Press fleet: two Newbilt Duplex systems with an extruder per press, plus a Classic

The current plan (user decision, October 2026) replaces the 50/50 target
(two semi-automatic presses and two Pheenix AD12s) with an all-Newbilt
fleet of five presses: two Duplex systems in Newbilt's two-extruder
configuration (two HRP 12 presses, an extruder each, one hydraulic unit)
and one Classic fully automatic press.

- pressing-line.md: new "Current plan" section (fleet table, what it
  means, phasing from the Single 2.1 as the first half of system 1,
  re-quote questions); site requirements per Duplex system.
- scale.md: capacity table and basis (368 to 448 records/h, ~1.06 to 1.5M
  a year on two shifts, same range as before); pressing electrical row;
  steam and cooling flagged, not re-based: five presses draw ~750 to 900
  kg/h of steam and up to ~625 kW of cooling at Newbilt's per-press
  figures, against the 400 kg/h / 250 kW sized for one Duplex.
- total-investment.md: fleet change as an added-scope row (system 2
  ~230k-300k and the Classic ~290k-460k, estimates; -60k / -160k against
  the two blocks it replaces); headline unchanged until the re-base.
- roadmap items 4, 5 and 24, revenue model mature row, crane doc (the
  Classic's weight now decides 5 t or 3.2 t), vendor landscape (AD12 is
  the comparison for the Classic), README.

The business plan docx is not regenerated.
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@@ -73,8 +73,9 @@ The detail lives in dedicated documents:
three current gates (market validation, BOI, land title check) through
quotes, commitment, build, launch, and expansion
- [Pressing line equipment plan](docs/equipment/pressing-line.md): the
50/50 automated/semi-automatic fleet strategy, the Newbilt system under
evaluation (~USD 232k quoted scope), and site requirements
current all-Newbilt fleet (two Duplex systems with an extruder per press,
plus one Classic automatic press), the 2024 Newbilt quote (~USD 232k,
expired), the 2026 product flyers, and site requirements
- [Galvanics and stamper prep equipment plan](docs/equipment/galvanics.md):
the metal path from lacquer to press-ready stamper, from vendor
datasheets: Pheenix Alpha's electroforming range as a second turnkey
@@ -91,7 +92,7 @@ The detail lives in dedicated documents:
used lathes and cutting-room contacts (via OMS),
stamper preparation
(Sibert), bridge stamper service (Stamper Discs), and automated presses
(Pheenix Alpha)
(Pheenix Alpha, the comparison for the Classic)
- [Equipment needs and supplier map](docs/suppliers/equipment-suppliers.md):
the full needs list per production step with supplier tables and contacts
- [Sustainability](docs/sustainability.md): the solar installation (Deye
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@@ -31,15 +31,15 @@ is an estimate.
| Newbilt press (HRP 12) | 1,350 kg | [Newbilt Duplex site requirements](equipment/newbilt/) |
| Newbilt extruder | 660 kg | same |
| Newbilt hydraulic aggregate (250 L tank, 50 L accumulator) | 600 kg | same, plus the [budgetary offer](equipment/newbilt/) |
| Pheenix AD12 automated press | **unknown**, ask Pheenix | not in any document yet |
| Newbilt Classic automatic press | **unknown**, ask Newbilt with the re-quote | not in any document yet (it replaced the Pheenix AD12 in the fleet plan, October 2026) |
| Sibert VSP punch / VSF finisher / VSC coiner | 200 / 250 / 1,000 kg; VSP and VSF on castors, the VSC sheet lists none, so it is a lift | [Sibert specifications](equipment/sibert/) (2022 and 2023) |
| Pheenix plating units (PPPU, PDPU), silvering unit, prep bench | unknown: dimensions published, weights not; each plating unit carries a 385 L tank, lifted empty | [Pheenix flyers](equipment/pheenix-alpha/), [galvanics and stamper prep](equipment/galvanics.md); ask with the quote |
| Water-treatment evaporator | unknown, lifted empty | to be asked with the quote |
**Planning capacity: 5 t safe working load** (estimate). It covers the
heaviest known lift with its lifting beam and slings at a wide margin and
leaves room for the automated presses until Pheenix states their weight.
