Re-base scale, pressing line, roadmap, revenue model and calculator on the launch plant
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Launch plant (user, October 2026): one Duplex system and one Classic,
with cutting and galvanics in-house, everything in one capital round.

- scale.md: capacity table now launch plant 0.71-0.97M records/yr, the
  second Duplex as a growth option; launch utilities (450-540 kg/h on
  B-1/B-2, ~390 kW on 2 x 250 kW); calculator figure ~0.94M.
- pressing-line.md: launch plant section on top; five-press fleet kept as
  the layout fleet the hall and backbone are built for.
- roadmap.md: long-lead orders for the launch plant, no bridge stampers
  or outsourced cutting, commissioning order, what stays revenue-gated.
- revenue-model.md: operating picture of the launch plant: central
  revenue ~3.75M USD, EBITDA ~1.6M, operating profit ~1.1M, payback ~4
  yr on 216M THB, break-even ~0.3M records; adverse corner cannot cover
  depreciation. Five-press table kept and labelled.
- fleet-calculator.html: start fleet 1 Duplex + 1 Classic, target 850k,
  capex base 6.55M (cases 8.9 / 6.55 / 4.9M), Duplex beyond one, chiller
  500 kW, imported machinery 2.3M, ladder from the launch plant.
- total-investment.md: superseded note updated.
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| Phase | Fleet | Rough output |
|---|---|---|
| Launch | 1 semi-auto press (Newbilt Single, the first half of Duplex system 1), 1 shift | ~90,000 to 135,000 records/yr |
| Duplex | 2 semi-auto presses (Duplex system 1: EX 50 main and EX 35 colour extruder), 1 to 2 shifts | ~175,000 to 540,000 records/yr |
| Mature | 4 semi-auto (two Duplex systems, each EX 50 + EX 35) + 1 automated (Newbilt Classic), 2 shifts | ~1.0 to 1.5 million records/yr |
| Expansion (option) | the mature fleet + up to 10 more Newbilt Classics, 2 shifts | ~4.7 to 5.8 million records/yr (estimate) |
| 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 | ~0.71 to 0.97 million records/yr |
| 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 |
| Expansion (option) | the five-press fleet + up to 10 more Newbilt Classics, 2 shifts | ~4.7 to 5.8 million records/yr (estimate) |
The [press fleet calculator](fleet-calculator.html) sizes the fleet for
any yearly output and specials share, with the people and utilities it
needs; at the user's planning rates (3 records a minute per Duplex
system, 2 per Classic, 65 % effectiveness, two shifts) the start fleet
makes ~1.5 million records a year and a full Payap press hall (two Duplex
systems and eleven Classics) ~5.2 million.
system, 2 per Classic, 65 % effectiveness, two shifts) the launch plant
makes ~0.94 million records a year, the five-press fleet ~1.5 million and
a full Payap press hall (two Duplex systems and eleven Classics) ~5.2
million.
Basis: the current fleet plan of October 2026
([pressing line](equipment/pressing-line.md)). The automated Classic
**Launch plant (October 2026).** The plant launches with one Duplex
system and one Classic, with cutting and galvanics in-house
([total investment](finance/total-investment.md#launch-plant-october-2026)).
Its utilities: steam 450 to 540 kg/h on boiler modules B-1 and B-2, cooling
~390 kW at the hot-afternoon peak on chillers CH-1 and CH-2 (2 × 250 kW),
with the boiler hall, chiller compound and ring mains built for the
larger fleet as in [utility phasing](#utility-phasing-backbone-once-modules-with-the-presses).
The building, electrical and steam sections below still size the
five-press fleet that the backbone is built for.
Basis: the fleet plan of October 2026
([pressing line](equipment/pressing-line.md)). Launch plant: two
semi-automatic presses at 60 to 80 records/hour each plus the Classic at
~128/hour, 248 to 288 records/hour, with 60 to 70 % effectiveness ~149 to
202 an hour, 0.71 to 0.97 million a year on the same 16 h and 300 days.
Five-press fleet: The automated Classic
~128 records/hour (28 s cycle, vendor flyer); semi-automatic throughput is
unpublished, assumed 60 to 80 records/hour per press with operator
handling (estimate); 16 h/day, 300 days/yr, with realistic overall