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