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
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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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