A clarification on Kodak coating practice

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Daniel;

I hate to tell you this, but this video and its translation from Dutch to English is posted here on APUG in several places. Sorry.

PE
 

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We should all kiss the ground each and every time we are able to buy a box of film...EC
 

DanielStone

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Daniel;

I hate to tell you this, but this video and its translation from Dutch to English is posted here on APUG in several places. Sorry.

PE


hey PE,

I knew that when I posted it. figured some people didn't know about it though.

still fun to watch !

-Dan
 
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I just thought people should be aware of the English translation.

BTW, in that film, in the scene showing the trough coater, the width of the support is probably not 54". It does not look wide enough. It is probably 42" which was used earlier.

PE
 
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Hello Ron,

thanks for the update!

In addition: Kodak has invested a lot in his production infrastructure over the last years. Especially in making much smaller batches due to current demand, more "just in time".

There was a very interesting report about these modernised production methods in the DemocratChronicle on 4th January, 2009.
Journalists visited the Rochester plant and reported about the new production in Building 38.

I quote from this article: "....And the company remains steadfast that camera film will continue to be a part of its business, though admittedly increasingly a niche product.
"You come back in 10 years, there will be a film business here," said Joel T. Proegler, general manager of film capture and a vice president in Kodak's film, photofinishing and entertainment group. It'll be smaller. Maybe there will be a bigger space between innovations."......

Kodak switched a year ago from churning out large batches of film at a time to doing almost daily runs of small batches that are tied to consumer demand. The advantage is that the company carries far less inventory on hand, said operations manager Sue Sweet."

These informations correspond exactly with a report in the German film magazine "Schmalfilm" 2/2008. Chief Editor J. Lossau reported from an interview with Kodak CEO Perez, in which he said that Kodak has recently made some long term contracts with film customers (movie and foto film) for the next ten years. Film is safe for at least another ten years at Kodak, and probably for much more years to come.

Probably a very interesting report from the Kodak plant in Windsor near Denver:

http://www.wittner-kinotechnik.de/info/kodak/kodak-en.php

In German:
http://www.wittner-kinotechnik.de/info/kodak/kodak-de.php

It is about the the small format movie film production (Super 8 etc.). Kodak has now moved it from Windsor to Rochester, that means they have recently invested lots of money in this "niche in the niche" production.
Although Super 8 is considered to be "dead" for almost 30 years now by the doom and gloom sayers, these films were produced by Kodak every single day, not one or two small batches a year. Millions of feet of Super 8 film per year.

This view at Super 8, over 30 years after the introduction of consumer video cams, should us let look much more relaxed at the future of photo film, which is a much, much bigger market.

Best regards,
Henning
 
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Henning;

Thanks. You are aware that Kodak has moved all film work back to Rochester and has sold the Colorado plant facilities to a Canadian company. Kodak rents time there to produce color paper, and that is being cut back as demand decreases. Oh, and the visitors must have misheard. Splitting is really called slitting at Kodak. Easy mistake.

PE
 
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Yes, digital film making is the real threat to us analog still photographers...EC

It is often said here on apug, but I think the threat is not so big.

Because of the following reasons:

1. Even if in 10 or 15 years most movies are made with digital equipment, the movie industry will still use film:
For long term storage. All 100% digital made movies are exposed on special archiv film for long term storage. Why? It is much more safe and about 5x- 10x cheaper than digital long term storage.
Film will be the leading media for archiving of movie film.

Fujifilm has recently won a scientific award for its new "Eterna" movie archiving film.

Both Simon Galley and Jerry Deeny (Fuji) had said: "There will always be a market for film". They know what they say.

2. Not all film manufacturers are in the movie film business. Only Kodak, Fuji, Agfa-Gevaert and partly Filmotec are producing movie film.
Ilford, Lucky, Foma, InovisCoat, Fotokemika, Tasma, Era, Shanghai are not in the movie film business.

Agfa-Gevaert has strong parts in aerial, surveillance, graphic and microfilm production. Probably they could do well without their movie print film production. They are not as dependant from movie film as Kodak is.

3. Ilford, Agfa-Gevaert, InovisCoat, Foma and Fotokemika have very flexible production lines. For example, all of them are coating film and paper on the same coating machines.
Last week I had a talk to a friend who is involved in the tests of the InovisCoat/Adox AP 400 (based on former APX 400). This film will probably have a first production run of only 3000m². That means very,very small runs are nowadays possible on this adapted/downscaled machinery.

Best regards,
Henning
 
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Hi Ron,

Color paper: AFAIK Kodak hast lost market share to the competitors, which are currently Fuji, DNP, Mitsubishi, InovisCoat.

