The DVD duplication project requirement

Alan works for a style company who specialise in the complete refurbishment of listed buildings. They give a project management service arranging and managing all project stages from brickwork to interior design. The business spend a lot of time and money on exhibitions related to their industry and Alan attends many different shows throughout the year in the UK and abroad. The key activity of the business at these shows could be the promotion of work they have already carried out and projects that they’re working on. To make the project information come to life, a lot of computer animation, computer generated mock-ups and visual imagery are employed and, previously, these records has been compiled onto a CD which can be given out to exhibition visitors who may be interested in their work or in utilising their services. The most recent compilation of project information that Alan has assembled involves some very sophisticated CGI and high definition images. The files are far too large to match onto a CD and he needs to find an alternative solution kind of media that will be accompanied with printed information concerning the building project information and also instructions detailing the use of the promotional information.

3D Printing with Cellulose

The CDs are generally compiled by Alan in-house. He prints a tag utilizing an inkjet printer and puts the CDs in to a plastic wallet. Recently, he’s noticed that their competitors at the exhibitions are providing their promotional information in good quality cases on discs with the print applied directly. Alan acknowledges that he will most likely need a DVD or perhaps a USB thumb drive to store his new information. He also anticipates the requirement for a big run of units given the popularity they’ve garnered over the past few years and is doubtful that he has the 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 locate a trustworthy, good quality DVD Duplication service provider. He searches under “DVD printing and duplication companies UK” and visits the web sites of the businesses on the first 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 among the companies follows up the request with an individual call from a sales agent named Grant. The business that Grant works for is merely a 30 minute drive away so Alan arranges a meeting to discuss 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 many years and his team has a lot 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 to 貼紙印刷 printing onto and applying stickers. A screen or litho printed DVD is likely to be water proof so there’s no risk of injury to the print from moisture. The print is also quite hard wearing and can only just be damaged through extremely rough handling of the disc or hard connection with abrasive surfaces. It is also possible to produce an eye fixed catching disc, cost effectively using a single or 2 colour screen printed design. Alan wants to fit what his competitors at the exhibitions are doing and has had along some types of their DVDs. Grant explains these are litho printed DVDs since the print jobs are based on complex photographic images incorporating rendered and stylised company logos. Although litho printing a DVD is the most expensive printing route, if the machine order number is 500 or maybe more then the fixed costs of printing the discs become merely a small part of the unit cost. Grant shows Alan around the printing facility and explains how a litho printing process works; in addition they discuss the important points of how to make sure a successful print job. Grant has these advice:

Make use of a DVD template to produce the design – Your chosen DVD printing partner should be able to supply you with a template showing the outer and inner borders for the print, these can vary slightly from supplier to supplier since the template is likely to be tailored to their particular print process. Ideally, the finished artwork should cover an area about 122mm square should not have 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 rule of thumb, any text needs to be kept at least 3 to 4 mm away from the outer and inner disc borders.

Selecting a suitable photographic image – It is essential to understand how a picture will look when printed. Dark photographs are not recommended unless the specific subject is well lit. Photos will have to be at least 300 dpi in resolution and preferably higher than this, to ensure the outcome is an excellent quality, sharp printed image.

Lithographic printing considerations – Litho printing is negative for printing large areas of solid colour because of the prospect of inconsistency. It is much better fitted to 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 really a clean room environment with dust extractors running constantly and all personnel are expected to wear clean lab coats and hats whilst working there. The procedure is fully automated with only the first 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 laden up with the info from the first master DVD and this then controls delivery of the info to all other DVD writing optical drives in the suite. The optical drives are like the units present in a typical desktop PC which burns the info onto a writable DVD using a laser diode.

Loading and unloading of the optical drives is performed automatically using robot arms which handle the discs via a vacuum cup system. This removes the prospect of injury to the discs through human error or incorrect handling. Also, loading and unloading of countless discs at the same time will be too time consuming and laborious to accomplish by hand.

A typical DVD can very quickly accommodate 4.5 GB of data and you will find dual layer versions available which can take twice that amount of data but these are generally much more costly than standard DVDs and the duplication process is more costly since it is more hours consuming.

Packaging the DVDs

Next, Grant and Alan discuss the packaging for the discs. There are many possibilities for Alan to pick from, including very basic packaging such as for example plastic or paper wallets, more protective options such as for example clamshell cases or trigger cases and then packaging types that could accommodate printed paper parts such as for example polycarbonate jewel cases and polypropylene DVD cases. Alan needs to incorporate a good amount of printed material and doesn’t want the booklet pages to be too small, so he opts for the standard DVD case option which can be just like that offered by his competitors at the exhibitions. A typical DVD case is moulded from a flexible polypropylene material which can be hard wearing but lightweight. A clear plastic sleeve is bonded to the outside the case allow a printed paper cover to be inserted which wraps around the case. In the case is really a moulded stud which holds the disc securely in place.

Cases are available that have around 4 moulded studs to put up 4 discs or “swing trays” that clip to the interior spine of the case allowing multiple DVDs to be housed in one single case. There are also clips moulded into the interior 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 typical case booklet should really be only 32 pages since the booklet becomes too thick to match in to the case. Cases with thicker spines are available where they need to accommodate more information.

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