COMMON FILM PROCESSING PROBLEMS & SOLUTIONS by Roy Duncan

We are often asked to provide staff training as part of a sale of new x-ray equipment and related darkroom accessories, including automatic film processors.  As most of us know the radiographic results we see on a film are based on many pieces of equipment properly performing.

With a little knowledge training and common sense, processors can be a wonderful addition and a means of obtaining more consistent films.  Perhaps the biggest headache with processors is monitoring chemical usage and maintaining the correct replenishment rates.  If your film come out gray and "washed out" the developer is generally depleted...too old!

This same problem can also be caused by a developer heater or associated circulation pump also failing, or a failed replenisher pump.  These specific problems generally result in a service call to have your technician repair your processor.

If your films come out "tacky" or hang up in the dryer, the fixer is generally depleted and should be replaced with fresh chemistry.  In general, your processor should consume slightly more fixer than developers.  There is no downside however to bumping the developer replenishment rate to equal the fixer rate since it is often easier to change both developer and fixer at the same time.  Be sure to check the lower storage tanks daily.  If you run out of chemistry and run the pumps dry, you can not only damage the pumps but you can induce a vapor lock or air gap that may require a service call to remedy.

Correct developer temperature is vital for both the proper development of the film as well as keeping patient radiation to a minimum.  We like to set the thermostats to hold the developer temperature at 95F.  A digital thermometer should be used to check the temperature.  (We sell an inexpensive model that works fine..contact us if you need one).

Another very common problem is the improper type of film matched to various and often different cassette screens.  While not technically a processing problem, it contributes to many unnecessary retakes because it appears to be a technique problem.

This problem is easily corrected by standardizing screen/film combinations and using the film recommended by the sceen manufacturer or your x-ray imaging technical representative.   We urge you to buy your film from an imaging company that understands radiology and can help solve rather than compound your problems.

Many processor replenishment rates are set too low as management tries to reduce the chemical consumption (and associated costs).  This can really be false economy however because developer must be discarded in approximately 30 days whether it is used or not.  Fixer will typically last a little longer, but it too will go bad in time.   Furthermore, if the rates are too low, the efficiency of the processor really falls off, resulting in "retakes".  We all agree that "retakes" are expensive any way you cut them.  This is one of the advantages to digital radiology...retakes tend to dramatically reduce.

Always dump the developer and fixer in the upper processor tanks and begin by adding freshly mixed chemistry to these tanks.  NEVER USE THE OLDER CHEMISTRY FROM THE STORAGE TANKS TO REPLENISH THE UPPER TANKS WHEN CLEANING THE PROCESSOR.  ALWAYS USE YOUR "NEW" CHEMISTRY AND THEN ADD THE REMAINING TO THE LOWER TANKS IF THE LOWER TANKS ARE NOT TOO OLD.  If your developer is dark and looks like coffee, dump it.   Adding fresh chemistry to old chemistry will only ruin your "fresh" chemistry.

Keep your processor clean and follow the manufacturer's instructions.  Always run one or two "green" unexposed films through the transport system before you run patient films, to clear cleaning artifacts.  Check that the replenishment pumps are working correctly.  Don't forget to add a few ounces of Starter to the upper developer tank per the manufacturer's instructions any time you mix new chemistry.

Last Updated 1/30/2012

Copyright 1999