This Thing is Crazy Fast - Kodak Part 3- Smarter Every Day 286

This is the third video in a three-part series about Kodak film manufacturing in Rochester, New York. Previous videos covered backing material production and light-sensitive coating application.

This episode covers the remaining steps: slitting film, adding sprocket holes, building cans, and final packaging for 35mm cameras.

All light-sensitive film must be kept in darkness until the camera shutter opens to expose the image.

The process demonstrates incredible engineering and technological innovation throughout multiple specialized machines and skilled operators.

The slitter takes wide rolls of Estar-backed film and cuts them down to 35mm width for cameras. One large roll contains 12,000 feet of film.

Tim, the slitter operator with nearly 30 years of experience, manages the entire process. He works in darkness without night vision goggles because he has adapted to the environment. The older generation teaches newer engineers like Patrick.

• Film passes through tension-controlled systems using directional clutches • Web steering mechanism keeps film centered on a pivot • Blades slit film into even and odd banks simultaneously • Edges are trimmed as salvage for silver recovery

Double-sided splice tape closes each 500-foot roll. The tape applies adhesive on both sides, reverses to split, and exits the roll cleanly before reaching the next operation.

Perforations allow mechanical cameras to grip and advance film correctly. Precision is critical to prevent feeding problems.

• Runs at 3000 feet per minute, compared to 100 feet per minute on older machines • Can produce different hole sizes and dimensions based on customer specifications • Automated arm loads film rolls and extracts punch information from data cards • Punch drum rotates with die drum to create perforations

Every roll includes a scratch test end sent to the quality lab for inspection. The metal detector system verifies proper can counts during packaging to catch any defects or jams.

• The punch and die assembly is nicknamed 'the heart' because oil mist flows through it like blood • Contains 96 paired punch-and-die sets requiring months to tune properly • Runs with direct-drive servo motor at extreme speeds creating vibration and harmonic challenges • Vacuum channels machined into the die drum extract perforated film pieces

Metal sheets are cut into strips with printed ISO information readable by cameras. End caps are stamped from metal. Velvet is applied to create light-tight seals between can edges.

• Metal strips are cut and crimped with precise edges • Adhesive-backed velvet is applied and heat-set • Velvet is cut separately from metal strips • Dies punch metal strips into individual pieces for assembly

One favorite machine takes cut metal, rolls it into a cylinder, applies end caps, crimps them securely, and stakes them to the magazine. Finished cans drop to a conveyor for quality inspection.

Visual inspection catches any defects in the metal strips. The crimping and staking processes must be perfectly controlled. Automatic systems measure and reject substandard cans.

Film from the perforator, metal cans, end caps, and plastic canisters all converge in this room. An automated system orients all parts correctly before assembly.

• Two film cabinets (A and B) allow auto-splicing between rolls without stopping the line • Light exposure system prints frame numbers and information on the leader • Eight-station rotor indexes all components into proper position • Tape applies film to center plastic spool, film rolls and cuts automatically

Can slides over rolled film, end cap seals it light-tight, rocker arm drops assembled can into plastic case, gray lid pops on top as the line advances, and finished product goes through pneumatic tube to packaging.

Large vacuum slack boxes manage continuous rotation of heavy film reels. Accumulators store slack to allow synchronized winding and stopping without straining the system.

• Single package units • Hang tab packages for retail display • Five-packs, three-packs, two-packs • Multiple configurations for different markets

Cartons arrive flat. Suction cups pull them open. Bottom kicker arm bends the bottom flap up. Forming bar bends and compresses the opposing side. Five spools drop into the carton via loader arm.

• Metal detectors verify all five cans are present in each package • Light sensors confirm flaps are properly closed • Emulsion number and expiration date print on the package • Visual inspection before final boxing

Glue stations apply adhesive to flaps. Compression rails hold package while drying. Ejection arm slides finished boxes down chute to operators. Boxes are visually inspected and placed on pallets with labels properly positioned.

Destin takes a freshly manufactured Kodak Gold 400 film roll directly off the production line and loads it into a camera to test immediately.

Destin photographs the manufacturing team, celebrating operators with 45+ years of experience and newer team members. The workers form a close-knit family working together.

Film is experiencing a resurgence. Filmmakers and photographers still prefer film despite digital alternatives. Record albums and analog media are also making a comeback because 'just because it's new doesn't mean it's improved.'

• Thank you to Kodak for allowing this documentation • Gratitude to Patreon supporters who make the videos possible • Encouragement for viewers to shoot and support film photography • Recognition of American manufacturing strength and intergenerational knowledge transfer