DVD replication
DVD replication - live online pricing that updates instantly, with no hidden fees. A new design is approved on a preview before production.
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1,353.00 PLN
1,100.00 PLN net · 2.20 PLN/pc.
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DVD replication - product details
DVD replication means producing discs from a glass master, not writing onto ready-made discs. The data is formed physically in the structure of the disc as it is moulded. This is a solution intended above all for larger publishing, training and archive series, from 500 pieces. The price and lead time are shown directly in the calculator.
DVD replication - production from a glass master
In replication a DVD is made from scratch out of polycarbonate granulate. The data is formed in the structure of the disc during production, rather than written onto a finished disc by laser afterwards.
That is the fundamental difference between replication and duplication.
Replicated discs are durable and work well with older playback equipment too. That is why this technology suits releases that go out to customers, training material, archives and other series that have to stay readable for a long time.
Where DVD replication works best
DVD has far greater capacity than CD, so it suits material there is simply a lot of.
The most common uses are:
- films and video material - documentaries, promotional films, event recordings and film releases,
- training and e-learning - video courses and material for conference, workshop and training participants,
- technical documentation - manuals, catalogues, drivers, software and documentation supplied with equipment,
- archives and data collections - copies of documents, projects, photographs and recordings passed to companies and institutions,
- releases and conferences - complete sets of material prepared in a larger run, with uniform printing and packaging.
The whole run is produced from one glass master, so every copy has the same content.
Replication or duplication - which to choose
These are two different technologies, and the choice depends above all on the size of the run.
Replication requires a master to be made. This is a preparation cost incurred once, regardless of how many discs are produced afterwards. On a larger run it is spread across many copies, so the cost per piece becomes more and more favourable.
In return you get a factory-produced disc, durable and working well with set-top players.
Duplication means writing data onto ready-made discs using industrial duplicators. It requires no master, so it works better for short and medium series.
If you need a few dozen or a few hundred discs, look at DVD printing and duplication. Minimum runs there start much lower.
How a replicated DVD is made
Production consists of four main stages.
1. Premastering
First the master material is prepared and checked. We verify the data structure, the correctness of the recording and whether the content works properly. With video material the DVD-Video structure is checked as well.
2. Glass master
A laser writes the data spiral onto a glass disc. This stage takes place under controlled conditions, because even a small contamination here could be reproduced across the whole run.
The working stampers used later in replication are prepared from the glass master.
3. Replication
The discs are produced from polycarbonate under high pressure. A thin layer reflecting the laser light is then applied by vacuum metallisation, and the whole is protected with lacquer.
4. Printing
Your artwork is printed on the finished surface of the disc: a logo, a title, a description of the material, contact details or other graphics.
The finished run goes through a check of the readability of the recording and the quality of the printing.
Disc: DVDs
This product covers replicated DVDs. In the calculator you do not have to choose a disc type; you mainly set the run you need.
Available capacities:
- single-layer DVD - up to 4,7 GB, the standard variant for films, training and typical sets of data,
- dual-layer DVD - up to 8,5 GB, intended for longer video material and more extensive archives.
Supported standards:
- DVD-ROM - computer data, files, programs and documentation,
- DVD-Video - video material prepared for playback in set-top DVD players.
DVD holds around seven times more data than CD. Capacity is the most common reason for choosing this disc.
If the material is small and consists mainly of audio, documents or a presentation, look also at CD replication.
Runs - why they start at 500 pieces
The runs available in the calculator are:
500, 1000, 2000, 3000, 5000 and 10 000 pieces.
The minimum threshold is higher than for duplication, because a master has to be prepared before production starts.
The glass master is made once, whether 500 or 10 000 copies are produced afterwards. On a very small run the preparation cost would be spread across too few discs.
In a larger series its share in the price of a single copy falls and replication starts to make economic sense.
If you need fewer than 500 discs, look at DVD duplication.
How to send material
You can supply material for replication in two ways.
- A master disc - a previously checked copy with the finished content. You can send it by post or courier. Protect the disc well so that it is not scratched in transit.
- A disc image - a file sent by FTP. We accept NRG, ISO and DDP 2.0 formats.
Include an MD5 checksum with the image sent.
It is a short string calculated from the contents of the file. Once we have downloaded the material we can calculate the value again and compare it with yours. If both are identical, the file arrived complete and was not damaged during transmission.
With replication this matters particularly, because the master for the whole run is made from that material.
Preparing the print artwork
Prepare the disc print artwork to the following rules:
- working format: 120×120 mm,
- prepare a full square, without drawing the edge of the disc and the central hole,
- the background should run beyond the actual print area, so that no white edges appear after production,
- colour in CMYK, not RGB,
- remember that automatic conversion from RGB to CMYK can change the tone of the design,
- prepare photographs at 300 dpi,
- fine elements and thin lines are best prepared at 600 dpi,
- a PDF file with fonts converted to outlines, or a flattened TIF in CMYK with LZW compression,
- black texts: 100% K,
- keep fine elements away from the edge of the print area.
More information and examples are in our file preparation guide.
Packaging and assembly
The discs do not have to be supplied loose. We can prepare the whole set, that is place the discs in the packaging chosen, add booklets and inserts and prepare the set for shipping.
The options include:
- digipaks,
- ecopaks,
- card sleeves,
- CD-Box cases with covers.
