Attachment_A-2_-_Metallic_Ink_Specification_I-METINK-2b_dated_27-April-2012.pdf

I: METINK-2b 27 April 2012 Supersedes:

I: METINK-2a 18 March 2008

DEPARTMENT OF THE TREASURY

BUREAU OF ENGRAVING AND PRINTING

WASHINGTON, DC 20228

BEP SPECIFICATION

FOR

INKS: CYLINDER-WIPE, NON-HEATSET, INTAGLIO,

SHEET-FED CURRENCY, WITH A METALLIC APPEARANCE

1.0 SCOPE AND CLASSIFICATION

1.1 Scope. This specification establishes performance and acceptance requirements for cylinder-wipe, non-heatset, intaglio inks with a metallic appearance, hereinafter referred to as “metallic inks.” These inks will be used as part of a counterfeit deterrent feature of United States currency. These inks shall be suitable for use in printing United States currency on De La Rue Giori I-10, and Super Orlof Intaglio (SOI) cylinder-wipe sheet-fed presses at the Bureau of Engraving and Printing’s Washington, DC and Fort Worth, Texas facilities, hereinafter referred to as the “BEP.”

1.2 Classification. This specification covers one type and various colors of metallic ink. Table I lists the BEP stock item numbers for the metallic inks.

Table I Metallic Ink Classification

Ink Color BEP Stock Item Number

Red 1I001377 Green 1I001369 Blue 1I001370

1.2.1 Additional Colors. Metallic-appearing inks in colors other than the colors listed in Table I may be identified for future use by the BEP. Future currency note designs may use existing metallic ink colors or may require new colors. BEP stock item numbers will be assigned to additional inks as needed.

2.0 APPLICABLE DOCUMENTS. The versions of the documents are those in effect on the date of the solicitation.

2.1 Government Documents.

Supersedes:

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this specification to the extent specified herein.

Federal Standards

FED-STD-141D — Paint, Varnish, Lacquer, and Related Materials; Methods of Inspection, Sampling and Testing

(Federal specifications and standards may be obtained from the General Services Administration;

Federal Supply Service; Specification Section (3FP-E); 470 East L’Enfant Plaza, SW; Suite 8100;

Washington, DC 20407.)

Bureau of Engraving and Printing Specifications:

P: CDT4 Paper: Currency, Distinctive, Type IV (current version) P: CDT5 Paper: Currency, Distinctive, Type V (current version) I: CSI Inks: Color Shifting, Cylinder-Wipe, Non-Heatset, Intaglio, Sheet-

Fed Currency Inks (current version) I: ICWC Inks: Cylinder-Wipe, Non-Heatset, Intaglio, Sheet-fed Currency Inks and Varnish (current version) I: ICWIR Ink: Cylinder-Wipe, Non-Heatset, Intaglio, Sheet-fed, Infrared-

Transparent Green Currency Ink (current version) I: SDOC Inks: Sheet-Fed Dry Offset Currency (current version) L: VAB-1 Specification for Vendor Affixed Barcode Labels for Bureau of

Engraving and Printing Materials

(Single copies of BEP specifications are available from the Contracting Officer, Bureau of Engraving and Printing, Office of Acquisition, 14th and C Streets, SW, Washington, DC 20228.)

2.1.2 Other Government Documents, Drawings, and Publications. The following other government documents, drawings, and publications form a part of this document to the extent specified herein.

Bureau of Engraving and Printing Test Methods:

STM 300.001 Crumple Test STM 300.002 Laundering Test STM 300.003 Chemical Resistance Tests STM 310.008 Determination of Metals in Printing Ink STM 320.009 Roller Compatibility Test for Inks and Fluids STM 320.010 Inks Compatibility with the Wastewater Pretreatment

Process STM 321.005 Fineness of Grind (FOG) Determination

Supersedes:

(Single copies of BEP Test Methods are available from the Contracting Officer, Bureau of Engraving and Printing, Office of Acquisition, 14th and C Streets, SW, Washington, DC 20228.)

Bureau of Engraving and Printing Document:

Environmental, Health and Safety for Materials Specifications

(Request for copies should be addressed to the Contracting Officer; Bureau of Engraving and Printing;

Office of Acquisition; 14th and C Streets, SW; Washington, DC 20228.)

2.2 Non-Government Publications. The following documents form a part of this specification to the extent specified herein.

