RFP 2031ZA23R00015 Cash PAK.pdf

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL PRODUCTS AND COMMERCIAL SERVICES

NOTE: OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30.

1. REQUISITION NUMBER PAGE 1 OF 118

2. CONTRACT NUMBER

7. FOR SOLICITATION

3. AWARD/EFFECTIVE

DATE

a. NAME

4. ORDER NUMBER 5. SOLICITATION NUMBER

2031ZA23R00015

b. TELEPHONE NUMBER (No collect calls)

6. SOLICITATION ISSUE

DATE

08/02/2023

8. OFFER DUE DATE/

LOCAL TIME

INFORMATION CALL: Laqulla Howard, Contracting Officer

(817) 847-3905 09/06/2023 4:00PM CST

9. ISSUED BY CODE 2031ZA 10. THIS ACQUISITION IS UNRESTRICTED OR SET ASIDE: 100 % FOR:

Bureau of Engraving and Printing 9000 Blue Mound Rd Forth Worth, TX 76131

11. DELIVERY FOR FREE ON 12. DISCOUNT TERMS

X SMALL BUSINESS

HUBZONE SMALL

BUSINESS

SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

(SDVOSB)

13a. THIS CONTRACT IS A

WOMEN-OWNED SMALL

BUSINESS (WOSB)

ECONOMICALLY

DISADVANTAGED

WOMEN-OWNED SMALL

BUSINESS (EDWOSB)

8(A)

13b. RATING

NORTH AMERICAN

INDUSTRY CLASSIFICATION

STANDARD (NAICS):

333993

SIZE STANDARD: 500

BOARD (FOB) DESTINATION RATED ORDER UNDER 14. METHOD OF SOLICITATION REQUEST

UNLESS BLOCK IS MARKED

SEE SCHEDULE

15. DELIVER TO

Net Days - 30

CODE

THE DEFENSE PRIORITIES

AND ALLOCATIONS

SYSTEM - DPAS (15 CFR 700)

16. ADMINISTERED BY

REQUEST

FOR QUOTE

(RFQ)

INVITATION

FOR BID

(IFB)

CODE

FOR

X PROPOSAL

(RFP)

2031ZA

See Section F.2 Place of Delivery of Performance Work Statement BEP-ACQUISITION Bureau of Engraving and Printing Forth Worth, TX 76131

17a. CONTRACTOR/

OFFEROR

CODE FACILITY

CODE

18a. PAYMENT WILL BE MADE BY CODE

BEP-OFM

Bureau of Engraving and Printing Office of Financial Management Washington, DC 20228-0001, US

2031FY

TELEPHONE NUMBER

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT SUCH ADDRESS IN 18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a UNLESS BLOCK

OFFER BELOW IS CHECKED SEE ADDENDUM

19.

ITEM NUMBER

20.

SCHEDULE OF SUPPLIES/SERVICES

21.

QUANTITY

22.

UNIT

23.

UNIT PRICE

24.

AMOUNT

Purchase of Cash PAK system in accordance with the requirements listed in section C of the Performance Work Statement.

(Use Reverse and/or Attach Additional Sheets as Necessary)

25. ACCOUNTING AND APPROPRIATION DATA 26. TOTAL AWARD AMOUNT (For Government Use Only)

27a. SOLICITATION INCORPORATES BY REFERENCE (FEDERAL ACQUISITION REGULATION) FAR 52.212-1, 52.212-4. FAR 52.212-3

AND 52.212-5 ARE ATTACHED. ADDENDA

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA

ARE

X ARE

ARE NOT ATTACHED

ARE NOT ATTACHED

X 28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN 1

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH

AND DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND

ON ANY ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS

SPECIFIED

29. AWARD OF CONTRACT: REFERENCE OFFER

DATED . . YOUR OFFER ON SOLICITATION

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a. UNITED STATES OF AMERICA (SIGNATURE OF CONTRACTING OFFICER)

30b. NAME AND TITLE OF SIGNER (Type or print) 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER (Type or print) 31c. DATE SIGNED

AUTHORIZED FOR LOCAL REPRODUCTION STANDARD FORM 1449 (REV. 11/2021)

PREVIOUS EDITION IS NOT USABLE Prescribed by GSA - FAR (48 CFR) 53.212

X

Table of Contents

B.1. SCHEDULE OF ITEMS AND PRICES

B.2 PRICING AND DELIVERY SCHEDULE

C.1. BACKGROUND

C.1.1 SCOPE

C.2 REFERENCES

C.2.1 NON-DISCLOSURE AGREEMENT

C.2.2 REFERENCED DOCUMENTS

C.2.3 SHRINK-WARP FILM SPECIFICATIONS or EQUIVALENT (MANDATORY MINIMUM

REQUIRMENT)

