diff --git a/README.md b/README.md index 9b8a2e8..61abc60 100644 --- a/README.md +++ b/README.md @@ -161,7 +161,7 @@ docs/ ├── consulting/ Consultancy proposals and overviews ├── equipment/ │ ├── newbilt/ Offers, site requirements, process schematic, -│ │ service rates (vendor PDFs) +│ │ service rates, 2026 product flyers (vendor PDFs) │ └── pressing-line.md Press fleet strategy and equipment plan ├── finance/ Project cost overviews, revenue model, │ construction RFQ diff --git a/docs/equipment/newbilt/flyers-2026/2024_flyer_newbilt_classic_v2_print.pdf b/docs/equipment/newbilt/flyers-2026/2024_flyer_newbilt_classic_v2_print.pdf new file mode 100644 index 0000000..da42a62 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/2024_flyer_newbilt_classic_v2_print.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_Classic_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_Classic_Flyer_EN.pdf new file mode 100644 index 0000000..7f229c9 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_Classic_Flyer_EN.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_Duplex_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_Duplex_Flyer_EN.pdf new file mode 100644 index 0000000..6ced096 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_Duplex_Flyer_EN.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_EX_35_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_EX_35_Flyer_EN.pdf new file mode 100644 index 0000000..3de8602 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_EX_35_Flyer_EN.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_Edge_Trimmer_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_Edge_Trimmer_Flyer_EN.pdf new file mode 100644 index 0000000..338ebf5 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_Edge_Trimmer_Flyer_EN.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_Granulator_400_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_Granulator_400_Flyer_EN.pdf new file mode 100644 index 0000000..4729b07 Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_Granulator_400_Flyer_EN.pdf differ diff --git a/docs/equipment/newbilt/flyers-2026/NEWBILT_Label_Punch_Flyer_EN.pdf b/docs/equipment/newbilt/flyers-2026/NEWBILT_Label_Punch_Flyer_EN.pdf new file mode 100644 index 0000000..a4c0f0f Binary files /dev/null and b/docs/equipment/newbilt/flyers-2026/NEWBILT_Label_Punch_Flyer_EN.pdf differ diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index a046dfe..2d930c2 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -6,8 +6,8 @@ and semi-automatic presses for splatter and other color effects, special editions, and small runs, where an operator working the mold directly is an advantage rather than a cost. The semi-automatic side is covered by the Newbilt evaluation below; a fully automated press line is an open -procurement item (see the [vendor landscape](../suppliers/vendor-landscape.md) -for the Pheenix Alpha candidate). +procurement item with two candidates: the Newbilt Classic (below) and the +Pheenix Alpha AD12 (see the [vendor landscape](../suppliers/vendor-landscape.md)). ## Semi-automatic line: Newbilt @@ -33,6 +33,47 @@ Thailand**: a ~400 kg/h steam generator (with water treatment) and a ~250 kW cooling water system. The quotation has passed its validity date and will need re-confirmation before ordering. +## Newbilt range: Making Vinyl Europe 2026 flyers + +Collected at the Newbilt booth in Haarlem (30 September to 2 October 2026); +the PDFs are in [`newbilt/flyers-2026/`](newbilt/flyers-2026/). Figures are +vendor-published, not quoted. + +| Machine | What it is | Flyer figures | +|---|---|---| +| **Classic** | Fully automatic press: hydraulic 3-column frame based on the Toolex Alpha, built-in extruder, automatic cake loading, label feed, record loading and unloading, cooling-plate handling and spindle stacking | 12" at 110, 140, 160 and 180 g, 7" in development; 28 s cycle at 180 g, claimed ≥95 % yield and ≥95 % uptime (2024 flyer); steam temperature, cooling-water temperature and flow monitored; cooling by time or by delivered water volume, adjusted automatically as the