Four photos of ResurRec's new Japan plant (October 2026) filed in
docs/finance/resurrec-japan/. Revenue model gets a "ResurRec Japan"
section: what the photos show (visitor window, automatic presses in
aluminium cabinets that Alexander identifies as a new red AD12
generation, ceiling services, air-conditioned room, no plating in view),
what it changes (scaling abroad, Japan export wedge narrows, Classic vs
AD12 evidence, collaboration depends on their metal path) and open
questions. Also notes a directory listing naming an M-Tech Allegro II in
Bangkok against the tour's Newbilt Classic.
Mirrors: Pheenix sections in vendor-landscape, exhibitor questions and
supplier map; pressing-line AD12 paragraph; roadmap item 5; visitor
corridor in crane-workshop-tours; README status and layout.
User, 19 Oct 2026: one plate every 5 records; how do we make sure the
plates don't scratch the records.
- Plate every 5 (10 per 50-record stack, ~15 kg a stack).
- Scratch rules: groove-guard profile keeps grooves off the plate (QRP);
plate flat, larger than the record (306 to 310 mm), deburred; clear
anodised (cost estimate, CNY 16 to 28/m2 China reference); vertical
handling only; no grit (trimmer extraction, ionised blow-off and wipe
on return, covered carts and racks); numbered plates, monthly check;
station compares scratches on plate faces vs record faces.
- About 700 plates for a 24 h queue (25 sheets, THB 245k to 315k cut,
+ 35k to 105k anodising, estimates); 200 to 260 for 8 h.
- Plate trial adds bare vs anodised and the scratch comparison.
User, 19 Oct 2026: stack records with spacers; the plates are aluminium
and should be cut locally.
- Where it sits: 50 records a stack (Cascade), a flat aluminium plate
every 10 records to start (MY45; Mobineko uses one per record; the
Classic handles plates itself), full discs not ring spacers.
- Plates: 5052 (5083 if anodised), 3 mm, diameter and hole to Newbilt's
drawing; 28 per 1220 x 2440 sheet, sheet about THB 8,300 ex VAT
(OneStockHome, 3003), THB 350 to 450 a plate cut and deburred
(estimate); fibre laser or waterjet, Chiang Mai shops listed; deburred,
flatness check, kept clean. About 350 plates for a 24 h queue
(THB 120k to 160k), 100 to 130 for 8 h.
- Spiral cooling tower considered and not taken (full queue USD 75k to
120k for 8 h, dust, no stack weight); a 30 to 60 min spiral stays a
later option.
- Next steps: Newbilt plate drawing; new plate and settling trial
(plate every 5/10/25, warp at 1 h and 24 h).
User, 19 Oct 2026: check github.com/qitechgmbh/control and
shop.qitech.de/collections/ethercat.
- QiTech Control (LGPL-3.0, Rust on an EtherCrab fork, NixOS, runs
QiTech's own machines): plan now uses its EtherCAT library qitech_lib,
pinned, as the layer under our station service; not the full Electron
app. It has DC SYNC0, SDO/PDO handling, EK1100/EL2809/EL3021/EL3024
drivers and a CiA402 MINAS A6 servo driver to copy for the A6-EC.
Drivers to write: EK1101, EL1809, EL3152, EL5101, A6-EC (upstream).
Kernel: start from QiTech's tested settings (6.18, preempt=full,
isolcpus 2,3); 6.12 PREEMPT_RT stays the fallback for IgH.
- QiTech shop (new Beckhoff stock from an insolvency, ships worldwide):
EK1101 EUR 85.13, EL1809 EUR 16.53, EL2809 EUR 41.03, EL9011 EUR 1.76
replace the geizhals offers, EUR 207.57 less. TwinSAFE and Beckhoff
STO servo terminals noted, not taken.
- EtherCAT parts EUR 1,684 to 1,897 + 2 servo kits (THB 72k to 80k);
bench parts about THB 56k; spare coupler/DI/DO now stocked.
- BOM total USD 16,671 to 32,681 (THB 0.55M to 1.08M).
User, 19 Oct 2026: plan the current EtherCAT setup, keep the 100 W servo,
check prices on geizhals.de.
- New docs/equipment/inline-qc-control-plan.md: decisions, bus layout
(drives at the end of the line because the A6-200EC takes control
power from the main supply), I/O list for EL1809/EL2809/EL3152/EL5101
and the drive touch probe, PDO and DC notes from the A6-EC manual,
geizhals.de price table (EUR 1,891.60 to 2,104.39 + USD 246.58 for the
servo kits, THB 80k to 88k), NixOS/EtherCrab software, safety circuit
(PNOZ s3, two contactors, dump valve), bench test with pass marks
(parts about THB 64k, all reused), build order, spares, open points.
- EL3102 replaced by EL3152: the optoNCDT 1420 output is 4 to 20 mA.
- Spindle encoder index goes to an EL5101 instead of the drive touch
probe; encoder 2,000 to 2,500 pulses.
- BOM: control lines split per part with geizhals.de prices (+30% high
end for shipping and Thai duty/VAT, estimate); total USD 16,912 to
33,061 (THB 0.56M to 1.09M). Doc, render caption and fleet calculator
text now say USD 17k to 33k.
- README links the plan.