American Society for Testing and Materials (ASTM) Methods:

D 1316 Fineness of Grind of Printing Ink By the NPIRI Grindometer D 1729 Visual Evaluation of Color Differences of Opaque Materials D 2369 Volatile Content of Coatings D 3792 Water Content of Water-Reducible Paints by Direct Injection into a

Gas Chromatograph G 155 Standard Practice for Operating Xenon Arc Light Apparatus for

Exposure of Non-Metallic Materials

(Request for copies should be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103-1137.)

National Motor Freight Classification Rules and Container Specifications

(Request for copies should be addressed to the American Trucking Association, Inc., 2200 Mill Road, Alexandria, Virginia 22314.)

Non-Government standards and publications are available from the organizations that prepare or distribute the documents. These documents may also be available from libraries or other information services.

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence.

However, nothing in this document supersedes applicable laws and regulations unless specific exemption has been obtained.

2.4 Internal References. All paragraph, section, and table references will be to paragraphs, sections, and tables of this specification unless stated otherwise.

Supersedes:

3.0 REQUIREMENTS

3.1 Material. The material shall be a cylinder-wipe, non-heatset intaglio ink of the color specified in each order, with a metallic appearance (See Section 3.3.4 Color Appearance). The metallic ink shall contain particles that specularly reflect incident light from the particle surface, with no light interference phenomenon. The ink shall meet the performance, health and safety, environmental, and other requirements specified herein when used in the printing of United States currency on cylinder-wipe intaglio presses at the BEP.

3.1.1 Recovered Materials. In accordance with the requirements of 42 United States Code 6901, et. seq., and 6962, the BEP encourages the use of the highest percentage of recovered materials practicable in the manufacture and delivery of the finished materials as specified herein, as long as all specification requirements are fulfilled.

3.2 Shelf Life. The ink shall not show any evidence of deterioration or change in properties that would render it unfit for its specified use when stored for periods not exceeding one (1) year from the date of manufacture.

3.3 Physical Requirements. The contractor shall provide critical test parameters for the measurement of color, initial tack, maximum tack, set time (time to maximum tack), viscosity, and yield value. The contractor shall identify the make and model of the test instruments used to determine each property. The contractor shall identify the test method or instrument operating procedure used for measuring each physical property.

3.3.1 Control Limits. The control limits define the maximum variation in physical properties that the BEP will accept within or between batches of production ink. The contractor shall supply ink that meets the control limits listed in Table II.

TABLE II

INK PROPERTIES AND CONTROL LIMITS

Property Control Limits Viscosity, Pascal-seconds (Pa·s) 6.12 – 7.48 Yield Value, Pascals (Pa) ≤ 400 Initial Tack, tack units (t. u.) 218 – 266 Maximum Tack, tack units (t. u.) 301 – 367 Set Time, seconds > 200

3.3.2 Viscosity and Yield Value. The viscosity and yield value of the ink shall be determined by the use of a recording cone and plate viscometer (rheometer) as specified in paragraph 4.3.5.

Supersedes:

3.3.3 Tack. The initial tack, set time, and maximum tack of the ink shall be determined by the use of a Tack-O-Scope®, inkometer, or equivalent equipment as specified in paragraph 4.3.6. Set time is defined as the time period from application of ink to the measuring roller until maximum tack.

3.3.4 Color Appearance. The ink shall be a close visual match in color to the BEP reference for the color specified. The ink shall exhibit a distinct metallic appearance.

3.3.4.1 Production Match. Production batches of ink shall be a close visual match in color and metallic appearance to the corresponding BEP approved formulation (reference) when drawn down on paper as specified in paragraph 4.3.1 (See also paragraph 3.4.6).

3.3.5 Opacity. Production batches of ink shall be visually equal in opacity to the corresponding BEP approved formulation (reference) when tested as specified in paragraph 4.3.2.

3.3.6 Lightfastness. The ink shall be lightfast, retaining its color appearance properties when exposed to the light produced by a xenon-arc for a period up to 72 hours. The lightfastness of the printed ink film of production batches of ink shall not be less than the lightfastness of the printed ink film of the corresponding BEP approved formulation (reference) when tested as specified in paragraph 4.3.3.

3.3.7 Fineness of Grind. The ink shall be uniformly dispersed, free from entrapped skin, agglomerates, and foreign substances and should have a smooth appearance when pulled down in the paths of the grindometer. The ink shall exhibit no more than three (3) scratches, 10 millimeters or longer, at or above the 20 micrometer channel depth when tested as specified in paragraph 4.3.4.

