Cassette Manufacture

Background Information

Duplication Methods

There are two types of cassette duplication, 'in shell' and 'loop bin'.

• 'In-shell' duplicating is where the tape is recorded in a normal cassette shell; it is often done in 'real time' (i.e. a 45 minute tape takes 45 minutes to record). Your production master is copied directly onto the cassettes. The quality of the final cassette is determined by the quality of tape used, the stability of the cassette shell and the stability of the deck used for the recording. This method is normally used for runs of up to 200.
• 'Loop bin' duplication is a high speed process where your production master is transferred onto a loop bin duplication master (normally a half inch width tape containing both sides of the tape, which is joined to form an endless 'loop' in a 'bin'). This process is closely monitored, and the master is optimised using test tones from the production master and information supplied by ourselves.

  The duplication master is played continuously at high speed and a number of 'slave machines' are used to record onto large spools (pancakes) of cassette tape. This tape is then quality checked and wound into standard cassette shells. At this point any 'on-body' printing is then applied using a screen printing technique. As standard we include printing in one colour (normally white on a clear shell) within our prices. You will need to supply finished 'film' which carries your design.*

  After quality checking, the cassettes are packed into library cases with any inlay cards and shrink wrapped, ready for boxing and despatch.

Loop bin duplicating normally provides the best quality copies. The Digital Audio Company employs this process. Because loop bin duplication is a mass production system there is a minimum order quantity of 250. As part of the quality control process we supply a test cassette which is taken from a slave machine. This provides a representative sample which should be very carefully checked for defects by you before the other copies are run. Alternatively, the factory offer a listening service where they will check the sample (extremely carefully!) at no extra cost.

Packaging Options

Shells

Cassettes can be supplied in different types of shell:

• Clear shell with white on-body print
• White shell with blue on-body print
• Black shell with white on-body print
• Other shell / print combinations are available but at increased cost

Cases

The majority of cassettes are packaged in library case, but there are other options:

• Crystal clear library case - all parts are see through
• Clear / black library case - the hinged section is black
• Clear / coloured library case - the hinged section is a colour other than black
• Double library case - similar to single cassette cases but will hold 2 cassettes and a larger inlay card.
• Poly box - a translucent, slightly flexible case, smaller than a library box. Good for posting, but difficult to get inlay cards to fit.
• Slip case - a card or stiff paper sleeve with either 4 or 5 sides. Often used to package singles. Can be printed before assembly.
• Video cases - a video box with a special moulded insert which can house 1 or more cassette. Often used for the presentation of multi-cassette sets. Usually uses a paper insert for print.

Inlay Cards

Inlay cards can be printed single or double sided and printed either black and white or colour. A 'basic' inlay card will have the front page, and to the left of that a narrow spin and 'back flap'. It is then possible to have additional flaps to the right of the front page, which fold round inside the library case. Prices are dependent on how many additional flaps are used and whether the print is black and white or colour.

Bar Codes

If you think that your products will be distributed by a commercial distribution company, or will be stocked by a 'large' retailer, you should consider using a bar code. Bar codes are often used in conjunction with ISRC codes for automatic royalty payments by radio stations. Bar code numbers are controlled in the UK by e-centre. Visit their web site or for more contact information see our links page.

Each bar code number consists of three parts:

• the company prefix (which also identifies the country of the producer),
• the reference item number (which identifies the particular item) and
• the check digit.

In order to use a bar code number you must be a member of e-centre who will allocate you a company prefix to which you add a reference item number. Only members of e-centre can use bar codes. It is illegal to use bar codes if you are not a member of e-centre! Companies offering to sell or give you a bar code risk prosecution of themselves and you. In addition, it is quite possible that your royalties and revenue from sales could end up being paid to other bands sharing the same company prefix as you. Finally, don't be persuaded to stick the bar code off a chocolate bar, etc. on your CD - it could lead to mass confusion in Woolies.

