DVD replication is the process whereby DVDs are injection moulded for mass production. Key Production offers a high quality DVD replication service for quantities of 500 or more with a wide range of special packaging options and a full complement of related services including mastering and authoring.
Duplication is the process whereby blank DVDs are copied for low quantity manufacture. For quantities smaller than 500, Key Production offers a DVD duplication service. This service provides a cost effective yet high quality alternative for small runs and fast turnaround.
Key Production offers a high quality DVD replication and duplication service to clients across the UK. DVD manufacture includes packaging ranging from the simple use of a PVC or printed wallet or standard DVD box, to more elaborate special packaging such as a DVD Digipak. Key Production can also provide a comprehensive authoring service if you need your raw video material prepared for DVD manufacture.
DVD-5 DVD-9 and DVD-10
The standard DVD has a capacity of 4.7GB in a single layer single sided form known as DVD-5. This is over seven times the capacity of a CD (650MB) and allows full color printing on one site of the disc. Greater capacity can be achieved using DVD-9 (8.5GB) and DVD-10 (9.4GB) formats.
Supplying your master
Supply a DLT (Digital Linear Tape) or a DVD-R. If you require CSS encryption please supply DLT's and make sure you have "enabled" the DLT to be encrypted at the authoring stage. Please keep a back up copy of your DVD master and your artwork.
It is important to allocate your master a catalogue number. This number should be unique and will be applied to your DVD label and artwork so that each part is correctly married up to ensure the final product is correct. Examples are PTDDVD001 or ZXDDVD1005. Check DVDs from your collection to see examples of this kind of number.
A glass master consists of glass, optically ground and polished, then coated with phostoresist. A laser exposes a pattern of pits - the digitised sound information - into the photoresist coating. Exposed pits are etched away (developed) to generate the final pit structure. This is then coated in silver to form the master. Electroforming replicates the master layer in a nickel plating bath, forming a negative (father). Multiple positives (mothers) are made in order to produce negatives (sons) which are used as stampers in the moulding process.
The stampers are then used to make the DVDs in an injection moulding process. Hot polycarbonate is forced under high pressure into a circular mould containing the stamper and then cooled so the polycarbonate takes on the mirror image of the mould. A thin metal "reflective layer" is added to one side of the disc. This reflective layer allows the laser to read the digital data that is created by the pits. Finally a lacquer coating it is added to protect the disc. This process makes about 100 DVDs per hour.
DVD replication is similar to the process used for CD replication although DVD discs require much more stringent manufacturing tolerances and also require a bonding step that is not required by CD replication. The bonding process involves two thinner discs (0.6mm) being glued together to form the final disc. In the case of DVD-5, the recorded side is bonded to a blank disc. DVD-9 and DVD-10 have metallised pit structure on both discs.
The DVDs are then moved to a printing machine where, using the label artwork with your catalogue number, silk screen or litho on body printing is applied. (note on DVD-10 the available print area is around the hub area only). From there the discs are moved to the packing area and depending on the packaging are either machine or hand packed. Booklets, inlays and wallets are all machine packable, but items such as digipaks and stickering are hand packed and a charge is made per hand pack movement.
For details on how to supply your artwork, see Artwork and Specs. Please take time to read this, as it will almost certainly save you time in the long run.
Please send your artwork on a separate clearly marked CD-R or use our FTP facility. Please keep a back up copy of your artwork. Your artwork is generally checked within 48 hours of it arriving at Key Production (delays can occur at busy periods). Once it has passed checking we will create final proofs for you to approve by an emailed PDF. Please take note that PDFs can never be colour accurate and they may look different on your screen than they do on ours.
When the artwork is approved the DVD labels are sent to the plant and the booklets & inlays are printed, cut and creased and sent to the manufacturing plant. Please note that process colours are used as standard. Special colours will cost you extra. Once at the printers the catalogue number on the print is matched to that on the disc and the packing process is completed.