If the AD12 turns out under about 2.5 t, price a **3.2 t** crane as the
leaves room for the automatic press until Newbilt states the Classic's
weight. If the Classic turns out under about 2.5 t, price a **3.2 t** crane as the
alternative: lighter runway and frame, and possibly a lighter inspection
regime. Thai cranes fall under the Ministry of Labour's 2021 Ministerial
Regulation on machinery, cranes and boilers (the same regulation that
@@ -401,7 +401,7 @@ goods into the phase 2 building.
## Open decisions
1. **Crane capacity**: 5 t or 3.2 t, once Pheenix states the AD12 weight
1. **Crane capacity**: 5 t or 3.2 t, once Newbilt states the Classic's weight
and the inspection intervals are confirmed.
2. **Low eave**: keep 7.0 m or raise to 8.0 m, once the contractor states
the achievable hook height.
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@@ -1,13 +1,66 @@
# Pressing Line: Equipment Plan
The target press fleet is a **50/50 split between fully automated and
semi-automatic presses**: automated presses for standard production volume,
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 with two candidates: the Newbilt Classic (below) and the
Pheenix Alpha AD12 (see the [vendor landscape](../suppliers/vendor-landscape.md)).
## Current plan: an all-Newbilt fleet of five presses (October 2026)
Two **Newbilt Duplex** systems, each in Newbilt's two-extruder
configuration (two HRP 12 presses, each fed by its own extruder, on one
hydraulic unit with shared control), plus one **Newbilt Classic** fully
automatic press:
| | Presses | Extruders | Hydraulics |
|---|---|---|---|
| Duplex system 1 | 2 semi-automatic | 2 | one unit for the system |
| Duplex system 2 | 2 semi-automatic | 2 | one unit for the system |
| Classic | 1 fully automatic | 1, built in | its own |
| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **5** | |
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
automated candidate). What it means:
- **The semi-automatic side carries most of the volume.** Splatter and
other colour effects, special editions and small runs are where an
operator working the mould is an advantage rather than a cost, and
Newbilt itself recommends the Duplex for splatter. With an extruder per
press, the two presses of a system can run different colours or
compounds at the same time and neither waits on a shared extruder (our
reading of the flyer's configurations; confirm with Newbilt). The
Classic takes the long standard runs.
- **One vendor, one mould family.** Classic and Duplex share insert sets
(below), so the whole fleet runs one family of moulds and spares and one
service relationship. The single-vendor risk is the same one the Pheenix
path would have carried.
- **Phasing.** The Newbilt Single 2.1 system of the 2024 quote (one press,
one extruder) is the launch configuration and the first half of Duplex
system 1: its hydraulic aggregate is already sized for the second press.
The second press and extruder complete system 1; system 2 and the
Classic complete the fleet ([scale](../scale.md) capacity table,
[roadmap](../roadmap.md) item 24).
- **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)
and the Classic at ~128 an hour (28 s cycle, vendor figure).
- **Utilities do not scale from the old figures.** At Newbilt's per-press
figures (steam 150 to 180 kg/h, cooling up to 125 kW per press), five
presses draw ~750 to 900 kg/h of steam and up to ~625 kW of cooling,
against the ~400 kg/h steam generator and ~250 kW cooling system that the
2024 quote's exclusions describe for one Duplex. The boiler, chiller,
electrical connection and [utilities CSV](../finance/utilities-investment.csv)
are **not yet re-sized** for this fleet; that waits for the re-quote's
figures ([scale](../scale.md)).
- **Investment**: the fleet change is carried in the added-scope table of
[total investment](../finance/total-investment.md) until the next
re-base.
- **For the re-quote** ([roadmap](../roadmap.md) item 4): the two-extruder
Duplex as an upgrade of the Single 2.1 and as a second complete system;
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).
The Pheenix AD12 leaves the plan; it stays in the
[vendor landscape](../suppliers/vendor-landscape.md) as the comparison if
the Classic re-quote disappoints, and Pheenix stays a galvanics candidate
([galvanics and stamper prep](galvanics.md)).
## Semi-automatic line: Newbilt
@@ -51,10 +104,11 @@ vendor-published, not quoted.
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.
machines, so the current all-Newbilt fleet (Duplex systems for the
semi-automatic side, the Classic for the automated press) runs one mould
family. Newbilt itself recommends the Duplex for splatter, which is why
the semi-automatic side carries most of the fleet. The Pheenix AD12
stays the comparison for the Classic.
