CD & DVD Duplication vs Replication: Analysis of both methods of Disc Production

Duplication Process - CD / DVD

Duplication is the process of Duplicating or "Burning" the data directly onto a Blank Printed CD-R or DVD-R  Media. The process is essentially the same as burning a disc in your PC, however on a much larger scale and with no direct software used.

Acceptable Formats Duplicated are:

• CD Audio, CD-ROM (Data)
• DVD Video, DVD ROM (Data)
• DVD-5 : Single Layer (4.7G)
• DVD-9 : Dual Layer (8GB)

Advantages of Duplication:

• Cost effective for short runs under 1000 Units
• The most flexible process as discs are produced much faster then replication, so content can be supplied the day before discs are required, where as a disc that is produced via the replication manufacturing process requires between 7-10  working days to complete
• Discs are printed "Digitally" so very low set up costs
• Part shipments are available , unlike if your disc is manufactured.

Disadvantages of Duplication:

• Not suitable for the retail market for Audio CD / DVD Video.
• DVD - Some compatibility issues may occur with DVD Players playing a DVD Video Disc, especially Dual Layer Discs.

More information on duplication can be found here.

CD/DVD Replication ( Pressed or Manufactured Disc)

Often called a  "Pressed" disc, this is the manufacturing process that creates a "Glass Master" of your original CD Master Disc. This Glass Master is used to generate a metal stamper which plays a similar role in the process to the old photo "negatives" or printing "plates". This Metal Stamper is then used to "press" multiple copies of each CD. 

In the case of DVD-9 - 2 metal stampers, which are used to then "press" multiple copies of your DVD.

Acceptable Formats are:

• CD Audio, CD-ROM (Data)
• Mini CD - 160 MB Capacity.
• DVD Video, DVD ROM (Data)
• DVD-5 : Single Layer (4.7G)
• DVD-9 : Dual Layer (8GB)

Advantages of Replication:

• Cost effective for quantities over 1000 Units
• All discs produced for retail market are required to be replicated
• The Optimal method to produce a DVD  Video and allows for Maximum Compatibility with DVD Video Players
• Premium offset quality disc print method
• CSS Copy protection is available for DVD Video projects.

Disadvantages of Replication:

• Minimum lead time for production is 7-10 Working Days
• Due to manufacturing process and high set up costs , production runs of 500 as a minimum
• Not as flexible a process as duplication as no part shipments are possible.

More information on replication can be found here.

Summary:

The Optimal process to produce your CD or DVD is to use the replication process, especially if your  project is distributed in a  retail environment or your are replicating quantities over 1000 units. If you don't require so many discs ( and most production runs are under 1000 units), then I would recommend the duplication process, and it will save you having hundreds of CD or DVD drink coasters as well!