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:
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three current gates (market validation, BOI, land title check) through
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quotes, commitment, build, launch, and expansion
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- [Pressing line equipment plan](docs/equipment/pressing-line.md): the
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50/50 automated/semi-automatic fleet strategy, the Newbilt system under
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evaluation (~USD 232k quoted scope), and site requirements
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current all-Newbilt fleet (two Duplex systems with an extruder per press,
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plus one Classic automatic press), the 2024 Newbilt quote (~USD 232k,
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expired), the 2026 product flyers, and site requirements
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- [Galvanics and stamper prep equipment plan](docs/equipment/galvanics.md):
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the metal path from lacquer to press-ready stamper, from vendor
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datasheets: Pheenix Alpha's electroforming range as a second turnkey
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@@ -91,7 +92,7 @@ The detail lives in dedicated documents:
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used lathes and cutting-room contacts (via OMS),
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stamper preparation
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(Sibert), bridge stamper service (Stamper Discs), and automated presses
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(Pheenix Alpha)
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(Pheenix Alpha, the comparison for the Classic)
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- [Equipment needs and supplier map](docs/suppliers/equipment-suppliers.md):
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the full needs list per production step with supplier tables and contacts
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- [Sustainability](docs/sustainability.md): the solar installation (Deye
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@@ -31,15 +31,15 @@ is an estimate.
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| Newbilt press (HRP 12) | 1,350 kg | [Newbilt Duplex site requirements](equipment/newbilt/) |
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| Newbilt extruder | 660 kg | same |
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| Newbilt hydraulic aggregate (250 L tank, 50 L accumulator) | 600 kg | same, plus the [budgetary offer](equipment/newbilt/) |
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| Pheenix AD12 automated press | **unknown**, ask Pheenix | not in any document yet |
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| 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) |
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| 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) |
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| 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 |
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| Water-treatment evaporator | unknown, lifted empty | to be asked with the quote |
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**Planning capacity: 5 t safe working load** (estimate). It covers the
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heaviest known lift with its lifting beam and slings at a wide margin and
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leaves room for the automated presses until Pheenix states their weight.
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If the AD12 turns out under about 2.5 t, price a **3.2 t** crane as the
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leaves room for the automatic press until Newbilt states the Classic's
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weight. If the Classic turns out under about 2.5 t, price a **3.2 t** crane as the
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alternative: lighter runway and frame, and possibly a lighter inspection
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regime. Thai cranes fall under the Ministry of Labour's 2021 Ministerial
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Regulation on machinery, cranes and boilers (the same regulation that
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@@ -401,7 +401,7 @@ goods into the phase 2 building.
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## Open decisions
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1. **Crane capacity**: 5 t or 3.2 t, once Pheenix states the AD12 weight
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1. **Crane capacity**: 5 t or 3.2 t, once Newbilt states the Classic's weight
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and the inspection intervals are confirmed.
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2. **Low eave**: keep 7.0 m or raise to 8.0 m, once the contractor states
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the achievable hook height.
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@@ -1,13 +1,66 @@
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# Pressing Line: Equipment Plan
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The target press fleet is a **50/50 split between fully automated and
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semi-automatic presses**: automated presses for standard production volume,
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and semi-automatic presses for splatter and other color effects, special
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editions, and small runs, where an operator working the mold directly is an
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advantage rather than a cost. The semi-automatic side is covered by the
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Newbilt evaluation below; a fully automated press line is an open
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procurement item with two candidates: the Newbilt Classic (below) and the
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Pheenix Alpha AD12 (see the [vendor landscape](../suppliers/vendor-landscape.md)).
