TEST AND EVALUATION REPORT (Sanitized)WIDE FILM PROCESSOR

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78B04747A002400050038-0
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 48
• Document Creation Date: December 28, 2016
• Document Release Date: May 7, 2003
• Sequence Number: 38
• Content Type: REPORT

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TEST AND EVALUATION REPORT
WIDE FILM PROCESSOR
Declass Review by
NIMA/DOD
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The purpose of this test and evaluation was to establish the parameters for
acceptance of the IProcessor by the using agency and evaluate the design
and operation of the liquid and air bearings. The liquid and air bearing, although
not new in concept or use, is utilized in the machine in a different configuration than
previously attempted in a processor of this size. In the machine the liquid "bearing"
is also the applicator for chemistry, and the air "knife" serves both as a support
and a means for limiting carryover between solution compartments.
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CONTENTS
Section Title
Page
I ENGINEERING EVALUATION . . . . . . . . . . . . . . . . 1
A. General . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Test Procedures and Results . . . . . . . . . . . . . . 1
C. Conclusions . . . . . . . . . . . . . . . . . . . . . . 4
D. Recommendations . . . . . . . . . . . . . . . . . . . 5
II SENSITOMETRIC EVALUATION . . . . . . . . . . . . . . . 5
A. General . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Conclusions . . . . . . . . . . . . . . . . . . . . . . 6
Appendix Title
Page
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Evaluation and subsequent testing were accomplished as outlined in the attached
program. This phase is objective insofar as design, workmanship, materials utilized
in the fabrication of the machine and in general, good engineering principles and
practice.
1. Test procedures are as outlined in Appendix I, and results are as
follows:
a. An examination of the processor after uncrating, as well as during and after
installation, revealed no damage to the machine. One pump was loose on its base but
was easily secured. All support equipment was found to be in good condition. The
exhaust blower motor was changed from 110 Vac to 220 Vac for more efficient operation
after approval was received from
Project Engineer
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All connections (plumbing, electrical, air and vacuum) were checked and found to
adhere to specifications.
b. All stainless steel and PVC work was excellent. Installation of the processor
was accomplished without problems, due to minimal plumbing and wiring requirements.
c. All systems were checked in sequence as outlined in the manual. Results
were good in all aspects, with the exception of temperature and its control.
d. Air and vacuum units checked and accepted.
e. Air squeegees, air bearings and vacuum roller accepted and considered well
designed.
f. Film transport of a total of 2, 000 ft. each of 70 mm and 9.5-inch thin and
heavy base (including 500 ft. of heavy film leader) film was excellent. All tanks during
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this phase were water filled, and machine was in full operational configuration for dry-
to-dry evaluation. No abrasions or edge distortions were noted.
Temperature control was tested during all runs and temperature variations from
liquid bearing impingement area to control indicator varied three to seven degrees.
This phase was rechecked during the first sensitometric run and the differences ranged
from two to three degrees.
g. Electrical components all acceptable and meet specifications.
h. Mechanical components were accepted with the following deficiencies noted.
(1). The film magazine, due to modification, will not accept the Air Force
1, 000 foot spool and the light trap remains open when attached to the machine. Use of
an Air Force standard magazine, that adapts to the machine, and with a full 1, 000
feet of film causes base abrasions in passing through the entry slit to splicer section.
Unless modified, the light trap on the Air Force magazine will remain in the "open"
position. Opening of the splice area could fog loaded film.
(2). Front take-up roller "drawer" requires excessive force to remove and
when in "operating" position, the air blast noise increases in intensity to an objection-
able degree and causes continuous flutter of the film, which in turn causes lateral abra-
sions of the film.
(3). Speed control knob increments are too small for accuracy and require a
tachometer to establish a true film trend speed. The use of the conversion chart to
convert the arbitrary numbering system is of little value. As an example, the
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Engineering Manual recommends a speed of 4.75 ft/min. for drying
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film, but the increments on the conversion chart do not include this figure. A direct
reading speed selector, calibrated in ft/min., is required.
(4). Temperature control units, unless started with cool chemistry, are difficult
to adjust. Calibrated controls on each unit would be of considerable value. Lack of a
cooling system makes the required temperature adjustments a time consuming and tedious
task, particularly in respect to the allowable tolerances involved in ?0.25? F control.
In tests these tolerances were not held at the film impingement plane.
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(5). The drain pan should be extended to include the wash tank section and the
drainage outlet should be made larger.
(6). Full opening and draining of all tanks at one time is not possible due to
limited pan capacity and small drainage opening.