cooling water warms up; Siemens safety PLC, cycle and trend recording, SCADA interface with OPC UA (2024 flyer) | +| **Duplex** | Semi-automatic system in three configurations: Single (1 press, 1 extruder), Duplex main (2 presses, 1 extruder), Duplex with two extruders (2 presses, 2 extruders run as one system with shared control and one hydraulic unit) | 12", 10" and 7"; solid colours, splatter, marble, half and half, picture discs; hydraulic unit normally supplied, or an external central supply shared by several systems | +| **EX 35** | Auxiliary extruder beside the main one, for a second or third colour | 35 mm PVC screw, 3 heating zones, 2 fans, frequency-controlled screw speed, PVC strand output, touchscreen HMI, prepared for Newbilt online support | +| **Edge Trimmer** | Trims the pressed record to its final diameter | Hardened heated blade with adjustable temperature; 7", 10" and 12" with one trimming plate per size (sold separately); standalone, or wired and piped to the Newbilt extruder and then part of the Duplex/Single emergency-stop circuit | +| **Granulator 400** | Grinds edge trim and label-free records into regrind | 200 to 250 kg/h, 7.5 kW, crushing chamber 410 × 270 mm, 12 rotor knives, 8 mm screen, 800 kg; cyclone collection with stainless contact surfaces, dust bags and outlet magnet, about 100 kg storage | +| **Label Punch** | Removes the label area so rejected records can be granulated | 106 mm punch for 7", 10" and 12"; manual loading, then automatic transport, punching and collection; optional dinker for 7" | + +What this changes in the plan: + +- **Classic and Duplex share inserts.** Insert sets move between the two + machines, so a Newbilt-only fleet (Duplex for the semi-automatic half, + Classic for the automated half) runs one mould family. Newbilt itself + recommends the Duplex for splatter, which matches the reason for the + 50/50 split. The Pheenix AD12 stays the comparison for the automated half. +- **Regrind loop.** The granulator flyer puts edge trim at about 20 to 40 g + per 12" 180 g record, 11 to 22 % of the record's mass, which brackets the + ~20 % recycled share in the process schematic. Rejected records go + through the Label Punch first; trim goes into the granulator directly. A + Classic at 28 s makes about 128 records/h, so roughly 2.5 to 5 kg/h of + trim per press (estimate): one Granulator 400 at 200 to 250 kg/h runs in + short batches, not continuously. +- **Hydraulics.** One central hydraulic supply for several systems is an + 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. +- **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, + 15 kW in this repo's earlier notes, source not recorded); 10" on the + Classic (in the 2024 flyer and on the website, not in the 2026 flyer); + and whether the Edge Trimmer is the Vario trimmer of the 2024 quote. + ## Site requirements Site planning for the semi-automatic line works from Newbilt's Duplex @@ -51,4 +92,5 @@ from press cycles come on top of the static figures, so the structural engineer gets the vendor data sheets, not just the totals. Source documents live in [`newbilt/`](newbilt/): the budgetary offer, the -Duplex site requirements, the process schematic, and the service rate card. +Duplex site requirements, the process schematic, the service rate card, and +the 2026 product flyers in [`newbilt/flyers-2026/`](newbilt/flyers-2026/). diff --git a/docs/plant-operation.html b/docs/plant-operation.html index 286df65..6f6819c 100644 --- a/docs/plant-operation.html +++ b/docs/plant-operation.html @@ -762,7 +762,7 @@ const DETAILS={ chiller:{t:'Process cooling',w:'Cooling water at 20 to 25 °C sets the vinyl after the steam phase. 