titre principal c -...
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Titre principal c.40
Kongres Świata Przemysłu
Farmaceutycznego i
Kosmetycznego
Aleksander Romanowski, Łódź 07-09.11.2017
Titre principal c.40BOCCARD POLSKA history
• 1996 March - Creation of Boccard Polska Sp. z o.o. in Kraków / Poland
• 1996 May - Starting of first project – Polfa Rzeszów new pharmaceutical factory
as subcontractor of BSA / France
• 1997 January - Starting of first independent project – Polser Sp.z o.o at Siemiatycze / dairy milk factory / new pasteurisation unit
• 2002 March - UDT licence No. UC-12-77-M/1-02 for supply of pressure and dangerous liquids piping
• 2004 June - PED licence for piping supply in module G
• 2006 December - Moving of company near Warsaw
• 2008 June – First Industrial Project over 6,5 mil EUR
• 2012 December - ISO certification (PN-EN ISO 9001:2008, PN-EN ISO 14001:2004, PN-N -18001:2004 / OHSAS 18001)
Titre principal c.40STRATEGYintegrator, process & utilities installations
OUR GLOBAL AND
LASTING OFFER
EngineeringProject Management
ManufacturingPrefabrication skids
Automation + FAT
Construction & CommissioningProject supervision - Commissioning
SAT / IQ / OQ / DQ
Operators training
Technology
& ServicesMaintenance
Training
Permanent improvements
FROMINDEPENDENT
MODULAR SKIDS TO FULL PRODUCTION
PLANTS
Titre principal c.40Expertise
Personnel:
• 148 permanent personnel
• Construction team with capacity - about 370 000 working hours yearly
• Site Managers, Project Managers, Project Engineers, Automation, Foreman's, Welders,
• Fitters
Experience:
• over 650 Industrial projects realised successfully, with last 5 years average >40
• projects/annum
• >60% repeatable business
Workshop:
1 500 sqm clean - dedicated for SS piping and skid’s prefabrication
3 200 sqm covered – dedicated for CS piping
Titre principal c.40Organisation
BOCCARD [PBO]
Dyrektor Generalny
[PSL]
Kierownik Sprzedaży
[PSL]
Starszy Inżynier ds. Ofertowania
[MST]Inżynier ds. Ofertowania
[WSO]
Specjalista ds. Wsparcia Sprzedaży i Marketingu [
EJA]
Kierownik Sprzedaży i
Rozwoju PHARMA
COSMETO [ARO]Kierownik
Sprzedaży i Rozwoju
INDUSTRIAL [KBI]Młodszy
Kierownik Sprzedaży i
Rozwoju FOOD [KJP]Młodszy
Kierownik Sprzedaży i
Rozwoju FOOD [wakat]
Kierownik BOCLUBE®
[AMA]Kierownik Sprzedaży EUROPE
BOCLUBE®
[wakat]Kierownik Wsparcia
Technicznego BOCLUBE®
[MSK]
Kierownik NGK [DCI]
Lider [LSW]
Serwisant [13]
Kierownik Projektu [MBO]
Lider TRW B-B [PHO]
SerwisantTRW B-B
[4]SerwisantTRW CZ-
DZ [8]
Specjalista ds. Administracyjnych [PMF]
Kierownik Realizacji i Inżynieringu [MKO]
Kierownik Produkcji
i Prefabrykacji [AWI]Młodszy
Inżynier Projektu
[AZA]
Brygadzista [RPI]
Spawacze [2]
Monterzy [5]
Kierownik Projektu [AWI]
Kierownik Budowy [ZBR]
Kierownik Robót [ZZI]
Inżynier Budowy [PMA]
Młodszy Inżynier
Budowy [KPI]
Brygadzista [RWE, EGA, ARE, KLE]
Spawacze i monterzy [13]
Kierownik Projektu [AJA]
Kierownik Projektu [LZA]
Kierownik Projektu [PTA]
Kierownik Projektów
Automatyki [BBI]
Inżynier Automatyki
[DST]Młodszy Inżynier
Automatyki [ASZ]Koordynator
Zasobów Produkcyjnych
[CPI]
Inżynier Projektu [JWA]
Inżynier Projektu [KPR]
Inżynier Projektu [WDU]
Inżynier Projektu [TKA]
Inżynier Projektu [PMU]
Inżynier Projektu [MRO]
Specjalista ds. Dokumentacji
[SKL]
Inżynier Budowy
BOCMAN [TKU]
BOCMAN Brygadzist
a, Spawacz,
Monter [36]
Kierownik Robót [RJA]
Kierownik ds. Operacyjnych
[DJA]
Kierownik HR [AJO]
Kontroler Operacyjno-Finansowy
[AOW]
Specjalista ds. Administracyjn
ych [MWD]
Recepcjonistka
[MLI]
Starszy Specjalista ds.
