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unpublished times marked as estimates.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