Press hall: five Duplex bays and four Classic positions (balanced at 60 % specials)

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.

README.md

@@ -150,8 +150,8 @@ The detail lives in dedicated documents:
   [isometric](docs/cnx_vinyl_parametric_payap-iso.png)) of the whole plant
   on a square placeholder plot of Payap land: a 128 x 25 m production-only
   factory with the five-press fleet, room for ten more Classics (drawn
-  before the October 2026 decision to lay the hall out 60/40 for Duplex
+  before the October 2026 decision to lay the hall out for Duplex
-  systems: four Duplex bays and six Classic positions), one
+  systems: five Duplex bays and four Classic positions), one
   shared hydraulic and air plant, a colour store with outdoor silos and a
   two-storey finishing and print block
   ([plans](docs/cnx_vinyl_parametric_payap-block.png)), a separate

docs/business-plan/build/content_a.py

@@ -551,9 +551,9 @@ def blocks():
              "~0.58 to 0.90 million records at 60 % specials (0.71 to 0.97 at ~20 %)"],
             ["Growth option: second Duplex", "4 semi-automatic + 1 Classic, 2 shifts; room reserved, not in "
                                              "the investment", "~1.0 to 1.5 million records"],
-            ["Full hall (option)", "4 Duplex systems + 6 Classics, the press hall laid out 60/40 for Duplex "
+            ["Full hall (option)", "5 Duplex systems + 4 Classics, the press hall laid out for Duplex "
-                                   "(special pressings first); a utility phase of its own", "~2.3 to 3.6 million records at 60 % "
+                                   "(special pressings first, ~73/27 by floor); a utility phase of its own",
-                                   "specials (estimate)"],
+             "~2.9 to 4.4 million records at 60 % specials (estimate)"],
         ], widths_mm=[40, 80, 50],
            caption="Basis: semi-automatic 60 to 80 records/h assumed; Classic ~128/h (vendor flyer); 16 h/day, "
                    "300 days/yr, 60 to 70% overall equipment effectiveness; specials (60 % and more) only on the Duplex. "

docs/business-plan/build/content_b.py

@@ -628,8 +628,8 @@ def blocks():
           "It is where finished goods move to free production floor, where pressing capacity can double, "
           "or where a CD replication line would go if that option is chosen (section 4.9). Where the "
           "second Duplex system stands on the Mueang Chi footprint is not drawn yet; the Payap scenario "
-          "model draws the five-press fleet; its press hall is now planned 60/40 for Duplex systems (four "
+          "model draws the five-press fleet; its press hall is now planned for Duplex systems (five Duplex "
-          "Duplex bays and six Classic positions), because the plant focuses on special pressings."),
+          "bays and four Classic positions), because the plant focuses on special pressings."),
         H3("What the construction RFQ asks"),
         P("The budget-level construction RFQ, with quantities from the parametric model, asks contractors "
           "for: the shell rate per m² at the insulated-panel specification (not a bare shed); heavy-duty "

docs/crane-workshop-tours.md

@@ -321,7 +321,7 @@ into a separate office building, so only production sits under the
 crane. The tour then starts in the office building, at the cutting-room
 window and the listening room, and crosses a covered link into a 98 m
 corridor. That is longer than the 45 to 55 m assumed below, because the
-press hall keeps room for four Duplex systems and six Classics and a
+press hall keeps room for five Duplex systems and four Classics and a
 colour store sits before it. In that model the crane runway ends at the press hall:
 finishing and packaging sit beyond it in a two-storey block with the
 print room and stocks upstairs, which the crane cannot serve, so loads

