FT HE Importance m= - of Chemistry inthe Motion Picture Industry. ‘GLENN E, MATTHEWS ss Research Laboratory Eastman Kodak Company eae, Rochester, Nj zy, The Importance of Chemistry in the Motion Picture Industry BY GLENN E. MATTHEWS Research Laboratory of the Eastman Kodak Company in the development of photography is aptly illustrated by a comparison of the crude, cumbersome apparatus which was necessary to make pictures years ago with the simple, compact, cameras and the stable and highly sensitive films available today. When a wet plate photographer started out for a day’s picture-making with his pack of chemicals, plates, and dark tent on his back he resembled a prospector more than a cam- era man (Figure 1). Of necessity he was his own manufacturing plant. He chemi- cally sensitized his own plates just before using, exposed them while wet, and de- veloped them at once. Prints were made later on paper which he sensitized himself. With the introduction of the dry plate and later the film, the crude methods of wet plate photography disappeared, the prep- aration of the materials became a commer- cial operation, and photographers now pur- chase almost all the materials that they use from firms who manufacture them in large quantities. This centralization has resulted in a far greater improvement in quality than would ever have been possible by individual effort. Motion picture film was first sold in Amer- ica in 1889 when George Eastman supplied narrow film “ribbon” to Thomas Fdison. As now manufactured, it consists of a trans- parent, flexible base or support on which is coated a very thin layer of gelatin in which are suspended microscopic particles of a light sensitive silver salt. This upper sensitive layer is called the emulsion. To turn out millions of feet of film a year maintaining an unvarying uniformity of thickness, sensitiveness and quality requires a highly skilled organization backed by trained chemical research. In view of these conditions it would be quite impossible for an individual to prepare his own motion picture film. Experimentation must also be always in progress to improve the film and to find new methods of manufacture. In all this work, chemistry plays an important part, not only Ti PART that chemistry has played Figure 1—A Photographic Pioneer in the manufacture and treatment but later in the processing, after treatment, tinting, toning, and renovating of the film. On the care with which these chemical operations are conducted depends the wearing quality or life of the film. Chemistry in the Manufacture of Motion Picture Film In the manufacture of motion picture films and other sensitized photographic materials, absolute cleanliness is very necessary at every stage of the process. All operations must ‘be conducted in dust-free rooms and only clean, chemical substances: are used. Eastman motion picture film is manufac- tured at Kodak Park, at Rochester, New York. The plant consists of about 230 acres situated in the northwest section of the city. The output of this plant is roughly, 150,000 miles of film per year. To make this quantity, over five million pounds of cotton are used yearly, several millions of pounds of gelatin, and over twelve tons of solid silver per month. pure, The water necessary to take care of the needs in manufacture is pumped through a private pipe line into large reservoirs from Lake Ontario, 4 miles away. The reser- voirs have constantly on hand water to supply a city of 150,000 people. The temperature of the workrooms is rigidly con- trolled at all times by refrigerating machin- ry, having a cooling capacity equivalent to the melting of 4,000 tons of ice every 24 hours. In the preparation of film base or sup- port, cotton is thoroughly washed in cir- cular rotary vats with caustic soda solution to remove vegetable gums and other im- purities. After carefully drying in huge dryers to eliminate all moisture (Figure 2), it is treated with two acids, nitric and sul- phuric, a process known as nitration. Ni- ‘trating centrifugals, made of perforated baskets rotating inside a vat, are used for this process. The cleansed cotton is fed into the basket and the acids run in until the cotton is immersed (Figure 3). The fibrous structure of the cotton is not de- stroyed by nitrating but the treatment makes it possible to dissolve the cotton later in a solvent. When nitrating is completed the acids are drawn off and the basket rotated at high speed for draining. Nitrated cotton is known as cellulose nitrate. The excess acid is removed by placing the nitrated cot- ton in centrifugal washers. After washing in these machines, it is placed in large tanks of water where it is drained and rinsed re- peatedly: for several weeks. Centrifugal wringers operated at high speed next re- move all the water. All these elaborate pre- cautions are necessary in order that the