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Information about DVD Replication

What is DVD Replication?

DVD replication is the process of ‘pressing’ copies of a DVD glass master onto aluminium/polymer blank discs. The results of DVD replication do not normally vary, as much of the DVD replication equipment used is standard throughout the industry. DVD replication companies and brokers are the only ones who can do the job for you. They usually also offer silkscreen or offset printing onto the DVD surface as well as printing and packaging. Some will even offer customised shapes (e.g. star shapes, oval DVDs), and mini (8cm) DVDs.

When is DVD Replication used?

DVD replication is the manufacturing process used to produce 500 or more copies of a DVD. DVD replication is used for these larger quantities because although the set-up costs of DVD replication are very high, it is very cheap to produce each unit once the process is going. DVD duplication set-up costs are low, as all that is required for DVD duplication is a blank DVD-R and a DVD burner, which is why DVD duplication is used for smaller quantities.

What DVD Replication Gets You

DVD replication gives you simple duplicates of your master DVD that will play on all DVD players and computers. The DVD can be printed on the label side and will be silver on the data side unless a special colour has been chosen.

In DVD Replication, what is DVD5, DVD9 and DVD10?

DVD5 is a single sided, single layer DVD disc. DVD replication is most often for this type of disc, as it can contain up to 120 minutes of high quality video, or up to 4.38GB. They are often advertised as being 4.7GB, but this is untrue. The 4.7GB capacity refers to the Japanese Gigabyte which is defined as 1,000 MB, rather than the 1,024GB we use in the West.

DVD9 is a single sided, dual layer DVD disc. This is a format usually used for DVD replication and rarely for DVD duplication, which is for smaller orders. A DVD9 can hold up to 4 hours of video or 7.95GB of data.

DVD10 is a double sided, single layer DVD disc. Think of it as two DVD5s glued together, back to back. Printing is only possible around the hub as both sides contain data (up to 120 minutes or 4.38 GB per side). This disc has to be turned over for the other side of the disc to be read, much like an old cassette tape. It is not very popular for either DVD replication or DVD duplication.

DVD Replication Equipment

DVD replication equipment includes injection moulding machines and other heavy industrial equipment. For this reason, DVD replication is always carried out in a large factory with automated assembly lines.

DVD Replication Media

DVD replication does not use blank DVD-R media as DVD duplication does. DVD replication involves making the discs from scratch and physically pressing the data into the none-label side, creating a series of pits that represents the information. This differs from DVD duplication, where the laser burns dots into the dye on the recordable side to fool the DVD player into thinking it has pits cut into the DVD.