Zakupów [WTO]Starszy
Specjalista ds. Zakupów
[KCY]
Specjalista ds. Logistyki [KCZ]
Specjalista ds. Zakupów
[AST]
KSIĘGOWOŚĆ I PŁACE [firma zewnętrzna]
Główny Specjalista ds. Jakości (Pełnomocnik ds. ZSZ, Główny Spawalnik)
[AMU]
Specjalista ds. BHP i Ochrony Środowiska
[RSM]
PROCESS SOLUTIONS
[JKO]
Asystentka ds. Administracyjnych
[DMI
Titre principal c.40Design/Sudies
PID Design and integrating your processes
Conception 3D / SOLID WORKS:
Complete database of suppliers integrated and referenced to ensure a
better adaptability
A better visibility of the project to allow better ergonomics and future use
of the installation
Optimization of modifications thanks to integration of all data in the 3D
model, including easy generation of drawings and isometrics
Compliance:
cGMP, GAMP4, ICH guidelines & FDA requirements
ATEX European guidelines
Titre principal c.40Qualification/Validation
Quality control methods for your installation qualification:
FAT: Factory Acceptance Test
SAT: Site Acceptance Test
DQ: Documentation Qualification
IQ: Installation Qualification
OQ: Operational Qualification
PQ: Support to Performance Qualification
Titre principal c.40Automation
Process Control
Functional analysis, supervision, production follow-up
Process automation engineers, experts in cosmetics and
pharma processes
Standardized integration: integration of the main market
solutions for a better flexibility and a quick configuration
Turnkey automation systems: integration of hardware,
software, network, administration tools and data management
Compliance: ISA S88, GAMP4, 21CFR part 11
Titre principal c.40Vessels and agitators production
Design and production of Stainless steel vessels
Agitators, homogenisers design and constriction
Stainless steel tanks for PW/DI/WFI and raw materials
0,2-50m3
Titre principal c.40Project Management
Planning
Quality plan
Technical doc reviewChange management
CLIENT Indice Diffusé le :
OBJET Projet A B C D E F
4. SPECIFICATIONS
249 SP01 PROCESSING VESSEL 6000 L
249 SP02 PREPHASE VESSEL 3600 L
249 SP03 CIP VESSEL02 /08 /2001
MTB
28 /08 /2001
MTB
04 /07 /2001
249 SP05 CENTRIFUGAL PUMP - CIP
20 /08 /2001
249 SP06 VACUUM PUMP
20 /08 /2001
249 SP07 METERING PUMP
249 SP08 BOTTOM VALVE
05 /04 /2001 09 /08 /2001
249 SP09 BUTTERFLY VALVE
05 /04 /2001 09 /08 /2001
249 SP10 DIAPHRAM VALVE
249 SP11 SEAT VALVE
249 SP12 PROCESS CHECK VALVE
249 SP13 SIGHT GLASS
249 SP14 PRESSURE TRANSMITTER05 /04 /2001 08 /08 /2001
249 SP15 TEMPERATURE TRANSMITTER
05 /04 /2001 08 /08 /2001
249 SP16 LEVEL SENSOR05 /04 /2001 08 /08 /2001
249 SP17 FLOWMETER
249 SP19 PRESSURE INDICATOR
249 SP20 THEMPERATURE INDICATOR
249 SP21 PRESSURE RELIEF VALVE
249 SP23 AUTOMATIC BALL VALVE
249 SP24 MANUAL BALL VALVE
249 SP25 UTILITIES CHECK VALVE
249 SP26 Y FILTER
249 SP27 STEAM TRAP
249 SP29 MICROMETRIC MANUAL VALVE
249 SP30 PRESSURE REDUCER
249 SP31 ELECTRIC VALVE
249 SP32 VACUUM BREACKER
249 SP35 POSITIVE DISPLACEMENT PUMP30 /07 /2001
BOC USA
03 /08 /2001
BOC USA