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## Current plan: an all-Newbilt fleet of five presses (October 2026)
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Two **Newbilt Duplex** systems, each in Newbilt's two-extruder
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configuration (two HRP 12 presses, each fed by its own extruder, on one
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hydraulic unit with shared control), plus one **Newbilt Classic** fully
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automatic press:
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| | Presses | Extruders | Hydraulics |
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|---|---|---|---|
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| Duplex system 1 | 2 semi-automatic | 2 | one unit for the system |
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| Duplex system 2 | 2 semi-automatic | 2 | one unit for the system |
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| Classic | 1 fully automatic | 1, built in | its own |
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| **Fleet** | **5: 4 semi-automatic, 1 automatic** | **5** | |
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This replaces the earlier target of a 50/50 split between automated and
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semi-automatic presses (two of each, with the Pheenix AD12 as the
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automated candidate). What it means:
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- **The semi-automatic side carries most of the volume.** Splatter and
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other colour effects, special editions and small runs are where an
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operator working the mould is an advantage rather than a cost, and
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Newbilt itself recommends the Duplex for splatter. With an extruder per
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press, the two presses of a system can run different colours or
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compounds at the same time and neither waits on a shared extruder (our
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reading of the flyer's configurations; confirm with Newbilt). The
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Classic takes the long standard runs.
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- **One vendor, one mould family.** Classic and Duplex share insert sets
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(below), so the whole fleet runs one family of moulds and spares and one
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service relationship. The single-vendor risk is the same one the Pheenix
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path would have carried.
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- **Phasing.** The Newbilt Single 2.1 system of the 2024 quote (one press,
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one extruder) is the launch configuration and the first half of Duplex
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system 1: its hydraulic aggregate is already sized for the second press.
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The second press and extruder complete system 1; system 2 and the
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Classic complete the fleet ([scale](../scale.md) capacity table,
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[roadmap](../roadmap.md) item 24).
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- **Capacity** at maturity stays at ~1.0 to 1.5 million records a year on
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two shifts, the range the [revenue model](../finance/revenue-model.md)
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uses: four semi-automatic presses at 60 to 80 records an hour (estimate)
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and the Classic at ~128 an hour (28 s cycle, vendor figure).
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- **Utilities do not scale from the old figures.** At Newbilt's per-press
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figures (steam 150 to 180 kg/h, cooling up to 125 kW per press), five
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presses draw ~750 to 900 kg/h of steam and up to ~625 kW of cooling,
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against the ~400 kg/h steam generator and ~250 kW cooling system that the
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2024 quote's exclusions describe for one Duplex. The boiler, chiller,
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electrical connection and [utilities CSV](../finance/utilities-investment.csv)
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are **not yet re-sized** for this fleet; that waits for the re-quote's
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figures ([scale](../scale.md)).
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- **Investment**: the fleet change is carried in the added-scope table of
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[total investment](../finance/total-investment.md) until the next
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re-base.
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- **For the re-quote** ([roadmap](../roadmap.md) item 4): the two-extruder
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Duplex as an upgrade of the Single 2.1 and as a second complete system;
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the Classic's price, weight, power, steam and cooling figures; and a
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central hydraulic supply shared by both Duplex systems (an option the
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flyer offers).
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The Pheenix AD12 leaves the plan; it stays in the
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[vendor landscape](../suppliers/vendor-landscape.md) as the comparison if
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the Classic re-quote disappoints, and Pheenix stays a galvanics candidate
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([galvanics and stamper prep](galvanics.md)).
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## Semi-automatic line: Newbilt
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@@ -51,10 +104,11 @@ vendor-published, not quoted.
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What this changes in the plan:
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- **Classic and Duplex share inserts.** Insert sets move between the two
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machines, so a Newbilt-only fleet (Duplex for the semi-automatic half,
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Classic for the automated half) runs one mould family. Newbilt itself
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recommends the Duplex for splatter, which matches the reason for the
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50/50 split. The Pheenix AD12 stays the comparison for the automated half.
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machines, so the current all-Newbilt fleet (Duplex systems for the
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semi-automatic side, the Classic for the automated press) runs one mould
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family. Newbilt itself recommends the Duplex for splatter, which is why
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the semi-automatic side carries most of the fleet. The Pheenix AD12
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stays the comparison for the Classic.
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- **Regrind loop.** The granulator flyer puts edge trim at about 20 to 40 g
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per 12" 180 g record, 11 to 22 % of the record's mass, which brackets the
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~20 % recycled share in the process schematic. Rejected records go
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@@ -84,7 +138,9 @@ Site planning for the semi-automatic line works from Newbilt's Duplex
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requirements: roughly 200 m² of production floor, 32 kVA connected
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electrical load, saturated steam at 10 bar, and compressed air and cooling
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water circuits, plus side rooms for materials, compressor, chiller, and
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finished goods.
