Engineering Improvements at Diamond Black

At Diamond Black, our dedication to innovation and quality in vinyl record manufacturing is unwavering. Our recent engineering improvements have significantly enhanced our production processes, ensuring that every vinyl record meets the highest standards of excellence.

A Legacy of Quality: Toolex Alpha Pressing Machines

Our pressing machines are old, which is brilliant. They are Toolex Alphas, a testament to enduring quality. Toolex is still in operation today, producing modern machines, but their older models are just as good as the new ones on the market. Built in 1990 with incredibly strong, high-quality materials, these machines are a cornerstone of our manufacturing process. Over the years, we have upgraded the hydraulics, steam and water valves, pneumatics, and electrics to ensure they continue to perform at their best.

We currently operate 5 auto presses and 2 manual presses, with 2 more manual presses and 1 additional auto press being built to expand our production capabilities further.

In-House Innovation and Expertise

All of these improvements have been conceived and executed by our talented in-house team. Unlike other companies that rely on external specialists, we design, order components, and build improvements from scratch. The same engineers who developed these enhancements are still with us, ensuring a deep understanding and seamless integration of every upgrade. This self-reliant approach sets us apart from other companies that purchase presses ready-made and often lack the capability to operate or improve them without external help.

1. Modernizing Our Manual Presses

We have transformed our manual presses by replacing outdated relay-based controls with Programmable Logic Controllers (PLCs). The custom-built PLCs allow for fine-tuning of the presses, ensuring superior consistency and quality. With this advanced control, we can now produce high-quality picture discs and intricate designs such as half/half, color-in-color, and A/B color records with unparalleled precision.This upgrade has provided us with precise control over all aspects of the manufacturing process, from timing to hydraulics, and has significantly streamlined troubleshooting, reducing downtime and enhancing productivity.

2. Improved Hydraulic System

Our manual presses have been upgraded with a two-pressure hydraulic system, replacing the previous up/down high-pressure only system. This allows us to switch between low and high-pressure settings, providing greater control and preserving the integrity of our high-pressure hydraulic pumps. The manual press hydraulic systems are now integrated with the same pack as our automated presses, a goal we've pursued for years. The new control panel has made this integration possible, streamlining our operations and enhancing efficiency.

3. Pneumatic and Structural Upgrades

All pneumatic valves on our new auto presses have been upgraded, addressing obsolescence issues with the previous design. This upgrade ensures reliable and efficient operation, reducing maintenance needs and improving overall performance. Additionally, we have expanded our manual press capabilities by building two additional presses on-site. Utilizing existing frames and bolsters, we've equipped them with new panels, pneumatics, steam and water valves, and moulds. We are also building an extra auto press, increasing our auto press count from 5 to 6, further enhancing our production capacity and flexibility.

4. Cooling System Enhancement

Our cooling tower has been repiped and optimized for better water distribution. This upgrade has improved the cooling efficiency, allowing us to achieve lower temperatures with the same energy consumption. This enhancement ensures optimal conditions for vinyl pressing, further improving the quality of our records.

These engineering improvements reflect our commitment to staying at the forefront of vinyl record manufacturing technology. By continually enhancing our processes and equipment, we ensure that every record produced by Diamond Black is of the highest quality, offering an unparalleled listening experience.