DVD

Information About DVDs

What is a DVD?

DVD (or Digital Versatile Disc) is the next generation of media which moves beyond CD in terms of its capacity (up to 17.5 Giga Bytes of data), speed and flexibility.

Like CDs, DVDs consist of a reflective metal layer embedded in a polycarbonate (clear plastic) disc. However, unlike a CD, DVDs can be double sided, and if required they can also contain two layers of data. The table below shows the capacities available. The reflective layer is covered with a pattern of millions of tiny pits which represent the ‘one and noughts’ that make up the DVD data. This data is recorded in a spiral (a bit like the groove on a vinyl disc): single layer discs start in the middle and wind towards the outside edge, whilst the second layer of a dual layer disc can start at the outside or inside, depending on whether continuous video play is required. 

Description	Nominal capacity	Type
DVD-5	4.7 GBytes	Single sided, single layer
DVD-9	8.5 GBytes	Single sided, dual layer
DVD-10	9.4 GBytes	Double sided, single layer
DVD-18	17 GBytes	Double sided, dual layer

The pattern of pits in the DVD is pressed from a master mould called a stamper (again a bit like vinyl records). Stampers are the end product of the process known as glass mastering. The data from the production master (normally a DLT) is used to switch a laser on and off (a laser beam recorder or LBR) which 'records' dots onto a photo coated piece of glass. This 'glass master' is then photographically processed and exposed to a powerful acid which burns pits into the surface of the glass where the dots were. The glass master is then electroplated to create the stampers which are used in the moulding of the DVDs

Once the discs have been pressed, any ‘on-disc’ printing is then applied using either a screen printing or on-disc litho (offset) technique. As standard we include printing in upto 5 colours within our prices. We supply finished ‘film’ which carries your design for both silk screen and litho (offset): computer to plate is not used for either process yet. DVD-5 and DVD-9 are single sided, allowing the non-playing surface to be printed. However DVD-10 and DVD-18 use both sides for playing, so the design must be limited to the central non-playing area and is only available in black and white.

All discs are examined for defects in the playing surface and sub-standard on-disc printing. Any discs which fail these quality checks are discarded. Finally, if required, discs are packed into cases, with any printed materials, before being boxed for despatch.

Packaging

A variety of packaging is now available for DVD. The main types comprise:

• Amaray style cases. Probably the most popular style, with a number of brands, all very similar. This is an injection moulded polyprolyene case designed specifically to protect the DVD. There is a clear outer which allows for the insertion of a video style wrapper (printed colour outside, blank inside - 4+0). Inside there is space for a booklet, together with the DVD itself. More details here.
• Super Jewel Case. Another popular format which resembles the CD jewel case but is taller. There is space for a booklet and tray card. These are available in three sizes. More details here.
• DVDigipak. A variant of the card and plastic Digipak designed to be a similar size to the Amaray style case and the Super Jewel Box. Available in a huge range of configurations. More details here.
• Standard Jewel Case. As used for ordinary CDs. This is the most cost effective solution, although it doesn't immediately differentiate the product as a DVD. Toi aid identification, special trays carrying the DVD logo are also available at extra cost. More details here.
• Ecopak. A card and plastic pack, as used by Warner's for their DVD-V movie discs.
• DVD Tins. Available in round or rectangular designs, with a variety of insert options, plus a special version to hold an Amaray style case. More details here.
• For other styles of packaging, check our Packaging page.