- **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
@@ -84,7 +138,9 @@ Site planning for the semi-automatic line works from Newbilt's Duplex
requirements: roughly 200 m² of production floor, 32 kVA connected
electrical load, saturated steam at 10 bar, and compressed air and cooling
water circuits, plus side rooms for materials, compressor, chiller, and
finished goods.
finished goods. These are per Duplex system: the current fleet needs two,
plus floor for the Classic (~400 m², plus ~50 to 75 m² for the Classic,
estimate).
**Floor loading is a building-selection criterion**: the slab must carry
multiple tons per m² in the machine areas. A Newbilt press weighs 1,350 kg
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@@ -99,7 +99,7 @@ as output.
| ResurRec, assuming one shift over 300 days | ~275k – 355k |
| **CNX launch** (1 semi-auto, 1 shift) | **90k – 135k** |
| CNX Duplex (2 semi-auto, 1–2 shifts) | ~175k – 540k |
| CNX mature (2 semi + 2 automated, 2 shifts) | 1.0M – 1.5M |
| CNX mature (4 semi + 1 automated, 2 shifts) | 1.0M – 1.5M |
All rows are on the same 300-day basis so they can be compared. CNX does
not overtake them on installed capability until the Duplex expansion, and
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@@ -16,8 +16,8 @@ July 2026; the underlying THB estimates are unchanged, because EUR/THB at
| Block | USD | THB | Basis |
|---|---|---|---|
| Newbilt semi-auto line, full Duplex | 350k – 370k | 11.5M – 12.2M | 2024 quote EUR 200,500 (~USD 232k) + quoted 2nd press/extruder ~USD 115k; expired, needs re-quote |
| 2 automated presses (Pheenix AD12) | 580k – 920k | 19.1M – 30.5M | unverified ~USD 340k/press indicative + delivery and commissioning |
| Newbilt semi-auto line, full Duplex | 350k – 370k | 11.5M – 12.2M | 2024 quote EUR 200,500 (~USD 232k) + quoted 2nd press/extruder ~USD 115k; expired, needs re-quote. The fleet has since changed, see the added-scope table |
| 2 automated presses (Pheenix AD12) | 580k – 920k | 19.1M – 30.5M | unverified ~USD 340k/press indicative + delivery and commissioning. Replaced by the Newbilt Classic in the current fleet, see the added-scope table |
| Galvanics line (Digital Matrix or Pheenix Alpha) | 320k – 650k | 10.7M – 21.4M | six-figure-USD turnkey inference from vendor research; the Pheenix range (2024 flyers, [galvanics and stamper prep](../equipment/galvanics.md)) is unpriced too; OMS's reference prices (letter, 9 October 2026) put a complete 4-cell wet room at EUR 224k basic to 311k advanced (~USD 259k to 359k; ~270k to 371k with know-how transfer), installation and water treatment extra: at or below this block's low end, kept until quotes exist |
| Zero-discharge water treatment (ZLD) | 90k – 240k | 3.0M – 8.0M | utilities CSV option row |
| Stamper prep (Sibert VSP, VSF, VSC) | 60k – 170k | 1.9M – 5.7M | estimate kept until the re-base; Sibert has since confirmed USD 250k for the three (its time, spares, shipping and travel extra), the difference is in the table below |
@@ -47,7 +47,8 @@ building, software and stamper prep lines, and the contingency on top).
