2031ZA19R00001_(draft).pdf

SOLICITATION, OFFER AND AWARD 1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

RATING PAGE OF PAGES

2. CONTRACT NUMBER 3. SOLICITATION NUMBER 4. TYPE OF SOLICITATION 5. DATE ISSUED 6. REQUISITION/PURCHASE NUMBER

CODE7. ISSUED BY 8. ADDRESS OFFER TO (If other than item 7)

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

9. Sealed offers in original and copies for furnishings the supplies or services in the Schedule will be received at the place specified in item 8, or if hand carried, in the depository located in until local time

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and conditions contained in this solicitation.

10. FOR

INFORMATION

CALL:

A. NAME B. TELEPHONE (NO COLLECT CALLS)

AREA CODE NUMBER EXTENSION

C. E-MAIL ADDRESS

11. TABLE OF CONTENTS

(X) SEC. DESCRIPTION PAGE(S) (X) SEC. PAGE(S)DESCRIPTION

A B C D E F G H

I

J

K

L

M EVALUATION FACTORS FOR AWARD

INSTRUCTIONS, CONDITIONS, AND NOTICES TO OFFERORS

REPRESENTATIONS, CERTIFICATIONS AND OTHER

STATEMENTS OF OFFERORS

PART IV - REPRESENTATIONS AND INSTRUCTIONS

LIST OF ATTACHMENTS

PART III - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACH.

CONTRACT CLAUSESSOLICITATION/CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/COSTS

DESCRIPTION/SPECS./WORK STATEMENT

PACKAGING AND MARKING

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

CONTRACT ADMINISTRATION DATA

SPECIAL CONTRACT REQUIREMENTS

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

OFFER (Must be fully completed by offeror)

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments to the SOLICITATION for offerors and related documents numbered and dated):

10 CALENDAR DAYS (%) 20 CALENDAR DAYS (%) 30 CALENDAR DAYS (%) CALENDAR DAYS(%)

DATEAMENDMENT NO.AMENDMENT NO. DATE

15A. NAME AND

ADDRESS

OF OFFER-

OR

CODE FACILITY 16. NAME AND THE TITLE OF PERSON AUTHORIZED TO SIGN OFFER

(Type or print)

15B. TELEPHONE NUMBER

AREA CODE NUMBER EXTENSION

15C. CHECK IF REMITTANCE ADDRESS IS

DIFFERENT FROM ABOVE - ENTER SUCH

ADDRESS IN SCHEDULE.

17. SIGNATURE 18. OFFER DATE

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL OPEN COMPETITION:

10 U.S.C. 2304 (c) ( )41 U.S.C. 3304(a)

24. ADMINISTERED BY (If other than Item 7)

26. NAME OF CONTRACTING OFFICER (Type or print)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

AUTHORIZED FOR LOCAL REPRODUCTION

Previous edition is unusable

23. SUBMIT INVOICES TO ADDRESS SHOWN IN

(4 copies unless otherwise specified)

25. PAYMENT WILL BE MADE BY

27. UNITED STATES OF AMERICA

(Signature of Contracting Officer)

28. AWARD DATE

CODE

ITEM

STANDARD FORM 33 (REV. 6/2014)

Prescribed by GSA - FAR (48 CFR) 53.214 (c)

SEALED BID (IFB)

NEGOTIATED (RFP)

(Hour) (Date)

PART I - THE SCHEDULE PART II - CONTRACT CLAUSES

1 127

See Box 7

2031ZA

Bureau of Engraving and Printing 301 14th Street, SW, Washington, DC 20228

2031ZA19R00001

via email 12:00PM

Frederick Porter frederick.porter@bep.gov

77 122

11/20/2018

202 8742707

10/02/2018

DRAFT

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SECTION B – SUPPLIES OR SERVICES AND PRICES/COSTS

The Contractor shall provide facilities, labor, materials, fabrication, assembly, delivery, and all other efforts necessary for a turn-key installation and operation of Single Note Inspection Finishing System (SNI) machines in accordance with Section C of this document, for the Bureau of Engraving and Printing (BEP).

This requirement will result in a firm fixed price contract for new equipment. Contractor shall provide one (1) Single Note Inspection Finishing System (SNI), with the option to purchase up to three (3) additional SNIs. Offeror is required to submit, at a minimum, an offer that conforms to the solicitation specifications with pricing for all Contract Line Item Numbers (CLINs). Contractor shall price each individual CLIN on a firm fixed price basis. Failure to submit an offer which conforms to the solicitation specification may render the proposal unacceptable. The Government will negotiate payments based on the deliverable schedule submitted by the Contractor and agreed to by the Government.

