How good is the quality of the records made on NEWBILT machinery?
The very best in the industry. Today, after about sixty years an estimated 100 of the first generation NEWBILT systems are still used in daily record production. Especially when it comes to delivering the best record quality, these systems with their bookmolds are the number one equipment choice.
What is the difference between a functional and an optimal record producing process?
Upon installing a NEWBILT system we make it function, and demonstrate the production of PVC cakes and vinyl records.
Will these records be of the best quality? Possibly, but not likely.
The characteristics of the PVC granulate used and the stamper quality in combination with ambient conditions and how the machinery is set influence where the optimal operating window lies. Process optimization is most likely required to achieve the best quality records.
Does NEWBILT equipment meet modern safety standards?
Absolutely. Our NEWBILT equipment meets today’s safety standards. In fact, also the refurbished equipment we supply meets those standards. It is mandatory by law.
Is NEWBILT equipment more efficient compared to its proven original?
Yes it is. Thanks to more precise machining technology, various product improvements, the use of high speed valves and modern Siemens machine controllers we achieve unmatched process optimization and a higher efficieny than ever before.
How records are made?
One can distinguish three major process steps to mass produce vinyl records:
-Mastering (also known as cutting)
Masters are typically created by either one of the following master cutting technologies; -Lacquer mastering or direct metal mastering (DMM)
The necessary process steps to create nickel stampers differ depending upon the mastering technology used to create the master.
The replication process consists of an extruder to create vinyl cakes from PVC-granulate, and a hydraulic press with the appropriate mold for the desired size and weight of the record.
The nickel stampers are placed in the mold together with paper labels and the vinyl cake, after which the pressing cycle can start. After the pressing cycle is completed the record is removed from the mold, the record is trimmed at the outer edge, and stacked to cool down, be inspected, packaged and shipped.
What does your company offer?
We offer machinery and after sales support to mass produce vinyl records in quantities typically upwards of a few hundred to millions of copies. We focus on replication and stamper making equipment.
How much does it cost?
You should budget upwards of €200.000 for setting up vinyl record replication. For the upstream equipment -stamper making and mastering- you should budget more. Through our network you can access stamper making and master cutting service providers.
Show us a video of a Duplex system in operation
Here are links to some videos.
How did you improve performance and durability?
We installed modern up-to-date hydraulic, electronic and process control systems, which are more robust and precise therewith enhancing productivity.
We replaced the retraction springs on the press’ main cylinder with hydraulic cylinders to assure more precise positioning.
The plasticizing screws undergo multiple surface treatments to better withstand the harsh chemical and thermal conditions inside the cylinder, improving their durability.
What is the cycle time?
Under 23 seconds per record is a safe number to calculate with for a NEWBILT Duplex system. We expect to improve on this as we proceed.
How does a semi-automatic system compare to a fully automatic system?
Today’s market is dominantly about small order sizes, even for “the majors”. For small order sizes a semi-automatic system is more cost effective than a fully automatic system. Also, special products like picture discs can be made on NEWBILT semi-automatic systems, which is not possible on fully automatic machinery.
Compare a general purpose vinyl extruder with a NEWBILT extruder
The NEWBILT extruder was developed specifically for vinyl records. It is small requiring minimal floor space. Its plasticizing unit is specifically designed for vinyl records; minimizing material and energy losses during stand-by time and optimizing color-change-over-times. Its modern Simatic control units allow for optimal process control, machine overload protection, and minimizing wear and tear in a manner unavailable in the past.
What is the life time of the molds you use?
Our partner Record Products of America has a unique and long track record in mold making and refurbishment for the record industry since day one.
What are the advantages of a NEWBILT system?
We couldn’t think of a lower risk proposition for obtaining this type of production equipment today.
The basic machine design is simple and proven. The product forming parts, the molds and the stampers, are standard off the shelve components, and have been proven over a thousand times.
In essence what we offer is process optimization on decades’ worth of proven technology.
Compared with pre-owned equipment we offer systems with high up-time, availability of spare parts, installation and after sales support and possible access to finance and leasing because the equipment is brand new.
Why do you recommend we source the steam boiler locally?
Local suppliers of steam boilers are familiar with the local rules and regulations surrounding the use and certification of steam boilers. As a global machine supplier we cannot possibly be aware of and keep up with the various local rules and regulations. Hence we recommend this equipment is sourced locally.