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1. ! " #!$ ! $ Company ARTENIUS PET PACKAGING EUROPE Zone d’Entreprises de Bergues Bierne F – 59380 BIERNE FRANCE Reason Risk Inspection / Survey Report Conferred with Mr.William Faye APPE – financial director Mr. JeanLuc Descarpentries APPE – risks and projects managerMr. David Molias LA SEDA DE BARCELONA – credit & risk head Mrs. Susan Uttley WILLIS S&C c.– director international unit Mr. Alberto Cantero Martínez WILLIS S&C c. – technical director Mr.Vincent Fraissé GRAS SAVOYE – account executive Mr. Carlos Carasusán ZURICH Global CorporateSpain – risk engineer Occupancy 4005 – Manufacturing of monolayer PET preforms Report No 68002108 Inspected on 27.02.2008 Surveyor Glenn van Mele HDIGerling Industrie Versicherug AGTervurenlaan 273 B 1 B – 1150 BRUSSELS BELGIUM Telephone Telefax email + 32 (0)2 773 08 54 +32 (0)2 773 09 90 glenn.vanmele@ hdigerling.be2. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 2 ! " #!$ ! $ List of Contents Page 1. Result of theSurvey............................................................................................................3 1.1.Summary.............................................................................................................................3 1.2. Change andComments......................................................................................................3 1.3. RiskImprovement...............................................................................................................4 1.3.1.Recommendation................................................................................................................4 1.3.2. List ofPriority ......................................................................................................................8 2. GeneralDescription ............................................................................................................9 3. Industrial Process.............................................................................................................11 3.1. Production ProcessDescription........................................................................................11 3.2. Production Flow Chart(Optional)......................................................................................12 3.3. Specific ProcessHazards.................................................................................................13 3.4. Result of the HGST GradingSystem...............................................................................14 4. Building Description,Stores..............................................................................................15 5. Technical
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Data..................................................................................................................17 5.1. MachineryBreakdown.......................................................................................................18 6. FireProtection...................................................................................................................19 7. Organisation andSafety Management .............................................................................21 8. Risk analysis BusinessInterruption ..................................................................................22 8.1. Basic data.........................................................................................................................22 8.2. Business Exposure...........................................................................................................22 8.3. Specific bottleneck units.Protection Measures ................................................................22 8.4. Interdependencies............................................................................................................22 8.5. Essential internal/externalSuppliers and Customers .......................................................22 9. Other Perils.......................................................................................................................24 10. Loss History......................................................................................................................24 Remark The result of thisrisk survey follows the current and actual risk situation, seen during the inspection. This re port does notfocus on the view of administrative regulation but in the entrepreneurial view to assure the avail abilityof productivity, the facilities or other units of the plants (like stores, bottlenecks etc.)3. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 3 1. Result of the Survey 1.1. Summary The site is located in the northwest of France, closeto Dunkerque. APPE only owns a part of the buildings (about 14.885 m²), with the majority owned by thecompany Ball Packaging used for the manufacturing of cans for the beverage industry. The 2 com paniesare separated by means of a fireproof wall (fire rating 2 hours) showing no defi ciencies. This plant,formerly known as Amcor PET Packaging France is involved in the manu facturing of monolayer PETpreforms using 20 injection moulding machines. The pre forms manufactured in this site are mainly usedfor the packaging of food, drinks and detergents, with CocaCola being the largest client. Operations takeplace in a 5shift system, 365 days per year. About 1,8 billion preforms are manufactured per year withthe total annual capacity being 2 to 2,1 billion preforms. It benefits a good fire safety organisation withattention to the ignition sources that are well under control. Only minor