98 % of the 250 kW cooling load is the molds. Open cooling tower with a heat exchanger, chiller in its own 60 m² room.',c:['Supply 20 to 25 °C, 10 bar, 7 to 8 °dH, max 200 µm particles','Flow 128 l/min typical, 220 l/min peak (Duplex)'],f:['~80 to 125 kW electrical','Outlet water reaches about 60 °C from the press']}, comp:{t:'Compressed air',w:'Dry, filtered air at 6 to 10 bar for press and extruder actuators.',c:['Dew point max 3 °C, impurities max 5 µm'],f:['14 m³/h for a Duplex system']}, hyd:{t:'Hydraulic aggregate',w:'Supplies the ~150 t press force at 180 bar from a gas-loaded accumulator. Sized for a second press from day one, which is the Duplex upgrade path.',c:['Oil temperature and pressure logged','200 l HLP 46 mineral oil, customer supplied'],f:['15 kVA, 12 kW average, 600 kg','Preferably outside the pressing room']}, - grind:{t:'PVC grinder',w:'Trims and rejected records are ground to regrind, which feeds back to the regrind silo as the ~20 % recycled share of the feedstock.',c:['No labels or paper into the grinder','Contamination check per regrind batch'],f:['In the Newbilt scope']}, + grind:{t:'PVC grinder',w:'Trims and rejected records are ground to regrind, which feeds back to the regrind silo as the ~20 % recycled share of the feedstock. Rejected records lose their label area in the label punch first; edge trim goes in directly.',c:['No labels or paper into the grinder','Contamination check per regrind batch'],f:['Newbilt Granulator 400 (flyer): 200 to 250 kg/h, 7.5 kW, so it runs in batches','Edge trim ~20 to 40 g per 12" 180 g record (Newbilt flyer)','Label punch: 106 mm, 7"/10"/12"']}, energy:{t:'Energy',w:'247 kWp of roof PV on the phase 1 building (~498 kWp with phase 2), a 271 kWh Gobel Power battery stack for peak shaving and ride-through, and a PEA medium-voltage connection with a 500 to 1,000 kVA transformer sized by the boiler decision.',c:['Plant peak 300 to 450 kW without electric boiler, 600 to 750 kW with it'],f:['Northern Thailand yield ~1,400 to 1,500 kWh/kWp/yr','PV covers roughly 28 to 45 % of consumption without electric steam']}, trace:{t:'Traceability',w:'Every step logs at the source: press and rectifier PLCs, lab instruments and vision stations write directly, manual steps get operator check-ins. Logs are append-only and retained for the life of the customer relationship. Customers get a per-order view of the whole chain.',c:['Record key: stamper + press + cycle timestamp + side','Every artifact has an ID and knows its parents','Environment (HVAC per zone) logged on the same timeline'],f:['Machine data access is a purchasing requirement','A complaint about one record resolves to stamper, press, shift, operator, compound lot, packaging lot']}, hvac:{t:'Whole-factory HVAC',w:'The press room is held at 20 to 26 °C and 35 to 60 % RH per the Newbilt site requirements; galvanics, archive and audio rooms have their own zones. Temperature, humidity and particulate per zone are logged with production.',c:['Temperature, RH and PM per zone','Correlate any production window with plant conditions'],f:['~100 to 200 kW peak (estimate)','~1,500 m² conditioned']}, diff --git a/docs/suppliers/equipment-suppliers.md b/docs/suppliers/equipment-suppliers.md index 9c6c9c2..b33b828 100644 --- a/docs/suppliers/equipment-suppliers.md +++ b/docs/suppliers/equipment-suppliers.md @@ -94,7 +94,7 @@ Suppliers identified: | Supplier | Location | Offering | Notes | |---|---|---|---| -| Newbilt machinery GmbH | Alsdorf, Germany | Single 2.1 system (VEX 50 extruder, HRP 12 press ~150 t, semi-auto), Duplex expansion, molds, Vario trimmer, grinder, label punch. **Also builds the Classic 12" fully automatic press**: hydraulic **3-column** frame, **built-in 15 kW extruder** (3 heated zones, water-cooled screw), automatic patty loading, automatic label supply, automatic cooling-plate management, spindle stack output, Siemens Security PLC on a 10" touchscreen with SCADA / OPC UA, CE approved, **28 s cycle (~128 records/h)**, vendor-claimed **≥95% yield and ≥95% uptime**. So Newbilt is a single-vendor candidate for *both* fleet halves, not only the semi-auto one. Note the half-automatic press is a **4-column book-mould** design — column count is the quickest way to tell the two apart on a factory floor | 2024 quote EUR 200,549.50 (~USD 232k / ~7.7M THB) incl. freight, expired, needs re-quote; ask for build time and order-book position in the re-quote; **ResurRec Bangkok already runs one automatic + one semi-automatic Newbilt — ask