3.3.8 Instrumentally Measured Color. The instrumentally measured color of production batches of ink and the corresponding BEP approved formulation (reference) shall be determined as specified in paragraph 4.3.15. The CIE 1976 (CIELAB) color coordinates (L*, a*, b*) shall be reported for each production lot sample, and the determination of ∆E* shall be based on these values and similarly measured L*, a*, b* for the BEP approved formulation (reference) sample.

3.3.9 Ink Reflectivity. The ink reflectivity shall match the BEP approved reference standard. The ink reflectivity shall be determined by measurements of the UV/Vis/NIR reflectivity spectrum measured in accordance to the procedures as specified in paragraph 4.3.16.

3.4 Printing Performance Requirements.

Supersedes:

3.4.1 Pumpability. The ink shall be pumpable at a rate that will keep the ink fountain on the press adequately supplied to keep the press printing at the required operating speed.

3.4.2 Ink Application. The press inking and ductor rollers shall not require cleaning due to ink drying or accumulation more often than one time during each eight-hour shift of press operation. The ink shall not cure in the fountain, on the rollers, or in the engravings during normal operations or during short press shutdowns of 30 minutes or less, to an extent which will require manual cleaning of the fountain, rollers, or plates.

Examples of short press shutdowns are stops required to make minor repairs, to remove misfed sheets, or to make press adjustments. The ink shall not cause the ink fountain drip pan to require cleaning more often than once during an eight-hour period of press operation.

3.4.3 Cylinder Wiping. The ink shall wipe cleanly from the chrome-plated engraved plates using the existing press cylinder wiping system. The ink shall not attack or degrade the wiping roller to the extent that damage or loss in wiper life occurs (see paragraph 3.4.9).

For the I-10 and Super Orlof presses, the wiper roller life should not be less than 100,000 impressions. The BEP uses press rollers comprised of polyvinyl chloride (PVC) plastisol or an elastomeric material other than PVC plastisol. The wiper roller is cleaned by an aqueous caustic cylinder wiping solution comprised of 98.5% soft water, 1.0% sodium hydroxide, and 0.5% sulfated castor oil. The ink shall disperse in the wiping solution and not remain on the wiping roller.

Manual cleaning shall not be required more often than once during an eight-hour period of press operation due to ink buildup in the wiper tank. The plate shall wipe cleanly and the plate wiping action should not cause more than 30 kilowatts per hour in additional power requirement by the press. Additional power requirement is defined as the difference in amperage when the press is run with and without engaging the wiping mechanism.

3.4.4 Press Speed. The ink shall print at a minimum of 8,000 sheets per hour on the I-8 press. The inks shall print at a minimum of 10,000 sheets per hour on the I-10 and Super Orlof presses (see paragraph 6.1).

3.4.5 Print Quality. The ink shall be capable of printing the currency design with quality that is equal to or superior to the BEP reference sheet. The print quality of sheets printed with the ink will be compared visually to the BEP reference sheet.

3.4.6 Production Visual Color Match. The image on work printed with the ink shall be a visual match in color and appearance to the same image of the BEP reference

Supersedes:

sheet when viewed in accordance with paragraph 4.3.7.

3.4.7 Abrasive Properties. The ink shall not contain any ingredient that will cause premature wear to the intaglio plates, press rollers, or poly chablon plates.

3.4.8 Corrosion. The ink shall not corrode the printing plates or any mechanical part of the press to the extent that damage to the plates or press occurs. The ink shall not have a pH value of less than 4.5.

3.4.9 Roller Compatibility. The ink shall not soften, harden, swell, shrink, or deteriorate the press rollers (ductor, inking, wiper, or chablon) to the extent that damage to the roller, poly chablon plate, or any other mechanical part of the press occurs.

3.4.10 Wastewater Pretreatment Compatibility Test. The ink shall be compatible with the BEP wastewater pretreatment process.

3.5 Printed Work Requirements.

3.5.1 Processing of Printed Sheets. Printed sheets shall be stackable immediately up to 10,000 sheets high without excessive set-off or blocking. Set-off is considered excessive when the ink transfers to the adjacent sheets to such an extent that it is noticeable during the examining process and is deemed to be unacceptable. Blocking is considered excessive when more force than normal is required to separate the printed sheets. Printed sheets shall be processable within 72 hours of printing. The ink shall be compatible with the sheet-fed dry offset inks and other inks used to print United States currency. The ink shall adhere to the currency paper and not cause flake and dust formation during processing of the printed sheets.