remarks were made in order tofurther eliminate or re duce these causes of fires. Furthermore, the site benefits a basic fire separationwith the warehouse being separated from the production area. Special attention is required in order tokeep the fire separation at high level. During the survey, it was observed that a fireproof door did notfully close and that some cable penetrations were not prop erly sealedoff. The housekeeping was foundto be at high level. The fire protection on the other hand was rated poor. First of all, the external walls arecomposed of double steel sheeting with the combustible polyurethane foam insulation. The warehousearea as well as the offices benefit an automatic fire detection installa tion, but the production area iscompletely unprotected. The sprinkler protection in the warehouse housing a very high fire load is totallyinadequate since the design criteria are no longer met. This is due to the type of material stored combinedwith the storage height. This is only slightly compensated by the adequate equipment for manual firefighting (fire extinguishers, hose reels, hydrants, …). With the highest values for property damageconcentrated in a nonprotected area and the consequent high business interruption exposure, this siterates poor from a fire safety point of view. 1.2. Change and Comments No changes are planned for thismoment.4. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 4 1.3. Risk Improvement The following recommendations can improve the current risksituation from our point of view. 1.3.1. Recommendation Organisation and Human Element 08.01 Reevaluation of the alarm procedures (callin of the public fire brigade) During the evaluation of the alarmprocedures, it was observed that the own fire fight ing team has to make a first attempt to extinguish thefire. Only if this attempt is not successful, the fire brigade is called in by a member of the fire fightingteam. Since in this case a lot of critical time would be lost, and bearing in mind the relatively longresponse time needed by the fire brigade, it is highly recommended to reevaluate these procedures. Itshould be so that if a fire is observed, the fire brigade is informed immediately. The only exception can bea very small fire that is extinguished within seconds. 08.02 Lighting installations: use of safety startersStrip lights using classic starters could invoke a fire when the lamp is defect resulting in a starter that triescontinuously to start the lamp. Often, this causes an overheating of the starter that could set the plasticmaterial on fire. Burning drops (or the lamp itself falling down) could cause a fire by igniting thecombustible materials stored be low. It is therefore recommended to use safety starters (with a red reset
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button). Not only is the risk of overheating avoided, the power consumption is also reduced since only alimited number of attempts to start up the lamp are made. 08.03 Control on mobile and household electricequipment Although the electrical installation is checked periodically, the mobile equipment and privateelectrical equipment is not checked. Since the fire statistics show that some losses have their origins inthis equipment, we highly recommend to have both the mobile equipment owned by Artenius PETPackaging Europe (e.g. electric heating units, coffee machines, microwaves, water cookers, …) as well asthe private equip ment brought in by staff (radio, …) checked at least once per year. The GermanVDE0702 guideline is a good example of how this test should be done: equipment with protectiveconductor: Protective conductor resistance < 0,3 Ohm Insulation resistance > 0,5 MOhm Equivalentleakage current: up to 6KW; < 7 mA, as from 6 kW: < 15 mA Protective conductor current < 3,5 mA –Touch current < 0,5 mA equipment without protective conductor: Insulation resistance > 2 MOhmTouch current < 0,5 MA The test should start with a visual check of deficiencies and should be completedby labelling and listing this equipment. Only approved equipment should be used. New equipment shouldbe labelled and listed before used. If some equipment does not meet the basic requirements, it shouldeither be repaired (and checked) or removed.5. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 5 08.04 Annual control of the smoke and heat release systems During the site tour, it wasobserved that the smoke an heat release system has not been checked since 2005. In order to guaranteethe good functioning of this system, it should be checked by a specialised company (e.g. the installer) onan annual basis. 08.05 Housekeeping in the server room (ITdepartment) The server room is equippedwith an automatic gas extinguishing installation using FM 200 as extinguishing medium. It is remindedthat the volume of extinguishing medium is calculated on the fire load in the room, where it is assumedthat only the necessary ITequipment is present. It was observed that the server room is used as a storageroom for old monitors, card board boxes and a lot of unnecessary fire load. Since this jeopardises theadequate functioning of the extinguishing installation and simply not belongs in a server room, allunnecessary items must be removed from this room. 08.06 Business contingency planning – developmentof corporate loss control guide lines During the business interruption discussion, it was noted that at thismoment a busi ness contingency planning does not exist. It was however announced that this will bedeveloped in the next 2 years. Since the market position of the group, it is extremely important to have acomplete overview of activities, deviation