2008 02 27 artenius ppe bierne (france) report hdi

6/3/2015 2008 0227 artenius ppe bierne (france) report hdi
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2008 0227 artenius ppe bierne (france) report hdi
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Graeme Cross (3 SlideShares) , Business Development Manager at Aon
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1. ! " #!$ ! $ Company ARTENIUS PET PACKAGING EUROPE Zone d’Entreprises de Bergues
Bierne F – 59380 BIERNE FRANCE Reason Risk Inspection / Survey Report Conferred with Mr.
William Faye APPE – financial director Mr. JeanLuc Descarpentries APPE – risks and projects manager
Mr. David Molias LA SEDA DE BARCELONA – credit & risk head Mrs. Susan Uttley WILLIS S&C c.
– director international unit Mr. Alberto Cantero Martínez WILLIS S&C c. – technical director Mr.
Vincent Fraissé GRAS SAVOYE – account executive Mr. Carlos Carasusán ZURICH Global Corporate
Spain – risk engineer Occupancy 4005 – Manufacturing of monolayer PET preforms Report No 680021
08 Inspected on 27.02.2008 Surveyor Glenn van Mele HDIGerling Industrie Versicherug AG
Tervurenlaan 273 B 1 B – 1150 BRUSSELS BELGIUM Telephone Telefax email + 32 (0)2 773 08 54 +
32 (0)2 773 09 90 glenn.vanmele@ hdigerling.be
2. HDIGERLING Sicherheitstechnik Report No. 000000/08 RISK Engineering Company, date of
survey Page 2 ! " #!$ ! $ List of Contents Page 1. Result of the
Survey............................................................................................................3 1.1.
Summary.............................................................................................................................3 1.2. Change and
Comments......................................................................................................3 1.3. Risk
Improvement...............................................................................................................4 1.3.1.
Recommendation................................................................................................................4 1.3.2. List of
Priority ......................................................................................................................8 2. General
Description ............................................................................................................9 3. Industrial Process
.............................................................................................................11 3.1. Production Process
Description........................................................................................11 3.2. Production Flow Chart
(Optional)......................................................................................12 3.3. Specific Process
Hazards.................................................................................................13 3.4. Result of the HGST Grading
System...............................................................................14 4. Building Description,
Stores..............................................................................................15 5. Technical

Data..................................................................................................................17 5.1. Machinery
Breakdown.......................................................................................................18 6. Fire
Protection...................................................................................................................19 7. Organisation and
Safety Management .............................................................................21 8. Risk analysis Business
Interruption ..................................................................................22 8.1. Basic data
.........................................................................................................................22 8.2. Business Exposure
...........................................................................................................22 8.3. Specific bottleneck units.
Protection Measures ................................................................22 8.4. Interdependencies
............................................................................................................22 8.5. Essential internal/external
Suppliers and Customers .......................................................22 9. Other Perils
.......................................................................................................................24 10. Loss History
......................................................................................................................24 Remark The result of this
risk survey follows the current and actual risk situation, seen during the inspection. This re port does not
focus on the view of administrative regulation but in the entrepreneurial view to assure the avail ability
of productivity, the facilities or other units of the plants (like stores, bottlenecks etc.)
survey Page 3 1. Result of the Survey 1.1. Summary The site is located in the northwest of France, close
to Dunkerque. APPE only owns a part of the buildings (about 14.885 m²), with the majority owned by the
company Ball Packaging used for the manufacturing of cans for the beverage industry. The 2 com panies
are separated by means of a fireproof wall (fire rating 2 hours) showing no defi ciencies. This plant,
formerly known as Amcor PET Packaging France is involved in the manu facturing of monolayer PET
preforms using 20 injection moulding machines. The pre forms manufactured in this site are mainly used
for the packaging of food, drinks and detergents, with CocaCola being the largest client. Operations take
place in a 5shift system, 365 days per year. About 1,8 billion preforms are manufactured per year with
the total annual capacity being 2 to 2,1 billion preforms. It benefits a good fire safety organisation with
attention to the ignition sources that are well under control. Only minor remarks were made in order to
further eliminate or re duce these causes of fires. Furthermore, the site benefits a basic fire separation
with the warehouse being separated from the production area. Special attention is required in order to
keep the fire separation at high level. During the survey, it was observed that a fireproof door did not
fully close and that some cable penetrations were not prop erly sealedoff. The housekeeping was found
to be at high level. The fire protection on the other hand was rated poor. First of all, the external walls are
composed of double steel sheeting with the combustible polyurethane foam insulation. The warehouse
area as well as the offices benefit an automatic fire detection installa tion, but the production area is
completely unprotected. The sprinkler protection in the warehouse housing a very high fire load is totally
inadequate since the design criteria are no longer met. This is due to the type of material stored combined
with the storage height. This is only slightly compensated by the adequate equipment for manual fire
fighting (fire extinguishers, hose reels, hydrants, …). With the highest values for property damage
concentrated in a nonprotected area and the consequent high business interruption exposure, this site
rates poor from a fire safety point of view. 1.2. Change and Comments No changes are planned for this
moment.