cotton be freed from every trace of acid. Washing and drying completed, the ni- trated cotton is ready for dissolving in the organic solvents. These are usually com- pounds such as methyl alcohol to which cer- tain other higher boiling liquids may be sufficient. =a referred to as “dope.” It is thee piped : large air tight tanks until ready for ce ing (Figure 4). To remove any undissolved specks and fibres, the dope is filtered und great pressure. It is then Wehadiee. solvents evaporate, the film dries, and is peeled off. The thin sheets of trenipateng ; base 2,000 feet long, 3% feet wide, and a proximately 5-1,000ths of an inch in thick: ness are wound up temporarily until ready 3 to be coated with the emulsion. : 4 For more pleasing presentation on he : screen, motion pictures are often tinted by bathing the flm in dye solutions which stain — the gelatin. To save the finisher, the time and trouble of this operation, Eastman posi-_ tive film is supplied in several different col-— ors of tinted bases. In this product the col- or is impregnated in the film base. ery For use in portable projectors which r. quire a non-inflammable film, a special safer base called cellulose acetate is manufacture a It is made in much the same way as t 4 nitrate except that acetic anhydride is u instead of nitric acid for treating the cottor so as to render it soluble in the orga ic solvents. Preparing and Coating sig We now turn to the making ats the of sion or the light sensitive layer that | ‘ the photographic image. It is. made_ in grades, negative emulsion which is very sitive to light and is used in the and positive emulsion which is much less light sensitive and is used for printing the - pictures afterwards viewed on_ ‘the screen, All emulsion making is conducted i in, lighted with safelights which have bie e cially preperie for ee PHOS ; ee in size wee in WP: ee he are less than 1-10 as large. — Silver, as used in pia '6 vices: (Figure 5). The bars are in nitric acid and after recrys’ porcelain dishes pure crystals of trate are obtained. (Figure 6). ‘auIyoOeU Surzeod (348A AMO) 2 eansy ‘syezsAad ozperAyIU ABATIS Surysem (19}U99 ABMOT) Q sAnNSYy ‘UOI[ING ASATIs JO steq (}J2] JAMO) G sANSY ‘sHUL. aseioys adop,, (74511 doy) p eanSy ‘fuo0zjoo Sues (az9;uaes doz) ¢ sinsyg ‘faahap u0z}09 9y} sI (79, doz) Z oansiy 66 gredients of the emulsion are potassium io- dide,» potassium bromide and gelatin. If these bromide and iodide salts are dissolved in water and to the solution thus prepared silver nitrate solution is added, an insoluble yellow salt is precipitated which is very sen- sitive to light, turning black after a few minutes exposure. If this solution is coated on the base, the film would have very little sensitiveness and for all practical purposes it would be worth- less. For this and other reasons the pre- cipitation must be conducted in the presence of some material that will avoid these dif- ficulties. The material commonly employed is gela- tin, a substance analagous to glue in com- position, and lixe glue in that it is extracted from the bones and hides of cattle. Photo- graphic gelatin is usually prepared from calf skin by soaking the skins in lime water, and subsequently extracting with hot water. The gelatin is dissolved in water and the bromide and iodide solutions carefully mixed with it. To this mixture heated to the correct temperature, is added the silver nitrate solu- tion. The precipitate of the sensitive silver salt is held in suspension throughout the solution by the gelatin and because of this it receives the term, “emulsion.” These actual operations are conducted in silver lined steam jacketed vessels provided with usitable agitators. Soluble salts formed during the reaction must be washed out of | ae the emulsion. Figure 8—Every photographic image is composed of coke-like masses of silver grains— i, = shown here under a powerful microscope. a This is accomplished by chil- — ling it to a jelly, shredding it by pressing — the mass through a chamber with a per-— forated bottom and sides, and washing the 7 spaghetti-like strands many times with cold — water. The shredded emulsion is then melted — and coated. as For coating the emulsion on the hase, spe- cial and delicate machinery is necessary in — order to carefully control the thickness. The © film base is handled in such a way that ot one side comes in contact with the heated ° emulsion. (Figure 7). After the film F coated, it is carried in large loops through ~ chilling rooms to set and harden or become — “conditioned.” When thoroughly dried, it — is automatically cut into strips 13% inches wide and wound into rolls varying from 100. to 1,000 feet in length. Perforating the film is carried on in a ~ special department and the greatest care — is required to have the work done accurately, 4 for unless the perforations are correct in — spacing, the