SNI#1

CLIN SUPPLIES/SERVICES QTY UNIT OF

MEASURE

UNIT PRICE AMOUNT

0001 SNI1 (DCF) 1 EA $__________ $___________

0002 FIT AND DEMOSTRATION

MATERIALS

1 EA

0003 SPARE PARTS 1 NTE $1,000,000.00 $1,000,000.00

0004 CENTRALIZED BAGGING &

BRIQUETTING SYSTEM - BASE

1 EA $__________ $___________

0005 OFFLINE TEST STATION 1 EA $__________ $___________

0006 AUTOMATIC CUTTING

ADJUSTEMENT

1 EA $__________ $___________

0007 UV INSPECTION CAPABILITY 1 EA $__________ $__________

0008 NARROW BAND IR INSPECTION

CAPABILITY

1 EA $__________ $__________

0009 HIGH RESOLUTION INSPECTION

CAPABILITY

1 EA $__________ $__________

0010 MAGNETIC INSPECTION CAPABILITY 1 EA $__________ $__________

0011 SPECIAL SENSOR INSPECTION 1 EA $__________ $__________

0012 Travel – DCF The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

1 NTE $74,000.00 $74,000.00

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OPTIONAL SNI#2

CLIN SUPPLIES/SERVICES QTY UNIT OF

MEASURE

UNIT PRICE AMOUNT

1001 SNI FINISHING SYSTEM (CUTTING-

SNI-PACKAGING) #2 (WCF)

1 EA $__________ $__________

1002 FIT AND DEMOSTRATION

MATERIALS

1 EA $__________ $__________

1003 SPARE PARTS 1 NTE $1,000,000.00 $1,000,000.00

1004 CENTRALIZED BAGGING &

BRIQUETTING SYSTEM - BASE

1 EA $__________ $___________

1005 OFFLINE TEST STATION 1 EA $__________ $___________

1006 AUTOMATIC CUTTING

ADJUSTEMENT

1 EA $__________ $___________

1007 UV INSPECTION CAPABILITY 1 EA $__________ $__________

1008 NARROW BAND IR INSPECTION

CAPABILITY

1 EA $__________ $__________

1009 HIGH RESOLUTION INSPECTION

CAPABILITY

1 EA $__________ $__________

1010 MAGNETIC INSPECTION CAPABILITY 1 EA $__________ $__________

1011 SPECIAL SENSOR INSPECTION 1 EA $__________ $__________

1012 SPARE BANDER TEST STAND 1 EA $__________ $__________

1013 Travel – WCF The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel

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OPTIONAL SNI#3

CLIN SUPPLIES/SERVICES QTY UNIT OF

MEASURE

UNIT PRICE AMOUNT

2001 SNI FINSIHING SYSTEM (CUTTING

SNI PACKAGING) #3 (DCF)

1 EA $__________ $__________

2002 FIT AND DEMOSTRATION

MATERIALS

1 EA $__________ $__________

2003 SPARE PARTS 1 NTE $1,000,000.00 $1,000,000.00

2004 CENTRALIZED BAGGING &

BRIQUETTING SYSTEM - BASE

1 EA $__________ $___________

2005 OFFLINE TEST STATION 1 EA $__________ $___________

2006 AUTOMATIC CUTTING

ADJUSTEMENT

1 EA $__________ $___________

2007 UV INSPECTION CAPABILITY 1 EA $__________ $__________

2008 NARROW BAND IR INSPECTION

CAPABILITY

1 EA $__________ $__________

2009 HIGH RESOLUTION INSPECTION

CAPABILITY

1 EA $__________ $__________

2010 MAGNETIC INSPECTION CAPABILITY 1 EA $__________ $__________

2011 SPECIAL SENSOR INSPECTION 1 EA $__________ $__________

2012 Travel – DCF The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel

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OPTIONAL SNI#4

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

3001 SNI FINISHING SYSTEM

(CUTTING-SNI

PACKAGING) #4 (WCF)

1 EA $__________ $__________

3002 FIT AND DEMOSTRATION

MATERIALS

1 EA $__________ $__________

3003 SPARE PARTS 1 NTE $1,000,000.00 $1,000,000.00

3004 CENTRALIZED BAGGING

& BRIQUETTING SYSTEM -

BASE

1 EA $__________ $___________

3005 OFFLINE TEST STATION 1 EA $__________ $___________

3006 AUTOMATIC CUTTING

ADJUSTEMENT

1 EA $__________ $___________

3007 UV INSPECTION

CAPABILITY

1 EA $__________ $__________

3008 NARROW BAND IR

INSPECTION CAPABILITY

1 EA $__________ $__________

3009 HIGH RESOLUTION

INSPECTION CAPABILITY

1 EA $__________ $__________

3010 MAGNETIC INSPECTION

CAPABILITY

1 EA $__________ $__________

3011 SPECIAL SENSOR

INSPECTION

1 EA $__________ $__________

3012 Travel – WCF The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

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SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF NEED

C.1 STATEMENT OF NEED

This Statement of Need (SON) is for the design, fabrication, assembly, integration, delivery, installation, set-up, testing, commissioning and training of one (1) SNI Finishing System that will convert previously printed sheets into finished currency. A SNI Finishing System shall consist of the ability to cut stacks of sheets into individual notes, inspect and sort notes against quality standards via integrated Single Note Inspection (SNI) machines, shred defective notes and package acceptable notes for shipment. The SNI Finishing System is anticipated to incorporate two (2) SNI machines.

The SNI Finishing System shall accept the stacks of 100 sheets, cut the stacks of sheets into individual notes, examine individual notes against quality standards, sort notes by the inspection results, shred defective notes and package acceptable quality notes for shipment. Currency produced by the system shall meet the Quality Standards of the BEP for the denominations processed. Notes and their packaging produced on the SNI Finishing System shall have the same appearance and forensic characteristics as notes and packages currently produced on the Currency Overprinting and Processing Equipment, Packaging (Cope-Pak) and Large Examining Printing Equipment (LEPE) machinery. The system shall utilize BEP existing consumable materials.