possibilities, dependencies, ... with an analysis of the risks andan action plan. This should be updated regularly. Since a lot of risks related to fire safety apply in almosteach site, it is highly recom mended to develop a corporate loss control guideline stating the protectionlevel or the organisational measures to be taken in each plant to tackle ignition sources and to upgrade thefire safety organisation. Physical Protection 08.07 Fire separation The site benefits a basic fire separationbetween the warehouse and the production area, between the warehouse and the neighbour and betweenthe production area and the offices. Furthermore, there is a fire separation of the technical rooms.Following deficiencies were observed: open cable penetration in the wall between the warehouse and theproduction area one fireproof door in this wall door did not completely close after a test some walkwayfireproof doors that should be selfclosing were found in open posi tion (e.g. in the firewall betweenwarehouse and production area, entrance door to the 2 nd technical room in the warehouse) cablepenetrations in the “TGBT” rooms were not completely sealed damage to the structural fire protection ofthe steel columns of the firewall between production and warehouse These deficiencies must be solved assoon as possible. Furthermore, it is required to organise a regular check of the fire separation and to havea plot plan developed with an indication of the fireproof walls (in detail) in order to make this controleasier. It is suggested to include this check in the monthly safety tour.6. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 6 08.08 ATEXdirective and explosion protection document (gas and dust explosion) SinceJune 30th 2006, it is a legal obligation to comply with the 2 ATEX directives (manufacturers directiveand users directive). This also includes the development of an explosion protection document. It wasstated that only for the silos for raw materi als, an ATEX study has been made. Since there are severalother areas where this applies, it is highly recommended to engage a certified company to have this studycompleted. At least following areas are involved: transport of resin and filling stations (e.g. colours)grinding unit battery charging area gas cylinder for propane filter installations In order to avoid staticelectricity, the metal wire in the flexible connections must be connected with the metal parts on both
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ends. It is also recommended to have an inter lock installed on the filling inlets for the silos since it wasobserved that the earthing connection is not always used. Furthermore, dust accumulations must beavoided since these could induce secondary explosions that are more threatening than the initialexplosion. 08.09 Protection of the cooling towers of the cooling installations During a production stop,the cooling towers basically containing a lot of plastic mate rial and well ventilated, are dry. In case of afire (caused e.g. by maintenance opera tions), these towers burn rapidly resulting in a businessinterruption for at least one week. It is therefore recommended to have either an extinguishing installationbuiltin (pref erably) or to have adequate procedures developed that in case of maintenance opera tionson or near these cooling towers, a fire water supply (either hydrants or hose reels) must be present (to beincorporated in the working permit). 08.10 Deficiencies regarding handheld fire extinguishers (missingunit / room TGBT 2) Since smaller deficiencies were observed during the site tour, they are listedhereafter: missing fire extinguisher on the mezzanine 3 powder extinguisher in the TGBT 2 to beremoved powder extinguisher to be installed on the welding post so that in case of an inci dent a fireextinguisher is always present7. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 7 08.11 Transformer stations: protection of and fire separation between the transfor mersThe site has 2 transformer stations: one containing 2 transformers, the other contai ning 4 transformers.All transformers are equipped with temperature monitoring with automatic shutdown and are situated ona retention pit. Since a fire or an explosion of a transformer will seriously damage all other transfor mersin the room, following safety precautions must be taken: have a Buchholzrelais with automatic shutdown installed on each transformer (this was not checked during the survey) have a brick wall installedbetween the transformers so that each transformer is situated in its own “cell” make sure that the retentionpit is also split per cell so that burning oil can not flow to the other cells 08.12 Sprinkler protection At thismoment, only the warehouse is equipped with automatic sprinkler protection. Due to the type of materialstored combined with the storage configuration and the storage height, the installation is no longeradequate and can not control the fire as it is expected to do. The production area housing the hightestvalues and being critical for business inte rruption is left completely unprotected, which is from a firesafety point of view not ac ceptable due to the high exposure. The only way of adequately protecting thesite against a fire, is to have automatic sprinkler protection installed in all areas. For the design criteria,either NFPA / FM guidelines or the european CEA 4001 (edi tion 2006) can be followed. As example,the minimum design criteria according to CEA 4001 are listed: offices and technical rooms: OH3 with 5mm over 216 m² 1 sprinkler per 12 m² production: HHP1 with 7,5 mm over 260 m² 1 sprinkler per 9m² (this depends on the storage height of the goods and must be confirmed when a detailed stu dy ismade) warehouse: ESFR K25 at 3,5 bar (12 sprinklers) – 1 sprinkler per 9 m² If the FM guidelines areapplied, densities are as follows: offices and technical rooms: 6 mm over 185 m² 1 sprinkler per 12 m²production: 12 mm over 230 m² 1 sprinkler per 9 m² warehouse: ESFR K25 at 3,5 bar (12 sprinklers) –1 sprinkler per 9 m² The engineering department of HDIGerling Industrie Versicherung AG is able toassist you in the sprinkler project. Please do not hesitate to contact our services.8. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 8 08.13 Protection of the propane gas cylinder A 7.300 l propane gas cylinder with fillingstation is situated at some 20 m away from the buildings. It was observed that this cylinder is standing ona small concrete floor, with grass around. Since a fire under or near the bottom of this cylinder can invokean explosion, it is re commended to have the gas cylinder equipped with a cooling system (grid aroundthe top of the cylinder with open sprinkler heads) that can either be activated from safe distance or that isactivated by a flame detector (preferably). Furthermore, it is recommended to have blocks used to fix theposition of the filling truck (and also the forklift trucks that come to fill) in order to avoid an incident incase the handbrake would fail or is not used. This should be included in the safety pres criptions. 1.3.2.List of Priority No. Short Description Priority* 08.01 Reevaluation of the alarm procedures A 08.02Lighting installations: use of safety starters D 08.03 Control on mobile and household electric equipmentC 08.04 Annual control of the smoke and heat release systems D 08.05 Housekeeping in the server room(ITdepartment) B 08.06 Business contingency planning – development of corporate loss controlguidelines D 08.07 Fire separation B 08.08 ATEXdirective and explosion protection document A 08.09Protection of the filter units of the cooling installations D 08.10 Deficiencies regarding handheld fireextinguishers C 08.11 Transformer stations: fire separation between the transformers C 08.12 Sprinkler
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protection A 08.13 Protection of the propane gas cylinder A *Evaluation of the measures (priority)Measures to be taken to prevent/eliminate/reduce a Measures a lifethreatening situation at present and/ora high probability of an occurrence of loss and/or an extreme high dimension of loss and/or a violation ofobligation / non fulfilment of official demands b Measures a medium probability of an occurrence of lossand/or a high dimension of loss c Measures a not insignificant dimension of loss d Measures best practice9. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 9 2. General Description Nature of business The site is involved in the manufacturing ofmonolayer PET preforms used in the food industry for packaging of food and liquids and in the cleaningproducts industry for packaging of detergents etc. The site was originally built by the company BallPackaging Europe for the manufacturing of cans for the food industry. In 1989, the buildings were splitand the manufacturing of preforms started at that time for Amcor PET Packaging France. In 2007, theAmcor group was acquired by the Spanish group La Seda de Barcelona. Today, about 1,8 billionpreforms are manufactured annually using 20 injec tionmoulding machines (with in total 50 moulds).The total capacity is some 2 to 2,1 billion preforms. The major clients are CocaCola (with a nextdoorproduction plant), NestléWaters, Unilever, ColgatePalmolive and Délifruits. The site houses aproduction area, an adjacent warehouse area and 2 office blocks of which one is housing some technicalrooms. The total site area occupied by Artenius is about 33.000 m², of which 14.885 m² is built area.Location The site is located in an industrial area, close to the village of Bierne in the northwest of France.Picture 1 gives an aerial overview of the area. Picture 2 gives an aerial overview of the site.Neighbourhood The Ball Packaging site is situated adjacent to the warehouse building. Furthermore, thesite is surrounded by agricultural land and the CocaCola company situated at more than 30 metres away.Employees About 103 people are employed on this site. Working Hours The site operates in a 5shiftsystem, with 12 people per shift. Maintenance operations take place during the annual production stop atChristmas time, in a dayshift system only.10. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 10 EQUIPE D’INTERVENTION INCENDIE Motorway A25 Lille Dunkerque BallPackaging Picture 1: Global site overview Picture 2: Artenius PET Packaging Europe buildings11. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 11 3. Industrial Process 3.1. Production Process Description The production process startswith the delivery of the raw material, being PET resins. These are delivered by truck and stored in 16outdoor silos, with the total storage ca pacity being 1.336 tons. 8 different types of resins are used, on anannual basis some 54.000 tons are processed. Earthing connection points are installed and mostly used,interlocks are not present. From the silo’s, the resins are transported to the drying units through a mixingstation by means of vacuum transport. In the mixing station, recycled material is added. Both the mixingstation as the drying units are installed on 3 mezzanines, situated above the injection moulding machines.For the transport of resins, mainly steel flexible connec tions are used. When using plastic flexibleconnections, no measures are taken to avoid static electricity. The