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New page docs/steam-cooling.html (site /demos/steam-cooling/): the utility plant as a clickable process diagram. Steam side: raw water, softener and dosing, feed tank with heat-pump feedwater recovery, feed pumps, a bank of two 500 kg/h boilers (third for N+1 as an option), separator and metering, optional accumulator, blowdown, the 10 bar header with a valved, metered branch and trap per press, drip legs and condensate return. Cooling side: Newbilt's press outlets are open (max. 2 bar), so returns drain to a warm tank, pass the heat pump, an optional dry cooler and a plate heat exchanger to a cold buffer tank, and VFD pumps feed the 20 to 25 C header at ~10 bar to every press, the extruders and the central hydraulic oil cooler; the chiller loop (three 250 kW air-cooled modules at 40 C ambient, fourth as option) stays closed and clean. Galvanics cooling (12 to 20 C) is a separate circuit. Operating cases (launch, Duplex system 1, five presses, one module down) show demand against installed capacity; design basis with sources, equipment schedule, RFQ questions. Static SVG, no per-frame work. Design basis at Newbilt's per-machine figures: steam 750 to 900 kg/h, cooling 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics), 305 to 540 l/min circulating. Also found: Newbilt's 53 l/min at ~60 C out is ~140 kW, above its 125 kW peak; listed as a re-quote question. Re-based in the same commit: - scale.md: electrical table (chiller bank ~210 to 325 kW electrical, plant peak ~430 to 700 kW, ~950 to 1,330 kW with electric steam), grid 800 to 1,000 kVA (1,250 to 1,600 with electric steam, Schedule 4 past 1,000 kW), tariff 4.5M to 6.8M THB/yr, battery ~1 h of chiller peak, boiler and chiller banks, biomass up to ~550 t/yr at 1.5 M records, utilities money line. - sustainability.md, biomass.md: same figures; electric steam 5.2M to 6.0M THB/yr mature, 1.6M to 1.8M early; fuel saving 4.0M to 5.4M. - utilities CSV: boiler bank, chiller bank with HX and tanks, softener and loop treatment re-sized; baseline 23.98M-41.63M -> 30.07M-51.33M. - total-investment.md: re-size as an added-scope row (+185k / +294k USD); headline 4.7M to 8.9M unchanged until the investment re-base. - pressing-line, equipment-suppliers, facility-security, fleet calculator (boiler 1000 kg/h, chiller 750 kW), plant page detail texts; README, landing page, build.sh.
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Total Investment: Rough Picture
Everything priced or estimated so far, rolled into one view. Blocks marked "estimate" have no vendor confirmation; the rest trace to quotes or the researched ranges in this repo. Treat all figures as budgetary with a wide margin (plus or minus 30 to 50% on the estimates) until RFQs replace them.
Currency: USD and THB. FX at 5 August 2026: 1 USD = 33 THB. Vendor quotes issued in another currency are kept in that currency wherever they appear next to their source document, and converted here at 1 EUR = 1.155 USD and 1 GBP = 1.35 USD. Original figures compiled July 2026; the underlying THB estimates are unchanged, because EUR/THB at ~38 is where it was when they were made.
Full vision, all blocks
| Block | USD | THB | Basis |
|---|---|---|---|
| Newbilt semi-auto line, full Duplex | 350k – 370k | 11.5M – 12.2M | 2024 quote EUR 200,500 (~USD 232k) + quoted 2nd press/extruder ~USD 115k; expired, needs re-quote. The fleet has since changed, see the added-scope table |
| 2 automated presses (Pheenix AD12) | 580k – 920k | 19.1M – 30.5M | unverified ~USD 340k/press indicative + delivery and commissioning. Replaced by the Newbilt Classic in the current fleet, see the added-scope table |
| Galvanics line (Digital Matrix or Pheenix Alpha) | 320k – 650k | 10.7M – 21.4M | six-figure-USD turnkey inference from vendor research; the Pheenix range (2024 flyers, galvanics and stamper prep) is unpriced too; OMS's reference prices (letter, 9 October 2026) put a complete 4-cell wet room at EUR 224k basic to 311k advanced (~USD 259k to 359k; ~270k to 371k with know-how transfer), installation and water treatment extra: at or below this block's low end, kept until quotes exist |
| Zero-discharge water treatment (ZLD) | 90k – 240k | 3.0M – 8.0M | utilities CSV option row |
| Stamper prep (Sibert VSP, VSF, VSC) | 60k – 170k | 1.9M – 5.7M | estimate kept until the re-base; Sibert has since confirmed USD 250k for the three (its time, spares, shipping and travel extra), the difference is in the table below |
| Mastering and cutting room (Agnew or Sillitoe lathe system, cutter amps, console, room treatment) | 290k – 580k | 9.6M – 19.1M | estimate, bespoke market; the Sillitoe SDMS lists at USD 125k for lathe, head, amplifier and automation (ex tax, shipping), which makes the low end reachable; band kept until both quotes exist |
| Metrology and QC stack (confocal, profiler, XRF, inline vision, audio station) | 350k – 810k | 11.5M – 26.7M | estimate, phaseable |
| Utilities, solar, HVAC, racking baseline | 730k – 1,270k | 24.0M – 41.6M | reviewed utilities CSV, THB-native; sized for one Duplex, the five-press re-size is in the table below |
| Building ~1,500 m² plus civil works | 650k – 1,100k | 21.4M – 36.2M | estimate at 12,000–20,000 THB/m² Thai industrial construction plus ~20% site works |
| Land 6–8 rai, if purchased | 360k – 970k | 12.0M – 32.0M | estimate at 2–4M THB/rai industrial; leasing cuts this to near zero upfront |
| Traceability and factory software | 60k – 170k | 1.9M – 5.7M | estimate |
| Freight, installation, training (non-Newbilt equipment) | 120k – 230k | 3.8M – 7.6M | estimate |
| Working capital, PVC stock, spares | 120k – 230k | 3.8M – 7.6M | estimate |
| Subtotal | ~4.1M – 7.7M | ~135M – 254M | |
| Contingency 15% | ~0.6M – 1.2M | ~20M – 38M | |
| Total, full vision | ~4.7M – 8.9M USD | ~155M – 294M THB |
Added scope, not yet in the roll-up
Decided, or re-priced by a vendor, after the roll-up above was compiled; carried here until the next re-base folds them into the blocks (the building, software and stamper prep lines, and the contingency on top).