docs/equipment/pressing-line.md

@@ -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
+- **Room to grow: a hall laid out for Duplex systems (October 2026).**
-  2026).** The plant will mainly press special editions (splatter, colour
+  The plant will mainly press special editions (splatter, marble, colour
-  effects, small runs), not mono colours, so the press hall keeps more
+  effects), not mono colours: the specials share is planned at 60 % and
-  floor for Duplex systems than for Classics: 60/40 by floor, four Duplex
+  more ([revenue model](../finance/revenue-model.md)), and specials run
-  bays (the launch system and three more) and six Classic positions (the
+  only on the Duplex systems. The press hall therefore keeps five Duplex
-  launch Classic and five more). At the calculator's floor figures (110 m²
+  bays (the launch system and four more) and four Classic positions (the
-  per Duplex bay, 50 m² per Classic) that is 440 + 300 = ~740 m² of the
+  launch Classic and three more). At the calculator's floor figures (110
-  ~870 m² hall; the rest stays open for mould carts and staging. Growth
+  m² per Duplex bay, 50 m² per Classic) that is 550 + 200 = ~750 m² of the
-  adds Duplex systems first. The full hall is eight semi-automatic presses
+  ~870 m² hall, ~73/27 by floor and 10 to 4 by presses; the rest stays
-  and six Classics, 57/43 by press count; by hourly output the six
+  open for mould carts and staging. Growth adds Duplex systems first.
-  automatic Classics still press more (~770 against 480 to 640 records an
+  This split balances the hall by output at 60 % specials: ten
-  hour, estimate). This is an option, not part of the plan or the
+  semi-automatic presses (600 to 800 records an hour, estimate) carry the
-  investment: the layout keeps the floor, and the central hydraulic and
+  specials and the four Classics (~512 an hour) the standard records. A
-  air plant should be sized or extendable for it. At Newbilt's per-press
+  60/40 floor split (four Duplex bays, six Classics), planned first the
-  figures, the fourteen presses would draw ~2.1 to 2.5 t/h of steam and up
+  same month, left the Classics about half loaded at that share. This is
-  to ~1.8 MW of cooling, so boiler, chiller and grid connection would be a
+  an option, not part of the plan or the investment: the layout keeps the
-  phase of their own ([scale](../scale.md)). The Payap scenario model in
+  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
+  Classic positions).
-  ([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)).
 - **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

docs/fleet-calculator.html

@@ -612,7 +612,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
     <button type="button" data-p="levers">Investor levers (216M)</button>
     <button type="button" data-p="lean">Lean: bought stampers, outsourced cutting</button>
     <button type="button" data-p="five">Five-press fleet (second Duplex)</button>
-    <button type="button" data-p="full">Full hall 60/40 (4 D + 6 C)</button>
+    <button type="button" data-p="full">Full hall (5 D + 4 C)</button>
   </div>
 </header>
 
