cnx_vinyl/docs/equipment/galvanics.md

# Galvanics and Stamper Prep: Equipment Plan

The metal path turns a cut lacquer into press-ready nickel stampers:
silvering, electroforming of father, mother and stampers, passivation
between generations, then punching, back-finishing and coining (stages 4
and 5 in the [process flow](../process-flow.md)). It is Phase 5 item 23 in
the [roadmap](../roadmap.md), with an open case for pulling it forward;
until it runs, bridge stampers come from Stamper Discs. This page holds the
equipment data for it, the way [pressing-line.md](pressing-line.md) does for
the presses.

Sources are vendor datasheets filed with the Making Vinyl Europe 2026
material in October 2026: Pheenix Alpha's electroforming range (four flyers
dated September 2024, in [`pheenix-alpha/`](pheenix-alpha/)) and Sibert's
vinyl stamper prep line (the current technical specifications and a
line-up drawing, sent by Sibert's Ian Locke on 5 October 2026, in
[`sibert/`](sibert/); the April 2021 issues they replace are in
[`sibert/specs-2021/`](sibert/specs-2021/)), plus Sibert's 2008 to 2009
optical-disc literature (below). Every figure here is vendor-published, not
quoted; the only prices are Sibert's budget confirmation by email and
OMS's reference prices in its introduction letter (both below).
Digital Matrix / Plating Power stays the comparison; its datasheets are not
in the repo yet (see the
[vendor landscape](../suppliers/vendor-landscape.md)).

## Electroforming: the Pheenix Alpha range

Pheenix Alpha, the AD12 press maker, also builds the galvanics line. The
four flyers:

| Unit | What it does | Datasheet figures |
|---|---|---|
| **PASU** Automatic Silvering Unit | Cleaning station plus silver spray unit: the lacquer is cleaned, then silvered by an automatic spray sequence; foot-controlled spray faucet, overspill collection; the silver unit mounts left or right of the cleaning bench | W 2188 × D 715 × H 1835 mm, working height 900 mm; cleaning station up to 120 rpm, spray unit 45 rpm, four nozzles; 100 to 230 VAC single-phase, 10 A; water Ø20 hose, 2 × G3/4"; compressed air G1/2" at 6 bar; exhaust Ø125 mm at 150 m³/h; drain Ø32 mm |
| **PPPU** Pre-Plating Unit | First nickel layer on the silvered master: up to four masters at once, each position controlled on its own with its own cathode movement; integrated dummy plating; PID temperature control | W 1062 × D 1245 × H 1750 mm; 400/480 VAC three-phase, 16 A; tank 385 L, pump 10 m³/h, heater 4.5 kW, 2 × 20" filters; up to 15 VDC and 30 A per position; exhaust Ø63 mm; 500 mm service access behind the tank |
| **PDPU** Dual Plating Unit | Production electroforming: two cells, each with its own rotating cathode shaft and digitally controlled rectifier; titanium anode baskets; adjustable anode-to-cathode distance; options for a flow meter, automatic lid and selective cleaning | W 1070 × D 1350 × H 1800 mm; 400/480 VAC three-phase, 16 A; tank 385 L, 40 L per cell, pump 10 m³/h, heater 4.5 kW, titanium cooling coil; filters 10 µm pre and 2.5 µm fine; 45 rpm; anode baskets 30 kg each; parts up to Ø355 mm; up to 15 VDC and 200 A per cell; cooling water 12 to 20 °C, 5 bar, 10 L/min; exhaust Ø63 mm; 500 mm service access behind the tank |
| **PMPB** Modular Preparation Bench | Passivation, cleaning and drying between generations: removes lacquer residue, anodic passivation and cathodic cleaning for nickel and DMM parts, integrated pump, filtration and temperature control, sink with foot-controlled spray, spin table | W 1588 × D 775 × H 1700 mm, working height 920 mm; spin table up to 120 rpm; 100 to 230 VAC single-phase, 10 A; DI water G3/4"; drain Ø32 mm; exhaust ready |

All four are built in stainless steel and polypropylene, the bench and
plating units with titanium in the wetted parts. The two plating
units are PLC-controlled with a 7" touch screen, user-programmable recipes
and a network connection for remote access; the range advertises alerts for
filter cartridge changes, nickel pellet top-up and anode basket cleaning.