C.2.4 PRODUCT REQUIRMENTS

C.2.4.1 BRICKS

C.2.4.2 CASH-PAKS

C.3 REQUIREMENTS

C.3.1 SYSTEM REQUIREMENTS (MANDATORY MINIMUM REQUIRMENT)

A. Brick In-Feed

B. Brick Barcode Reader Integration

C. Wrapper

D. Sealing Bar

E. Cutting Sealing Bar

F. Oven

G. Cooling System

H. Compression Unit

C.3.1.1 Processing Rate:

C.3.1.2 Central Operation Station

C.3.1.3 Safety Requirements (Mandatory Minimum Element)

C.3.1.4 Environmental Protection (Mandatory Minimum Element)

C.3.1.5 Unscheduled Maintenance

C.3.1.6 Fault Recovery

C.3.1.7 Preventative Maintenance

C.3.1.8 Manning

C.3.1.9 Spoilage

C.3.1.10 Set-up Time

C.3.2 DESIGN REQUIREMENTS

C.3.2.1 IT Components, Configurations and Controls

C.3.2.2 Uniformity

C.3.2.3 Component Access

C.3.2.4 Programming - Interrogation (PI)

C.3.2.5 Drive Controls

C.3.2.6 Locking Arrangement

C.3.2.7 General Design and Construction Requirements

C.3.3 SUPPORT MATERIALS AND SERVICES

C.3.3.1 SECURITY REQUIREMENTS (Minimum Mandatory Element)

C.3.3.2 ON-SITE SERVICES (Minimum Mandatory Element)

C.3.3.3 TECHNICAL DOCUMENTATION

C.3.3.4 SITE PREPARATION PLAN

C.3.3.5 SPECIAL TOOLS

C.3.3.6 SHIPPING, DELIVERY AND INSTALLATION

C.3.3.7 WARRANTY

C.3.3.8 TRAINING

C.3.3.9 TESTING

C.3.3.10 START-UP ASSISTANCE

C.3.3.11 PROJECT MANAGEMENT

C.3.3.12 CONTRACTOR PROVIDED MATERIALS

TECHNICAL EXHIBIT 1 – DELIVERABLES

C4. OPTIONAL PURCHASE

C.4.1 REPACK OPTION UNIT

C.5 CONTRACTOR QUALIFICATIONS & RESOURCES

SECTION D – PACKAGING AND HANDLING

SECTION H – SPECIAL CONTRACT REQUIREMENTS

SECTION I – CONTRACT CLAUSES

DTAR 1052.228-70, Insurance Requirements (APR 2015)

SECTION J – ATTACHMENTS

SECTION K – CERTIFICATIONS

SECTION L – INSTRUCTIONS, CONDITIONS, AND NOTICES TO OFFERORS OR

RESPONDENTS

SECTION M – EVALUATION FACTORS FOR AWARD

SECTION B – SUPPLIES OR SERVICES AND PRICES/COSTS

B.1. SCHEDULE OF ITEMS AND PRICES

The Bureau of Engraving and Printing (BEP) Western Currency Facility (WCF) located in Fort Worth and District Currency Facility (DCF) located in Washington, DC, requires replacement of the existing Cash-Pak oven and wrapping system.

The Contractor shall be responsible for the design, fabrication, assembly, integration, delivery, installation, set-up, testing, commissioning, and training for up to two (2) cash-pak systems that will plastic-wrap and heat shrink a cash-pak in accordance with BEP packaging requirements. The first system will be installed at the WCF. An optional second system and spare parts, if procured, will be for the DCF.

NOTE: Please indicate volume discount pricing for additional purchases of optional Cash PAK System(s) from date of contract award to a specified period of time.

B.2 PRICING AND DELIVERY SCHEDULE

CLIN

SUPPLIES DELIVERY QTY UNIT UNIT

PRICE

TOTAL

0001 Cash PAK System #1 WCF:

Input Converter, System controls with PLCs, Pusher System (Pre-Packaging), Packaging System (Wrapping) uses BEP plastic film or equivalent, Forming Unit Wrap, Perforation Wrap, Sealing Bar, Conveyor for Oven and Pusher, Oven System, Cooling System, Compression Packaging Unit (Shaper), Back Side Pusher, Barcode Labeler, BEP Labeler, Backside Conveyor, Warranty.