survey Page 4 1.3. Risk Improvement The following recommendations can improve the current risk
situation from our point of view. 1.3.1. Recommendation Organisation and Human Element 08.01 Re
evaluation of the alarm procedures (callin of the public fire brigade) During the evaluation of the alarm
procedures, it was observed that the own fire fight ing team has to make a first attempt to extinguish the
fire. Only if this attempt is not successful, the fire brigade is called in by a member of the fire fighting
team. Since in this case a lot of critical time would be lost, and bearing in mind the relatively long
response time needed by the fire brigade, it is highly recommended to reevaluate these procedures. It
should be so that if a fire is observed, the fire brigade is informed immediately. The only exception can be
a very small fire that is extinguished within seconds. 08.02 Lighting installations: use of safety starters
Strip lights using classic starters could invoke a fire when the lamp is defect resulting in a starter that tries
continuously to start the lamp. Often, this causes an overheating of the starter that could set the plastic
material on fire. Burning drops (or the lamp itself falling down) could cause a fire by igniting the
combustible materials stored be low. It is therefore recommended to use safety starters (with a red reset

button). Not only is the risk of overheating avoided, the power consumption is also reduced since only a
limited number of attempts to start up the lamp are made. 08.03 Control on mobile and household electric
equipment Although the electrical installation is checked periodically, the mobile equipment and private
electrical equipment is not checked. Since the fire statistics show that some losses have their origins in
this equipment, we highly recommend to have both the mobile equipment owned by Artenius PET
Packaging Europe (e.g. electric heating units, coffee machines, microwaves, water cookers, …) as well as
the private equip ment brought in by staff (radio, …) checked at least once per year. The German
VDE0702 guideline is a good example of how this test should be done: equipment with protective
conductor: Protective conductor resistance < 0,3 Ohm Insulation resistance > 0,5 MOhm Equivalent
leakage current: up to 6KW; < 7 mA, as from 6 kW: < 15 mA Protective conductor current < 3,5 mA –
Touch current < 0,5 mA equipment without protective conductor: Insulation resistance > 2 MOhm
Touch current < 0,5 MA The test should start with a visual check of deficiencies and should be completed
by labelling and listing this equipment. Only approved equipment should be used. New equipment should
be labelled and listed before used. If some equipment does not meet the basic requirements, it should
either be repaired (and checked) or removed.
survey Page 5 08.04 Annual control of the smoke and heat release systems During the site tour, it was
observed that the smoke an heat release system has not been checked since 2005. In order to guarantee
the good functioning of this system, it should be checked by a specialised company (e.g. the installer) on
an annual basis. 08.05 Housekeeping in the server room (ITdepartment) The server room is equipped
with an automatic gas extinguishing installation using FM 200 as extinguishing medium. It is reminded
that the volume of extinguishing medium is calculated on the fire load in the room, where it is assumed
that only the necessary ITequipment is present. It was observed that the server room is used as a storage
room for old monitors, card board boxes and a lot of unnecessary fire load. Since this jeopardises the
adequate functioning of the extinguishing installation and simply not belongs in a server room, all
unnecessary items must be removed from this room. 08.06 Business contingency planning – development
of corporate loss control guide lines During the business interruption discussion, it was noted that at this
moment a busi ness contingency planning does not exist. It was however announced that this will be
developed in the next 2 years. Since the market position of the group, it is extremely important to have a
complete overview of activities, deviation possibilities, dependencies, ... with an analysis of the risks and
an action plan. This should be updated regularly. Since a lot of risks related to fire safety apply in almost
each site, it is highly recom mended to develop a corporate loss control guideline stating the protection
level or the organisational measures to be taken in each plant to tackle ignition sources and to upgrade the
fire safety organisation. Physical Protection 08.07 Fire separation The site benefits a basic fire separation
between the warehouse and the production area, between the warehouse and the neighbour and between
the production area and the offices. Furthermore, there is a fire separation of the technical rooms.