User, 18 Oct 2026, asked about the A6-EC400H2B1-M17-STO (400 W, STO,
brake, USD 157.91). STO comes only from 400 W; its manual gives no SIL
or PL and no certificate, so it cannot replace the contactor; the brake
holds nothing on a horizontal axis. Recommendation recorded: keep the
100 W kit; if a rated STO is confirmed in writing, take the brake-less
A6-EC400H2A1-M17-STO (USD 129.60) on both axes, 1:2 to 1:3 belt, no
contactor.
User, 18 Oct 2026: use an EtherCAT based system.
- Spindle and conveyor on the StepperOnline A6-EC100L2A1-M17 kit
(100 W, A6-200EC drive, USD 123.29), spindle through a 1:6 belt in
cyclic synchronous position, conveyor in cyclic synchronous velocity.
- The A6-EC drive has no divided encoder output, so an RS-422
incremental encoder on the spindle shaft clocks both line-scans; its
index goes to the drive touch probe for one angle reference.
- Station controller: fanless N100 mini PC with 2x Intel i226, NixOS
PREEMPT_RT, EtherCAT master EtherCrab (Rust, MIT/Apache) first, IgH
(nixpkgs, igc native driver on 6.12 LTS) as fallback; no PLC.
- EtherCAT I/O: EK1100, EL1809, EL2809, EL3102 (warp lasers sampled with
the spindle position, ~1,000 points a turn at 1 ms).
- Safety stays hardwired (safety relay, contactor; no STO at 100 W).
- Edge PC with the GPU stays off the real-time loop.
- BOM: drives, encoder, controller and I/O lines with sources; total
USD 16,112 to 32,938 (THB 0.53M to 1.09M). Next step: EtherCAT bench.
- Investor render: cabinet and outfeed labels.
User, 18 Oct 2026, asked about the StepperOnline A6-EC100L2A1-M17
(100 W EtherCAT kit).
- The motor fits: torque about 0.02 N m needed at the motor through a
1:6 belt (0.32 rated); the belt brings the load inertia (about 25 to
35 kg cm2, estimate; record 20.5) to about 28x the 0.03 kg cm2 rotor.
- Take the pulse/RS-485 twin A6-RS100L2A1-M17 (USD 108.78): its drive
outputs the encoder as divided A/B/Z pulses for the line-scans and
takes pulse/direction from the planned PLC. The EtherCAT drive has no
divided output (A6-EC manual, CN1: 5 DI, 3 DO) and needs an EtherCAT
master.
- inline-optical-qc.md: spindle servo paragraph, sensor table, BOM
group; BOM line 109 to 250 (was 300 to 700). Total USD 16,073 to
32,734, THB 0.53M to 1.08M.
User, 18 Oct 2026: list the sensors the optical QC station uses.
- inline-optical-qc.md: sensor table in the station setup (4 cameras,
2 warp lasers, spindle encoder, 3 presence sensors and a through-beam,
6 cylinder position switches, door switch; thermal camera option and
laser line profiler alternative), with where each sits, what it
measures and the price signal.
- BOM: cylinder position switches were missing (6, SMC D-M9 class,
USD 25 to 60 each, estimate). Total now USD 16,264 to 33,184, still
16k to 33k; THB 0.54M to 1.10M.
User, 18 Oct 2026: for now one QC station for both machines; let the
records cool in a queue before testing them.
- inline-optical-qc.md "Where it sits": launch setup. Spindle stacks
from the Duplex system and the Classic, labelled at the press (press,
stamper set, first and last cycle), cool in FIFO racks (24 h accepted
practice, 8 h at the shortest, Stamper Discs; about one day of output,
2,800 to 3,100 records); the finishing operator feeds the station from
the cooled stacks. Gains: warp and centring measured on settled records
(the release value), one station instead of two, no Classic unloader
change, no warm-record sag or thermal camera. Cost: defects found hours
later, covered by the Duplex operator, per-cycle telemetry and an early
lane for the first records of each run and after stamper changes.
Record key from the stack label and stack position, checked against the
run-out stamper number. Capacity 10 to 12 a minute against 5 to 6:
one station to about two Duplex systems and two Classics. A station at
each press stays the later option. Cost table, open points, infeed row,
thermal camera note and the Newbilt question follow.
- Fleet calculator: the per-press stations and the release station are
gone; the finishing block shows the cooling racks with record stacks
and the one optical station by the corridor glass; tooltips, corridor
and conveyor texts; machine park back to its legend, finishing box
"cooling, QC, packing".
- quality-automation.md layer 1, digital-factory.md QC row,
process-flow.md stage 6, site-candidates.md block ground floor,
crane-workshop-tours.md tour stop 6.
- Investor render: infeed label "the operator sets each cooled record
down".
Checks: node --check; pw_bp_calc.py 0 fails; pw_iso_view_check.py OK;
info for every data-id at all presets, levels and rotations; GF nodes
2,414 at the full preset; zoomed shots in two rotations.
User, 18 Oct 2026: add the new inline inspection machine to the factory.