8 Months after award

1 EA $ $

0002 Design Review 1 Section C.3.3.11

2 Months after award

1 EA $ $

0003 Design Review 2 Section C.3.3.11

3 Months after award

1 EA $ $

0004 Design Review 3 Section C.3.3.11 Test Plan Finalized (Optional)

4 Months after award

1 EA $ $

0005 Final Test by Contractor Section C.3.3.11

4 Months after award

1 EA $ $

0006 Factor Inspection Test (FIT) Section C.3.3.9

6 Months

1 EA $ $

0007 BEP Approval of FIT Section C.3.3.9 (Optional)

7 Months after award

1 EA $ $

0008 Shipping and Installation Section C.3.3.6

9 Months after award

1 EA $ $

0009 Site Preparation Plan C.3.3.4 9 Months after award

1 EA $ $

0010 IT integration Installation 9 Months after award

1 EA $ $

0011 Bureau Acceptance Test (BAT) Section C.3.3.9

10 Months after award

1 EA $ $

0012 Training Section C.3.3.8 11 Months

TOTAL $ $

OPTIONAL

PURCHASE 1

0012 Cash PAK System #1 DCF:

Input Converter, System controls with PLCs, Pusher System (Pre-Packaging), Packaging System (Wrapping) uses BEP plastic film or equivalent, Forming Unit Wrap, Perforation Wrap, Sealing Bar, Conveyor for Oven and Pusher, Oven System, Cooling System, Compression Packaging Unit (Shaper), Back Side Pusher, Barcode Labeler, BEP Labeler, Backside Conveyor, Warranty.

4 Months

1 EA $ $

0013 Spare Parts Section C.3.3.7 (B)

1 Month after optional purchase

1 EA $ $

0014 FIT Section C.3.3.9 2 Months after optional purchase

1 EA $ $

0015 Repack Option Unit Section C.4.1

3 Months after optional purchase

1 EA $ $

0016 BEP Approval FIT Section C.3.3.9 (Optional)

3 Months after optional purchase

1 EA $ $

0017 Shipping and Installation Section C.3.3.6

9 Months after optional purchase

1 EA $ $

0018 BAT Section C.3.3.9 10 Months after optional purchase

0019 BEP Approval BAT Section C.3.3.9

11 Months after optional purchase

1 EA $ $

0020 Training Section C.3.3.8 11 Months after optional purchase

OPTIONAL

PURCHASE 2

0021 Spare Parts Section C.3.3.7 (B)

1 Month after optional purchase

1 EA $ $

0022 Repack Option Unit Section C.4.1

1 Month after optional purchase

The BEP may exercise Optional Purchase 1 after successful completion of the FIT on the Base System. Additional optional Purchase may be exercised within the delivery timeframe stated above thereafter dependent upon the need of the BEP.

[END OF SECTION]

SECTION C – PERFORMANCE WORK STATEMENT

CASH PAK SYSTEM

C.1. BACKGROUND

The Bureau of Engraving and Printing’s (BEP) mission is to develop and produce United States currency notes, trusted worldwide. BEP’s vision is to be the world standard securities printer providing its customers and the public with superior products through excellence in manufacturing and innovation. As its primary function, the BEP prints billions of dollars, referred to as Federal Reserve notes, each year for delivery to the Federal Reserve System.

C.1.1 SCOPE

The Contractor shall provide the BEP with a Cash PAK system. Under this requirement, the Contractor shall perform the design the design, fabrication, assembly, integration, delivery, installation, set-up, testing, commissioning, and training of one (1) cash-pak and wrap system that will plastic-wrap and heat shrink a cash-pak in accordance with BEP packaging requirements.

The first Cash Pak and Wrap System shall be delivered to the Bureau of Engraving and Printing (BEP) Western Currency Facility (WCF). Under Optional Purchase (1) the 2nd Cash Pak and Wrap System, shall be delivered to the BEP Washington D.C. Facility (DCF). Under Optional Purchase (1) the first Repack Option shall be delivered to WCF. Under Optional Purchase (2) the 2nd Repack Option shall be delivered to DCF. Spare parts are required in Optional Purchase 1 and 2.

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.

C.2.1 NON-DISCLOSURE AGREEMENT

During the course of this contract, the Contractor will require controlled unclassified information (CUI) 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 001.

The notarized agreement shall be returned to LaQulla Howard, Contracting Officer at Laqulla.Hoaward@bep.gov.

C.2.2 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 industry 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.2.3 SHRINK-WARP FILM SPECIFICATIONS or EQUIVALENT (MANDATORY

MINIMUM REQUIRMENT)

It is desired that the cash-pak and wrap system use the BEP’s Shrink-wrap Film Specification for the packaging of the notes. The Cash-Pak film is a Linear Low-Density Polyethylene (LLDPE) material that has been printed and laminated with a thickness of 10 MIL with ± 0.0175mm. The film has a heat seal strength of 10 psi min. for more specifications on film, see Exhibit 002. The vendor shall provide for a solution with similar test impact result as the BEP’s shrink-wrap film.

The vendor can provide a solution with similar test impact result as the BEP’s shrink-wrap film. See Exhibit 020.

C.2.4 PRODUCT REQUIRMENTS

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

All cash-pak’s produced on the system shall have an identical appearance, forensic characteristics, durability, and strength as compared to existing cash-pak’s produced by the BEP. For more specifications See Exhibit 005 and Exhibit 014.