Following deficiencies were observed: open cable penetration in the wall between the warehouse and the
production area one fireproof door in this wall door did not completely close after a test some walkway
fireproof doors that should be selfclosing were found in open posi tion (e.g. in the firewall between
warehouse and production area, entrance door to the 2 nd technical room in the warehouse) cable
penetrations in the “TGBT” rooms were not completely sealed damage to the structural fire protection of
the steel columns of the firewall between production and warehouse These deficiencies must be solved as
soon as possible. Furthermore, it is required to organise a regular check of the fire separation and to have
a plot plan developed with an indication of the fireproof walls (in detail) in order to make this control
easier. It is suggested to include this check in the monthly safety tour.
survey Page 6 08.08 ATEXdirective and explosion protection document (gas and dust explosion) Since
June 30th 2006, it is a legal obligation to comply with the 2 ATEX directives (manufacturers directive
and users directive). This also includes the development of an explosion protection document. It was
stated that only for the silos for raw materi als, an ATEX study has been made. Since there are several
other areas where this applies, it is highly recommended to engage a certified company to have this study
completed. At least following areas are involved: transport of resin and filling stations (e.g. colours)
grinding unit battery charging area gas cylinder for propane filter installations In order to avoid static
electricity, the metal wire in the flexible connections must be connected with the metal parts on both

ends. It is also recommended to have an inter lock installed on the filling inlets for the silos since it was
observed that the earthing connection is not always used. Furthermore, dust accumulations must be
avoided since these could induce secondary explosions that are more threatening than the initial
explosion. 08.09 Protection of the cooling towers of the cooling installations During a production stop,
the cooling towers basically containing a lot of plastic mate rial and well ventilated, are dry. In case of a
fire (caused e.g. by maintenance opera tions), these towers burn rapidly resulting in a business
interruption for at least one week. It is therefore recommended to have either an extinguishing installation
builtin (pref erably) or to have adequate procedures developed that in case of maintenance opera tions
on or near these cooling towers, a fire water supply (either hydrants or hose reels) must be present (to be
incorporated in the working permit). 08.10 Deficiencies regarding handheld fire extinguishers (missing
unit / room TGBT 2) Since smaller deficiencies were observed during the site tour, they are listed
hereafter: missing fire extinguisher on the mezzanine 3 powder extinguisher in the TGBT 2 to be
removed powder extinguisher to be installed on the welding post so that in case of an inci dent a fire
extinguisher is always present
survey Page 7 08.11 Transformer stations: protection of and fire separation between the transfor mers
The site has 2 transformer stations: one containing 2 transformers, the other contai ning 4 transformers.
All transformers are equipped with temperature monitoring with automatic shutdown and are situated on
a retention pit. Since a fire or an explosion of a transformer will seriously damage all other transfor mers
in the room, following safety precautions must be taken: have a Buchholzrelais with automatic shut
down installed on each transformer (this was not checked during the survey) have a brick wall installed
between the transformers so that each transformer is situated in its own “cell” make sure that the retention
pit is also split per cell so that burning oil can not flow to the other cells 08.12 Sprinkler protection At this
moment, only the warehouse is equipped with automatic sprinkler protection. Due to the type of material
stored combined with the storage configuration and the storage height, the installation is no longer
adequate and can not control the fire as it is expected to do. The production area housing the hightest
values and being critical for business inte rruption is left completely unprotected, which is from a fire
safety point of view not ac ceptable due to the high exposure. The only way of adequately protecting the
site against a fire, is to have automatic sprinkler protection installed in all areas. For the design criteria,
either NFPA / FM guidelines or the european CEA 4001 (edi tion 2006) can be followed. As example,
the minimum design criteria according to CEA 4001 are listed: offices and technical rooms: OH3 with 5
mm over 216 m² 1 sprinkler per 12 m² production: HHP1 with 7,5 mm over 260 m² 1 sprinkler per 9
m² (this depends on the storage height of the goods and must be confirmed when a detailed stu dy is
made) warehouse: ESFR K25 at 3,5 bar (12 sprinklers) – 1 sprinkler per 9 m² If the FM guidelines are
applied, densities are as follows: offices and technical rooms: 6 mm over 185 m² 1 sprinkler per 12 m²
production: 12 mm over 230 m² 1 sprinkler per 9 m² warehouse: ESFR K25 at 3,5 bar (12 sprinklers) –
1 sprinkler per 9 m² The engineering department of HDIGerling Industrie Versicherung AG is able to
assist you in the sprinkler project. Please do not hesitate to contact our services.
survey Page 8 08.13 Protection of the propane gas cylinder A 7.300 l propane gas cylinder with filling
station is situated at some 20 m away from the buildings. It was observed that this cylinder is standing on
a small concrete floor, with grass around. Since a fire under or near the bottom of this cylinder can invoke
an explosion, it is re commended to have the gas cylinder equipped with a cooling system (grid around
the top of the cylinder with open sprinkler heads) that can either be activated from safe distance or that is
activated by a flame detector (preferably). Furthermore, it is recommended to have blocks used to fix the
position of the filling truck (and also the forklift trucks that come to fill) in order to avoid an incident in
case the handbrake would fail or is not used. This should be included in the safety pres criptions. 1.3.2.
