Maintain an X-ray film processor

X-ray film processor (manual and automatic)

o principles of operation
construction
o troubleshooting
preventive maintenance theory
o safety considerations
performance monitoring
o

o 18.6.4 Maintain an x-ray film processor

o Unit C18.6 Maintaining Medical Imaging Equipment

Module 279 19 C Medical Instrumentation II

© dr. Chris R. Mol, BME, NORTEC, 2016

 X-ray Film
X-ray film is made of a transparent plastic sheet, coated on both sides with a light
sensitive emulsion. The emulsion becomes black when exposed to light or X-ray. The
emulsion is soft and can easily be damaged if not handled in the correct way.
To maintain the films in good condition, it is important that they are stored and handled
properly:
• Each packet of film has an expiry date marked on the box. You cannot achieve
good results with old films.
• Films should be kept in the coolest place available. If stored at a high
temperature, they will be spoiled several months before the expiry date.
• A film that has been accidentally exposed to x-rays will be spoiled (fogged). Don’t
store films in the x-ray room.
• X-ray films are sensitive to pressure. Do not store the boxes of film lying on top of one another, but put them on
a shelf in an upright position like books on a bookshelf.
• X-ray film is easily marked or scratched. Do not touch the film surface with your fingernails or other hard
objects such as scissors or screwdrivers. Keep the film away from dust.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Darkroom for manual film
processing
When the door of the darkroom is shut, there must not be any light
coming into the darkroom. To check this, go into the darkroom, close
the door, and stay inside without light for 10 minutes. Then look
around carefully for any light entering the room through holes or
cracks; cover these holes, thus blocking out the light.
The darkroom should be clean at all times. Both the bench (or table)
and the floor must be kept clean and dry. There should be no dust,
dirt, or moisture in the area where the x-ray films and cassettes are
handled.
The tanks containing the processing chemical should also be kept very
clean, and should be covered when not actually in use. The covers
must be put on the tanks whenever you leave the darkroom, even if
only for a short time. The lights used in the darkroom may be
green, orange, yellow, or brown,
depending on film sensitivity (see
packaging).

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Film Processing
(manual)
Processing is a series of actions by which exposed x-ray film yields an
image. In processing a film, the sequence of actions should be as follows:
(a) Mark the patient’s name on the film
(b) Develop the film
(c) Rinse developer from the film
(d) Fix the film
(e) Wash the fixer from the film
(f) Dry the film
Steps a-d must be carried out with only the (colored) safelights on.

See video on manual film processing (on USB)

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Automatic X-ray film processors
Automatic x-ray film processors develop film exposed to x-rays and/or visible light. They
automate film processing by mechanically developing, fixing, washing, and drying films.
Careful control of film development is critical in producing x-ray film of the highest diagnostic
quality with minimum patient exposure to radiation.

Automatic film processors, along with rapid-processing

chemistries (i.e., developer and fixer) and film, have
improved control of radiographic quality and shortened the
time between film exposure and availability of the finished
image.
By reducing patient waiting time, equipment space, and
personnel requirements, these devices can increase patient
throughput, departmental productivity, and overall return
on investment.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Components of Automatic X-ray film processors
All automatic film processors have the same basic components, including:
• a feed and detection mechanism for initiating and executing film
transport. The film is transported by a series of rollers and is guided
through the processing system.
• a processing system consisting of chemical tanks and transport
racks.
• a washer. As the film enters the washer, externally supplied water
removes residual fixer from the processed film to prolong storage life.
• a dryer. The dryer passes warm air over the film as it exits the processor
and falls into the receiving bin.
• a receiving bin
• controls and indicators, providing machine control and current status
information. The number and types of status indicators vary depending
on the processor.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Components of Automatic X-ray film processors
Major (sub-) systems:
• water supply and filtration system, including hot and cold incoming
water lines, water filters, pressure gauges and valves, a thermostatic
mixing valve and a flowmeter.
• temperature regulation system. Optimum developer temperature is
needed for consistent image quality.
• The chemical replenishment system maintains a proper chemical
concentration by adding developer and fixer. Replenishing tanks are
usually located outside or under the processor so that the chemicals will
not be affected by the heater and dryer systems.
• The solution recirculation system, which usually consists of a simple
pump, provides agitation during processing to continually bring fresh
chemicals to the surface of the film.
• The silver recovery system. Silver reclamation systems recover silver
residue in the fixer solution and processed films that would otherwise
be flushed down the drain, which is environmentally hazardous and
wasteful.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Types of processors and installation
Automatic processors can be installed totally inside a darkroom, through
a darkroom wall, or outside a darkroom (daylight processors).
• Inside-darkroom processors, while easy to install, necessitate
frequent, time-consuming travel from the x-ray suite to the
darkroom for film processing, film retrieval, and processor
maintenance.
• Through-the-wall processors can be configured in two ways. In the
most common and convenient arrangement, only the feed tray is in
the darkroom, while the rest of the unit is accessible from the
outside. In the other arrangement, the processor is placed in the
darkroom, with only the drop bin accessible from the outside.
• Daylight processing equipment allows processing outside the
darkroom under normal lighting conditions. The film cassettes are
unloaded directly into the processor, eliminating the need for a
darkroom.
A low to medium automatic processor is able to process 150 to 200
films per hour, a high volume unit more than 200 films per hour.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Sensitometry /
Densitometry
For performance management as well as trouble shooting, sensitometry and densitometry are used.