Best regards,
Henning
 
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Henning;

I am aware of that. However, the R&D needed to get high stability dyes was mostly Kodak and Fuji. I wonder how well these others stand up on keeping? OTOH, they may license technology from EK or Fuji.

As for motion picture archiving, most of it is done via separation negatives on B&W film stock. This is another big product for EK.

PE
 
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Henning;

I am aware of that. However, the R&D needed to get high stability dyes was mostly Kodak and Fuji. I wonder how well these others stand up on keeping?

PE

Ron,

due to statements from german paper base manufacturer Schoeller the color paper market is at least doing much better than expected some years ago. Thats because digital prints in the mass labs are made on RA-4 paper.
The mass of digital shooters who want prints are using online services and mass labs. A minority is using home inkjet printing.
DNP is quite strong, Fuji has made a big deal with CEWE, the biggest mass laboratory chain in Europe. AFAIK Fuji Chrystal Archive is still considered as the paper with the best long term archiving capabilies.

By the way (yes, it is off-topic): The digital market collapsed last year in Germany:
Digital cameras: -10 to - 30% (dependant on camera type)
Storage media (flash cards): - 37%
Beamers: - 44%

Market saturation will be a big problem for digital equipment in the next years.

Film products performed much better in relative terms .....

Best regards,
Henning
 
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Hi all,

just a little update, which may be interesting in this context:

1. Agfa-Gevaert: There is a current statement that they stay committed to film production.
They are coating 1 million m² of film every day (!), all different film products together (PCB films, movie films, aerial films, surveillance films, micro- and document films, graphic films).
The official statement:
http://www.agfa.com/en/sp/news_events/news/MAT_20100303_PCB_Commitment_EN.jsp

2. Inoviscoat: They are making progress with their 400 emulsion. This film will have some significant differences compared the former APX 400 (targets are finer grain and better anti halation layer).
Furthermore Inoviscoat has another new distribution partner: Lupus Imaging http://www.lupus-imaging-media.com
The first production run will be sold to Lupus, and they will offer it as AgfaPhoto APX 400.
Here are two official statements about it:

Dead Link Removed (Posting No. 9)
http://www.aphog.de/forum/viewtopic.php?f=45&t=13694

Best regards,
Henning
 

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This is a great thread and without the "conspiracy theory" tinge that taints most discussions about the future of film! Very encouraging and informative to boot.

Thanks for spreading the word
 
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haaa must bookmark that wonderfull thread and send it to film killers.

THE biggest danger to film is not digital, it is FUD - fear, uncertainity and dismay - as a tactic used by salespersons to sell you digicams. How many people do you know personnaly that have been told that film did not exist anymore when they tried to get some? I know a whole bunch.

spread the good news!

K
 
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Hello,

just a little update concerning Kodaks efforts keeping Super 8 alive:
This spring they have introduced another Super 8 film, Ektachrome 100 D color reversal film.

http://motion.kodak.com/US/en/motion/Products/Production/Spotlight_on_Super_8/index.htm

Best regards,
Henning
 
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Hi Ron,

Color paper: AFAIK Kodak hast lost market share to the competitors, which are currently Fuji, DNP, Mitsubishi, InovisCoat.

Best regards,
Henning

Sorry, I had forgotten one of the major RA-4 paper manufacturers:
Ilford Imaging Switzerland with their Ilfocolor RA-4 color paper line.

Some weeks ago on the German fineartforum in Paderborn (film only) Kodak, Adox and Maco Photo Products presented their (new) products and H. Brümmer from Kodak, M. Böddecker from Adox and H. Schroeder from Maco gave lectures about their plans, the situation of the market and the future of film photography.

H. Brümmer said that rumors about production stop of TMZ, Plus-X and BW 400 CN are wrong. They stay in production (BW 400 CN as 135).
Furthermore Kodak realized that lots of professionals prefer film for certain projects.
And they see a trend, that a significant amount of digital snapshot photographers use SUC film cameras in some cases, e.g. in holidays at the beach, or in the water the waterproof SUCs. This market stays quite robust.
Mr. Schroeder said the same, increasing demand for SUCs, one reason why Maco/Rollei-Film has recently introduduced several new models, even with B&W and slide film.
Maco presented their new Retro 100 Tonal there, and the Agfa APX 100 glass plates. They reported increasing demand for their products. With some products they have capacity problems because demand is higher than current production.

Both Mr. Böddecker and Mr. Schroeder said it is difficult for independant manufacturers at the moment to get paper cut and packed. The specialist companies for that are operating at full capacity, mainly because of a high demand for RA-4 paper.

