grabowski
c95874ce6f
All derived figures reviewer-recomputed; BESS runtime corrected to the chiller's electrical draw (2-3 h, not 1 h of thermal rating)
4.8 KiB
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Basis: the automated AD12 presses ~140 records/hour each (vendor datasheet); semi-automatic throughput is unpublished, assumed 60 to 80 records/hour per press with operator handling (estimate); 16 h/day, 300 days/yr, with realistic overall effectiveness of 60 to 70% applied.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), 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)
- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: ~24M to 42M THB (~€630k to 1.1M), detail in the utilities CSV
- Not yet priced: automated presses (indicative ~$340k each, unverified), galvanics line, mastering/cutting room, metrology, building construction/fit-out, land