grabowski
11b7df3be4
- docs/process-flow.md: mermaid chart plus stage table of every check and the three artist approval gates, from audio intake to fulfillment - docs/process-flow.drawio with PNG and PDF exports - pressing-line.md: floor must carry multiple tons per m2 in machine areas - README: process-flow entry in document index and layout tree
54 lines
2.8 KiB
Markdown
54 lines
2.8 KiB
Markdown
# Pressing Line: Equipment Plan
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The target press fleet is a **50/50 split between fully automated and
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semi-automatic presses**: automated presses for standard production volume,
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and semi-automatic presses for splatter and other color effects, special
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editions, and small runs, where an operator working the mold directly is an
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advantage rather than a cost. The semi-automatic side is covered by the
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Newbilt evaluation below; a fully automated press line is an open
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procurement item (see the [vendor landscape](../suppliers/vendor-landscape.md)
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for the Pheenix Alpha candidate).
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## Semi-automatic line: Newbilt
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The core semi-automatic machinery under evaluation comes from
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**Newbilt machinery GmbH** (Alsdorf, Germany):
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- **Newbilt Single 2.1 system**: one VEX 50 extruder feeding one HRP 12
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hydraulic press (~150 t press force), pressing 12" records at 140 or 180 g
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with a Newbilt book mold set. A Vario trimmer handles 12" cuttings, with
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a 7"/10" upgrade path.
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- **Duplex upgrade path**: the hydraulic aggregate is already sized for a
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second press, and an additional press and extruder are quoted options, so
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the plant can scale from Single to Duplex without replacing infrastructure.
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- **Supporting equipment**: label dry oven, shrink wrapper, PVC grinder
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(scrap feeds back as the ~20% recycled share of the feedstock), 7" center
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label punch, buffer spindles and separator plates.
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The June 2024 Newbilt quotation totals **≈ €200,500** including freight from
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Alsdorf to Thailand and seaworthy packaging. Two major utility systems are
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deliberately excluded and will be **sourced and installed locally in
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Thailand**: a ~400 kg/h steam generator (with water treatment) and a ~250 kW
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cooling water system. The quotation has passed its validity date and will need
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re-confirmation before ordering.
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## Site requirements
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Site planning for the semi-automatic line works from Newbilt's Duplex
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requirements: roughly 200 m² of production floor, 32 kVA connected
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electrical load, saturated steam at 10 bar, and compressed air and cooling
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water circuits, plus side rooms for materials, compressor, chiller, and
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finished goods.
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**Floor loading is a building-selection criterion**: the slab must carry
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multiple tons per m² in the machine areas. A Newbilt press weighs 1,350 kg
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on a footprint under 1 m², and the boiler, chiller, hydraulic aggregate,
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battery stack, and stacked material storage all concentrate weight the same
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way. The floor must also be flat but not slippery (machine levelling pads
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need grip) and resistant to the solvents used in production. Dynamic loads
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from press cycles come on top of the static figures, so the structural
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engineer gets the vendor data sheets, not just the totals.
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Source documents live in [`newbilt/`](newbilt/): the budgetary offer, the
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Duplex site requirements, the process schematic, and the service rate card.
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