The first system will be installed at the BEP’s Washington, DC Currency Facility (DCF). Optional systems will be installed at either the Western Currency Facility (WCF) located in Fort Worth, Texas or in Washington, DC. Options for additional machinery, spare parts and FIT/Demonstration materials are included.

A critical characteristic of the system is the capability to identify and track the serial numbers of every note processed. The SNI Finishing System shall have an integrated data collection system that shall ensure absolute accountability of every note and shall be able to identify the serial number of every note packaged into Straps, Bundles and Cash-paks by package identification numbers. Integration with a BEP database for the tracking of the serial numbers by package shall be provided as part of this contract.

C.2 REFERENCES

The following are referenced under this contract; Documents, Government Furnished Materials (GFM) and Product Requirements. The equipment and services to be provided under this contract shall abide by the requirements of these referenced materials.

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C.2.1 DOCUMENTS

C.2.1.1 Non-Disclosure Agreement

During the course of this contract, the contractor will require sensitive but unclassified information that is proprietary to the United States Government. A Non-Disclosure Agreement (NDA) shall be signed and notarized as part of the submission package for consideration, Attachment 023.

The notarized agreement shall be returned to:

Bureau of Engraving and Printing Office of Acquisitions, Room 705-A 14th and C Sts, SW Washington, DC 20228 Attn: Fred Porter, Contract Specialist

C.2.1.2 Referenced Documents

Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industrial environment. At a minimum, all equipment shall conform to National Electric Code, NEC, standards.

The following is a listing of specific standards that machinery supplied under this contract shall meet:

• All applicable sections of American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org)

• All applicable documents related to Energy Policy Act of 1992 with specific reference to Executive Order 13123 (www.omb.gov)

• All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov)

• All applicable codes and standards and environmental permitting of U.S.

Environmental Protection Agency (EPA) (www.epa.gov) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

C.2.1.3 Attached Documents

The following lists the documents attached to this SON.

NOTE – Attachments identified with an asterisk (*) require a Non-Disclosure Agreement (NDA).

All NDA documents provided under this contract shall be considered proprietary and sensitive to the government. NDA documents shall not be copied, scanned or reproduced without written approval by the contracting officer. All NDA documents shall be returned to the BEP when no longer required.

http://www.acgih.org/ http://www.omb.gov/ http://www.osha.gov/ http://www.epa.gov/

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NOTE – Some documents will only be made available in redacted versions. Request to have copies of the original versions must be made to the Contracting Officer with information on why the information is required.

Identifier Title/Description 001 Paper Specifications* P: CDT5-1C Type V Currency Paper – 12Aug2015_abridged

P: CDT4-1B Type IV Currency Paper – 12Aug2015_abridged P: CDT1-B Type I Currency Paper – 12Aug2015_abridged P: NDBT5A NBP Type V – 12Aug2015_abridged P: NDBT4A NBP Type IV – 12Aug2015_abridged P: NDBT1A NBP Type I – 12Aug2015_abridged

002 Technical Requirements Data Sheet – Currency Pallets 003 Currency Pallet Drawing 55229BB 004 Paper Band Specification 005 Shrink-wrap Films Specification 006 BEP Label Specifications PSC-5 July27 2015 - Label Specification Drawing 30084 r1 - Cash-Pak Shipping Label Drawing 30085 - Cash-Pak Eagle Label 007 Drawing 30100 Strap of 100 Notes* 008 Drawing 30101 Bundle of 1000 Notes* 009 Drawing 30102 Brick of 4000 Notes* 010 Drawing 30083 Cash-Pak of 16000 Notes* 011 Cash-Pak Drop Test 012 Skid of 640000 Notes* 013 Load Tag Sample 014 SNI Finishing System Process Report 015 Site Drawing 016 IT Computer Attachments DOJ Ref Mapping PIVCard Certificates to a Privileged Account Open

Version FIPS-PUB-199-final NIST.SP.800-53r4 USGCB-Windows-Settings 017 75D-07.0-04 EHS Contractor Requirements 018 75D-07.0-06 EHS Requirements for Large Equipment Purchases 019 75D-07.0-07 Restricted Materials at DCF 020 Draft Test Plan 021 75W-08.0-02 EHS Boilerplate Requirements for Construction Services

Contractors

C.2.2 GOVERNMENT FURNISHED MATERIALS

The items listed in this section will be supplied by the government for utilization with the SNI Finishing System. Any other materials required for successful operation of the equipment shall be

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C.2.2.1 Currency Sheets

The SNI Finishing System shall accept previously printed currency sheets. Federal Reserve currency sheets are presently processed in multiple sheet sizes and formats.

32-subject $1s and $2s – 561 +/- 1 mm long by 631 +/- 1 mm wide (22.09 inches +/- 0.04” by

24.84 inches +/- 0.04”). The sheets are printed with thirty-two (32) images; four notes across the sheets by eight down the sheet. The sheets are face and back Intaglio printed.