3.5.2 Ink Adhesion (Crumple Test). The ink on the printed note shall adhere and retain its metallic-appearance and color properties when subjected to the BEP Crumple Test. Ink loss shall not exceed acceptable levels at 7 to 10 days after printing and during the life of the currency note when tested as specified in paragraph 4.3.8.

3.5.3 Ink Resistance to Laundering. The ink on the printed note shall adhere, retain its metallic-appearance and be resistant to ink loss, loss of clarity, and color change when laundered. Ink resistance to laundering shall meet or exceed acceptable levels at 7 to 10 days after printing and during the life of the currency note when tested as specified in paragraph 4.3.9.

3.5.4 Chemical Resistance. The ink on the printed note should adhere, retain its metallic-appearance and be resistant to ink loss, loss of clarity, and color change when subjected to various chemicals as specified in paragraph 4.3.10. The chemical resistance of the ink shall meet or exceed acceptable levels at 7 to 10 days after

Supersedes:

printing and during the life of the currency note. The ink shall not be completely removed from the note by any one of the nine chemicals used to test chemical resistance.

3.5.5 Magnetic Properties. The ink shall not contain any ingredient that can be magnetized and therefore shall not exhibit a magnetic signal when tested using the equipment identified in paragraph 4.3.11.

3.6 Environmental, Health and Safety Requirements. All materials delivered to the BEP shall be designed to minimize all risks of injury & illness to BEP employees. All materials shall be in full compliance with government and commercial environment, safety and health regulations and requirements. The following are specific safety, health and environmental requirements for the acquisition, purchase or samples of materials (e.g., paper, ink, rigging boards, chemicals, etc.) for the BEP.

3.6.1 General Environment, Health, and Safety

3.6.1.1 Materials shall be designed to prevent injury and illness to operation and maintenance personnel at all times.

3.6.1.2 All materials shall comply with the Occupational Health and Safety Administration (OSHA), Environmental Protection Agency (EPA), Department of Transportation (DOT), or any other applicable standards.

3.6.1.3 The BEP retains the right to reject any material that may potentially cause an injury or adverse health effect upon its employees. Health and injury effects include but are not limited to:

• headache;

• eye, dermal, nasal, or throat irritation;

• sensitization;

• nausea; and

• dizziness.

3.6.1.4 The BEP maintains a list that identifies chemicals which are prohibited for use on BEP property and other chemicals which are targeted for reduction (BEP Quality System Procedure Prohibited Materials & Materials Targeted for Reduction, 75.00 (4.4.6) 34.4 DC). Prohibited chemicals are not allowed on-site under any circumstances and chemicals that have been targeted for reduction will only be allowed when no suitable alternative is available.

3.7 MATERIAL SAFETY DATA SHEET (MSDS)

Supersedes:

3.7.1 The contractor shall submit an MSDS for all chemicals and applicable materials to the BEP Office of Environmental, Health, and Safety (OEHS) through the Contract Officer’s Representative (COR) for review and approval (EHS Review Procedure 75.00

(4.4.6) 2.3 DC).

3.7.2 The MSDS shall comply with the OSHA regulations set forth in 29 CFR 1910, Part 1200 Hazard Communication (HazCom).

3.7.3 The materials are not to be used until written approval is received from the

OEHS.

3.8 ENVIRONMENTAL PROTECTION REQUIREMENTS

3.8.1 All materials and processes must meet or exceed standards in the regulations and executive orders listed below. Other environmental regulations, executive orders and guidance may also be applicable.

Federal Regulation: Environmental Protection Agency, EPA Clean Air Act, as Amended;

40 CFR 60 - Appendix A – Test Methods;

Information in printed paper copies of this document and document referred to herein in not guaranteed valid beyond 24 hours of the print date. Page 3 of 6 Document 75.00 (4.4.6) 34.2 DC Materials Boilerplate

40 CFR Part 247 – Comprehensive Guideline for Procurement of Products Containing Recovered Materials, May 1, 1996;

40 CFR 261 – Identification and Listing of Hazardous Waste;

40 CFR 355 –Requirements for Emergency Planning and Notification under

CERCLA;

40 CFR 370 – Hazardous Chemical Reporting and Community Right to Know

Requirements;

40 CFR 372 – Toxic Chemical Release Reporting;

40 CFR 403 – General Pretreatment Regulations for Existing and New Sources of Pollution;

40 CFR 433.15 Pretreatment Standards for Existing Sources (PSES);

40 CFR 720 – Pre-manufacture Notification: Pre-manufacture Notice

Requirements and Review Procedures;