C.2.4.1 BRICKS

A brick consists of four thousand (4,000) notes that grouped in four (4) one thousand note (1,000) note bundles that are shrink wrapped together using a Polyvinyl Chloride (PVC) single ply film to form an enclosure package. A brick is approximately 16 cm x 46 cm x7 cm (w x l x h). A Brick of 4000 Notes is shown in the attached drawing, Exhibit 004.

Brick

Four Bundles shrinkwrapped together in PVC Brick film.

Film is not sealed on overlap.

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

C.2.4.2 CASH-PAKS

A cash-pak consist of four (4) currency bricks, (16,000 notes), shrink-wrapped together using a Linear Low-Density Polyethylene (LLD-PE) laminated film to form a total enclosure package.

Drawing 30083 Cash Pak of 16000 Notes show the cash-pak, including placement of the brick labels, Exhibit 005.

Cash-pak

Four Bricks to be packaged together as Cash-pak

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

The enclosed cash-pak shall have both ends of the film sealed together by a seal bar. The film overlap shall be sealed together down the length of the package. The package is approximately 12.5” x 19.75” x 5.25” (w x l x h). The package shall be tampered evident and shall not contain any trapped air during the wrapping process. 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 are placed over the clear windows at both ends of the package covering the currency within the package.

C.3 REQUIREMENTS

The following are the requirements of the cash-pak wrapper and oven system be delivered to the BEP. The cash-pak wrapper and oven system shall have capability to seal the four (4) bricks into a cash-pak. The cash-pak wrapper and oven system shall utilize the Government Furnished Materials (GFM) (H.11) and produce cash-pak’s in accordance with the Product Requirements (C.2.4).

C.3.1 SYSTEM REQUIREMENTS (MANDATORY MINIMUM REQUIRMENT)

The cash-pak wrapper and oven system shall have the capability of packaging four (bricks) into cash-paks in full compliance with product requirements. Fusing or accumulation of film onto the oven conveyor shall not be allowed.

The system shall have provisions for detection of abnormal packaging of the product along the process and alert the operators for corrective actions. If the system detects abnormal behaviors of film feed, sealing, air pressure etc., it shall stop operation and prompt for operator intervention. If the operator determines the product to be incorrectly packaged, the system shall allow the operator to repackage the product.

The functional elements of the cash-pak and wrap system shall include the following elements:

A. Brick In-Feed

The cash-pak wrapper and oven system shall be able to utilize an existing flex power expandable in-feed conveyor for feeding the four bricks into the system for processing.

The expandable conveyor model is B/FP1.5. The existing conveyor in-feed dimensions are approximately 939.8 mm (37”) height and 431.8 mm (17”) width.

Conveyor height Conveyor Width

For full flex power expandable conveyor specifications see BestFlex Power BFP 1.5 and BFP 1.9 Conveyor System Exhibit 003.

The system shall automatically package the bricks into cash-paks when present without operator activation.

B. Brick Barcode Reader Integration

Four (4) bricks stacked 2x2 will enter the wrapping system from the flex conveyor.

The system shall have the ability to scan the barcodes from each brick and display the data.

A location for existing barcode readers to scan and store the bar-coded information on the bricks shall be provided. Bricks shall not continue for wrapping until successful reading of the bar codes. The vendor is to specify the electrical interface requirements to signal successful reading of the bar codes. The BL-1301_Datasheet full specification can be found on F.

C. Wrapper

The system shall wrap BEP cash-pak film over the four bricks for the formation of a cash-pak. The overlap the film shall be on top of the cash-pak and totally seals without voids or gaps. The wrapper shall be designed for the intended film, accommodating the slip of the film. Films shall move smoothly through the machine former. The currency bricks shall slide easily into the final overwrap film to form the cash-pak. The system shall provide a means of continuously feeding cash-pak film for sustained processing. The approximate dimensions of the rolls used to wrap the bricks are 12” circumference, 140lbs of weight and 40.5” in width.

The wrapper system shall have the ability to remove any trapped air inside the cash pak.

An example of such mechanism is found in the BEP current packaging process. A to punch two (2) holes on the plastic film are added before it wraps the four bricks together as a cash pak to remove any excess of air as it comes out of the oven. For more details see Exhibit 007.

In the event of a miss-wrapped package, the system shall have a re-wrap capability at the central operation station to allow the operator to pause and stop the in-feed for re-wrapping a cash-pak. The system shall allow the operator to place the cash pak into the correct sequence and continue operations.

D. Sealing Bar

The system shall be equipped with a sealing bar to apply heat and pressure to the overlap on top of the cash-pak film. Target pressure shall be 10 psi in 1 psi increments. The sealing bar temperature shall be adjustable up to 300 degrees Celsius in 1-degree increments. The dwell-time shall be adjustable from 0.1 seconds to 4 seconds. The seal bar shall seal the entire overlap of the film. The operator shall have the ability to control and adjust temperature, pressure, and dwell time from the central operation station.

Figures 1, 2 and 3 provide a pictorial description of the top overlap seal.