DVD Formats

There are already a plethora of different formats in use, such as:

DVD-V	Digital video with non-linear random access, picture quality way better than VHS, full surround sound capability, plus the possibility of adding text, graphics and a navigation interface to allow much more interactivity than has ever been available before. Unlike VHS, it is not possible to record video onto DVD (although you can on DVD recordables). DVD-V discs can be region coded to ensure that they can only be played in certain territories.
DVD-Rom	Computer read only storage with capacities currently up to 4.7 GB. You will need a DVD-Rom drive to use these discs (standard CDRom drives will ignore them). However DVD-Rom drives will also allow you to access current CDRom discs.
DVD-Ram	Computer re-writable storage discs. Capacity is currently about 4.1GB
DVD-A	Audio only discs. The standards for these discs has recently been finalised, and allows for several different versions of the same track (i.e. stereo and surround mixes) with the potential to use audio quality up to 192kHz, 24 bit. However with the rival SACD (Super Audio Compact Disc) format also available, it is by no means certain that DVD-A will flourish. Using our Pyramix digital audio work station, The Digital Audio Co can currently work at upto 192kHz, 24bit.
DVD-R/+R	DVD recordable discs are now available in four types: write once DVD-R, DVD+R, and rewritable DVD-RW and DVD+RW. Write once DVD is a generic format, originally developed for data storage, although it is now regularly used for pre-release copies of DVD-V, and even as masters. There are 3 types available: Authoring media (DVD-R) storing 3.9 GBytes of data. This is the most reliable and compatible type, which can also be used as a master format for both duplication and pressing (subject to certain limitations). It can only be written on an authoring drive. Authoring media (DVD-R) storing 4.7 GBytes of data. A higher capacity disc, but it can only be written on an authoring drive and is not recommended as a source for pressing. General media (DVD-R/+R/-RW/+RW) storing 4.7 GBytes of data. Cheaper media for the new generation of general media drives (fitted to many newer Macs and PCs). DVD-R/+R general media can be used as a master for pressing, although this is the least reliable method, unless the data is transferred to an interim format. Also, some programs which generate DVD-V data for writing to general media are not fully compliant and might not work correctly in all drives. Duplication of DVD-V to DVD-R/+R is used for short run copying but not all set-top DVD-V players can't read them! Dual layer DVD-recordables, offering just under 9GBytes of data. You need a special 'dual layer' drive in order to read or write these discs. DVD+R are the only dual layer recordable discs which can be used as DVD9 masters. Please note that DVD-RW and DVD+RW should never be used as masters for duplication or manufacture!

Other formats will be available soon.

DVD Authoring

Authoring is complex, and shares much in common with the creation of a CDRom. Typically the process for creating a DVD Video master involves:

• creating an overview of the functionality of the disc, often in the form of a 'story board', and allocation of the amount of storage to be used for the different assets. This stage is critical to the success of any disc.
• collection of relevant 'assets', for example -
  • video clips which need to be encoded to MPEG2 (NTSC for USA / Japan, and PAL for UK / Europe and almost everywhere else)
  • audio clips which need to be encoded in one of several formats depending on which region they are intended for and the type of disc being created, ie audio for an American DVD-V will normally be encoded using Dolby AC3, whereas a surround mix for a DVD-A disc might be encoded using MLP (Meridian Lossless Packing).
  • creation of graphics for menus
  • scanning of still images
• assembly of all assets, linked by the authoring software to determine the functionality of the disc, including any additional 'computer' programming, such as links to the internet or interactivity for training discs.
• testing the programme to ensure that every function and feature works correctly (most authoring systems feature an 'emulation' mode.
• creation of test discs on DVD-R. This stage depends on the type of disc being produced, and is currently limited to project of around 4.7 GBytes due to the capacity of DVD-R. Test discs should be tried on as many systems as possible, although it should be noted that not all DVD-V players will play DVD-R discs due to minor incompatibilities!
• creation of a DLT (Digital Linear Tape) or DVD-R master which can be sent for manufacture of DVDs. This should only be done once you are sure the project is complete!

Please call us for more details and costings.

Master Formats

There are 2 principle ways of supplying a master. Either on a recordable DVD, or a DLT (Digital Linear Tape). DLT is the fully professional method and is the most reliable. Recordable DVD is becoming more widely acceptable and if used with caution can yield good results. For a more detailed examination of formats and 'rules' for their use, please see our supplementary information page here.