(7). Noise level extremely high. The exhaust blower should be mounted away
from work area and redesign of the dryer assembly is recommended in order to lower
the noise level and also reduce film flutter (Ref. B-1-h-(2) above).
(8). Leakage or spillage drains onto electrical motors and pumps.
(9). 1, 000 foot roll pull through causes wrinkling at the 90 degree turn-around,
take up idler roller.
Due to the power requirements and physical characteristics of the
processor, it is estimated that a minimum of eight to ten tons of air
conditioning will be required to maintain equilibrium for the specified
70? F ?5? and 50% ?5%RH.
i. Dryer is inadequate and it is apparent that processing speeds, types and
temperatures of chemistry are all dependent on the drying capability.
This phase of the test, although involving chemistry, will not be included
in Section li, but will be mentioned at this point. Deficiencies noted,based on high
temperature processing, are as follows:
(1). The ratio of metol to hydroquinone is high.
(2). Sodium sulphite concentration is not high enough.
(3). It is our opinion that borax should be added to the hydroxide alkali
buffer system.
(4). Sulphate should be added to prevent the excessive swelling which is one
of the primary reasons for the film drying problem.
NOTE
Chemistry tests will be continued in Section II
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Processor, as a prototype, is good in concept
with exceptions noted in paragraph B-1-H. The air knife and liquid bearing-applicator
principles have been well adapted to the photographic process, and they do establish
that it is possible to transport film with little or no abrasions, scratches or other
defects that have been one of the major problems in film processing machines. The
dryer section is poor in design. The loading design and drying section negated the
possibility of transporting film dry-to-dry with no abrasions in the processors present
configuration.
From an engineering standpoint, the machine, as a prototype, is acceptable if
the deficiencies noted are corrected. This recommendation does not include or pertain
to the acceptability of the processor as a sensitometric, chemical, or controlled
process machine. These questions will be discussed in Section II.
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SENSITOMETRIC EVALUATION
A. GENERAL
Evaluation and subsequent testing were accomplished as outlined in Appendix I,
but due to the deficiencies noted in Section I Engineering Evaluation, the complete
series of sensitometric tests was not considered feasible at this time. The purpose
of this testing was to establish a basis for the acceptance of the processor by the
using agency. Specifications, as set forth by the using agency, were not available,
but an objective approach to the evaluation was followed and limited to the quality of
the product and sensitometric stability.
1. Test Procedures
Test procedures that were used deviated from the original program and will
be presented within the confines of the actual tests accomplished.
a. Chemistry = Sensitometric curves representative of processing runs indicate
that high temperature and high agitation turbulence (potential oxidation of developing
agent(s) upset the formula balance, creating instability in the sensitometric control.
The replenishment is based on a "demand" principle and varies from 1 to 3 quarts of
developer during the processing of 500 feet of film, (70 mm and 9.5-inch wide). Re-
plenishment of other solutions vary according to capacity of their respective tanks.
A foam buildup was apparent in the wash section. Although not excessive, it caused
a slight overflow around the edge of the cover. Reference Testing for Correlated De-
ficiencies.
b. Sensitometric - Limited sensitometric testing was done with
~ilm. Dryer problems encountered in testing
evaluation of this film.
prevented a thorough
Discussion with the using agency resulted in limiting the testing to the
two duplicating and one acquisition film; therefore, only the NRD-29
developer was used in accordance with the Manual.
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Testing of the I Ifine grain duplicating film and I acquisition STAT
film showed good drying of these materials is possible, although the temperature control
of the infrared heater unit was somewhat critical. High velocity air turbulence in the
dryer section caused lateral abrasions on both film types.
Lateral density plots showed variations on I Ifilm up to .04 density. STAT
Density variations on film were as high as . 06 at a nominal density of 1. 5.
Thel 'de film processor prototype, from the stand-
point of precision, high quality controlled processing, is not acceptable. As stated in
Section I, although good in the concept of the Principle (air knife and liquid STAT
"bearings"), the processor is lacking in good engineering practice in respect to satis-
factory loading-splicing design. Also the volume of drying air has not been controlled,
or baffled, thereby creating excessive film flutter which is the major cause of the film
abrasions that are apparent on test films processed (which include thick and thin bases.)
Sensitometric control is not possible and can be attributed to the Replenishment System
which is a "demand" type system. On a processor of this design, it is not controllable.
For precision processing it was noted that the developer replenishment bottle, due to
back pressure in the circulation system, received "back up" of oxidized developer.
The unpredictable flow of chemicals and the lack of sufficient fresh chemistry in the
system not only changed the chemical balance, but a definite increase in KBr was noted.