Figure 1 - Top Sealing Bar Orientation

Figure 2 - Top View Cash-Pak

Figure 3 - Detail View Cash-Pak

E. Cutting Sealing Bar

The system shall be equipped with a horizontal sealing bar to apply heat and pressure to simultaneously cut the trailing edge of the first pak and leading edge of the subsequent cash-pak. Target pressure shall be 10 psi in 1 psi increments.

The sealing bar temperature shall be adjustable up to 300 degrees Celsius in 1-degree increments. The dwell-time shall be adjustable from 0.1 seconds to 4 seconds.

The operator shall have the ability to control and adjust temperature, pressure, and dwell time from the central operation station

The figure 4 below provides a pictorial description of the sealing bar at the trailing edge of the cash-pak.

Figure 4 - Cutting Bar

F. Oven

It is desired to have two (2) ovens working and receiving product straight form the cutting sealing bar. Ovens shall be provided to shrink wrap the BEP cash-pak film. The ovens shall be capable of operating temperatures up to 300 degrees Celsius with temperature adjustment in 1-degree increments. The ovens shall display upper and lower temperature limits. The ovens shall have an airflow pattern that maintains air flow uniformity and constant contact flow surface area to the cash-paks. At the COS each oven control adjustments shall include, temperature, air flow and PID constants that can be set by performing auto tuning or self-tuning

Fusing or accumulation of film onto the oven conveyor shall not be allowed. Redundant temperature control of the oven to prevent the oven from exceeding temperatures shall be provided. In the event of the oven exceeding upper temperature levels, the oven shall stop automatically. The oven shall have access to mechanical components for regular maintenance or replacement of parts.

In the event of a defective cash-pak coming out of the oven, the central operation station shall have the capability to pause operation. This pause shall allow the operator to rewrap the cash-pak and continue with the correct production sequence.

The design of the oven shall be presented during the 1st Design Review meeting for discussion and review.

G. Cooling System

The cash-pak and wrap system shall be able to remove excess heat and reduce temperature as soon as the cash-pak is out of the oven.

H. Compression Unit

The cash-pak and wrap system shall be equipped with a compression unit to ensure excess air is removed from inside the package and provide a flat surface for subsequent label application.

As product exits the compression unit, the system shall have a minimum of five (5’) feet segment of conveyor length prior to label application and delivery to the palletizer. This area is intended for visual inspection of cash-paks and provide the operator an opportunity to re-wrap packages.

I. Label Application

The contractor shall provide design options for the label application unit to apply the Eagle label and apply the Cash-Pak label to the cash pack itself. The print and apply Cash-Pak labeler shall have the ability to use pre-printed labels for application. This task shall be completed prior to placement of cash-pak on skids by the palletizer.

Eagle labels shall be applied over the “back” of the cash-pak, Specifications for placement on the cash-pak are provided as Drawing 30085 Cash Pak Eagle Label Exhibit 008.

Cash-pak labels shall be applied over the “face” of the cash-pak. The specifications for placement and dimensions of the label are provided as Drawing 30084 r1 Cash Pak Shipping Label Exhibit 009. The system shall use the information scanned from the printed barcode labels on the four bricks prior to the wrapping step for the production of the cash-pak label. Information regarding cash-pak number to brick sequence will be provided by the government prior to the first design review.

Labels shall be applied to the ends of the packages within +/- 0.125 in tolerance vertically and horizontally.

C.3.1.1 Processing Rate:

The cash-pak and wrap system shall demonstrate a minimum of 6 (six) cash paks per minute. The system shall produce 1200 cash paks within a standard 8-hour production shift within the system shall be in production for 6 ½ hours.

The wrapping and sealing units shall be designed to handle the maximum processing rate of the cash-pak and wrap system.

C.3.1.2 Central Operation Station

A free-standing Central Operation Station (COS) shall be provided. The COS shall be equipped with a computerized graphical operational interface, which will display all machine status and operational information, and allow adjustment of all parameters and settings for the machine operation. The cash-pak and wrap system shall include a digital control system to capture and save all settings and all data points for each cash-pak at every station along the way. The interface shall utilize windows and drop-down menus. All controls shall be clearly and permanently marked in English or universally recognized symbols.

If necessary, additional displays shall be strategically located to facilitate operation of the cash-pak and wrap system to minimize the time required for operators to determine the cause of a stoppage and take corrective actions.

C.3.1.3 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.

If applies, equipment shall be furnished 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 1910.23, 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 All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

(B) Noise Level:

The maximum noise produced by the continuous operation of the equipment at full production rate shall comply with the OSHA standard 1910.95, 85 decibels measured on the A-scale (slow response) or, equivalent, a dose of fifty (50) percent.

(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. Covers and guards shall be manufactured for easy removal by Bureau personnel to facilitate removing mechanical and electrical parts for repair.

