughput It is recommended that confirmation of daily paper throughput be checked – many processors are fitted with a replenishment counter for just this purpose. These figures are important for many reasons. They allow for consumption of replenishment volumes to be compared to actual paper throughput, so that confirmation of replenishment system operation can be made. They provide criteria for determining fine Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 61 replenishment rate adjustments for all solutions, helping to reduce chemical consumption and cost. They will also assist the chemical mixing personnel in laying out a rational replenishment preparation schedule. Replenisher Consumption Replenishment compensates for processing solution exhaustion, aerial oxidation and loss by carry-out and evaporation. It also maintains uniform solution concentration by diluting chemicals released by processed paper (paper by-products). Ideally, the replenisher volumes consumed should be accurately determined at the end of each day, although a weekly check will be found to be adequate on less heavily used processors. The volume should correlate with the paper area processed to ensure that the replenishment systems are functioning properly. Accurate replenishment promotes consistent photographic results. Replenishment rate variations should be kept to a minimum since they adversely affect processing results. The replenishment consumption for the Developer should be maintained within ±5% of specification while all other solutions should be replenished as recommended. Machine Standby Time All process solutions become less stable at higher temperatures. Excessively long standby time, without paper throughput, will result in changes in solution activity, concentrations and density (specific gravity). Therefore, if service and use requirements allow, it is highly recommended that heaters and pumps be turned off when no paper processing is anticipated for an extended period of time. 2.7. Processor Inspection The paper processor(s) should be periodically inspected, as suggested in Table 31 and Table 32 . Inspection results should be recorded on the Process Check Sheet (see APPENDIX 1). These results may correspond to process control problems recorded on the daily control chart. Processing should start only after quality processing conditions are confirmed. Variations in processor conditions will result in photographic property variations. The check sheet provides a reliable means of ensuring that the processor is in control. Also, the check sheet will be of help in detecting and diagnosing process problems. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 62 Table 31 : PROCESSING INSPECTION CHECK LIST (ALL TYPES) PROCESSOR CHECK CHECK RATE RECOMMENDED MAINTENANCE COMMENTS TEMPERATURE CONTROL • Solution temperature • Solution levels Daily Daily • Clean solution temperature control heaters/thermostats. • Note solution levels after adjusting solution temperatures. Foreign matter deposited on solution temperature control heaters and thermostats can be the cause of inaccurate/uneven solution temperatures resulting in a loss of process quality. Evaporation will vary based on specific operating conditions and machine type. All solution levels should be checked after specified temperature is set. CIRCULATION • Circulation rates, circulation systems. • Filter clogging. (Exercise special care for Developer). Daily Weekly • Remove filters from circulation systems. Fill empty processor tanks with water at 40°C. Scrub tank walls. Operate recirculation system for 15 minutes. In particular, if cleaning Bleach- Fix or Fixer tanks, ensure tanks and circulation systems are very thoroughly cleaned before refilling. • Replace tank filters with 25 micron filters; Developer every 2-3 weeks. All others: monthly. Use only polyethylene or polypropylene. (Nylon, cotton or metal screen filters are not suitable or recommended). When air is drawn into circulation systems, solutions may become exhausted beyond use. Using a flow meter or pressure gauge in the developer circulation systems may help to determine when filters are clogged. When circulation is reduced, the tank solution temperatures may become inaccurate. Unfavourable paper processing may result, particularly causing uneven development in DMax (black) areas on prints, especially in roller transport processors. REPLENISHMENT • Replenishment systems (Pipes, clogging, leaks) • Verify replenishment rate specifications Monthly Monthly • Remove chemical build-up in replenishment pumps and in replenishment strainers. Under or over replenishment will adversely affect photographic properties. Consistent replenishment rates help ensure consistent process results. DRYING • Dirt and dust particles in dryer assembly. • Drying air temperature. • Drying air humidity. Weekly Weekly Weekly • Clean the interior of the dryer section and air filter. • The dryer temperature should be kept below 90°C – and normally considerably lower, according to paper and processor manufacturers’ guidelines. Improper drying conditions may result in paper curling and emulsion damage. Drying air temperature and humidity must be monitored to ensure even drying. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 63 Table 32 : PROCESSING INSPECTION CHECK LIST (SPECIFIC TYPES) PROCESSOR CHECK CHECK RATE RECOMMENDED MAINTENANCE COMMENTS SQUEEGEES (MINILAB / LEADER BELT / LEADER-FREE [AGFA VSP- type] PROCESSORS) • Check spring clips and spring on wiper blades. • Final squeegee. Daily Daily • Wash wiper blades every day when they are checked. Replace worn or inefficient blades. • Inspect paper / leader during processing for excessive carryover on paper or leader. Faulty spring wiper blades and worn spring clips can cause excess carryover. Solution carry-over may adversely affect photographic properties, leading to high stain, streaking and chemical wastage. SQUEEGEE ROLLERS (MINILAB / ROLLER TRANSPORT PROCESSORS) • Check any squeegee rollers for signs of damage. • Final squeegee roller. Daily Daily • Clean squeegee rollers daily. Replace any damaged rollers. • Inspect paper / leader during processing for excessive carryover on paper or to dryer. Faulty squeegee rollers can cause excess carryover. Solution carry- over may adversely affect photographic properties, leading to high stain, streaking and chemical wastage. CIRCULATION (MINILAB AND ROLLER TRANSPORT PROCESSORS) • Check for good circulation pattern on surface of all chemical baths Monthly Monthly • Clean spargers / distributor bars; check for torn paper or developer deposits inside spargers or distributors. • Occasionally clean out holes in spargers and distributors to ensure all are clear. Process fogged paper across the whole width of the processor (widest roll / sheet size available); look for signs of uneven development – typically dark blue streaks in the otherwise black paper. A combination of marginal developer activity plus marginal agitation / recirculation can be as bad or worse than poor agitation alone. PAPER TRANSPORT (LEADER BELT AND LEADER-FREE [AGFA VSP- type] PROCESSORS) • Elevator frames, transport frames, dryer transport. • Abnormal noise. • Limit switches. • Elevator and communication chains. • Twisting, overlapping or crooked paper run on Agfa VSP-type processors. Daily Daily Weekly Weekly • Follow equipment manufacturers' recommended maintenance. • Identify/correct noise. • Adjust limit switches. • Check chains for excessive slack. Wear in racks / drive gears / chains can lead to not only paper processor damage but also to paper tracking problems, particularly on leader belt processors. Paper tracking under a drive belt will almost certainly lead to a paper jam and often to developer contamination. Improperly threaded leaders (usually following a paper break or jam) may cause paper to overlap or twist in transport causing paper to scratch, crease or break. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 64 PAPER TRANSPORT (MINILAB AND ROLLER TRANSPORT PROCESSORS) • Racks, transport frames, dryer transport. • Rack crossovers. • Abnormal noise. • Limit switches. • Print cutting and sorting (minilabs). Daily • Follow equipment manufacturers' recommended maintenance. • Clean all crossovers. • Identify/correct noise. • Adjust limit switches. • Check chains for excessive slack. • Clear paper slithers from cutter. Wear in racks / drive gears / chains can lead to not only paper processor damage but frequently to paper jams. Check all racks and crossovers are seated correctly in the processor and locked in place. PAPER TRANSPORT (ALL PROCESSOR TYPES) • Rotation, wear and damage to rollers. • Chemical residue on rollers. Weekly Weekly Weekly • Replace worn or damaged parts. • Clean rollers. • Clean rollers and rack transport.. If rollers are worn or damaged, scratches and improper paper transport may occur. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 65 3. MONITORING PROCESS QUALITY 3.1. Processing Quality As indicated in Table 33, processing quality is affected by two different categories of factors; physical and sensitometric. To ensure optimum processing quality it is necessary to acquire familiarity with all related factors. Table 33 : FACTORS AFFECTING PROCESSING QUALITY PHYSICAL FACTORS SENSITOMETRIC FACTORS Scratches (front or back) Creasing Edge Damage Uneven Development Drying Marks; Spots Severe Curl (Excessive Drying) Inefficient Drying Dirt and Dust Deposits Water or Splice Marks Density Speed) Gradation (Contrast) Colour Balance Stain Low Maximum Density Retained Silver 3.2. Physical Factors Physical factors can be identified through careful visual inspection. Paper rolls after processing and finished prints should be examined carefully. The cause of any problems detected should be identified and corrected immediately. Sensitometric factors Control Strips and Control Limits In order to maintain a continuing check on process performance, paper strips, which have been accurately exposed to a fixed pattern, are used. These strips are processed in the same manner as other paper and the results are measured by a densitometer to determine whether they are within specified control limits. Fujicolor Process RA4 / Super FA Control Strips are available for this purpose and should be used by all laboratories processing Fuji paper or other Fuji RA4 materials. When other makes of paper are being processed, control strips from that paper manufacturer should be evaluated; use the control strips for the main paper make being processed. If you are using more than one make of paper, the strips from the most commonly processed paper should be used for routine process control, and the second either regularly or occasionally as a cross-check. Note : For purposes of overall process control, visual inspection of processed paper alone is inadequate for process monitoring and control. It is very difficult to evaluate the RA4 process simply from looking at colour prints; even direct visual comparison of a processed control strip with a reference strip is insufficient for proper control; measurement of control strips must be done with a densitometer in order to achieve meaningful results. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 66 Fuji RA4 Process Control Strip The criteria for evaluating process performance includes action limits and control limits. Action limits refers to control areas within the process that must be maintained to ensure quality results. It is therefore necessary to maintain the process so that it always results in control values that remain within the action limits. If the process drifts out of the action limits, corrections must be made to return process conditions to normal. Film processing may continue as corrective actions are taken. Control Limits refers to absolute tolerance limits. When control limits are exceeded, customer film processing should be stopped until corrective action is taken. Unsatisfactory film quality will result from film processed under conditions where control limits are exceeded. It is essential to monitor and chart daily processing plots to maintain control values within the control limits. Density Measurements After control strips are processed, the indicated portions in the Control Strip Diagram and Table 34 are measured with a precision reflection densitometer. Table 34 : CONTROL STRIP DENSITY MEASUREMENT GREY SCALE STEP DENSITY AT POINT OF MEASUREMENT PURPOSE Yellow (Y-Max) About 0.18 red Check for silver retention. D-Max About 2.0 – 2.2 red/green/blue Check for maximum density. High Density (HD) About 1.5 – 1.7 red/green/blue Check for shadow gradation, colour balance. Low Density (LD) About 0.65 – 0.75 red/green/blue Check for speed and colour balance. Stain (DMin) About 0.06 – 0.10 red/green/blue Check for stain, silver retention. Control Value Calculation, Plotting and Checking Control Chart After density measurements are made, calculate control values from the control strip density measurements obtained and plot the values on the Process Control Sheet. Use of one of the Fuji Hunt OASIS Pro family of programs is particularly recommended for this purpose. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 67 A plotted control chart will show whether or not control values are within the action or control limits. The chart will also show any trends of control values that drift in any particular direction. Detailed procedures for reading daily control strips are contained in APPENDIX 2, Process RA4 / Super FA Control Strips. Tabl e 35 : CONTROL VALUE ACTION AND CONTROL (TOLERANCE) LIMITS ACTION LIMITS CONTROL LIMITS Step Density Density Yellow R - DMin R ‡ +0.05 +0.08 DMax - 0.10 - 0.15 Contrast (HD-LD) ±0.08 ±0.10 Speed (LD) ±0.08 ±0.10 Stain (D-Min) ±0.02 ±0.03 There are no limits for colour spread for Fuji RA4 / Super FA process control strips. ‡ Note : Reading the Yellow patch and plotting the Yellow R - DMin R parameter is optional, and is not shown in process control plots and process manuals issued by Fuji Photo Film. In the Fuji Hunt OASIS Pro program, Fuji RA4 strips defined to include this parameter are called (by default, unless changed by the user) “Fuji RA4 +Silver”; strips without this parameter are simply called “Fuji RA4”. Which strip definition you wish to use is up to the user. 3.3. Process Control Fundamentals Proper process control is essential to achieving the highest quality of work. It consists of the following fundamental elements : Maintain Process Specifications On a regular basis, ensure that all process solutions and conditions remain constant and at recommended specifications. Physically Inspect Processed Paper Check processed paper for physical abnormalities, density, and base colour. Do not forget to check the back of the paper for scratching – a common problem that indicates problems with rollers in the processor (or possibly printer – check also paper before processing). Record results on the process check sheet and process control chart. All paper types are sensitive to common problems such as bleach-fix contamination of the developer, and this can often be seen as colour shifts in the grey patch of a control strip, or deterioration of the DMax. Evaluate Process Control Strips If monitoring results are well within the prescribed action limits and the quality of the work meets the lab's customer requirements, the process is in control. Plan Corrective Action In the event of any process problem, review all process control data and implement the necessary corrective action immediately. Be familiar with these procedures and the Process Check Flow indicated in Table 36. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 68 Table 36 : PROCESS CHECK FLOW To Check for Physical and Sensitometric Factors – See Table 33 on page 65. 1.2. NORMAL RETAIN PRESENT CONDITION 1.1. ABNORMAL DETECT PROBLEM TAKE CORRECTIVE ACTION QUALTIY PROCESSING CONDITIONS PROCESSING WORK PHYSICAL FACTORS --- CHECKING--- SENSITOMETRIC FACTORS DATA RECORDING AND PLOTTING ANALYSIS Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 69 4. APPENDIX 1 4.1. RA4 PROCESS CHECK SHEETS AND PROCESSING SOLUTION CONTROL CHART To ensure highly reliable and consistent process quality control, it is necessary to maintain process condition data records on a process check sheet. This allows for quick detection of conditions fluctuating from the standard and permits immediate corrective response to any such condition. Standard process check sheet examples are explained below and examples are provided on the pages that follow. It is suggested that copies of these pages be made to be used as worksheets. Process Check Sheet 1 or 3 (Used Every Operating Day) Process Check Sheet 1 (Process Check Sheet 3 for Process RA404) is used to record daily processing conditions at the beginning and end of each work day. Process specifications will be used in conjunction with control plots to quickly identify process variations. pH measurement is optional, but desirable. pH measurement is of particular value when regenerated chemical systems are used within the laboratory. Process Check Sheet 2 or 4 (Used Every Month) Process Check Sheet 2 (Process Check Sheet 4 for Process RA404) is used mainly for checking automatic processor control conditions. Data entered on this sheet should be recorded at a regular monthly intervals of time. In addition, process specifications should be recorded and verified whenever process setup conditions change, or when the process is subject to long periods of low or limited use. Process Solution Control Chart From the results entered on Process Check Sheet 1, recommended processing solution quality data, relative to that specific processor, should be recorded on the Processing Solution Control Chart, as the following example indicates : Developer (Dev) : temperature, density, pH (or replenishment rate) Bleach-Fix : density, pH (or replenishment rate) or, for Process RA404, using Check Sheet 3 : Developer (Dev) : temperature, density, pH (or replenishment rate) Stop Bath : pH Bio-Bleach : density, pH (or replenishment rate) Fixer : density, pH (or replenishment rate) By comparing the Processing Solution Control Chart data against that of the Process Control Sheet, relationships will be verified. Through the use of these charts and the accurate monitoring of process data, process solution control can be maintained for consistent high quality results. Users of the Fuji Hunt OASIS Pro Compact process control program can store much of this data in the Tank Checks section of the program. Users of the OASIS Pro program can create as many types of solution control checks as they wish, and all of the above data can be easily stored. Both programs allow easy plotting of (for example) solution density variations against the aim value, giving you a graph of chemical stability in much the same way as you can view a process control graph. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 70 PROCESS CHECK SHEET 1 – FOR RA4 DAILY CONTROL Processing Conditions Record Data Prior to the Start of Daily Processing DEVELOPER BLEACH-FIX WASH or STABILISER DRY Recommended Temperature Measured Temperature pH Density Recirculation Systems Replenishment Rate (ml/m²)* Solution Condition Comments * : Replenishment rate may be recorded as ml/m 2 , ml/min, ml/shot, or other meaningful value Replenishment Rates Record Data at Conclusion of Work Day DEVELOPER BLEACH-FIX STABILISER † THROUGHPUT A : Starting Volume B : Addition C : (A) +(B) D : Ending Volume E : Consumption (C) – (D) F : Specified Volume G : Replenishment Balance (E-F ÷ F) x 100 % Comments TOTAL m² † where used Temperature Adjustment Note any temperature changes and the solution changed Bath and Change Bath and Change Bath and Change Temperature Adjustments Solution Adjustments For Reference Purpose Only DEVELOPER BLEACH-FIX STABILISER Amount of Additive (Litres) pH Density Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 71 PROCESS CHECK SHEET 2 – FOR RA4 MONTHLY CONTROL In Solution Time MEASURED TIME SPECIFIED TIME COMMENTS Developer Processor Temperatures PROCESS STEP MEASURED TEMPERATURE SPECIFIED TEMPERATURE COMMENTS Developer Bleach-Fix Stabiliser † Dryer † where used Replenishment and Recirculation Systems PROCESS STEP PUMP RECIRCULATION RATE FILTER PUMP FLOW RATE SPECIFIED FLOW RATE COMMENTS Developer Bleach-Fix Stabiliser † † where used Wash Water WASH 1 WASH 2 TOTAL Flow Rate (L/min) Filter Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 72 PROCESS CHECK SHEET 3 – FOR RA404 DAILY CONTROL Processing Conditions Record Data Prior to the Start of Daily Processing DEV STOP BLEACH FIXER STAB † WASH DRY Recommended Temperature Measured Temperature pH Density Recirculation Systems Replenishment Rate (ml/m²)* Solution Condition Comments * : Replenishment rate may be recorded as ml/m 2 , ml/min, ml/shot, or other meaningful value † : where used Replenishment Rates Record Data at Conclusion of Work Day DEV STOP BLEACH FIXER STAB † THROUGHPUT A : Starting Volume B : Addition C : (A) +(B) D : Ending Volume E : Consumption (C) – (D) F : Specified Volume G : Replenishment Balance (E-F ÷ F) x 100 % Comments TOTAL m² † where used Temperature Adjustment Note any temperature changes and the solution changed Bath and Change Bath and Change Bath and Change Temperature Adjustments Solution Adjustments For Reference Purpose Only DEV STOP BLEACH FIXER STAB † Amount of Additive (Litres) pH Density † where used Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 73 PROCESS CHECK SHEET 4 – FOR RA404 MONTHLY CONTROL In Solution Time MEASURED TIME SPECIFIED TIME COMMENTS Developer Processor Temperatures PROCESS STEP MEASURED TEMPERATURE SPECIFIED TEMPERATURE COMMENTS Developer Stop Bleach Fixer Stabiliser † Dryer † where used Replenishment and Recirculation Systems PROCESS STEP PUMP RECIRCULATION RATE FILTER PUMP FLOW RATE SPECIFIED FLOW RATE COMMENTS Developer Stop Bleach Fixer Stabiliser † † where used Wash Water WASH 1 WASH 2 TOTAL Flow Rate (L/min) Filter Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 74 RA4 PROCESS SOLUTION CONTROL CHART Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 75 RA404 PROCESS SOLUTION CONTROL CHART Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 76 5. APPENDIX 2 5.1. PROCESS RA4 / SUPER FA MONITORING WITH FUJICOLOR CONTROL STRIPS Fujicolor Control Strips and Process RA4 Monitoring Fujicolor Control Strips (for Monitoring Process RA4 / Super FA) Control Strips are pre-exposed, unprocessed cut sheets of paper that retain the pattern indicated in Figure AP-1 and are used to monitor Process RA4 and RA404. TABLE AP-1 FUJI RA4 CONTROL STRIP SPECIFICATION CUT STRIPS Pattern Figure AP-1 Strip Width 3.5 inches (8.9 cm) Strip Length About 34.9 cm Quantity per Package 5 Envelopes with 10 each Each control strip has been exposed to a 5-step scale, including a yellow patch. One reference strip is included in each box. Figure AP-1 Fuji Process RA4 Control Strip Reference Strips Each control strip package contains a reference strip and a correction factor sheet. The reference strip is factory exposed under the same conditions as the control strips, but has already been processed under rigid control conditions. Since the reference strip serves as a basis for evaluating laboratory processed control strips, special care should be taken in avoiding finger prints, scratches or other damage on all surfaces. Each reference strip is to be used only with control strips contained in that package or those having the same lot code number. Reference Strip Correction Factors The reference strip is factory processed under rigidly controlled conditions, but various factors may cause slight density variations. The sheet enclosed in the control strip package contains correction factors which compensate for reference strip deviations from standard. When evaluating processed results, it is necessary to derive control data (control values) using the correction value sheet. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 77 Control Strip Storage and Handling Control strips are used in monitoring Process RA4 for subtle changes in processing results. If proper storage and handling care is not exercised, control strips may not provide full monitoring capabilities. In order to obtain optimum control strip performance at all times, it is essential that the precautions indicated below are observed. Control Strip Storage • Immediately upon receipt, store control strip packages in a freezer with a temperature below – 10°C. • Control strips supplied in rolls may exhibit signs of latent image changes if the whole package is removed from the freezer and allowed to remain out in room temperature for several hours every day. To prevent such undesired changes, it is recommended that the package be divided into smaller quantity units, with enough for one week to process testing. These smaller packages should be kept in moisture proof envelopes inside light tight boxes – old control strip boxes are ideal. This will allow for the emulsion code lot numbers be clearly written on each box or envelope to ensure proper sequential use and stock rotation. • Once removed from the freezer, remove the reference strips supplied with the control strips from the package and keep the reference strips at room temperature. Repeated freezing and thawing of reference strips can have a significant effect on readings from the reference strips, resulting in incorrect aim values. Control Strip Handling • Control strip packages and envelopes should not be opened immediately after being removed from the freezer. To prevent moisture condensation on the control strips, boxes and envelopes should be allowed to warm to room temperature for approximately 30 minutes before use. • Handle control strips only by their edges or the ends of the strips to avoid fingerprints or surface damage. This applies to both unprocessed and processed strips. The particular care not to get any fingerprints on the DMax patch, as this can have a great effect on density readings. • Expiration dates are printed on control strip packages. Control strips that are used after the manufacturers' expiration date may provide false readings and, therefore, indicate inaccurate process control. Old strips show (in particular) high stain and reduced contrast and DMax. • The control strips, reference strips and the correction factor sheet packaged as a unit and bearing the same code number should be used together, otherwise false, inaccurate readings may occur. Control Strip Processing • Daily process monitoring through the use of control strips should be done at each of the following times : 1. At the beginning of each day. 2. At the beginning of each successive processing shift of that day. 3. Whenever corrections to any working tank solution are made. • Control strips should also be processed when each package or code number changes. For further details refer to page 82 (Changing Control Strips) of this appendix. • Control strip positioning for processing purposes differs with the processor type. 1. Roller Transport, Leader Belt or Leader-Free [Agfa VSP-type] Processors Control strips should always be processed in the same position / track on the processor. Ensure that any staples or splicing tape do not come anywhere near the patches on the strips; also ensure that enough leader is attached (where required) to prevent fogging. 2. Minilab Paper Processors Follow the minilab manufacturer’s instructions regarding leader length and strip loading procedures to prevent fogging. Ensure correct emulsion orientation for processing – usually emulsion up - check the strip carrier when loading. • Record the processing date and time on the processed control strip, utilising an area which will not obstruct density measurements. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 78 • When using strip readers such as the X-Rite 88x/89x series or GretagMacbeth iCColor, ensure that not too much paper is cut from the end of the strip after processing, leaving it too short for proper readings on the densitometer. • When density measurements have been made, store processed strips in an old control strip box. Reference Value Calculation Process monitoring reference values are calculated from reference strip density values combined with the correction factor sheet values supplied with the reference strip. The Fuji Hunt OASIS Pro family of process control programs is ideal for the reading and plotting of reference and process control strip values, and make the whole process much quicker, easier and more accurate; please contact your Fuji Hunt representative. The calculation method for manual reading of reference strips is as follows : 1. Place the reference strip in the densitometer and, through red, green and blue filters, read the respective DMin densities in the order named. Make the same measurements for LD, HD, and DMax. If required, the Yellow patch (only the red value) can also be read to allow calculation of the Yellow Red -DMin Red parameter for retained silver monitoring. Status A Reflection filters should be used for all Process RA4 strip readings; the densitometer should be allowed to stabilise and be re-calibrated before reading any reference strips. 2. For each of the three colours add the appropriate correction factors to the DMin, Step 2, Step 3, Step 5 and DMax density values. A set of reference values derived from reference strip density measurements and correction factors is shown as a calculation (see example in Table AP-2). For each density measurement of a control strip, reference strip densities are also to be measured and the reference values calculated. TABLE AP-2 REFERENCE VALUE CALCULATION DATE : TIME : CODE NO. (# PN0R ) RED GREEN BLUE Yellow Measured Density Correction Factor Reference Value 0.18 0.00 0.18 Yellow R - DMin R † Calculated Aim 0.08 DMax Measured Density Correction Factor Reference Value 2.00 0.00 2.00 2.18 -0.02 2.16 2.16 -0.09 2.07 HD Measured Density Correction Factor Reference Value 1.66 -0.02 1.64 1.62 -0.03 1.59 1.61 -0.07 1.54 HD-LD (Contrast) ‡ Calculated Aim 0.93 0.93 0.85 LD Measured Density Correction Factor Reference Value 0.75 -0.04 0.71 0.69 -0.03 0.66 0.71 -0.02 0.69 DMin Measured Density Correction Factor Reference Value 0.10 0.00 0.10 0.10 0.00 0.10 0.06 0.00 0.06 † The Yellow R – DMin R parameter aim (for measuring retained silver) is calculated by subtracting the DMin red reading reference value from the yellow patch red reading reference value. Reading of the Yellow patch, and Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 79 calculation of this parameter, are optional and do not form part of the official Fuji Photo Film recommendations. ‡ The HD-LD (contrast) parameter aim is calculated by subtracting the LD step reference values from the HD step reference values – but only after any correction factors for the LD and HD steps have been applied. Control Strip Value Calculation To obtain control strip density values it is necessary to measure control and reference strip densities. Subsequent density measurements are to be obtained with a processed control strip and the reference strip of the same code number. The control strip values are obtained by subtracting the reference strip values from the control strip density values being processed. Table AP-3 show a set of control strip density values obtained at the same time as the reference values shown in Table AP-2. Note : The correction factors must not be added to the density values obtained from the control strips. TABLE AP-3 CONTROL STRIP DENSITY VALUE EXAMPLE RED GREEN BLUE Y (Yellow) 0.20 Y R - DMin R (calculated) 0.64 DMax 2.08 2.17 2.10 HD-LD (calculated) 1.03 0.98 0.91 HD 1.72 1.59 1.59 LD 0.69 0.61 0.68 DMin 0.10 0.11 0.08 The control strip values which were obtained by subtracting the reference values from the control strip density values are shown in Table AP-4. The process monitoring controls derived from Tables AP-2, AP-3 and AP-4 are shown in Table AP-5. TABLE AP-4 CONTROL STRIPS VALUE EXAMPLE FOR HD-LD STEP RED GREEN BLUE (A) (B) (B) – (A) (A) (B) (B) – (A) (A) (B) (B) – (A) HD-LD 0.9 3 1.0 3 +0.10 0.9 3 0.9 8 +0.05 0.8 5 0.9 1 +0.06 (A) : Reference Value (B) : Measured Control Strip Density (C) : Control Strip Value TABLE AP-5 CONTROL STRIP VALUE EXAMPLE RED GREEN BLUE Y R - DMin R +0.02 DMax +0.08 +0.01 +0.03 HD-LD +0.10 +0.05 +0.06 LD - 0.02 - 0.05 - 0.01 DMin 0.00 +0.01 +0.02 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 80 Control Chart Plotting As soon as the control values are obtained, they should be plotted as indicated in Figure AP-3, the Process Control Sheet. In this example, the control strip values recorded in Table AP-5 are used. Plots obtained in this manner provide a bases for deciding at the beginning of each day or any given work shift whether customer film can be processed. The Fuji Hunt OASIS Pro family of process control programs are particularly recommended for reading and plotting of process control strips. Errors in calculation of deviations are eliminated, the graphs are automatically generated, and the whole process control task becomes much more convenient. Additionally, use of OASIS Pro allows generation of an unlimited history of control strip data for every processor, provides for process diagnostics for all common process strip makes and types, and allows the possibility of very easily sending your process data to a monitoring service for further advice and troubleshooting. Please consult your Fuji Hunt representative for further details, or check the Fuji Hunt web site at www.fujihunt.com. The sample chart on the next page is typical of the charts employed by most users; the Retained Silver step, Y R – DMin R , is not plotted; only the DMin, LD, HD-LD and DMax are used. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 81 Figure AP- 3 PROCESS CONTROL SHEET AND PLOT EXAMPLE Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 82 Action and Control Limits Process RA4 / RA404 should be constantly maintained between the following action and control limits. The limits shown below are those recommended for use with Fuji RA4 / Super FA control strips. Action Limits The action limits represent the control value range within a process that is certain to provide quality results. As long as the process is under control, all the parameters will be plotted within the action limits. For quality results, the process must be controlled so that control plots do not exceed the action limits. When parameters drift outside the action limits, film processing should be stopped and corrective action taken. Problems should be diagnosed and detected promptly and corrective action taken to return the process to within the action limits. If no corrective action is taken, not only will the quality of processed film be unacceptable, but all processing solutions may need to be replaced. Problem handling procedures are explained in Table 30 – Process Troubleshooting, starting on page 55. TABLE AP-6 PARAMETER ACTION LIMITS DENSITY Silver (Y R – DMin R ) ‡ +0.05 DMax - 0.10 HD-LD ±0.08 LD ±0.08 DMin +0.02 ‡ where plotted Control Limits The control limits represent the control value range in which the process may be allowed to drift because of everyday process variations. When the control limits are exceeded, customer film must no longer be processed. Satisfactory processing can no longer be insured. It is therefore essential that all parameters are maintained within the control limits. It should be noted that the action limits fall within the control limits. TABLE AP-7 PARAMETER CONTROL LIMITS DENSITY Silver (Y R – DMin R ) ‡ +0.08 DMax - 0.15 HD-LD ±0.10 LD ±0.10 DMin +0.03 ‡ where plotted Changing Control Strip Batches When a new package of control strips is put into use, check for differences between the older and the new batch of control strips. According to the procedures indicated below, modify the correction factors as necessary. Considering the fact that control strips vary relative to storage conditions, handling, and manufacturing, it is advisable to make this check even when new control strips have the same lot code number as the older strips that were used. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 83 Control Strip Crossover 1. When a control strip package contains no more than three control strips, process them along with three new ones from a different code number package. (They may be processed on three different days). 