grabowski
c8482b7a76
docs/plant-operation.html: one self-contained static page showing the whole plant running, from PVC intake and the material lab gate through extruder, press cycle (load/close/steam/cool/open/eject), trimmer, 100% optical inspection, sampled audio comparison, finishing, packaging (matrix code vs barcode) and fulfillment. The metal path (audio intake, mastering, cutting, silvering, father/mother/stamper, stamper prep) runs above with the three artist gates; utilities (steam, cooling, air, hydraulics, grinder/regrind, energy, traceability, HVAC) below with live-looking tags. Numbers are taken from the repo (Newbilt site requirements, scale.md, quality-automation.md, process-flow.md). Every station is clickable for what happens there and the checks that gate it. Two demo buttons show a steam pressure dip holding the press and a new PVC lot held by the lab until a test pressing releases it. README links the page.
167 lines
8.6 KiB
Markdown
167 lines
8.6 KiB
Markdown
# CNX Vinyl / Poy Records
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A vinyl record factory in planning for the Chiang Mai area of northern
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Thailand (site candidates include Lamphun and Lampang provinces). This
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repository is the source of truth for the project: planning documents and
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cost data today. As the factory takes shape it will also hold the data and
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software used to run it.
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## Team
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- **Simona Meesaiyati**, Project Lead
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- **Alexander Grabowski**, Technical Consultant
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[buildfor.life](https://buildfor.life) supports the project in a consulting
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capacity.
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## Vision: Full-Service Production
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The goal is the complete vinyl production chain under one roof, from audio
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file to delivered record:
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1. **Mastering**: audio mastering for vinyl
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2. **Lathe cutting**: cutting the master disc
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3. **Silvering**: metallizing the cut master
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4. **Stamper production**: electroforming nickel stampers in-house
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5. **Pressing**: extrusion and pressing of the finished records
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6. **Finishing**: trimming, labels, shrink wrapping
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7. **Packaging**: folded paper cartons (jackets and sleeves), produced in
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collaboration with local packaging manufacturers
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8. **Fulfillment**: dropshipping directly to end customers on behalf of
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labels and artists, alongside conventional bulk delivery
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In-house galvanics (steps 3 and 4) removes the dependency on overseas stamper
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suppliers, a common bottleneck for pressing plants, and shortens turnaround
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for clients. Partnering with local carton manufacturers keeps packaging
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sourcing close to the plant, in line with the local-sourcing preference for
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materials. The pressing line is documented in detail; equipment, partners,
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and budgets for the other steps are open planning items.
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## Project Status
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**Planning stage** (as of mid-2026).
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- Industry outreach has been ongoing for several years: equipment vendors,
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material suppliers, and independent consultants.
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- Alexander and Simona will soon travel to
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[Making Vinyl](https://makingvinyl.com/) in Haarlem, Netherlands, to gather
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further insights from the pressing industry.
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- A collaboration with [ResurRec](https://www.resurrec.com/) is under
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discussion.
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## Planning Documents
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The detail lives in dedicated documents:
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- [Roadmap](docs/roadmap.md): next steps in dependency order, from the
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three current gates (market validation, BOI, land title check) through
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quotes, commitment, build, launch, and expansion
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- [Pressing line equipment plan](docs/equipment/pressing-line.md): the
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50/50 automated/semi-automatic fleet strategy, the Newbilt system under
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evaluation (~USD 232k quoted scope), and site requirements
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- [Vendor landscape](docs/suppliers/vendor-landscape.md): researched
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candidates for mastering and cutting (Agnew Analog), galvanics equipment
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(Plating Power / Digital Matrix), stamper preparation (Sibert), bridge
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stamper service (Stamper Discs), and automated presses (Pheenix Alpha)
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- [Equipment needs and supplier map](docs/suppliers/equipment-suppliers.md):
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the full needs list per production step with supplier tables and contacts
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- [Sustainability](docs/sustainability.md): the solar installation (Deye
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inverters, 271 kWh Gobel Power battery stack), the zero contaminated water
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commitment, and the materials strategy
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- [Worker safety](docs/worker-safety.md): safety training, galvanics clean
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rooms and decontamination, PPE
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- [Biomass fuel strategy](docs/biomass.md): the 60 rai own-grown coppice
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idea (with the forestry-classification check that comes first), northern
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agricultural waste as the main supply, and the staged electric-to-biomass
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path
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- [BOI investment promotion](docs/boi.md): the promotion strategy (Group B
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base activity plus solar, automation, and R&D measures for the tax value),
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requirements, Northern-region angle, and why BOI approval precedes
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machinery orders
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- [Facility security and site systems](docs/facility-security.md): access
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control, CCTV, whole-factory HVAC (temperature, humidity, PM), archive and
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audio protection, fire and life safety, plant monitoring, Thai compliance