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

1910.212. 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) as well as warning labels where hands, fingers or any other body parts could become caught between moving parts.

A certified training record be provided detailing the personnel that have been trained on these procedures be delivered to the Bureau.

(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. Warning labels should be visible for any heated surfaces.

(G) Prohibited Materials:

Some materials shall not be used in the equipment. These materials are noted in 75W-08.0-04 Restricted Materials at WCF Attachment 005, and 75D-07.0-07 Restricted Materials at DCF Attachment 008

(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).

(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.

(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.

(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) 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.

(T) Material Handling Assistance:

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

C.3.1.4 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);

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.3.1.5 Unscheduled Maintenance

An unscheduled corrective maintenance event is considered any time maintenance personnel must be called by the operators or when the machine is unable to operate within conformance to the product, functional or performance requirements for more than fifteen (15) minutes.

The mean time between unscheduled corrective maintenance is defined as the Mean-Time- Between-Failure (MTBF). The cash-pak and wrap system shall be designed for a MTBF of components of at least 150 hours. The MTBF will be measured during the extended operation of the system after BAT and Training.

The mean time required to perform corrective maintenance on the system is defined as the Mean- Time-To-Repair (MTTR). The machine shall have a MTTR of less than 4 hours. The MTTR will be measured during the extended operation of the system after BAT and Training. If during the extended operation of the system, the system fails to successfully demonstrate the required MTTR, the contractor shall make any and all corrective actions necessary to decrease the time required to perform maintenance or repair activities.

The MTBF and MTTR of the cash-pak and wrapping System shall be monitored monthly during the warranty period. If the system fails to demonstrate a capability to meet the reliability and maintainability requirements during the warranty period, the Contractor shall take all appropriate actions to make improvements to the system; including but not limited to design changes and/or replacement parts for the system, re-training operator and maintenance personnel, and making recommendations to change operational procedures to enable the system to achieve satisfactory performance.

If during the last 6 months of the warranty period the system has an average MTBF less than 150 hours or an average MTTR of greater than 2 hours; the warranty period may, at the government discretion, be extended for an additional 6 months at no additional cost to the government. If the required reliability cannot be achieved after the six-month extension, a negotiated settlement will be developed.

C.3.1.6 Fault Recovery

The contractor shall provide detailed plans on each operator station detailing the step-by-step activities and corrective actions required to correct the fault condition and return to production.

The vendor shall provide information on the robustness of their control system design to enable the timely return to operation without loss of product tracking. The vendor is encouraged to provide sufficient detail to ensure a complete understanding by the government of their capabilities, experience and knowledge that will support this effort to minimize the risk of non-conformance

C.3.1.7 Preventative Maintenance

The yearly average for time utilized for preventative maintenance on the cash-pak system shall not exceed 3% of the operational time for the Cash-pak system. Major components shall have a MTTR of not more than 2 hrs. Major components shall include the labeler, oven, conveyor system, wrapping unit, delivery unit, and any other component(s) that require that the cash-pak system be down for more than two hours to remove a component for maintenance and replace it with a spare.

All Preventative Maintenance work shall be detailed within the Maintenance Manual, including all checklists, procedures, and recommendation for the time to perform based on a single 10-hour production shift over four days and two 10-hour production shifts over four days.

C.3.1.8 Manning

The cash-pak and wrap system shall require no operator intervention during sustained operation.

Operator responsibility shall be limited to initiating the system and addressing miss-wrapped cash-paks and system alerts.

C.3.1.9 Spoilage

The cash-pak and wrap system shall yield at least 99% acceptable work (no plastic holes, no incorrect labels, cosmetic issues), no more than 1% spoilage.

C.3.1.10 Set-up Time

Set-up time is defined as the time it takes from when a crew begins working on the equipment until the equipment begins production, operating at full speed and meeting the quality requirements for the product.

The total time to set up the equipment to process currency shall be less than one (1) hour.

C.3.2 DESIGN REQUIREMENTS

The machine shall meet the following requirements:

(A) Size

The cash-pak and wrap system will be installed at the WCF in the area as shown in Cash-pak machine area Exhibit 011. The cash-pak and wrap system shall fit within an area of 50’x 200’.

The area provided shall be sufficient for the operation and maintenance of the equipment including material handling based upon maximum production rate. Maintenance access to any area of the equipment to support part replacement shall not be less than 36” (915mm); Contractor is to propose location of access doors/gates to comply with this requirement. Operator aisles for passage around the machine, with the machine in full production, shall not be less than 20” (510mm) in width within the existing DCF; 36” (915mm) for WCF.

