VIDEO Printing plus VIDEO Replication Originating from a Customer’s View

The DVD duplication project requirement

Alan works for a style company who specialise in the whole refurbishment of listed buildings. They offer a project management service arranging and managing all project stages from brickwork to interior design. The organization spend lots of time and money on exhibitions related to their industry and Alan attends a variety of shows throughout every season in the UK and abroad. The key activity of the organization at these shows is the promotion of work they’ve already carried out and projects that they’re working on. To make the project information come to life, lots of computer animation, computer generated mock-ups and visual imagery are employed and, previously, this information has been compiled onto a CD which will be given out to exhibition visitors who may be thinking about their work or in utilising their services. The most recent compilation of project information that Alan has put together involves some very sophisticated CGI and high definition images. The files are far too big to suit onto a CD and he needs to find an alternative solution form of media which is accompanied with printed information relating to the building project information and also instructions detailing the usage of the promotional information.

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The CDs usually are compiled by Alan in-house. He prints a label utilizing an inkjet printer and puts the CDs right 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 he will probably require a DVD or perhaps a USB thumb drive to store his new information. He also anticipates the requirement for a large run of units given the popularity they have garnered during the last couple of years and is doubtful he has the full time or necessary resources to manage 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 “DVD printing and duplication companies UK” and visits the websites 貼紙 of the companies on the initial search page. He selects 5 of the best sites with good customer feedback that convey a high quality feel and requests quotes for 1000 printed DVDs from each to observe how they respond. The quotes he receives are fairly similar but one of the companies follows up the request with a personal call from the sales agent named Grant. The organization that Grant works for is merely a 30 minute drive away so Alan arranges a meeting to talk about 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 consider 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 advantages of printing directly onto the disc surface in comparison with printing onto and applying stickers. A display or litho printed DVD will be water proof so there is no danger of injury to the print from moisture. The print can be quite strong and can only just be damaged through extremely rough handling of the disc or hard contact with abrasive surfaces. It can be possible to create an eye fixed catching disc, cost effectively using a single or 2 colour screen printed design. Alan wants to complement what his competitors at the exhibitions are doing and has taken along some examples of their DVDs. Grant explains why these are litho printed DVDs as the print jobs are derived from complex photographic images incorporating rendered and stylised company logos. Although litho printing a DVD is the absolute most expensive printing route, if the unit order number is 500 or more then a fixed costs of printing the discs become merely a small the main unit cost. Grant shows Alan across the printing facility and explains how the litho printing process works; in addition they discuss the important points of how to make certain a fruitful print job. Grant has these advice:

Use a DVD template to create the design – Your chosen DVD printing partner should manage to supply you with a template showing the outer and inner borders for the print, these may vary slightly from supplier to supplier as the template will be tailored to their particular print process. Ideally, the finished artwork should cover a place about 122mm square should not have the central disc hole removed although it is important 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 needs to be kept at the least 3 to 4 mm away from the outer and inner disc borders.

Selecting a suitable photographic image – It is important to know how an image will appear when printed. Dark photographs aren’t recommended unless the actual subject is well lit. Photos will need to be at the least 300 dpi in resolution and preferably greater than this, to ensure the end result is a great quality, sharp printed image.

Lithographic printing considerations – Litho printing is not good for printing large areas of solid colour as a result of prospect of inconsistency. It is much 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 he can easily see how their process works. The suite is really 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 procedure is fully automated with only the original delivery of printed DVDs on spindles being handled manually. The duplication is carried out using many duplication towers linked together and controlled by a central master drive. The master drive is loaded with the information from the first master DVD and this then controls delivery of the information to any or all other DVD writing optical drives in the suite. The optical drives are like the units within a standard desktop PC which burns the information onto a writable DVD employing a laser diode.

Loading and unloading of the optical drives is conducted automatically using robot arms which handle the discs with a vacuum cup system. This removes the prospect of injury to the discs through human error or incorrect handling. Also, loading and unloading of hundreds of discs at any given time could be too time consuming and laborious to complete by hand.

A typical DVD can very quickly accommodate 4.5 GB of data and you can find dual layer versions available which holds twice that quantity of data but these tend to be much more expensive than standard DVDs and the duplication process is more expensive because it is more time consuming.

Packaging the DVDs

Next, Grant and Alan discuss the packaging for the discs. There are many options available for Alan to pick from, including very basic packaging such as for instance plastic or paper wallets, more protective options such as for instance clamshell cases or trigger cases and then packaging types that could accommodate printed paper parts such as for instance polycarbonate jewel cases and polypropylene DVD cases. Alan needs to add a fair quantity of printed material and doesn’t want the booklet pages to be too small, so he opts for the standard DVD case option which will be exactly like that offered by his competitors at the exhibitions. A typical DVD case is moulded from the flexible polypropylene material which will be strong but lightweight. An obvious plastic sleeve is bonded to the not in the case to enable a published paper cover to be inserted which wraps across the case. Within the case is really a moulded stud which holds the disc securely in place. 

Cases are available that contain around 4 moulded studs to keep 4 discs or “swing trays” that clip to the inside spine of the case allowing multiple DVDs to be housed in one case. There’s also clips moulded into the inside left-hand side of the case which hold any printed information in place. The printed booklet can contain around 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 as the booklet becomes too thick to suit in to the case. Cases with thicker spines are available where they have to accommodate more information.

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