| Artist platform, public side (calculator, campaigns, payments) | 40k – 90k | 1.3M – 3.0M | estimate, [artist platform](../artist-platform.md) |
| PVC material lab, day-one tier (incl. plaque press and sample conditioning) | 55k – 150k | 1.8M – 5.0M | estimate, [quality automation](../quality-automation.md); not costed in the metrology block above. The mature tier (torque rheometer, DSC, FTIR, ~120k – 240k) is deferred, with partner labs in between |
| Stamper prep re-priced: USD 250k for VSP, VSF and VSC against the 60k – 170k block above | +190k (low case) / +80k (high case) | +6.3M / +2.6M | Sibert's budget confirmation, email of 5 October 2026 ([galvanics and stamper prep](../equipment/galvanics.md)); itemised quotation to follow. Its time, spare parts, shipping and travel are extra and fall into the freight/installation and spares blocks above |
| **Added so far** | **~480k – 770k** | **~15.8M – 25.5M** | about 10 to 12% on the full-vision subtotal |
| Press fleet changed (October 2026) to two Newbilt Duplex systems with an extruder per press plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k), system 2 ~230k – 300k (two press and extruder sets at the quoted ~115k each, plus its hydraulic unit, estimate), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are not re-sized yet ([scale](../scale.md)) |
| **Added so far** | **~420k – 610k** | **~13.8M – 20.2M** | about 8 to 10% on the full-vision subtotal |
## Phased entry
@@ -60,8 +61,9 @@ A credible launch phase is far smaller, roughly **1.7M to 2.9M USD
metrology deferred; the PVC lab's day-one tier is the added-scope row
above
- Leased building instead of purchase, modest first solar array
- Galvanics, automated presses, full metrology, and the biomass boiler
follow as revenue-funded or second-round expansions
- Galvanics, the second Duplex system and the Classic, full metrology,
and the biomass boiler follow as revenue-funded or second-round
expansions
The planning already supports this: the Duplex-ready hydraulics, the
bridge-supplier role for Stamper Discs, the staged electric-to-biomass
@@ -80,7 +82,7 @@ exactly this reason.
[project-timeline.md](../project-timeline.md)
- **Biggest uncertainty bands**: metrology (partly a choice of ambition),
the mastering/cutting room (bespoke vendor, no public pricing), the
automated presses (single unverified price point), and land
Newbilt Classic (no price on file), and land
- **Currency exposure is real and is not modelled here.** Revenue is
mostly USD/EUR from export customers, the cost base is mostly THB, and
the largest single equipment block is EUR-denominated and unhedged
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@@ -40,12 +40,15 @@ These three run in parallel and gate everything downstream:
## Phase 1: Quotes and site (parallel with the BOI decision window)
4. **Newbilt re-quote** (2024 offer expired), with PLC/data access as a
4. **Newbilt re-quote** (2024 offer expired) for the current fleet: the
two-extruder Duplex as the Single 2.1 upgrade and as a second system,
the Classic automatic press, and a central hydraulic supply option
([pressing line](equipment/pressing-line.md)), with PLC/data access as a
stated purchasing requirement per the
[traceability spec](traceability.md)
5. **Pheenix Alpha**: current metric datasheet and quotes for the AD12 and
AD12 Manual, evaluating the single-vendor option against Newbilt for
the semi-auto half. After Haarlem the CEO offered a Teams call,
5. **Pheenix Alpha**: the AD12 left the current fleet plan in October
2026 (an all-Newbilt fleet); Pheenix stays the comparison for the
Classic and a galvanics candidate (item 6). After Haarlem the CEO offered a Teams call,
reference clients and a factory visit near Stockholm; the call follows
once our questions are ready, and the next Europe trip is planned
for February 2027 ([exhibitor briefing](suppliers/making-vinyl-europe-2026-exhibitors.md#after-the-show))
@@ -140,7 +143,8 @@ These three run in parallel and gate everything downstream:
before every manufacturing step is in place
([exhibitor briefing](suppliers/making-vinyl-europe-2026-exhibitors.md#after-the-show));
supplier advice to weigh against the market evidence, not a decision
24. Automated press line (the 50/50 fleet target)
24. Second Duplex system and the Newbilt Classic automatic press, which
complete the five-press fleet ([pressing line](equipment/pressing-line.md))
25. Full metrology stack and the sampled audio QC station
26. Biomass boiler, fed by the by-then-mature coppice plus regional fuel
27. Mastering and cutting room (can move earlier if title-services demand
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@@ -9,16 +9,20 @@ page as real quotes and the site decision land.
| Phase | Fleet | Rough output |
|---|---|---|
| Launch | 1 semi-auto press (Newbilt Single), 1 shift | ~90,000 to 135,000 records/yr |
| Duplex | 2 semi-auto presses, 1 to 2 shifts | ~175,000 to 540,000 records/yr |
| Mature | 2 semi-auto + 2 automated (50/50 fleet), 2 shifts | ~1.0 to 1.5 million records/yr |
| 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, an extruder per press), 1 to 2 shifts | ~175,000 to 540,000 records/yr |
| Mature | 4 semi-auto (two Duplex systems, an extruder per press) + 1 automated (Newbilt Classic), 2 shifts | ~1.0 to 1.5 million records/yr |
Basis: the automated AD12 presses ~140 records/hour each (vendor datasheet);
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 effectiveness of 60 to 70% applied. The theoretical
ceiling of the mature fleet at 100% uptime is roughly 1.9 to 2.1 million
records per year.
