DVD Duplication and Replication
When a project is completed it will most likely have resulted in the creation of a 'Master DVD' from which additional copies can be made. There are two different processes for making copies: DVD Duplication and DVD Replication.
Duplication
Ideal for quantities of less than 1000 discs and for 'on-demand' services, Duplication is the most common of the two options. The technology used is similar to that which is availble in most personal computers, however it is done much more effeciently through the use of a Duplication Tower. The process is fairly labour-intensive, and thus more expensive than Replication (on a cost per disc basis) however it requires very little set-up time and allows for these shorter runs of even a dozen or so to be completed very quickly.
Labeling is then done using an industrial-grade inkjet printer, which allows for high-resolution, full-colour printing, directly to the surface of the DVD.
Replication
When more than 1000 discs are required, Replication becomes the most economical option. The cost per disc drops drastically when using this method, however it involves a more lengthy and costly set-up process. For this reason, most replication facilities won’t do jobs smaller than 1000 units.
Replication begins with the creation of a Glass Master, which is a complicated process involving a Class 100 clean room, and a machine called a Laser Beam Recorder. The glass master is then copied using high temperature polycarbonate injection moulders able to make hundreds of copies an hour. Needless to say, the set-up process is more complicated, costly and time consuming than Duplication, however the cost effectiveness per disc, once the Glass Master has been created, is significant.
Labeling for replicated discs is done using a process called silkscreening. Though not as high resolution as inkjet printing, silkscreening is much more durable and long lasting, as well as cheaper on a per disc basis.
Although we do not offer 'in-house' Replication services, there are benefits to having us out-source this work for you. We are better able to communicate with these service providers, and as we tend to receive industry discounts your costs should not be higher than if you had used these suppliers directly.
Packaging
No matter which method is used, you are likely going to need some form of packaging of which there are several options.
Some clients opt for a standard Hollywood-style DVD case with a full insert. This is exactly like the movie cases on the shelves at Blockbuster, with full front and back cover, as well as the option to insert a booklet.
A more popular approach is to put your disc in a clear plastic CD-style slim case. The clear cover allows the disc’s face label to act as the cover art. This style of packaging comes in a variety of textures, shapes and colours.
Most cost effective is to simply have the discs slipped inside paper sleeves with a clear plastic window on the front allowing the disc's label to show through. Of course, discs can be delivered without a case if you plan on incorporating them into some other packaging.
In Summary
Duplication: Quicker turnaround, able to do small run jobs (minimum 10 discs), photo-quality printing on disc.
Replication: Lower cost per disc (once Glass Master has been created), more durable label, restricted to larger quantities.