What this changes in the plan:

- **A second turnkey galvanics vendor.** Until now Digital Matrix was the
  only one in the plan ([roadmap](../roadmap.md) item 6, the galvanics block
  in [total investment](../finance/total-investment.md)). The Pheenix range
  covers the same four steps: silvering (PASU against Digital Matrix's
  VLSS), pre-plate (PPPU against VLPP), production electroforming (PDPU
  against the VLFP 2/4/6-cell system) and passivation (PMPB against the
  EC-1000). Pheenix calls itself the only manufacturer of both
  electroforming and pressing systems (vendor claim), so it can quote the
  whole chain from lacquer to pressed record: AD12 and AD12 Manual for the
  presses, this range for the metal. One conversation covers roadmap items
  5 and 6, and the single-vendor risk is the same as for the presses.
- **Lacquer and DMM.** The PMPB passivates and cleans DMM parts as well as
  nickel, and Pheenix describes the range as built for lacquer and DMM
  families, so a DMM lathe (the open Sillitoe question in the
  [vendor landscape](../suppliers/vendor-landscape.md)) would not need
  different galvanics equipment, by the vendor's description.
- **No water treatment in the flyers.** None of the four covers rinse-water
  treatment or metal recovery, the same gap as Digital Matrix. The
  zero-discharge plant stays a separate vendor
  ([sustainability](../sustainability.md)); ask Pheenix which treatment
  partner its customers use.
- **Utilities the galvanics room needs** (from the datasheets):
  - Electrical: two 16 A three-phase units (~11 kVA each at 400 V) and two
    10 A single-phase units (~2.3 kVA each), so **~27 kVA connected** for
    one line by the rated currents (estimate). Actual draw is lower: at
    most 6 kW DC in the PDPU (2 cells × 15 V × 200 A) and 1.8 kW in the
    PPPU (4 × 15 V × 30 A), plus a 4.5 kW heater in each. Thai 400 V / 50
    Hz three-phase fits. Not in the [scale](../scale.md) electrical table
    yet, because galvanics is Phase 5.
  - **DI water** at the PMPB: a deionised (RO plus polishing) water supply
    belongs in the galvanics utility list. The RO skid in the
    [utilities CSV](../finance/utilities-investment.csv) is an option row
    sized for boiler feed, not for this.
  - **Cooling water** at the PDPU: 12 to 20 °C at 5 bar and 10 L/min
    through its titanium coil, either a branch of the process chiller loop
    or a small dedicated chiller. 10 L/min is small next to the press
    moulds' ~220 L/min peak.
  - **Extraction**: Ø63 mm on each plating unit, Ø125 mm at 150 m³/h on the
    silvering unit. The fume-extraction interlock in
    [facility security](../facility-security.md) (no extraction, no
    plating) applies to every one.
  - Compressed air at 6 bar for the PASU; drains Ø32 mm.
- **Water treatment in its own building (proposed, October 2026).** The
  zero-discharge effluent treatment, the DI water plant and the chemical
  store move out of the factory into a small building next to the
  galvanics room. A buried service duct carries the effluent by gravity
  from the galvanics floor at +1.2 m and brings DI water back, and a
  covered crossing joins the two doors. The galvanics room keeps only a
  chemical day store at the duct head. The
  [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws it as a 12 × 10 m building
  (estimate).
- **Stamper prep open to galvanics (October 2026).** No wall between the
  galvanics room and stamper prep: stampers go from the last bath straight
  to the Sibert line inside one clean zone, as the
  [Payap scenario model](../site-candidates.md#payap-scenario-model-october-2026) draws it.
- **Space.** One of each unit is ~5.6 m² of footprint (PASU 1.56, PMPB
  1.23, PPPU 1.32, PDPU 1.44 m²), plus 500 mm service access behind the two
  tank units and working space around them: comfortably inside the 80 to
  150 m² the [zone table](../scale.md) holds for clean room, water
  treatment and chemical store. At 1.70 to 1.84 m tall they fit under the
  room-in-room ceilings in the crane zone
  ([crane, workshop and tours](../crane-workshop-tours.md)), and by their
  published dimensions all four pass through a 1.2 m double door, so the
  crane hatch in the clean-room lid is for the water-treatment evaporator
  rather than the plating units (check against crated sizes).
- **Weight.** Not published. Each tank unit holds 385 L of electrolyte,
  roughly half a tonne filled (estimate), plus 60 kg of nickel in the
  PDPU's anode baskets. Ask for empty and filled weights with the quote,
  for the slab design and the crane table.
- **Data.** PLC, recipes, network connection and maintenance alerts are on
  the datasheets; the protocol is not. Per the
  [digital factory](../digital-factory.md) RFQ clauses: read access over
  Modbus TCP or OPC UA with the tag list, remote support through our mesh,
  no vendor cloud. The maintenance alerts are the bath events the
  galvanics record in [traceability](../traceability.md) needs anyway.