drying units (with a capacity from3.000 up to 10.000 l) are heated electrically, equipped with a temperature monitoring system and singlethermostatic protection. The temperature is about 170 degrees Celsius. From the drying unit / hoppers, theresin is fed to the injection moulding machines, with adding of colours (either solid or liquid) on top ofthe machine. The injection moulding process takes place at about 285 degrees Celsius, with the machinesheated electri cally. There are 20 injectionmoulding machines (make Husky), 14 with a clamping forceof 300 t, 1 with a clamping force of 500 t and 5 with a clamping force of 600 t. The oil reservoirs containsome 1.500 l up to 2.000 l hydraulic oil, the operating pres sure exceeds 100 bar. The flexibleconnections are checked every 5 and every 10 days and replaced whenever needed. There is no detectionsystem for small leakages, emergency shutdowns are present on each machine and there is a generalemergency shutdown for the entire plant. The preforms (about 6 million per day) are in every machinetransferred to a robot plate where they are cooled down using an icewater circuit at 6 degrees Celsius,and packed in metal boxes. These boxes are stored in the warehouse that has a storage capacity of 7.600boxes. From there, the preforms are shipped to the clients, situated mainly in France (60 %) but also inGreece, UK, The Netherlands and Belgium (mainly CocaCola). An external warehouse (about 6.000 m²)is also used for the storage of finished products in order to meet the seasonal activity. The control andhandling is done by an external company. A grinding unit is situated in a separate, not fireproof room in
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the warehouse building. The grinder has no specific protection, but a permanent magnetic separator isinstalled on the feeding line.12. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 12 3.2. Production Flow Chart13. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 13 3.3. Specific Process Hazards The following table describes the general risk potentialshown in the flow chart as squares. These hazards could in general occur in this type of production apartfrom the current protective measures for the company. R= Recommendation number Risk PotentialProperty R B Battery charging units are potential sources of ignition and explosion. During charginghydrogen and oxygen can be produced! N.A. BL Large accumulations and high piled storage offlammable and combustible materi als (more than 0.7 t/m²) in conjunction with combustible packing andcontainers, e.g. PP trays / bins and pallets, can lead to a rapid spread of fire. 08.12 CP Fire risk associatedwith the use of oil in (screw) compressors. 08.12 EI Faults in electrical installation(s) are one of the mostfrequent causes of fire. Igni tion occurs by overheating/shorting due to damaged cable, defectiveequipment, electromagnetic incompatibility or faulty controls. Ex2 Danger/Risk of fire and explosioncaused by ignition of combustible or self ignitable dust. 08.08 ExL Risk of explosion caused by leakagein pipes, gas cylinders or seals at furnaces, ovens, burners and gas houses. F Film shrinkwrap units arepotential sources of ignition. N.A. HS Leaking flammable materials can be ignited by hot surfaces(usually > 300°C). Hot surfaces can also be produced by steam (> 30 bars). HT Heat transfer oils areoften used for heating of vessels, reactors and extruders if steam is not available or acceptable. Workingtemperature can exceed 300 °C and in the event of leakage, released oil or oil vapour can ignite. N.A HYLubricants and hydraulic oils are used within mechanical equipment. Pumps can either be dedicated to asingle machine or form a centralised station. In the event of leakage from the pipework or connections theoil can form a flammable mist. 08.08 O Danger/Risk of voltage spikes caused by lightning stroke, shortcircuit or electrical switching causing damage to electrical equipment, switch or control rooms. TO Firein oil filled transformers possibly caused by overloading of the transformer (capacity in relation torequirements). 08.11 WS Danger of water and soil contamination Note: N.A.: not applicable14. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 14 3.4. Result of the HGST Grading System The figure shows the result of the GerlingGrading System. The evaluation has been done on the basis of the survey. held covered Risk Evaluationon Company: ARTENIUS PET PACKAGING EUROPE Works/Place: Bierne 05/03/08 Unit:ARTENIUS PET PACKAGING EUROPE RMOrderNo: 680021/08 Points Max. Points PrecentProcess safety 27.9 40 69.8% Fire protection 10.3 20 51.5% Organisation 36.6 40 91.5% Total evaluation74.8 100 74.8% 69.8% 51.5% 91.5% 74.8% 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0%80.0% 90.0% 100.0% Process safety Fire protection Organisation Total evaluation15. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 15 4. Building Description, Stores Complex I /Area I / Building No 1 (see layout plan)Building No. 1 Office building with meeting room, restroom and social rooms Noncombustible buildingwith moderate fire load, equipped with automatic fire detection and handheld fire extinguishers. Thebuilt area is approximately 350 m² (single floor) Building No. 2 Office building, with social rooms,canteen, high and low voltage room, technical room (air compressors, cooling compressors with pumpsta tion, …) Noncombustible building with moderate fire load, equipped with automatic fire detectionand handheld fire extinguishers. The kitchen has no special protection, a small frying installation ispresent. The server room, situated in the middle of this building, has an automatic gas extinguishinginstallation using FM 200. The fire load in this room is high, with the room used as storage area (seerec’s). The built area is approximately 1.250 m² (single floor). The wall between this building and theproduction area is a fireproof wall, equipped with selfclosing fireproof door and 1 fireproof dooractivated by fusible link or fire detection. Building No. 3 Production building with production offices,maintenance area and mould cleaning area; including 3 mezzanines The building was erected using anunprotected steel frame. It has a steeldeck roof with mineral wool insulation and a roofing on top. Theexterior walls are composed of a double steel sheeting with polyure thane foam insulation. It is equippedwith a manual smoke and heat release system and has hose reels as well as an adequate number of handheld fire extinguishers. The mezzanines are made of steel sheet ing. This building has a built area of4.615 m². The wall towards the warehouse building is made of concrete panels and should have a fire
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resistance of 2 hours. The steel structure has been coated with a fire retardant product, although damagehas been observed. Storage Areas With exception of the boxes being filled with the PET preforms, thereis no storage. Building No. 4 Warehouse building with maintenance storage area, battery charging zonefor the robots, grinding room, high and low voltage room and tech nical room (housing the coolingcompressors) The building was erected using an unprotected steel frame. It has a steeldeck roof withmineral wool insulation and a roofing on top. The exterior walls are composed of double steel sheetingwith polyure thane foam insulation. It is equipped with a manual smoke and heat release system, anautomatic fire detection system and an inadequate sprinkler system. Furthermore, an adequate number ofhandheld fire extinguishers is spread over the area and there are 12 hose reels. The grinder is housed in aroom with steel sheeting. The battery charging area is an open area. The other technical rooms arefireproof rooms (concrete and bricks, with fireproof doors). Storage Areas The finished products arestored either in metal boxes or in cardboard boxes, in a block storage configu ration with a storage heightof 5 tiers (some 6 metres). The building itself is higher than 12 metres. The fireproof wall between thewarehouse and the neighbour is made of concrete bricks and has a fire rating of 2 hours. The fireproofdoors (3) are blocked in closed position and equipped with an alarm switch in case they would be opened.No deficiencies were observed.16. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 1617. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 17 5. Technical Data Power Supply Electricity is supplied through 2 underground 20 kVfeeding lines. There are no emergency power generators on site. A lightning protection is present on thesilos with 1 extra on the building, including a counter. The low voltage installations are centralised in 2rooms, each being a fireproof room equipped with an automatic gas extinguishing installation. Theelectrical installations are checked annually by a certified company. Also a thermographic analysis isdone on an annual basis. Mobile and household electric equipment is not checked, there are no guidelinesfor this equipment. Transformer Stations In total, there are 6 transformers, each with a capacity of 2.000kVA. All transformers are oil cooled and equipped with a temperature monitoring system. The first levelsounds an alarm, the second level shuts down the transformer. 4 transformers are situated in a single roomnext to the office block, the other are situated in a technical room in the warehouse. The rooms arefireproof and equipped with automatic fire detection. An oil analysis takes place on an annual basis, athermographic scan is also performed. About 85 % of the capacity is used. Water Supply Water issupplied through 1 feeding line, with a section of 150 mm. The pressure is about 4 bar. Cooling Water,Process Water For cooling purposes, a closed loop system is in force with chilled water (6 degreesCelsius). 2 cooling groups are situated next to the ware house building, with their cooling tower. 7 moregroups are situated on top of the technical room next to the office building. The 2 cooling tow ers aresituated next to the raw material silo’s. Freon R22 or R134 is used as a coolant. There is no specificprotection for the cooling towers in case of production shutdown. Compressed Air In a fireproof room,next to the production building, there are 6 screw type air compressors (4 x Atlas Copco GA90 FF, 1 xAtlas Copco GA90 VSD FF and a compare). The operating pressure is 12 bar. The compressor room isequipped with automatic fire detection, a hose reel is present in the room. Flammable Liquids or GasesThe flammable liquids used (e.g. degreasers, …) are adequately stored in safety cabinets (in themaintenance warehouse situated in the ware house building as well as one in the production building).Safety cans are in use. Combustible liquids (oils, …) are stored outdoor in dedicated containers situated atmore than 20 metres away from the buildings. For the forklift trucks, a propane gas cylinder with acapacity of 7.300 litres and filling station is situated at about 20 metres away from the productionbuilding. The pressure is 5 bar. Technical Gas Not applicable18. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 18 Heating Systems, Boilers, Steam, Heat transfer oil The production area as well as thewarehouse area can be heated using electrical heating units (hot air generators). The offices also have anelectrical heating system and an air conditioning system on the chilled water circuit. Waste water Notapplicable Filter Systems Dust filter systems are present on the hoppers, there are no special protectiondevices installed. 5.1. Machinery Breakdown Listing of important machines and equipment There are 20injection moulding machines, make Husky. Every unit has its mainte nance schedule. Generalmaintenance Once per year, there is a production shutdown that allows preventive maintenance. The