List of Priority No. Short Description Priority* 08.01 Reevaluation of the alarm procedures A 08.02
Lighting installations: use of safety starters D 08.03 Control on mobile and household electric equipment
C 08.04 Annual control of the smoke and heat release systems D 08.05 Housekeeping in the server room
(ITdepartment) B 08.06 Business contingency planning – development of corporate loss control
guidelines D 08.07 Fire separation B 08.08 ATEXdirective and explosion protection document A 08.09
Protection of the filter units of the cooling installations D 08.10 Deficiencies regarding handheld fire
extinguishers C 08.11 Transformer stations: fire separation between the transformers C 08.12 Sprinkler

protection A 08.13 Protection of the propane gas cylinder A *Evaluation of the measures (priority)
Measures to be taken to prevent/eliminate/reduce a Measures a lifethreatening situation at present and/or
a high probability of an occurrence of loss and/or an extreme high dimension of loss and/or a violation of
obligation / non fulfilment of official demands b Measures a medium probability of an occurrence of loss
and/or a high dimension of loss c Measures a not insignificant dimension of loss d Measures best prac
tice
survey Page 9 2. General Description Nature of business The site is involved in the manufacturing of
monolayer PET preforms used in the food industry for packaging of food and liquids and in the cleaning
products industry for packaging of detergents etc. The site was originally built by the company Ball
Packaging Europe for the manufacturing of cans for the food industry. In 1989, the buildings were split
and the manufacturing of preforms started at that time for Amcor PET Packaging France. In 2007, the
Amcor group was acquired by the Spanish group La Seda de Barcelona. Today, about 1,8 billion
preforms are manufactured annually using 20 injec tionmoulding machines (with in total 50 moulds).
The total capacity is some 2 to 2,1 billion preforms. The major clients are CocaCola (with a nextdoor
production plant), NestléWaters, Unilever, ColgatePalmolive and Délifruits. The site houses a
production area, an adjacent warehouse area and 2 office blocks of which one is housing some technical
rooms. The total site area occupied by Artenius is about 33.000 m², of which 14.885 m² is built area.
Location The site is located in an industrial area, close to the village of Bierne in the northwest of France.
Picture 1 gives an aerial overview of the area. Picture 2 gives an aerial overview of the site.
Neighbourhood The Ball Packaging site is situated adjacent to the warehouse building. Furthermore, the
site is surrounded by agricultural land and the CocaCola company situated at more than 30 metres away.
Employees About 103 people are employed on this site. Working Hours The site operates in a 5shift
system, with 12 people per shift. Maintenance operations take place during the annual production stop at
Christmas time, in a dayshift system only.
survey Page 10 EQUIPE D’INTERVENTION INCENDIE Motorway A25 Lille Dunkerque Ball
Packaging Picture 1: Global site overview Picture 2: Artenius PET Packaging Europe buildings
survey Page 11 3. Industrial Process 3.1. Production Process Description The production process starts
with the delivery of the raw material, being PET resins. These are delivered by truck and stored in 16
outdoor silos, with the total storage ca pacity being 1.336 tons. 8 different types of resins are used, on an
annual basis some 54.000 tons are processed. Earthing connection points are installed and mostly used,
interlocks are not present. From the silo’s, the resins are transported to the drying units through a mixing
station by means of vacuum transport. In the mixing station, recycled material is added. Both the mixing
station as the drying units are installed on 3 mezzanines, situated above the injection moulding machines.
