Fleet: each Duplex has an EX 50 main and an EX 35 colour extruder

Correction from the user: the two Duplex systems are not in the
two-extruder configuration. Each runs two HRP 12 presses from an EX 50
main extruder with an EX 35 auxiliary extruder beside it for a second
colour; the Classic stays. Fleet still five presses. Updated in
pressing-line (table, phasing, re-quote: EX 50 vs the VEX 50 of the 2024
quote, and whether one EX 50 keeps both presses at full rate), scale,
total investment (wording; estimates unchanged), roadmap item 4, README.

README.md

@@ -73,8 +73,9 @@ The detail lives in dedicated documents:
   three current gates (market validation, BOI, land title check) through
   quotes, commitment, build, launch, and expansion
 - [Pressing line equipment plan](docs/equipment/pressing-line.md): the
-  current all-Newbilt fleet (two Duplex systems with an extruder per press,
-  plus one Classic automatic press), the 2024 Newbilt quote (~USD 232k,
+  current all-Newbilt fleet (two Duplex systems, each with an EX 50 main
+  and an EX 35 colour extruder, plus one Classic automatic press), the 2024
+  Newbilt quote (~USD 232k,
   expired), the 2026 product flyers, and site requirements
 - [Galvanics and stamper prep equipment plan](docs/equipment/galvanics.md):
   the metal path from lacquer to press-ready stamper, from vendor

docs/equipment/pressing-line.md

@@ -2,17 +2,17 @@
 
 ## Current plan: an all-Newbilt fleet of five presses (October 2026)
 
-Two **Newbilt Duplex** systems, each in Newbilt's two-extruder
-configuration (two HRP 12 presses, each fed by its own extruder, on one
-hydraulic unit with shared control), plus one **Newbilt Classic** fully
-automatic press:
+Two **Newbilt Duplex** systems, each with two HRP 12 presses on one
+hydraulic unit, fed by an **EX 50** main extruder with an **EX 35**
+auxiliary extruder beside it for a second colour, plus one **Newbilt
+Classic** fully automatic press:
 
 | | Presses | Extruders | Hydraulics |
 |---|---|---|---|
-| Duplex system 1 | 2 semi-automatic | 2 | one unit for the system |
-| Duplex system 2 | 2 semi-automatic | 2 | one unit for the system |
-| Classic | 1 fully automatic | 1, built in | its own |
-| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **5** | |
+| Duplex system 1 | 2 semi-automatic | EX 50 main + EX 35 colour | one unit for the system |
+| Duplex system 2 | 2 semi-automatic | EX 50 main + EX 35 colour | one unit for the system |
+| Classic | 1 fully automatic | built in | its own |
+| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **2 EX 50, 2 EX 35, 1 built in** | |
 
 This replaces the earlier target of a 50/50 split between automated and
 semi-automatic presses (two of each, with the Pheenix AD12 as the
@@ -21,11 +21,10 @@ automated candidate). What it means:
 - **The semi-automatic side carries most of the volume.** Splatter and
   other colour effects, special editions and small runs are where an
   operator working the mould is an advantage rather than a cost, and
-  Newbilt itself recommends the Duplex for splatter. With an extruder per
-  press, the two presses of a system can run different colours or
-  compounds at the same time and neither waits on a shared extruder (our
-  reading of the flyer's configurations; confirm with Newbilt). The
-  Classic takes the long standard runs.
+  Newbilt itself recommends the Duplex for splatter, and the EX 35 on
+  each system adds the second colour strand for splatter, marble and
+  half-and-half work, which is what the flyer offers it for. The Classic
+  takes the long standard runs.
 - **One vendor, one mould family.** Classic and Duplex share insert sets
   (below), so the whole fleet runs one family of moulds and spares and one
   service relationship. The single-vendor risk is the same one the Pheenix
@@ -33,7 +32,7 @@ automated candidate). What it means:
 - **Phasing.** The Newbilt Single 2.1 system of the 2024 quote (one press,
   one extruder) is the launch configuration and the first half of Duplex
   system 1: its hydraulic aggregate is already sized for the second press.
-  The second press and extruder complete system 1; system 2 and the
+  The second press and the EX 35 complete system 1; system 2 and the
   Classic complete the fleet ([scale](../scale.md) capacity table,
   [roadmap](../roadmap.md) item 24).
 - **Capacity** at maturity stays at ~1.0 to 1.5 million records a year on
@@ -51,9 +50,12 @@ automated candidate). What it means:
 - **Investment**: the fleet change is carried in the added-scope table of
   [total investment](../finance/total-investment.md) until the next
   re-base.
-- **For the re-quote** ([roadmap](../roadmap.md) item 4): the two-extruder
-  Duplex as an upgrade of the Single 2.1 and as a second complete system;
-  the Classic's price, weight, power, steam and cooling figures; and a
+- **For the re-quote** ([roadmap](../roadmap.md) item 4): the Duplex with
+  an EX 50 and an EX 35 as an upgrade of the Single 2.1 and as a second
+  complete system, and whether the EX 50 is the VEX 50 of the 2024 quote;
+  whether one EX 50 keeps both presses of a system at full rate (the
+  flyer's Duplex main configuration runs two presses on one extruder); the
+  Classic's price, weight, power, steam and cooling figures; and a
   central hydraulic supply shared by both Duplex systems (an option the
   flyer offers).
 