film will not run smoothly in~ cameras, printers, or projectors and the pic- 4 ture will be unsteady on the screen. The rolls of perforated film are then taken to — the packing room to be wrapped in selected — pure black paper and packed in tin cans which are sealed to keep the contents air and light tight. The cans are stamped with the emulsion number, the footage, and are then placed in strawboard containers ready — for shipment. . a To make film of the high average quality — demanded, inspection tests are necessary at — wegen pee every step in the manufacture. These in- clude the actual making of pictures which are projected to show the photographic qual- ity and to test the strength and wearing properties of the base. Thousands of feet of film are used up weekly in this way in a critical inspection of the manufactured product. No stock is permitted to reach the consumer which does not come up to the standard requirements. Research on the Chemistry of Emulsions In the manufacture of photographic emul- sions, the art has preceded the science. Great refinements have been introduced in manufacture on a large scale but the real chemical causes and the factors controlling the reactions have until recently remained as much a mystery as in the early years when all emulsions were coated by hand. As a result of a large program of intensive re- search that has been in progress now for many years in the Eastman Research Lab- oratory and other laboratories, some of the uncertainty has been removed but much ad- ditional work remains to be done. To gain a better understanding of this research work, something should be known of the actual characteristics of the emulsion. Ii a piece of exposed and developed motion picture film is examined under a high power microscope, the image will be found to be composed of minute grains or clumps of metallic silver, resembling tiny masses of coke. (Figure 8). These grains are de- rived from the original grains of the emul- sion, which under the microscope are found to be crystals varying in shape from spheres to triangular or hexagonal plates in the larger grains. (Figure 9). They are of all sizes from very small grains to quite large ones and the properties of the photographic emulsion depend largely upon the various sizes which are present. One part of this comprehensive plan of research has been the determination of the systematic relations which exist between the methods employed in the preparation of the emulsion and the photographic properties of the material obtained. That such relation- ships exist is now definitely established and before many years have passed a fairly com- plete understanding of these will have been arrived at. One phase of this investigation has been the direct microscopic study of the grains in thousands of different samples of emul- sions. This type of research is exceedingly tedious and progresses very slowly but it has proven one of the best lines of attack Figure 9—Silver Halide Grains of a Photographic Emulsion on the problem. It will not be possible to fully describe the method but some idea of its complexity may be gained from the fol- lowing statement. The emulsion sample is coated as a layer only one =tiny grain in thickness by a scheme requiring a high de- gree of skill. A minute area of this layer is then photographed so as to enlarge it 10,000 diameters. The grains are next meas- ured, classified according to size and from the results of hundreds of thousands of such measurements, a tentative conclusion may be drawn. This is essentially a_ statistical method of attacking the problem. The chemistry of gelatin has also come in for a thorough study. That this is well worth while was forcibly proven by the recent dis- covery of a group of chemical substances which must be present in samples of gela- tin even .though in very small amounts in order that the gelatin be useful for making photographic emulsions. These great problems of the chemistry of the preparation of the sensitive materials are only one part of the entire problem; the other is the use of the photographic materials. The faithfulness with which the final print reproduces the different tone gra- dations of the subject under various light conditions is known as the problem of tone reproduction. It may be reasonably said that this problem is fully solved and a state- ment of the accuracy of the reproduction of the tone gradations. of any subject is now possible on any photographic material under any given condition of. illumination. Color Sensitivity of Motion Picture 7 Films When a beam of white light (usually sun- light) is passed through a prism it spreads out into a multi-colored band called the Visible spectrum. The normal eye can dis- tinguish several prominent hues in this spec- trum, violet at one end, then blue, green, yellow, orange, and red.’ If this colored spectrum is photographed upon ordinary film, only the violet and blue would be com- pletely recorded and the green very slightly while the yellow and red would have scarcely any effect at all. A red object therefore, which appears relatively bright to the eye photographs as black whereas blue and vio- let objects photograph as white. The result is a false reproduction of almost the entire range of color tones. The chemist was re- sponsible for making photographic emul- sions sensitive to colors. It was found that on adding certain dyes called sensitizing dyes the sensitiveness of the emulsion to green and yellow was increased. Such emul- sions are called orthochromatic emulsions. Negative motion picture film is of this type but is relatively insensitive to red light and may be handled safely in darkrooms lighted with red safelights. It is manufactured in two speeds, par-speed and super-speed film; the latter being about twice as sensitive as the former. Within the past twenty years other sensitizing dyes have been discovered which on incorporation in emulsions made them sensitive to the entire spectrum. An Figure 10—Spectrum photograph showing sensitivity range of several emulsions. emulsion of this type is known as a pan- chromatic emulsion. (Figure 10). color photography has been made possible by the chemist’s discovery of these dye sub- stances and their use in the manufacture ~ of panchromatic film. Such pictures as Douglas Fairbank's “Black Pirate’ could never have been produced without panchro- matic film. Color Filters for Absorption.—Although panchromatic motion picture film is strongly | sensitive to red, yellow and green, it re-_ mains more sensitive to blue and violet espe- cially when photographing by daylight. To correct for this extra sensitiveness to the blue and violet, color filters are used be- fore the lens. These filters consist of thin Natural — Se re ee sheets of dyed gelatin cemented between two ‘ pieces of optical glass. The dyes are care- fully selected with reference to the por- — tions of the spectrum which they trans- mit and absorb. For example, filter is most commonly used with panchro- matic film since this filter absorbs a definite a yellow portion of the violet and blue light to which © the emulsion is most sensitive thereby equal- izing the exposure for all the colors. tones of the subject. When exposed to daylight or are lamps, — Thea result is a more accurate rendering of the ——— Eastman Panchromatic Negative Film is | about equal in speed to Eastman Negative Film, regular speed. Negative Film. Because of keeping qualities and its accurate rendering of tone values, panchromatic film is now being used extensively for both portraiture and landscape work. Panchromatic film can be supersensitized by bathing for 1% minutes in 4 percent am- monia at 50 degrees F., and drying as rapidly as possible. When given this treatment, the a a, ere With tungsten lamps, A it is considerably faster than standard speed — its excellent — —_— x. film is known as hypersensitized film and is — about as fast as super speed negative film for daylight work (see Figure 10). It should be used as soon as possible after hypersen- sitizing but if necessary to store for a week — or so, it should be kept dry and at a tem- perature not higher than 50 degrees F. The © red and green sensitiveness of the film is — increased three or four times by this hyper- sensitizing treatment which is a great ad- vantage if exposures through red filters are to be made. By the use of appropriate filters and © treatment with certain sensitizing dye solu- — tions, panchromatic film finds important ap- — plications for making “night scenes” in the © daytime (Figure 11), and for making distant It may also be used for making duplicate negatives from posi- ~ shots through haze. Figure 11--“Night scenes” photographed in daylight on specially sensitized film. tives on tinted base when no other print is available. Colored spots and stains can be eliminated by duplicating in this way. More complete information regarding pan- chromatic film is given in the booklet “East- man Panchromatic Negative Film for Motion Pictures,” supplied on application to the Mo- tion Picture Film Department, Eastman Ko- dak Company, Rochester, N. Y. ‘Chemistry in the Processing of Motion Picture Film After manufacture, motion picture film has little contact with chemistry until it has been exposed and is ready tc be processed. The various treatments which it then re- ceives such as development, rinsing, fixation, washing, and drying, are all chemical and determine in large measure the future per- manency of the film. Besides the action of the different solutions in processing the film, there is considerable chemistry involved in the actual mixing of the solutions and in the action of the liquids on the vessels or tanks used for containing them. Too