For the transport of resins, mainly steel flexible connec tions are used. When using plastic flexible
connections, no measures are taken to avoid static electricity. The drying units (with a capacity from
3.000 up to 10.000 l) are heated electrically, equipped with a temperature monitoring system and single
thermostatic protection. The temperature is about 170 degrees Celsius. From the drying unit / hoppers, the
resin is fed to the injection moulding machines, with adding of colours (either solid or liquid) on top of
the machine. The injection moulding process takes place at about 285 degrees Celsius, with the machines
heated electri cally. There are 20 injectionmoulding machines (make Husky), 14 with a clamping force
of 300 t, 1 with a clamping force of 500 t and 5 with a clamping force of 600 t. The oil reservoirs contain
some 1.500 l up to 2.000 l hydraulic oil, the operating pres sure exceeds 100 bar. The flexible
connections are checked every 5 and every 10 days and replaced whenever needed. There is no detection
system for small leakages, emergency shutdowns are present on each machine and there is a general
emergency shutdown for the entire plant. The preforms (about 6 million per day) are in every machine
transferred to a robot plate where they are cooled down using an icewater circuit at 6 degrees Celsius,
and packed in metal boxes. These boxes are stored in the warehouse that has a storage capacity of 7.600
boxes. From there, the preforms are shipped to the clients, situated mainly in France (60 %) but also in
Greece, UK, The Netherlands and Belgium (mainly CocaCola). An external warehouse (about 6.000 m²)
is also used for the storage of finished products in order to meet the seasonal activity. The control and
handling is done by an external company. A grinding unit is situated in a separate, not fireproof room in

the warehouse building. The grinder has no specific protection, but a permanent magnetic separator is
installed on the feeding line.
survey Page 12 3.2. Production Flow Chart
survey Page 13 3.3. Specific Process Hazards The following table describes the general risk potential
shown in the flow chart as squares. These hazards could in general occur in this type of production apart
from the current protective measures for the company. R= Recommendation number Risk Potential
Property R B Battery charging units are potential sources of ignition and explosion. During charging
hydrogen and oxygen can be produced! N.A. BL Large accumulations and high piled storage of
flammable and combustible materi als (more than 0.7 t/m²) in conjunction with combustible packing and
containers, e.g. PP trays / bins and pallets, can lead to a rapid spread of fire. 08.12 CP Fire risk associated
with the use of oil in (screw) compressors. 08.12 EI Faults in electrical installation(s) are one of the most
frequent causes of fire. Igni tion occurs by overheating/shorting due to damaged cable, defective
equipment, electromagnetic incompatibility or faulty controls. Ex2 Danger/Risk of fire and explosion
caused by ignition of combustible or self ignitable dust. 08.08 ExL Risk of explosion caused by leakage
in pipes, gas cylinders or seals at furnaces, ovens, burners and gas houses. F Film shrinkwrap units are
potential sources of ignition. N.A. HS Leaking flammable materials can be ignited by hot surfaces
(usually > 300°C). Hot surfaces can also be produced by steam (> 30 bars). HT Heat transfer oils are
often used for heating of vessels, reactors and extruders if steam is not available or acceptable. Working
temperature can exceed 300 °C and in the event of leakage, released oil or oil vapour can ignite. N.A HY
Lubricants and hydraulic oils are used within mechanical equipment. Pumps can either be dedicated to a
single machine or form a centralised station. In the event of leakage from the pipework or connections the
oil can form a flammable mist. 08.08 O Danger/Risk of voltage spikes caused by lightning stroke, short
circuit or electrical switching causing damage to electrical equipment, switch or control rooms. TO Fire
in oil filled transformers possibly caused by overloading of the transformer (capacity in relation to
requirements). 08.11 WS Danger of water and soil contamination Note: N.A.: not applicable
survey Page 14 3.4. Result of the HGST Grading System The figure shows the result of the Gerling
Grading System. The evaluation has been done on the basis of the survey. held covered Risk Evaluation
on Company: ARTENIUS PET PACKAGING EUROPE Works/Place: Bierne 05/03/08 Unit:
ARTENIUS PET PACKAGING EUROPE RMOrderNo: 680021/08 Points Max. Points Precent
Process safety 27.9 40 69.8% Fire protection 10.3 20 51.5% Organisation 36.6 40 91.5% Total evaluation
74.8 100 74.8% 69.8% 51.5% 91.5% 74.8% 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0%
80.0% 90.0% 100.0% Process safety Fire protection Organisation Total evaluation
survey Page 15 4. Building Description, Stores Complex I /Area I / Building No 1 (see layout plan)
Building No. 1 Office building with meeting room, restroom and social rooms Noncombustible building
with moderate fire load, equipped with automatic fire detection and handheld fire extinguishers. The
built area is approximately 350 m² (single floor) Building No. 2 Office building, with social rooms,
canteen, high and low voltage room, technical room (air compressors, cooling compressors with pump
sta tion, …) Noncombustible building with moderate fire load, equipped with automatic fire detection
and handheld fire extinguishers. The kitchen has no special protection, a small frying installation is
present. The server room, situated in the middle of this building, has an automatic gas extinguishing
installation using FM 200. The fire load in this room is high, with the room used as storage area (see
rec’s). The built area is approximately 1.250 m² (single floor). The wall between this building and the
production area is a fireproof wall, equipped with selfclosing fireproof door and 1 fireproof door
