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 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.
Not scaled here: mastering (1 to 2), QC (1 to 2), maintenance (2) and admin, sales and logistics (3 to 5), from scale.md; cover for leave and sickness; the boiler fuel and the PV share of the power.
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).