(B) Ambient Conditions

Machinery shall be designed for normal operations under the following ambient conditions at the installation site:

(1) Temperature: 72 +/- 3 oF (22.8 +/- 1.7 oC) (WCF is held to +/- 2 oF)

(2) Relative Humidity: 50 +/- 5 %

(C) Utilities

The equipment shall operate with the following BEP provided utilities:

(3) Electrical power: 480 volts, 3 phase, 60 hertz, four wire alternating current

(4) Compressed Air: (ECF) 94 psig, Max dew point of 37.4 F, Max oil content is below

0.1 mg/m3, filtered to 1.0 micron; (WCF) 120 psig, maximum oil content is below

0.01 ppm, filtered at 0.1 microns

(5) Vacuum: up to 20 inches of Mercury (Hg) at ECF; up to 21 inches of Mercury (Hg) at WCF. The use of compressed air driven venture pumps will be considered for low volume applications that require more than 20 inches Hg.

(D) On-Grade Installation

The machine shall be installed on a flat slab. It shall be designed to use no trenches, pits, floor covers or decking. Floor recesses may be approved by the COR at feeder and delivery ends to facilitate material handling if they are between the internal supporting structures of the machine.

Floor recesses shall be no deeper than 1 inch (25 mm). Piping and wiring shall be connected internally in the system, and as necessary, routed via overhead troughs.

C.3.2.1 IT Components, Configurations and Controls

(A) Managing Cybersecurity Risks

BEP reserves the right to request the Contractor provide information related to the non-embedded IT components and how the Contractor solution may be configured or implemented for supporting management of cyber risks in accordance with FAR 39.10; compliance with Federal Information Security Management Act (FISMA) (44 U.S.C. 3544); OMB’s implementing policies including Appendix III of OMB Circular A-130; and guidance and standards from the Department of Commerce’s National Institute of Standards and Technology (NIST). To assist with scoping, BEP has identified the following Federal Information Processing Standards (FIPS) that are applicable to the non-embedded IT components that may be present within the Contractor solution:

FIPS 200: Minimum Security Requirements for Federal Information and Information Systems for a FIPS 199 LOW Baseline system (Reference:

http://csrc.nist.gov/publications/PubsFIPS.html).

FIPS 201-2: Personal Identification Verification (PIV) of Federal Employees and Contractors; and

Combined Treasury TD P 85-01 and BEP Minimum Standard Parameters for Unclassified Systems TD P 85-01 Exhibit 012.

(B) Operating Systems (OS) and Third-Party Applications (TPA)

For host operating systems (OS) of non-embedded IT components, the components shall utilize software under mainstream support by the OS Contractor. For example, if the OS is Microsoft Windows Workstation, then the solution must use a version of the operating system that is still supported by Microsoft. Similarly, if the OS is Linux based, then the solution must use a version that is actively supported by the distribution being utilized (e.g., RedHat, SUSE, Debian, etc).

The OS shall be configured using the configuration standards in accordance with NIST SP 800- 70 Rev 3. Relevant configuration standards are found at <https://web.nvd.nist.gov/view/ncp/repository> with preference given to Tier 3 and 4 (SCAP validated) configuration standards with the exception that Windows 7 may only utilize the US Government Security Baseline (USGCB).

BEP recognizes that the configuration standards may not be compatible with full system functionality. To this end, the Contractor shall identify the standard selected for the OS and document any deviations from the standard required for normal operations. The Contractor shall provide baseline deviations as part of the response package or within agreed upon number of days after contract award to provide sufficient time to assess and coordinate remediation actions to minimize impact to contract schedules and efforts. The requested deviation(s) shall include the justification for the need to deviate from the setting and identify any risk mitigation either existing or planned to compensate for the deviation. BEP IT Security shall review all deviation requests and make a risk-based determination to allow or reject the request. Depending on the associated risk level for rejected deviation requests, the Contractor shall address the rejected deviation requests prior to or during the first maintenance period after system deployment.

For third-party applications (TPA) running on non-embedded IT components, the components shall utilize software under mainstream support by the TPA Contractor. For example, if the solution required the use of Microsoft Office, then the solution must use a version of Microsoft Office that is still supported by Microsoft.

For third-party hardware and peripherals of non-embedded IT components, the components shall utilize hardware and peripherals that are supported and maintained by the third-party equipment or hardware Contractor. This shall include being able to obtain replacement or spare parts for the components from the Contractor.

For components identified as obsolete, the contractor shall coordinate the replacement or upgrade such that the process is completed a minimum of 6 months prior to the expected date of obsolescence. For these special cases, the contractor shall provide the procedures to execute in order to perform the replacement or upgrade or the identified obsolete component(s) and return the system to operational capacity.

Obsolete shall be interpreted as no longer supported by the hardware or software Contractors or third-parties to include but not limited to hardware components no longer being manufactured, or software end-of-life.

Computer systems located in production or hazardous areas shall be housed in NEMA-12 rated enclosures to protect equipment from dust (and splashing liquid).

