radiographic processing processing equipment. typical manual processing unit

Radiographic processingRadiographic processing

Processing equipment Processing equipment

Typical manual processing unitTypical manual processing unit

Automatic processingAutomatic processing Introduced by Pako in Introduced by Pako in

1942. Film hangers 1942. Film hangers dunked from tank to tankdunked from tank to tank

First roller transport First roller transport system introduced by system introduced by Eastman Kodak in 1956. Eastman Kodak in 1956.

10 ft long, weight 750 kg10 ft long, weight 750 kg

Modern Film Processing EquipmentModern Film Processing Equipment

Automatic film processorAutomatic film processor

First 90 second processor produced by kodak in 1965. First 90 second processor produced by kodak in 1965. 45 second processor produced by Konoca in 198745 second processor produced by Konoca in 1987

Feed tray

Film receiving bin

Major componentsMajor components

Film Cross-over system

Turn around system

Dev Fixer

Squeegee Rollers

Wash Dry

Film transport systemFilm transport system

Film Transport SystemFilm Transport System

Film is placed on the input tray and gently Film is placed on the input tray and gently advanced until taken by theadvanced until taken by the entry rollersentry rollers

It is then transported via a system of It is then transported via a system of rollers and guide plates in and out of rollers and guide plates in and out of Developer, Fixer, Wash and Drying Developer, Fixer, Wash and Drying sectionssections

Finally the dried film is delivered to the Finally the dried film is delivered to the output trayoutput tray

The rollers are arranged in racksThe rollers are arranged in racks

The individual rollers may be in ‘face to The individual rollers may be in ‘face to face’ or ‘staggered (Zig-Zag)’ configurationface’ or ‘staggered (Zig-Zag)’ configuration

A system of guide plates are used where the A system of guide plates are used where the film needs to change the direction, e.g 180film needs to change the direction, e.g 1800 0 (in (in turn over and cross over assemblies)turn over and cross over assemblies)

The rollers are driven through a system of The rollers are driven through a system of gear wheels or cogs by either a main drive gear wheels or cogs by either a main drive shaft or chain, powered by a motorshaft or chain, powered by a motor

For safety, the processor lid operates a For safety, the processor lid operates a switch to stop the roller drive when the lid switch to stop the roller drive when the lid is open is open

The rollers may be made from PVC or The rollers may be made from PVC or rubberrubber

The speed of the rollers determine the The speed of the rollers determine the processor processor cycle timecycle time and the and the processor processor capacitycapacity

Processing cycle timeProcessing cycle time

The expression of the time that it takes a The expression of the time that it takes a film to travel from its dry unprocessed film to travel from its dry unprocessed condition on the input tray to the dry condition on the input tray to the dry processed state in the output trayprocessed state in the output tray

Rapid cycle :- 90 sec, 115 secRapid cycle :- 90 sec, 115 sec

In 90 sec cycle : Dev – 26 s, Fix- 15 s, In 90 sec cycle : Dev – 26 s, Fix- 15 s, Wash- 15 s, Drier –24 s, travel time-10sWash- 15 s, Drier –24 s, travel time-10s

Processor capacity/production Processor capacity/production capacitycapacity

A measure of a processor’s ability to A measure of a processor’s ability to process a given number of films in a process a given number of films in a given time and is expressed in given time and is expressed in number of ways.number of ways.

i. i. Number of single-size films capable Number of single-size films capable of being processed in 1 hr.of being processed in 1 hr.

ii.ii. Number of films of mixed sizes Number of films of mixed sizes capable of being processed in 1 hr.capable of being processed in 1 hr.

iii. iii. The speed of film through the The speed of film through the processor (cm/s or m/h)processor (cm/s or m/h)

The film feed sectionThe film feed sectionWhen no films are being processed the When no films are being processed the

processor is in processor is in stand-bystand-by condition condition

When a film is fed, the following events will be When a film is fed, the following events will be initiated.initiated.

Drive motor energized to turn the rollersDrive motor energized to turn the rollers Safelight above the feed tray is extinguishedSafelight above the feed tray is extinguished Developer and fixer replenisher pumped into Developer and fixer replenisher pumped into

tankstanks Drier heater energizedDrier heater energized Wash water flow rate boostedWash water flow rate boosted Film signal delay timer activatedFilm signal delay timer activated

i.i. Entry roller detection systemEntry roller detection systemii. Infrared detectorsii. Infrared detectors

How are these activities triggered?