Mr. Böddecker presented the new 400 BW emulsion, made by InovisCoat and based on former APX 400. He said the first production run this summer is planned for 10000 m², distributed as AgfaPhoto APX 400 (Lupus Imaging) and Adox AP 400.
He gave a very detailed and honest insight in the current status of building up the little new Adox plant in Bad Saarow. He talked about the difficulties and the recent progress. At the moment they are concentrating on getting the machine for 120 confectioning work properly (it's the former Forte machine), and are preparing the first "Fällung" of Polywarmtone emulsion.

All three gave a quite confident outlook concerning the future of film based photography.

Best regards,
Henning
 
OP
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Please go here: http://makingkodakfilm.com/ for an excellent book about Kodak's manufacturing processes.

The author will donate a portion of the sale price to APUG if ordered by an APUG member or subscriber and if APUG is mentioned in the order.

PE
 
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Thanks Ron, I have already seen your link in the product availability forum.
I will order the book.

Best regards,
Henning
 

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This, and this alone, is the salvation of the film market for us unless some new and as yet undiscovered use emerges that demands astronomical amounts of film. (An unlikely expectation at best.)

Note that this (3000 m2) is only about 500 boxes of 100 sheets of 8x10. Or about 500 (give or take a lilttle) cases of roll film. (Assuming a yield of about .85. I have no idea what a slitting organizations real yield would be, but 85% seems like a reasonable guess.)

Flexible manufacturing of small batches will keep the dwindling but active users stocked.

God (and Man) rest the soul of Kodachrome, but it couldn't be made economically enough to sell in small batches.

MB
 

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... Next, regarding the machines, they must be kept in a state of "threadedness" . The machines must remain threaded as the threading operation is tedious.

I'm curious how the process changes from the leader to the production base.

I've been in a offset plate making operation a number of times, but the substrate they coated is aluminum instead of film.

In that operation there are a number of rollers which hold tens of meters of material, and they are movable in such a way that the process line can be fed at a continuous rate while the injection point is stopped. The slack feeds out of the spools under a PLC controlled process.

When the tail is stopped, the roll is cut and the next roll welded to the first by an arc.

I'm sure there must be something similar, but my question is how do you adhere the two pieces in short order so you can begin feeding the process again?

Michael
 
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Hello Michael,

This, and this alone, is the salvation of the film market for us unless some new and as yet undiscovered use emerges that demands astronomical amounts of film. (An unlikely expectation at best.)

"astronomical amounts", that is probably unlikely, but there are already market segments with very strong increasing numbers of photo film sales. For example films for the toy camera / Lo-Fi / Lomography segment.
There you have growth rates of 30 - 50% p.a..
There is a reason why in the last three years several special films for this segment were introduced by the Lomographic Society and Maco/ Rollei-Film: Increasing demand. These films are selling in seven digit numbers. The LSI is permanently introducing new films under their own label because of this increasing demand.
They have developed very successful marketing strategies for film.


Please have a look at my posting from yesterday: The first production run will be 10000m². The number of 3000m² was mentioned by Mirko at a former date.
I've had a long talk with him at the fineartforum. 3000m² would be possible, but then the film would be a bit pricey. A production run of 10000m² makes attractive prices possible. Therefore as well the cooperation with Lupus Imaging / Germany, who will sell the film under their AgfaPhoto label.

Best regards,
Henning
 
OP
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Film support is spliced together with tape. It is done on the fly at high speed. It is a totally machine controlled operation and humans had better not be in the way!

As for coating film and paper on the same machine, consider this. Film coating is benign, but paper coating (both FB and RC, but FB is far worse) create fluff made of paper fibers and baryta dust. After coating paper, the machine must be shut down and the room and machine must be cleaned before film coating can be resumed. This is why Kodak used 2 separate facilities and specially enclosed coating machines. It was to isolate the two products and then isolate the problem and confine it to the coating machine itself.

PE
 
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Hello Ron,

interesting that it can be even a problem with RC paper, I've been told it's only a problem with FB paper. And that the necessary cleaning process of the machinery after FB paper coating is one major reason for the higher price of FB paper.
But it looks that the companies have solved the technical challenges of coating both paper and film on the same coating machine
(looking at my Ilford films and papers, I've never had any quality problems).

Best regards,
Henning
 
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The problem with RC is orders of magnitude less than with FB.

Even so, paper is restricted to a tight schedule if coated on the same machines as film. There is a schedule with most companies with combined paper and film coating and a non-dedicated line. There is also a prescribed cleaning time between changeover from paper to film.

PE
 
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