The DVD duplication project requirement
Alan works for a design company who specialise in the whole refurbishment of listed buildings. They give a task management service arranging and managing all project stages from brickwork to interior design. The organization spend lots of time and money on exhibitions related with their industry and Alan attends a variety of shows throughout every season in the UK and abroad. The key activity of the business at these shows may be the promotion of work that they have already carried out and projects that they are working on. To make the project information come your, lots of computer animation, computer generated mock-ups and visual imagery are utilized and, previously, these records has been compiled onto a CD which will be handed out to exhibition visitors who may be interested in their work or in utilising their services. The latest compilation of project information that Alan has come up with involves some very sophisticated CGI and high definition images. The files are far too large to fit onto a CD and he needs to find an alternative form of media which will be accompanied with printed information concerning the building project information and also instructions detailing the utilization of the promotional information.
The CDs are generally compiled by Alan in-house. He prints a brand using an inkjet printer and puts the CDs into a plastic wallet. Recently, he has noticed that their competitors at the exhibitions are providing their promotional information in top quality cases on discs with the print applied directly. Alan acknowledges that he will probably need a DVD or a USB thumb drive to store his new information. He also anticipates the requirement for a large run of units given the popularity they’ve garnered during the last couple of years and is doubtful that he has the full time or necessary resources to be able to reproduce the discs and printed information himself.
Sourcing a Reputable and Reliable DVD Duplication Company
Alan begins some internet research to find a trustworthy, top quality DVD Duplication service provider. He searches under 書刊設計 “DVD printing and duplication companies UK” and visits the websites of the companies on the first search page. He selects 5 of the finest sites with good customer comments that convey a top quality feel and requests quotes for 1000 printed DVDs from each to observe how they respond. The quotes he receives are all fairly similar but one of many companies follows up the request with an individual call from the sales person named Grant. The organization that Grant works for is merely a 30 minute drive away so Alan arranges a meeting to go over the existing project requirements and a possible future contract.
A Meeting to Discuss The Project
Two days later Alan meets Grant at his company’s offices and manufacturing unit to go through the alternatives for the project. Grant’s company has been operating for several years and his team has lots of experience with screen printing, lithographic (litho) printing and duplication of DVDs and CDs. He explains the benefits of printing directly onto the disc surface in comparison with printing onto and applying stickers. A display or litho printed DVD will soon be water proof so there’s no danger of harm to the print from moisture. The print can be quite hard wearing and can only be damaged through extremely rough handling of the disc or hard connection with abrasive surfaces. It can be possible to produce a watch catching disc, cost effectively by using a single or 2 colour screen printed design. Alan wants to complement what his competitors at the exhibitions are doing and has brought along some examples of their DVDs. Grant explains why these are litho printed DVDs whilst the print jobs derive from complex photographic images incorporating rendered and stylised company logos. Although litho printing a DVD is the most expensive printing route, if the system order number is 500 or even more then a fixed costs of printing the discs become merely a small area of the unit cost. Grant shows Alan around the printing facility and explains how the litho printing process works; in addition they discuss the facts of how to make sure a fruitful print job. Grant has the next advice:
Use a DVD template to produce the style – Your chosen DVD printing partner should be able to supply you with a template showing the outer and inner borders for the print, these may vary slightly from supplier to supplier whilst the template will soon be tailored with their particular print process. Ideally, the finished artwork should cover a place about 122mm square should not need the central disc hole removed although it is essential to be conscious that the hole will exist on the finished unit and so no pertinent information should encroach upon this area. As a principle, any text must be kept at the least 3 to 4 mm far from the outer and inner disc borders.
Picking a suitable photographic image – It is essential to know how a graphic will appear when printed. Dark photographs are not recommended unless the actual subject is well lit. Photos should be at the least 300 dpi in resolution and preferably higher than this, to ensure that the end result is an excellent quality, sharp printed image.
Lithographic printing considerations – Litho printing is not good for printing large areas of solid colour as a result of potential for inconsistency. It is way better suited for printing complex images with colour gradients and variations.
The DVD Duplication Process
Grant then takes Alan to the DVD Duplication suite so that he can easily see how their process works. The suite is just a clean room environment with dust extractors running constantly and all personnel are required to wear clean lab coats and hats whilst working there. The method is fully automated with only the initial delivery of printed DVDs on spindles being handled manually. The duplication is carried out using many duplication towers linked together and controlled by a main master drive. The master drive is packed with the data from the first master DVD and this then controls delivery of the data to all other DVD writing optical drives in the suite. The optical drives are like the units present in a standard desktop PC which burns the data onto a writable DVD utilizing a laser diode.
Loading and unloading of the optical drives is completed automatically using robot arms which handle the discs via a vacuum cup system. This removes the potential for harm to the discs through human error or incorrect handling. Also, loading and unloading of hundreds of discs at a time could be too frustrating and laborious to do by hand.
A standard DVD can simply accommodate 4.5 GB of data and you can find dual layer versions available which can hold twice that quantity of data but these tend to be much more expensive than standard DVDs and the duplication process is more expensive since it is more hours consuming.
Packaging the DVDs
Next, Grant and Alan discuss the packaging for the discs. There are lots of possibilities for Alan to choose from, including very basic packaging such as plastic or paper wallets, more protective options such as clamshell cases or trigger cases and then packaging types that will accommodate printed paper parts such as polycarbonate jewel cases and polypropylene DVD cases. Alan needs to include a good quantity of printed material and doesn’t want the booklet pages to be too small, so he opts for the conventional DVD case option which will be exactly like that offered by his competitors at the exhibitions. A standard DVD case is moulded from the flexible polypropylene material which will be hard wearing but lightweight. A clear plastic sleeve is bonded to the outside the case allow a published paper cover to be inserted which wraps around the case. Within the case is just a moulded stud which holds the disc securely in place.
Cases can be found that contain as much as 4 moulded studs to keep 4 discs or “swing trays” that clip to the within spine of the case allowing multiple DVDs to be housed in one case. Additionally, there are clips moulded into the within left-hand side of the case which hold any printed information in place. The printed booklet can contain as much as 16 pages if the spine is stapled but more if the spine is glued. Generally, a standard case booklet should be no more than 32 pages whilst the booklet becomes too thick to fit to the case. Cases with thicker spines can be found where they need to accommodate more information.