High temperature processing required by the short developer time in the processor will
require chemistry other than recommended in the Nanual. STAT
In the dryer section,the infrared, in conjunction with warm air impingement,
requires critical and balanced control and could be considered extremely difficult
with the existing configuration and control system. The distance between the wet
section air knife, and the infrared area, then into the film guide air cluster, is too
short. At this critical point drying is minimum upon entry into the cluster causing
the flutter abrasions to be unacceptable by normal standards.
process unit.
Processor is not acceptable in its present design as a controlled
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1. Purpose
The purpose of the test program is to determine if the
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processor meets the specifications as outlined in this test plan. The processor must
perform within the outlined standards to be considered acceptable.
2. Responsibility
It will be the responsibility of the Photo Engineering personnel assigned to super-
vise and run all phases of the acceptance test and to handle the procurement of test
film, instruments and other support materials as required. Technical assistance in
other than photographic areas will be provided as required by coordination with Elec-
tronic and Engineering personnel.
3. Acceptance Test, Phase I
The criteria set forth in this plan are intended to serve as the minimum acceptable
standards. Slight deviation from the procedures is permitted in order to utilize mate-
rials and personnel available during certain phases.
3.2 Documentation
3.2. 1 A written detailed history will be maintained of all tests performed and results
obtained.
3.3 Quality Control
3.3. 1 Quality control will be exercised in all phases of this test to preclude introduction
of contamination which would degrade test results during mechanical and sensitometric
testing.
3.4 Processor
3.4.1 Exterior
3.4. 1. 1 Check exterior of machine for workmanship, i. e., loose or missing screws,
I-1
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proper fitting of components, hardware, accessories, check for any signs of damage
(and probable cause).
3.4.1.2 Check all materials used in construction to assure that component parts that
come in contact with corrosive solutions are correct, i. e. , SS 316, PVC, etc. , and
that steel screws are not used to mate with SS 316.
3.4. 1.3 Check that all knobs, mounts, hoses, lines and rollers are in place and that
correct electrical wiring is connected.
3.4.2 Installation
3.4.2.1 Check level and jack screws to insure that machine and main frame are rigid
and not subject to stress.
3.4.3 Controls
3. 4. 3. 1 Check the following controls for proper operation in sequence as outlined in
operational manual, i.e., main power, drive, take up, air, vacuum, temperature, etc.
During this phase check indicator lamps and fuses.
3.4.4 Air and Vacuum Units
3.4.4.1 Check air inlet for pressure at source and at indicator. Also check filtration
of air to bearings.
3.4.5 Air Squeegees, Air Bearings and Vacuum
3.4.5. 1 Check for evenness of flow and for proper operation and amount of control for
3.4.6 Film Transport
3.4.6.1 Film, 70 mm, and 9.5-inches wide, in lengths of 500 feet each, will be run
through machine without chemistry. In all components and bearings normally requiring
chemistry, water will be substituted. This phase has no connection with the sensitometric
evaluation.
3.4.6.2 Check for proper alignment and transport through all components from maga-
zine through take up and note discrepancies. This test will be run under room lighting
condition.
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3.4.6.3 In conjunction with above, water filled replenishment system will be tested
for rates and temperature control and all discrepancies noted.
3.4. 6.4 Check for any erratic movement of the film during transport and at the
vacuum roller in conjunction with the take-up roller assembly.
3.5
Electrical Components
3.5.
1
Check all electrical mechanisms for operation.
3.5,
1.2
Check electrical wiring for coding.
3.5.1.3 Check all electrical connections and components for secure mounting.
Check
ease of replacement of components such as pumps, relays, etc., that experience has
shown will require periodic replacement during normal use.
3.5. 1.4 Check all electric mechanisms for proper operation, i. e. , motors, indicator
light switches.
3. 6 Mechanical Components
3. 6. 1 This phase depends on prior component testing. Check for secure mountings
and connections prior to actual test run listed previously.
3.7 Quality Checks
3. 7. 1 Material utilized in testing will be closely checked for the following defects
(exclusive of sensitometric testing):
a. Scratches
b. Folding due to tracking
c. Abrasions
d. Torn or ripped edges
e. Sediment
3.7. 1. 1 Overall ability to maintain quality.
3.7.2 Processing
3.7.2.1 The following films shall be tested during the tracking phase:
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a. 9.5-inch wide thin base and heavy base (minimum 500 foot lengths).
b. 70 mm wide thin base and heavy base (minimum 500 foot lengths).
4.
Acceptance Test and Evaluation Report
4. 1
Me
chanical T
est Phase
4. 1.
1
Consolidati
on of all results listed in 3. above.