40 CFR 761 – Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions;

P.L. 102-486, Energy Policy Act of 1992, October 24, 1992;

Executive Order 13148 – Greening the Government through Leadership – April

21, 2000;

Executive Order 13423 – Strengthening Federal Environmental, Energy and

Transportation Management, January 26, 2007;

Supersedes:

Executive Order 13514 – Federal Leadership in Environmental, Energy and Economic Performance, October 5, 2009;

Superfund Amendments Reauthorization Act (SARA), Title III;

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle A, Air

Quality Regulations;

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle E, Hazardous Waste Regulations; and District of Columbia Municipal Regulations (DCMR), Title 21, Water and

Sanitation, Chapter 15, Discharges to Wastewater System Regulations

3.9 AIR EMISSIONS

3.9.1 The Contractor shall identify all regulated air pollutants that are ingredients in the product(s) to be purchased by the BEP.

3.9.2 Volatile Organic Compounds (VOC): The ink shall have a volatile organic compound content of less than or equal to 4% by weight when tested (VOC) as specified by the DC Air Quality regulations and other EPA guidelines.

DDOE Ink VOC Content Limits

Press Type Maximum VOC Concentration Intaglio, non-heatset, cylinder wipe 12%

Inks may not exceed ink VOC limits.

Cleaning materials must meet compliance requirements for the printing applications as specified by the DC Air Quality regulations, 20 DCMR Title A The vapor pressure limit for organic cleaning solvents is ten (10) millimeters (mm) of

Mercury (Hg) (or 1.3332 kPa) at 20 degrees Celsius (°C) or 68 degrees Fahrenheit (°F).

3.9.3 Air Toxics. The material shall not contain, as an ingredient, any of the chemicals regulated as Air Toxics by the Clean Air Act Amendments of 1990, Section 112.

3.10 Wastewater. Information shall be provided to the OEHS through the COR on the characteristics of all material/effluents (can be pumped or gravity flow liquids) that will come from the equipment, either regularly or intermittently, including routine or scheduled maintenance work. This information will be used to determine the feasibility and method of treating the effluents either in the Wastewater Pretreatment Plant or requiring that the materials be handled through the Solid/Hazardous Waste Program.

3.11 Energy/Water/Recovered Materials Usage Policy. The Contractor shall make every reasonable effort to provide the most environmentally friendly materials to the Bureau. The Contractor shall comply with:

Supersedes:

EO 13423 – Strengthening Federal Environmental, Energy and Transportation

Management;

40 CFR Part 247, Comprehensive Guideline for Procurement of Products

Containing Recovered Materials; May 1, 1996;

EO13514, "Federal Leadership in Environmental, Energy, and Economic

Performance"; and EO13148 – Greening the Government through Leadership

3.12 SOLID/HAZARDOUS WASTE

3.12.1 Material that results in solid/hazardous wastes (wastes which cannot be pumped or which do not flow by gravity) either continuously or intermittently, including scheduled or routine maintenance work, in addition to normal operation must be designed to allow for removal of the waste in an ergonomic manner and to allow the operator to transfer the waste into a 55 gallon drum – 1A1, 1A2, or other appropriate container, as needed.

3.12.2 Information shall be provided as to the specific quantity, nature and characteristics of the waste generated so that a waste determination may be performed by OEHS in accordance with 40 CFR 261 – Identification and Listing of Hazardous Waste.

3.13 Polychlorinated Biphenyls. The materials shall comply with the regulations set forth with the requirements in 40 CFR 761.30 and shall not contain polychlorinated biphenyls (PCBs) in excess of 1 ppb as required in Title 21, DCMR, Chapter 15, Section 1501.4.

3.14 Identification And Listing Of Hazardous Waste. Materials shall not contain contaminants in excess of those listed in Table I, 40 CFR Part 261.24, for the Toxicity Characteristic Leaching Procedure (TCLP).

3.15 Pre-Manufacture Notification. The contractor shall comply with the regulations set forth in 40 CFR Part 720 Pre-manufacture Notification. All suppliers, foreign and domestic, shall certify that the pre-manufacture notification requirements are met for ingredients used in manufacturing the product.

3.16 Proposition 65. No substance listed by California's "Safe Drinking Water and Toxic Enforcement Act of 1986" (Proposition 65) shall be used as an ingredient in the manufacture of the product. If any listed substance is present as a trace, (ie., not an ingredient) the contractor shall provide a list of such substances with their respective amounts (concentrations).