### A third candidate: Optical Media Services (OMS)

Asked after the show which electroforming route he would take, Sibert's
Ian Locke named two (email, 5 October 2026): **OMS through Lou Wullms**, "a
long-standing industry colleague who makes good equipment" and very
familiar with the Asian market, or **Pheenix** for a full turnkey package
with long international experience, electroforming systems and presses
together (he calls Pheenix the de facto standard for vinyl presses
worldwide; his view, not a market figure).

OMS is Optical Media Services B.V. in Baarlo, Netherlands, established
1996 (vinyl-pressing-plants.com directory and Lou Wullms' own profile): an
independent vinyl stamper service from lacquers and DMMs that also builds
and refurbishes vinyl electroforming equipment, including conversions of
CD/DVD electroforming lines to 14" vinyl. The same directory gives
Newbilt's equipment page as OMS's website, and that page announces new
Newbilt electroplating equipment with the portfolio "presented here soon";
whether OMS builds it is not confirmed, so ask both. OMS's introduction
letter (below) presents the units as its own designs (EFS2-200, AEFS4-250)
and does not mention Newbilt.

What it adds: a third galvanics vendor next to Digital Matrix and Pheenix,
named by a supplier who knows Lou Wullms and has installed equipment at
Pheenix; a stamper service that could
also serve as a European bridge supplier next to Stamper Discs; and, if
the Newbilt link holds, a galvanics route that pairs with the Newbilt
presses the way the Pheenix range pairs with the AD12.

**First email** (to Alexander in German, 7 October 2026, after meeting in
Haarlem). Lou Wullms introduces himself as the Dutchman who works with nickel
sulfamate (the electroforming electrolyte), asks Alexander to confirm he
received the email, and will then send material so that we can start
calculating and see what the line involves. He also asks whether Simona
will work on the project. Company details as OMS gives them:

| | |
|---|---|
| Company | Optical Media Services B.V., Tangweg 16, 5991 PE Baarlo, Netherlands |
| Technical | Lou Wullms, lou.wullms@gmail.com, mobile +31 6 5490 3443 |
| Accounting and logistics | Wilma Peeters, wilmapeeters6@gmail.com |
| Office phone | +31 77 477 8054 |
| Registration | KvK 12037670 (Venlo), VAT NL806459335B01, EORI NL806459335 |

Alexander has replied to confirm (October 2026), with the split Lou asked
about: Simona covers management and the audio side, Alexander the
technical side, so galvanics questions go to Alexander.

#### OMS introduction letter (9 October 2026)

Lou Wullms sent his material two days later: an introduction letter to
Alexander and Simona, filed as
[`oms/OMS_Introduction_letter_2026-10-09.docx`](oms/OMS_Introduction_letter_2026-10-09.docx).
He asks Alexander to give Simona a copy so that she can work through the
figures. **Open:** forward the letter to Simona. It is an introduction,
not an offer: the prices are "for reference only", final pricing comes
with an official quote, and a dedicated offer needs our plans first. Lou
would rather explain the options in Baarlo, where the equipment can be
seen.

Background, as Lou gives it: from 1986 to 1994 at Philips' optical-disc
equipment business (ODM, then OD&ME and ODME, the company later called
Toolex Alpha); two years setting up a CD plant with mastering and
electroforming at WPME in Kaarst, Germany; then OMS, for service to the
optical-disc industry; involved in setting up Mimeos, a CD and later DVD
stamper service that closed in 2012; in vinyl stamper production since
2015. OMS runs an independent stamper service for vinyl plants and builds
the wet-room equipment to its own designs.

The wet room for a turnkey line, with the letter's reference prices:

| # | Unit | What it does | EUR, reference |
|---|---|---|---|
| 1 | Wet bench | Cleaning, rinsing, soaking, wetting and pre-treating the lacquer | 20,000 |
| 2a | Silvering booth, manual (\*) | Silvering the lacquer | 16,000 |
| 2b | Silvering booth, automatic/manual (\*) | The same, automatic | 22,000 |
| 3 | Pre-plate, 4 positions (\*) | First plating of the silvered lacquer at lower temperature and current | 45,000 |
| 4a | Electroforming unit EFS2-200, 2 cells | Fast plating; the basic unit | 55,000 each |
| 4b | Electroforming unit AEFS4-250, 4 cells with PLC | The advanced unit | 155,000 |
| 5 | Cleaning / passivation | Extra cleaning of the stamper at high temperature and current; passivation | 25,000 |
| 6 | Spin dryer | Spin-drying DMMs, lacquers and stampers; scuffing (pre-treatment) of DMMs and lacquers | 14,000 each |
| 7 | Know-how transfer, including training at OMS | | 10,000 |
| 8 | Silvering recipe | | 5,000 |

(\*) Not needed for stampers made only from DMMs: these are the lacquer
path. The model names of the electroforming units come from the
letter's expansion lines.