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finished goods. These are per Duplex system: the current fleet needs two,
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plus floor for the Classic (~400 m², plus ~50 to 75 m² for the Classic,
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estimate).
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**Floor loading is a building-selection criterion**: the slab must carry
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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.
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| ResurRec, assuming one shift over 300 days | ~275k – 355k |
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| **CNX launch** (1 semi-auto, 1 shift) | **90k – 135k** |
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| CNX Duplex (2 semi-auto, 1–2 shifts) | ~175k – 540k |
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| CNX mature (2 semi + 2 automated, 2 shifts) | 1.0M – 1.5M |
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| CNX mature (4 semi + 1 automated, 2 shifts) | 1.0M – 1.5M |
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All rows are on the same 300-day basis so they can be compared. CNX does
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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
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| Block | USD | THB | Basis |
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|---|---|---|---|
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| 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 |
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| 2 automated presses (Pheenix AD12) | 580k – 920k | 19.1M – 30.5M | unverified ~USD 340k/press indicative + delivery and commissioning |
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| 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 |
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| 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 |
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| 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 |
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| Zero-discharge water treatment (ZLD) | 90k – 240k | 3.0M – 8.0M | utilities CSV option row |
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| 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 |
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@@ -47,7 +47,8 @@ building, software and stamper prep lines, and the contingency on top).
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| Artist platform, public side (calculator, campaigns, payments) | 40k – 90k | 1.3M – 3.0M | estimate, [artist platform](../artist-platform.md) |
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| 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 |
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| 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 |
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| **Added so far** | **~480k – 770k** | **~15.8M – 25.5M** | about 10 to 12% on the full-vision subtotal |
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| 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)) |
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| **Added so far** | **~420k – 610k** | **~13.8M – 20.2M** | about 8 to 10% on the full-vision subtotal |
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## Phased entry
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@@ -60,8 +61,9 @@ A credible launch phase is far smaller, roughly **1.7M to 2.9M USD
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metrology deferred; the PVC lab's day-one tier is the added-scope row
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above
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- Leased building instead of purchase, modest first solar array
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- Galvanics, automated presses, full metrology, and the biomass boiler
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follow as revenue-funded or second-round expansions
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- Galvanics, the second Duplex system and the Classic, full metrology,
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and the biomass boiler follow as revenue-funded or second-round
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expansions
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The planning already supports this: the Duplex-ready hydraulics, the
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bridge-supplier role for Stamper Discs, the staged electric-to-biomass
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@@ -80,7 +82,7 @@ exactly this reason.
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[project-timeline.md](../project-timeline.md)
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- **Biggest uncertainty bands**: metrology (partly a choice of ambition),
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the mastering/cutting room (bespoke vendor, no public pricing), the
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automated presses (single unverified price point), and land
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Newbilt Classic (no price on file), and land
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- **Currency exposure is real and is not modelled here.** Revenue is
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mostly USD/EUR from export customers, the cost base is mostly THB, and
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the largest single equipment block is EUR-denominated and unhedged
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+9
-5
@@ -40,12 +40,15 @@ These three run in parallel and gate everything downstream:
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## Phase 1: Quotes and site (parallel with the BOI decision window)
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4. **Newbilt re-quote** (2024 offer expired), with PLC/data access as a
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4. **Newbilt re-quote** (2024 offer expired) for the current fleet: the
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two-extruder Duplex as the Single 2.1 upgrade and as a second system,
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the Classic automatic press, and a central hydraulic supply option
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([pressing line](equipment/pressing-line.md)), with PLC/data access as a
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stated purchasing requirement per the
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[traceability spec](traceability.md)
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5. **Pheenix Alpha**: current metric datasheet and quotes for the AD12 and
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AD12 Manual, evaluating the single-vendor option against Newbilt for
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the semi-auto half. After Haarlem the CEO offered a Teams call,
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5. **Pheenix Alpha**: the AD12 left the current fleet plan in October
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2026 (an all-Newbilt fleet); Pheenix stays the comparison for the
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Classic and a galvanics candidate (item 6). After Haarlem the CEO offered a Teams call,
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reference clients and a factory visit near Stockholm; the call follows
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once our questions are ready, and the next Europe trip is planned
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for February 2027 ([exhibitor briefing](suppliers/making-vinyl-europe-2026-exhibitors.md#after-the-show))
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@@ -140,7 +143,8 @@ These three run in parallel and gate everything downstream:
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before every manufacturing step is in place
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([exhibitor briefing](suppliers/making-vinyl-europe-2026-exhibitors.md#after-the-show));
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supplier advice to weigh against the market evidence, not a decision
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24. Automated press line (the 50/50 fleet target)
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24. Second Duplex system and the Newbilt Classic automatic press, which
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complete the five-press fleet ([pressing line](equipment/pressing-line.md))
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25. Full metrology stack and the sampled audio QC station
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26. Biomass boiler, fed by the by-then-mature coppice plus regional fuel
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27. Mastering and cutting room (can move earlier if title-services demand
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+28
-13
@@ -9,16 +9,20 @@ page as real quotes and the site decision land.
