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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grabowski committed 2026-10-16 20:57:51 +07:00
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@@ -96,30 +96,29 @@ automated candidate). What it means:
between machines. The EX 35 and trimmer footprints are not published,
so those are estimates. The [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws
both systems this way.
- **Room to grow: a hall laid out 60/40 for Duplex systems (October
2026).** The plant will mainly press special editions (splatter, colour
effects, small runs), not mono colours, so the press hall keeps more
floor for Duplex systems than for Classics: 60/40 by floor, four Duplex
bays (the launch system and three more) and six Classic positions (the
launch Classic and five more). At the calculator's floor figures (110 m²
per Duplex bay, 50 m² per Classic) that is 440 + 300 = ~740 m² of the
~870 m² hall; the rest stays open for mould carts and staging. Growth
adds Duplex systems first. The full hall is eight semi-automatic presses
and six Classics, 57/43 by press count; by hourly output the six
automatic Classics still press more (~770 against 480 to 640 records an
hour, estimate). This is an option, not part of the plan or the
investment: the layout keeps the floor, and the central hydraulic and
air plant should be sized or extendable for it. At Newbilt's per-press
figures, the fourteen presses would draw ~2.1 to 2.5 t/h of steam and up
to ~1.8 MW of cooling, so boiler, chiller and grid connection would be a
phase of their own ([scale](../scale.md)). The Payap scenario model in
- **Room to grow: a hall laid out for Duplex systems (October 2026).**
The plant will mainly press special editions (splatter, marble, colour
effects), not mono colours: the specials share is planned at 60 % and
more ([revenue model](../finance/revenue-model.md)), and specials run
only on the Duplex systems. The press hall therefore keeps five Duplex
bays (the launch system and four more) and four Classic positions (the
launch Classic and three more). At the calculator's floor figures (110
m² per Duplex bay, 50 m² per Classic) that is 550 + 200 = ~750 m² of the
~870 m² hall, ~73/27 by floor and 10 to 4 by presses; the rest stays
open for mould carts and staging. Growth adds Duplex systems first.
This split balances the hall by output at 60 % specials: ten
semi-automatic presses (600 to 800 records an hour, estimate) carry the
specials and the four Classics (~512 an hour) the standard records. A
60/40 floor split (four Duplex bays, six Classics), planned first the
same month, left the Classics about half loaded at that share. This is
an option, not part of the plan or the investment: the layout keeps the
floor, and the central hydraulic and air plant should be sized or
extendable for it. At Newbilt's per-press figures, the fourteen presses
would draw ~2.1 to 2.5 t/h of steam and up to ~1.8 MW of cooling, so
boiler, chiller and grid connection would be a phase of their own
([scale](../scale.md#production-capacity)). The Payap scenario model in
FreeCAD still draws the earlier layout (two Duplex bays and eleven
Classic positions). The specials share is planned at 60 % and more
([revenue model](../finance/revenue-model.md)); specials run only on the
Duplex systems, so at that share the Duplex presses set the output of
the launch plant and of the full hall, and a hall balanced by output
would give them ~70 to 75 % of the floor (estimate,
[scale](../scale.md#production-capacity)).
Classic positions).
- **Capacity** at maturity stays at ~1.0 to 1.5 million records a year on
two shifts, the range the [revenue model](../finance/revenue-model.md)
uses: four semi-automatic presses at 60 to 80 records an hour (estimate)
@@ -148,7 +147,7 @@ automated candidate). What it means:
flyer's Duplex main configuration runs two presses on one extruder); the
Classic's price, weight, power, steam and cooling figures; and the
central hydraulic supply (an option the flyer offers) for the whole
fleet, extendable to the full hall (four Duplex systems, six Classics),
fleet, extendable to the full hall (five Duplex systems, four Classics),
including whether the Classic
can run from it, whether the presses hold their pressure from it over
the ring-main lengths of the hall, the filtration and isolation each