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A Comparison Between Replication and Duplication.
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Discs are manufactured from clear polycarbonate granules heated to more than 300°C. The molten plastic is injected into a mould cavity containing the master/stamper. During the few seconds that the mould is closed, all of the digital information is pressed into the plastic. | Information is burnt onto existing blank discs with a special dye layer. During the write process the dye layer undergoes a chemical change when exposed to the laser light beam, creating bits (marks) containing the data. The process can be done using a single CD/DVD writer or by using multiple-drives. |
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A fully equipped replication plant with mastering, injection moulding and printing facilities. There are fewer replicators than duplicators due to the expense involved in purchasing and maintaining machinery. Our DSR (Direct Stamper Recorder) mastering machine costs $3 million alone! | A CD/DVD burner and computer. Duplicators may use multiple stacked burners with automatic loading so that they can efficiently duplicate large quantities of discs. |
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Just like a CD or DVD bought from a retailer. Silver underside with professional face printing. | The underside is blue, due to the writeable layer of dye required to be able to burn the disc. |
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The most common methods are screen-printing and offset. Both are used in the production of discs by major record companies and achieve a high-quality result (the latter is the best choice for complex photographic artwork). | Similar to burning a disc at home, duplicators tend to print their discs using either an inkjet or thermal printer. |
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Close to 100%. Most CD or DVD players won't have problems playing a replicated disc, provided the disc is reproduced in line with red book (CD) or blue book (DVD) specifications and that the manufacturing equipment and materials used are of high quality. | It's estimated that around 97% of duplicated CDs will play without errors in all players, while only 90% of DVDs are expected to play without errors in all players. |
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With the data well embedded into the polycarbonate plastic disc and protected by a lacquer layer, replicated discs are extremely durable (so long as they are handled correctly). | The writeable dye layer in duplicated discs makes them more susceptible to damage and data loss. This is due to the dye deteriorating with age. High humidity and temperature as well as exposure to sunlight accelerates the problem. |
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Dependent on quantity, packaging, paper parts and printing requirements. For a new production, turnaround usually takes from 5 to 10 working days and for a repeat order 3 to 5. If all components including the master are available and thoroughly checked the turnaround can take less time with 1-2 days being achieved in special circumstances. | Approximately 2-3 days, depending on individual job requirements. |
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Replication is best suited to quantities over 300. There is no maximum order quantity that cannot be handled by replication - it is the most efficient way to produce large quantities of discs. | Better suited to short runs of less than 300. |
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Where the entire replication process is managed under one roof, quality control can be carefully managed and any problems identified and solved quickly by the correct personnel. Mastering and production machinery have built in testing mechanisms that ensure faulty masters and/or discs are removed from the production line. Specialist test equipment ensures that the discs conform to international specifications. | Duplicators are reliant on the quality of the blank CD-Rs they receive from external suppliers. Burners do not always burn CDs accurately so all discs need to be tested individually for variances. Most duplicators only have very simple test equipment to measure data errors and have no means of checking the quality of the electrical signals generated from of the disc. |
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