2. Through the red (cyan), green (magenta) and blue (yellow) filters, measure the DMin, LD, HD, DMax and Yellow densities from each control strip. 3. Obtain the measurement average for each scale step. When calculating averages, disregard all extreme density values. 4. Calculate the R, G and B control values for the old and new control strips and subtract the new values from the old. Add the products to the reference strip correction factors. These modified correction factors are to be used with the new control strips for process monitoring. These procedures should be used whenever a new batch of control strips is received and introduced into the process control cycle. They are critical to control chart continuity. The correction factor modification procedures are illustrated in Tables AP-8 and AP-9 for the blue (yellow) densities. TABLE AP-8 CONTROL VALUE DIFFERENCE CALCULATION (EXAMPLE) FOR BLUE (YELLOW) DENSITIES STEP OLD CODE # NEW CODE # AVERAGE CONTROL VALUE OF 3 PROCESSED STRIPS DIFFERENCE* Yellow Old Control Strip New Control Strip 0.00 0.00 0.00 DMax Old Control Strip New Control Strip - 0.02 +0.01 +0.03 HD Old Control Strip New Control Strip - 0.01 +0.02 +0.03 LD Old Control Strip New Control Strip 0.00 - 0.02 - 0.02 DMin Old Control Strip New Control Strip +0.01 +0.01 0.00 * : New strip average control values minus old strip average control values. TABLE AP-9 CORRECTION FACTOR CALCULATION (EXAMPLE) FOR BLUE (YELLOW) DENSITIES STEP NEW CONTROL STRIPS CORRECTION FACTOR DIFFERENCE CALCULATED MODIFIED CORRECTION FACTOR FOR NEW CONTROL STRIPS Yellow DMax HD LD DMin 0.00 0.00 - 0.01 +0.02 +0.01 0.00 +0.03 +0.03 - 0.02 0.00 (0.00) +(0.00) =0.00 (0.00) +(+0.03) =+0.03 (- 0.01) +(+0.03) =+0.02 (+0.02) +(- 0.02) = 0.00 (+0.01) +( 0.00) =+0.01 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 84 6. APPENDIX 3 6.1. RA4 PROCESSING DURING LOW UTILIZATION PERIODS During low utilisation periods, when the volume of developer replenisher used daily as a result of paper processing remains at levels less than 0.1 tank volumes (or 0.5 tank volumes per week), it may become difficult to maintain equilibrated processing solutions. During these periods it may be necessary to make adjustments, such as tank and replenisher solution modifications and changes in the replenishment rate based on actual tank turnover to maintain optimum chemical and film quality. When normal production is restored and 0.1 tank volumes or more of replenisher is used daily, processing chemical conditions should be returned to normal. Problems are normally limited to the developer, but the bleach-fix (or bleach and fixer for Process RA404) may also be affected during periods of very low throughput. Low utilisation problems are also largely dependent on the type of processor involved; roller transport processors of the type typically found in professional laboratories (for example) have large tank surface areas relative to the volume, and usually large areas of rollers – covered in chemical – exposed to the air. Such machines are far more susceptible to the effects of low throughput than the typical minilab printer / processor, where tank area is small relative to tank volume, and tanks are in any case often much smaller and require less paper throughput to achieve reasonable levels of tank turnover. For such minilab printer / processors, a turnover of 0.33 or even 0.25 tank volumes per week may be sufficient to avoid problems. General Guidelines Fresh tank solution may be added directly to any seasoned tank solution to flush any seasoned working tank solution that may become dirty, unacceptably oxidised or chemically unbalanced as a result of low utilisation from the working tank, thus maintaining the chemical composition integrity of the bath. This addition may be accomplished in either of two ways : The first way is use an alternative developer, such as EnviroPrint Developer Replenisher, instead of a low replenishment system such as EnviroPrint Developer Replenisher LR AC. This procedure is recommended to maintain consistency in extended periods of low utilisation, for example during winter months when paper throughput is generally much lower in minilabs and photofinishing laboratories. This does not require any changes to the working tank solution – simply a change of replenisher and adjustment of the replenishment rate. When paper volumes increase, it is easy to switch back to the previous LR system, again requiring only a change in replenisher and replenishment rate. The EnviroPrint MP family of developers has been designed with this in mind. If MP60 (for example) does not give you a fast enough rate of tank turnover, switch to MP108. If MP108 does not provide enough tank turnover,, change to MP160. All developers operating at 38°C may be interchanged without retanking; simply replenish in on top of your existing developer and change the replenishment rate. The same applies to the CPRA family of developers, operating at 35°C. It is, however, strongly recommended that you do not try and change from a 38°C developer to a 35°C developer (or vice versa) simply by replenishing in on top; the change in process activity between 38°C and 35°C is considerable and will cause problems with print quality. A developer retank is the best approach here. The second way is to make bulk additions of fresh tank solution to any seasoned working tank solution – in other words, partial replacement of the working tank. If bulk additions of fresh tank solution are added directly to the working tank, a known percentage of the existing working tank must be removed and replaced with an identical volume of fresh working tank solution. Measuring the specific addition Developer fresh tank solution is necessary so that the appropriate volume of starter and water can be measured and added to the working tank. Bulk additions are particularly beneficial after periods of long processor shut down. This procedure will result in an immediate correction in the working tank solution and in process control. It is recommended for periods of inconsistent utilisation or for periods of extended low utilisation. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 85 The following outlines the specific procedures recommended to add fresh working tank solutions through replenishment methods. Developer Aerial oxidation causes a considerable decrease in the developing agent and preservative. In addition, evaporation causes the developer solution to become concentrated. As a result, speed changes and overall gradation changes occur in the paper process, often with a noticeable drop in blue DMax and increase in stain. The overall effects vary with the chemistry in use; low replenishment rate developers – and particularly the very low replenishment rate MP45 AC and MP60 developers – initially suffer greatly from overconcentration (unless corrected by water additions), with consequent overall increases in process activity, but often also a reduction in DMax as restrainer (chloride) levels in the developer also increase. With higher replenishment rate chemistry such as CPRA Pro Developer, oxidation is usually a much more significant problem than evaporation. Recommended Corrective Action Add water to the Developer tank solution to maintain the recommended specific gravity as required – do not allow the Developer density to get very high and then be forced to make a large water addition to bring the density back within control. If using a Low Replenishment (LR) system, consider a change to a higher replenishment rate chemistry – for example from EnviroPrint LR AC to EnviroPrint Developer; from CPRA or CPRA AC to CPRA Pro, or perhaps adding some fresh EnviroPrint Developer Replenisher to regenerated systems to flush out some of the oxidised by-products building up in the developer. The previous chemical system can be restored when volumes increase. See the chapter Chemical Recycling at page 96 for further details of handling problems with recycled developers. Bleach-Fix Evaporation causes the solution to concentrate. Additionally, the developer carried over on the paper raises the solution pH significantly. As a result, incomplete silver removal and unwanted colour dye formation (staining or streaking) may occur. The problems usually appear first as high stain (DMin) levels in the paper (poor whites), and later as retained silver (muddy or dirty looking yellows) and even magenta streaking, particularly if bleach-fix agitation is low. On some papers, and under very severe conditions, the silver retained in the emulsion – which is always highest in the DMax (black) areas of a print – can be high enough to interfere with automatic print cutting equipment, as it can fool infrared cut mark detection systems. Effects vary greatly between different processor types. Problems seen with regenerated bleach-fix systems can also be more severe than with non-regenerated normally replenished bleach-fix systems, given otherwise identical processing conditions – although users of regenerated systems usually have more than enough throughput so that this does not become a major issue. These additional problems are chiefly due to the extra time and opportunity for developer carryover oxidation within the bleach-fix collection and replenisher tanks. Recommended Corrective Action Control bleach-fix density by regular density checks and water additions – although density is unlikely to prove a major problem except with low or very low replenishment rate bleach-fix systems being operated under less-than-ideal conditions (too little throughput for the bleach-fix being used). On minilab, leader belt and leader-free (Agfa VSP-type) processors, ensure that all squeegees (in this case, developer squeegees) are regularly checked, cleaned and replaced as necessary. With regenerated systems, ensure that aeration in bleach-fix collection systems and replenisher tanks is not excessive and that density and pH of the bleach-fix are controlled to within Fuji Hunt guidelines. See the chapter Chemical Recycling at page 99 for further details of handling problems with recycled bleach-fixes. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 86 Low Throughput Bleach-Fix with CPRA Digital Pro Developer AC Oxidation of the bleach-fix reduces the amount of sulphite (the anti-oxidant) present in the bleach-fix, and this is a significant parameter when using CPRA Digital Pro Developer AC. Sodium sulphite levels in the bleach-fix should ideally be >10 g/L, and certainly >8 g/L, with this developer. Failure to maintain adequate sulphite levels will result in increased base stain (poor whites). Please consult your Fuji Hunt representative. Bio-Bleach (Process RA404) Evaporation causes the solution to concentrate. Additionally, the wash water carried over on the paper compensates for this to a large extent, and with even a moderately used processor the net result is dilution of the bleach. In practice, few low throughput problems will be found with EnviroPrint Bio- Bleach. Recommended Corrective Action Control Bio-Bleach pH density by regular density checks and water additions; ensure that all squeegees are regularly checked, cleaned and replaced as necessary. See the chapter Chemical Recycling 104 for further details of handling problems with recycled bleaches. Fixer (Process RA404) Evaporation causes the solution to concentrate. Evaporation, combined with silver released from the paper emulsions, causes the solution specific gravity to increase above the recommended specifications. As a result, inadequate fixing problems may occur. Oxidation of the fixer, particularly in cases of low throughput or excessive aeration, may cause precipitation of silver sulphide or general sulphurisation of the fix tank (heavy grey/brown deposits). A more significant problem, however, can be deposits of silver metal or silver sulphide on rollers in the fix tank, giving rise to paper tracking problems and/or metallic silver marks (often mirror-like) on the surface of the prints (front and/or back of the prints). Laboratories using either batch recycled or closed loop recycled fixer systems must also be aware of halide build-up in the fixer; this is not removed during silver recovery. Increasing halide content as the fixer is continually rebuilt back to replenisher standards is not easily measured and can cause severe fixer underactivity, but this is not usually a major problem in paper processing unless the same fixer is also used for film processing (in a common film and paper fixer regeneration circuit) and is regenerated to excessive levels. Even then, the problems are more likely to appear first in the film process rather than on paper. The sulphite content of recycled fixer systems must be carefully monitored, especially during low throughput periods, to prevent fixer breakdown (sulphurisation), and also the pH. Recommended Corrective Action Increase the replenishment rate by 20% or more or reduce regeneration levels. Fixer cannot be over- replenished. In cases of low throughput, occasional replacement of the fixer bath is recommended to prevent formation of silver deposits. See Appendix 10, Fixer Recycling (page 105) for further details of handling problems with recycled fixers. Super Stabiliser In washless processors using super stabilisers – minilabs or larger machines – the most common problem is growth of algae or bacteria in the “wash” tanks, especially the tank immediately following the bleach-fix. These problems can occur in any processor from time to time, depending on local water quality, water treatment and other factors, but are generally much more severe under low throughput conditions or in processors with very large numbers of counter-current wash tanks and therefore very low replenishment rates. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 87 Recommended Corrective Action Increase the replenishment rate by 20% or more, or switch to EnviroPrint Super Stabiliser. Super stabilisers cannot be over replenished. Regular replacement of super stabiliser baths, especially the first tank, is the best way to avoid problems – changing the first tank removes a very high percentage of the bleach-fix carryover (which is the main food for the algae/bacteria) from the processor. Fuji Hunt can also supply special anti-algae additives for use with EnviroPrint Superflo Stabiliser where required. Alternate Low Utilisation procedure For All Solutions : Flush all solutions that are subject to oxidation or dirt accumulation with fresh tank solution. It is completely safe to add any volume of fresh tank solution to a seasoned tank solution. Developer starter additions (plus water) are required to maintain proper tank equilibration. Control plots should be monitored at all times. Using Carbon Filters Activated carbon filters are available from major filter suppliers in a variety of sizes to fit most types of processor. These filters can often be used in place of a standard filter when it is necessary to remove excess organic matter, and especially oxidised developing agent from developers, from process baths. In the RA4 process, the main use is reduction or removal of developer carryover from the bleach-fix bath, especially with roller transport processors found in professional laboratories. Developer carryover into the bleach-fix is unavoidable, and does not generally cause significant problems. However, the longer this developer remains in the bleach-fix – and the more of it that there is – the greater will be the effects on the processed paper. With systems only using fresh replenisher, the fresh bleach-fix being replenished into the working tank keeps the developer carryover to relatively low levels, and problems do not usually arise. With very low replenishment rate or recycled bleach-fix systems, and particularly in roller transport processors, developer content can reach high levels. An increase in stain (DMin) levels (typically the blue rising first, giving a yellow or creamy colour to the base white) can occur in the paper, and in extreme cases spots of developer tar on racks and rollers. If you are experiencing these problems, there are basically two solutions available – partial or complete replacement of the bleach-fix, or use of a carbon filter to remove the compounds causing the problem. When replacing a standard filter in a processor with a carbon filter, it should not be left in the filter housing for extended periods of time. These filters have a very fine pore size and block very easily; if left in place they will reduce and eventually stop recirculation of the bleach-fix bath. It is recommended, depending on the rate of recirculation with your processor bleach-fix tank, that a carbon filter should not be left in the processor for more than 2 to 4 hours at a time; after this period replace the carbon filter with a standard filter and run a process control strip. Carbon filters may often be successfully washed out and reused several times until they become ineffective (i.e. full of oxidised developer); the effect of the filters can be easily judged by the reduction in stain or tarry deposits coming from the bleach-fix tank. If your processor bleach-fix is showing signs of sulphurisation (heavy powdery or sludge-like deposits in the filter or visible floating on the surface of the bleach-fix tank), the bleach-fix should be discarded and replaced with a fresh tank solution. A carbon filter used under these conditions will block virtually immediately. Using Carbon Filters in the Developer Tank If cleaning up the bleach-fix does not get rid of paper stain problems (and your wash/stabiliser tanks are clean! – the other major source of high stain levels), it may be that your problem is coming from the Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 88 developer. If you plan to try and clean up the developer, you must be very careful as not only oxidised developing agent (the unwanted stain-producing by-product in the developer) will be removed but also some of the active developing agent as well. Improper use of carbon filters in the developer can create more problems than it solves. Before using carbon filters in a developer recirculation system, they must first be soaked in developer (waste developer overflow is ideal) for an hour or so in order that the filter becomes saturated with developing agent; failure to do this will result in excess developing agent being removed from the developer, giving reduced developer activity – probably showing as reduced DMax (poor blacks, typically blue-blacks) or streaking in DMax areas. Do not leave carbon filters in developer recirculation systems for extended periods of time. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 89 7. APPENDIX 4 7.1. pH ADJUSTMENTS/SOLUTION PREPARATION PROCEDURES 5N Aqueous Sodium Hydroxide (5N NaOH) Solution 1. Fill a 2 litre glass heat resistant beaker with 800 ml of water. 2. Measure 200 grams of NaOH. 3. While stirring, slowly add the NaOH to the glass beaker. Guard against boiling and splattering. 4. Cool this solution to room temperature and add water to make 1000 ml. Stir to mix. 5N Aqueous Sulphuric Acid (5N H 2 SO 4 ) Solution 1. Fill a 2 litre glass heat resistant beaker with 800 ml of water. 2. Measure 140 ml of concentrated H 2 SO 4 (98 %). 3. While stirring, slowly add the concentrated H 2 SO 4 to the glass beaker. Guard against boiling and splattering. 4. Cool this solution to room temperature and add water to make 1000 ml. Stir to mix. 10 % Aqueous Hydrochloric Acid (HCl) Solution 1. Fill a 2 litre glass heat resistant beaker with 800 ml of water. 2. Measure 100 ml of concentrated HCl. 3. While stirring, slowly add the concentrated HCl to the glass beaker. 4. Cool this solution to room temperature and add water to make 1000 ml. Stir to mix. 10 % Aqueous Nitric Acid (HNO 3 ) Solution 1. Fill a 2 litre glass heat resistant beaker with 800 ml of water. 2. Measure 100 ml of concentrated HNO 3 to the glass beaker. 3. While stirring, slowly add the concentrated HNO 3 to the glass beaker. 4. Cool this solution to room temperature and add water to make 1000 ml. Stir to mix. 7.2. WARNING Sodium hydroxide is a strong alkali. Concentrated and 5N sulphuric acid, hydrochloric acid and nitric acid are strong acids. All of these substances are corrosive, toxic and otherwise hazardous. Eye and skin contact can cause severe burns. When handling these chemicals, observe all the precautionary information listed below: • Be sure to use protective gear, such as safety goggles, rubber gloves and protective clothing. Adequate ventilation should be maintained at all times. • In case of eye contact, flush with large amounts of running water for at least 15 minutes. Obtain immediate medical attention. • In case of skin contact, wash the affected area with large amounts of running water. • In case of clothing contact, change clothes and wash clothing in large amounts of running water. • To prevent solution boiling and/or splattering from chemical mixing containers, use beakers that are at least 1.5 to 2 times as large as the desired solution volume. • Add concentrates slowly to water while mixing. Exothermic reactions (the generation of heat caused by chemical change) result from the addition of these concentrated chemicals to water. Never add the total volume of any of these concentrated chemicals quickly to water. Boiling or splattering of chemicals may result. Always add chemicals gradually to water while stirring slowly. • Stir gently to prevent solution splattering. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 90 8. APPENDIX 5 8.1. REPLENISHER FUNCTIONS AND FACTORS AFFECTING TANK SOLUTION COMPOSITION Tank solution composition is affected by the various factors indicated in the outlined boxes below. To prevent changes in tank solution composition, and to maintain solutions at constant activity levels, it is necessary to replenish them using specific replenishers at specified replenishment rates. This appendix records the various processing solution characteristics in concise form. Such information will assist laboratory personnel to understand the implications of solution composition changes and to recognising the necessity of stabilised solution composition. Replenisher Roles 1. Replaces exhausted components. 2. Dilutes processing by-products. 3. Maintains solution consistency. Overflow Role Removal of excess replenishment-related processing tank solution. Figure AP-6 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 91 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 92 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 93 9. APPENDIX 6 9.1. DENSITY AND SPECIFIC GRAVITY MEASUREMENT PRECAUTIONS Process Control Strip Density Measurements Densitometers To insure measurement accuracy it is essential that a densitometer, guaranteed for both precision and reliability, be used when measuring control strips. Densitometer Location Requirements • Vibration prevention: Densitometers are sensitive to vibrations. Densitometers should be located on a firm, flat surface of a desk or sturdy table. • Illumination levels: Accurate measurements cannot be obtained if the densitometer is exposed to direct sunlight. Room illumination levels should be adjusted to below 500 lux. • Room temperature and humidity: The densitometer should be used at temperatures below 35°C with less than 80% relative humidity. Standard Calibration Density Strip Handling Precautions • Dirty strips: Using a soft, lint-free cloth, remove all dirt, dust and any foreign matter from the standard density strip measurement areas. • Scratched strips: Scratched strips or defective strips will give false readings; they are of no use and should be promptly replaced. • It is recommended that standard calibration density strips can be replaced every year. Dirty Densitometer and Control Strips If the densitometer’s optical system and/or the control strip are dirty, accurate density measurements cannot be obtained. To insure measurement accuracy, the densitometer’s optical system must he regularly cleaned and the control strip must be free from dirt, streaks and smudges before measurement. Cotton gloves should be worn when handling control strips. Measurement The centre of the area to be measured should be placed under the densitometer measuring head and the level gently lowered to obtain the reading. Cleaning Densitometer Colour Filters Colour filters incorporated within the densitometer may become dirty or dusty. If so, accurate measurements may no longer be obtained. For consistent results, the densitometer’s filters should be periodically checked and cleaned according to the manufacturer’s instructions. Compliance with Instructions To obtain optimum performance and life from your densitometer, it is highly recommended that all of the manufacturer’s maintenance and operational instructions be strictly followed. Process Solution Density (Specific Gravity) Measurements Hydrometers It is recommended that certified precision hydrometers, calibrated in 0.001 increments, be used for Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 94 density measurements. Hydrometer Handling and Storage Care should be exercised when handling hydrometers. Hydrometers that have been dropped or cracked will produce incorrect measurements. When the glass surface of a hydrometer is unclean, a complete meniscus (the point where the hydrometer and solution come in contact) may not form, resulting in an incorrect measurement. It is recommended that each hydrometer be thoroughly washed, dried and stored safely after each use. Solution Temperature Adjustment • Measured density (specific gravity) values vary with solution temperatures. • To adjust the solution temperature, fill a glass cylinder with the solution to be measured, as shown in Fig. AP-7. Place the glass cylinder in a thermostatically controlled bath. • When the test solution temperature stabilises at the specified measurement temperature, it is recommended to begin density measurements. Figure AP-7 Solution Temperature Adjustment Density (Specific Gravity) Measurements After the solution temperature has been stabilised, gently lower the hydrometer into the solution so that the hydrometer does not bump or rest on the cylinder bottom or sidewalls. Release the hydrometer after it begins to float. Gently spin the hydrometer to insure that it does not rest on the sidewall of the cylinder. When the hydrometer ceases to bob in the solution but continues to spin, read the density of that test solution at the meniscus. Fig. AP-8 will assist you in this procedure. Figure AP-8 Reading the Hydrometer Note : Foam Removal: Periodically, in the transfer of a solution for measurement purposes, foam may form on the solution surface in the measurement container. It is difficult to read the specific gravity under this condition. Remove any foam by completely filling the cylinder and removing any foam with a spoon, spatula or mixing rod. Let the remaining foam dissipate before final density (specific gravity) measurements are made. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 95 Fig. AP-9 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 96 10. APPENDIX 7 10.1. DEVELOPER RECYCLING Fuji Hunt Developer Recycling Systems Fuji Hunt offer two recycling systems for RA4 developer, depending on the amount of developer overflow recovered. These are : EnviroPrint Developer Regenerator : for developer regeneration without ion exchange resins; rebuild ratio 55% (550 ml overflow to make 1000 ml replenisher) at 160 ml / m² paper replenishment rate EnviroPrint Developer Regenerator HR: for developer regeneration without ion exchange resins; rebuild ratio 65% (650 ml overflow to make 1000 ml replenisher) at 160 ml / m² paper replenishment rate. This product may also be used to rebuild EnviroPrint Developer overflow at a rebuild ratio of 70% (with modified mixing instructions) or to even higher levels (where developer carryover is very low). Selection of the best option for your laboratory should be made after discussion with your Fuji Hunt Representative. These systems do not require use of ion exchange resins – or even detailed chemical analysis; simple pH and density (specific gravity) checks are sufficient. Developer Regeneration It is the policy of Fuji Hunt to offer regeneration procedures and products wherever possible with the intention of reducing chemical effluent and laboratory processing costs as much as possible. Regeneration can be operated in two ways : 1. Rebuild a measured volume of overflow to make replenisher, 2. Dehalide all developer overflow and then rebuild the solution to make replenisher. Method 1 is almost universally the only method now used. No analyses or resin regenerations are necessary. Method 2 has the advantage of using all the developer overflow but this is counterbalanced by having to regenerate the resin when it is full of halide. The regeneration effluent contains some developer chemical plus a lot of halide. In the past Fuji Hunt sold Rapigen 4 Developer Regenerator for use with CPRA Developer Regeneration at 35°C, but today we are only offering the EnviroPrint Developer Regenerators as rebuilding concentrates, based on use of EnviroPrint Developer running at 38°C. For more details consult your Fuji Hunt representative. System Startup / Tank Replacement An EnviroPrint Developer regeneration system is usually started from a normal replenished system. Originally the developer replenisher would have been standard EnviroPrint Developer; when a new regeneration system is started, the first step is to collect the developer overflow from the processor in a suitable tank. As more replenisher is required, this collected overflow is regenerated to make more replenisher following the instructions below. This rebuilt replenisher is then used exactly as before, with no change of replenishment rate. If you do not have enough regenerated replenisher to keep the system running for some reason – such as contamination, loss of developer overflow due to poor squeegees, or leakage – you can always make more fresh replenisher from standard EnviroPrint Developer packs as required. Replacement of a working tank solution in a processor – because of contamination or some other reason – is much the same as for non-regenerated chemistry. Instructions are given below : Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 97 EnviroPrint Developer Regeneration – Tank Solution Replacement To make 1 litre Water Part A† Part B† Part C† Fresh or Regenerate d Replenisher EnviroPrint Universal Dev. Starter TANK 884.5 ml 28 ml 9 ml 38.5 ml / 40 ml Tank from fresh or regenerated Repl 260 ml / / / 700 ml 40 ml † When making replacement working tank solutions from concentrates, standard EnviroPrint Developer Replenisher kits must be used. Replacement working tank developers cannot be made from EnviroPrint Developer Regenerator chemistry parts. EnviroPrint Developer EnviroPrint Developer is very easily regenerated by using EnviroPrint Developer Regenerator HR or EnviroPrint Developer Regenerator concentrates. Parts 1R, 2R and 3R or Parts 1R, 2R and 4R are available, depending on the volume of overflow recovered. EnviroPrint Developer Regenerator HR allows a substantial volume of developer overflow to be re- utilised. The High Ratio (HR) system can be used to rebuild 650 or 700 ml of overflow. This is equivalent to an effective replenishment rate of just 56 ml/m² or 48 ml/m² respectively. In this case, EnviroPrint Developer Regenerator Part 1R, 2R and EnviroPrint Developer Regenerator HR Part 3R will be used. If carry-over is between 56 ml/m² and 73 ml/m² then EnviroPrint Developer Regenerator Part 4R must be used in conjunction with EnviroPrint Developer Regenerator Parts 1R + 2R and 550 ml of overflow. Normally it is not necessary to carry out analytical tests whilst rebuilding, but if a laboratory wishes to monitor its process analytically, operating concentrations of key ingredients can be provided by Fuji Hunt. In particular, the Fuji Hunt OASIS Pro chemical and process control system is ideally suited to this task. The attention of users of EnviroPrint Developer Regenerator HR is drawn on the fact that any regeneration system is a dynamic balance achieved under the specific conditions of a given processor. Processors vary from one to another in operating characteristics, in particular carry over on paper and leader belts. Processors without leader belts may need modified chemical rebuild formulae compared to machines with leader belts. All formulae for rebuilding specified volumes of overflow are only approximate. More particularly it is not possible to guarantee the achievement of the correct pH or solution density. It is essential for optimum photographic quality that adjustments at the rebuilding stage are made by the laboratory to achieve pH and density within specification. Out of specification rebuilt developer replenisher will certainly give rise to out of control photographic results. 10.2. Mixing Instructions To regenerate EnviroPrint Developer overflow : EnviroPrint Developer Regenerator HR Option 1 : Rebuilding Ratio 65/35 EnviroPrint Developer Overflow Water Part 1R Part 2R or Multigen CD50 (2) EnviroPrint Developer Regenerator HR Part 3R 650 ml 308.6 ml 14.4 ml (1) 8.1 ml 18.9 ml (1) Recommended addition. It is possible, in case of high throughput, to reduce the addition of Part 1R. (2) If CD60 is used, addition will be 6.75 ml. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 98 EnviroPrint Developer Regenerator HR Option 2 : Rebuilding Ratio 70/30 EnviroPrint Developer Overflow Water Part 1R Part 2R or Multigen CD50 (2) EnviroPrint Developer Regenerator HR Part 3R 700 ml 262.4 ml 13.7 ml (1) 7.8 ml 16.1 ml (1) Recommended addition. It is possible, in case of high throughput, to reduce the addition of Part 1R. (2) If CD60 is used, addition will be 6.5 ml. EnviroPrint Developer Regenerator Rebuilding Ratio 55/45 EnviroPrint Developer Overflow Water Part 1R Part 2R or Multigen CD 50 (1) Part 4R 550 ml 395.9 ml 16.7 ml 8.2 ml 29.3 ml (1) If CD60 is used, addition will be 6.8 ml. These volumes may be varied to modify replenisher activity if required. Fuji Hunt recommends measuring pH after rebuilding and to adjust to the specification if necessary, using either potassium hydroxide or sulphuric acid. Caution : If acid is added to the developer, there will be an effervescence of carbon dioxide due to the carbonate present in the developer. It is also necessary to control the density within the given specification. This can be achieved by adjusting the density of the overflow prior to regeneration if automatic blending equipment is used. Do not change replenishment rate from 160 ml/m². Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 99 11. APPENDIX 8 11.1. BLEACH-FIX RECYCLING Three bleach-fix recycling systems are available from Fuji Hunt. A conventional regeneration system for use with electrolytic silver recovery systems, using EnviroPrint Electrolytic Bleach-Fix Regenerator, is widely used. With increasing environmental pressure on the photo processing industry, Fuji Hunt has introduced a partly biodegradable bleach fix system called EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator, which reduces EDTA discharge to waste by 50%. A third system, using EnviroPrint Bleach-Fix Regenerator, transfers the removal of silver from the bleach-fix to the low flow wash. With this process it is no longer necessary to desilver the bleach-fix overflow before regenerating it for reuse as replenisher. Details on these three systems may be found below. A. EnviroPrint Electrolytic Bleach-Fix Regenerator EnviroPrint Electrolytic Bleach-Fix regeneration is a conventional regeneration system for those laboratories who wish to desilver the Bleach-Fix prior to rebuilding. When implementing the Electrolytic Bleach-Fix regeneration system, chemical waste can be reduced and carry over levels of silver into the wash-water will be decreased to an absolute minimum. Further chemical waste reduction can be achieved when installing a well configured low flow wash followed by a main wash, or go for the ultimate waste control system by installing a chemical wash concept. In order to recover the maximum amount of silver, desilvering of the low flow wash or chemical wash is recommended. The bleach-fix system is started by filling the processor and replenisher tank with CPRA Bleach-Fix. EnviroPrint Bleach-Fix 215 AC can also be regenerated with EnviroPrint Electrolytic Bleach-Fix Regenerator chemicals using the conventional route of desilvering the bleach-fix prior to regeneration. Important : In the Photographic market, two systems are being offered of which system 2 is a “pirate” version. The so called “Economical and low high tech approach”. Fuji Hunt is in favour of offering the original “high tech” version, guaranteeing a more stable chemistry (system 1) but if customers insist on using the “economical, low tech version” (system 2), your local Fuji Hunt Technical representative will give you all support you need. System 1 - to regenerate the Bleach-Fix overflow : 1. Collect overflow from bleach-fix tank. 2. Add 15 ml EnviroPrint Electrolytic Bleach-Fix Regenerator Part A for every litre of overflow. 