diff --git a/README.md b/README.md index ed1e044..6e80d81 100644 --- a/README.md +++ b/README.md @@ -89,6 +89,9 @@ The detail lives in dedicated documents: - [Process flow](docs/process-flow.md): the whole chain from audio file to delivered record as a chart and stage table, with every check and the three artist approval gates (printable diagram alongside) +- [Project scale](docs/scale.md): rough numbers for everything on one page: + output capacity, building area, land, electrical demand, solar and + storage, steam and fuel, headcount, and money cross-references ## Repository Layout @@ -106,6 +109,7 @@ docs/ ├── facility-security.md Security, HVAC, fire and life safety, compliance ├── process-flow.md Audio file to delivered record, with all checks ├── quality-automation.md Stamper metrology and layered record QC +├── scale.md Rough project sizing on one page ├── sustainability.md Energy, water, materials commitments ├── traceability.md Process logging and per-order traceability └── worker-safety.md Training, clean rooms, PPE diff --git a/docs/scale.md b/docs/scale.md new file mode 100644 index 0000000..86b0038 --- /dev/null +++ b/docs/scale.md @@ -0,0 +1,108 @@ +# Project Scale: Rough Numbers + +One-page sizing of the whole project. Everything here is a planning +estimate derived from the session's vendor data and standard ratios; +figures marked "estimate" have no vendor confirmation yet. Update this +page as real quotes and the site decision land. + +## Production capacity + +| 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 | ~300,000 to 600,000 records/yr | +| Mature | 2 semi-auto + 2 automated (50/50 fleet), 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| + +Basis: the automated AD12 presses ~140 records/hour each (vendor datasheet); +semi-automatic throughput is unpublished, assumed 60 to 80 records/hour per +press with operator handling (estimate); 16 h/day, 300 days/yr, with +realistic overall effectiveness of 60 to 70% applied.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. + +## Building + +| Zone | Rough area | +|---|---| +| Semi-auto press hall (Newbilt Duplex spec) | ~200 m² | +| Automated press zone | ~100 to 150 m² | +| Galvanics clean room + water treatment + chemical storage | ~80 to 150 m² | +| Mastering and cutting room | ~40 to 60 m² | +| Stamper prep | ~30 m² | +| Packaging + finished goods warehouse | ~300 to 500 m² | +| Utility rooms (boiler, compressor, chiller, electrical) | ~100 to 150 m² | +| Offices, QC/listening, archive, IT, entrance | ~150 to 200 m² | +| Circulation, walls, misc | ~150 to 250 m² | +| **Total under roof** | **~1,200 to 1,700 m²** | + +The HVAC budget in the utilities CSV already assumes ~1,500 m² conditioned. +Single story throughout: all heavy equipment needs ground-slab floor +loading (multiple tons per m²). + +## Land: factory plot + +Industrial plots typically allow 50 to 60% building coverage, and the site +needs truck access and turning, parking, the outdoor cooling tower, the +separated BESS enclosure, possible ground-mount solar, and expansion room. + +- Minimum workable: **~4 rai** (6,400 m²) +- Comfortable with expansion and ground-mount solar: **~6 to 8 rai** + (9,600 to 12,800 m²) + +Separate asset: the **60 rai** forestry-classified parcel for coppice +fuelwood (see [biomass](biomass.md)), pending its title check. It is a fuel +plantation, not a factory site candidate unless the classification allows +conversion, which forestry land generally does not. + +## Electrical scale + +| Load | Rough figure | +|---|---| +| Pressing machinery (semi-auto line + 2 automated presses) | ~70 to 80 kW installed | +| 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 | +| Compressed air, lighting, IT, misc | ~30 to 50 kW | +| **Plant peak demand** | **~300 to 450 kW without electric boiler; ~600 to 750 kW with it** | + +Grid connection: a medium-voltage connection with a transformer in the +**500 to 1,000 kVA** class from PEA, sized by the boiler decision. + +## Solar and storage + +- Roof of a ~1,500 m² building fits roughly **150 to 200 kWp**; reaching the + illustrative 300 kWp in the utilities CSV needs carport or ground-mount + on the plot (about 1 rai of ground per additional 100 kWp, estimate) +- Northern Thailand yield ~1,400 to 1,500 kWh/kWp/yr, so 300 kWp produces + roughly **420 to 450 MWh/yr** +- Plant consumption at mature two-shift operation: roughly **1,000 to + 1,500 MWh/yr** without electric steam, up to **~2,500 MWh/yr** with it + (estimate), so 300 kWp covers on the order of **20 to 35%** of + consumption; a bigger array shifts that up +- Battery: **271 kWh** Gobel stack (peak shaving and ride-through, roughly + two to three hours of the chiller's electrical draw) + +## Steam and fuel + +- Boiler: **400 kg/h at 10 bar / 180 °C** (~300 kW thermal) +- 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) + +## People + +Rough mature-operation headcount (estimate): 4 to 6 press/finishing +operators per shift, 2 to 3 galvanics, 1 to 2 mastering/cutting engineers, +1 to 2 QC, 2 maintenance, 3 to 5 admin/sales/logistics. Roughly **15 to 25 +people** across shifts at maturity, fewer than half that at launch. + +## Money (cross-references) + +- Newbilt semi-auto line: **~€200,500** (2024 quote, expired, in + [pressing-line](equipment/pressing-line.md)) +- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: **~24M to + 42M THB** (~€630k to 1.1M), detail in the + [utilities CSV](finance/utilities-investment.csv) +- Not yet priced: automated presses (indicative ~$340k each, unverified), + galvanics line, mastering/cutting room, metrology, building + construction/fit-out, land