@Joerg Bergs . Can you explain your workflow, please?
- How you extract the film from the cassette for processing?
- Are the films processed by hand or machine?
- What type of machine?
- Do you use twinchecks to match film to docket/order pouch?
- What type (if any) of film clips do the lab use, for hanging negative strip prior to scan/print?
And the other question for @Joerg Bergs is: how many people are doing the loading, and is it all happening on one site?
With an awful lot of these intermittent faults, while there might have been small manufacturing changes (e.g. to plasticiser or gelatin extenders) that make the emulsions fractionally more sensitive to physical mishandling in some specific lab environments, I do also wonder if a significant percentage also relates to people advancing the film until it's taught at the end of the roll, then on rewinding it somehow ends up getting wound back into the cartridge the opposite way out - on thinking further about it, this was the one time I saw the fault (or something similar) to the one described.
And while all 135 Kodak colour is now on Estar, the B&W is (as far as I can tell) still on CTA - the bases are quite readily identifiable by handling characteristics on loading to reels.