249 SP36 PLATE EXCHANGER
249 SP38 PROCESS FILTER
249 SP39 WEIGHING SYSTEM
23 /08 /2001
249 SP40 FLOW DETECTION
249 SP41 RUPTURE DISK
249 SP42 SAMPLE VALVE08 /08 /2001
249 SP43 AIR / LIQUID SEPARATOR
02 /08 /2001
MTB
249 SP45 PROXIMITY SWITCH
249 SP46 HOSES
249 SP47 SECURITY BARRIER
249 SP48 ANALOGIC LEVEL
08 /08 /2001
E+H
N° DE
DOCUMEN
T
Doc lists
Organisation chart
Risk analysisProductivity reporting
Titre principal c.40Prefabrication / Workshops
Spawanie orbitalne Endoskopia
Welds Marking
Material Take Off
Spool Drawing
Iso Receiving
Data Book
Welding procedures
Welders Performance
Progress Reports
NDE
Material Traceability(bar-coding)
Weld Traceability(bar-coding)
Material Allocation
Material Receiving
Purchase Order
Requisition
• 1 500 sqm covered dedicated
for SS piping and skid’s
prefabrication
• 3 200 aqm covered dedicated
for CS piping
• BOCCARD Piping dedicated
workshops
• Same BOCCARD
methodology over all world
• Dedicated software to follow
all prefab process -
BOCTRACK
Titre principal c.40Mechanical package
Expertise in Installation services
Spawanie orbitalne Endoskopia
Follow up of work progress
Daily weld sampling
Isometric drawing
Material lists
• LOCAL resources – GLOBAL
Expertise
• Integration of mechanical
package, process control and
electrical package
• Own resources specialized in
installation services since many
years
• Relocations of complete lines
and equipment
• Revamping and rebuilding
Progress Diagram
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Weeks
Pro
gre
ss in
%
Forecast
Done
Titre principal c.40PQP
(Prevention and Quality )
• PQP (Prevention, Quality and
Productivity) same standards,
methods and procedures as
BOCCARD Enterprises
• Certified for integrated system:
PN-EN ISO 9001:2009
PN-EN ISO 14001:2005
PN-N -18001:2004 / OHSAS
18001:2007
0,0
2,0
4,0
6,0
8,0
10,0
12,0
Mondelez
EKO -Benz
ABB COLGATE
DANONE
Fortum
Wskaźnik (Suma punktów/liczbakontroli)
11,1 10,5 7,9 8,0 9,0 10
Wart
ość w
skaźn
ika o
cen
y
Podsumowanie ocen stanu bhp na budowach 2017
Titre principal c.40Maintenance Services
• Dedicated team for Maintenance
• Process Expertise and support in automation –
breakdown service 24/7
• Preventive and Corrective Maintenance contracts for
different sites
• Highly specialised services for fluids handling (Total
Fluid Management)
Titre principal c.40Some reference PROJECTS
• BIOETANOL – Goświnowice
2008-09
• Processing and Technological
piping installation for 2 main
building
• Delivery, prefabrication,
erection and start-up of
complete pipe lines – 600 T of
SS and CS piping materials
(including valves) ASME.
• Start-up and As-build
documentation
• Over 140 000 hours
Titre principal c.40Some reference PROJECTS
• ZACHEM – Bydgoszcz 2012
• Delivery, prefabrication,
erection and start-up of
complete pipe lines – 180 T of
SS, CS, PVDF, Teflon and Glass
lined piping materials
• Mechanical erection and
assembly of all equipment –
250T (columns with glass
packing, vessels, reactors, ect.)
