Press hall laid out 60/40 for Duplex systems (special pressings first)
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User (October 2026): "the factory should have more space for duplex
setups than classic, we will mainly focus on special prints and not mono
colours plan it to be 60/40 duplex classic".

- Press hall (~870 m2) planned 60/40 by floor: four Duplex bays along the
  visitor corridor and six Classic positions in the second row (440 + 300
  = ~740 m2 at 110 / 50 m2), the rest open for mould carts and staging;
  the launch plant fills one of each, growth adds Duplex systems first.
  Replaces "room for ten more Classics".
- Full hall: 8 semi-automatic presses + 6 Classics, 57/43 by press count,
  ~1,250 to 1,410 records/h gross, ~3.6 to 4.7M a year on the scale.md
  basis (was 4.7 to 5.8M for 2 Duplex + 11 Classics); ~2.1 to 2.5 t/h
  steam and up to ~1.8 MW cooling, still a utility phase of its own.
  By hourly output the six automatic Classics still press more than the
  eight semi-automatic presses (estimate).
- pressing-line.md, scale.md (capacity table, utilities), site-candidates
  .md, crane-workshop-tours.md, roadmap.md, README (the FreeCAD Payap
  model still draws the earlier layout; noted, not redrawn).
- Calculator: preset "Full hall 60/40 (4 D + 6 C)", fleet ladder Duplex
  first (1+1, 2+1, 3+2, 4+3, 4+6) plus the same floor Classic-led (2+11)
  and Duplex-only (7+0) for comparison; plant view reserves 4 Duplex
  bays and 6 Classic positions.
- Business plan draft 0.2 rebuilt (capacity table row, plot fit, layout).

Checks: renderer 720 checks pass (node budget 2,700 for the Duplex-heavy
stress preset, 60 fps), calculator regression 0 fails, level selector and
page checks clean at 390 / 1024 / 1440 px dark and light; PDF 47 pages
with a filled table of contents.
This commit is contained in:
grabowski committed 2026-10-16 20:09:56 +07:00
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@@ -96,14 +96,25 @@ automated candidate). What it means:
between machines. The EX 35 and trimmer footprints are not published,
so those are estimates. The [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws
both systems this way.
- **Room to grow: possibly ten more Classics.** The plant may add up to
ten more Newbilt Classics at some point. This is an option, not part of
the plan or the investment: the layout keeps floor for it (ten Classic
positions in the Payap scenario model), and the central hydraulic and
- **Room to grow: a hall laid out 60/40 for Duplex systems (October
2026).** The plant will mainly press special editions (splatter, colour
effects, small runs), not mono colours, so the press hall keeps more
floor for Duplex systems than for Classics: 60/40 by floor, four Duplex
bays (the launch system and three more) and six Classic positions (the
launch Classic and five more). At the calculator's floor figures (110 m²
per Duplex bay, 50 m² per Classic) that is 440 + 300 = ~740 m² of the
~870 m² hall; the rest stays open for mould carts and staging. Growth
adds Duplex systems first. The full hall is eight semi-automatic presses
and six Classics, 57/43 by press count; by hourly output the six
automatic Classics still press more (~770 against 480 to 640 records an
hour, estimate). This is an option, not part of the plan or the
investment: the layout keeps the floor, and the central hydraulic and
air plant should be sized or extendable for it. At Newbilt's per-press
figures, fifteen presses would draw ~2.3 to 2.7 t/h of steam and up to
~1.9 MW of cooling, so boiler, chiller and grid connection would be a
phase of their own ([scale](../scale.md)).
figures, the fourteen presses would draw ~2.1 to 2.5 t/h of steam and up
to ~1.8 MW of cooling, so boiler, chiller and grid connection would be a
phase of their own ([scale](../scale.md)). The Payap scenario model in
FreeCAD still draws the earlier layout (two Duplex bays and eleven
Classic positions).
- **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)
@@ -132,7 +143,8 @@ automated candidate). What it means:
flyer's Duplex main configuration runs two presses on one extruder); the
Classic's price, weight, power, steam and cooling figures; and the
central hydraulic supply (an option the flyer offers) for the whole
fleet, extendable to ten more Classics, including whether the Classic
fleet, extendable to the full hall (four Duplex systems, six Classics),
including whether the Classic
can run from it, whether the presses hold their pressure from it over
the ring-main lengths of the hall, the filtration and isolation each
branch needs, and whether the Single 2.1's aggregate can be its first