3. Check pH, and adjust if necessary to within the range 7.8 - 8.1 using ammonia solution or 30% sodium hydroxide solution. 4. Desilver electrolytically to 0.5 - 1.0 g/L silver. 5. If necessary aerate desilvered overflow until most of the ferrous iron is converted back to ferric iron (2-4 hours). The maximum ferrous iron level is 10% of the total iron. 6. Add EnviroPrint Electrolytic Bleach-Fix Regenerator Parts B & C, plus acetic acid as follows : Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 100 EnviroPrint Electrol ytic Bleach-Fix Regenerator Desilvered, aerated Overflow Part B Part C Acetic Acid 60% w/w Water 860 ml 35 ml 57 ml 13 - 18 ml (1) To make 1 L 1000 ml 40.7 ml 66.3 ml 15 - 21 ml (1) Makes ±1160 ml (1) It may be necessary to vary additions of acetic acid to obtain the correct pH. See page 51. 7. Pump regenerated overflow back to bleach-fix replenisher tank. System 2 - to regenerate the Bleach-Fix overflow : 1. Collect overflow from bleach-fix tank. 2. Check pH, and adjust to pH range 7.8 - 8.1 using ammonia solution or 30% sodium hydroxide solution. 3. Desilver electrolytically to 0.5 - 1.0 g/L silver. 4. If necessary aerate desilvered overflow until most of the ferrous iron is converted back to ferric iron (2-4 hours). The maximum ferrous iron level is 10% of total iron. 5. Add EnviroPrint Electrolytic Bleach-Fix Regenerator Parts B & C, plus acetic acid as follows: EnviroPrint Electrol ytic Bleach-Fix Regenerator Desilvered, aerated Overflow Part B Part C Acetic Acid 60% w/w Water 880 ml 25 ml 40 ml 13 - 18 ml (1) To make 1 L 1000 ml 28.4 ml 45.5 ml 15 - 21 ml (1) Makes ±1135 ml (1) It may be necessary to vary additions of acetic acid to obtain the correct pH. See page 51. 6. Pump regenerated overflow back to bleach-fix replenisher tank. System 2 does not necessarily guarantee a long-term stable rebuilt replenisher. Some additional Bleach-fix stabilising compound is omitted by not adding part A. B.EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator is using a 100% readily biodegradable complexing agent achieving a drastic reduction of minimum 50% of the hard complexing agent EDTA in the waste stream. The product is designed for use in the conventional RA4 Bleach-Fix regeneration system and for those laboratories that wish to desilver prior to rebuilding. The processing and handling conditions of this product are exactly the same as for the EnviroPrint Electrolytic Bleach-Fix Regenerator; however, addition volumes of the regenerator parts do differ. This formula design guarantees long-term product and image stability. Fresh start-up The bleach-fix system is started by filling the processor and replenisher tank with EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 101 Tank solution Replenisher solution Water 764 ml 764 ml EnviroPrint Electrolytic Bio-Bleach-Fix Part A 112 ml 112 ml EnviroPrint Electrolytic Bio-Bleach-Fix Part B 124 ml 124 ml End volume 1000 ml 1000 ml Regeneration As for standard bleach-fix regeneration, two regeneration routines are offered of which System 2 is a so-called “economical and low tech approach”. Fuji Hunt is in favour of offering the “high tech” version, guaranteeing a stable chemistry (System 1). Whenever customers insist on using the “economical, low tech version”, your local Fuji Hunt technical representative will give you all support you need. System 1 - to regenerate the Bleach-Fix overflow : 1. Collect overflow from the bleach-fix tank. 2. Add 12 ml EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator Part C for every litre of overflow. 3. Check the pH and adjust if necessary to within the range 7.8 – 8.1, with ammonia solution or sodium hydroxide 30%. 4. Desilver electrolytically to 0.5 – 1.0 g/l silver or lower to meet your requirement. 5. Aerate the desilvered overflow until most of the ferrous iron is converted back to ferric iron (2-4 hours). Fuji Hunt’s advised maximum level of ferrous iron level is set at 10% of the total iron. 6. Add EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator Parts A & B, plus acetic acid as follows: EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator – System 1 Desilvered & aerated overflow Part A Part B Acetic acid, 60% w/w Water 860 ml 30 ml 35 ml 15-20 ml (1) to make 1 litre 1000 ml 35 ml 41 ml 17-22 ml (1) to make ±1160 ml (1) It may be necessary to vary additions of acetic acid to obtain the correct pH. See page 51 for specifications. 7. Pump the regenerated overflow to the bleach-fix replenisher tank. System 2 - to regenerate the Bleach-Fix overflow : 1. Collect overflow from the bleach-fix tank. 2. Check the pH and adjust if necessary to within the range 7.8 – 8.1, with ammonia solution or sodium hydroxide 30%. 3. Desilver electrolytically to 0.5 – 1.0 g/l silver or lower to meet your requirement. 4. Aerate the desilvered overflow until most of the ferrous iron is converted back to ferric iron (2-4 hours). Fuji Hunt’s advised maximum level of ferrous iron is set at 10% of the total iron. 5. Add EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator Parts A & B, plus acetic acid as follows: Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 102 EnviroPrint Electrolytic Bio-Bleach-Fix Regenerator – System 2 Desilvered & aerated overflow Part A Part B Acetic acid, 60% w/w Water 900 ml 25 ml 30 ml 15-20 ml (1) to make 1 litre 1000 ml 28 ml 33 ml 17-22 ml (1) to make ±1160 ml (1) It may be necessary to vary additions of acetic acid to obtain the correct pH. See below for specifications. 6. Pump the regenerated overflow to the bleach-fix replenisher tank. Chemical specifications A. Fresh chemistry Tank solution Replenisher solution Density at 20°C (g/cm³) 1.072 ±0.005 1.072 ±0.005 pH (25°C) 6.50 ±0.10 6.50 ±0.10 ATS (g/l) 71 ±10 71 ±10 Total iron (g/l) 5.8 ±0.5 5.8 ±0.5 Sodium sulphite (g/l) 23 ±5 23 ±5 B. Rebuilt chemistry Tank solution Replenisher solution Density at 20°C (g/cm³) 1.115 ±0.020 1.125 ±0.020 Density at 35°C (g/cm³) 1.110 ±0.020 pH at 25°C 6.60 ±0.20 6.30 ±0.20 ATS (g/l) 65 ±5 75 ±5 Total iron (g/l) 6.0 ±0.5 6.8 ±0.5 Ferrous iron (% of total Fe) <30 <10 Sodium sulphite (g/l) 15 ±5 20 ±5 Operating temperature The temperature of the EnviroPrint Electrolytic Bio-Bleach-Fix tank solution is 35°C ±3°C. This is the standard RA4 Bleach-Fix temperature. Mixing instructions Replenishment rate Processor with carry-over <40 ml/m² Processor with carry-over >40 ml/m² Replenishment rate 160 215 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 103 With the Agfa VSP 50 processor, a replenishment rate of 160 ml/m² can be set, as on average a carry- over of less than 40 ml/m² is very realistic. EnviroPrint Bleach-Fix Regenerator CPRA Bleach-Fix can readily be regenerated with EnviroPrint Bleach-Fix Regenerator chemicals. Because of the difficulties associated with electrolytic desilvering of the low pH EnviroPrint Bleach- Fix AC solutions, Fuji Hunt has designed a system whereby the removal of silver has been transferred from the bleach-fix to the low flow wash. With this process it is no longer necessary to desilver the bleach-fix overflow before regenerating it for reuse as replenisher. The bleach-fix system is started by filling the processor and replenisher tank with EnviroPrint Bleach- Fix 215 AC. The overflow is collected and regenerated by the addition of EnviroPrint Bleach-Fix Regenerator Part 1F, 2F and 3F. The solution is checked for pH and density, and adjustments made if necessary. It is then ready to be used as bleach-fix replenisher. Volume increases within the system are limited to the volume of regenerator chemicals added, less any evaporation that occurs. - To regenerate bleach-fix overflow : EnviroPrint Bleach-Fix Regenerator Bleach-Fix Overflow Part 1F Part 2F Part 3F (2) (Acetic Acid) 883.3 ml 82 ml 21.2 ml 13.5 ml (1) 1000 ml 93 ml 24 ml 15.3 ml (1) (1) It is desirable to operate with the lowest density possible in order to reduce chemical waste. Normally a regenerated overflow with a density of 1.100 will produce acceptable bleaching and fixing. If difficulties are experienced, e.g. retained silver or leuco-cyan dye, the density should be increased. It should not be allowed to exceed 1.150 in the regenerated replenisher. (2) Part 3F is acetic acid. Adjust volume used to achieve a pH within specification. See page 51. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 104 12. APPENDIX 9 12.1. EnviroPrint BIO-BLEACH RECYCLING (Process RA404) Bleach Regeneration The rebuilding instructions given below are approximate. The volume of the concentrate and acid required to obtain a rebuilt replenisher within specification, depends on the characteristics of the processing machine. To regenerate bleach overflow : EnviroPrint Bio-Bleach Overflow Concentrate Nitric Acid 20% w/w 1000 ml 53 ml 8.5 ml 942 ml 50 ml 8 ml It is essential for this bleach that the density of the tank solution does not drop below the minimum required value of 1.024 g/cm³ at 20°C. For the correct pH value, See page 51. Important : Conversion from EnviroPrint Bleach or from competitor bleaches to EnviroPrint Bio-Bleach can be easily done by regenerating on top with the EnviroPrint Bio-Bleach concentrate. A conversion procedure needs to be followed in this case. For further details on how to convert from your old bleach system to EnviroPrint Bio-Bleach, ask your local Fuji Hunt representative for the separate technical information sheets on EnviroPrint Bio-Bleach. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 105 13. APPENDIX 10 13.1. FIXER RECYCLING It is possible to run a closed loop silver recovery system for a paper processor fixer with both Unilec Fixer and XL Rejuvenator fixers, or with the ammonia-free EnviroPrint Fixer. Fixer systems for paper processors are often combined with film processors to enable a higher overall level of fixer regeneration to be achieved; film fixer alone is limited to around 60-70% maximum regeneration due to by-products (halides) released from the film emulsions; paper emulsions do not release the same levels of fixer-deactivating halides. It is helpful to be able to understand the changes that occur in a fixing bath in order to ensure that you do not have problems when recycling fixers. Changes that occur in the fixing bath There are three basic changes that take place in the fixing bath when photographic materials are fixed: 1. The photographic materials entering the fixing bath carry in solution from the previous bath (either bleach or water, depending on the process). This liquid dilutes the fixing bath and, if the previous bath was a bleach, leads to a build-up in bleach concentration. 2. The photographic material leaving the fixing bath carries out fixer solution. 3. All the silver halide in the emulsion is dissolved into the fixing bath. In summary, due to 1 and 2, the concentration of fixer will continually fall with processing. There will be a gradual increase in the concentration of bleach, even if the immediate bath prior to the fixer is a water-wash, and due to 3 the silver halide concentration will continue to increase. The ability of ammonium thiosulphate to absorb silver halide reduces as its concentration increases. In practice this means that the “clearing-time” increases and furthermore the ability of the subsequent water washes to remove the soluble silver halide complex salts becomes less effective because of lower solubility of the complex silver salts. The effect of this is for the processed photographic film or paper to retain a higher level of silver salts than is desirable, leading eventually to stain formation or attack of the colour image. In order to nullify the effects of 1, 2 and 3, it is necessary to replenish the fixer solution with a suitable fixer replenisher. In practice the fixer replenisher is usually the same solution as was originally installed in the fixing tank in the processor. Each manufacturer of fixers gives information on the correct rate of replenishment to be applied for various colour materials. Fixer Management Because fixers are expensive solutions and readily lend themselves to desilvering and reuse, the main purpose of this Appendix is to indicate to users the various possibilities that exist for the “management” of fixing solutions. In paper processing most fixing is carried out at the same time as bleaching in a solution called a bleach-fix. In photofinishing operations as opposed to professional and minilab, the paper process may be separated into bleach and fix stages - RA404 and R303 process for RA4 and R3 processes. The advantage of this splitting into two solutions means that the bleach and fix can be separately regenerated and reused continuously, thus reducing considerably environmental pollution. The paper fixer may, if required, be combined with the fixer from the C41 negative process, thus reducing the number of mixing vats and replenisher storage tanks overall. A central desilvering operation can also be carried out if required. A further major benefit of running a combined fixer recycling system involving both film and paper fixers is that the paper side effectively “dilutes” the halide coming from the film side, as less halide is released from paper fixing. This allows higher overall levels of fixer recycling than can be obtained from a simple film-only fixer recycling system, as halide is a major factor that governs fixing speed in recycled fixers. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 106 It is very much easier to electrolytically desilver a fixer solution than a bleach-fix solution. The desilvering equipment is less costly to manufacture and electricity consumption is much reduced. Finally the yield of high quality silver is increased over bleach-fix desilvering. The following schemes indicate various ways in which fix-management can be practised with products available from Fuji Hunt. It must be emphasised however that there are many possibilities all varying slightly in the method of working. Scheme 1 : Simple fixer replenishment Replenisher Dilution Process Product Conc. Water Replenishment Rate RA4 Paper Unilec/Unimatic Fixer 1 4 200 - 290 ml/m² Both Unilec or Unimatic Fixers are suitable. Further details as published in the technical brochure for the process. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 107 Scheme 2 Fixer overflow should be desilvered by either A, Electrolysis or B, Steel wool cartridges (or a combination of both). Use recommendations for Unilec/Unimatic same as for Scheme 1. This scheme allows silver recovery from the fixer tank overflow but does not reuse the desilvered fixer. Process Product Dilution Replenishment Rate Conc. Water RA4 Paper Unilec/Unimatic Fixer 1 4 200 - 290 ml/m² Both Unilec or Unimatic Fixers are suitable. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 108 Scheme 3 Process Product Fresh tank dilution Replenisher tank dilution Replenishment Rate Conc. Water Conc . Water RA4 Paper Unilec Fixer 1 4 1 3 55 ml/m² or lower The scheme as shown above is the optimum for maximum silver recovery. The user decides the maximum concentration of silver in the processor fixer tank. Usually, for practical operating reasons, this will be 0.5 - 1.0 g/litre. It must be remembered that every square metre of processed paper will carry out 40 - 80 ml of fixer solution from the fixer tank thus resulting in lost silver carried into the wash tanks. The lower the silver concentration in the fixer tank, the lower will be the quantity of silver carried out and lost to the wash tanks. If it is required to maintain the silver level below 0.5 g/l in the fixer tanks it will be found that higher electricity densities are required for the electrolysis and the risk of poor quality silver plating, including sulphiding, will increase. The effect of decomposition on the fixer will also be greater making it harder to maintain a stable fixer. For these reasons Fuji Hunt recommends a minimum silver level of 0.5 g/l in the fixer tank. In order not to exceed the aim silver concentration in the fixer tank the electrolytic desilvering unit must be capable of removing all the silver released from the processed material as it is released. