By J.R. Bookwalter

DVD-R duplication is a cost-effective method for small-quantity distribution, and allows you to keep the process largely in-house, if you so desire. But what if your project happens to catch the eye of a large retailer or your needs exceed 1,000 discs for a single title?

That’s where replication comes into play, which is the process of taking your DVD-R master, creating what’s known as a glass master, and actually pressing discs instead of burning them via duplication. This method is similar to the old vinyl recordings of the past, where plastic is poured into a stamper that can spit out large quantities of discs in no time flat. While some replicators will do as low as 500 pieces (usually not cost-effective), generally this method is considered best for 1,000 or more discs (with 2,000 discs minimum as the norm).

There’s another compelling reason to go with replication over duplication, especially if your project is a commercial feature, documentary or special interest subject: Netflix! While Amazon and many of the wholesalers who handle DVDs (Ingram, Baker & Taylor, VPD, et al) don’t expressly forbid DVD-R product as long as it’s professionally packaged, Netflix flatly refuses them. While it’s probably a holdover from the days when compatibility was a big issue with many players, replicated discs are also considered more durable (a big issue when your whole business is centered on discs being shipped through the mail). So if you’ve got your eye on a Netflix sale, it’s worth considering replication at the outset to save yourself headaches and additional expenses later down the line.

Before you approach your replicator, you’ll need to know what type of DVD you’re making. Most common is a DVD-5, which is essentially the same as a standard single-layer DVD-R and holds approximately two hours of content (4.4GB). Many commercial discs are DVD-9, which is similar to dual-layer DVD-R discs and can hold 3-4 hours of content (7.95 GB). There are other less-common options such as DVD-10 (a double-sided disc, basically two separate DVD-5 masters) or DVD-18 (also double-sided but two DVD-9 masters), but manufacturing costs will increase accordingly.

Most companies these days will accept the DVD-R disc burned from your software for replication, but it’s worth noting that these can’t be used if you need region coding, CSS encryption or Macrovision copy protection (which requires a separate license and per-piece fee).

Region coding is used for tying the disc to certain countries; for instance, all of North America is Region 1. If you want to be able to sell your content all over the world, it’s not a bad idea to leave it region-free (also known as all-region or Region 0), although most international buyers will probably have a player that defeats the region coding anyway. CSS encryption is supposed to protect the disc from being copied (usually at additional expense during replication), but in reality there are so many commercially available software programs to crack it that it’s probably not worth the extra cost (unless it helps you sleep better at night).

In these cases, a DLT tape master is required, which adds to the overall cost. If you do your own authoring, you’ll want to hit eBay in search of a used DLT drive for cheap — but be forewarned, many of them will use the now-ancient SCSI connection to connect to your computer. Some service bureaus also offer DLT output, where your authoring session can be sent on hard drive. Note that regardless of the storage space listed on your DLT tape, a DVD-5 will always require a single tape and a DVD-9 will always require two tapes (one for each layer). Many replicators now accept dual-layer DVD-R as well, so be sure to inquire before spending the extra money to go DLT.

Prices vary wildly on replication, depending on how the disc will be packaged, but the average disc will run $1.00 to $1.50, complete with the disc itself (with full-color face label), wrap, case and shrink wrap. Replicators usually use a more attractive method of shrink wrap called “overwrapping” with folded edges at the top and bottom like the commercial discs you see in stores. While this gives the disc a more professional polish, you’ll want to keep in mind that the maturing DVD market is oversaturated and most self-distributed titles will be lucky to sell a couple thousand copies over time.

If you want to be able to sell your replicated disc to Netflix but keep your costs and inventory low, consider having bulk discs made (no wrap or case). Netflix generally prefers to receive inventory this way since that’s how they’ll be shipping the discs to their members (they won’t have to remove the shrink wrap and discard the case and wrap), and it’s cheaper to ship, both from your replicator and to Netflix. For other vendors that require packaged discs, you can always purchase a quantity of cases and have the wraps printed, then assemble them yourself as orders come in.

Companies such as U.S. Digital Media and Discmakers offer replication as well as duplication, but their prices tend to be higher than going with a vendor dedicated to replication, such as Chicago-based Idea Media Services. Idea is a full-service house with replication facilities in California and a dedicated, attentive staff who takes care of your needs from purchase order to shipping (and in my experience, one of the lowest-priced, too).

While replication is usually a bigger cash outlay than duplication, it’s generally considered the best route for commercial distribution. With a little creative planning, you can have the best of both worlds — professionally manufactured discs while cutting a few financial corners to keep your costs lower.

Next Up: Thoughts on Web Distribution (Part III of III)

A Versatile Disc Indeed (Part I of III)