@@ -120,7 +122,8 @@ What this changes in the plan:
   option; it changes the machine-floor layout and the utility list in
   [scale.md](../scale.md).
 - **Colour effects.** The EX 35 is the add-on for multi-colour work on the
-  semi-automatic side. It is not in the 2024 quote.
+  semi-automatic side. It is not in the 2024 quote; the current plan has
+  one per Duplex system.
 - **For the re-quote**, where sources disagree: the Classic's operator panel
   (two 21" touchscreens in the 2024 flyer, one 10" on the Newbilt website);
   its built-in extruder power (7.5 kW, 400 V drive motor in the 2024 flyer,

docs/finance/total-investment.md

@@ -47,7 +47,7 @@ building, software and stamper prep lines, and the contingency on top).
 | Artist platform, public side (calculator, campaigns, payments) | 40k – 90k | 1.3M – 3.0M | estimate, [artist platform](../artist-platform.md) |
 | PVC material lab, day-one tier (incl. plaque press and sample conditioning) | 55k – 150k | 1.8M – 5.0M | estimate, [quality automation](../quality-automation.md); not costed in the metrology block above. The mature tier (torque rheometer, DSC, FTIR, ~120k – 240k) is deferred, with partner labs in between |
 | Stamper prep re-priced: USD 250k for VSP, VSF and VSC against the 60k – 170k block above | +190k (low case) / +80k (high case) | +6.3M / +2.6M | Sibert's budget confirmation, email of 5 October 2026 ([galvanics and stamper prep](../equipment/galvanics.md)); itemised quotation to follow. Its time, spare parts, shipping and travel are extra and fall into the freight/installation and spares blocks above |
-| Press fleet changed (October 2026) to two Newbilt Duplex systems with an extruder per press plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k), system 2 ~230k – 300k (two press and extruder sets at the quoted ~115k each, plus its hydraulic unit, estimate), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are not re-sized yet ([scale](../scale.md)) |
+| Press fleet changed (October 2026) to two Newbilt Duplex systems (two presses each, EX 50 main extruder and EX 35 colour extruder) plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k; the quote's second-extruder option becomes the EX 35), system 2 ~230k – 300k (two presses at the quoted ~115k per press and extruder set as the yardstick, plus hydraulic unit and EX 35, estimate; no EX 35 price on file), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are not re-sized yet ([scale](../scale.md)) |
 | **Added so far** | **~420k – 610k** | **~13.8M – 20.2M** | about 8 to 10% on the full-vision subtotal |
 
 ## Phased entry

docs/roadmap.md

@@ -41,7 +41,8 @@ These three run in parallel and gate everything downstream:
 ## Phase 1: Quotes and site (parallel with the BOI decision window)
 
 4. **Newbilt re-quote** (2024 offer expired) for the current fleet: the
-   two-extruder Duplex as the Single 2.1 upgrade and as a second system,
+   Duplex with an EX 50 and an EX 35 as the Single 2.1 upgrade and as a
+   second system,
    the Classic automatic press, and a central hydraulic supply option
    ([pressing line](equipment/pressing-line.md)), with PLC/data access as a
    stated purchasing requirement per the

docs/scale.md

@@ -10,8 +10,8 @@ page as real quotes and the site decision land.
 | Phase | Fleet | Rough output |
 |---|---|---|
 | Launch | 1 semi-auto press (Newbilt Single, the first half of Duplex system 1), 1 shift | ~90,000 to 135,000 records/yr |
-| Duplex | 2 semi-auto presses (Duplex system 1, an extruder per press), 1 to 2 shifts | ~175,000 to 540,000 records/yr |
-| Mature | 4 semi-auto (two Duplex systems, an extruder per press) + 1 automated (Newbilt Classic), 2 shifts | ~1.0 to 1.5 million records/yr |
+| Duplex | 2 semi-auto presses (Duplex system 1: EX 50 main and EX 35 colour extruder), 1 to 2 shifts | ~175,000 to 540,000 records/yr |
+| Mature | 4 semi-auto (two Duplex systems, each EX 50 + EX 35) + 1 automated (Newbilt Classic), 2 shifts | ~1.0 to 1.5 million records/yr |
 
 Basis: the current fleet plan of October 2026
 ([pressing line](equipment/pressing-line.md)). The automated Classic