Automated CD-R Recording, Duplication or Replication?
Over the past year the option of duplicating CD-Recordables as a viable alternative to CD replication has blossomed, and several new and previously existing CD-R automation devices are available. Today we'll explore some of the reasons for this, and talk about the reasons for choosing one or the other methods of creating multiple copies of discs.
First, some definitions
CD-Recordable, or CD-R
This method of producing CDs uses a desktop recorder to put a premastered image on a disc that has a polymer dye layer, using a laser to burn the data into the dye. Recorders are available that work at single speed (76 minutes for 650MB of data or 74 minutes of audio/video including time to record leadout), 2x, 4x and 6x. 2x drives are the most common, requiring 39 minutes for a full 650MB disc.
CD replication
This is the process of making a glass master from a premastered image, creating stamplers from the master, then pressing discs with the stamper using injection molding. Once the stamper is made and the machine is set up, a disc can be produced in a matter of seconds.
Duplication
Duplication produces many copies of a disc at once. Duplicators use CD-R media, and usually a bank of recorders controlled by a single processor. The number of recorders that can be in a single array is limited by SCSI protocols, and usually cannot exceed 17 plus one reader for the source material.
Replication requirements
Time
At least two days, usually more, up to weeks or even months is needed for creating master, stampers and scheduling press runs. Don't forget to include shipping time to and from the plant as well, and if they have to send the premaster to another facility to have the master made, that can add hours or even days to the turnaround time.
Coordination
Everything must be delivered to the replication plant together up front -- label artwork, packaging, premaster.
Quantity
Mass replication is generally unavailable for short runs (less than 1000-2000, sometimes 3000) because of the setup requirements. Every time an injection molding machine is stopped, some materials and time are lost, so manufacturers prefer to do large runs so the unit cost for small runs will be higher. Also, during a busy season many replicators do not like to schedule small runs at all because large runs are more profitable and less trouble for them. Some replicators will contract for a small number of discs, but actually charge for a minimum number and throw away the excess.
However, when large numbers of discs are required, replication is certainly the most cost-effective solution, with unit costs as low as $1.50 including mastering for large quantities on long turnaround times.
CD-ROM Packaging Today
What are the current packages being used today? Interestingly, the answer to this question is only limited by your imagination. Just as the applications for CD-ROM are numerous, so are the packaging options available. When the CD-ROM format was first introduced, it only made sense for most publishers to follow the current "standard" used in the CD audio industry -- the hard plastic jewel box. But, as handling costs and sensitivity for the environment have become concerns, packaging companies have focused toward developing smarter, more ecological packages rather than a bigger, egocentric ones. In light of these developments, a whole host of products began to emerge. Publishers are now able to choose from a full range of options: from expensive, high end packages to very inexpensive, low end ones. Each has its advantages and disadvantages. Typical methods used today are:
Jewel
boxes
Multiple
disc jewel boxes
Jewel
box and printed retail box combinations
Plastic
tray and paperboard variations
Vacuum
formed plastic tray
Sleeve
products which include the Univenture Safety-sleeves, paper, Tyvek, or
polybags
Self-mailers
Disc
caddies
Other
custom designed packages
With the changing needs of CD-ROM publishers, this list will only continue to increase in length and variety. That fact alone has caused some concern for replicating and fulfillment facilities as this lack of a "standard" for packaging can be a logistical and laborious nightmare. To add to this, several different companies have rushed to declare that their own packages should be the standard for DVD. So far there has been no agreement. Although a single standard for CD-ROM or DVD packaging may never develop, there are certain elements for finding the right package that all publishers can consider.
Conclusion
As you can see, there are more than a few issues involved with packaging CD-ROMs. Although the process can be daunting, allowing enough time and finding the right people to guide you through the process can make all the difference in the world. We hope that this article has shed some light on where to begin.
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