Set the records you want a year and the share of splatter and other specials. The calculator sizes the press fleet from Newbilt Duplex systems (two HRP 12 presses, an EX 50 and an EX 35 colour extruder each) and Newbilt Classic automatic presses, starting from the planned two Duplex systems and one Classic. It then lists what that fleet needs: people, power, central hydraulics, steam, cooling, compressed air, floor, compound and stampers. Vendor figures are from Newbilt's Duplex site requirements and offer; the rest are planning figures and estimates from the CNX Vinyl documents. Every figure can be changed under Assumptions.
The output is what this fleet makes at the set effectiveness and specials share.
Splatter, multi-colour and effect records run only on the Duplex, with its EX 35 colour extruder (Newbilt recommends the Duplex for splatter). Black and single-colour records run on either press.
The price and cost ends of the revenue model; editing a figure makes it your own case.
Central is the revenue model's midpoint. The revenue model itself calls that case optimistic: its EBITDA sits well above the 15 to 25 % pressing plants earn, because the cost table still misses indirect labour, inbound freight, inventory, effluent and sales commission. Read the adverse case as the honest one until those lines exist. Prices are a Western benchmark; Thai domestic invoices run far higher (650 to 950 THB all-in at 300 units).
The fleet above as a schematic, not to scale: each Duplex cell as in the cell sketch (presses either side of the operator, EX 50 and EX 35 behind him, trimmer in front), each Classic with its built-in extruder; above it the stamper line that feeds the presses, sized from the cycle times in galvanics.md; below it the central utilities. Bars show how busy each station is; an amber box exceeds the plant as planned today.
Fleets from the start fleet to a full Payap press hall (about 870 m²: the two Duplex bays plus the Classic and ten more Classic positions, or the same floor with more Duplex systems), at the current settings. Click a row to load it.
Every result above comes from these figures. Changed values are kept in the link, so a scenario can be shared with "Copy link".
Classic utilities. Newbilt has published no power, steam, cooling or weight figures for the Classic, so it counts here as one HRP 12 press plus one extruder on the central hydraulics. Cross-check from the Toolex Alpha leaflet the Classic is based on: 1.2 kg steam, 15 l cooling water, 18 l air and 3.15 l hydraulic oil per cycle (about 144 kg/h of steam at 2 a minute), 2.18 × 1.30 m, 1,850 kg. These go into the re-quote questions in pressing-line.md.
EX 35. Counted at the EX 50's electrical, air and water figures; it is the smaller extruder, so this errs high.
Central hydraulics. Newbilt's aggregate serves two presses; the per-press figures are half of it, summed without any diversity. Whether the Classic can run from the shared plant is an open question for Newbilt.
Peaks add up. Steam, cooling and air are summed at each machine's peak, as Newbilt states them. A real plant staggers cycles, so the boiler and chiller can be sized lower once a utility engineer has the cycle data.
Money. Prices, per-record costs, wages, overheads and depreciation come from finance/revenue-model.md, capex from finance/total-investment.md (the start fleet plan plus each Duplex system or Classic added or removed), the electricity tariff and PV from scale.md, the biomass heat price from biomass.md. Electricity and steam follow the fleet: machines, chiller and compressors at the hours run, steam from the presses' running time, plus an estimated base load for the rest of the plant. Lacquer blanks (70 EUR each) and the cutting engineer (50,000 THB a month) are team figures; shipping cartons have no figure on file and are an estimate. Missing as the revenue model lists: indirect labour, freight, inventory, effluent, commission, styli, extra galvanics units' capex.
BOI. The capex blocks in total-investment.md are vendor prices without Thai import duty or VAT, so they already assume BOI promotion: machinery imported under it pays no duty (Investment Promotion Act section 28) and, with the duty, no import VAT (Revenue Department, BOI OSOS FAQ). "Not promoted" adds the duty on the imported machinery to the capex and shows the import VAT as cash paid at the border, reclaimable as input tax. Raw material: no duty on compound for exported records, 90 % off for domestic sales. Revenue is net of VAT (exports zero-rated, 7 % on domestic sales passed on). Corporate income tax and BOI's CIT exemptions (solar, automation, R&D) are not modelled.
Labour. Base salaries per role (revenue-model.md, its loaded rates divided by 1.3; the cutting engineer a team figure), plus the employer's 5 % social security up to the 17,500 THB ceiling, 25 % for overtime, bonus and PPE, and the company's health care for every member of staff, office included: group health insurance, a yearly check-up, and the risk-factor tests Thai law requires for the press floor, galvanics and maintenance; and unified Engelbert Strauss workwear with the company logo for everyone, shipped from Germany with Thai duty (worker-safety.md).
Not scaled here: admin, sales and logistics wages (in the overheads line); cover for leave and sickness.
Sources in the CNX Vinyl planning repository: equipment/pressing-line.md, equipment/newbilt/ (Duplex site requirements V14, offer 240620-04, 2026 flyers), equipment/galvanics.md (cycle times per step; the stamper line counts each station from them, before remakes and test pressings), scale.md, finance/revenue-model.md, site-candidates.md (Payap scenario model).