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maintenance is done according to fixed schedules, with a series of maintenance jobs done regularly (5daily, 10daily, …). The maintenance department (18 people) operates in a 5shift system. Spare partsSpare parts are stored in a separate maintenance warehouse situated in the main warehouse (630 m²).There are about 2.500 listed references with a value of some 400.000 Euro. Evaluation of machinery Allmachinery and equipment was found in a good state.19. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 19 6. Fire Protection Fire Alarms A general warning system is in force, with push buttonsspread over all areas. They are connected to the control panel of the automatic fire detection installationwith the alarms wired to the guards with additional display in the production area and in the team leader’soffice. Automatic Fire Detection An automatic fire detection system was installed in the warehouse, inthe office buildings and in the technical rooms (Desautel – Cerberus Siemens). The installation is checkedtwice per year. Each detector has its own address, appearing on the panels. Alarms are wired to the guardswith additional display in the production area and in the team leaders’ office. Smoke and Heat VentingSys tems A manual smoke and heat release system is present in all buildings. The operating panels aresituated near the emergency exits. Until some years ago, maintenance was done on an annual basis buthas not been done since 2005. Hand Extinguishers An adequate number of handheld fire extinguishers ispresent in all areas. Powder, water and CO2 extinguishers are used, listed and num bered. They areannually checked (last check in April 2007). Fire Water Reservoir There are no firewater reservoirs, withexception of the sprinkler reser voir (owned by Ball Packaging). Fire Water Supply There is no separatefire water supply. Fire Hoses Fire hoses are present in all areas and are fed by the public grid, with aseparate control valve on a 100 mm pipe. These are checked annually (last check in April 2007). FireHydrants There are 3 underground hydrants (with equipment in a box) situated around the buildings, on a150 mm main supplied by the public grid. 4 more are situated on the site. It could not be confirmed if thesystem is a closed loop system. Sprinklers Automatic sprinkler protection is only present for thewarehouse build ing. The installation was built in 1995, by Ball Packaging. The system is connected tothe Ball pump installation and the water reservoir. No information could be obtained about the testing,pump capacity and other design criteria. There are 2 control valves (6”), each for a warehouse section.The design criteria are 18,3 l/min over 186 m² (3.607,4 l/min and 3.766 l/min) at a pressure of 4,849 barfor the one valve and 6,028 bar for the other one. This is with the current stored products and storageconfiguration inade quate. Once per month, an endofline test is performed. Foam systems Notapplicable20. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 20 Inert Gas Extinguishing Sys tems For the 1 st low voltage distribution room, anautomatic extinguishing system with CO2 was installed. For the 2 nd room, nitrogen was used. Bothinstallations are activated by an air sampling system and include the raised floors. These installations areannually checked. Other fire suppression systems An FM 200 extinguishing system was installed in theserver room (instal lation Siemens), activated by smoke detection in the room. The system is checkedannually.21. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 21 7. Organisation and Safety Management Type Remarks Public fire brigade The public firebrigade is the volunteer fire brigade of Bergues, situated at some 3 km resulting in a response time of atleast 10 minutes. The nearest professional fire brigade is the fire brigade of Dunkerque, situated at some12 km resulting in a response time of at least 15 minutes. Fire prevention safety officer Artenius has itsown fire safety responsible (Mr. Descarpentries), having an own safety budget and taking care of allsafety aspects. Private fire brigade A first intervention team consists of at least 4 people per shift. Duringdaytime, there are 4 people more. Fire safety manual, emergency plan Emergency plans are partlyavailable, intervention plans and evacuation plans were made in the past and are updated when evernecessary. Some items need improvement (e.g. fire water supply systems). Fire fighting exercise Atraining for the intervention team is organised on an annual basis and includes alarm procedures, use offire fighting equipment and extinguishing installations as well as the procedures for waste fire fightingwater retention (in total 900 m³). Safety work information/instruction Safety instructions arecommunicated to the workers, temporary people, third parties and visitors. For new people and thirdparties, this takes about 1 hour, including a registration. Written hot work permit, other permits A writtenhot work permit form is in use and well applied including control rounds and signoff procedures. Also