32-subject $5s, $10s, $20s, $50s and $100s – 582 +/- 1 mm long by 657 +/- 1 mm wide (22.91 inches +/- 0.04” by 25.87 inches +/- 0.04”). The sheets are printed with thirty-two (32) images;

four notes across the sheet by eight notes down the sheet, and have color bars and other non-note printing within trim margins. The sheets are face and back Offset and Intaglio printed.

50-subject $1s – 700 +/- 1 mm long by 818 +/- 1 mm wide (27.56 inches +/- 0.04” by 32.20 inches +/- 0.04”). The sheets are printed with fifty (50) images; five notes across the sheets by ten down the sheet. The sheets are face and back Intaglio printed.

Specifications for the papers are provided as Attachment 001. The drawings of the skids are Attachment 002.

During the term of this contract, the size and format of currency sheets and the printing previously applied for a denomination may change. Sheets shall not be considered square due to the intaglio printing process. All sheet dimensions are for blank paper prior to printing.

Sheets will be supplied in a Process size batch for cutting, inspection, sorting and packaging. A Process will be made up of sheets from multiple loads. Process sizes vary, for 32 subject size sheets processes are 200,000 sheets or 100,000 sheets, depending upon denomination. For 50 subject size sheets, processes are 128,000 or 64,000 sheets. The BEP shall be able to specify any process size in 100 sheet increments.

C.2.2.2 Currency Skids

The SNI Finishing System shall utilize the existing BEP-FRB Currency Skids for the stacking of up to forty (40) cash-packs and stretch-wrapping in preparation for shipment to the Federal Reserve. The drawing of the skid is provided as Attachment 003.

C.2.2.3 Bands (Strap and Bundle)

The SNI Finishing System shall use the BEP’s spools of paper bands for application around the 100 notes to form a Strap and around the 10 Straps to form a Bundle. Strap bands are printed.

Bundle bands are plain unprinted bands. The specifications for the paper bands are provided as Attachment 004.

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C.2.2.4 Packaging Films (Bundle, Brick, Cash-Pak and Skids)

The SNI Finishing System shall use the BEP’s Bundle, Brick and Cash-Pak shrink-wrap films for the packaging of the notes. The Bundle film is a Linear Low Density Polyethylene (LLD-PE) material. The Brick film is a Polyvinyl Chloride (PVC) material. The Cash-Pak film is a LLD- PE material that has been printed and laminated. The specifications for the films are provided as Attachment 005.

The SNI Finishing System shall use the BEP’s stretch-wrap film for the wrapping of the skids of Cash-Paks after palletizing. The BEP’s stretch-wrap film specification is included in Attachment 005.

C.2.2.5 Labels (Bundle and Cash-Pak)

The SNI Finishing System shall use the BEP’s Labels for the Bundles and Cash-Paks. One label is applied to each Bundle that contains bar-coded information applied over the face of the Bundle.

Each Cash-Pak has two (2) labels applied, a shipping label that contains bar-coded information applied over the face and a BEP-FRB label that covers the window on the back of the Cash-Pak.

The specifications and drawings of the labels are provided as Attachment 006.

C.2.3 PRODUCT REQUIREMENTS

The following are the product requirements for currency produced by the system.

All currency and currency packages produced on the system shall have an identical appearance, forensic characteristics, durability and strength to existing currency and currency packages produced by the BEP.

C.2.3.1 Currency Notes

Federal Reserve Currency Notes shall have a nominal width of 156 mm +/- 2 mm (6.14 inches +/- 0.079”) with a nominal height of 66.5 mm +1.1/-2.5 mm (2.62 inches +0.043”/-0.098”).

Notes shall be cut so that the printed images are centered within +/- 1.5 mm of the centerline of the notes, taking into account the placement of the printed images on the sheet (Step and Repeat).

Notes may contain several previous printing operations as part of the design. Sheets and notes to be processed on the finishing system will contain serial numbers for each note.

Serial numbers for every note produced for a denominational series consisting of between ten (10) and twelve (12) alpha-numeric characters. The length of serial number varies by the denomination and design series. Current $1s and $2s contain a ten (10) digit serial number; where $5s - $100s contain an eleven (11) digit serial number. Future designs may require up to twelve (12) digit serial number. Serial numbers consist of one up to three prefix letter(s), eight numerals and one

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C.2.3.2 Straps

A Strap is one hundred (100) currency notes bound together face up, held together with a paper band. The paper band shall be tight enough to hold the notes together for processing and packaging. Position of the band on the Strap is shown on the attached drawing.

Strap

Straps contains 100 notes.

Strap are held together with 39.0 mm +/- 0.2 mm wide paper band.

Image on paper band may be registered around strap.

31.8mm 1.25"

39.0mm 1.535"

The Strap with paper band is shown in the attached drawing, Attachment 007. The appearance, strength and durability of the Straps produced on the system shall be identical to the existing Straps produced by the BEP.

C.2.3.3 Bundles

A Bundle is ten (10) Straps, one thousand (1000) notes, bound together face up, held together with a paper band, shrink-wrapped and labeled. All Straps within a Bundle shall be face up with every other Strap rotated 180°. A Bundle with paper band is shown in the attached drawing, Attachment 008. The paper band shall be tight enough to hold the Straps together for processing and packaging.