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| Phase | Fleet | Rough output |
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|---|---|---|
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| Launch | 1 semi-auto press (Newbilt Single), 1 shift | ~90,000 to 135,000 records/yr |
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| Duplex | 2 semi-auto presses, 1 to 2 shifts | ~175,000 to 540,000 records/yr |
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| Mature | 2 semi-auto + 2 automated (50/50 fleet), 2 shifts | ~1.0 to 1.5 million records/yr |
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| Launch | 1 semi-auto press (Newbilt Single, the first half of Duplex system 1), 1 shift | ~90,000 to 135,000 records/yr |
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| Duplex | 2 semi-auto presses (Duplex system 1, an extruder per press), 1 to 2 shifts | ~175,000 to 540,000 records/yr |
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| 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 |
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Basis: the automated AD12 presses ~140 records/hour each (vendor datasheet);
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semi-automatic throughput is unpublished, assumed 60 to 80 records/hour per
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press with operator handling (estimate); 16 h/day, 300 days/yr, with
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realistic overall effectiveness of 60 to 70% applied. The theoretical
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ceiling of the mature fleet at 100% uptime is roughly 1.9 to 2.1 million
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records per year.
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Basis: the current fleet plan of October 2026
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([pressing line](equipment/pressing-line.md)). The automated Classic
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~128 records/hour (28 s cycle, vendor flyer); semi-automatic throughput is
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unpublished, assumed 60 to 80 records/hour per press with operator
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handling (estimate); 16 h/day, 300 days/yr, with realistic overall
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effectiveness of 60 to 70% applied: 368 to 448 records/hour, ~1.06 to 1.5
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million a year. The theoretical ceiling of the mature fleet at 100% uptime
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is roughly 1.8 to 2.2 million records per year. (The earlier 50/50 fleet,
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two semi-automatic presses and two Pheenix AD12s, landed in the same
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range.)
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**The 60–70% effectiveness assumption is worth challenging, but not yet
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changing.** Newbilt publishes ≥95% yield and ≥95% uptime for the Classic
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@@ -29,7 +33,7 @@ for the Duplex. Three reasons not to adjust anything on that basis:
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stamper and mould changes, label reels, colour changeovers, PVC lot
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changes, first-article QC and breaks — precisely the losses that
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dominate a short-run boutique plant. They are different quantities.
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- It would apply only to the **automated half** of the fleet. The
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- It would apply only to the **automated press** (the Classic). The
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60–80/h semi-auto figure already embeds operator handling, so applying
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an uplift to that half would double-count.
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- 0.95 × 0.95 is 0.90 before any performance factor; reaching 80% OEE
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@@ -159,7 +163,7 @@ conversion, which forestry land generally does not.
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| Load | Rough figure |
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|---|---|
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| Pressing machinery (semi-auto line + 2 automated presses) | ~70 to 80 kW installed |
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| 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) |
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| Process chiller (250 kW cooling) | ~80 to 125 kW electrical |
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| Whole-factory HVAC | ~100 to 200 kW peak (estimate) |
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| Electric steam boiler (if chosen over biomass/LPG) | ~300 kW |
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@@ -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
|
||||
@@ -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
|
||||
|
||||
Reference in new issue
Block a user