CD/DVD Disc Replication:
This process is typically most cost effective for long runs of discs from 1000 to 100,000 and up. This process requires some set up and has a little longer turn around. Replication is done from scratch, and CDs/DVD's are injection molded from plastic pellets and then are covered in reflective material and stamped with the information. Disc faces are printed by
transferring ink through a fine mesh screen (silk screen process).
CD/DVD Disc Duplication:
This process uses the CD-R or DVD-R discs people normally use to burn their masters from their office. Our process utilizes the HIGHEST quality CD-R/DVD-R blanks and we will use a 300 dpi to 600 dpi thermal process to print either black text or full color on the disc faces.
This process is especially cost effective for shorter runs of discs from as low as 10 DVD's up to 500 DVD's or 50 CDs up to 1000 CDs. The turnaround is also much faster than the disc replication process, duplicated discs can be produced in as little as 24 hours for up to approx. 500 CD disc orders.
Are There Noticeable Differences?
Both CD duplication and CD replication extract data from the original in the same way. In terms of manufacturing, however, this is where the similarities end. The finished product of either process performs in the same manner, although there will be difference to the eye depending upon the whether the discs are digitally, screened, or offset printed.
Advantages of CD/DVD Duplication
The standard turn-time is 2-3 business days, even for runs up to 5,000 units.
Digital full color printing is available with no prepress charges.
Disadvantages of CD/DVD Duplication
The cost per unit for duplication is higher than replication.
DVDs can have up to 2 layers of information on each side of the media. DVD-R duplicates can have 1 layer of information on the entire DVD.
Most duplication facilities are small and are commonly limited to hand assembly of the media into packaging as a result of their low volume runs.
Advantages of CD/DVD Replication
The unit costs are lower than duplicated discs.
Both offset printing and screen printing is available for replicated discs.
Replicated DVDs can contain 1 layer (DVD-5) of information, 2 layers on one side (DVD-9), 1 layer on each side (DVD-10) or 2 layers on each side (DVD-18). Many replication facilities are not yet set up for DVD-18 replication.
Disadvantages of CD/DVD Replication
The standard turn-time is 7-10 business days, longer for runs exceeding 100,000 units. Standard duplication turn times are 2-3 business days.