- Fleet calculator, isometric plant view: qcStation() draws the concept
station (1.9 x 0.65 x 1.5 m: aluminium conveyor table with the two rim
belts, light-tight tunnel, stack light, record on the infeed, reject
bin) in front of the operator in every Duplex cell (after the trimmer)
and at the unload side of every Classic, in the hall and in phase 2;
own ids qc-duplex-n / qc-classic-n with tooltips from
inline-optical-qc.md (Classic hand-off open with Newbilt). Cell floor
extended to take the bin.
- The finishing block's end-of-line optical station becomes the release
inspection: the same station measuring cooled samples (records settle
~24 h); corridor, block and conveyor tooltips reworded.
- Machine park schematic: a QC bar in every Duplex cell and Classic, an
"inline QC" legend entry; the legend moved to the bottom of the hall
box (it collided with the hall heading).
- Docs: inline-optical-qc.md (release station location, plant view),
site-candidates.md block ground floor, crane-workshop-tours.md tour
stop 6.
Checks: node --check on all scripts; pw_bp_calc.py 0 fails;
pw_iso_view_check.py OK; every data-id has info at all presets, levels
and rotations; legend clear of cells and heading up to 30M records;
zoomed shots in both themes and two rotations. GF node count at the full
preset 2,523 (was 2,388), 8M records ~2,980; rebuild under 60 ms.
User, 18 Oct 2026: use real 40x40 profiles, make a render with text
pointing out the parts to show the investor; the ring lights looked
like they were floating.
- build_station.py: frame drawn from the real 8-slot 40 series section
(profile_shape: slots, centre bore, corner cavities; 40x80 with centre
cavity) and 24 cast angle brackets; top beams now butt between the
uprights; label-camera posts moved beside the cameras so both ring
lights clamp straight to them; top line-scan on a side post with
visible camera plate and light hangers; slide strips on carrier angles,
pulley axles, end-stop posts, presence-sensor brackets, backlight post,
cabinet on base crosses, chute on two supports and clear of the rail,
pneumatics rail, stack light on the back upright, touch screen on the
front end upright. A connectivity check at the end lists any part that
does not reach the floor through touching parts: none.
- render_annotated.py (FreeCAD): front three-quarter view, camera backed
off so nothing is clipped, no navigation cube or preselection, label
positions projected from the camera and checked with marker renders.
- annotate_render.py (Pillow): title, 16 labels in two columns, leaders
assigned so none cross -> inline-qc-station-annotated.png.
- render_station.py: same camera and preselection fixes; all six views
re-rendered.
- BOM: 32 m of 40x40 in 45 pieces; total still USD 16k to 33k.
- inline-optical-qc.md and README updated; .gitignore for the render
intermediates.
User, 18 Oct 2026: create a setup for the inline optical QC, an
aluminium extrusion frame with all sensors and a conveyor mounted to it.
- docs/equipment/inline-qc-station/: FreeCAD script (build_station.py)
and model (.FCStd) of one station, 1.9 x 0.65 x 1.5 m on 27 m of
40x40 and 3.8 m of 40x80 profile: rim-belt conveyor (two 6 mm PU round
belts under the unrecorded rim, open centre), label gate with top and
bottom colour cameras on the fly, inspection position with a lift and
rotate chuck (75 mm lift, expanding mandrel, belt-driven servo), top and
bottom 4k line-scans on opposite radii with coaxial, dark-field and
backlights, two warp lasers, optional thermal camera, light-tight black
tunnel with door switch, rodless-cylinder reject pusher with chute and
bin, outfeed stop, cabinet, PLC, NixOS edge PC, HMI, stack light.
- render_station.py renders six views (open and closed iso, front, plan,
inspection detail and elevation via clipped temporary documents).
- inline-qc-station-bom.csv: 32 lines with sources; USD 16k to 33k per
station without the thermal camera.
- inline-optical-qc.md: new section "The station setup" (flow table,
inspection zone, cycle ~5 to 6 s, control, BOM by group, open points);
cost table updated (two launch stations ~USD 50k to 105k, still inside
the metrology launch tier); Duplex/Classic flow now via the conveyor.
- README bullet and tree.
User, 17 Oct 2026: research on the inline QC equipment, which devices
can be used for the optical check.
- New docs/equipment/inline-optical-qc.md: defect-by-defect table with
the optical signature, device and limit (IEC 98 / DIN 45547 hole and
eccentricity, Stamper Discs targets, Mobineko warp limits), precedents
(no vinyl product; Dr. Schenk ISM CD scanner as template; Basler/Xiris;
PRP AQA 2023; CTU thesis), a station design (centring turntable, 4k
line-scan per side with dark-field, bright-field and transmitted light,
colour label camera, two laser warp sensors or a line profiler,
optional thermal camera) with sourced price signals, resolution and
eccentricity math, throughput, placement at the Duplex cell and the
Classic, smart-camera vs open GenICam/Aravis/OpenCV/anomalib on NixOS,
specials, Thai channels, next steps.
- Estimate USD 12k-30k hardware per station, ~USD 40k-100k for the two
launch stations; inside the existing metrology launch tier, no plan
price change.
- Backlinks: quality-automation.md layer 1, digital-factory.md QC
integration row, README bullet and tree.
User (October 2026): price the Pheenix galvanics line at OMS's reference
plus 20 %, and work on a new business plan in two versions, one at
roughly 180M THB and one at +25 %; the plans do not include contingency;
Plan A keeps every machine and uses cost levers only.