@@ -814,8 +814,8 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
   <section class="card">
     <h2>From small to fully equipped</h2>
     <p class="note" style="margin-top:0">Fleets from the launch plant to a full Payap press hall (about 870 m²,
-      laid out 60/40 by floor for Duplex systems because the plant focuses on special pressings: four
+      laid out for Duplex systems because the plant focuses on special pressings: five Duplex bays
-      Duplex bays and six Classic positions, ~740 m²), then the same floor filled Classic-led or with
+      and four Classic positions, ~750 m², balanced by output at 60 % specials), then the same floor filled Classic-led or with
       Duplex systems only, for comparison, at the current settings and plant configuration. Click a row to load it.</p>
     <div class="tscroll"><table id="ladT"></table></div>
   </section>
@@ -1239,9 +1239,9 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
   function X(fx) { return FX + fx; }
   function Y(fy) { return FY + fy; }
   // Press hall: 2 rows, 8 m deep. Slot lengths follow the calculator's floor
-  // figures (110 m2 per Duplex bay, 50 m2 per Classic, 870 m2 hall). Laid out 60/40 by floor
+  // figures (110 m2 per Duplex bay, 50 m2 per Classic, 870 m2 hall). Laid out for Duplex
-  // for Duplex systems (special pressings first, October 2026): 4 Duplex bays + 6 Classic positions.
+  // systems (60 %+ specials, October 2026): 5 Duplex bays + 4 Classic positions, ~73/27 by floor.
-  var HALL_D = 4, HALL_C = 6;
+  var HALL_D = 5, HALL_C = 4;
   var HALL = { cap: 870, aD: 110, aC: 50 };
   var HROWS = [{ x: X(40), y0: Y(3.6), y1: Y(11.6), len: 52 }, { x: X(47.8), y0: Y(12.4), y1: Y(20.4), len: 44.2 }];
   var LTOT = 52 + 44.2, WD = HALL.aD / HALL.cap * LTOT, WC = HALL.aC / HALL.cap * LTOT;
@@ -1565,7 +1565,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
     sc.inf("factory", "Factory, 128 x 25 m",
       "Production floor only (Payap scenario model): workshop, galvanics, stamper prep, PVC lab, colour store, press hall, finishing block; warehouse and dispatch behind the fire wall. Monopitch roof, low eave 7.0 m, high side 11.4 m.");
     sc.inf("presshall", "Press hall, ~870 m2",
-      al.Dh + " Duplex system" + (al.Dh === 1 ? "" : "s") + " and " + al.Ch + " Classic" + (al.Ch === 1 ? "" : "s") + " in the hall; laid out 60/40 by floor for special pressings: 4 Duplex bays and 6 Classic positions, ~740 m2 (pressing-line.md)" +
+      al.Dh + " Duplex system" + (al.Dh === 1 ? "" : "s") + " and " + al.Ch + " Classic" + (al.Ch === 1 ? "" : "s") + " in the hall; laid out for special pressings: 5 Duplex bays and 4 Classic positions, ~750 m2, balanced by output at 60 % specials (pressing-line.md)" +
       (al.p2need ? "; " + (al.ovD + al.ovC) + " more in the phase 2 building" : ""));
     sc.inf("galvanics", cfg.galvanics ? "Galvanics clean room (Pheenix Alpha line)" : "Galvanics room: stampers bought in",
       cfg.galvanics ? "PASU, PPPU, PDPU, PMPB; one PDPU covers full-capacity demand, a second is redundancy (galvanics.md). Room-in-room under the crane, open to stamper prep." :
@@ -1683,7 +1683,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
         fl.flat(pts, z + 0.015, "iso-slot iso-empty", id);
         sc.inf(id, sl.t === "D" ? "Duplex bay (room reserved)" : "Classic position (reserved)",
           sl.t === "D" ? "Growth option: room, utility modules and ring-main tees reserved, not in the investment (pressing-line.md)" :
-            "Classic position kept for growth (option, not in the investment); the hall is laid out 60/40 for Duplex systems (pressing-line.md)");
+            "Classic position kept for growth (option, not in the investment); the hall is laid out mainly for Duplex systems (pressing-line.md)");
       } else fl.flat(pts, z + 0.015, "iso-slot", sl.t === "D" ? "duplex-" + sl.n : "classic-" + sl.n);
       if (!sl.e && sl.t === "D") {
         var cx = (sl.x0 + sl.x1) / 2, cy = (sl.y0 + sl.y1) / 2;
@@ -3080,9 +3080,9 @@ function caseNow() {
   return "";
 }
 const LADDER = [
-  // Duplex systems first: the hall is laid out 60/40 by floor for them (special pressings, October 2026)
+  // Duplex systems first: the hall is laid out for 5 Duplex + 4 Classics (60 %+ specials, October 2026)
   ["Launch plant", 1, 1], ["Second Duplex", 2, 1], ["Step 1", 3, 2], ["Step 2", 4, 3],
-  ["Full hall 60/40", 4, 6], ["Same floor, Classic-led", 2, 11], ["Same floor, Duplex only", 7, 0],
+  ["Full hall", 5, 4], ["Same floor, Classic-led", 2, 11], ["Same floor, Duplex only", 7, 0],
 ];
 // presets: fleet plus plant configuration; prices, case and assumptions stay as they are
 const CFG0 = Object.fromEntries(CFGK.map(k => [k, S0[k]]));
@@ -3092,7 +3092,7 @@ const PRESETS = {
   levers: { ...LAUNCH, solar: "ppa", metro: "launch", galvPrice: "oms", corridor: "later" },
   lean: { ...LAUNCH, galv: "bought", cut: "out" },
   five: { mode: "fleet", dFleet: 2, cFleet: 1, ...CFG0 },
-  full: { mode: "fleet", dFleet: 4, cFleet: 6, ...CFG0 },
+  full: { mode: "fleet", dFleet: 5, cFleet: 4, ...CFG0 },
 };
 