The letter totals two configurations:

| | Basic | Advanced |
|---|---|---|
| Units | 1, 2a, 3, 2 × 4a, 2 × 6, 8 | 1, 2b, 3, 1 × 4b, 5, 3 × 6, 8 |
| Cells | 4 (two EFS2-200) | 4 (one AEFS4-250, PLC) |
| Total in the letter | **EUR 224,000** (~USD 259k) | **EUR 311,000** (~USD 359k) |
| One 8-hour day (30 min lunch included) | "7 runs should be possible", then counted with 6: 6 × 4 = **24 shells** | 8 × 4 = **32 shells** |
| Doubling | 2 more EFS2-200, EUR 110,000, "over 50 stampers a day" | 1 more AEFS4-250, EUR 155,000, "over 68 stampers a day" |

USD at the [total investment](../finance/total-investment.md) rate of
1 EUR = 1.155 USD. Reading the letter:

- **The sums.** The basic total adds up; the advanced units add up to EUR
  314,000, not the 311,000 stated. A re-quote point.
- **Know-how transfer is left out of both totals**, with the note that
  electroplating know-how "is already present at your facility". That is
  not the case for CNX: nobody on the team has run a plating room. With
  the EUR 10,000 item (training at OMS included) the totals are EUR
  234,000 and 321,000, ~USD 270k and 371k (our reading).
- **The basic set has no cleaning/passivation unit** (item 5). Ask how
  parts are passivated between generations without it.
- **Installation is extra**: training and start-up on site at EUR 1,200 a
  day each, travel days at EUR 600, all other costs invoiced on top.
- **Used equipment** is also on offer ("good used/pre-owned equipment").
- **Finishing is not OMS's scope.** For back-polishing, centre punching and
  forming/trimming the letter points to Sibert and Ian Locke as the
  reference, as Sibert pointed to OMS for electroforming.

What it changes in the plan:

- **Price.** A complete 4-cell wet room at ~USD 259k to 371k, depending
  on the configuration and the know-how item, is at or below the low end
  of the USD 320k to 650k galvanics block in
  [total investment](../finance/total-investment.md). Neither includes
  water treatment (its own block) or installation days. Since October
  2026 the plan prices the Pheenix line at **OMS's reference plus 20 %**
  (user decision): EUR 280.8k to 385.2k, ~USD 324k to 445k, replacing the
  320k to 650k estimate until Pheenix quotes.
- **Capacity.** 6 to 8 runs in a 7.5-hour working day is roughly an hour a
  run, which matches the 1 to 1.5 hours per part the cell count below
  assumes. Full capacity needs 8 to 20 parts a working day, so either
  4-cell configuration covers it on one shift, and the doubling options
  buy headroom only. This is the first vendor figure on cycle times.
- **Staff.** One person runs about 20 stampers a day; from about 30 a day
  it takes two. Lou asks for people who work accurately and precisely,
  attentively, and like clean work. At the plant's 8 to 20 parts a day that
  is one operator per shift ([scale](../scale.md) people estimate).
- **Utilities and rooms.** Compressed air, a demineralised-water system,
  waste-water collection or treatment, and cooling water, which Lou says
  can be passive, with no active chiller (he expects this needs more
  discussion). The Pheenix PDPU asks for 12 to 20 °C cooling water, so
  whether passive cooling holds at 30 °C and more ambient is a question for
  Lou. Space beyond the wet room: an acid cabinet with fume extraction for
  mixing chemicals, storage for stampers, lacquers and DMMs, a quality
  room with turntable, speakers and inspection microscope, spare parts and
  consumables. Smaller items: a drill stand for removing lacquer from the
  back of lacquers, lab ware (glass and PP ware, temperature sensor,
  density meter, pH meter), and a laundry washing machine and a concrete
  mixer for cleaning the anode baskets and anode bags.
- **Data.** The AEFS4-250 has a PLC: programs of up to 20 steps, each step
  setting time, voltage, current, flow and rotation; an automatic wake-up
  function and pump-curve calibration; a modified cell flow that allows
  higher current "without stretching the bath solution". Lou calls it very
  energy-efficient with extremely low maintenance (vendor claims). The
  protocol is not stated, so the [digital factory](../digital-factory.md)
  RFQ clauses apply. The letter mentions no PLC for the basic EFS2-200,
  which would keep galvanics a manual check-in station.
- **DMM.** The lacquer-path units (2a or 2b, and 3) are EUR 61,000 to
  67,000 of either configuration; a plant cutting only DMM would not need
  them, which bears on the Sillitoe DMM question in the
  [vendor landscape](../suppliers/vendor-landscape.md).
- **Cutting lathes.** The letter ends with five contacts for buying a
  lathe, second-hand included; they are in the
  [vendor landscape](../suppliers/vendor-landscape.md#used-lathes-and-cutting-room-contacts-via-oms).

