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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# 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