activated by fusible link or fire detection. Building No. 3 Production building with production offices,
maintenance area and mould cleaning area; including 3 mezzanines The building was erected using an
unprotected steel frame. It has a steeldeck roof with mineral wool insulation and a roofing on top. The
exterior walls are composed of a double steel sheeting with polyure thane foam insulation. It is equipped
with a manual smoke and heat release system and has hose reels as well as an adequate number of hand
held fire extinguishers. The mezzanines are made of steel sheet ing. This building has a built area of
4.615 m². The wall towards the warehouse building is made of concrete panels and should have a fire

resistance of 2 hours. The steel structure has been coated with a fire retardant product, although damage
has been observed. Storage Areas With exception of the boxes being filled with the PET preforms, there
is no storage. Building No. 4 Warehouse building with maintenance storage area, battery charging zone
for the robots, grinding room, high and low voltage room and tech nical room (housing the cooling
compressors) The building was erected using an unprotected steel frame. It has a steeldeck roof with
mineral wool insulation and a roofing on top. The exterior walls are composed of double steel sheeting
with polyure thane foam insulation. It is equipped with a manual smoke and heat release system, an
automatic fire detection system and an inadequate sprinkler system. Furthermore, an adequate number of
handheld fire extinguishers is spread over the area and there are 12 hose reels. The grinder is housed in a
room with steel sheeting. The battery charging area is an open area. The other technical rooms are
fireproof rooms (concrete and bricks, with fireproof doors). Storage Areas The finished products are
stored either in metal boxes or in cardboard boxes, in a block storage configu ration with a storage height
of 5 tiers (some 6 metres). The building itself is higher than 12 metres. The fireproof wall between the
warehouse and the neighbour is made of concrete bricks and has a fire rating of 2 hours. The fireproof
doors (3) are blocked in closed position and equipped with an alarm switch in case they would be opened.
No deficiencies were observed.
survey Page 16
survey Page 17 5. Technical Data Power Supply Electricity is supplied through 2 underground 20 kV
feeding lines. There are no emergency power generators on site. A lightning protection is present on the
silos with 1 extra on the building, including a counter. The low voltage installations are centralised in 2
rooms, each being a fireproof room equipped with an automatic gas extinguishing installation. The
electrical installations are checked annually by a certified company. Also a thermographic analysis is
done on an annual basis. Mobile and household electric equipment is not checked, there are no guidelines
for this equipment. Transformer Stations In total, there are 6 transformers, each with a capacity of 2.000
kVA. All transformers are oil cooled and equipped with a temperature monitoring system. The first level
sounds an alarm, the second level shuts down the transformer. 4 transformers are situated in a single room
next to the office block, the other are situated in a technical room in the warehouse. The rooms are
fireproof and equipped with automatic fire detection. An oil analysis takes place on an annual basis, a
thermographic scan is also performed. About 85 % of the capacity is used. Water Supply Water is
supplied through 1 feeding line, with a section of 150 mm. The pressure is about 4 bar. Cooling Water,
Process Water For cooling purposes, a closed loop system is in force with chilled water (6 degrees
Celsius). 2 cooling groups are situated next to the ware house building, with their cooling tower. 7 more
groups are situated on top of the technical room next to the office building. The 2 cooling tow ers are
situated next to the raw material silo’s. Freon R22 or R134 is used as a coolant. There is no specific
protection for the cooling towers in case of production shutdown. Compressed Air In a fireproof room,
next to the production building, there are 6 screw type air compressors (4 x Atlas Copco GA90 FF, 1 x
Atlas Copco GA90 VSD FF and a compare). The operating pressure is 12 bar. The compressor room is
equipped with automatic fire detection, a hose reel is present in the room. Flammable Liquids or Gases
The flammable liquids used (e.g. degreasers, …) are adequately stored in safety cabinets (in the
maintenance warehouse situated in the ware house building as well as one in the production building).
Safety cans are in use. Combustible liquids (oils, …) are stored outdoor in dedicated containers situated at
more than 20 metres away from the buildings. For the forklift trucks, a propane gas cylinder with a
capacity of 7.300 litres and filling station is situated at about 20 metres away from the production
building. The pressure is 5 bar. Technical Gas Not applicable
survey Page 18 Heating Systems, Boilers, Steam, Heat transfer oil The production area as well as the
warehouse area can be heated using electrical heating units (hot air generators). The offices also have an
electrical heating system and an air conditioning system on the chilled water circuit. Waste water Not
applicable Filter Systems Dust filter systems are present on the hoppers, there are no special protection
devices installed. 5.1. Machinery Breakdown Listing of important machines and equipment There are 20
injection moulding machines, make Husky. Every unit has its mainte nance schedule. General
maintenance Once per year, there is a production shutdown that allows preventive maintenance. The

maintenance is done according to fixed schedules, with a series of maintenance jobs done regularly (5
daily, 10daily, …). The maintenance department (18 people) operates in a 5shift system. Spare parts
Spare parts are stored in a separate maintenance warehouse situated in the main warehouse (630 m²).
