CDs & DVDs - Duplication Vs Replication
What is the difference?
Simply put Duplication is the process of copying the data/ audio on to pre-manufactured blank CDr’s / DVDr's and then printing the artwork on to the top of the disc.
It only takes a few days to copy, print and pack the discs because the orders are usually much lower, the set ups are small and the process is quite quick. Any printed parts would normally be digitally printed (as opposed to litho printed).
The Replication option is more cost effective on larger runs but it takes a lot longer to manufacture the product. A Glass Master is created from your master, and through a galvanic process, nickel Stampers are grown from the Glass. The Stamper is then loaded onto an injection molding line/ replication line and CD / DVD copies are replicated by pressing the Stamper into liquid polycarbonate that has been injection molded to the shape of the CD.
Once the discs are pressed, metalised, lacqured and UV cured, they will be printed directly to the surface of the silver discs. We can Litho print and Silk screen print to the disc On-Body depending on the look of the design. Any printed parts (Booklets & Inlays, Card Wallets, Digi-packs etc) would be Litho printed as opposed to digitally printed as per the low volume Duplication runs.
|MIN ORDER QTY||25 units||1,000 units|
|MAX ORDER QTY|| Normally around 500 units
|APPROX LEAD TIME||1-3 working days||10-14 wk days|
|DISK PRINT|| Digital, Thermal, Ink-Jet,
Duplication is most cost effective from 1 unit up to 500 units. Replication is more cost effective OVER 1,000 units
Duplication you can have as few as 1 copy if you really need to. The Replication entry quantity is 1,000 but there is no maximum.
Duplication doesn’t have the economy of scale that Replication has, but the set up costs for Duplication is much less.
4. Lead times
Duplication is a very fast service – often SAME DAY. This is because the pre run setups are minimal compared to the several process's of Replicated discs.
5. Manufacture Method
The Duplication process is the burning of content to a blank Recordable disc. The Replication process requires several time consuming steps just to get to the disc printing stage.
Final Product comparison
The Replication process is sometimes considered the more professional of the two techniques as Replicated discs are favoured for retail - however in reality, there is very little difference between a Replicated disc and a Duplicated disc from Amstore.
Amstore only use the highest quality, Grade 'A' blank media in our production process so we do not experience rejects. However, if the Blank media used to copy the data is a low end option, then playability issues have been known where some older CD / DVD players have not been able to play the discs. This could be a mixed result of the player and the media.
Because of the speed and flexibility that is needed with the Duplication process, Digital printing technology is favoured for the printing of paper parts instead of the Litho printing technique that is used for the printing of the paper parts in the Replication process. The Litho printing process of the paper parts follows the same rules as Replication i.e. cost effective over 1,000 units but takes longer and has complex pre-printing set ups.
The Litho printing of the paper parts takes place whilst the CDs and DVDs are being manufactured, so by the time the discs are manufactured and printed, the print should be ready in time for the discs and print to be married up in the chosen packing. Delays in one element (disc or print) will mean the order can’t get packed; often resulting in delivery delays of the finished product.
If you are interested in ordering replicated CDs or DVDs, or would like more information on our short run CD duplication and DVD duplication services, then please contact a member of our team using the enquiry form, or call us on 020 7232 5820. We also have CD DVD replication in South Africa