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the guards are in formed when hot works take place. In case the automatic fire detection is to be shutoffto avoid false alarms, no special proce dures are applied. Non smoking areas The site is entirely nonsmoking. There are 2 smoking corners (one near the entrance and one near the restroom), with ashtrays.Housekeeping The housekeeping was found to be at good level. Certifications The site benefits an ISO9001 certificate. Shift Handover Information There is a formal shift handover procedure, with an overlapof at least 15 minutes for the team leaders. Startup / Shut – down procedures Yes, although this is quiteeasy for this type of activity. Management of Change Not applicable Contingency / reconstruction planNo – will be studied on group level in the coming years. Protection of the area The site is completelyfenced, with climbing protection. There is a guard on site (1 person per shift) taking care of the accesscontrol. This team also takes care of the safety instructions for visitors and third parties. Furthermore,there is a camera guarding system with the images recorded and checked by the guards. The entire sitealso benefits an outdoor lighting system, activated by shimmering sensors. Intruder alarm systems Thereare no intruder alarm systems. Security patrol The guards perform regular control rounds outside thebuildings, the alarms are transferred from the gatehouse when they are on tour.22. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 22 8. Risk analysis Business Interruption 8.1. Basic data Rough Evaluation of GrossEarnings/Income at risk: Turnover p.a. 100.000.000 € + ./. Change in stock + ./. € ./. cost of rawmaterials, energy, freight (variable costs) ./. € Gross Earnings (=Profit + fixed costs) € Seasonal Business:yes. During the first and the second quarter, the production runs at full capacity. In the third quarter, theproduction is slowed down and in October and November the production takes place with 16 or 14injection moulding machines. There is one week production stop at Christmas. The EBITDA was told tobe 7 million Euro in 2007. 8.2. Business Exposure Each of the machines takes care of a part of the totalproduction, with a lot of machines being capable of taking over part of the production in case the mouldsare available. The difference between machines is caused by the number of cavities. 8.3. Specificbottleneck units. Protection Measures It was announced that there are no specific bottlenecks on themachines. The mixing unit can be a bottleneck, but there is some deviation possibility within thecompany us ing the other mixing units. 8.4. Interdependencies There are no other sites within the groupthat depend on the production of Bierne. For the delivery of raw materials, there is a dependency onArtenius Advance in the UK since this is the biggest supplier. Alternatives are present, but this has to beapproved by the client. There is a spare capacity of 0,2 billion units per year, this of course is an actualsitua tion and can change. 8.5. Essential internal/external Suppliers and Customers 8 different types ofPET resins are used, for which there are 5 suppliers. For some of the used resins, there is only 1 supplierat this moment, but this can be changed within short period of time but only after approval of the client.Most of the suppliers have several production sites. The average stock should tackle a minimum of 3 dayspro duction.23. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 23 For the colours, there are several suppliers. Packing materials do not pose any problem.The customers are in order of importance: CocaCola (50 %) – sites in France, Belgium and TheNetherlands Unilever Colgate – Palmolive Délifruits Lessieur NestléWaters CadburySchweppes Thefirst 4 clients represent 80 % of the turnover. 60 % is generated by sales on the local market (France), 40% is export (UK, Greece, The Netherlands, Belgium). The PETpreforms are shipped by truck, with eachmetal box representing some 350 Euro. There is a stock of finished products for at least 2 weeks (2 to 3weeks is an average). The value of the raw materials on site is about 1,6 million Euros, the value of thefin ished products is about 3,7 million Euros. The volumes manufactured were: 1,7 billion in 2006 1,8billion in 2007 forecast 2008: 1,830 billion24. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date ofsurvey Page 24 9. Other Perils Flood Limited hazard, a “flood plan” was developed in the past years inorder to tackle water coming from the higher positioned site of CocaCola Lightning Medium hazard,about 2 – 6 strikes per km²/year Volcanism No hazard Storms/Hail High to very high hazard – thebuildings were designed to withstand high velocity wind storms, there are no sheds or canopies Nature ofsubsoil No details available Earthquake (CRESTA ZONE) Zone 1 (MM VI) Collapse (incl. snowloading) Limited hazard Landslide / Avalanche Limited hazard Sprinkler/Water Leakage Applicable inthe warehouse area Vicinity to Airports There are no airports situated near the site, the closest is theregional airport of Lille, situated at about 70 km Riot / Civil Commotion/ Sabo tage/Terrorism/
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Vandalism Limited hazard, no loss experience in the past 10. Loss History In 1997, a fire incidentoccurred in an electrical room. After this fire, automatic extin guishing installations were installed inboth electrical rooms. No other losses have occurred. 5 th of March 2008 H D I G E R L I N G IndustrieVersicherungsAG Sicherheitstechnik GmbH Glenn van Mele
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