- total-investment.md: Pheenix block 324k to 445k USD (OMS 4-cell wet
room with know-how transfer, EUR 234k to 321k, plus 20 %; was 320k to
650k estimate); launch plant now ~161M to 285M THB with contingency,
midpoint ~223M. New section "Two plans": Plan A = launch plant with
solar PPA, metrology launch tier, corridor later, cassette and CD-R
later, rented crane, Chinese boilers and compressor: subtotal ~161.7M
+ ramp-up reserve 10 to 20M = ~177M THB (127M to 226M). Plan B = second
Duplex at launch (five presses), everything in: subtotal ~209.2M +
reserve = ~224M THB (162M to 286M). Contingency listed as not in
either price (~24M / ~31M at 15 %). The 180M / 216M answer marked
superseded.
- revenue-model.md: operating pictures of both plans at 60 % specials.
Plan A central EBITDA 1.73M USD, operating profit 1.34M, payback ~3.1
yr on the plan price; adverse loses money. Plan B (1.0 / 1.25 / 1.5M
records) central EBITDA 3.14M, operating profit 2.63M, payback ~2.2 yr;
adverse just covers depreciation; needs ~1.25M records sold.
- Calculator: Pheenix price basis "OMS +20 %" and "OMS directly"; new
contingency switch (in the total / shown separately); presets Plan A
and Plan B (replace "investor levers" and "five-press"); budget card
against 180M and 225M.
- galvanics.md price note, README, roadmap.
Checks: calculator regression updated and passing (0 fails, no page
errors), node --check on all scripts, site build (no dead links), no em
dashes added.
User (October 2026): "change the hall layout" after the finding that the
60/40 floor split leaves the Classics about half loaded at 60 %+
specials (specials run only on the Duplex systems).
- Press hall now keeps five Duplex bays (four along the visitor
corridor, the fifth at the head of the second row) and four Classic
positions: 550 + 200 = ~750 m2 of ~870 m2, ~73/27 by floor, 10 to 4 by
presses; launch plant fills one of each, growth adds Duplex first.
- Full hall: ~2.9 to 4.4M records a year at 60 % specials, Classics ~80
to 100 % loaded (60/40 gave ~2.3 to 3.6M); ~3.2 to 4.4M at ~20 %;
fourteen presses as before: ~2.1 to 2.5 t/h steam, up to ~1.8 MW
cooling, a utility phase of its own.
- pressing-line.md, scale.md, site-candidates.md, crane-workshop-tours.md,
roadmap.md, README (FreeCAD model still the earlier layout, not
redrawn); calculator preset "Full hall (5 D + 4 C)" and ladder; plant
view reserves 5 Duplex bays and 4 Classic positions; business plan
draft 0.2 rebuilt.
Checks: renderer 720 checks and functional checks pass, calculator
regression 0 fails, level checks clean; PDF 47 pages, TOC filled.
User (October 2026): "lets say 60+% special prints" (the plant focuses on
special prints, not mono colours).
- Specials (splatter, marble, colour effects) run only on the Duplex
systems, so at 60 % the Duplex sets the launch plant's output: ~0.58 /
0.74 / 0.90M records a year (was 0.71 / 0.84 / 0.97 at ~20 %), the
Classic at about two thirds load. Full 60/40 hall: ~2.3 to 3.6M (Duplex
-limited, Classics about half loaded); five-press fleet unchanged. A
hall balanced by output at 60 % would give Duplex ~70 to 75 % of the
floor (estimate; noted, not applied).
- Blended price 3.76 / 4.49 / 5.27 USD (standard 3.40 / 3.80 / 4.25 plus
the 0.60 / 1.15 / 1.70 specials premium on 60 %). Launch operating
picture: revenue 2.28 / 3.65 / 5.41M USD, EBITDA 0.23 / 1.73 / 3.79M,
operating profit -0.66 / 1.21 / 3.46M, payback ~3.8 yr central,
break-even ~0.25M records; adverse needs ~1.1M records to cover
depreciation. Specials' extra direct cost (coloured compound, purge,
trim only into black) is not in the cost table yet: flagged as an
upper bound until compound quotes.
- Calculator default specials share 20 -> 60 % (planning rates keep the
launch plant balanced at 850k: revenue 4.14M, EBITDA 2.07M, payback
3.3 yr, cash payback year ~4.8, IRR ~18 %).
- revenue-model.md, scale.md, pressing-line.md, README; business plan
draft 0.2 rebuilt (sections 1, 4, 9, risks).
Checks: calculator regression 0 fails, no page errors, node --check on
all scripts; PDF 47 pages, table of contents filled; no em dashes added.
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.
Launch plant (user, October 2026): one Duplex system and one Classic,
with cutting and galvanics in-house, everything in one capital round.
- scale.md: capacity table now launch plant 0.71-0.97M records/yr, the
second Duplex as a growth option; launch utilities (450-540 kg/h on
B-1/B-2, ~390 kW on 2 x 250 kW); calculator figure ~0.94M.
- pressing-line.md: launch plant section on top; five-press fleet kept as
the layout fleet the hall and backbone are built for.
- roadmap.md: long-lead orders for the launch plant, no bridge stampers
or outsourced cutting, commissioning order, what stays revenue-gated.