little thought is usually given to the preparation of solutions used in photography. “NI We are apt to be satisfied to dump the cheniicals into the water, stir the bath cas- ually and proceed with the more important business of processing the film. Conversely, it is true, that it is unnecessary to take too great precautions and waste too much time in mixing the solutions, but more care should be exercised than is usually given. Although distilled water or rain water are to be preferred for mixing solutions, experi- ence has shown that it is only rarely that tap water which usually contains dissolved salts cannot be used. Providing the solution 1s filtered through a canvas cloth or allowed to settle before drawing off for use, very little trouble need be anticipated. The important thing is, however, to use only pure chemicals, dissolve each separately before adding the next, always mix them in the order recom- mended, agitate the entire volume of solution thoroughly as each constituent is poured in, and finally make up the solution to a definite volume with cold water. Hydrometer meas- urements are best avoided in mixing solu- tions (unless it is impossible to keep the chemicals dry), because it takes considerable time to adjust the strength of the solution. Hydrometer readings also vary with the tem- perature and no idea is conveyed as to the percentage strength. A good arrangement for mixing the solu- tions is to place the chemical room directly above the developing room. Wax impreg- nated wooden tanks, enamelled vats or smoothly glazed earthenware crocks are recommended as containers connected with chemical lead piping to convey the solutions to the developing and fixing tanks in the room below. Further details may be found by consult- ing the chapter on “Preparing Solutions” in the booklet, “Elementary Photographic Chemistry,’ published by Eastman Kodak Company. See also “The Development of Motion Picture Film’ by J. I. Crabtree, Trans. Soc. M. P. Eng. No. 16, p. 163 (1922). Developers and Development The purpose of a developing solution is to change the exposed silver salt in the emul- sion to metallic silver without affecting the unexposed silver salts. The constituent of the developer which accomplishes this change is called the reducing agent. The reducing agents now generally employed are elon, hydroquinone, pyro, and glycin. These sub- stances are ineffective as developing agents until the solutions are made alkaline, usually with sodium carbonate, which activates the reducing agent. In the presence of the oxy- gen of the air, however, the reducing agent is oxidized and the solution turns brown. A product somewhat like a dye is formed which stains the film and slows up the developing power of the solution. When the carbonate is added this rate of oxidation is increased, but if sodium bisulphite or sodium sulphite is added, the oxidation tendency is reduced and the solution turns brown very slowly. The sulphite, therefore, generally should be dissolved first as it acts as a preservative. Besides the reducing agent, the activitator, and the preservative, the developer contains a restraining agent or potassium bromide which assists in controlling the rate of de- velopment and preventing developer fog. The various reducing agents differ con- siderably in their rate of development: elon, for example, develops the image much more rapidly than hydroquinone, but on pro- longed development they produce similar images (Figure 12). Both these developing agents are usually added to a developer be- cause hydroquinone, when used alone, de- velops too slowly, especially at low tem- peratures. For negative development, when soft images are desired, the proportion of elon should preponderate, while in the case of a jeositive developer, when more contrast cL re aan. MIN. tein. are 12—Graded strips eae comparative rates of develogaaan of (E) Elon and (H) Hydroquinone. is wanted, the hyarceiaean ‘seni be in ex % cess of the elon. The difference between the blackness of the silver image of the lowest exposure and the highest exposure is a meas- ure of the “density contrast” of the nega- density a tive. This difference in density increases with time of development, usually occurring in the first 5 or 7 minutes of development. Every picture is really a series of varying tones and the particular developer used, the time and temperature of development of both the negative and the — positive print all influence the range of the density value of the tones. If development is continued too long, a chemical reduction of the unexposed grains of the emulsion takes place which is com- monly spoken of as “fog.” It is never ad- visable to develop longer than one minute less than the fogging point, and it is there- fore important to know the time required to produce visible fog with the type of film being used. Occasionally