• Start-up and As-build
documentation
• Over 100 000 hours
Titre principal c.40Some reference PROJECTS
• POLONIA AREO – RENCO 2014-15
• Cold Flow Turbine Test Facility in Zielonka near Warsaw
• Main contractor for piping and mechanical installation
• Prefabrication, erection and start-up of complete pipe lines –
350 T of SS and CS piping materials
• Mechanical erection of 550 T equipment
• Start-up and As-build documentation
• Over 120 000 hours
Titre principal c.40Some reference PROJECTS
Process Solutions
• Toothpaste skid
• Design, delivery,
prefabrication, erection and
start-up of complete skid for
toothpaste production
• SS piping materials ASME BP
• Valves GEA and PBM
• Start-up and As-build
documentation
Titre principal c.40Some reference PROJECTS
Process Solutions
• Hair care cosmetics platform
• Design, delivery,
prefabrication, erection and
start-up 6 different skids
• Installation of Storage and
Reactor tanks
• As-build documentation
Titre principal c.40Some reference PROJECTS
Process Solutions
• Danone Kemerowo and
Labinsk 4 lines CIP stations
• Prefabrication of
complete 4 lines CIP
stations
• Valves GEA, Spirax
• Complete delivery and IO
tests of Electrical Cabinets
based on Simens equipment
• As-build documentation
Titre principal c.40Some reference PROJECTS
COSMET market
• L’Oreal Kosmepol Kanie - 1999 -2007
Skid Valinox revamping – new valves , control system and electric cabinet
Mixing veesel ( pilot batch ) 500 dm3 – delivery , utilities piping connection
Piping installation for hair dye – production skid and storage tanks delivery , piping for product , control
system
TA installation - storage tanks ( 6x25m³) for raw materials delivery , transfer piping and CIP connection ,
control system
Alcohol installation (ATEX) - storage tanks ( 2x30m³) delivery , transfer piping , control system
Piping installation for hair dye UP2– storage tank 5m³ delivery , piping for product and utilities , control
system
Krieger mixing veesel relocation - piping for product and utilities , control system
• L’Oreal Kosmepol Kanie - 2009 – 2012
Goavec platform revamping - installation of storage and distribution of product and complete installation
of utility delivery , control system , InTouch and process programme delivery , operation platform
modernization , wiring and electric cabinet , electric documentation delivery
Modernization of utility installation UP1- (steam , condensate , compresed air , DEMI water , sewage
and nitrogen) - piping delivery
Etanol installation audit – raport after audit and proposition of problem solving
Titre principal c.40Some reference PROJECTS
COSMET market• Oriflame Warszawa – 1998-2006
PW cold water – storage and piping distribution , control system , IQ/OQ qualification
Liquid production department revamping – proces and utility piping modernization , new operation
platform from AISI 304 delivery , existing skids relocation ,6 new skids installation
New platform for cream and lotions installation - product and utility piping connection delivery , electric
installation , new operation platform delivery
DEMI water loop with connection to reactors - piping for water distribution delivery
Utility installation for new production building – piping for media (steam , condensate , compresed air,
DEMI water hot and DEMI water cold )– delivery with detail design and start up
• Oriflame Warszawa – 2016-2017
Shampoo production platform- design and delivery production reactor 5000l with 300l additional tank,
automation and control system , operation platform delivery , product and utility piping connection, FAT
and SAT, commissioning and start up installation, qualification
• Oriflame Warszawa – 2012-2015
Heating and cooling jacket UDT 1-11 skid’s revamping- pressure test and termovision for lackig
identification , welding methodology preparing , UDT body documentation
Raw material installation - storage tanks ( 2x30m³) for raw materials delivery , transfer piping and
Ystral delivery and connection , control system, detail design, electric cabinet
Titre principal c.40Some reference PROJECTS
COSMET market
• Colgate Palmolive-Świdnica – 2013-2016
WIP Tanks phase I and phase II– the scope of project was design , delivery and execution installation for
toothpaste, pumps and indicators assembly, pipelines passivation, pipelines suport material, pressure
test, endoscopy , marking, existing pipelines disassembly, sliders prefabrication and assembly, detail
design and 3D drawings, start up installation
MAKING –liquid installation for oral rinse production- product and media installation detail design
(heat water, CIP, EP water, sewage, compressed air, nitrogen installation, vacuum installation, steam and
condensat for main mixer nr1), new pipeline 316L acc. ASME BPE Ra<0.63μm, delivery and assembly:
pumps , filters , valves , PIG station, installation passivation, pipelines insulation, orbital welding, as-built
documentation, start up installation
TANKFARM PIPELINES- raw materials distribution installation - installation detail design, new
pipeline 316L acc. ASME BPE Ra<0.63μm, delivery and assembly: pumps , filters , valves, installation
passivation, orbital welding, as-built documentation, start up installation
Titre principal c.40Some reference PROJECTS
COSMET market
• Colgate Palmolive- Świdnica – 2013-2017
WIP pipelines – 9 products pipeline 4" with the supports , detail design , pressure test , endoscopy ,
marking, as built documentation, start-up, new pipeline 316L acc. ASME BPE Ra<0.63μm, orbital welding