A sensitometer is used to imprint film consistently After illumination with the sensitometer, the film is
with a standard set of exposures. Then the film is developed. Next, a densitometer is used to read out
developed and with a densitometer you read out the the density values on different positions on the film.
density values on the film. This helps you analyse If the measured densities fluctuate over time,
the quality and consistency of the film development something in the film processor is not constant and
process. needs to be fixed.

Densitometer, measuring
Sensitometer:
the optical density at a
illuminating film
position on the film

This helps you analyse the quality and consistency of the film development process.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Trouble Shooting
Frequent User complaints Associated system problems and solutions
• The processed film appears dirty • The processing tank rollers are dirty: Clean
• Dirt or algae contamination of the wash water. Replace, check
supply & filters (replace)
• Dirt or contamination of the processor solutions. Clean,
replace.
• The feed tray is dirty.
• Pressure marks on the film • Clean the film rollers.

• Film scratched or jammed • feed a test film through the processor & Listen for any noise.
• Racks incorrectly installed: Reposition
• Loose or damaged roller pressure springs.
• Film crossover guides not properly installed or faulty.
• Damaged gears
• Film appears under-developed
• etc.
The most common cause of poor performance in automatic film processors is dirt build-up in the transport
mechanisms.
© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor
 Daily Maintenance
General precautions Daily maintenance
• Ensure the processor power is switched off. • Remove processor lid
• Record all adjustable settings of the processor •
Remove crossovers, and wash in warm water,
• Protect yourself with plastic apron, coat to protect with a sponge or plastic cleaning pad
clothing from chemical splashes, Rubber gloves •
Wash tank covers and splash guards
protective glasses and mask, to protect the face from •Wipe over all rack rollers that are above solution
chemical splashes. levels
• An emergency eye kit should be available in the •
Clean interior exposed surfaces
darkroom. •
Check replenishment tanks/bottles levels
• Do not wear long loose clothing; this may become • Check for unusual colour or smell
caught in the rollers. •Check replenishment hoses for possible leaks
• Ensure that the darkroom is adequately ventilated. • Ensure the wash water drain valve is closed
• Clean up any spills or splashes. •
Turn on water, and check that wash tank is
• filling
Replace crossovers and tank lids

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Daily Maintenance
On start up Normal working
• Switch on the processor. • Follow manufacturers operating instructions.
• Listen for any unusual noise or vibration. • Be aware of any changes in operation, noises,
• Check film transport system. Ensure all rollers are leaks, or deterioration of processed films.
operating normally. • Do not pull processed films out until they are
• If not previously filled, check that wash water is now clear of the rollers.
filling correctly. • Wait for the ‘ready’ signal or light before feeding
• Check replenishment system is working. the next film.
• Feed in one unprocessed 35x43cm film as a clean-up • When feeding films, insert the wide side as the
film. leading edge. The film should be lined up against
• Inspect processed ‘clean up film’. • one side of the tray, not in the centre.
• Clean exterior surfaces; wipe over all darkroom • Do not allow anyone to lean on the processor.
surfaces. • Ensure the darkroom ventilation is correct.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Weekly / monthly
Maintenance
On shut down Weekly, monthly maintenance (selection only)
• Remove processor lid and observe transport system. • Follow manufacturers instructions
• Observe level of solutions and wash water. • Perform a sensitometry test
• Switch off. • Check/adjust solution temperatures, (34-36oC)
• Look for any leaks. • Check replenishment rates
• Remove and wash all crossovers, splashguards and tank • Check lid safety switches, if fitted
lids. • Divert the developer inlet to the tank, into a 100ml
• Replace tank lids. measuring-cylinder.
• Turn off wash water, if appropriate. • Pass five 35 x 43cm fresh films through the processor.
• Wash off all chemical splashes on surfaces Divide the measuring cylinder contents by five, to find
• Replace processor lid. Leave it slightly raised at one end, the replenishment rate.
to avoid build up of fumes and condensation. The • Repeat the above for the fixer tank.
darkroom door should be left open. • Record the results and check with previous results for
• Observe levels of replenishment tanks. If required prepare any significant variation
a fresh solution. • Clean filters, drain all and clean all tanks.
• Check stocks of films, chemicals. Restock as required. • Manufacturers usually recommend replacement of all
• Update the logbook chemicals on a monthly basis.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 Safety

In terms of patient care, a poor-quality radiograph may be more harmful

than the patient not having an X-ray examination at all.

Proper venting of automatic film processors is necessary to

remove excessive heat and chemical fumes that can cause both
acute and chronic respiratory illness.

© dr. Chris R. Mol, BME, NORTEC, 2016 X-ray Film Processor

 END
The creation of this presentation was supported by a grant from THET:
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