CD / DVD Replication

CD or DVD replication is the manufacturing process used to produce high quality, professional CDs or DVDs the same as those you get when purchasing a film or album.

This is done by producing a glass master and pressing it onto aluminium/polymer blank discs. This gives a very professional finish and creates exact replicas (hence the name) of the original discs. DVD replication companies and brokers are the only ones who can do the job for you. There is also the option of silkscreen or offset printing onto the DVD surface as well as a variety printing and packaging options, including everything from a simple clear plastic sleeve called polywallet to a fully retail packaged shrinkwraped DVD as you find in the shops.

When using DVD Replication, what is DVD5, DVD9 and DVD10?

DVD replication is most often used for DVD5. This is a single sided, single layer DVD disc that can contain 4.38GB of data or up to 120 minutes of high quality video footage. They are often advertised as being 4.7GB, but this is not actually correct. The 4.7GB capacity is used to refers to the Japanese Gigabyte which is defined as 1,000 MB, rather than the 1,024GB that we use in UK England and Europe.

DVD9 is a dual layer, single sided, DVD disc. This is the format of most DVDs that you buy in the shops. This is the most common format used for DVD replication and only occasionally for DVD duplication. A DVD9 can hold 7.95GB of data which is up to 4 hours of video footage.

DVD10 is a single layer, double sided DVD disc. Have you ever bought a DVD that you can turn over and it plays on both sides, well this is a DVD10. As both sides contain data (up to 120 minutes or 4.38 GB per side) there can be no printing on the body of the disc. This is not very popular choice for either CD/DVD replication or CD/DVD duplication.

DVD Replication Process

The DVD replication process is much different from duplication as it requires injection moulding machines and other manufacturing equipment. This is why CD/DVD replication has a longer turnaround time (usually 10 - 14 days) and is always carried out with automated assembly lines in a large factory.

DVD Replication Media

DVD replication does not copy onto blank DVD-R discs as DVD duplication does. DVD replication is a manufacturing process making the discs from scratch. Then the data is physically pressed into the none-label side. This differs from DVD duplication, where the laser burns the information on the recordable side.

When is DVD Replication used?

DVD replication is used when producing 500 or more copies of a DVD. The setup costs of replicating DVDs are very high however once the glass masters have been created it then becomes very cheap to produce each unit once the first 1000 have been pressed. DVD duplication setup costs are low because there are no initial costs to get started. All you need is a blank disc or discs and your on your way. However as the quantity gets higher the costs remain the same so it starts to become less viable.

What is the purpose of DVD Replication?

DVD replication is used because either a larger quantity of discs is required than duplication can offer, or because a professional finish is required. If the purpose of mass producing DVDs is to sell in retail outlets then replication is the only option. Replicated DVDs will generally play on all DVD players and computers unlike duplicated discs. The DVD can be printed on the top using either screen or litho printing.