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anchors
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- [Process logging and traceability](docs/traceability.md): end-to-end
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per-order traceability for customers, batch genealogy from audio file to
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shipment, and the requirements this sets for the factory software
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- [Quality automation](docs/quality-automation.md): stamper metrology
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(Keyence-class confocal, profiler, XRF), layered pressed-record QC (100%
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optical inspection, per-cycle press telemetry, sampled automated audio
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comparison), and how it feeds traceability
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- [Process flow](docs/process-flow.md): the whole chain from audio file to
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delivered record as a chart and stage table, with every check and the
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three artist approval gates (printable diagram alongside)
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- [Plant operation page](docs/plant-operation.html): a single static page
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animating the whole plant as a simulated SCADA overview, from PVC intake
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and the material lab through extruder, press, trim, optical inspection,
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finishing, packaging and fulfillment, with the metal path, utilities and
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energy alongside; open it in a browser, every station is clickable
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- [Production timeline](docs/production-timeline.md): how long an order
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takes stage by stage, launch vs mature configuration, the repress fast
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path, and what lead time can honestly be quoted to a customer
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- [Project timeline](docs/project-timeline.md): the calendar from today to
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first paying release, the BOI-to-machinery critical path, and where the
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float actually sits
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- [Project scale](docs/scale.md): rough numbers for everything on one page:
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output capacity, building area, land, electrical demand, solar and
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storage, steam and fuel, headcount, and money cross-references
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- [Total investment](docs/finance/total-investment.md): the full-vision
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roll-up (~4.7M to 8.9M USD) and the ~1.7M to 2.9M USD phased entry, with
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the basis of every block
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- [Phase 1 construction RFQ](docs/finance/phase1-construction-rfq.md):
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the spec sheet for asking a contractor to price the phase 1 buildings
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and site works, with quantities taken from the parametric BIM model
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- [Revenue model](docs/finance/revenue-model.md): rough full-capacity
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revenue (~3.7M to 6.8M USD/yr), direct cost and margin per record, and
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the levers and caveats behind the numbers
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- [Business plan](docs/business-plan/CNX-Vinyl-Business-Plan.docx): the
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investor-facing roll-up of everything above, built from
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`docs/business-plan/build/` (run `python build_plan.py` to regenerate
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after the numbers move). Draft 0.1 carries the land-lease decision, the
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cassette and CD scope, and Ploy Printing as packaging partner and
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intended co-investor
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## Repository Layout
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```
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docs/
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├── business-plan/
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│ ├── CNX-Vinyl-Business-Plan.docx Investor business plan (generated)
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│ └── build/ Python source of the plan; regenerate with
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│ build_plan.py
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├── consulting/ Consultancy proposals and overviews
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├── equipment/
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│ ├── newbilt/ Offers, site requirements, process schematic,
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│ │ service rates (vendor PDFs)
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│ └── pressing-line.md Press fleet strategy and equipment plan
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├── finance/ Project cost overviews, revenue model,
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│ construction RFQ
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├── suppliers/ Supplier contacts, vendor landscape, supplier map
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├── biomass.md Biomass fuel strategy and the 60 rai coppice idea
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├── boi.md BOI promotion strategy and requirements
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├── facility-security.md Security, HVAC, fire and life safety, compliance
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├── process-flow.md Audio file to delivered record, with all checks
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├── production-timeline.md Order turnaround, stage by stage
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├── project-timeline.md Calendar to first paying release, critical path
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├── quality-automation.md Stamper metrology and layered record QC
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├── roadmap.md Next steps in dependency order
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├── scale.md Rough project sizing on one page
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├── sustainability.md Energy, water, materials commitments
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├── traceability.md Process logging and per-order traceability
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└── worker-safety.md Training, clean rooms, PPE
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```
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Vendor PDFs and spreadsheets are primary sources and reflect the state of
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negotiations at their file dates. Treat prices and lead times as snapshots,
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not commitments.
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## What This Repo Will Grow to Hold
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- Accumulate planning and vendor documents as decisions firm up, including
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the mastering, cutting, and galvanics chain
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- Add structured data (inventory, orders, production batches) once operations
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begin
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- Host the software/tooling built to run the factory (tracking, ERP-style
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workflows)
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