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Bundle

10 Straps, every other strap rotated 180'.

2 5/16" wide paper band applied around 10 straps, centered on bundle

58.7mm 2 5/16"

The Bundle shall be shrink-wrapped as a total enclosure package with plastic film. The film shall be shrink-wrapped tight around the Bundle without wrinkles. All edges of the film shall be sealed together. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The appearance, strength and durability of the Bundles produced on the system shall be identical to the existing Bundles produced by the BEP.

The wrapped package shall be labeled with unique labels designating the individual Bundles. The labels shall be applied over the top note. The font shall be “Impact” and the bar code shall be code

39. A bundle label with printed information is shown in Attachment 008.

Bundle with Label

Shrink wrapped in LLD-PE film, totally enclosed.

Bundle Label applied on face of bundle over shrinkwrap film.

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C.2.3.4 Bricks

A Brick is four (4) Bundles, four thousand (4000) notes, shrink-wrapped together. A Brick is shown in the attached drawing, Attachment 009. Only the two ends of the film need be sealed, the overlap of the film does not require sealing.

Brick

Four Bundles shrinkwrapped together in PVC Brick film.

Film is not sealed on overlap.

Bricks typically vary between 17" and 20" in length.

The package shall have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. All Bundles shall be face up within the Brick. The Brick wrapping film over the Bundle label shall not prevent scanning of the bar code on the Bundle label or reading of the information printed on the label.

The Brick film shall not fuse to the Bundle film. The appearance, strength and durability of the Bricks produced on the system shall be identical to the existing Bricks produced by the BEP.

C.2.3.5 Cash-Paks

A Cash-Pak is four (4) Bricks, sixteen thousand (16,000) notes, shrink-wrapped together using a polyethylene laminated film as a total enclosure package. The attached drawings show the Cash- Pak, including placement of the labels, Attachment 010. The system shall have the ability to handle up to 24 ½” long Cash-Paks.

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Cash-pak

Four Bricks to be packaged together as Cash-pak

All edges of the film shall be sealed together. The film shall be shrink-wrapped around the Cash- Pak tight without wrinkles. The package shall be tamper evident and have no holes other than holes within the film to allow air removal during the wrapping process. Air escape holes shall be no larger than 6.35 mm (¼”) diameter. The clear windows along the top and bottom of the Cash- Pak shall allow counting of the Straps paper bands contained within the Cash-Pak. Labels shall be placed over the clear windows at both ends of the package covering the currency within the package. The Cash-Pak film shall not fuse to the Brick film nor cause the Brick film to fuse to the Bundle film. The appearance, strength and durability of the Cash-Paks produced on the system shall be identical to the existing Cash-Paks produced by the BEP. The performance requirement for Cash-Paks, drop test, is Attachment 011.

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Cash-pak

Bricks shrinkwrapped together in LLD-PE Cash-pak film.

Film is sealed on all sides.

Regular Cash-pak film used; film color matches denomination.

Labels applied over window.

BEP-FRB Eagle Label applied to back of package

Cash-pak Shipping Label applied to front of package

XX####X

At operator initiation, a partial Cash-Pak at the end of a process to empty out the machine may be produced. The system shall be capable of either producing complete Cash-Paks with manual removal of any partials or producing a partial Cash-Pak at the end of a process. A partial Cash- Pak may contain 1 to 3 bricks and cannot meet the tightness of the film or wrinkle requirements.

Labels for partial Cash-Paks would be hand applied by the operator.

C.2.3.6 Skids

A skid is forty (40) Cash-Paks, six hundred forty thousand (640,000) notes, stacked and stretch-wrapped on a BEP provided currency skid. The Cash-Paks shall be stacked as shown in the attached drawing, Attachment 012. The appearance, strength and durability of the skids produced on the system shall be identical to the existing skids produced by the BEP.

C.2.3.7 Future Currency Designs

Changes to the design of the currency to be produced on the system is anticipated to change every seven to ten years; therefore the design of the system shall accommodate future changes to the images printed on notes and characteristics of the notes to be produced.

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C.3 SYSTEM REQUIREMENTS

The following are the requirements of the SNI Finishing System to be delivered to the BEP.

The SNI Finishing System shall consist of cutting, single note inspecting, and packaging components. The SNI Finishing System shall utilize the Government Furnished Materials (GFM) (C.2.2) and produce currency in accordance with the Product Requirements (C.2.3).

C.3.1 SYSTEM FUNCTIONALITY

The SNI Finishing System shall have the following functionality capabilities.

C.3.1.1 Safety Requirements (Mandatory Minimum Element)

All equipment delivered to the BEP shall be designed to minimize all risks of injury to BEP employees. All equipment shall be in full compliance with government and commercial safety and health regulations and requirements. The following are specific safety and environmental requirements for major production machinery for the BEP.

(A) General Safety:

Equipment shall be designed to prevent injury to operation and maintenance personnel at all times.

Equipment shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29CFR 1910.24, Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with ANSI and OSHA standards. Special attention shall be given in providing proper ‘angle of steps’ as indicated in paragraph (e) of the referenced standard. All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

The presses shall comply with ANSI Standard B65.1, Safety Standard-Printing Presses.