- revenue-model.md: operating picture of the launch plant: central
revenue ~3.75M USD, EBITDA ~1.6M, operating profit ~1.1M, payback ~4
yr on 216M THB, break-even ~0.3M records; adverse corner cannot cover
depreciation. Five-press table kept and labelled.
- fleet-calculator.html: start fleet 1 Duplex + 1 Classic, target 850k,
capex base 6.55M (cases 8.9 / 6.55 / 4.9M), Duplex beyond one, chiller
500 kW, imported machinery 2.3M, ladder from the launch plant.
- total-investment.md: superseded note updated.
Checked October 2026 on the investor's budget question. New
docs/suppliers/china-utilities.md: boiler makers (ZOZEN, Sitong,
Fangkuai, Taiguo, Yuanda, Yongxing, Taishan, Nobeth) with fit for 500
kg/h at 1.25 MPa, claimed certificates, Thai references and listing
prices; the Thai rules for an imported boiler (MR and MOI notification
B.E. 2549: ASME/JIS/EN or equivalent, certification-body verification,
once-through relief does not reach 10.5 bar, licensed controller, annual
inspection); compressor makers with Thai offices (Kaishan, Denair) and
sizing; hydraulic pump sets and accumulators (Huade, Yuci, Hengli, WMD,
Renowell, Inovance, NXQ makers), the shared-ring-main risks and Thai HPU
builders; duty and freight; open RFQs.
Result: about 2M THB at the midpoint (~2.5M with contingency), ~1 % of
the 216M target, mostly the boilers; Newbilt aggregates stay Newbilt's.
total-investment notes it and lists the uncosted central hydraulic
plant; utilities CSV gets the Chinese candidates and route estimates;
backlinks from equipment-suppliers, pressing-line, README.
Decided (October 2026): the plant keeps the father and the mother of every
side. production-timeline.md (repress section) records the decision and the
rule of thumb with sources: about 10 stamper sets per mother before it
degrades (Third Man Pressing FAQ, a Nashville plater via WPLN), fewer in
quality-minded sources (5 VinyLab, 6 to 8 Stereo Review 1962); a father
grows about 5 to 10 mothers. So a mother covers roughly ten represses
(10,000 to 20,000 records a side) and a worn one is replaced from the
archived father without a new cut. galvanics.md: 4 archived parts per
title, ~1,200 to 2,400 a year; new open question to all galvanics
candidates (sets per mother, mothers per father, storage).
artist-platform.md repress paragraph.
Demos: make-a-record and artist-order say father and mother are archived;
factory console archives the father on represses too, counts stamper sets
per mother (shown in the genealogy and the customer's metal card), and the
metal archive counts fathers and mothers.
Phased build list for steam, cooling and hydraulics (launch, Duplex 1,
Duplex 2, Classic, options): everything cheap to oversize and costly to
retrofit (rooms, pads, headers and ring mains with a valved branch per
press position, tanks, HX frame, feeders, one sequencer) is built for the
five-press fleet at launch; boilers, chillers and hydraulic pump sets come
in identical modules as presses arrive. The Single 2.1 aggregate is
proposed as the first central pump set; per-branch isolation and filters.
Rooms sized for four modules each (user decision, estimates until vendor
footprints): boiler hall ~18 x 9 m for four 500 kg/h positions (fired case,
AIX DZL0.5 body), open screened chiller compound ~12.5 x 10.8 m with four
pads (250 kW at 40 C ~ Carrier 30RB 080-090), ~40 m2 pump and HX room; the
cooling tower pad of the water-cooled concept is dropped. Yard 178 -> ~379
m2. Four boilers carry ~8 presses with N+1; four 250 kW chillers carry the
five presses with CH-4 as reserve and no growth position unless the pads
take the ~350 kW frame (RFQ option).
- scale.md: yard table and basis, utility phasing section
- pressing-line.md: hydraulics phasing and re-quote questions
- steam-cooling.html: B-4 position, phasing and rooms card, details, RFQ
questions (pw_sc_check clean)
- construction RFQ: yard table, sealed area 6,549 m2 (68 %)
- total-investment: added-scope row +73k to +122k USD (building rate on
the ~200 m2 the yard grows by)
- Payap parts model: yard rebuilt from Params (blr_n, blr_inst, ch_*,
bh_*, cy_*, pr_*), renders updated
New page docs/steam-cooling.html (site /demos/steam-cooling/): the
utility plant as a clickable process diagram. Steam side: raw water,
softener and dosing, feed tank with heat-pump feedwater recovery, feed
pumps, a bank of two 500 kg/h boilers (third for N+1 as an option),
separator and metering, optional accumulator, blowdown, the 10 bar
header with a valved, metered branch and trap per press, drip legs and
condensate return. Cooling side: Newbilt's press outlets are open (max.
2 bar), so returns drain to a warm tank, pass the heat pump, an optional
dry cooler and a plate heat exchanger to a cold buffer tank, and VFD
pumps feed the 20 to 25 C header at ~10 bar to every press, the
extruders and the central hydraulic oil cooler; the chiller loop
(three 250 kW air-cooled modules at 40 C ambient, fourth as option) stays
closed and clean. Galvanics cooling (12 to 20 C) is a separate circuit.
