diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index 3d1d962..37eafdc 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -2,17 +2,18 @@ ## Current plan: an all-Newbilt fleet of five presses (October 2026) -Two **Newbilt Duplex** systems, each with two HRP 12 presses on one -hydraulic unit, fed by an **EX 50** main extruder with an **EX 35** -auxiliary extruder beside it for a second colour, plus one **Newbilt -Classic** fully automatic press: +Two **Newbilt Duplex** systems, each with two HRP 12 presses fed by an +**EX 50** main extruder with an **EX 35** auxiliary extruder beside it for +a second colour, plus one **Newbilt Classic** fully automatic press. The +whole fleet runs from **one shared hydraulic supply and one shared +compressed-air supply** (October 2026): -| | Presses | Extruders | Hydraulics | +| | Presses | Extruders | Hydraulics and air | |---|---|---|---| -| Duplex system 1 | 2 semi-automatic | EX 50 main + EX 35 colour | one unit for the system | -| Duplex system 2 | 2 semi-automatic | EX 50 main + EX 35 colour | one unit for the system | -| Classic | 1 fully automatic | built in | its own | -| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **2 EX 50, 2 EX 35, 1 built in** | | +| Duplex system 1 | 2 semi-automatic | EX 50 main + EX 35 colour | shared central supply | +| Duplex system 2 | 2 semi-automatic | EX 50 main + EX 35 colour | shared central supply | +| Classic | 1 fully automatic | built in | shared central supply (to confirm with Newbilt) | +| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **2 EX 50, 2 EX 35, 1 built in** | **one hydraulic plant, one air plant** | This replaces the earlier target of a 50/50 split between automated and semi-automatic presses (two of each, with the Pheenix AD12 as the @@ -35,6 +36,24 @@ automated candidate). What it means: The second press and the EX 35 complete system 1; system 2 and the Classic complete the fleet ([scale](../scale.md) capacity table, [roadmap](../roadmap.md) item 24). +- **One shared hydraulic and air supply.** A central hydraulic plant + (pumps, tank, accumulators) and one compressed-air plant feed every + press through ring mains, instead of a hydraulic unit per system. It + means one plant room to maintain and one place for noise and heat, and + it makes adding presses a matter of tapping the ring main. In the + [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) + it is a plant room at the west end of the press hall, with a service + trench along the press rows. Open for the re-quote (below): whether the + Single 2.1's own aggregate becomes part of the central plant or a + standby, and whether the Classic can run from it. +- **Room to grow: possibly ten more Classics.** The plant may add up to + ten more Newbilt Classics at some point. This is an option, not part of + the plan or the investment: the layout keeps floor for it (ten Classic + positions in the Payap scenario model), and the central hydraulic and + air plant should be sized or extendable for it. At Newbilt's per-press + figures, fifteen presses would draw ~2.3 to 2.7 t/h of steam and up to + ~1.9 MW of cooling, so boiler, chiller and grid connection would be a + phase of their own ([scale](../scale.md)). - **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) @@ -55,9 +74,10 @@ automated candidate). What it means: complete system, and whether the EX 50 is the VEX 50 of the 2024 quote; whether one EX 50 keeps both presses of a system at full rate (the flyer's Duplex main configuration runs two presses on one extruder); the - Classic's price, weight, power, steam and cooling figures; and a - central hydraulic supply shared by both Duplex systems (an option the - flyer offers). + 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 ten more Classics, including whether the Classic + can run from it. The Pheenix AD12 leaves the plan; it stays in the [vendor landscape](../suppliers/vendor-landscape.md) as the comparison if @@ -119,8 +139,9 @@ What this changes in the plan: 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). + option on the flyer and is now the plan, together with one shared + compressed-air supply (see "Current plan" above); 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; the current plan has one per Duplex system. diff --git a/docs/scale.md b/docs/scale.md index 08903b5..7dec7d8 100644 --- a/docs/scale.md +++ b/docs/scale.md @@ -12,6 +12,7 @@ page as real quotes and the site decision land. | 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) | Basis: the current fleet plan of October 2026 ([pressing line](equipment/pressing-line.md)). The automated Classic @@ -22,7 +23,10 @@ effectiveness of 60 to 70% applied: 368 to 448 records/hour, ~1.06 to 1.5 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.) +range.) The expansion row is an option the plant keeps room for, not a +plan: ten more Classics add ~1,280 records/hour on the same basis, and +neither the [revenue model](finance/revenue-model.md) nor the investment +includes them. **The 60–70% effectiveness assumption is worth challenging, but not yet changing.** Newbilt publishes ≥95% yield and ≥95% uptime for the Classic @@ -178,7 +182,11 @@ and peak rows above are sized for one Duplex's ~250 kW of cooling; at Newbilt's up to 125 kW of cooling per press, five presses need up to ~625 kW, so the chiller's electrical draw and the plant peak rise accordingly. Re-size with the Newbilt re-quote figures, together with the steam below -([pressing line](equipment/pressing-line.md)). +([pressing line](equipment/pressing-line.md)). The presses share one +central hydraulic plant and one compressed-air plant; their draw replaces +the per-system hydraulic units in the pressing row above. The optional +ten more Classics would need up to ~1.9 MW of cooling and ~2.3 to 2.7 t/h +of steam: a utility phase of its own. Tariff: PEA Schedule 3.2.2, Medium General Service on time of use at 22 kV (the flat rate is closed to new customers): 132.93 THB/kW demand