titre principal c -...

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


Rozwoju FOOD [KJP]Młodszy


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


• 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.)


documentation



• 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



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


documentation


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


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


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


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


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


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


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


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


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.40

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

mailto:[email protected]

titre principal c -...

Documents