Operating cases (launch, Duplex system 1, five presses, one module down)
show demand against installed capacity; design basis with sources,
equipment schedule, RFQ questions. Static SVG, no per-frame work.
Design basis at Newbilt's per-machine figures: steam 750 to 900 kg/h,
cooling 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics), 305 to
540 l/min circulating. Also found: Newbilt's 53 l/min at ~60 C out is
~140 kW, above its 125 kW peak; listed as a re-quote question.
Re-based in the same commit:
- scale.md: electrical table (chiller bank ~210 to 325 kW electrical,
plant peak ~430 to 700 kW, ~950 to 1,330 kW with electric steam),
grid 800 to 1,000 kVA (1,250 to 1,600 with electric steam, Schedule
4 past 1,000 kW), tariff 4.5M to 6.8M THB/yr, battery ~1 h of chiller
peak, boiler and chiller banks, biomass up to ~550 t/yr at 1.5 M
records, utilities money line.
- sustainability.md, biomass.md: same figures; electric steam 5.2M to
6.0M THB/yr mature, 1.6M to 1.8M early; fuel saving 4.0M to 5.4M.
- utilities CSV: boiler bank, chiller bank with HX and tanks, softener
and loop treatment re-sized; baseline 23.98M-41.63M -> 30.07M-51.33M.
- total-investment.md: re-size as an added-scope row (+185k / +294k
USD); headline 4.7M to 8.9M unchanged until the investment re-base.
- pressing-line, equipment-suppliers, facility-security, fleet
calculator (boiler 1000 kg/h, chiller 750 kW), plant page detail
texts; README, landing page, build.sh.
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).
User sketch, October 2026 (filed as docs/equipment/
duplex-cell-layout-sketch.png; arrangement only, the user notes it is not
to scale): operator in the middle, the two presses either side turned 45
degrees towards him, EX 50 and EX 35 side by side behind him, one trimmer
per cell in front on the left.
Sized from the Newbilt site requirements p. 10 (press ~0.9 m2, extruder
~0.5 m2, hydraulic aggregate ~1.0 m2, walk-around space, >= 60 cm to
walls, room height >= 2.5 m): cell ~5 x 3 m, 0.6 to 0.8 m between
machines; EX 35 and trimmer footprints are estimates. The layout drawing
the site requirements refer to on p. 11 is missing from our copy: ask
for it with the re-quote. README layout line for the sketch.
User, October 2026: special designs will need tens of colours, so the
compound store needs far more space, with maybe a few silos for black and
the standard colours; and the wall between stamper prep and galvanics is
to go.
- pressing-line: "Compound storage" bullet (colour store with pallet
racking, ~100 positions in the Payap model, estimate; outdoor silos
proposed; compound stays on the ground floor, ~160 to 270 t a year at
the mature fleet; sacks vs big bags decides the silo filling).
- galvanics: stamper prep open to galvanics, one clean zone.
User, October 2026: the factory is too small and needs room to grow
(possibly ten more Classics), one shared hydraulic and air supply, water
treatment perhaps in a separate building connected to the galvanics lab,
and a fully equipped workshop (maintenance tools, 3D printers, maybe a
lathe and a small CNC mill).
Model (rebuilt live in FreeCAD 26.3, BIM objects, Params-driven,
parametric check plot 135->145 m and factory 112->120 m passed):
- plot 135 m (11.4 rai) with a reserve; factory 112 x 25 m, 16 bays,
82 m visitor corridor, fire wall at 90 m;
- press hall ~870 m2: two Duplex systems (EX 50 + EX 35), the Classic,
ten future Classic positions in two rows on a service trench;
- central hydraulics and compressed-air plant room (~62 m2);
- water treatment building 12 x 10 m behind galvanics: buried duct
(gravity from the +1.2 m floor), covered crossing 6 m clear;
- workshop ~200 m2 with benches, tool cabinets, 3D printers, lathe,
small CNC mill, drill, saw, welding bay, press, washer, measuring table.
Docs: galvanics (water treatment building, proposed), crane doc (workshop
fit-out; lathe and CNC mill not yet priced; corridor now 82 m),
site-candidates Payap section rewritten, README bullet.
User, October 2026: the presses run from one shared hydraulic supply
and one compressed-air supply, and the plant may add up to ten more
Newbilt Classics at some point.
- pressing-line: fleet table and intro (shared central supply), new
bullets on the shared supply and the expansion option, re-quote point
(central supply for the whole fleet, extendable, can the Classic run
from it), Hydraulics bullet now the plan.
- scale: "Expansion (option)" capacity row, ~4.7 to 5.8M records/yr on
the same basis, explicitly outside revenue model and investment;
utilities note: fifteen presses would need ~2.3 to 2.7 t/h steam and
up to ~1.9 MW cooling, a utility phase of its own.
Correction from the user: the two Duplex systems are not in the
two-extruder configuration. Each runs two HRP 12 presses from an EX 50
main extruder with an EX 35 auxiliary extruder beside it for a second
colour; the Classic stays. Fleet still five presses. Updated in
pressing-line (table, phasing, re-quote: EX 50 vs the VEX 50 of the 2024
quote, and whether one EX 50 keeps both presses at full rate), scale,
total investment (wording; estimates unchanged), roadmap item 4, README.
