Press hall: five Duplex bays and four Classic positions (balanced at 60 % specials)
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User (October 2026): "change the hall layout" after the finding that the 60/40 floor split leaves the Classics about half loaded at 60 %+ specials (specials run only on the Duplex systems). - Press hall now keeps five Duplex bays (four along the visitor corridor, the fifth at the head of the second row) and four Classic positions: 550 + 200 = ~750 m2 of ~870 m2, ~73/27 by floor, 10 to 4 by presses; launch plant fills one of each, growth adds Duplex first. - Full hall: ~2.9 to 4.4M records a year at 60 % specials, Classics ~80 to 100 % loaded (60/40 gave ~2.3 to 3.6M); ~3.2 to 4.4M at ~20 %; fourteen presses as before: ~2.1 to 2.5 t/h steam, up to ~1.8 MW cooling, a utility phase of its own. - pressing-line.md, scale.md, site-candidates.md, crane-workshop-tours.md, roadmap.md, README (FreeCAD model still the earlier layout, not redrawn); calculator preset "Full hall (5 D + 4 C)" and ladder; plant view reserves 5 Duplex bays and 4 Classic positions; business plan draft 0.2 rebuilt. Checks: renderer 720 checks and functional checks pass, calculator regression 0 fails, level checks clean; PDF 47 pages, TOC filled.
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@@ -96,30 +96,29 @@ automated candidate). What it means:
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between machines. The EX 35 and trimmer footprints are not published,
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so those are estimates. The [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws
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both systems this way.
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- **Room to grow: a hall laid out 60/40 for Duplex systems (October
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2026).** The plant will mainly press special editions (splatter, colour
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effects, small runs), not mono colours, so the press hall keeps more
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floor for Duplex systems than for Classics: 60/40 by floor, four Duplex
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bays (the launch system and three more) and six Classic positions (the
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launch Classic and five more). At the calculator's floor figures (110 m²
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per Duplex bay, 50 m² per Classic) that is 440 + 300 = ~740 m² of the
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~870 m² hall; the rest stays open for mould carts and staging. Growth
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adds Duplex systems first. The full hall is eight semi-automatic presses
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and six Classics, 57/43 by press count; by hourly output the six
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automatic Classics still press more (~770 against 480 to 640 records an
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hour, estimate). This is an option, not part of the plan or the
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investment: the layout keeps the floor, and the central hydraulic and
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air plant should be sized or extendable for it. At Newbilt's per-press
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figures, the fourteen presses would draw ~2.1 to 2.5 t/h of steam and up
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to ~1.8 MW of cooling, so boiler, chiller and grid connection would be a
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phase of their own ([scale](../scale.md)). The Payap scenario model in
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- **Room to grow: a hall laid out for Duplex systems (October 2026).**
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The plant will mainly press special editions (splatter, marble, colour
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effects), not mono colours: the specials share is planned at 60 % and
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more ([revenue model](../finance/revenue-model.md)), and specials run
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only on the Duplex systems. The press hall therefore keeps five Duplex
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bays (the launch system and four more) and four Classic positions (the
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launch Classic and three more). At the calculator's floor figures (110
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m² per Duplex bay, 50 m² per Classic) that is 550 + 200 = ~750 m² of the
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~870 m² hall, ~73/27 by floor and 10 to 4 by presses; the rest stays
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open for mould carts and staging. Growth adds Duplex systems first.
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This split balances the hall by output at 60 % specials: ten
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semi-automatic presses (600 to 800 records an hour, estimate) carry the
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specials and the four Classics (~512 an hour) the standard records. A
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60/40 floor split (four Duplex bays, six Classics), planned first the
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same month, left the Classics about half loaded at that share. This is
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an option, not part of the plan or the investment: the layout keeps the
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floor, and the central hydraulic and air plant should be sized or
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extendable for it. At Newbilt's per-press figures, the fourteen presses
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would draw ~2.1 to 2.5 t/h of steam and up to ~1.8 MW of cooling, so
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boiler, chiller and grid connection would be a phase of their own
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([scale](../scale.md#production-capacity)). The Payap scenario model in
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FreeCAD still draws the earlier layout (two Duplex bays and eleven
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Classic positions). The specials share is planned at 60 % and more
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([revenue model](../finance/revenue-model.md)); specials run only on the
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Duplex systems, so at that share the Duplex presses set the output of
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the launch plant and of the full hall, and a hall balanced by output
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would give them ~70 to 75 % of the floor (estimate,
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[scale](../scale.md#production-capacity)).
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Classic positions).
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- **Capacity** at maturity stays at ~1.0 to 1.5 million records a year on
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two shifts, the range the [revenue model](../finance/revenue-model.md)
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uses: four semi-automatic presses at 60 to 80 records an hour (estimate)
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@@ -148,7 +147,7 @@ automated candidate). What it means:
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flyer's Duplex main configuration runs two presses on one extruder); the
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Classic's price, weight, power, steam and cooling figures; and the
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central hydraulic supply (an option the flyer offers) for the whole
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fleet, extendable to the full hall (four Duplex systems, six Classics),
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fleet, extendable to the full hall (five Duplex systems, four Classics),
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including whether the Classic
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can run from it, whether the presses hold their pressure from it over
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the ring-main lengths of the hall, the filtration and isolation each
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