Duplication Centre

There are two distinct technologies available for producing Optical Discs, whether CD, DVD or Blu-ray, and the choice of which to use for any given project is not always immediately obvious.

In order to help with that decision, it is important to understand the differences and the effects that those differences can have:

The first thing to remember is that whatever process is used, the data at the beginning and end are exactly the same, though there will be slight differences in the appearance and performance of the finished product.

Duplication is the name given to the process whereby the data are written to individual blank recordable discs using banks of high-speed writers.  Artwork is then typically thermal printed or paper labeled.

Replication is a much more involved process in which a glass master is first created from the original data. This master is used to make metal stamping discs which are used in presses to press the data wholesale onto polycarbonate blanks.  A reflective aluminium layer is then applied, and the discs are then lacquered, sealed and artwork typically silk-screened or offset printed.

All retail discs are replicated.

Replicated discs have no compatibility issues – they will play in all players and drives, whereas duplicated discs will sometimes not play on older stand-alone players or set-top boxes.  Recordable media are also more vulnerable to damage by prolonged exposure to sunlight.

The big advantage of Duplication is very quick turnaround time, and digital printing with no prepress charges, BUT the unit cost is higher than for replication, and duplicates can only have one layer of information, meaning their data capacity is up to 4 times less.

With Replication, the unit costs are lower (after mastering and other setup costs are taken into account), and multilayering is possible so the data capacity is much greater.

Because of the need for mastering etc., however, the turnaround time is longer, and the setup costs make it uneconomical for runs less than 500.

So, the ultimate decision is yours: is a lower price or time more important to you?

In general, though, up to 500, discs will be duplicated; over 10,000, discs will be replicated.  In between, the decision is yours!

Please do not hesitate to call Replicationcentre where our knowledgeable staff will be pleased to advise based on your individual requirements.

Most often when discussing CD and DVD replication, the conversation revolves around the production aspect. We don’t often think about the destruction or, in other words, what to do with the waste. As in many other industries, the CD/DVD replication business is trending toward sustainable packaging and other eco-friendly means of production, so that when discs reach the end of their life, they’re making the smallest possible impact on the environment.

Packaging

In addition to regulations trending toward more pollution controls for trashed CDs and DVDs, individual companies are taking the initiative toward sustainable packaging and printing. Recycled papers and cardboards are being used in the production of CD sleeves, and jackets can be made from 100 percent recycled fiber. These materials are not only eco-friendly, they are comparable to traditional products in terms of durability and longevity and aren’t limiting in terms of printing options. Plus, this new style of eco-conscious packaging is typically lighter and, therefore, cheaper to ship.

Printing

When it comes to printing, it’s difficult to avoid some of the harsh, petroleum-based chemicals used in the production process, but now the printing process is trending toward more natural inks. Soy and vegetable extracts can be used as an ink base, and several ink producers have introduced products into the market that are compatible with existing printers. And with these “green” inks you won’t lose anything in quality; your print jobs will be flawless just like they’ve always been.

Our Commitment

Here at Replication Centre, we strive to be at the leading edge of currently available technology, and are always on hand to advise on every aspect of the replication process, so don’t hesitate to give us a call to discuss your individual requirements.