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 109 Example : Aim maximum concentration of silver in fixer tank =1.0 g/litre Aim maximum concentration of silver in fixer leaving the desilvering unit =0.8 g/litre The desilvering unit must therefore remove 0.2 g silver for each litre of fixer solution passing through. Suppose the processor speed is 30 metres/minute with two bands of 15.2 cm wide paper containing 0.55 g silver/m². The area of paper processed per minute is : 30 m x 2 x 0.152 m =9.12 m² This will release 9.12 x 0.55 g =5.02 g silver/min. The flow rate of fixer solution through the silver recovery unit must be : 25.1 0.2 5.02 = litre per minute. The desilvering unit must be capable of removing 5.02 g silver per minute at a flow rate of 25.1 litre per minute. If the rate of release of silver to the tank is less than 5.02 g silver per minute, the desilvering unit will continue to remove silver until the pre-set minimum concentration is reached e.g. 0.5 g/litre. If this desilvering rate can not be reached, the silver concentration in the fixer tank will increase and the loss of silver due to carry-over to the wash tanks will be higher than planned. The fact that fresh fixer, which does not contain silver, is added to the tank as replenisher has a small diluting effect on the silver concentration. This gives rise to an overflow of fixer solution from the fixer tank which cannot be reused. The replenishment rate is the minimum necessary to maintain a constant fixer concentration in the fixer tank after compensating for carry-in and carry-out. Fuji Hunt recommends a maximum replenishment rate of 55 ml/m² for paper. For film, the replenishment rate should be between one half and two thirds of the normal recommended replenishment rate. These values may be reduced if the fixer solution density increases above the aim density and fixing is adequate. The replenisher consists of 1 part Unilec Fixer concentrate mixed with 3 parts water. The Unilec formula is especially formulated to contain a high concentration of alkali and sulphite to offset the degradation associated with the electrolysis of the fixer solution. Unimatic LR Fixer is not designed for and is not recommended for closed loop desilvered systems. This method of fix replenishment will consume less fixer concentrate than the simple replenishment system in schemes 1 and 2. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 110 Scheme 4 It is less easy to balance flow rates into each tank so the silver concentration can be expected to differ from fix tank to fix tank. This means that where concentrations are higher more silver will be lost through carry out to the wash tanks. This scheme is essentially the same as scheme 3. A holding tank will be necessary to receive the overflows from the processors. Since the system volume will increase due to the volume of added replenisher it is convenient to remove unwanted fixer from the holding tank as required. If the silver recovery unit is not big enough to remove silver at the rate at which it is liberated from the photographic material to the system, then the silver recovery unit can continue to work during shutdown periods until the silver concentration has been reduced to the aim value. If this method is employed it must be recognised that the silver concentration in the system will rise during periods of processing with subsequent silver losses through carry-out to wash tanks. The final arbiter will be cost of equipment balanced against cost of recuperated silver and reduced fixer replenisher usage. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 111 Scheme 5 (using XL Rejuvenator) Process Product Dilution per litre of fix overflow Replenishment Rate RA4 Paper XL Rejuvenator 35 - 50 ml/l 290 ml/m² NB : The pH of the replenisher tank fix solution should be between 6.2 and 7.2. This system operates on the principle of adding a concentrated fix rejuvenator solution to each litre of desilvered fixer overflow and to reuse this rejuvenated solution as fix replenisher. No mixing tanks or dilution of fixer concentrate are required for the rejuvenation process. The silver concentration in the fixer tank should be as low as possible to minimise silver carry-over into the wash tank. For each litre of fixer desilvered a set quantity (35 - 50 ml) of XL Rejuvenator is added to the desilvered fix solution on its return to the replenisher tank. The silver recovery unit can be mounted in line as shown above or in closed circuit with fixer tank or holding tank as required. XL Rejuvenator is designed to maintain both pH and density within tolerances when used as recommended. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 112 Scheme 6 (using Unilec) Process Product Dilution per litre of fix overflow Replenishment Rate RA4 Paper Unilec 27 - 38 ml/L 290 ml/m² NB : The pH of the replenisher tank fix solution should be between 6.2 and 7.2. This system operates on the principle of adding a concentrated fix Rejuvenator solution to each litre of desilvered fixer overflow and to reuse this rejuvenated solution as fix replenisher. A mixing vessel is required for the adjustment of the pH and the addition of water can be necessary to keep the density of the replenisher within tolerance. The pH can be adjusted with either ammonium or 30% sodium hydroxide. The silver concentration in the fixer tank should be as low as possible to minimise silver carry-over into the wash tank. For each litre of desilvered fixer, a set quantity (27 - 38 ml) of Unilec Fixer concentrate is added to the desilvered fix solution on its return to the replenisher tank. The desilverer can be mounted in line as shown above or in closed circuit with fixer tank or holding tank as required. ELECTROLYTIC DESILVERING AND FIXER REGENERATION UNILEC Unilec Conc. Water supply Mixer pH adjust -ment Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 113 Scheme 7 (using EnviroPrint Fixer) Process Product Dilution per litre of fix overflow Replenishment Rate RA4 Paper EnviroPrint Fixer 250 ml/L 80 ml/m² NB : The pH of the replenisher tank fix solution should be between 7.0 and 8.0. This system operates on the principle of adding a concentrated fix rejuvenator solution to each litre of desilvered fixer overflow and to reuse this rejuvenated solution as fix replenisher. A mixing tank is required for the adjustment of the pH with sulphuric acid 20%. The silver concentration in the fixer tank should be as low as possible to minimise silver carry-over into the wash tank. For each litre of fixer desilvered a set quantity (250 ml) of EnviroPrint Fixer is added to the desilvered fix solution on its return to the replenisher tank. The desilverer can be mounted in line as shown above or in closed circuit with fixer tank or holding tank as required. Notes - It is possible that bleach will slowly enter the system through carry-over and may necessitate the fixer being dumped when bleach concentration is too high (to prevent leuco cyan dye formation). In some cases an excessive build-up of halides can occur resulting in unfixed film or paper. In this case it will be necessary to add fresh fixer (diluted) to the system until fixing becomes acceptable. ELECTROLYTIC DESILVERING AND FIXER REGENERATION ENVIROPRINT FIXER pH adjust- ment EnviroPrint Fixer. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 114 Fixers Unimatic Fixer Concentrate : A fixer for film or paper fixing where continuous recirculation through an electrolytic silver recovery unit is not practised. Unilec Fixer Concentrate : A fixer for film or paper fixing for any condition, whether simple replenishment or continuous desilvering is practised. The pH is ±7.5. Unimatic LR Fixer Concentrate : A fixer for the C41 or RA404 process giving reduced replenishment rate. XL Rejuvenator : A fixer additive for continuous desilvering and recycling. It is more diluted than normal fixer concentrates to remedy evaporation and excessive halide build-up. EnviroPrint Fixer : An ammonia-free fixer for paper (RA4) fixing, whether simple replenishment or continuous desilvering is practised. The product can also be used for fixer regeneration in combination with continuous desilvering. Both Unimatic Fixer and Unilec Fixer can be used as regenerators but the pH and Density must be maintained within specification on a daily basis by appropriate additions of concentrate and ammonium hydroxide. This method is not recommended. Unimatic Fixer is not designed for continuous closed loop recycling. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 115 Technical Specifications TANK SOLUTION REPLENISHER SOLUTION Density g/cm³ pH Density g/cm³ pH Product (20 °C) (25 °C) (25 °C) (20 °C) (25 °C) (25 °C) Unimatic (1+4) Fresh 1.080 ±0.010 1.079 ±0.010 6.50 ±0.10 1.080 ±0.010 1.079 ±0.010 6.50 ±0.10 Equilibrated 1.085 ±0.010 1.084 ±0.010 6.40 ±0.20 - - - Unimatic (1+9) Fresh 1.041 ±0.010 1.040 ±0.010 6.50 ±0.20 1.041 ±0.010 1.040 ±0.010 6.50 ±0.10 Equilibrated 1.065 ±0.020 1.064 ±0.020 6.50 ±0.50 - - - Unimatic LR (1+4) Fresh 1.085 ±0.010 1.084 ±0.010 8.00 ±0.20 - - - (tank solution) Equilibrated 1.105 ±0.010 1.104 ±0.010 7.90 ±0.20 - - - Unimatic LR (1+3) Fresh - - - 1.103 ±0.010 1.102 ±0.010 8.10 ±0.20 (replenisher) Equilibrated - - - - - - Unilec (1+3) Fresh - - - 1.110 ±0.010 1.109 ±0.010 7.50 ±0.20 (replenisher) Equilibrated - - - - - - Unilec (1+4) Fresh 1.087 ±0.010 1.086 ±0.010 7.50 ±0.20 1.087 ±0.010 1.086 ±0.010 7.50 ±0.20 Equilibrated 1.090 ±0.010 1.089 ±0.010 6.70 ±0.50 - - - Unilec (1+9) Fresh 1.046 ±0.010 1.045 ±0.010 7.50 ±0.20 1.049 ±0.010 1.048 ±0.010 7.50 ±0.20 Equilibrated 1.065 ±0.020 1.064 ±0.020 6.70 ±0.50 - - - Unimatic or Unilec regenerated with Fresh - - - - - - XL Rejuvenator Equilibrated 1.080 ±0.020 1.079 ±0.020 6.70 ±0.50 1.100 ±0.020 1.099 ±0.020 6.70 ±0.50 General Notes - Silver Limits and Clearing Times : Fixing solutions for colour paper and films can operate over a relatively wide range of pH - from 6.2 to 7.2. Beyond 7.2 there will be release of ammonia fumes which will be unacceptable because of the smell. Providing a minimum density of 1.070 g/cm³ is maintained* there should be no problems in obtaining adequate fixing whilst silver concentration does not exceed 10 g/litre or, if continuous desilvering is practised, the concentration of halide (iodide, bromide and chloride) is not too high. Values cannot be set for this effect because the type of emulsion plays an important role. Most users of the RA404 process (with the separate bleach and fix baths) will also be running a common fix system with their C41 film process. Therefore, some information on combined C41/RA404 fix systems now follows. A very important factor in the level of halide that can be tolerated in a fixer is the fixing time available on a film processor in a common film / paper recycling system. Satisfactory fixing demands that the fixing time available is double the clearing time for the film emulsion under test. Therefore, if a piece of undeveloped film is completely clear after, say, 90 seconds of gentle agitation in a fixer taken from the processor, then the fixing time that must be provided in a processor (with the same fixer) is 180 seconds – or longer. Longer fixing times allow you to recycle an increased amount of fixer as the reduction in fixing speed due to increased halide (and possibly silver) content is compensated for by the longer fixing time. Laboratories recycling fixer that have all of their C41 processors using a 6 minute 30 second fixing time can push fixer recycling to significantly higher levels than those that have a 4 minute 20 second fixing time. This factor may need to be taken into account when controlling your fixer recycling with film / paper systems. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 116 If fixing, particularly in high speed films, is incomplete under the conditions on your film processor, it is likely that halide concentration is too high. Analysis of halides in fixers is quite difficult so the simplest remedy is to add fresh fixer solution to the system and check whether this improves fixing. A quick test of hand fixing a piece of unprocessed film of the problem emulsion types will tell you the clearing time required with your current fixer; after adding fresh fixer this can be re-tested to monitor the improvement. Usually the best films for this type of test are those that are the most difficult to fix – typically 400 ISO films, and in particular those from a major competitor brand. Fuji 400 films are less of a problem. 200 ISO APS format films are also a notorious source of fixing problems in laboratories and are ideal for testing. The halide can easily rise in concentration because silver halide is removed from the emulsions by the fixer and if the silver is removed by electrolysis the halide still remains. There is no realistic way of removing this halide other than by partial replacement of the fixer by adding fresh chemistry. High silver concentration has the most effect in reducing fixing rate (or inability to remove silver thiosulphate complex in the wash tank) but high halide also has an inhibiting effect in recycled fixer systems. * : For Unimatic (1+9) and Unilec (1+9), the minimum density is 1.045 g/cm³. Regeneration of fix baths The most suitable system is to use Unilec fixer in the processor tank, with silver removal by electrolysis either by closed loop in the processor tank or batchwise on the fixer overflow and rebuild the desilvered fixer to replenisher by addition of XL Rejuvenator. This will ensure correct composition of the fixer tank although the effect of over concentration of halide can still occur. Some laboratories prefer to use Unimatic or Unilec concentrates as additive to the system after electrolysis. Providing the density and pH range specified in the above table are maintained this is feasible. It will probably be necessary to add sodium or ammonium hydroxide to prevent decomposition of the thiosulphate fixing agent. Too much sodium salts addition may lead to crystallisation. Technical advice can be offered by the Fuji Hunt Sales representative if problems are encountered. Electrolysis of fixers The action of electrolytically desilvering a fixer solution causes a loss of sodium sulphite and a loss of alkalinity. Unilec Fixer and XL Rejuvenator both contain the necessary additions of these chemicals to maintain the fix bath in good condition so as to give acceptable results over long periods of time. However, due to machine problems or unidentified conditions errors it is possible for the fix bath to fail to meet the above specifications. In this case the source of the problem must be sought and corrected. If the pH of a fixer is too low, the addition of ammonia solution or sodium hydroxide solution will raise the pH. Conversely, sodium metabisulphite or acetic acid will lower the pH. Addition of Unilec Fixer or Unimatic Fixer concentrate will increase the density of a fix bath. If difficulty is experienced in obtaining a good solid deposit of silver on the silver recovery unit electrode it is possible that : The current is too high The silver content is too low (below 0.5 g/l) The fixer has been oxidised too much (sulphite concentration below 10 g/litre) The pH is too low (below 5.0) Insufficient agitation or circulation in the electrolytic silver recovery unit Too high a bleach content (solution appears dark red) Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 117 EnviroPrint Fix and Regenerator This ammonia-free fixer is available for use where there is need to reduce the discharge of ammonia or nitrogen to the drain. One concentrate only is required, and it offers a complete system of tank, replenisher and regenerator based on sodium salts, without any ammonia content. It is only suitable for RA4 and R3 paper. The fixer solution in the processor should be continuously or batch-wise electrolytically desilvered to a silver content of 0.5 - 1 g/L. Fixer Regeneration The rebuilding instructions given below are approximate. The volume of the concentrate and acid required to obtain a rebuilt replenisher within specification, depends on the processor characteristics. To regenerate the fix overflow : EnviroPrint Fixer Overflow Concentrate Sulphuric Acid 20% 800 ml 200 ml 6 ml 1000 ml 250 ml 7.5 ml XL Rejuvenator When an ammonium based fixer for the RA4 process is used, the fixer circuit can be regenerated with XL Rejuvenator concentrate. The fixer solution in the processor should be continuously electrolytically desilvered in the processor or batch-wise before regeneration to a silver concentration of 0.5 - 1.0 g/L. Either Unilec or Unimatic Fixer can be used to fill the processor. To regenerate the fixer overflow : XL Rejuvenator Fixer overflow Conc. 966 ml ± 34 ml (1) 1000 ml ± 35 ml (1) (1) It may be necessary to add more XL Rejuvenator concentrate if there is a high carry over of wash water into the processor fixer tank. The pH aim of 6.70 ±0.50 in the processor tank may need addition of acetic acid (to decrease pH) or ammonia solution (to increase pH) to the rebuilt overflow. CAUTION : Use of black & white fixers : Fuji Hunt does not recommend using any fixer which is designed for processing black & white films or papers with colour materials. The main reason is that the pH is usually between 4 and 5 which may lead to leuco cyan dye occurring in the processed material. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 118 14. APPENDIX 11 14.1. RA4 CHEMICALS FOR FAST PROCESSING Description Fuji Hunt's recommended chemistry to be used in today's fast RA4 process is EnviroPrint Developer Replenisher MP45 AC in combination with EnviroPrint Bleach-Fix 35 AC. As an alternative, EnviroPrint Developer Replenisher MP60 in combination with EnviroPrint Bleach-Fix 70 AC or EnviroPrint Bleach-Fix VR AC may also be used. All products have been extensively tested and have now become a reference in the Minilab market for fast processing. By simply mixing a more concentrated fresh tank solution and adjusting the replenishment rate accordingly, excellent print quality is obtained. Besides, the EnviroPrint Developer Replenisher MP45 AC and MP60 are homogeneous monopart liquid concentrates that easily mix with water and are designed to run at a low replenishment rate. This single part developer also reduces the risk of mixing errors, package waste and the required storage space. All products give excellent process stability and can be installed in processes having a development time as short as 22 to 33 seconds, and also the standard RA4 processing time of 45 seconds. Please ask your Fuji Hunt technical representative for further information if required. EnviroPrint Superflo Stabilizer & Replenisher AC or EnviroPrint Super Stabilizer & Replenisher AC are the best choice for fast processing, allowing a stabilizer time as low as to 50 seconds if the replenishment rate has been adjusted accordingly. Process parameters Time Temperature (°C) Replenishment Rate ml/m² EnviroPrint Developer Rep. MP45 AC (1) 33" 27" 22" 39 ±0.3 39.5 ±0.3 40 ±0.3 55 60 70-75 EnviroPrint Developer Replenisher MP60 33" 27" 22" 38.5 ±0.3 39 ±0.3 39.5 ±0.3 75 75-90 90-100 EnviroPrint Bleach-Fix 35 AC 22 - 33" 36 - 38 45 - 55 EnviroPrint Bleach-Fix 70 AC 22 - 33" 36 - 38 90 EnviroPrint Bleach-Fix VR AC 22 - 33" 36 - 38 90 EnviroPrint Superflo Stabilizer AC 50 - 90" 32 - 38 250-300 EnviroPrint Super Stabilizer AC 50 - 90" 32 - 38 250-300 (1) EnviroPrint Bleach-Fix 35 AC must be used in combination with EnviroPrint Developer MP45 AC. The wide variety of "fast" processing equipment as well as the different paper brands on the market makes it difficult to standardise the process parameters. The table above shows recommended replenishment rates and processing temperatures. As with other chemistries, differences between paper brands and processing equipment may mean that you need to fine-tune your process. For more information please contact your Fuji Hunt representative or consult the Fuji Hunt Minilab guide. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 119 Mixing instructions EnviroPrint Developer Replenisher MP45 AC (2) Water EnviroPrint Developer MP45 AC concentrate Replenish er Starter (1) To make Replenisher 740 ml 260 ml / / 1000 ml Tank : 33 sec, 39.0°C 27 sec, 39.5°C 22 sec, 40.0°C 840 ml 850 ml 865 ml 100 ml 100 ml 100 ml / / / 60 ml 50 ml 35 ml 1000 ml Tank from Replenisher 33 sec, 39.0°C 27 sec, 39.5°C 22 sec, 40.0°C 555 ml 565 ml 580 ml / / / 385 ml 385 ml 385 ml 60 ml 50 ml 35 ml 1000 ml (1) Please note that a special starter (RA4 Quick Starter) is needed. (2) EnviroPrint Bleach-Fix 35 AC must be used in combination with EnviroPrint Developer MP45 AC. EnviroPrint Developer Replenisher MP60 Water EnviroPrint Developer MP60 concentrate Replenish er Starter (1) To make Replenisher 750 ml 250 ml / / 1000 ml Tank : 33 sec, 38.5°C 27 sec, 39.0°C 22 sec, 39.5°C 815 ml 825 ml 840 ml 125 ml 125 ml 125 ml / / / 60 ml 50 ml 35 ml 1000 ml Tank from Replenisher 33 sec, 38.5°C 27 sec, 39.0°C 22 sec, 39.5°C 440 ml 450 ml 465 ml / / / 500 ml 500 ml 500 ml 60 ml 50 ml 35 ml 1000 ml (1) Please note that a special starter (RA4 Quick Starter) is needed. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 120 EnviroPrint Bleach- Fix 35 AC Water Part A Part B Replenisher To make Replenisher 330 ml 335 ml 335 ml / 1000 ml Tank 666 ml 167 ml 167 ml / 1000 ml Tank from Replenisher 500 ml / / 500 ml 1000 ml EnviroPrint Bleach- Fix 70 AC and VR AC Water Part A Part B Replenisher To make Replenisher 560 ml 220 ml 220 ml / 1000 ml Tank 700 ml 150 ml 150 ml / 1000 ml Tank from Replenisher 320 ml / / 680 ml 1000 ml EnviroPrint Superflo Stabilizer & Repl AC Water Concentrate To make Tank & Replenisher 992 ml 8 ml 1000 ml EnviroPrint Super Stabilizer & Repl AC Water Part A To make Tank & Replenisher 990 ml 10 ml 1000 ml pH and Density specifications Fresh Seasoned pH (25 o C) Tank Replenisher Tank Tolerance EnviroPrint Developer MP45 AC 10.20 12.50 10.15 ±0.05 EnviroPrint Developer MP60 10.15 (1) 10.05 (2) 12.20 10.10 ±0.05 EnviroPrint Bleach-Fix 35 AC 6.20 6.00 6.80 ±0.20 EnviroPrint Bleach-Fix 70 AC 5.70 5.65 6.75 ±0.20 EnviroPrint Bleach-Fix VR AC 5.70 5.75 6.75 ±0.20 (1) Starter addition : recommended volume of RA4 Quick Starter for process 27 seconds. (2) Starter addition : recommended volume of RA4 quick Starter for process 33 seconds. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 121 Fresh Seasoned Density (20°C) g/cm³ Tank Replenisher Tolerance Tank Tolerance EnviroPrint Developer MP45 AC 1.027 1.042 ±0.003 1.050 ±0.003 EnviroPrint Developer MP60 1.029 1.037 ±0.003 1.040 ±0.003 EnviroPrint Bleach-Fix 35 AC 1.085 1.160 ±0.005 1.125 ±0.010 EnviroPrint Bleach-Fix 70 AC 1.082 1.115 ±0.005 1.100 ±0.010 EnviroPrint Bleach-Fix VR AC 1.082 1.115 ±0.005 1.100 ±0.010 EnviroPrint Superflo Stabilizer AC 0.998 - 1.002 ~1.000 EnviroPrint Super Stabilizer AC 0.998 - 1.002 ~1.000 Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 122 PROCESS CONTROL CHARTS The following charts result from extensive testing carried out on the latest available paper emulsions using standard and LR chemistry (during 2002) by Fuji Hunt Photographic Chemicals, NV. Note that significantly different responses to process variations may be found with emulsions from competitor paper manufacturers. Please contact your Fuji Hunt representative if you require process control charts for Agfa or Konica papers. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 123 E. PROCESSI NG PROBL EMS AND CORRECTI VE MEASURES 1. Problem Handling Procedures Processing problems will rarely occur as long as the process is controlled following the procedures set forth in this manual. Should any problems occur, it is critical that systematic corrective action be taken. 1.1. Causes of Processing Quality Deterioration • Drifting of processing temperatures, times, and replenishment rates from standard. • Faulty conditions or poor processor control. • Faulty processing solution preparation. • Contamination of running solutions, especially developer contamination with bleach-fix. • Concentration or exhaustion of seasoned solutions through prolonged solution temperature control or by the use of replenishers stored beyond their expiry date. 1.2. Sensitometric Problems a) Start by ensuring that no errors were made in plotting control data. • Be certain that the control and reference strips used retain identical code numbers and packaging. • Take density measurements again and calculate control values to ensure that no calculation or recording errors were made. • Process another control strip and repeat density measurements and control value calculations. The data obtained should then be compared with those obtained from the previous control strip. This procedure confirms that control strips have been properly stored and handled. b) If it has been proven that no errors were made in the procedures thus far, go on to the following. Compare the abnormal check results with the examples given in Table 30 “Process Troubleshooting” at page 55 for purposes of cause delineation and institute the necessary correctional procedures. Note : It is recommended that the related processing solution control charts be checked; this will help problem detection and diagnosis. Note also that separate sets of charts are provided for use with standard and LR type developers, as the effect on photographic papers and control strips of many problems is somewhat different in the different types of developer. Use the charts most suitable for your chemistry. See the chart index for more information. c) When any corrective action is taken, be sure to process a RA4/FA control strip and plot its control values to confirm that the problem has been eliminated by the action taken. d) When, as a result of corrective action, the process has been brought back to within action limits, take care to stabilise said normalised conditions. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 124 1.3. Physical Problems a) To delineate problems and take corrective action, analyse the abnormal results referring to Section Part 1 at page 123. b) When locating problems, also check the control strips to determine whether or not processing results have been affected. c) When any corrective action has been taken, perform a test run to ensure that the problem has been eliminated by the action taken. d) Review the process monitoring system and remedy deficiencies, if any, to prevent the recurrence of similar problems. To maintain proper process control levels so that consistently high quality results are obtained on a daily basis, it is necessary to define any questions with clarity and take necessary corrective action. Briefly, it is essential to keep track of those steps where processing conditions have changed and of those steps where processing conditions remain unchanged. This practice will facilitate locating processing problems, determining condition drifts in any particular direction, and finding the cause for such abnormalities. 2. Processing Conditions Variations and Photographic Property Changes Problems such as faulty processor temperature control systems, faulty replenishment systems, errors made in replenisher preparation, and significant variation in throughput, all show up as control chart abnormalities. The effects of process variability and solution contaminations on processing results are indicated by the charts on the following pages. The charts represent a comparison of performance denoting sensitometric data (Dmin, LD, HD-LD, Dmax, Retained Silver) for Fujicolor, Kodak and Kodak Professional control strips. Briefly, in these graphs the photographic property changes resulting from processing factor variations are indicated as sensitometric variations for each control strip step. It should be kept in mind that the graphs do not necessarily cover all possible problem combinations. Note that (for all strip types) Retained Silver is monitored by calculating the Y R -Dmin R value (red reading on the Yellow patch – red reading on the Dmin). Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 125 F . PROCESS CONTROL CHARTS ( Us e thes e char ts f or C P R A, C P R A P r o, MP 160, E nvi r oP r i nt and al l r egener ated E nvi r oP r i nt devel oper s . These charts will also give a good indication of process variations to be expected with Fuji CP40 chemistry); 1. Chart 1 : Standard Developer Density Variations There are two main reasons for developer density variations in the processor – evaporation and mixing errors. A mixing error for either a fresh working tank or a replenisher produces an effect which can wholly be attributed to the concentration of the developer bath; evaporation may also be linked to other effects such as oxidation, and the problem then needs extra consideration. In event of any suspected problems with developer concentration, measure the solution density with an accurate hydrometer (see APPENDIX 6 for details of density measurement methods). Take care to ensure that you take note of the bath temperature when comparing values with aims; adjust temperature before reading as required. 1.1. Tank solutions The amount of water used when preparing a fresh working tank of developer has a direct effect on developer activity. Excess water results in some reduction in process activity, with less dye being formed. This is partly compensated for by a reduction (caused by dilution) of chloride (the “development restrainer” in the developer). This results in the plot dropping a little below aim. Insufficient water addition results in an over-concentrated developer. The plot may rise above aim on the LD step, but increased chloride levels have a major effect and cause significant reduction in contrast and especially Dmax. The blue layer is most affected. If you are preparing a fresh working tank developer directly from concentrates, check all mixing instructions and the volumes used for mixing. If you are preparing a fresh working tank starting from pre-mixed replenisher, also check the density of the replenisher to trace the source of the problem. For a fresh developer with low density : If the developer measures 20% or more below that aim density (i.e. approx. 0.005 or more below aim), and the control limits are exceeded, the mix should be considered as unsatisfactory and should be replaced. Similarly, and replenisher found to be more than 10% below the aim density should be discarded and replaced. For a seasoned developer with low density : This can be a serious problem. Unlike the effect with fresh developers (see above), dilution of a seasoned developer is likely to result in a significant and possibly very large reduction in the blue Dmax (in particular), with blue blacks on all papers. Check for excessive topping up with water and mix errors. For a developer with high density : If the developer measures 20% or less above the aim density (i.e. approx. 0.005 or less above aim), then you may attempt to recover the developer by adding up to 20% extra water to the working tank (or replenisher if this is over-concentrated). Developers or replenishers more than 20% above aim density, where the control limits are exceeded, should be discarded and replaced. For developers that remain within the control limits, small water additions may be made to improve the process with over-concentrated developers. For slightly dilute and underactive developers, please see below. 1.2. Evaporation All processors, but particularly roller transport and low throughput processors, are subject to evaporation increasing the developer density. Be sure to top up tanks to the correct level daily at start-up to avoid problems. In all cases of suspected evaporation, the replenisher density should also be checked to ensure that this is not the cause of the problem. Evaporation of up to 10% (density 0.002 above aim) can be safely corrected by water additions. Above this point, there may also be a factor due to low throughput – see RA4 Processing During Low Utilisation Periods on page 84. Over compensation for evaporation (excess water additions) – or slightly low developer density with a fresh working tank – can often be simply corrected by reducing or stopping completely any evaporation compensation water additions to the developer tank. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 126 Chart 1 : Standard Developer Density Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 127 2. Chart 2 : Standard Developer Temperature Variations Developer temperature has a direct effect on developer activity. Low developer temperature results in a reduction in process activity, with less dye being formed. This results in the plot dropping below aim, particularly for the Dmax. High developer temperature results in an overactive developer, with too much dye being formed. The plot will rise above aim; contrast is usually less affected than speed and Dmax. Developer temperature should be checked daily with an accurate thermometer. It is not good enough to simply look at the temperature indicator on the outside of the processor - many temperature control problems are actually caused by faulty probes or temperature control units. Temperature control problems may come and go if the developer temperature is fluctuating. Check developer temperatures regularly with a thermometer if this is suspected, and also check for poor developer recirculation as this can also be the cause of the problem. If your processor is fitted with a developer cooling circuit, also check this as a possible source of problems. 2.1. Using developer temperature to correct problems Depending on your processor characteristics, a “normal” process should run within ±0.5°C of the official RA4 process aim temperature of 35.0°C or 38.0°C, depending on the developer used. Once your optimum temperature has been set, the operating tolerance is ±0.15°C. However, temporary changes of developer temperature within the range ±1.0°C may be applied as a correction for problems in preference to a chemical change. If you make a mistake with a chemical addition, it is very difficult to correct. Developer temperature can be changed without a long-lasting effect on the process if it proves to be the wrong answer. If a process is showing a continual trend up or down, do not use developer temperature as a means of correcting the problem, as a chemical fault is indicated. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 128 Chart 2 : Developer Temperature Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 129 3. Chart 3 : Standard Developer Time Variations The RA4 process was designed to operate with a standard developer and bleach-fix time of 45 seconds. While the great majority of processors use a developer time of 45 seconds, there are now many modern minilabs that run with shortened process times in order to get more paper through the small paper processor built into the minilab. Conversion of older EP2 process equipment has also left non-standard process times. The true effects of these time variations may be seen in the graph opposite. Common problems causing incorrect developer times include incorrect setting of the process time on processors that use variable speed drive motors, incorrect replacement of drive gears on processor drives or racks during maintenance, voltage variations in the power supply, paper slipping or even stopping during processing, or drive belts slipping on leader belt processors. This last problem can quite easily occur when both leader belts on a large leader belt processor are changed together and the processor is then run almost immediately under heavy load. New belts get rapidly roughed up and gain grip in the first few hours of running, but when very new are a common cause of problems. Check developer times with a stop watch; check the time from paper entry into the developer to paper entry into the bleach-fix. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 130 Chart 3 : Standard Developer Time Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 131 4. Chart 4 : Standard Developer Starter Addition Variations Developer starter has a direct effect on developer activity. Insufficient developer starter when preparing a fresh working tank developer causes significant increase in developer activity, especially in the LD and Dmax steps. Excessive developer starter addition reduces developer activity, especially in the blue Dmax. The effects of mixing errors involving incorrect developer starter additions can be seen in Chart 4 opposite. 4.1. Starter additions for correcting the process In Chart 4, the effects of starter additions on developer activity can be seen. The graph can be used to estimate starter additions in the event of, for example, and over-replenished developer. Note that for optimum correction, water additions may also be required. Chart 5 shows the effects of over or under replenishment of a standard developer, and should also be examined before estimating any start additions. Please see Chart 1 or the effects of water additions on process activity. 4.2. Fresh tank solutions If you are sure that the developer over-activity problem is caused by a mixing error during preparation of a fresh working tank solution, starter and/or water can be added. For starter addition errors, it is suggested that you add starter in steps of 3-5 ml/litre of EnviroPrint Universal Developer Starter (for non-AC developers) or 3-5 ml/litre EnviroPrint Developer Starter AC (for all AC developers) at a time, processing and evaluating a control strip after each starter addition. Allow 5-10 minutes for mixing after making a starter addition before processing a control strip. 