 let S = { ...S0 }, A = { ...A0 };

docs/roadmap.md

@@ -173,5 +173,5 @@ Since October 2026 the plant launches with everything in one capital
 round (~161M to 292M THB, target ~216M with the levers in
 [total investment](finance/total-investment.md#launch-plant-october-2026));
 the gates still come before the round is spent, and the growth options
-(more Duplex systems first, then Classics, in a press hall laid out 60/40
+(more Duplex systems first, then Classics, in a press hall laid out for
-for Duplex) are funded from revenue.
+five Duplex systems and four Classics) are funded from revenue.

docs/scale.md

@@ -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
+plan: the press hall is laid out for Duplex systems (five Duplex bays and
-the plant focuses on special pressings
+four Classic positions, ~73/27 by floor), since the plant focuses on
-([pressing line](equipment/pressing-line.md)). Eight semi-automatic
+special pressings ([pressing line](equipment/pressing-line.md)). Ten
-presses and six Classics give 1,250 to 1,410 records/hour gross, ~3.6 to
+semi-automatic presses and four Classics give 1,110 to 1,310
-4.7 million a year on the same basis, and neither the
+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
+0.90 million (the Classic runs at about two thirds load). The
-hall to ~2.3 to 3.6 million (the six Classics about half loaded). 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
+launch plant stays balanced at ~0.94 million. The full hall is laid out
-at 60 % specials would give the Duplex systems ~70 to 75 % of the floor
+for this share: with five Duplex systems and four Classics it makes ~2.9
-(estimate), e.g. five Duplex bays and four Classic positions.
+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
+compressed-air plant. The optional full hall (five Duplex systems and
-Classics, fourteen presses) would need up to ~1.8 MW of cooling and ~2.1
+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

docs/site-candidates.md

@@ -122,8 +122,8 @@ dropped. Source record with the zone's full rules and annex:
 5. **Plot fit.** Shape and size against the 60 × 25 m building, the
    detached utility yard and the phase 2 footprint (6 to 8 rai). The
    Payap scenario model below needs a 150 m square (14.1 rai) as drawn,
-   with a press hall laid out 60/40 for Duplex systems, a colour store and
+   with a press hall laid out for Duplex systems, a colour store and a
-   a reserve.
+   reserve.
 6. **Galvanics on a campus.** Phase 5 electroplating needs the lessor's
    written consent; the zero-discharge design
    ([sustainability](sustainability.md)) becomes a lease condition, not
@@ -180,12 +180,13 @@ and every equipment envelope is an estimate.
     that special designs need, about 100 positions on four levels
     (estimate), with weighing and mixing and a vacuum conveying station
     ([pressing line](equipment/pressing-line.md)).
-  - **Press hall** (~870 m²), laid out 60/40 by floor for Duplex systems
+  - **Press hall** (~870 m²), laid out for Duplex systems because the
-    because the plant focuses on special pressings (October 2026,
+    plant focuses on special pressings (October 2026, ~73/27 by floor,
-    [pressing line](equipment/pressing-line.md)): four Duplex bays, each
+    [pressing line](equipment/pressing-line.md)): five Duplex bays, each
-    for two HRP 12 presses with an EX 50 and an EX 35, along the visitor
+    for two HRP 12 presses with an EX 50 and an EX 35, four of them along
-    corridor, and six Classic positions in the second row; the launch
+    the visitor corridor and the fifth at the head of the second row,
-    plant fills one of each. The FreeCAD model still draws the earlier
+    followed by four Classic positions; the launch plant fills one of
+    each. The FreeCAD model still draws the earlier
     layout (two Duplex systems, the Classic and ten more Classic
     positions). Each Duplex is one operator's cell of about
     5 × 3 m at Newbilt's machine sizes: presses either side turned