There are about 2.500 listed references with a value of some 400.000 Euro. Evaluation of machinery All
machinery and equipment was found in a good state.
survey Page 19 6. Fire Protection Fire Alarms A general warning system is in force, with push buttons
spread over all areas. They are connected to the control panel of the automatic fire detection installation
with the alarms wired to the guards with additional display in the production area and in the team leader’s
office. Automatic Fire Detection An automatic fire detection system was installed in the warehouse, in
the office buildings and in the technical rooms (Desautel – Cerberus Siemens). The installation is checked
twice per year. Each detector has its own address, appearing on the panels. Alarms are wired to the guards
with additional display in the production area and in the team leaders’ office. Smoke and Heat Venting
Sys tems A manual smoke and heat release system is present in all buildings. The operating panels are
situated near the emergency exits. Until some years ago, maintenance was done on an annual basis but
has not been done since 2005. Hand Extinguishers An adequate number of handheld fire extinguishers is
present in all areas. Powder, water and CO2 extinguishers are used, listed and num bered. They are
annually checked (last check in April 2007). Fire Water Reservoir There are no firewater reservoirs, with
exception of the sprinkler reser voir (owned by Ball Packaging). Fire Water Supply There is no separate
fire water supply. Fire Hoses Fire hoses are present in all areas and are fed by the public grid, with a
separate control valve on a 100 mm pipe. These are checked annually (last check in April 2007). Fire
Hydrants There are 3 underground hydrants (with equipment in a box) situated around the buildings, on a
150 mm main supplied by the public grid. 4 more are situated on the site. It could not be confirmed if the
system is a closed loop system. Sprinklers Automatic sprinkler protection is only present for the
warehouse build ing. The installation was built in 1995, by Ball Packaging. The system is connected to
the Ball pump installation and the water reservoir. No information could be obtained about the testing,
pump capacity and other design criteria. There are 2 control valves (6”), each for a warehouse section.
The design criteria are 18,3 l/min over 186 m² (3.607,4 l/min and 3.766 l/min) at a pressure of 4,849 bar
for the one valve and 6,028 bar for the other one. This is with the current stored products and storage
configuration inade quate. Once per month, an endofline test is performed. Foam systems Not
applicable
survey Page 20 Inert Gas Extinguishing Sys tems For the 1 st low voltage distribution room, an
automatic extinguishing system with CO2 was installed. For the 2 nd room, nitrogen was used. Both
installations are activated by an air sampling system and include the raised floors. These installations are
annually checked. Other fire suppression systems An FM 200 extinguishing system was installed in the
server room (instal lation Siemens), activated by smoke detection in the room. The system is checked
annually.
survey Page 21 7. Organisation and Safety Management Type Remarks Public fire brigade The public fire
brigade is the volunteer fire brigade of Bergues, situated at some 3 km resulting in a response time of at
least 10 minutes. The nearest professional fire brigade is the fire brigade of Dunkerque, situated at some
12 km resulting in a response time of at least 15 minutes. Fire prevention safety officer Artenius has its
own fire safety responsible (Mr. Descarpentries), having an own safety budget and taking care of all
safety aspects. Private fire brigade A first intervention team consists of at least 4 people per shift. During
daytime, there are 4 people more. Fire safety manual, emergency plan Emergency plans are partly
available, intervention plans and evacuation plans were made in the past and are updated when ever
necessary. Some items need improvement (e.g. fire water supply systems). Fire fighting exercise A
training for the intervention team is organised on an annual basis and includes alarm procedures, use of
fire fighting equipment and extinguishing installations as well as the procedures for waste fire fighting
water retention (in total 900 m³). Safety work information/instruction Safety instructions are
communicated to the workers, temporary people, third parties and visitors. For new people and third
parties, this takes about 1 hour, including a registration. Written hot work permit, other permits A written
hot work permit form is in use and well applied including control rounds and signoff procedures. Also

the guards are in formed when hot works take place. In case the automatic fire detection is to be shutoff
to avoid false alarms, no special proce dures are applied. Non smoking areas The site is entirely non
smoking. There are 2 smoking corners (one near the entrance and one near the restroom), with ashtrays.