Supersedes:

3.17 Superfund Amendments Reauthorization Act (Sara). The contractor shall provide a list of the chemicals and their quantities in the materials which are reportable under the Superfund Amendments Reauthorization Act (SARA) Title III of 1986.

3.18 Total Toxic Organics. The material shall not contain, as an ingredient, any of the total toxic organic chemicals listed in DCMR Title 21, Chapter 15, and Section1501.4.

3.19 Recycled Materials. The BEP recommends the use of the highest percentage of post-consumer recovered material practicable in the manufacture of the finished material.

NOTE: The Environmental Protection Agency (EPA) defines Post-consumer recovered paper in

40 CFR 247.3.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Product Conformance. The ink shall meet the requirements of this specification and conform to the contractor’s own specifications, standards, and quality assurance practices. The BEP reserves the right to require proof of such conformance.

4.1.1 Contractor Quality Assurance. The BEP will rely on the contractors’ existing quality assurance system. The BEP reserves the right to perform any inspections and tests that the BEP deems necessary upon receipt of the material to assure conformance to requirements. The BEP may conduct periodic site visits and quality audits of the facilities of the manufacturer or major first-tier subcontractors in cases where the contractor is a “broker” or “regular dealer.” Upon request by the BEP, the contractor shall provide a copy of their current quality assurance system document, e.g., quality assurance plan, to the BEP. If the contractor is a “broker” or a “regular dealer” and not the manufacturer of supplies to be delivered under the terms of the contract, the BEP may request that the contractor provide a copy of the current quality assurance system document of its major first-tier subcontractors. The quality assurance system document will be used by the BEP as the basis for conducting the quality audit.

4.2 Inspection and Testing.

4.2.1 Responsibility for Inspection and Testing. Unless otherwise specified herein, in the contract or in the purchase order, the supplier is responsible for the performance of all inspection and testing specified. Except as otherwise specified, the supplier may utilize his own facilities or any commercial laboratory acceptable to the BEP. The BEP reserves the right to perform any inspection and testing that the BEP deems necessary to assure that supplies and services conform to prescribed requirements. This may include site visits and periodic quality audits at the facilities of

Supersedes:

the manufacturer.

4.2.2 Sampling. Sampling for inspection and testing shall be conducted in accordance with Federal Test Method Standard No. 141, Method 1022. The criteria for acceptance or rejection shall be as specified in Method 1022. The lot size shall be expressed in units of pounds or kilograms and shall consist of a manufacturer's single batch or run which has uniform properties. The supplier, based on the supplier’s knowledge of the manufacturing process, shall determine the lot or batch size.

4.2.3 Batch Samples. The contractor shall provide one (1) sample of approximately 50 cubic centimeters of each batch or lot of production ink supplied to the BEP. The samples shall be packaged in sealed air-tight containers and shall be identified with the BEP stock item number, the contractor’s formula or identification number, the batch or lot number, and the date of manufacture. The over-pack box containing the samples shall be addressed to the Contracting Officer’s Representative (COR). The batch or lot samples shall be delivered at the same time that the production ink is delivered to the

BEP.

4.2.4 BEP Testing. The BEP will evaluate the ink on BEP equipment for conformance to the requirements of Sections 3.4, 3.5, and 3.6 since these evaluations necessitate the use of BEP equipment and materials.

4.3 Testing. Testing shall be conducted in accordance with the following methods.

Reference to specific instruments is for information only. The use of a company and/or product name in this document does not imply approval or recommendation of the product in preference to others that may also be suitable. The BEP will work with the contractor to establish correlations between various instruments when required.

4.3.1 Color Match and Appearance. The sample shall be drawn down side by side with the corresponding BEP reference using a wide blade ink or putty knife on an Ink Drawdown Test Sheet, BEP Form 9677-2 or equivalent. After drying, the inks shall then be compared when viewed under D65 and cool white fluorescent light in accordance with ASTM method D1729.

4.3.2 Opacity. A sample of the ink shall be drawn down side by side with the corresponding BEP approved formulation (reference) on a drawdown test sheet (BEP Form 9677-2 or equivalent) with a wide blade ink or putty knife. The ink drawdown test sheet has a heavy black line printed on it near the center, running horizontally. On the basis of the show through of the printed black line, the sample ink shall be reported as equal to, more, or less opaque than the reference ink.

