From c6bec7144225e27d1bc947994be00163ae269986 Mon Sep 17 00:00:00 2001 From: grabowski Date: Sat, 10 Oct 2026 18:21:47 +0700 Subject: [PATCH] Press fleet calculator: target output and specials share to fleet mix and needs User, October 2026: calculations for the later business plan, starting from 2 Duplex + 1 Classic at 3 records a minute per Duplex and 2 per Classic, as an interactive tool on the website: pick the yearly output and the share of splatter/specials, get the machine mix and all the requirements (people, hydraulics, power, ...). docs/fleet-calculator.html (single static page, no dependencies): - target mode sizes the fleet (specials only on Duplex with its EX 35; grow with Classics or with Duplex systems; start fleet as the floor); fleet mode takes a fleet and gives its output at the specials share; - output, capacity, utilisation and the mix bar per machine type; - needs: people per shift and in total, galvanics operators, machines, connected kVA and average kW, MWh/yr, central hydraulics (flow, motor, oil, accumulator), steam, cooling and cooling water, compressed air, press floor, room climate, compound, trim, titles, electroformed parts and plating units; checks against the 400 kg/h boiler, 250 kW chiller and the 870 m2 Payap press hall; - ladder from the start fleet to a full Payap press hall, click to load; - every assumption editable with its source (Newbilt Duplex site requirements V14 and offer 240620-04, scale.md, galvanics.md, revenue model, Payap model; estimates labelled), shareable link via the hash. The Classic counts as one HRP 12 press plus one extruder until Newbilt states figures (Toolex Alpha leaflet as a cross-check). Site: DEMOS entry (/demos/fleet-calculator/) and landing-page entry. README bullet and layout line; backlinks from scale.md (capacity) and pressing-line.md (current plan). --- README.md | 9 + docs/equipment/pressing-line.md | 7 +- docs/fleet-calculator.html | 596 ++++++++++++++++++++++++++++++++ docs/scale.md | 7 + site/build.sh | 1 + site/public/index.html | 12 + 6 files changed, 631 insertions(+), 1 deletion(-) create mode 100644 docs/fleet-calculator.html diff --git a/README.md b/README.md index bebe1df..3c47da0 100644 --- a/README.md +++ b/README.md @@ -173,6 +173,14 @@ The detail lives in dedicated documents: 1× is real time, up to 3600× (a day in 24 s); every station is clickable and names the source of its figures; on phones and tablets held sideways it pinch-zooms and opens station details in a side sheet +- [Press fleet calculator](docs/fleet-calculator.html): a single static + page for the business plan: set the records a year and the share of + splatter and specials, and it sizes the mix of Duplex systems (3 + records a minute each) and Classics (2 a minute) from the start fleet + of two Duplex and one Classic up to a full press hall, with the people, + power, central hydraulics, steam, cooling, air, floor, compound and + stampers that fleet needs; every assumption is editable, with its + source, and a scenario can be shared by link - [Test site](site/README.md): `site/` builds https://cnxvinyl.lol/, the internal test site with demo pages from `docs/` (the plant operation page first) and any static site we want to share by link; Gitea Actions @@ -248,6 +256,7 @@ docs/ ├── crane-workshop-tours.md Overhead crane, workshop, visitor corridor ├── digital-factory.md Data platform, NixOS/Clan fleet, acquisition, app ├── facility-security.md Security, HVAC, fire and life safety, compliance +├── fleet-calculator.html Press fleet calculator: output, mix, requirements ├── payap-partnership.md Joint student programmes with Payap University ├── plant-operation.html Animated plant overview (simulated SCADA) ├── process-flow.md Audio file to delivered record, with all checks diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index ee1ff2b..d1ba251 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -35,7 +35,12 @@ automated candidate). What it means: system 1: its hydraulic aggregate is already sized for the second press. 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). + [roadmap](../roadmap.md) item 24). The + [press fleet calculator](../fleet-calculator.html) works out the mix of + Duplex systems and Classics for a target output and specials share, + with the utilities from Newbilt's site requirements; the Classic counts + there as one HRP 12 press plus one extruder until Newbilt states its + figures. - **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 diff --git a/docs/fleet-calculator.html b/docs/fleet-calculator.html new file mode 100644 index 0000000..1611af7 --- /dev/null +++ b/docs/fleet-calculator.html @@ -0,0 +1,596 @@ + + + + + + +CNX Vinyl · press fleet calculator + + + +
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Press fleet calculator