| Block | USD | THB | Basis |
|---|---|---|---|
| Overhead crane, runway, frame premium, machine door | 97k – 227k | 3.2M – 7.5M | estimate, crane, workshop and tours |
| Maintenance workshop and machine bay fit-out | 30k – 76k | 1.0M – 2.5M | estimate, same |
| Visitor corridor and accessible entrance | 67k – 148k | 2.2M – 4.9M | estimate, same |
| Artist platform, public side (calculator, campaigns, payments) | 40k – 90k | 1.3M – 3.0M | estimate, artist platform |
| PVC material lab, day-one tier (incl. plaque press and sample conditioning) | 55k – 150k | 1.8M – 5.0M | estimate, quality automation; not costed in the metrology block above. The mature tier (torque rheometer, DSC, FTIR, ~120k – 240k) is deferred, with partner labs in between |
| Stamper prep re-priced: USD 250k for VSP, VSF and VSC against the 60k – 170k block above | +190k (low case) / +80k (high case) | +6.3M / +2.6M | Sibert's budget confirmation, email of 5 October 2026 (galvanics and stamper prep); itemised quotation to follow. Its time, spare parts, shipping and travel are extra and fall into the freight/installation and spares blocks above |
| Press fleet changed (October 2026) to two Newbilt Duplex systems (two presses each, EX 50 main extruder and EX 35 colour extruder) plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k; the quote's second-extruder option becomes the EX 35), system 2 ~230k – 300k (two presses at the quoted ~115k per press and extruder set as the yardstick, plus hydraulic unit and EX 35, estimate; no EX 35 price on file), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, pressing line; the Newbilt re-quote replaces it. The utilities for five presses are re-sized in the row below |
| Utilities re-sized for the five-press fleet (October 2026): boiler bank 2 × 500 kg/h, chiller bank 3 × 250 kW with plate heat exchanger and tanks, larger softener and loop treatment (steam and cooling) | +185k (low case) / +294k (high case) | +6.1M / +9.7M | estimate, utilities CSV re-based from 24.0M – 41.6M to 30.1M – 51.3M THB |
| Added so far | ~605k – 905k | ~19.9M – 29.9M | about 12 to 15% on the full-vision subtotal |
Phased entry
A credible launch phase is far smaller, roughly 1.7M to 2.9M USD (~57M to 95M THB):
- Newbilt Single system (not Duplex yet)
- Bridge stampers from Stamper Discs, so no galvanics line at launch
- Basic QC (microscope, benchtop PVC lab, sampled listening), full metrology deferred; the PVC lab's day-one tier is the added-scope row above
- Leased building instead of purchase, modest first solar array
- Galvanics, the second Duplex system and the Classic, full metrology, and the biomass boiler follow as revenue-funded or second-round expansions
The planning already supports this: the Duplex-ready hydraulics, the bridge-supplier role for Stamper Discs, the staged electric-to-biomass steam path, and the phaseable metrology stack are all documented for exactly this reason.
What moves the number
- BOI: machinery duty exemption applies across most of the equipment blocks, and the solar and automation spend converts into CIT-exemption headroom; the application precedes every purchase order (see boi.md). The blocks are vendor prices without Thai duty or import VAT, so the headline assumes promotion: without it, ~0.14M USD of duty and ~0.2M USD of import VAT (reclaimable later) come on top at the start fleet (estimate)
- Buy vs lease on land and building swings roughly 1.0M to 2.1M USD (~34M to 69M THB) of upfront capital, and also moves the launch date by about three quarters — see project-timeline.md
- Biggest uncertainty bands: metrology (partly a choice of ambition), the mastering/cutting room (bespoke vendor, no public pricing), the Newbilt Classic (no price on file), and land
- Currency exposure is real and is not modelled here. Revenue is mostly USD/EUR from export customers, the cost base is mostly THB, and the largest single equipment block is EUR-denominated and unhedged against an order that will not be placed for roughly a year (see project-timeline.md). A 10% move in EUR/THB between now and the Newbilt order is worth ~USD 25–35k on that line alone. Ask for the re-quote to state its currency and validity period.
- Every band narrows only with RFQs; the supplier map in equipment-suppliers.md lists who to ask