4.3.3 Lightfastness. Prints of the ink prepared as described in STM 320.007 shall be exposed to the light produced by a xenon-arc light-exposure apparatus following

Supersedes:

ASTM G 155, under exposure conditions defined in Table X 3.1 Cycle 11 of the Test Method for a period of 72 hours. The print color before and after exposure of the samples shall be measured in accordance with STM 320.007 and the color difference (∆E) calculated.

4.3.4 Fineness of Grind. The fineness of grind test shall be completed in accordance with ASTM D 1316, modified accordingly: report the number of scratches at or above the 20 micrometer channel depth. The BEP uses a G-3 Fineness of Grind gauge manufactured by the Precision Gauge and Tool Company.

4.3.5 Viscosity and Yield Value. The viscosity and yield value shall be determined using a recording viscometer or rheometer with a cone and plate measuring system.

The viscosity and yield value shall be measured using test settings that give optimal sensitivity for the material being tested. Refer to paragraph 6.2 for additional information.

4.3.6 Tack. Tack versus time data shall be obtained using a Tack-O-Scope® (Testprint Inc, Cherry Hill, NJ), inkometer, or equivalent. Test parameters will be set to give optimal sensitivity for the material being tested.

4.3.7 Production Color and Appearance Match. The printed image will be visually compared to the same image of the BEP reference sheet for color and metallic appearance. This comparison shall be made with D65 daylight and cool white fluorescent light in accordance with ASTM method D 1729.

4.3.8 Ink Adhesion (Crumple Test). The crumple test shall be performed in accordance with STM 300.001.

4.3.9 Resistance to Laundering. The laundering test shall be performed in accordance with STM 300.002.

4.3.10 Chemical Resistance. The chemical resistance tests shall be performed in accordance with STM 300.003.

4.3.11 Magnetic Properties. The BEP will evaluate the magnetic signal of notes with automated currency verification equipment.

4.3.12 Lead. The total lead concentration in the ink shall be determined in accordance with STM 310.008.

4.3.13 Cyanide Content. The total cyanide concentration shall be determined in accordance with Method 4500-CN of the Standard Methods for the Examination of Water and Wastewater by the American Public Health Association, American Water

Supersedes:

Works Association, and the Water Pollution Control Federation.

4.3.14 Volatile Organic Compounds (VOC) Content. Volatile organic compounds content shall be determined as the difference between the total volatile content (determined in accordance with ASTM D 2369, Procedure B) and the water content (determined in accordance with ASTM D 3792).

4.3.15 Instrumentally Measured Color. The mass color of the sample shall be determined instrumentally in accordance with ASTM D 2244 (using illuminant D65 and standard 10-degree observer with specular reflectance excluded) and expressed in the CIE 1976 Uniform Color Space. The dried ink film sample is prepared with a 1.5 mil (0.0015 inches) standard width Bird Film Applicator.

∆E* is calculated from the CIE 1976 (CIELAB) Uniform Color Space as follows:

)*b(+)*a(+)*L(=E 222 *

The report shall be as specified in ASTM D 2244. Refer to paragraph 6.5 for additional information.

4.3.16 Ink Reflectivity. UV/Vis/NIR reflectance spectra are acquired according to the following methodology:

Instrument: The UV/Vis/NIR spectrophotometer shall be capable of acquiring spectra in the range of 200 to 2,200 nm. The instrument should contain an integrating sphere for sampling.

Sampling: The dried film sample shall be prepared with a Prüfbau printer as described in STM 320.007.

Range: 200 – 2,200 nm

4.4 Examination.

4.4.1 Weight. Examination for weight shall be conducted in accordance with the provisions for inspection in Federal Standard No. 141, Method 1022. Any container containing less ink than is marked on the container shall be considered discrepant.

4.4.2 Preparation for Delivery. Examination for Preparation for Delivery shall be completed in accordance with Federal Standard No. 141, Method 1022. Inspection shall be covered by the requirements of Section 5.

4.5 Contractor Documentation.

4.5.1 Certifications and Reports. The contractor shall certify in writing that the ink

Supersedes:

supplied in each delivery conforms to all the requirements including health, safety, and environmental as set forth in this specification. The signed and dated certification shall include a statement of the recovered material content. This certification of compliance shall accompany the report of inspections and tests. The specification control limits shall be included in the contractor report of inspections and tests. The contractor shall furnish copies of the reports showing the results of inspections and tests performed for each batch or lot to the Contracting Officer’s Technical Representative (COTR). The results of inspection and tests shall be provided in electronic form along with the hard copy of the data.