Micro switch

Entry roller detection systemEntry roller detection system

Film

Infrared detectorsInfrared detectors

X ray filmFeed tray

Infra-red detectors

Infra-red emitters below feed tray level

Developer sectionDeveloper section

Main activitiesMain activities RecirculationRecirculation Temperature controlTemperature control ReplenishmentReplenishment DrainageDrainage

Developer Water

RPPRPF

F

P

THS

Overflow

From replenisher tank

Heater

TS

Heat exchange system

To drain

Developer sectionDeveloper section

Developer tank with roller rack removedDeveloper tank with roller rack removed

Fixer Recirculation & ReplenishmentFixer Recirculation & Replenishment

Fixer tank

P F

RP

P

F

overflow

Rollers

Wash sectionWash section

Spray washSpray wash – consists of a series of water – consists of a series of water pipes containing perforations through pipes containing perforations through which the water is forcibly sprayed onto which the water is forcibly sprayed onto each surface of the film. Water flow rate is each surface of the film. Water flow rate is about 10 l/min.about 10 l/min.

Tank immersionTank immersion ; water is warmed by the ; water is warmed by the developer heat exchanger. Water flow rate developer heat exchanger. Water flow rate is between 4 and 7l/min.is between 4 and 7l/min.

Wash sectionWash section

Water

F

Over flow

Flow rate

control

(Developer) From and to

developer tank Drain

Removable stand pipe

Heat exchanging

Drying sectionDrying section

Hot airHot air drying – dust free hot air is blown drying – dust free hot air is blown onto the surface of the film – temperature onto the surface of the film – temperature is about 55 degrees C.is about 55 degrees C.

InfraredInfrared (radiant heat) drying – contains a (radiant heat) drying – contains a range of electrically heated elements to range of electrically heated elements to radiate heat onto both film surfaces.radiate heat onto both film surfaces.

The used hot air should be ducted out of The used hot air should be ducted out of the room to prevent rise in humiditythe room to prevent rise in humidity

Cross section – dryer rackCross section – dryer rack

Hot air tube

Film transport rollers

film

Mixing of chemicalsMixing of chemicals

Manual mixing – according to the Manual mixing – according to the manufacturer’s recommendationsmanufacturer’s recommendations

Auto-mixersAuto-mixers

AutomixersAutomixers

FixDev

Display

Water in

To Fixer Tank

To Developer Tank

Dev/Fix. Replenisher packDev/Fix. Replenisher pack

Developer replenisher Fixer

A BC

A B

Automixer-OperationAutomixer-Operation

Developer Replenisher

waterWater spray

Full

AlarmEmpty

Sensors

Automixer- operationAutomixer- operation

Fixer

waterWater spray

Full

Warning AlarmEmpty

Sensors

Standard of Development & Standard of Development & processingprocessing

Standard of development & processing is Standard of development & processing is ensured by maintaining the followingensured by maintaining the following

Constant temperature of chemicalsConstant temperature of chemicals Constant concentration of chemicals by Constant concentration of chemicals by

regular replenishmentregular replenishment Constant agitation of chemicalsConstant agitation of chemicals Constant processing timeConstant processing time

Care & Maintenance of Care & Maintenance of ProcessorsProcessors

Operating proceduresOperating procedures

i. Start-up procedurei. Start-up procedure

ii. Shutting down procedureii. Shutting down procedure Maintenance proceduresMaintenance procedures

i. Daily maintenancei. Daily maintenance

ii. Weekly maintenanceii. Weekly maintenance

iii. Monthly maintenanceiii. Monthly maintenance

Daylight processorsDaylight processorsFunctionsFunctions Load cassettes with unexposed filmsLoad cassettes with unexposed films Mark each film with patient name, Number Mark each film with patient name, Number

etc.etc. Unload cassettes Unload cassettes Process filmsProcess films

TypesTypes Composite typeComposite type Modular typeModular type

Composite type Daylight processor Composite type Daylight processor (Dupont) - (Dupont) -

Kodak daylight processorKodak daylight processor

Needs special type of Needs special type of cassettes, which can cassettes, which can be opened by the be opened by the mechanical system of mechanical system of the machine.the machine.

Has a barcode Has a barcode attached to indicate attached to indicate the size of the film to the size of the film to be usedbe used

Alternative processing methodsAlternative processing methods

Rapid processing – 45 - 30 second Rapid processing – 45 - 30 second processorsprocessors

Extended processing – 3 minute Extended processing – 3 minute processing for mammographyprocessing for mammography

Dry processing- using heatDry processing- using heat Photothermography – print with laser & Photothermography – print with laser &

process with heatprocess with heat Thermography – print & process with heatThermography – print & process with heat

PhotothermographyPhotothermography

Uses a laser beam to Uses a laser beam to form the latent image form the latent image and heat to process and heat to process the imagethe image

SummarySummary

Efficient Performance and Maintenance of Efficient Performance and Maintenance of Processing equipment is necessary to Processing equipment is necessary to maintain standards of film qualitymaintain standards of film quality

It is necessary to have a thorough It is necessary to have a thorough knowledge of the equipment knowledge of the equipment

A quality control programme is essential to A quality control programme is essential to monitor the performance of film processing monitor the performance of film processing equipmentequipment

EndEnd

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