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.
OMS (Lou Wullms) sent its introduction letter, filed in
docs/equipment/oms/: wet-room units with reference prices, two 4-cell
configurations (EUR 224,000 basic with two EFS2-200, EUR 311,000 advanced
with one AEFS4-250 and PLC; installation days extra), capacities of 24
and 32 shells in an 8-hour day, utilities, rooms, staffing, used
equipment, and five contacts for buying a cutting lathe. Recorded in
galvanics.md (tables, our reading: the advanced units add up to EUR
314,000, know-how transfer is left out of both totals although CNX has no
plating know-how, the basic set has no passivation unit), the exhibitor
follow-ups, vendor landscape (new section on used lathes and cutting-room
contacts, plus Lou's three websites), supplier map, roadmap items 6 and
13, total investment (basis note only, block unchanged) and the scale
people estimate. Open: forward the letter to Simona, as Lou asked.
Sibert (Ian Locke, 9 October): footprints and formal quotations when we
are ready; settle the pressing side first, hopefully with Pheenix, and
mention his recommendation if we do; impressed by the green-factory
plans (supplier feedback). Open: pass on the recommendation if Pheenix is
chosen.
CNX-01 in proplan: OMS basic and advanced added as options to D-002 with
their reference prices in THB; budget line 3 notes the OMS range.
- Sibert: back in Thailand, investor meeting in preparation, his OMS/Pheenix
advice noted; itemised quotation not yet requested.
- OMS: met in Haarlem; role split given to Lou (Simona management and audio,
Alexander technical); waiting for his calculation material.
- README: team roles, investor meeting in the status list.
- Pheenix Alpha (Robert Gunnarsson, 5 Oct; Simona's reply 9 Oct): offers
a Teams call, reference clients and a factory visit near Stockholm;
300+ presses (vendor figure); we call once questions are concrete,
next Europe trip planned for February 2027. CEO contact and Marsta
address added.
- OMS (Lou Wullms, 7 Oct): first email contact, company data, contacts
(Lou Wullms technical, Wilma Peeters accounting/logistics); open: reply
to confirm, then OMS sends material to calculate from.
- SST Frankfurt (Daniel Krieger, 7 Oct): cut the lacquers for POY003,
005, 006 and 013; on good terms with ResurRec; offered help. New cutting
service entry in the supplier map and vendor landscape; corrected the
briefing, which had SST as DMM (its site lists lacquer and dubplates).
- Roadmap items 5, 6 and 14 and the production timeline launch basis
updated accordingly.
Ian Locke's email of 5 October 2026 after Making Vinyl Europe:
- Budget of USD 250k for VSP, VSF and VSC confirmed; his time, spares,
shipping and travel extra; itemised quotation on request. The
total-investment block keeps its estimate until the re-base, the
difference (+190k low case / +80k high case) goes into the
not-yet-rolled-up table.
- Current specifications filed (VSF and VSC 2022, VSP 2023) plus the
VSF/VSP/VSC line-up drawing (4958 x 833 mm); the 2021 issues move to
sibert/specs-2021/. VSC is now 1000 kg with split OD hydraulic / ID
pneumatic forming; VSF 0-30 psi, 4-station head. Crane table, supplier
map, vendor landscape and the plant page details updated.
- Fully automatic VSPa exists; Sibert offers to move features to the VSP.
- Electroforming: OMS (Optical Media Services, Lou Wullms) named next to
Pheenix; added as a third galvanics candidate with open questions.
- Sequencing advice (presses, boilers, operators and live feedback loops
first) recorded in the exhibitor briefing, roadmap item 23, and as
digital-factory design decision 9 (operators see the data first).
Rebuild docs/plant-operation.html from the single P1 press into the mature
plant: Newbilt Duplex (two HRP 12 on a VEX 50, EX 35 for splatter), two
Newbilt Classic automatic presses with edge trimmers, label punch and
Granulator 400; Pheenix Alpha PASU, PPPU, two PDPU and PMPB; Sibert VSF,
VSP and VSC in that order; father and mother archive and the stamper rack.
Time runs at 1x real time with speeds up to 3600x. Press cycles are
Newbilt's (Classic 28 s, Duplex ~30 s), plating follows Faraday's law at
the PDPU current, and the operator steps use the galvanics.md table, with
unpublished times marked as estimates. Titles flow through the three artist
gates in days; test pressings unmount and the presses run approved work
meanwhile; worn stampers and represses come from the archived mothers.
Two shifts, unplanned press stops sized to scale.md's 60 to 70 %
effectiveness, and demos for a steam dip, a new PVC lot and a repress.
The boiler and chiller are shown at 800 kg/h and 500 kW (estimates) and
the detail panels flag that scale.md's 400 kg/h and 250 kW are Duplex
figures; scale.md itself is unchanged.
Also commits the galvanics.md cycle-time table the page runs on (one PDPU
covers demand, the second is redundancy) and updates the README and the
test-site descriptions.
docs/equipment/pheenix-alpha/: the four Pheenix Alpha electroforming flyers
(2024: PASU silvering, PPPU pre-plating, PDPU dual-cell plating, PMPB
passivation bench), renamed from their download hashes.
docs/equipment/sibert/: the VSP, VSF and VSC technical specifications
(2021), plus Sibert's 2008-09 optical-disc SPS literature and the 2008
Blu-ray stamper characteristics paper in sps-optical-disc-2009/. Two
byte-identical duplicates in the download were dropped.