### Cycle times and cell count

Pheenix publishes no cycle times. Published practice from other plating
rooms agrees with Faraday's law at the PDPU's 200 A ceiling (1.095 g of
nickel per ampere-hour), and these are the times the
[plant operation page](../plant-operation.html) runs on:

| Step | Time | Source |
|---|---|---|
| Silvering (clean, sensitise, spray, rinse) | ~15 min | estimate; no published figure |
| Pre-plate | 15 to 30 min at 10 to 20 A | ~15 min at 35 °C (flight 13 duplication, Freiburg, in Leuze Verlag's Galvanotechnik report "Of fathers, mothers and sons"); ~20 min at ~20 A (Welcome to 1979, Nashville, on a Digital Matrix line, in Finishing and Coating); 30 min at 10 to 20 A (US patent 4,363,705) |
| Father | ~1 h 15 min | ~0.2 mm and ~200 g at 150 A and 11 V (flight 13); 1¼ h with the current raised from 20 to 200 A (US 4,363,705) |
| Mother | ~1 to 1¼ h | 1¼ h at 200 A (US 4,363,705); "as little as one hour" (Wikipedia, Production of phonograph records) |
| Stamper | ~45 min | a 145 g stamper in 45 min (Wikipedia, same article) |
| Separation, passivation, cleaning and drying (PMPB) | ~10 to 15 min | estimate |
| Back-finish (VSF), centre punch (VSP), coin (VSC) | ~5 to 10, 3 to 5 and 1 to 2 min | estimate; Sibert publishes none |

The count, from this repo's own demand figures:

- At full capacity the [revenue model](../finance/revenue-model.md) assumes
  300 to 600 titles a year across 1.0 to 1.5 million records, so 2,500 to
  3,300 records per title.
- Each title needs, per side, a father, a mother and two to three stampers
  (at 1,000 to 2,000 pressings per stamper): 8 to 10 electroformed parts per
  title, **~2,400 to 6,000 parts a year**, 8 to 20 per working day at 300
  days, before remakes.
- The father and the mother of every side go into the archive (decided
  October 2026): 4 parts per title, **~1,200 to 2,400 parts a year** at 300
  to 600 titles. A mother carries about 10 stamper sets and a father about
  5 to 10 mothers by the industry rule of thumb (sources and the repress
  arithmetic in the
  [production timeline](../production-timeline.md#repress-the-shortest-path-in-the-plant)),
  so a repress normally grows stampers from the archived mother, and a
  worn mother is replaced from the father without a new cut. The room
  that holds them is planned in
  [facility security](../facility-security.md#protecting-the-irreplaceable).
- With ~15 minutes of loading, rinsing and unloading on top of 45 to 75
  minutes of deposition, a cell turns a part in ~1 to 1.5 hours: 10 to 16
  parts per cell per two-shift day, **20 to 32 per PDPU**.

So **one PDPU covers full-capacity demand** with headroom for remakes, and
a second PDPU buys redundancy rather than capacity, which is how Pheenix
itself sells it ("more capacity as well as enhanced redundancy"). The
first version of this page assumed 2 to 3 hours per part and concluded
that the high end needed two. One PASU, one PPPU (pre-plate is for the
masters, 2 to 4 a day at full capacity, and the unit takes four at once)
and one PMPB cover the rest. Ask Pheenix for measured cycles at the
plant's thickness before this goes into a budget. OMS's letter (above) is
the first vendor figure: 6 to 8 runs on 4 cells in a 7.5-hour working day,
roughly an hour a run, which fits these times.