4.2
Se
nsitometric
Test Phase
4.2.
1
Consolidati
on of all results listed in sensitometric test.
4.3.3
Graphs, ch
arts, photographs and other materials will be used wherever
possible to illustrate results.
4.4 The following format will be used for this report:
a. Abstract
b. Purpose
c. Test Procedures
d. Test Results
e. Conclusions
f. Recommendations
g. Appendixes (This should include all materials,in 4.3, above required to
support the conclusions.)
h. Copy of the test plan.
5. Acceptance Test Phase II (See Sensitometric Test and Evaluation).
A rather extensive installation and initial test program has been supplied by the
manufacturer. This procedure will be followed in the initial starting and testing of
the machine. Following this, a repeatability evaluation phase will be initiated utilizing
material with NRD-29 chemistry at 1000 F. The specific processing
speed will be determined in a series of preliminary tests.
The uniformity tests will consist of two 500-foot rolls of 9.5-inchI material
run per day for two days. Throughout the length of these rolls 1951 USAF targets,
uniform density exposure and step wedges will be exposed. Density measurements will
be made on the processed material to determine the latitudinal processing uniformity,
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., STAT
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the inter-roll repeatability, the intra-roll repeatability and the day-to-day repeatability.
The repeatability measurements will be stated as processing variances, associated with
which will be a probability of conformance statement.
Also, at the time of the running this series of tests, the washing capability and
quality will be evaluated in terms of the quantity of residuals remaining in the emulsion
after the film has passed through the standard washing procedure within the processor.
The criterion for comparison will be the standard permissible hypo quantities for archival
quality washing.
Following the repeatability determinations, the conformance to the sensitometric
standards, as listed in the manufacturer's operation manual, will be tested. The
following data are for the various films to be tested and the sensitometric results are
those taken to be the film manufacturer's standards:
curves presented therein are not representative of the specific emulsion batch being
utilized and tests will be run with the same emulsion number. Curves, resulting from
processing with NRD-29 developer at 110?F and the following film drive
velocities will be provided:
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These films will be evaluated in sensitometric test lengths for friskets of 10 feet
each spliced in five increments, including head and tail throughout 1000 feet of the
same emulsion film. Four wedges will be placed on each frisket and five friskets
(70 mm and 9.5-inch) of each emulsion type will be processed under each condition.
All wedges will be read two times on a diffuse densitometer, thus providing a measure
of densitometer error. Also included in the friskets will be L targets, edges and
uniform exposures for granularity analysis. Edge analyses will be performed on a
limited basis, as will adjacency effect measurements. The latter are particularly
valuable as an indication of processing induced nonlinearities.
Following the sensitometric testing, the uniformity-repeatability test will again
be run and the latitudinal, inter-roll, intra-roll and day-to-day variances will again
be determined and compared to those achieved in the first repeatability-uniformity
test. If no differences exist, then the uniformity repeatability state of the processor
will be taken as stable and the respective variance estimations from both tests will
be pooled. If the results of the second test are not equal to those of the first, then
the latest (second) estimate will be taken as the current variance and attempts will
be made to locate the source and the cause of the variance inhomogenity.
It will be noted that no mention has been made of the running of time-gamma-tem-
perature curves for the emulsions under test. This is because the determination of
these functions, on a reliable basis, is a time-consuming task. If the customer
desires time-temperature-gamma functions to be generated, then it is best that he
specify what variables and emulsions should be considered to permit maximum effort
to be directed towards generating results that will be most beneficial in terms of the
customer's needs.
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TEST AND EVALUATION OF THE
STAT
9.5" FILM PROCESSOR
A rather extensive installation and initial test program has been supplied by the
manufacturer. This procedure will be followed in the initial starting and testing of the
machine. Following this a repeatability evaluation phase will be initiated utilizing 9. 5
STAT inch material developed to a gamma of 2. 0 with NRD-29 chemistry at 1100F. The
0
specific processing speed necessary to obtain this gamma will be determined in a series
of pretests.
The uniformity tests will consist of three 250 foot rolls of 9. 5 inch material STAT
run per day for three days. Throughout the length of these rolls L bar targets, imagery,
and step wedges will be exposed, as well as grainless exposures for granularity deter-
minations. Density measurements will be made on the processed material to determine
the latitudinal processing uniformity, the inter-roll repeatability, the intra-roll
repeatability and the day-to-day repeatability. The repeatability measurements will be
stated as processing variances associated with which will be a probability of conformance
statement to the following tolerances:
latitudinal uniformity
density range
tole
diff
rance
use den
in
sity
. 65 < D