MCPS

The Mechanical Copyright Protection Society administer the mechanical copyright of the vast majority of music in the UK on behalf of songwriters and publishers. If you are going to use someone else's material, you will almost always have to pay a royalty. In order to progress your manufacture, you will need to fill in an Application For License form (available from us or MCPS), regardless of whether you are recording your own or someone else's songs. Once the form is completed and returned to MCPS they will let you know how much you will owe (if anything) in royalty payments, and then once this is paid, they issue a License To Manufacture. Other than for runs of less than 500 units, we (along with all other reputable duplication facilities) will require a license before we can commence manufacture. Visit their web site or for more contact information see our links page.

Cassette Prices from October 1998

In order to calculate the cost of cassettes, you will need the following items:

1. Production master (price based on duration)
2. Duplication master (price based on duration)
3. Cassettes and cases (price based on duration and type of tape used)
4. Print (price based on number of flaps required and the number of colours used)

There is an example pricing below. See also re-ordering information and the small print.

Production Master

Creation of production master on DAT	Up to C60	£52.50
	Over C60	£69.00

Additional Audio Mastering / Editing: Eq, compression, multi-band dynamics, limiting, reverb, etc. £60.00 per hour

Duplication Master

1/2" Duplication Master	250 - 3000 units	£1.00 per minute of playing time
	Over 3000 units	Free Of Charge

.

Unit price for cassettes (minimum 250 units)

Duration	C20	C30	C35	C40	C45	C50	C55	C60	C65	C70	C80	C90
Ferric	£0.43	£0.45	£0.47	£0.48	£0.49	£0.50	£0.52	£0.53	£0.54	£0.56	£0.58	£0.61
Chrome	£0.47	£0.50	£0.52	£0.53	£0.55	£0.56	£0.58	£0.59	£0.61	£0.62	£0.65	£0.68

Price includes cassette in clear shell with on body print in a clear library case, insertion of inlay card and shrink wrapping.

Prices for runs of 250 - 3000 units. Over 3000 units, please call for a quotation.

Inlay cards

Number of extra flaps	0	2	4	5
Colour outside, black and white inside	£75.60	£100.80	£152.40	£172.80
Colour both sides	£164.40	£196.80	£236.40	Call

(price per 1000 units, minimum 1000 units)

Example pricing

1000 chrome cassettes from a master tape where Side 1 is 25:43 and Side 2 is 24:55 long, including an inlay card colour outside, black and white inside) with 2 extra flaps. In order to work out the cost of duplication:

1	Calculate the length of the cassette. To do this take the length of the longest side of the cassette, then round it up to the nearest minute and double it (Side 1 is the longest at 25:43, so round it up to 26:00, then double it, hence a C52).
2	Production master (less than 60 minutes)	£52.50
3	Calculate the price of the 1/2" duplication master (in this case 52 minutes).	£52.00
4	Multiply the unit price of the cassette by the number required (i.e.. chrome C52 would be 58p)	£580.00
5	Inlay cards	£100.80
6	Total (excluding VAT)	£732.80

Re-orders

For re-orders there are no production master or duplication master charges, just the unit costs of cassettes and print (if there are no spare inlays from previous orders).

The Small Print

• To guarantee the quality of our work we listen to all audio sources (DAT, CD, 1/4" etc.) as they are loaded in. We also monitor cassette production master DATs on a four head DAT machine to ensure that there are no audible errors.
• Manufacturing plants work to a tolerance of +/- 10% of the ordered quantity to allow failures to be removed during quality control. You will be charged for the exact number of units delivered. (Average is 3% over ordered quantity).
• All materials (tapes, discs, films, etc.) are the sole responsibility of the client.
• Print prices are for print from your supplied colour separated finished film.
• Delivery of manufactured CDs and cassettes is normally free of charge to one UK mainland address. Other carriage will be charged at cost.
• Prices accurate at time of printing.
• Accounts must be settled in accordance with invoice dates.
• All prices are subject to VAT at the current rate.
• Copyright clearance and royalty payments (where applicable) are the sole responsibility of the client. Please contact MCPS for advice. See our links page.
• The Digital Audio Company also offers a very comprehensive sound for TV and video service, with projects completed for Yorkshire TV, Anglia TV, Sky TV, Channel 4, as well as a large number of corporate clients and independent production houses. Call us for more details.
• For full terms and conditions, please click here.