for the Thai install base and a service-response precedent**; contact via Hans-Juergen Helm | +| Newbilt machinery GmbH | Alsdorf, Germany | Single 2.1 system (VEX 50 extruder, HRP 12 press ~150 t, semi-auto), Duplex expansion, molds, Vario trimmer, Granulator 400 grinder, Label Punch, EX 35 auxiliary colour extruder. **Also builds the Classic 12" fully automatic press**: hydraulic **3-column** frame, **built-in extruder** (3 heated zones, water-cooled screw; 7.5 kW drive motor per the 2024 flyer, earlier noted here as 15 kW, confirm), automatic patty loading, automatic label supply, automatic cooling-plate management, spindle stack output, Siemens Security PLC (two 21" touchscreens per the 2024 flyer, one 10" per the website) with SCADA / OPC UA, inserts shared with the Duplex, CE approved, **28 s cycle (~128 records/h)**, vendor-claimed **≥95% yield and ≥95% uptime**. So Newbilt is a single-vendor candidate for *both* fleet halves, not only the semi-auto one. Note the half-automatic press is a **4-column book-mould** design — column count is the quickest way to tell the two apart on a factory floor | 2024 quote EUR 200,549.50 (~USD 232k / ~7.7M THB) incl. freight, expired, needs re-quote; ask for build time and order-book position in the re-quote; **ResurRec Bangkok already runs one automatic + one semi-automatic Newbilt — ask for the Thai install base and a service-response precedent**; contacts Hans-Juergen Helm (Sales Manager) and Erwin Neubauer (Managing Director); 2026 flyers in [`../equipment/newbilt/flyers-2026/`](../equipment/newbilt/flyers-2026/), summarised in [pressing-line.md](../equipment/pressing-line.md) | | Pheenix Alpha | Solna, Sweden | AD12 fully automatic press (24-26 s cycle, ~140 records/h, 1 operator per 4 presses); AD12 Manual semi-auto | Direct Toolex Alpha successor; possible single-vendor option for both fleet halves; andreas.runsten@pheenixalpha.com | Open: decision between Newbilt semi-auto + Pheenix automatic vs. single diff --git a/docs/suppliers/making-vinyl-europe-2026-exhibitors.md b/docs/suppliers/making-vinyl-europe-2026-exhibitors.md index e092f32..7455d71 100644 --- a/docs/suppliers/making-vinyl-europe-2026-exhibitors.md +++ b/docs/suppliers/making-vinyl-europe-2026-exhibitors.md @@ -238,12 +238,24 @@ automation spec asks for. **What they are.** Our primary semi-automatic candidate (Single 2.1: VEX 50 extruder + HRP 12 press, Duplex upgrade path; June 2024 quote EUR 200,549.50 incl. freight, expired) and builder of the Classic 12" fully -automatic press (3-column hydraulic frame, built-in 15 kW extruder, -automatic patty/label/cooling-plate handling, Siemens Safety PLC with -10" touchscreen, 28 s cycle even at 180 g, claimed ≥95 % yield and ≥95 % -uptime). Duplex: two presses on one extruder, ~30 s average cycle. +automatic press (3-column hydraulic frame, built-in extruder, +automatic patty/label/cooling-plate handling, Siemens Safety PLC, +28 s cycle even at 180 g, claimed ≥95 % yield and ≥95 % uptime). Duplex: +two presses on one extruder, ~30 s average cycle. ResurRec Bangkok runs one Classic 12" plus one semi-automatic Newbilt. -Contact in this repo: Hans-Juergen Helm. +Contacts: Hans-Juergen Helm (Sales Manager), Erwin Neubauer (Managing +Director). + +**Collected at the booth**: six 2026 product flyers (Classic, Duplex, +EX 35, Edge Trimmer, Granulator 400, Label Punch) plus the 2024 Classic +flyer, in [`../equipment/newbilt/flyers-2026/`](../equipment/newbilt/flyers-2026/) +and summarised in [pressing-line.md](../equipment/pressing-line.md). They +answer part of the list below: Classic and Duplex share inserts; the +Classic is 12" (110 to 180 g) with 7" in development, and Newbilt +recommends the Duplex for splatter; the Classic monitors steam +temperature and cooling-water temperature and flow, records cycles and +trends, and offers SCADA/OPC UA. They also raise new conflicts (panel +size, extruder power, 10" on the Classic); see pressing-line.md. Site: https://newbilt-machinery.com/machines-equipment/ **Why they matter.** The Newbilt-only path covers both fleet halves from