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.
This commit is contained in:
grabowski committed 2026-10-16 20:57:51 +07:00
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@@ -11,7 +11,7 @@ page as real quotes and the site decision land.
|---|---|---|
| Launch plant (decided October 2026) | 2 semi-auto (Duplex system 1: EX 50 main + EX 35 colour extruder) + 1 automated (Newbilt Classic), commissioned in sequence, 2 shifts at volume | ~0.58 to 0.90 million records/yr at the planned 60 % specials (Duplex-limited); ~0.71 to 0.97 million at ~20 % |
| Growth option: second Duplex | 4 semi-auto (two Duplex systems) + 1 Classic, 2 shifts; room reserved, not in the investment | ~1.0 to 1.5 million records/yr |
| Full hall (option) | 4 Duplex systems + 6 Classics, the hall laid out 60/40 for Duplex, 2 shifts | ~2.3 to 3.6 million records/yr at 60 % specials, ~3.6 to 4.7 million at ~20 % (estimate) |
| Full hall (option) | 5 Duplex systems + 4 Classics, the hall laid out for Duplex (~73/27 by floor), 2 shifts | ~2.9 to 4.4 million records/yr at 60 % specials, ~3.2 to 4.4 million at ~20 % (estimate) |
The [press fleet calculator](fleet-calculator.html) sizes the fleet for
any yearly output and specials share, with the people and utilities it
@@ -45,24 +45,27 @@ million a year. The theoretical ceiling of the mature fleet at 100% uptime
is roughly 1.8 to 2.2 million records per year. (The earlier 50/50 fleet,
two semi-automatic presses and two Pheenix AD12s, landed in the same
range.) The full-hall row is an option the plant keeps room for, not a
plan: the press hall is laid out 60/40 by floor for Duplex systems, since
the plant focuses on special pressings
([pressing line](equipment/pressing-line.md)). Eight semi-automatic
presses and six Classics give 1,250 to 1,410 records/hour gross, ~3.6 to
4.7 million a year on the same basis, and neither the
plan: the press hall is laid out for Duplex systems (five Duplex bays and
four Classic positions, ~73/27 by floor), since the plant focuses on
special pressings ([pressing line](equipment/pressing-line.md)). Ten
semi-automatic presses and four Classics give 1,110 to 1,310
records/hour gross, ~3.2 to 4.4 million a year on the same basis, and
neither the
[revenue model](finance/revenue-model.md) nor the investment includes
them.
**Specials share 60 % and more (October 2026).** Specials run only on the
Duplex systems, so at 60 % they set the output wherever the Duplex makes
less than 60 % of the fleet's records: the launch plant drops to ~0.58 to
0.90 million (the Classic runs at about two thirds load) and the full
hall to ~2.3 to 3.6 million (the six Classics about half loaded). The
0.90 million (the Classic runs at about two thirds load). The
five-press fleet is not affected. At the planning rates of the
[calculator](fleet-calculator.html) (3 a minute per Duplex system) the
launch plant stays balanced at ~0.94 million. A hall balanced by output
at 60 % specials would give the Duplex systems ~70 to 75 % of the floor
(estimate), e.g. five Duplex bays and four Classic positions.
launch plant stays balanced at ~0.94 million. The full hall is laid out
for this share: with five Duplex systems and four Classics it makes ~2.9
to 4.4 million records at 60 % specials, the Classics ~80 to 100 %
loaded; the 60/40 floor split planned first (four Duplex bays, six
Classics) would have made ~2.3 to 3.6 million with the Classics about
half loaded (estimates).
**The 60–70% effectiveness assumption is worth challenging, but not yet
changing.** Newbilt publishes ≥95% yield and ≥95% uptime for the Classic
@@ -269,8 +272,8 @@ kW hydraulic oil cooler) at 305 to 540 l/min of circulating water. The
peak rows assume all five presses cooling hard on a hot afternoon; the
Classic counts as one HRP 12 press plus one extruder until Newbilt states
its figures. The presses share one central hydraulic plant and one
compressed-air plant. The optional full hall (four Duplex systems and six
Classics, fourteen presses) would need up to ~1.8 MW of cooling and ~2.1
compressed-air plant. The optional full hall (five Duplex systems and
four Classics, fourteen presses) would need up to ~1.8 MW of cooling and ~2.1
to 2.5 t/h of steam: a utility phase of its own.
Tariff: PEA Schedule 3.2.2, Medium General Service on time of use at