## Stamper prep: the Sibert VS line

Sibert's three vinyl machines, from the current technical specifications
(VSF and VSC dated May 2022, VSP June 2023, by their file dates), sent by
Ian Locke on 5 October 2026 together with a line-up drawing of the three
(July 2023):

| Machine | What it does | Specification figures |
|---|---|---|
| **VSP** Vinyl Stamper Punch | Punches the centre hole after optical centring on the groove | Punch and die M2 high-speed steel, Ø25.4 mm standard (other sizes available), ±0.002 mm; turntable Ø360 mm, 6 mm centring travel, ±0.0015 mm rotational accuracy; pneumatic automatic pre-centring, then manual fine centring; optics ×100, graticule 15 divisions at 0.10 mm, viewing diameter Ø90 to 110 mm (centres on the lead-out groove); pneumatic punch cylinder 100 mm bore, 50 mm stroke; 115 to 230 VAC single-phase, 250 VA; air 6 to 8 bar, 4.5 L/s during the punch stroke; 200 kg; spare punch and die on request |
| **VSF** Vinyl Stamper Finisher | Automatic wet back-finishing with automatic stamper cleaning | Turntable up to Ø362 mm, sized to the customer's stamper, vacuum plus mechanical quick-release clamping on moulded rubber mats, 150 to 1500 rpm; head pressure 0 to 30 psi, brushless DC head drive and traverse, 150 to 1500 rpm; 4-station quick-change disc head including a cleaning pad; abrasive grades P120 to P2500 (nine grades); closed water loop, 0.6 µm absolute or 5 µm nominal filtration plus a 10 µm bag in the tank; 115 to 230 VAC single-phase, 1200 VA; air 6 to 8 bar, 3.1 L/s; 250 kg |
| **VSC** Vinyl Stamper Coiner | Fully automatic forming of the centre hole (ID) and the edge (OD), with the outer diameter punched to a preset size, so no trimming | Press of 40 mm structural steel plate and pillar box section on four hardened pillars and eight linear ball races; independent twin hydraulic OD forming and adjustable pneumatic ID forming; automatically interchangeable 7", 10" and 12" tooling carriages, up to three stations in the machine, loaded by ball rollers and a brushless DC lead screw; D2 and M2 high-speed steel tools, vacuum hardened three times, tempered and precision ground; removable precision-ground ID spigot with height and pressure adjustment; OD insert made to the customer's mould profile ("quick change tooling to suit all vinyl moulds"); 115 to 230 VAC single-phase, 1 kVA; air 6 to 8 bar, 4.5 L/s during forming; 1000 kg; about 2.0 × 0.8 × 1.6 m (width with the tool carriages × depth × height, from the sheet's render) |

All three have aluminium frames and 5 mm cast acrylic guarding and ship
with a pressure regulator and filter. The VSP and VSF sheets list castors
and levelling feet; the current VSC sheet does not.

Against the 2021 sheets, the VSC is a heavier machine (1000 kg, was 600;
40 mm plate, four pillars and eight ball races) with forming split into
hydraulic OD and pneumatic ID; the VSF turntable is now sized to the
stamper (up to 362 mm, was 365), its head pressure range is 0 to 30 psi
(was 0 to 50), its drives are brushless and its disc head has four stations
(was five); the VSP sheet changed only a typo.

What this changes in the plan:

- **Budget: USD 250k for all three.** Sibert confirmed by email (5 October
  2026) that a budget of USD 250k covers "all 3 auto-machines"; Ian
  Locke's own time, spare parts, shipping and travel come on top. This is a
  budget confirmation, not a quote: Sibert offers a fully itemised
  quotation once we go ahead. Ian Locke repeated on 9 October 2026 that
  equipment footprints and formal quotations follow when we are ready, and
  advised settling the pressing side first. It sits above the 60k to 170k estimate in
  [total investment](../finance/total-investment.md), which carries the
  difference in its not-yet-rolled-up table until the next re-base.
- **Single-phase power.** All three run on 115 to 230 VAC, 50/60 Hz, ~2.5
  kVA together, so the three-phase question from the
  [Haarlem briefing](../suppliers/making-vinyl-europe-2026-exhibitors.md)
  falls away. Each needs 6 to 8 bar compressed air at ½" BSP minimum, so
  the air network has to reach the stamper prep room.
- **Weights 200, 250 and 1000 kg.** The VSP and VSF stand on castors:
  pallet-truck moves. The VSC weighs a tonne and its sheet lists no
  castors, so it is a crane or forklift lift; stamper prep is under the
  crane runway ([crane table](../crane-workshop-tours.md) updated).
- **Line-up: 4958 × 833 mm.** Sibert's drawing sets the machines in a row,
  VSF, VSP, VSC, 500 mm apart: 4.96 m long overall and 0.83 m deep. With an
  operator aisle in front and access at the ends, the line needs a strip of
  roughly 6 × 2.5 m (estimate) in the stamper prep room, before stamper
  racks and the inspection bench.
- **Order of operations: finish, punch, coin.** Gotta Groove's
  Electromastering Lab in Cleveland, which runs a Sibert VSF and VSP,
  back-sands first, then centres and punches on the VSP, then trims and
  coins the edge and forms the centre hole for the press type
  (recordplating.com). The VSC locates on the punched hole, which fits the
  same order, and Sibert's line-up drawing places the machines in it. The
  [process flow](../process-flow.md)'s "punch, back-finish, coin" names
  the operations, not their sequence.
- **Centring is manual.** The VSP pre-centres pneumatically, then the
  operator centres the lead-out groove under ×100 optics against the
  graticule. Concentricity depends on the operator, so the stage 5 check
  stays, and it is the measurement most worth automating. Sibert's 2009
  optical-disc punch offered automatic centring with a measured centring
  value, a barcode reader for the stamper card and a LAN connection as
  options; the VS sheets list none of these. Sibert also builds a fully
  automatic punch, the **VSPa**; Ian Locke thinks it may not be right for
  this application and offered to discuss it, or to carry some of its
  features across to the VSP as a special exception. Which features
  (automatic centring, a measured centring value written out against a
  stamper serial) is the question to settle before the quotation: the
  answer decides whether stamper prep stays a manual check-in station in
  the [digital factory](../digital-factory.md).
- **Mould fit.** The standard punch is Ø25.4 mm, other sizes on request,
  and the VSC makes its OD insert to each customer mould profile, with
  interchangeable ID spigots. Gotta Groove keeps nine
  centre-hole forming tools to fit the presses its customers run, which
  shows the scale of the question. Which centre hole and
  edge form each mould needs (Newbilt book mould, Pheenix/Toolex, M-Tech)
  has to come from the press vendors, and the tooling sets per mould type
  are a quote line. Whether the VSC duplicates anything a press vendor
  supplies is still open.
- **The finisher's water carries nickel.** The VSF's closed loop collects
  nickel fines and abrasive in its filters and bag. Spent water and filters
  go to the galvanics treatment and hazardous-waste route, never the drain
  ([sustainability](../sustainability.md)). Consumables: abrasive discs in
  up to nine grades, filter cartridges and bags, turntable mats.
- **Service model** (from the 2009 optical-disc literature; confirm for the
  VS line). Sibert services punch-and-die sets at its own works: resharpen,
  check alignment and vacuum, test-punch the customer's own stampers and
  issue a certificate (measured ID, ID-to-data concentricity, roundness,
  surface finish, front and back hardness HV0.3). It advises against local
  resharpening and sets shot-count warnings in the machine. For a plant in
  Thailand that means a spare punch and die in rotation (the VSP lists one
  on request) and a UK freight leg per service. In 2009 Sibert also had a
  Singapore branch; ask whether regional service still exists. The
  certificate's fields are a ready list for the stamper prep record in
  [traceability](../traceability.md). Installation and training are not in
  the budget: Ian Locke's time and travel are charged on top, so they are
  a quote line of their own.

## Optical-disc reference material

[`sibert/sps-optical-disc-2009/`](sibert/sps-optical-disc-2009/) holds
Sibert's SPS (Stamper Preparation System) literature from 2008 and 2009,
punching and finishing modules with their workflows, maintenance lists and
upgrade options, and the August 2008 Blu-ray stamper characteristics paper
by Sony DADC, Singulus, Sibert and technotrans. These are optical-disc
documents and their limits are not vinyl specifications. What carries over:

- **The structure of a stamper acceptance spec**: thickness, flatness,
  hardness, back roughness before and after finishing, outer diameter,
  centre hole, eccentricity, burr and visual defect counts, each with a
  measurement method. CNX has the instruments
  ([quality automation](../quality-automation.md)) but no written limits
  yet; this paper is the model to write them against.
- **Hardness on the centre slug.** Hardness is measured on the disc punched
  out of the centre, never on the part, and a fresh nickel bath plates soft
  at first, which changes how stampers punch and finish. Taken into
  [quality automation](../quality-automation.md).
- **Back-finish pattern.** Random crossing scratches, uniform over the
  surface, worked best for Blu-ray; concentric scratches were not
  recommended. The SPS finisher reached Ra 0.03 µm. No vinyl figure is on
  file: ask Sibert what the VSF reaches and what vinyl plants specify.
- **Tool wear shows in the hole.** Hole size shrinks by a few microns as
  the punch and die wear, so a shot count per punch-and-die set belongs in
  the genealogy record next to each stamper's concentricity.