New docs/equipment/galvanics.md, the metal-path counterpart to
pressing-line.md: datasheet tables for both ranges and what they change.
Pheenix is a second turnkey galvanics vendor next to Digital Matrix and
can quote lacquer-to-record as one vendor; neither range includes water
treatment. Utilities from the sheets (~27 kVA connected per line, DI water,
12-20 C cooling water, extraction sizes), ~5.6 m2 of footprint, and a cell
count estimate (one PDPU at the low end, two at the high end). The Sibert
machines are single-phase, 200/250/600 kg on castors, centre manually and
list no data interface; the VSC locates on the punched hole; the finisher's
water carries nickel. Weights, cycle times, prices and mould fit are listed
as quote questions.
Backlinks and small updates: README (bullet, layout tree, vendor list),
roadmap items 6 and 23, vendor landscape, supplier map, exhibitor briefing
(on-file notes, Sibert three-phase question answered), digital factory
(Pheenix PLC data, Sibert data question, RFQ clause 5), quality automation
(hardness on the centre slug, BD paper as the acceptance-spec model),
sustainability (finisher water), total investment block label (numbers
unchanged), scale (galvanics feeder note), crane weight table, process
flow, pressing-line stamper-fit question, plant page detail lines.
docs/equipment/newbilt/flyers-2026/: the six 2026 product flyers
(Classic, Duplex, EX 35, Edge Trimmer, Granulator 400, Label Punch) and
the 2024 Classic print flyer, collected at the booth in Haarlem.
pressing-line.md gets a range table with the flyer figures and what they
change: Classic and Duplex share inserts (one mould family for a
Newbilt-only fleet, Classic now named as automated candidate next to the
Pheenix AD12), edge trim of 20 to 40 g per 12" 180 g record brackets the
~20 % regrind share, the Granulator 400 runs in batches, central
hydraulics is an option, and the EX 35 is not in the 2024 quote.
Sources disagree on the Classic's panel (two 21" vs one 10"), extruder
power (7.5 kW drive in the 2024 flyer vs 15 kW noted earlier) and 10"
support; recorded as re-quote points instead of picking one. Supplier
table and exhibitor briefing corrected to match and given Erwin Neubauer
as a second contact; plant page grinder detail cites the flyer figures.
Currency
- Base currency moves from EUR to USD and THB throughout. Rates at
5 Aug 2026: 1 USD = 33 THB, 1 EUR = 1.155 USD, 1 GBP = 1.35 USD.
EUR/THB lands at ~38, so existing THB research needed no change.
- Vendor quotes keep their original currency with a USD/THB equivalent
alongside, so they stay checkable against the source PDFs.
- Full vision ~4.7-8.9M USD; phased entry ~1.7-2.9M USD.
New documents
- production-timeline.md: order turnaround stage by stage. Launch
8-14 weeks, mature 5-10, repress 2-3. Quantifies the in-house
galvanics turnaround claim the repo had asserted without a number,
and flags artwork as an unmodelled fourth approval gate.
- project-timeline.md: calendar to first paying release, ~Q4 2028.
Critical path is BOI certificate to press order to build to
commissioning. Two findings: Newbilt build time is absent from the
repo yet carries ~40% of the schedule, and the BOI rule may be
over-serialised since duty exemption attaches at importation rather
than at contract signature.
First market data (ResurRec, Bangkok)
- Invoice-derived prices, a factory tour, and a confirmed fleet of one
Newbilt Classic 12" automatic plus one semi-automatic.
- Price ladder recorded at 300/500/1000-3000/3000+ units. Decomposes
to roughly 34-50k THB fixed per title and 535-780 THB variable per
unit, which is 4-7x the price this model assumes.
- The incumbent presses 230-350k records/yr but buys every stamper as
an import. That single constraint plausibly explains their 150-unit
floor, their flat discount ladder and their large-run lead time, and
it is what an in-house galvanics line attacks. Logged as an open
question on whether galvanics should move from phase 5 to phase 1.
- Inferences are marked as inferences; the whole set is one buyer and
one plant, and the model is deliberately left unrebased until a
second data point exists.
Corrections
- Gross margin arithmetic did not follow from its own inputs. Restated
as ~1.95 USD at the midpoint with the 0.75-3.15 spread shown; the
previous "40 to 55%" was not supported.
- Direct cost low total 1.50 to 1.45 USD; contingency THB high 40M
to 38M.
- README indexes the construction RFQ, which was missing.
- docs/process-flow.md: mermaid chart plus stage table of every check and
the three artist approval gates, from audio intake to fulfillment
- docs/process-flow.drawio with PNG and PDF exports
- pressing-line.md: floor must carry multiple tons per m2 in machine areas
- README: process-flow entry in document index and layout tree
- docs/: Newbilt equipment offer, site requirements, process schematic,
service rates, project cost overview, PVC supplier list, consultancy overview
- .gitignore excluding local tooling config and runtime state
grabowski