Housekeeping The housekeeping was found to be at good level. Certifications The site benefits an ISO
9001 certificate. Shift Handover Information There is a formal shift handover procedure, with an overlap
of at least 15 minutes for the team leaders. Startup / Shut – down procedures Yes, although this is quite
easy for this type of activity. Management of Change Not applicable Contingency / reconstruction plan
No – will be studied on group level in the coming years. Protection of the area The site is completely
fenced, with climbing protection. There is a guard on site (1 person per shift) taking care of the access
control. This team also takes care of the safety instructions for visitors and third parties. Furthermore,
there is a camera guarding system with the images recorded and checked by the guards. The entire site
also benefits an outdoor lighting system, activated by shimmering sensors. Intruder alarm systems There
are no intruder alarm systems. Security patrol The guards perform regular control rounds outside the
buildings, the alarms are transferred from the gatehouse when they are on tour.
survey Page 22 8. Risk analysis Business Interruption 8.1. Basic data Rough Evaluation of Gross
Earnings/Income at risk: Turnover p.a. 100.000.000 € + ./. Change in stock + ./. € ./. cost of raw
materials, energy, freight (variable costs) ./. € Gross Earnings (=Profit + fixed costs) € Seasonal Business:
yes. During the first and the second quarter, the production runs at full capacity. In the third quarter, the
production is slowed down and in October and November the production takes place with 16 or 14
injection moulding machines. There is one week production stop at Christmas. The EBITDA was told to
be 7 million Euro in 2007. 8.2. Business Exposure Each of the machines takes care of a part of the total
production, with a lot of machines being capable of taking over part of the production in case the moulds
are available. The difference between machines is caused by the number of cavities. 8.3. Specific
bottleneck units. Protection Measures It was announced that there are no specific bottlenecks on the
machines. The mixing unit can be a bottleneck, but there is some deviation possibility within the
company us ing the other mixing units. 8.4. Interdependencies There are no other sites within the group
that depend on the production of Bierne. For the delivery of raw materials, there is a dependency on
Artenius Advance in the UK since this is the biggest supplier. Alternatives are present, but this has to be
approved by the client. There is a spare capacity of 0,2 billion units per year, this of course is an actual
situa tion and can change. 8.5. Essential internal/external Suppliers and Customers 8 different types of
PET resins are used, for which there are 5 suppliers. For some of the used resins, there is only 1 supplier
at this moment, but this can be changed within short period of time but only after approval of the client.
Most of the suppliers have several production sites. The average stock should tackle a minimum of 3 days
pro duction.
survey Page 23 For the colours, there are several suppliers. Packing materials do not pose any problem.
The customers are in order of importance: CocaCola (50 %) – sites in France, Belgium and The
Netherlands Unilever Colgate – Palmolive Délifruits Lessieur NestléWaters CadburySchweppes The
first 4 clients represent 80 % of the turnover. 60 % is generated by sales on the local market (France), 40
% is export (UK, Greece, The Netherlands, Belgium). The PETpreforms are shipped by truck, with each
metal box representing some 350 Euro. There is a stock of finished products for at least 2 weeks (2 to 3
weeks is an average). The value of the raw materials on site is about 1,6 million Euros, the value of the
fin ished products is about 3,7 million Euros. The volumes manufactured were: 1,7 billion in 2006 1,8
billion in 2007 forecast 2008: 1,830 billion
survey Page 24 9. Other Perils Flood Limited hazard, a “flood plan” was developed in the past years in
order to tackle water coming from the higher positioned site of CocaCola Lightning Medium hazard,
about 2 – 6 strikes per km²/year Volcanism No hazard Storms/Hail High to very high hazard – the
buildings were designed to withstand high velocity wind storms, there are no sheds or canopies Nature of
subsoil No details available Earthquake (CRESTA ZONE) Zone 1 (MM VI) Collapse (incl. snow
loading) Limited hazard Landslide / Avalanche Limited hazard Sprinkler/Water Leakage Applicable in
the warehouse area Vicinity to Airports There are no airports situated near the site, the closest is the
regional airport of Lille, situated at about 70 km Riot / Civil Commotion/ Sabo tage/Terrorism/

Vandalism Limited hazard, no loss experience in the past 10. Loss History In 1997, a fire incident
occurred in an electrical room. After this fire, automatic extin guishing installations were installed in
both electrical rooms. No other losses have occurred. 5 th of March 2008 H D I G E R L I N G Industrie
VersicherungsAG Sicherheitstechnik GmbH Glenn van Mele
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