# Project Scale: Rough Numbers

One-page sizing of the whole project. Everything here is a planning
estimate derived from the session's vendor data and standard ratios;
figures marked "estimate" have no vendor confirmation yet. Update this
page as real quotes and the site decision land.

## Production capacity

| Phase | Fleet | Rough output |
|---|---|---|
| Launch | 1 semi-auto press (Newbilt Single), 1 shift | ~90,000 to 135,000 records/yr |
| Duplex | 2 semi-auto presses, 1 to 2 shifts | ~300,000 to 600,000 records/yr |
| Mature | 2 semi-auto + 2 automated (50/50 fleet), 2 shifts | ~1.0 to 1.5 million records/yr |

Basis: the automated AD12 presses ~140 records/hour each (vendor datasheet);
semi-automatic throughput is unpublished, assumed 60 to 80 records/hour per
press with operator handling (estimate); 16 h/day, 300 days/yr, with
realistic overall effectiveness of 60 to 70% applied. The theoretical
ceiling of the mature fleet at 100% uptime is roughly 1.9 to 2.1 million
records per year.

## Building

| Zone | Rough area |
|---|---|
| Semi-auto press hall (Newbilt Duplex spec) | ~200 m² |
| Automated press zone | ~100 to 150 m² |
| Galvanics clean room + water treatment + chemical storage | ~80 to 150 m² |
| Mastering and cutting room | ~40 to 60 m² |
| Stamper prep | ~30 m² |
| Packaging + finished goods warehouse | ~300 to 500 m² |
| Utility rooms (boiler, compressor, chiller, electrical) | ~100 to 150 m² |
| Offices, QC/listening, archive, IT, entrance | ~150 to 200 m² |
| Circulation, walls, misc | ~150 to 250 m² |
| **Total under roof** | **~1,200 to 1,700 m²** |

The HVAC budget in the utilities CSV already assumes ~1,500 m² conditioned.
Single story throughout: all heavy equipment needs ground-slab floor
loading (multiple tons per m²).

## Land: factory plot

Industrial plots typically allow 50 to 60% building coverage, and the site
needs truck access and turning, parking, the outdoor cooling tower, the
separated BESS enclosure, possible ground-mount solar, and expansion room.

- Minimum workable: **~4 rai** (6,400 m²)
- Comfortable with expansion and ground-mount solar: **~6 to 8 rai**
  (9,600 to 12,800 m²)

Separate asset: the **60 rai** forestry-classified parcel for coppice
fuelwood (see [biomass](biomass.md)), pending its title check. It is a fuel
plantation, not a factory site candidate unless the classification allows
conversion, which forestry land generally does not.

## Electrical scale

| Load | Rough figure |
|---|---|
| Pressing machinery (semi-auto line + 2 automated presses) | ~70 to 80 kW installed |
| Process chiller (250 kW cooling) | ~80 to 125 kW electrical |
| Whole-factory HVAC | ~100 to 200 kW peak (estimate) |
| Electric steam boiler (if chosen over biomass/LPG) | ~300 kW |
| Compressed air, lighting, IT, misc | ~30 to 50 kW |
| **Plant peak demand** | **~300 to 450 kW without electric boiler; ~600 to 750 kW with it** |

Grid connection: a medium-voltage connection with a transformer in the
**500 to 1,000 kVA** class from PEA, sized by the boiler decision.

## Solar and storage

- Roof of a ~1,500 m² building fits roughly **150 to 200 kWp**; reaching the
  illustrative 300 kWp in the utilities CSV needs carport or ground-mount
  on the plot (about 1 rai of ground per additional 100 kWp, estimate)
- Northern Thailand yield ~1,400 to 1,500 kWh/kWp/yr, so 300 kWp produces
  roughly **420 to 450 MWh/yr**
- Plant consumption at mature two-shift operation: roughly **1,000 to
  1,500 MWh/yr** without electric steam, up to **~2,500 MWh/yr** with it
  (estimate), so 300 kWp covers on the order of **20 to 35%** of
  consumption; a bigger array shifts that up
- Battery: **271 kWh** Gobel stack (peak shaving and ride-through, roughly
  two to three hours of the chiller's electrical draw)

## Steam and fuel

- Boiler: **400 kg/h at 10 bar / 180 °C** (~300 kW thermal)
- If biomass: **~350 to 400 t/yr** air-dry wood at mature operation, of
  which the 60 rai coppice could supply **~80 to 135 t/yr**
- If LPG: **~2.5 to 5 t** bulk tank on site (no gas pipeline in the North)

## People

Rough mature-operation headcount (estimate): 4 to 6 press/finishing
operators per shift, 2 to 3 galvanics, 1 to 2 mastering/cutting engineers,
1 to 2 QC, 2 maintenance, 3 to 5 admin/sales/logistics. Roughly **15 to 25
people** across shifts at maturity, fewer than half that at launch.

## Money (cross-references)

- Newbilt semi-auto line: **~€200,500** (2024 quote, expired, in
  [pressing-line](equipment/pressing-line.md))
- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: **~24M to
  42M THB** (~€630k to 1.1M), detail in the
  [utilities CSV](finance/utilities-investment.csv)
- Not yet priced: automated presses (indicative ~$340k each, unverified),
  galvanics line, mastering/cutting room, metrology, building
  construction/fit-out, land