It is most convenient to decide on packaging while ordering the discs. Production of all the elements can then be planned together.
How to order
Choose the run you need in the calculator. The price and lead time appear immediately with the quote.
After placing the order, send the material for replication - a master disc or a disc image with an MD5 checksum - and the print artwork.
If you are not sure whether the file is prepared correctly, write to us before sending it.
We work for publishers, companies, institutions and training and medical facilities.
DVD replication - questions and answers
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What is the difference between DVD replication and duplication?
Replication means producing a disc from scratch from a glass master. The data is reproduced physically in the structure of the polycarbonate while the disc is being moulded.
In duplication, data is written by laser onto a ready-made disc with a writable layer.
Replicated discs work well with older players and are intended above all for larger, repeated series.
Duplication needs no master, so it suits smaller runs better.
When should I choose replication and when duplication?
The most important factor is the number of discs needed.
DVD replication starts at 500 pieces. On larger series the cost of preparing the master is spread across the whole run and the technology becomes more and more economical.
If you need a few dozen or a few hundred discs, duplication on industrial duplicators will be the more convenient solution.
You can compare both technologies for a specific run.
What is the minimum run for DVD replication?
500 pieces.
The runs available in the calculator are:
500, 1000, 2000, 3000, 5000 and 10 000 discs.
These are the standard production steps for replication.
If you need fewer copies, choose DVD duplication, which needs no master and is therefore available from much lower runs.
Why is the minimum run higher for replication than for printing?
Because a glass master has to be made before replication starts.
This is a one-off preparation stage, carried out regardless of whether 500 or 10 000 discs are produced afterwards.
On a small run the cost of the master would fall on a small number of copies. On a larger series it is spread across the whole run.
With printing and duplication there is no master, so minimum quantities can be far smaller.
How much data fits on a DVD, and which standards do you support?
A single-layer DVD holds up to 4,7 GB, and a dual-layer one up to 8,5 GB.
That is around seven times more than a standard CD, which is why DVD is chosen mainly for films, larger archives and extensive training material.
We support the standards:
- DVD-ROM - computer data,
- DVD-Video - film material prepared for playback on set-top DVD players.
What are premastering and the glass master?
Premastering is the preparation and checking of material before actual production begins.
The data structure, the correctness of the recording and the readability of the material are checked. With video, the DVD-Video structure is verified as well.
The glass master is the source used in production. A laser writes the data spiral onto a glass disc, and the working stampers used to replicate the whole run are then made from it.
How do I send material for replication?
You can send a physical master disc or a disc image.
Send the master disc by post or courier and protect it well against scratching.
A disc image can be sent by FTP. We accept NRG, ISO and DDP 2.0 formats.
Include an MD5 checksum with the image. You will receive the FTP access details after placing the order.
Why an MD5 checksum?
MD5 is a short string calculated from the contents of a file. You can think of it as a digital fingerprint.
Before sending the disc image you generate its MD5 and pass it to us with the material.
After downloading the file we calculate the value again. If the results match, the file arrived complete and was not damaged during transfer.
With replication this is particularly important, because an error in the master material would then be reproduced across the whole run.
Will a replicated disc work in an older DVD player?
Usually yes. That is one of the advantages of a replicated disc.
The data is written physically into the structure of the disc, as in factory DVD releases that set-top players have handled for years.
Written discs use a recordable layer, and some older devices can cope with them less well.
For a release going out to many recipients that difference can matter.
How do I prepare the disc print artwork?
Prepare the artwork as a 120×120 mm square.
Do not draw the outline of the disc or the central hole. The background should run beyond the actual print area, so that no white areas appear at the edges.
Work in CMYK. Prepare photographs at 300 dpi, and fine elements preferably at 600 dpi.
Set black texts as 100% K.
Detailed requirements are in our file preparation guide.
What format should I send the artwork file in?
Best as a PDF in CMYK with fonts converted to outlines.
The second option is a TIF in CMYK, flattened to one layer and saved with LZW compression.
Keep fine elements and thin lines away from the edge of the print.
Before production starts we send a preview for approval. If anything needs correcting, we will contact you before the run is launched.
Will I receive the discs in packaging?
Yes, we can prepare the whole set.
The options include card sleeves, digipaks, ecopaks and plastic CD-Box and SLIM cases with covers.
We can also prepare booklets and inserts for the matching packaging.
If you order packaging together with the discs, we can carry out assembly straight away and hand over finished sets ready for sale or shipping.
Who is responsible for rights to the material recorded on the disc?
Rights to all content sent for production are the customer's responsibility.
That covers recordings, films, music, photographs, software and the graphics used in the print, among other things.
By placing an order you confirm that you have the right to reproduce the material in the given run.
We carry out production on the technical side and do not verify the legal status of the content supplied.
I don't have finished print artwork - what then?
Write to us and describe what should appear on the disc.
Send a logo, a title, a description of the content, contact details and any colour guidelines.
We can help prepare artwork that meets the technical requirements for printing on DVDs.
If you already have graphics prepared for a different disc, we will check whether they can be adapted.
How do I check the price and lead time?
Choose the run you need in the calculator on the product page.
The price and lead time appear together with the quote.
If you also need packaging, booklets or assembly, order them as separate products. For a more unusual configuration you can also write to us with a description of the whole release.