Basis: the current fleet plan of October 2026
([pressing line](equipment/pressing-line.md)). 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
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.)
**The 60–70% effectiveness assumption is worth challenging, but not yet
changing.** Newbilt publishes ≥95% yield and ≥95% uptime for the Classic
@@ -29,7 +33,7 @@ for the Duplex. Three reasons not to adjust anything on that basis:
stamper and mould changes, label reels, colour changeovers, PVC lot
changes, first-article QC and breaks — precisely the losses that
dominate a short-run boutique plant. They are different quantities.
- It would apply only to the **automated half** of the fleet. The
- It would apply only to the **automated press** (the Classic). The
60–80/h semi-auto figure already embeds operator handling, so applying
an uplift to that half would double-count.
- 0.95 × 0.95 is 0.90 before any performance factor; reaching 80% OEE
@@ -159,7 +163,7 @@ conversion, which forestry land generally does not.
| Load | Rough figure |
|---|---|
| Pressing machinery (semi-auto line + 2 automated presses) | ~70 to 80 kW installed |
| Pressing machinery (two Duplex systems + the Classic) | ~90 to 120 kW installed (estimate: 32 kVA per Duplex system by Newbilt's requirements; the second extruders and the Classic not yet published) |
| Process chiller (250 kW cooling) | ~80 to 125 kW electrical |
| Whole-factory HVAC | ~100 to 200 kW peak (estimate) |
| Electric steam boiler (if chosen over biomass/LPG) | ~300 kW |
@@ -169,6 +173,13 @@ conversion, which forestry land generally does not.
Grid connection: a medium-voltage connection with a transformer in the
**500 to 1,000 kVA** class from PEA, sized by the boiler decision.
**Not yet re-based for the five-press fleet** (October 2026). The chiller
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)).
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
charge on the peak-hour maximum, 4.1839 THB/kWh peak (09:00 to 22:00 on
@@ -205,7 +216,10 @@ small against the connection, but its own feeder and meter.
## Steam and fuel
- Boiler: **400 kg/h at 10 bar / 180 °C** (~300 kW thermal)
- Boiler: **400 kg/h at 10 bar / 180 °C** (~300 kW thermal), sized for
one Duplex. The current five-press fleet draws **~750 to 900 kg/h** at
Newbilt's 150 to 180 kg/h per press: not yet re-based, and the fuel
figures below scale with it
- If biomass: **~350 to 400 t/yr** air-dry wood at mature operation, of
which the 60 rai coppice could supply **~80 to 135 t/yr**
- If LPG: **~2.5 to 5 t** bulk tank on site (no gas pipeline in the North)
@@ -232,6 +246,7 @@ keep their original currency alongside.
- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: **~24M to
42M THB (~USD 730k to 1.27M)**, detail in the
[utilities CSV](finance/utilities-investment.csv)
- Not yet priced: automated presses (indicative ~USD 340k each, unverified),
- Not yet priced: the second Duplex system and the Newbilt Classic
(estimates in [total investment](finance/total-investment.md)),
galvanics line, mastering/cutting room, metrology, building
construction/fit-out, land
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@@ -255,9 +255,11 @@ press has 25 kW installed electrical power and consumes per cycle roughly
in the Netherlands runs its AD12 steam from wood-fired biomass boilers, a
working precedent for the renewable-steam question. Pheenix also offers the
**AD12 Manual**, a semi-automatic press on the same platform aimed at
splatter and short runs, which makes them a possible single-vendor
alternative covering both halves of the 50/50 fleet; that option should be
weighed against the Newbilt plan on price, spares, and support.
splatter and short runs, which made them a possible single-vendor
alternative for the earlier 50/50 fleet. Since October 2026 the current
plan is an all-Newbilt fleet ([pressing line](../equipment/pressing-line.md)),
so the AD12 is the comparison for the Newbilt Classic rather than part of
the plan.
Pheenix also builds **electroforming equipment**: an automatic silvering
unit (PASU), a four-position pre-plating unit (PPPU), a two-cell production