(B) Noise Level:

The maximum noise produced by the operation of the equipment at full production rate shall not exceed 85 decibels A-weighted sound level (85 dBA) when measured at 914 mm (3 feet) distance along the plan view of the equipment and at an elevation of 1,524 mm (5 feet). These noise level limits do not affect the warning horn levels described in C.3.2.3.

(C) Machine Guarding:

All covers and safety guards shall be interlocked with the equipment’s controls to prevent its operation while any cover or guard is open or absent. The location of opened switches shall be displayed on the Master Control Station. Only local jogging control at a reduced speed is allowable provided no other covers are opened or removed. Covers and guards shall be manufactured for easy removal by Bureau personnel to facilitate removing mechanical and electrical parts for repair.

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All rotating and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR

2910.212. All equipment and service access panels shall be guarded as required by applicable portions of OSHA Regulations.

(D) Mechanical Entrapment Response Procedures:

The manufacturer shall provide mechanical entrapment response procedures for the emergency release of persons trapped in machinery. Training on the procedures shall also be provided. This requirement applies to equipment that has any potential entrapment point(s) where hands, fingers or any other body parts could become caught between moving parts.

(E) Sharp Edges:

All sharp edges and corners, which present personnel hazards, shall be guarded or padded.

(F) Heated Surfaces:

Prevent heated surfaces from causing burns to personnel during operation.

(G) Prohibited Materials:

Some materials shall not be used in the equipment. These materials are noted in 75D-07.0-07 Restricted Materials at DCF.(Attachment 019)

(H) Hazardous Emissions:

Operation of the equipment shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by (OSHA) and the American Conference of Governmental Industrial Hygienists (ACGIH) standards. When the standards differ, the most stringent shall apply.

(I) Equipment Locking Arrangement:

The equipment shall be equipped with a locking arrangement that will prevent unauthorized manual or power operation. An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

(J) Safety Data Sheets:

Safety Data Sheets (SDS) for all contractor supplied and specified chemicals that are part of the process shall be supplied by the contractor to the BEP’s WCF EHS Branch or DCF (OEHS) Office of Environmental, Health and Safety prior to their bringing the material onto the respective site.

The SDS shall comply with the OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs (g) and (i).

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(K) Overload Protection:

Press shall be equipped with overload protection and power factor correction devices to prevent damage to its components and operating personnel.

(L) Safe-Ready:

All control stations shall include a "safe-ready" collar or equivalent. Upon turning the collar to the safe position, it shall be impossible to start the press from any other station. Console shall indicate that the particular interlock including emergency stop buttons causes the press to start or not.

(M) Emergency Stop:

Whenever an Emergency Stop is activated, the machine shall stop within one (1) second to reduce damage to the machinery and injury to personnel. An Emergency Stop may be initiated due to the machine’s internal control logic detecting an emergency situation, activation of personnel safety devices (i.e. safety curtains, cover interlocks or other devices designed to protect personnel), or by personnel manually activating an Emergency Stop Button.

Emergency Stop Buttons shall be provided at strategic locations, including the drive side of the machinery in the areas of the drive motors and delivery, to minimize the time required to reach them. Emergency Stop Buttons shall be of the pronounced mushroom type, red in color, with no raised guards to prevent accidental depression. Emergency stop buttons shall remain activated once depressed until manually reset.

(N) Inching Interlock:

Whenever an inching of the press occurs, only the control station from where the inch was performed shall be able to cause the press to move until the safe-ready is activated and deactivated.

(O) Energy Isolation:

Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the presses. This includes electrical, hydraulic, pneumatic, and kinetic sources of energy.

All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.) shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock. Stored sources of energy such as pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

(P) UV Curing/Exposing Equipment:

All equipment with ultraviolet radiation systems shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

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(Q) Hydraulic & Pneumatic Systems:

All hydraulic and/or pneumatic systems shall have functional isolation, i.e., when part of a system is operating, no other part of the system shall be adversely affected by pressure drop, flow transients, etc. All hydraulic and pneumatic equipment employed in the system shall conform to the Joint Industrial Council (JIC) standards. Hydraulic and pneumatic pumps shall be energy efficient.

(R) Laser Systems:

All equipment with laser systems shall comply with the latest version of the Laser Institute of America’s ANSI-Z136.1 standard, American National Standard for Safe Use of Lasers, and 21 CFR 1040 and shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

(S) Illumination:

Large equipment (such as printing presses) with covered work stations such as impression cylinder, wiping roller, inking-in areas, etc., shall include illumination of at least 20 foot-candles of luminance by the equipment manufacturer, in accordance with the latest version of ANSI RP- 7.

(T) Industrial Ventilation:

Equipment which emits airborne contaminants which exceed permissible exposure concentrations as established by OSHA, ACGIH and National Institute of Occupational Safety and Health (NIOSH) shall be equipped with local exhaust ventilation (LEV). LEV shall be designed in accordance with the ACGIH Industrial Ventilation: A Manual of Recommended Practice for Design, (latest edition). All industrial ventilation system parameters and design shall comply with the OSHA Ventilation Standard, 29 CFR 1910.94.

(U) Material Handling Assistance:

The equipment shall include ergonomic lifting aids for any lifting of more than 32 pounds by the operators.