substances get in the developer which fog emulsions very rapidiy. A serious trouble of this nature was traced to the presence of certain bacteria — we MN the greatest change © ie i gai A a a De ed at A le i al at S Pos < Fs Hina at? hp wets peas mS, iu Sign Sc Meg ro i, ee eee , a SA of phe ie eid ‘) Me 2 eee a Rie Behe eS 6 — Fa oe ee Be Penne cals or solvents must be used with discre- tion, however, and the liquid allowed to completely evaporate before the film is rewound, or the image may be subsequently attacked. Traces of sulphur chloride pres- ent in impure samples of tetrachloride prob- ably cause fading due to deposition of sul- phur which combines with the image form- ing silver sulphide. If pure tetrachloride is used and the film wound spirally on a drum, and the solvent applied with a soft cloth or velvet, the solvent will have suffi- cient time to evaporate before rewinding the film. Another non-inflammable solvent which does not fade the film is tetrachlor-ethylene. Similar precautions for cleaning on a large drum should be used. There are machines on the market in which the film passes over several moist felt pads saturated with sol- vents and then over a series of polishing wheels made with small pieces of velvet fastened around the periphery of the wheels. The polishing wheels rotate very rapidly and ensure thorough drying and polishing of the film before rewinding. It is now usual practice to apply a narrow line of melted wax to new or first run prints along the center of the perforation area which provides against the liability of strain in first projection. Similarly when film is renovated it should always be rewaxed as the cleaning chemicals remove all or nearly all the wax. Splicing and Varnishing Film.—Splicing of film is essentially a chemical problem since the film cement must possess certain prop- erties, such as good adhesiveness, fairly rapid evaporation on drying, and have no corrosive action on the film support. When film has been projected many times it sometimes acquires scratches which fill up with dirt and grease and show up plainly on projection. Cleaning the film removes the dirt from the scratches but as soon as the film is put into use again the tiny groves O\ap as much as before. To prevent this, varnishes have been compounded for treat- faethe film. Such varnishes have to be made very carefully as they must possess the saine refractive index as film base or in other words the varnish layer must not change the direction of the light rays when ‘the film is projected. Furthermore these varnishes must give a hard, non-abrasive surface when coated very thinly on the film and must not attack the support, the gelatin or the image. Chemistry and Color Motion Pictures A field which is demanding more attention yearly 1s that of natural color motion pic- tures. This problem is both an optical as well as chemical one; optically it demands unusual refinements in the design of lens systems and chemically it imposes a dif- ficult problem in processing and in final dye- ing of the films. There are two general classes of natural color motion pictures: those produced by additive and those by subtractive methods. These are further sub- divided according as they use three color or two color ranges in color reproduction. In the additive process, several distinct color records are taken and projected separately and are either superimposed or shown in rapid succession, the colors being added to or built up on the screen. These processes usually require complicated and expensive apparatus. Whereas, in the _ subtractive method which has found most public favor the color records are taken separately but are finally incorporated on a single film and projected in the same way as standard pic- tures. In the foregoing description of the value of chemistry in the motion picture industry, it has not been possible in view of the nature of this article and the diversity of the sub- ject matter to discuss in much detail the actual chemistry involved. It is hoped that some idea may have been gained, however, of the importance of chemistry in every phase of the industry from the assembling of the raw material for manufacture to the final projection of the film. Additional References “The Fundamentals of Photography,” by C. E. K. Mees, published by Eastman Kodak Co. “Significant Progress in Research on Photography,” by C. E. K. Mees, Annals of Amer. Acad. Polit. Sci., 69, 10 (1925). “Application of Microscopy to the Photo- tographic Industry,” by A. P. H. Trivelli and Re P, Loveland, J. Rov; -Micro, Soc., 1925, -p: 293. “The Home of Film,” published by East- man Kodak Co. “Moving Pictures,’ F. A. Talbot, Lippin- Cote bub. Co, Phila... Paz 1923. “Handbook of Projection,” F. H. Richard- son, Chalmers Pub, Co., New York, N. Y. “Chemistry in Industry,’ Chapt. 18. Chemical Foundation, Inc., 1924. The