+ planning estimates · not a quote +

+ Set the records you want a year and the share of splatter and other + specials. The calculator sizes the press fleet from Newbilt Duplex systems + (two HRP 12 presses, an EX 50 and an EX 35 colour extruder each) and Newbilt + Classic automatic presses, starting from the planned two Duplex systems and + one Classic. It then lists what that fleet needs: people, power, central + hydraulics, steam, cooling, compressed air, floor, compound and stampers. + Vendor figures are from Newbilt's Duplex site requirements and offer; the + rest are planning figures and estimates from the CNX Vinyl documents. Every + figure can be changed under Assumptions. +

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What you want

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Grow the fleet with
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Start fleet, never fewer than:
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Splatter, multi-colour and effect records run only on the Duplex, with + its EX 35 colour extruder (Newbilt recommends the Duplex for splatter). Black and + single-colour records run on either press.

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Operation

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Press rates

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Fleet

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Output and machine mix

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What the fleet needs

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From small to fully equipped

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Fleets from the start fleet to a full Payap press hall (about 870 m²: + the two Duplex bays plus the Classic and ten more Classic positions, or the same floor + with more Duplex systems), at the current settings. Click a row to load it.

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Assumptions

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Every result above comes from these figures. Changed values are + kept in the link, so a scenario can be shared with "Copy link".

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Basis and limits

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Classic utilities. Newbilt has published no power, steam, cooling or weight figures for + the Classic, so it counts here as one HRP 12 press plus one extruder on the central hydraulics. + Cross-check from the Toolex Alpha leaflet the Classic is based on: 1.2 kg steam, 15 l cooling + water, 18 l air and 3.15 l hydraulic oil per cycle (about 144 kg/h of steam at 2 a minute), + 2.18 × 1.30 m, 1,850 kg. These go into the re-quote questions in pressing-line.md.

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EX 35. Counted at the EX 50's electrical, air and water figures; it is the smaller + extruder, so this errs high.

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Central hydraulics. Newbilt's aggregate serves two presses; the per-press figures are + half of it, summed without any diversity. Whether the Classic can run from the shared plant + is an open question for Newbilt.

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Peaks add up. Steam, cooling and air are summed at each machine's peak, as Newbilt + states them. A real plant staggers cycles, so the boiler and chiller can be sized lower once + a utility engineer has the cycle data.

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Not scaled here: mastering (1 to 2), QC (1 to 2), maintenance (2) and admin, sales and + logistics (3 to 5), from scale.md; cover for leave and sickness; the boiler fuel and the PV + share of the power.

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Sources in the CNX Vinyl planning repository: equipment/pressing-line.md, + equipment/newbilt/ (Duplex site requirements V14, offer 240620-04, 2026 flyers), + equipment/galvanics.md, scale.md, finance/revenue-model.md, site-candidates.md (Payap scenario model).

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+ + + + + diff --git a/docs/scale.md b/docs/scale.md index 7dec7d8..6f60e4e 100644 --- a/docs/scale.md +++ b/docs/scale.md @@ -14,6 +14,13 @@ page as real quotes and the site decision land. | 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) | +The [press fleet calculator](fleet-calculator.html) sizes the fleet for +any yearly output and specials share, with the people and utilities it +needs; at the user's planning rates (3 records a minute per Duplex +system, 2 per Classic, 65 % effectiveness, two shifts) the start fleet +makes ~1.5 million records a year and a full Payap press hall (two Duplex +systems and eleven Classics) ~5.2 million. + 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 diff --git a/site/build.sh b/site/build.sh index 6b27cb9..b3caf04 100644 --- a/site/build.sh +++ b/site/build.sh @@ -19,6 +19,7 @@ cp -R site/public/. "$out/" # " " DEMOS=( "docs/plant-operation.html demos/plant-operation/index.html" + "docs/fleet-calculator.html demos/fleet-calculator/index.html" ) for entry in "${DEMOS[@]}"; do read -r src dst <<<"$entry" diff --git a/site/public/index.html b/site/public/index.html index 160bc42..e41854c 100644 --- a/site/public/index.html +++ b/site/public/index.html @@ -63,6 +63,18 @@ to zoom. +
  • + + Press fleet calculator + Set the records a year and the share of splatter and specials; + it sizes the mix of Newbilt Duplex systems and Classic automatic + presses and lists what that fleet needs: people, power, central + hydraulics, steam, cooling, compressed air, floor, compound and + stampers, from the start fleet to a fully equipped press hall. + Every assumption is editable and a scenario can be shared by + link. + +