C.3.1.2 Environmental Protection (Mandatory Minimum Element)

All equipment installed at the Bureau shall meet all local, state, and federal environmental regulations. Including but not limited to air quality, industrial solid waste, hazardous waste, and wastewater.

The equipment installed at the Bureau shall comply with the following regulations:

• Federal Regulation: Environmental Protection Agency, EPA Clean Air Act Amendments of 1990, Section 112-Air Toxics (http://www.epa.gov/air/oaq_caa.html);

http://www.epa.gov/air/oaq_caa.html

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• 40 CFR 403-General Pretreatment Regulations for Existing and New Sources of Pollution (http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm);

• 30 TAC (Texas Administrative Code) - Chapters 101, 115, and 116 for Air Quality Rules and air permitting

• City of Forth Worth Code – Chapter 12.5 for Industrial Wastewater

• 30 TAC – Chapter 335 for Industrial Solid Waste and Municipal Hazardous Waste

C.3.1.3 Product Tracking (Mandatory Minimum Element)

The machinery shall track and verify the movement of product (Sheets, Notes, Straps, Bundle, Bricks and Cash-Paks) through the production process and ensure that no product is missing or misplaced. Since stacks of 100 sheets will be fed into the system, this will preclude the tracking of notes via Serial Numbers until the notes are fed into the SNI modules. All product exiting the module shall be tracked and verified by the serial numbers on the notes. The module shall report to the tracking system the serial numbers of the notes within each strap as they are delivered for packaging to enable tracking and verification of the product into Bundles, Bricks and Cash-paks.

If the machine detects that any product is not in the correct position or missing, the machine shall stop and signal the operator for corrective action and not allow continued operation until corrective action is complete. The system shall require the scanning of the serial numbers of any sheets or notes removed prior to the SNI module to ensure accountability of the product.

With the elimination of the numeric sequence of the product, the accountability of the notes is of paramount importance. The machine shall record and display on accountability reports (see C.3.2.7) the Serial Numbers of all notes removed from the production process and not packaged into Cash-Paks as finished goods. The machine shall be designed to ensure that no product is removed from the system without recording of the serial number for later verification.

The system shall create a database of the serial numbers for all notes processed. Serial numbers shall be stored for each batch processed (process) and shall identify the end location for every note:

Strap – serial number of the top note shall be used for the tracking Bundle – bundle label number shall be used for the tracking Cash-Pak – Cash-pak label shall be used for the tracking Notes removed from the production process shall be recorded within the database with their respective disposition (Sample, Reject, etc.)

The machine shall have Optical Character Recognition (OCR) stations for the removal of printed material. The contractor shall propose the number of OCR stations, locations and methodology for the logging of product out of the machine to ensure the absolute tracking of all products.

The Product Tracking capability of the system shall not be labor intensive or obtrusive that would prevent the system from meeting the labor or productivity requirements. The system shall automatically perform tracking and minimize manual entry of information or verification of results.

http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm

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C.3.1.4 SNI Finishing System

The system shall accommodate a wide range of substrates for the production of currency and other security documents, including polymer or combinational substrates that include both paper and polymer materials.

The system shall have the capability of processing sheets ranging up to a maximum size of 820 mm wide by 700 mm long (32.28” by 27.56”). The image area for the sheets shall be at least 800 mm wide by 666 mm long (31.496” x 26.22”).

The system shall allow for variations in the format of the sheets. The system shall accommodate between three (3) and five (5) notes across the sheet (columns) and between five (5) and ten (10) notes down the sheet (rows); minimum of fifteen (15) subject up to fifty (50) subject format.

The system shall have the capability of producing currency notes ranging from a minimum of 120 mm wide by 60 mm tall (4.724 by 2.362 inches) up to a maximum of 180 mm wide by 83 mm tall (7.087 by 3.268 inches).

A Raised Tactile Feature (RTF) and/or another feature may be added to future currency designs that may impact the heights of stacks of sheets and thicknesses of Straps and other packages. The placement, height and nesting characteristic of the feature are unknown at this time. The inclusion of the feature onto denominations is anticipated to increase the height of 100 sheet stacks up to 25 mm thick and Straps after application of the paper band are anticipated to be up to 23 mm thick.

The SNI Finishing System shall be capable of accommodating notes with a RTF.

The SNI Finishing System shall incorporate two (or more) Single Note Inspection (SNI) machines as modules for the inspection and sorting of notes. The SNI Finishing System can employ individual feeding and cutting components for the individual SNI machines or one feeding and cutting section that supports multiple SNI machines. The packaging section shall integrate the output from the SNI machines into one integrated packaging system. The contractor shall propose the configuration of the system based on the ability of the system to meet the functional, performance, and design requirements.

(A) Stack Feeding

The SNI Finishing System shall have the ability to accept 100 sheet stacks into the system. The SNI Finishing System shall incorporate provisions to facilitate alignment of the stack to ensure proper cutting of the sheets in registration to meet the quality standards. The contractor shall propose the methodology for the feeding of the stacks that shall address the following, listed in order of priority:

1 Minimize risk of injury to employees 2 Minimize the creation of spoilage 3 Maximize the efficiency and operational capability of the system

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(B) Stack Counting

The SNI Finishing System shall verify that each stack contains 100 sheets. The SNI Finishing System shall count a corner to verify that 100 sheets are contained within the stack. If a discrepancy is detected, the SNI Finishing System shall stop and notify the operator. The SNI Finishing System shall allow for a recount to occur without removal of the stack from the system.