(C) Standard Operating Processes/Procedures

Non-embedded IT hardware and software components shall be included in the overall equipment preventive and operational maintenance (O&M) processes and schedules to include replacing or upgrade obsolete and worn components. For normal hardware and software preventive and O&M processes, the contractor shall provide standard operating procedures (SOPs) that include, at a minimum, the procedures for backup and recovery, installation, and configuration of TPA’s, and the deployment patches and updates for the OS and TPA’s.

Notes: For workstation-class components, backup processes may leverage the BEP Acronis application to make images of system and data drives. For server-class components, backup processes may leverage the enterprise common vault backup services.

(D) Network Connection

All components attached to the BEP Local Area Network (LAN) shall support Gigabit Ethernet (10/100/1000Mb/sec) and TCP/IP protocols. Network interface cards (NIC) shall support 10/100/1000Base-Tx/RJ-45 connections. If utilized, Simple Network Management Protocol (SNMP) enabled equipment shall support SNMPv.3.

All physical network connections and addressing to and from the BEP network (not within networks of embedded systems) shall be initiated and maintained by the Office of Information Technology (IT) Operations. The Contractor may assume that they will be provided IP addresses within the same class C network for connectivity to the BEP Network. If a secondary, internal network is used, the contractor shall not utilize addresses in the 10.0.0.0/8 range but shall use IP addresses that are compliant with RFC 1918 for IPv4/IPv6 addresses. The contractor will coordinate with OITO on this address space assignment to verify that the addresses and networking configuration do not conflict with existing network configurations. In accordance with BEP Directives, this acquisition requires all functionality, capabilities, and features of non-embedded IT components to be supported and operational in both a dual-stack IPv4/IPv6 environment and an IPv6 only environment. Any IT component or system utilizing a second internal network for connecting to a machine network must use a separate NIC for such a connection and is considered an embedded IT component or system; as such this component is exempt from the “IPv6 only” requirement as it relates to this separate NIC because the machine network may use “IPv4 only” or a proprietary protocol.

(E) Database Connection

The Contractor solution shall provide for the ability to send data to the BEP Database management systems (DBMS). The DBMS is currently Oracle version 12.1 as of this writing. The Contractor solution shall be able to get raw PLC data to Oracle 12.1

(F) Backup and Recovery

All production systems shall be specified with backup and recovery mechanisms and standard operating procedures. The contractor shall provide SOP and support to allow BEP to establish at a minimum backups capability consisting of at least three separate backups, Grandfather, father, son; two (2) copies of each backup, one of on-site storage and one for off-site storage; store on non-volatile media. The contractor shall assume that BEP is responsible for coordinating the storage of the off-site backups.

(G) Fault Tolerant System Design

All Computer systems critical to the continuous operation of the equipment (i.e., the equipment will not operate without it running) whether internal or external to the equipment, should have some form of high availability built into the design of the systems. High Availability describes a computer system or component designed in a manner to maintain a high degree of uptime and ease system restoration in a failure. Specifically, systems are designed in a way to ease the replacement of entire systems or system components in the event of a failure. (i.e., hard drives are easily accessible and replaceable; computer systems are easily accessible for inspection or replacement.)

C.3.2.2 Uniformity

All equipment delivered to the BEP under the terms of this contract shall be of the same type, model, software version etc. Any changes that are made to the machine or support systems, including software shall be retrofitted onto previously accepted system(s) under this contract. The installation of changes on a machine previously accepted shall not occur until after the change has been proven during a BEP Acceptance Test.

C.3.2.3 Component Access

Components that require regular service, such as motors, pumps, etc., shall be located to facilitate maintenance and repair. Access to these parts shall not take more than 15 minutes by no more than 2 persons. All enclosures, which conceal gears, shafts, bearings, etc., shall be accessible without the requirement of dismantling or removing of sub-units or components.

Sub-assemblies that require frequent adjustment, maintenance, replacement and repair, such as main motor, banding units, numbering blocks, note counters, sealing bars, etc., shall be of modular design to facilitate easy and quick replacement.

C.3.2.4 Programming - Interrogation (PI)

A Programming-Interrogation (PI) unit shall be provided with the machine to allow trained maintenance personnel to perform diagnostic, maintenance and support services with all embedded electronics; PLCs, PCs, Linear Drives, etc.

The PI shall be capable of accessing all programs in use on the machine, cloning hard drives, making back-up copies, modifying programs, and interrogation of control functions. The PI shall be software password locked to ensure against unauthorized access. The PI shall be provided with all necessary applications to interface all control systems, all source/project files, and all parameter listings for individual units.

C.3.2.5 Drive Controls

The main electrical drive of the machine shall have infinitely variable speeds. The range of the drive speed shall be from a crawl speed to the maximum operational speed. The speed shall remain at the set point within +/- 1%. Variations in speed of any preset value between no load and full load shall not affect the performance of the machine or any subsystem. The main drive motor shall be selected for high efficiency and continuous operation without overheating.

Upon initiation of the start button, the electronic drive controller shall immediately monitor all system circuits.