The SPS material is directly relevant only if CD replication, the
investor's request in the [project timeline](../project-timeline.md), ever
goes ahead.

## Open questions for the quotes

- **Pheenix Alpha**: price and lead time for one line (PASU, PPPU, PDPU,
  PMPB) and for a second PDPU, quoted alongside the AD12; empty and filled
  weights; measured cycle per part per cell at stamper, mother and father
  thickness; PLC protocol and tag list; DI water quality; which
  water-treatment partner its customers use; reference plants running the
  range. CEO Robert Gunnarsson offered a Teams call, reference clients and
  a factory visit near Stockholm (email, 5 October 2026); the call
  follows once these questions are ready, and a visit could fit the
  February 2027 Europe trip
  ([exhibitor briefing](../suppliers/making-vinyl-europe-2026-exhibitors.md#after-the-show)).
- **Sibert**: the itemised quotation against the confirmed USD 250k
  budget, with Ian Locke's time, spare parts, shipping and travel priced,
  and lead time; tooling sets per mould type and their cost; which VSPa
  features can move to the VSP (automatic centring, a measured centring
  value, barcode and network); punch-and-die service from Thailand (UK
  works or a regional partner); the roughness the VSF reaches; crated
  sizes and weights (the VSC is now 1 t); what it installed at Pheenix in
  January 2025, and whether Pheenix sells Sibert machines with its line.
- **OMS (Optical Media Services)**: a dedicated offer once we send our
  plans (lacquer, DMM or both; parts per day; shifts), ideally after seeing
  the equipment in Baarlo (the February 2027 Europe trip could fit);
  datasheets for the EFS2-200 and AEFS4-250 (dimensions, empty and filled
  weights, power, cooling water); how parts are passivated in the basic set
  without the cleaning/passivation unit; the advanced total (the units add
  up to EUR 314,000, the letter says 311,000); whether passive cooling holds
  at Thai ambient; the AEFS4-250's PLC protocol and tag list; the used
  equipment on offer; installations and service in Asia; stamper service
  prices and turnaround; which water-treatment partner his customers use;
  and whether OMS builds the electroplating equipment Newbilt announces.
- **All galvanics candidates** (Pheenix, Digital Matrix, OMS): how many
  stamper sets a mother gives and how many mothers a father gives with
  their process before quality drops, how they check it (mother playback,
  metrology), and how they recommend storing archived fathers and mothers
  (passivation, sleeves, humidity) for years.
- **Press vendors** (Newbilt, Pheenix, M-Tech): the stamper centre hole and
  edge form each mould expects, so the punch size and coiner tooling can be
  ordered to match ([pressing line](pressing-line.md)).

## Source documents

- [`pheenix-alpha/`](pheenix-alpha/): PASU, PPPU, PDPU and PMPB flyers
  (September 2024; renamed from their download names). The flyers give
  Pheenix Alpha AB's address as Skepptuna, Märsta, Sweden;
  info@pheenixalpha.com, helpdesk@pheenixalpha.com.
- [`sibert/`](sibert/): VSF and VSC technical specifications (May 2022),
  VSP technical specification (June 2023) and the VSF/VSP/VSC line-up
  drawing (July 2023), attached to Ian Locke's email of 5 October 2026;
  the April 2021 issues they replace are in
  [`sibert/specs-2021/`](sibert/specs-2021/). Sibert Instruments Ltd,
  Medstead, Hampshire, UK, by the email signature (the specification
  sheets still carry the older Alton address); sales@sibert.co.uk,
  ian.locke@sibert.co.uk.
- [`oms/`](oms/): OMS's introduction letter of 9 October 2026 (Word;
  sent as "Introduction letter BUILDFOR.LIFE.docx", attached to Lou
  Wullms' email of the same day): wet-room units with reference prices,
  two configurations, capacities, utilities, staffing, used equipment and
  lathe contacts. Optical Media Services B.V., Tangweg 16, Baarlo,
  Netherlands.
- [`sibert/sps-optical-disc-2009/`](sibert/sps-optical-disc-2009/): SPS
  punching and finishing literature (2008 to 2009), the punch-and-die
  return form, and the Blu-ray stamper characteristics paper (2008).