If the second count is successful, the SNI Finishing System shall proceed without operator intervention being required.

If second count fails, sheets need to be returned to operator load point for removal. Data for counting (successful, fails, and incompletes) need to be accumulated for tracking/accountability purposes.

The sheet counter shall be modular unit with quick-connections to facilitate removal and replacement with a spare.

(C) Sheet Cutting

The SNI Finishing System shall trim all four edges of the sheets and cut the sheets into individual notes. Cutting shall be registered with sufficient accuracy such that all notes fall within ±0.5 mm (±0.020 inches) of the size set by the operator. All adjustments for cutting shall be performed automatically by entering the size of the notes desired by the operator into the Central Operation Station (COS). The SNI Finishing System shall adjust for cutting a fixed number of notes in equal increments between two end points or specify the individual cutting points for each column or row.

Operator shall be able to make adjustment in 0.1 mm increments.

The SNI Finishing System shall provide ease of access to accommodate knife changes. Knife blade changes shall require no more than 1 hour by qualified personnel. The knives provided by the contractor shall be capable of no less than 200,000 cut cycles prior to renewing under normal operating conditions.

It is desirable for the system to include as an OPTION for the automatic adjustment of the cutting based on inspection results for the note size and margins. At a minimum, a feedback display of the note size and margins for each note location shall be provided for the operator to make adjustments to optimize the notes based on the sheet layout.

Each cutting station shall have a resettable, independent counter that increment after each cutting stroke. Each counter shall allow a preset number up to seven digits and displays a message on the COS as well as stops the machine once the preset value is met. Once the machine completes its current loaded set of 100 sheet stacks in the machine; reaching the preset number will prevent the loading of additional stacks unless authorized by an override by a supervisor. Preset value may be reset by a supervisor at any time without impacting current tracking number. COS should display a warning of nearing the preset number by a settable x%.

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All settings for cut dimensions shall be automatic but some manual adjustment may be required when changing note sizes. Photocells and transfer devices for moving Straps and Bundles may require manual adjustments for a change in the note size.

The SNI Finishing System shall have a means in place to detect an incomplete cut on each cutting unit. The activation of this mechanism shall stop the SNI Finishing System and alert the Operators to which cutting unit the error occurred.

(D) Note Feeding

The SNI Finishing System shall incorporate the ability to automatically transport the cut notes into the Single Note Inspection (SNI) module(s), manually insert pre-cut notes into the modules or to manually offload cut notes from the system before SNI processing.

All notes shall be fed in the same orientation. The Orientation used by the SNI Finishing System is at the discretion of the Contractor but shall be consistent for all notes processed.

Carrier units, if utilized, shall provide easy removal and replacement from any driven mechanism. The carrier units themselves shall be built in a manner that the original shape in maintained under harsh operating conditions. Product jams shall not deform the shape or functionality of the carrier unit.

(E) Single Note Inspection

The SNI Finishing System shall incorporate Single Note Inspection (SNI) machines as modules (SNI module) for the examination, sorting, shredding of notes, and accumulation of samples and acceptable notes for packaging. The number and configuration of the SNI machines shall be based on meeting the productivity and performance requirements in this specification for the resulting system.

(1) General Requirements

The feeding system shall separate individual notes from the cut stacks produced by the cutting operation for consistent and reliable processing with minimum operator intervention being required and minimum spoilage due to marking, damaging or misorienting notes for processing.

The SNI Finishing System machine shall require no more than five operator interventions for each SNI machine within a normal 10 hour operational shift due to inconsistent or unreliable feeding of the notes. Notes damaged or destroyed due to misfeeding shall be included in the calculation of spoilage rate associated with the system.

The SNI shall inspect each note, on both sides, in a single pass to determine the acceptability of the note to conform to the established quality specifications. The SNI shall have at least 8 positions for the mounting of detectors or sensors, 6 of which shall be on

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The SNI shall allow for the random sampling of acceptable quality notes, defective quality notes, or combination. It is desirable for samples to be separated into good and defective notes. The system shall allow for the operator to select to randomly collect notes at variable frequencies.

(2) Master Image

The SNI shall use a “Master” Image for the inspection of all notes. A “Master” may also be called an Inspection Algorithm, Golden, Adaptation, Model or Reference; it shall contain the image(s) that all inspection is performed against as well as all parameters for the SNI to inspect notes of a specific denomination and determine the acceptability of the notes for issuance. The “Master” image may be a single image or composite of multiple images depending upon the Contractor’s design.

The system shall:

1. Allow the operator to load a pre-existing “Master” from the BEP Server to be used for the inspection of the notes.

2. Allow the operator to create a new “Master” on the SNI. The operator shall save the

“Master” to the BEP Server. System shall store “Master” indefinitely for an individual denomination/design. “Master” shall be namable to denote the denomination and any specific inspection characteristics for easy identification.

3. The system shall store all “Master” files and trace the creation, utilization and amendment of each file.

4. Allow the operator to define as part of the “Master” individual regions within each image for…