4.3. Seasoned tank solutions If your working developer tank has been seriously overreplenished, perhaps due to a fault on the replenishment system, corrections can be made to the working tank to bring the process back into control. Follow the instructions given above to correct for overreplenishment, ensuring that the cause of the problem is also rectified. Water and/or starter additions may be required. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 132 Chart 4 : Standard Developer Starter Addition Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 133 5. Chart 5 : Standard Developer Replenishment Rate Variations (2 TTO) Developer replenishment rate variations shown here may be compared with the effects of insufficient developer starter addition shown on Chart 4. In Chart 5 opposite, you are seeing the effects of incorrect replenishment, which therefore includes the effects of changes in water and CD3 (developing agent) levels, as well as changes in the sodium chloride (restrainer / starter) content in the developer. Note that recommendations in this manual and in Fuji Hunt Technical Bulletins for replenishment rates are nominal starting points only. Required replenishment rates may be subject to change depending on work volumes and materials processed, the type of processor, agitation within the developer tank and replenisher mixing and storage. Chart 5 may be used to estimate required changes in replenishment rate, but replenishment changes must NOT be used as a day-to-day control tool. Significant changes in work patterns on a processor may require an adjustment to the replenishment rate, but these change should only be applied when a consistent over- or under-active process is seen. 5.1. Replenishment rate changes For most laboratories, the graphs in Chart 5 for replenishment rate errors can be used to estimate required changes, but you should first consider whether a change in temperature is a more suitable option. Ensure that developer density is running within limits before changing replenishment rates; do not try to correct underlying evaporation or dilution problems by changing the replenishment rate. See also Chart 9 which shows the effects of low Part B in a developer mix, and is also a guide to the effects of severe developer under-replenishment. Note that replenishment rates assume a normal print density; replenishment may need to be increased when the average print density is significantly above normal. 5.2. Avoiding future problems Check replenishment rates – especially developer replenishment rates – regularly, and check the replenishment system for correct operation. Also check for possible interruptions in replenisher supply, e.g. caused by a partially blocked in-line filter in the replenisher pipes. Check that your replenishment rate calculations are correct, and that replenishment rates have been calculated/set for the paper width being used. Incorrect replenishment can result from changes in paper width processed on your processor, particularly on processors not fitted with a device for measuring paper area processed. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 134 Chart 5 : Standard Developer Replenishment Rate Variations (2 TTO) Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 135 6. Chart 6 : Standard Developer Contaminated with Bleach-Fix All paper developers are very sensitive to bleach-fix contamination, even at very low levels. There is a major effect on LD (speed), HD-LD (contrast) and Dmax (black patch), with the large colour spreads and blue Dmax resulting in making it impossible to produce saleable prints. Increased contamination may also result in increasing Dmin (stain) levels. The problem is chiefly caused by the thiosulphate content of the bleach-fix. The usual cause of bleach-fix contamination of the developer is splashing of bleach-fix when removing racks from or returning racks to the bleach-fix tank, or paper jams in the processor that result in paper being dragged back into the developer after having been in the bleach-fix tank (typically on large leader belt processors, but occasionally on minilab and roller transport processors as well). Also check mixing procedures. Mixers used for preparation of bleach-fix (or fixer) solutions should not be used for developer preparation due to the high risk of causing contamination. Another fairly common cause of (usually low level) bleach-fix contamination of the developer on leader belt processors is dirty leader belts caused by too low wash rates or worn out leader belts, or by washes (and especially low flow washes) leaking from wash tanks on to the leader belt as it is returned to the feed end of the processor. 6.1. Corrective Action With VERY LOW levels of bleach-fix contamination it MAY be possible to adjust a printer balance or change the colour correction on a manual enlarger and continue processing. This largely depends on what is an acceptable black in the print according to your quality standards. If print quality is still acceptable, the bleach-fix will gradually be replenished out of the developer, and the developer activity will return to normal (assuming no further contamination). Increased contamination (typically showing as a cyan or cyan-blue colour in the LD patch on a control strip) will also result in cross curves on the paper, resulting in failure to reproduce a neutral grey scale on the paper, as well as an unacceptable Dmax (usually blue). Production should be stopped immediately until the cause of the problem is found. Any significant levels of bleach-fix contamination in a developer can only be corrected by replacement of the developer tank with a fresh solution. There are no chemical additions that can be made to compensate for the effects of bleach-fix contamination. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 136 Chart 6 : Standard Developer Contaminated with Bleach-Fix Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 137 7. Chart 7 : Standard Developer pH Variations Paper developer pH has a major effect on developer activity, with the greatest effect noticeable on the Dmax step. High pH gives increased developer activity; low pH reduces developer activity. Chart 7 shows the effects of pH variations on Fuji and Kodak control strips. Note that under normal conditions with pre-packed chemistry, developer pH variations should never occur. Any variations in developer pH are likely to be caused by one of the following : Inaccurate pH reading (wrong temperature, pH meter setup, etc.) Incorrect chemical mixing, particularly if splitting packs or using an automatic mixer (check calibration) Incorrect replenishment rate Any pH errors should only be corrected if the process control deviations seen on your strips agree with the pH measurement results obtained from your pH meter. Adjusting the developer pH should never be used as a routine quality control tool with standard non-regenerated developers. Developer pH errors can also be due to variations in developer regeneration with recycled systems. pH should always be checked after rebuilding a developer and adjusted to standard before use as replenisher. 7.1. Corrective Action pH aim values may be found in this manual or in the Fuji Hunt RA4 Technical Bulletin. To increase the developer pH, use potassium hydroxide solution (between 20 and 45% concentration) and monitor the pH change with your pH meter until the correct value is achieved. To reduce the developer pH, use 20% sulphuric acid. The quantity of sulphuric acid or potassium hydroxide to be added (per litre of developer) to achieve the correct pH must be determined by testing. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 138 Chart 7 : Standard Developer pH Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 139 8. Chart 8 : Standard Developer Mix Error – Part A Using too much Part A reduces the developer activity; using not enough Part A increases developer activity. Chart 8 shows the effects of Part A variations on Fuji and Kodak control strips. Note that under normal conditions with pre-packed chemistry, these problems should never occur. Any variations in developer Part A are normally the result of a mixing error, particularly if splitting packs or using an automatic mixer. If an automatic mixer is used, recheck mixer calibration before preparing more replenisher. If splitting packs, please check your calculations and/or measurements. Review all mixing procedures. 8.1. Corrective Action It is not possible to correct for Part A mixing errors (a) unless you know how much Part A has been omitted, so that you can add the missing part, or (b) without extensive chemical analysis. In general, any mixing errors should be corrected by dumping the solution and replacing it with a fresh mix. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 140 Chart 8 : Standard Developer Mix Error – Part A Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 141 9. Chart 9 : Standard Developer Mix Error – Part B Using too little Part B reduces the developer activity, particularly affecting the blue Dmax step on control strips or causing bluish blacks or generally uneven blacks or streaking in the black areas on prints; using too much Part A has relatively little effect on developer activity, except for perhaps a slight reduction in Dmax with some papers. Chart 9 shows the effects of Part B variations on Fuji and Kodak control strips. Note that under normal conditions with pre-packed chemistry, these problems should never occur. Any variations in developer Part B are normally the result of a mixing error, particularly if splitting packs or using an automatic mixer. If an automatic mixer is used, recheck mixer calibration before preparing more replenisher. If splitting packs, please check your calculations and/or measurements. Review all mixing procedures. A similar effect to having too little Part B in the developer may also be caused by severe under- replenishment of the developer, or by developer oxidation due to low throughput, both particularly applying to roller transport processors. Another similar result is seen by processing large numbers of unusually dark (low key) prints, or large amounts of transparency material such as Fujitrans without adequate replenishment bearing in mind the image density. Replenishment rates assume a normal print density; replenishment may need to be increased when the average print density is significantly above normal. See also Chart 5. 9.1. Corrective Action It is not possible to correct for Part B mixing errors (a) unless you know how much Part B has been omitted, so that you can add the missing part, or (b) without extensive chemical analysis. In general, any mixing errors should be corrected by dumping the solution and replacing it with a fresh mix, particularly if a faulty replenisher mix has been prepared. In case of emergency – very low blues and especially low blue Dmax – it is sometimes possible to recover a developer bath by adding Part B directly to the developer tank. This is very much a case of trial and error, but some guidelines are provided on Fuji Hunt RA4 training courses. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 142 Chart 9 : Standard Developer Mix Error – Part B Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 143 10. Chart 10 : Regenerated Developer pH Variations Paper developer pH has a major effect on developer activity, with the greatest effect noticeable on the Dmax step. High pH gives increased developer activity; low pH reduces developer activity. pH errors are a common problem resulting from incorrect developer regeneration. Chart 10 shows the effects of pH variations on Fuji and Kodak control strips. Variations in developer pH are likely to be caused by one of the following : Inaccurate pH reading (wrong temperature, pH meter setup, etc.) Incorrect chemical mixing, particularly using an automatic mixer (check calibration) with few or no analytical cross-checks Incorrect replenishment rate Oxidised developer carryover from processor Correct developer pH is an essential part of using regenerated developers. However, small errors in pH should only be corrected if the process control deviations seen on your strips agree with the pH measurement results obtained from your pH meter. pH should always be checked after rebuilding a developer and adjusted to standard before use as replenisher. 10.1. Corrective Action pH aim values may be found in this manual or in the Fuji Hunt RA4 Technical Bulletin. To increase the developer pH, use potassium hydroxide solution (between 20 and 45% concentration) and monitor the pH change with your pH meter until the correct value is achieved. To reduce the developer pH, use 20% sulphuric acid. The quantity of sulphuric acid or potassium hydroxide to be added (per litre of developer) to achieve the correct pH must be determined by testing. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 144 Chart 10 : Regenerated Developer pH Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 145 11. Chart 11 : Regenerated Developer Mix Error – Part B Using too little Part B reduces the developer activity, particularly affecting the blue Dmax step on control strips or causing bluish blacks or generally uneven blacks or streaking in the black areas on prints; using too much Part A has relatively little effect on developer activity, except for perhaps a slight reduction in Dmax with some papers. Chart 11 shows the effects of Part B variations on Fuji and Kodak control strips with a regenerated developer. Part B regeneration errors are likely to be caused by incorrect chemical mixing, particularly when using an automatic mixer (check calibration) with few or no analytical cross-checks. Incorrect replenishment rate may be another major factor. A similar effect to having too little Part B in the developer may also be caused by severe under- replenishment of the developer, or by developer oxidation due to low throughput, both particularly applying to roller transport processors. 11.1. Corrective Action It is not possible to correct for Part B mixing errors (a) unless you know how much Part B has been omitted, so that you can add the missing part, or (b) without extensive chemical analysis. In general, any mixing errors should ideally be corrected by dumping the solution and replacing it with a fresh mix, particularly if a faulty replenisher mix has been prepared. In real life, laboratories are not going to dump regenerated developers unless this is completely unavoidable, so increasing or decreasing the Part B addition as appropriate is the most likely corrective action to be used. This is very much a case of trial and error, but some guidelines are provided on Fuji Hunt RA4 training courses. In all cases of suspected regeneration error, thoroughly check chemical blender calibration. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 146 Chart 11 : Regenerated Developer Mix Error – Part B See next page for additional Process Variation charts for Fuji Hunt EnviroPrint Developers and Fuji Hunt CPRA and EnviroPrint Bleach-Fixes. Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 147 (Use these charts for EnviroPrint LR, MP108, MP60 and MP45 developers. These charts will also give a good indication of process variations to be expected with Fuji CP43, CP47 and CP48 chemistry). No process diagnostics are currently available for these charts; please see the related charts for Standard developers for additional information and corrective actions. 12. Chart 12 : LR Developer Density Variations Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 148 13. Chart 13 : LR Developer Temperature Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 149 14. Chart 14 : LR Developer Time Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 150 15. Chart 15 : LR Developer Starter Additions Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 151 16. Chart 16 : LR Developer Replenishment Rate Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 152 17. Chart 17 : LR Developer Contaminated with Bleach-Fix Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 153 18. Chart 18 : Bleach-Fix Contaminated With Developer Under normal circumstances, the bleach-fix can absorb large quantities of developer without causing any problems. However, extremely high rates of developer carryover (typically on a fast roller transport processor), incorrect or excessive bleach-fix regeneration, or, most likely, severe bleach-fix under- replenishment can and will cause an apparent increase in process activity. Chart 18 opposite shows these effects. At first sight, you may consider the problems due to high developer temperature or slight developer over-replenishment, but the plot increase is in fact due to retained silver in the paper plus stain generated by the (now very dirty) bleach-fix. Check the bleach-fix replenishment system for correct operation. Check any processor squeegees, and for the possibility of developer overflowing into the bleach-fix tank. Check that an operator has not mixed developer and put it into the bleach-fix replenisher tank! The effects of long-term bleach-fix under-replenishment are more severe on regenerated bleach-fix systems due to the increased staining effects of fully oxidised developer carried over into the bleach- fix. 18.1. Corrective Action Low bleach-fix activity is easy to correct, and will not normally require a complete replacement of the processor tank. Simply replace part of the processor bleach-fix tank with fresh working solution, made up following the instructions found on page 41 of this manual. The amount to be replaced will depend on the severity of the problem; typically around 25% will be sufficient. (Use this chart for CPRA and EnviroPrint bleach-fixes. This chart will also give a good indication of process variations to be expected with Fuji CP43, CP47 and CP48 chemistry.) Fuji Hunt RA4 Chemicals, 3rd Edition J une 2004 Page 154 Chart 18 : Bleach-Fix Contaminated With Developer