4.5.2 Control Chart. Upon request by the BEP, the contractor shall provide a control chart for each of the following control variables, i.e., characteristics or properties of the ink: viscosity, yield, initial tack, maximum tack, set time, color and, VOC content. The control chart is a plot of the control variable of each lot or batch of ink plotted sequentially by the date of manufacture and shall contain the specification control limits for the characteristic or property. If requested, the contractor shall furnish a copy of the control chart of each control variable to the Contracting Officer’s Technical Representative (COTR).

4.5.3 Instrumentally Measured Color. The contractor shall supply instrumentally measured color (CIE 1976) of each production batch of ink and the corresponding BEP approved formulation (reference).

4.5.4 Spectral Curve. The contractor shall supply a spectral curve of each batch of production ink versus the spectral standard of the corresponding BEP approved formulation (reference) in the range of 200 to 2,200 nm.

4.5.5 Batch Drawdown Sample. A second drawdown sample shall be prepared as specified in paragraph 4.3.1 when the first drawdown sample is prepared. The second drawdown sample shall be provided to the BEP with each ink batch retain sample.

5.0 PREPARATION FOR DELIVERY

5.1 Packaging. The packaging and packing shall conform to the Department of Transportation Rules and Regulations (which require a MSDS with each shipment) and to the applicable requirements of the National Motor Freight Classification Rules and Container Specifications.

5.1.1 Container Packaging. The ink shall be packaged in a plastic 5-gallon (18.9-liter) pail with handle. The pail shall be tightly sealed with a plastic lid and shall be white in color (another color may be substituted upon approval by the contracting officer).

Supersedes:

The quantity of ink from pail to pail shall be consistent and uniform. Each pail should contain forty-five (45) pounds (20.4 kilograms) of ink. The surface of the ink in the container shall be completely covered with a plastic film to minimize or prevent ink skin formation. The containers should be compatible with the BEP pumping equipment specified in paragraph 3.4.1.

5.1.2 Palletization. The containers shall be delivered on sturdy pallets that allow four-way entry by forklift truck. The pallets may be slatted, and if slatted, the space between two adjacent boards shall not exceed 12.5 centimeters (4.9 inches). Pallet loads should be shrink-wrapped and/or strapped to prevent shifting of the containers during shipping and handling.

5.2 Marking.

5.2.1 Container Marking. Each container shall be plainly labeled with the description of the material, the formula or identification number, the batch or lot number, the date of manufacture, the net weight, the BEP purchase order number, the BEP stock item number, and the contractor’s name, address, and phone number. These markings shall be legible. Container labels shall be color-coded to match the color of each ink.

5.2.2 Hazard Warning Labels. Each container of ink shall be labeled in accordance with the provisions of the Hazard Communication Standard, 29 CFR 1910.1200 (f).

This labeling shall include the name and address of the manufacturer, the identity of the hazardous materials, and the appropriate hazard warnings.

5.2.3 Barcode Label. The barcode label shall conform to the “Specification for Vendor Affixed Barcode Labels for Bureau of Engraving and Printing Materials.” Each container shall be marked in accordance with the categories in Section 3 of the cited barcode label specification with the information listed in Table III.

TABLE III

BARCODE INFORMATION

Specification Category Label Information Product Description INK: METALLIC [insert INK COLOR] PO# BEP Purchase Order Number Part# BEP Stock Item Number Quantity Net Weight of Pail Contents in Pounds Serial/Lot# Manufacturer's Lot/Batch Number

NOTE: Color in the product description shall be determined by the type ordered.

Supersedes:

6. NOTES

6.1 Press Speed. The printing speed of the I-8 press is rated at 8,000 sheets per hour. The printing speed of the I-10 and Super Orlof presses are rated at 10,000 sheets per hour.

6.2 Viscosity and Yield Value Measurement. The BEP uses a Haake Rheostress 1 Rheometer operated in accordance with the manufacturer's instructions.

Currently, BEP test settings are: shear rate 300 s-1, 3 minute ramp time, temperature 50° C, and 25 millimeter (1° angle) cone.

6.3 Definitions. Certain words and phrases are frequently used in this specification. The following definitions will apply:

6.3.1 “Shall,” the emphatic form of the verb, is used whenever a requirement is intended to express a provision that is binding.

6.3.2 “Will” is intended to express a declaration of purpose on the part of the Government. It may also be used to indicate simple futurity.

6.3.3 “Should” is used whenever a non-mandatory characteristic is judged to be desirable for the material. As such, this characteristic may be graded during the evaluation of the material in order to assist in the selection of the best-qualified material.

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