Skids dilution- detail design and 3D drawings, two skids v=500l for concentrate oral rinse liquid dilution
prefabrication on workshop and assembly on site delivery, FAT test , 316L acc. ASME BPE Ra<0.63μm,
orbital welding, pressure test, endoscopy, marking, as built documentation, start-up and commissioning
on site, SAT
Skid LEE 7– detail design and 3D drawings, prefabrication skid for components ( pigment, flavour and
SLS suspension) mixing with toothpaste base , static mixers prefabrication , material 316L acc. ASME
BPE Ra<0.63μm, pressure test, endoscopy, marking, as built documentation, start-up and commissioning
on site, SAT
• Colgate Palmolive-Therwil (Switzerland) – 2015-2016
Meridol Active Solution skid – Meridol Active Solutions installation , detail design and 3D drawings
skid prefabrication on workshop and assembly on site, dynamic FAT test , automation and control
system, new CIP, HCl, ozonated water and nitrogen pipelines execution, IQ/OQ installation qualification,
pipelines passivation, pipelines suport , pressure test , endoscopy , X-ray and marking, as built
documentation, start-up and commissioning on site, SAT, equipment delivery: mixing vessel v=2000l
(duplex 1.4410) with bottom agitator, pumps, valves, filters, manometers , flexible connections
Titre principal c.40Some reference PROJECTS
PHARMA market
• ICN Valeant Polfa Rzeszów– 1996-2006
Drug Forms II
Ointment department – revamping piping installation
Syrup department – revamping skid production
Suppository department – revamping installation
System PW & WPW -installation storage and piping distribution,
start up, IQ/OQ qualification
System CIP installation
Drug Forms II
Suppository production line modernization for suspension production
Drug Forms I
Clean compresed air installation conceptual design
Mobile tank 300l with stirrer– detail design and delivery with electrical cabinet and automation, DQ/IQ/OQ qualification, FAT and SAT, commissioning, as buit documentation
• GSK Poznań– 1998-2000
DEMI water installation –storage and piping distribution , control system , IQ/OQ qualification
Nitrogen installation for aerosols production department
Ointment production deparment revamping
CIP system installation
Titre principal c.40Some reference PROJECTS
PHARMA market
• Polpharma S.A.- Starogard Gdański– 2015-2016
Production hall H26- the scope of project was detail drawings ,
delivery and execution installation for API production, new production
and media installation execution, production equipments assembly,
pumps and indicators assembly, pipelines passivation, pipelines suport
Execution pressure test , endoscopy , marking, equipment delivery:
valves, filters, manometers , flexible connections, piping materials
and AKPiA elements.
• Polpharma S.A.- Starogard Gdański– 2003-2005
Department of Infusion solutions
Purified Water Loop
Vials Department
Storage and distribution PW system
Storage and distribution WFI system
Distribution clean steam system
Laboratory
Purified Water Loop
Department of Infusion solutions
Storage and distribution WFI system
Titre principal c.40Some reference PROJECTS
PHARMA market
• IBA Bioton S.A.- Macierzysz– 2010-2011
Insulin installation- Complete installation for the production of insulin
with passivation , pipe insulation type ”pipe in pipe insulation ” , orbital welding ,
weld inspection 100% endoscopy, as-built documentation, commissioning
• Sandoz LEK S.A.- Stryków– 2014
Clean compressed air installation modernisation
PW water installation modernisation
Execution of detergents installation connections
Piping passivation , detail design
DQ/OQ/IQ qualification
• Gedeon Richter - Grodzisk Mazowiecki – 2011-2015
Execution and delivery connection of technical utilities installation and passivation , insulation , piping
pressure tests: compressed air, DI purified water, clean water, ventilation .
Execution and delivery connection of technical utilities installation and passivation , insulation , piping
pressure tests to fluide granulator.
DI water loop passivation
Titre principal c.40Benefits
• Access to the vast knowledge and many years of BOCCARD
experience in cosmet and pharma projects (in Poland since
1996 in the world almost 100 years)
• Methods and procedures to ensure the realization of projects
in the sector of design and built at a very attractive cost
while maintaining the highest standards of quality and safety
• The possibility of projects of different scale and scope (thanks
to the presence in the local market)
• You can reduce costs by managing as general contractor
metody
Titre principal c.40Our values
Crucial values:
Boccard „Alliance for success” – relations with the
Customer are our priority
Safety of our employees - zero accidents are our
purpose
We are putting our Employees to the development–
Boccard Academy
In 2013 we received a prize from „Le Figaro Économie”
for our efforts in area HR – BocFollow
Boccard
Polska –
862 days
without
accident !
Titre principal c.40Corporate Social Responsibility
Obligations :
“Safety first, On Time, On Spec, On Budget”
Global Compact Of the United Nations - annual report of the
Boccard company in four areas:
Human rights,
Labor standards
Environment
The fight against corruption
Cost opptimalization - Opex i Capex
Titre principal c.40THANK YOU FOR YOUR ATTENTION
BOCCARD POLSKA Sp. z o. oAleje Jerozolimskie 270, 05-816 Michałowice
tel.: (+48) 22 380 01 30
[email protected] www.boccard.com