PAL / NTSC and Region Coding for DVD Video

There is a lot of confusion surrounding the issue of region coding. There are really two issues here:

PAL / NTSC Compatibility

Video elements on a DVD-Video must conform to one of the two main international standards: NTSC (for USA, Japan and some other territories) or PAL (for UK, Europe and most of the rest of the world). It is not possible for a single DVD title to contain both PAL and NTSC video. In addition because the picture sizes are different, menus and background images must be separately created for PAL and NTSC. 

If you create an NTSC title for the USA and / or Japan, it is worth noting that many PAL players will also playback NTSC discs (subject to the TV to which it is connected also being able to display NTSC, which many newer sets can). Also note, that computers will playback PAL and NTSC without problem because they are not tied to a TV standard. So if you don't want to create versions for PAL and NTSC (often due to budget!), you will still reach a large part of the PAL market. BUT, there is a further complication : -

Region Coding

The DVD specification allows the producer of the master to determine the territories in which the disc will play (subject to the PAL / NTSC restrictions above).

The world is divided into 6 regions (1 to 6), with region 7 being unused and region 8 being for "International territory" (ships, planes etc). In addition, Region 0 is what is known as 'region free' which means it will work in all territories (subject to PAL / NTSC playback compatibility). There is a good explanation of the issue on Wikipedia here with a detailed list of countries and a map here.

A DVD can be set to region 0 (play anywhere), or any combination of regions 1 to 6 or 7.

Bar Codes

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.

CD | CDR | Icon Disc | Card CD | Packaging

Disc Comparison Page

DVD Manufacture Prices
Revised Prices From January 2006 And The Best Quality Available Anywhere
Glass masters	DVD Unit Costs	Packaging

In order to work out your manufacturing costs, you will need to include the following items:

• Glass master (for quantities up to 2000 units)
• Replication of DVDs
• Packaging if required (including case, any print, packing and wrapping)

Please read the 'small print' at the bottom of the page for final details!

For small orders or very fast turnaround, we can duplicate to DVD-R.

 

Glass Masters
DVD-5 (from DLT or DVD-R to our specification) - initial order 500 to 999 DVD-5	£285.00
DVD-5 (from DLT or DVD-R to our specification) - initial order 1000 to 1999 DVD-5	£210.00
DVD-5 (from DLT or DVD-R to our specification) - initial order over 2000 DVD-5	£0.00
DVD-9 (from 2 x DLT or dual layer DVD+R to our specification) - initial order 500 - 999 DVD-9	£570.00
DVD-9 (from 2 x DLT or dual layer DVD+R to our specification) - initial order 1000 - 1999 DVD-9	£420.00
DVD-9 (from 2 x DLT or dual layer DVD+R to our specification) - initial order over 3000 DVD-9	£0.00
DVD-10 (from 2 x DLT or 2 x DVD-R to our specification) - initial order 500 - 999 DVD-9	£570.00
DVD-10 (from 2 x DLT or 2 x DVD-R to our specification) - initial order 1000 - 1999 DVD-9	£420.00
DVD-10 (from 2 x DLT or 2 x DVD-R to our specification) - initial order over 3000 DVD-9	£0.00

 

 

Replication Quantity	500	1000	2000	3000	5000	10000
DVD-5 with 5 colour litho (offset) on-disc print	£0.58	£0.47	£0.43	£0.39	£0.38	£0.36
DVD-9 with 5 colour litho (offset) on-disc print	£0.63	£0.53	£0.48	£0.45	£0.42	£0.39
DVD-10 with black and white ring print	£0.63	£0.53	£0.48	£0.45	£0.42	£0.39

 

PACKAGING	500	1000	2000	3000	5000	10000
Amaray Style Packaging (more details here)
Case to hold 1 DVD (grey or clear, including insertion of disc, inlay and booklet)	£0.19	£0.19	£0.19	£0.19	£0.19	£0.19
Cases for more than 1 disc or other colours	Please contact us for other case prices
Inlay sheet (4+0)	£0.15	£0.08	£0.06	£0.05	£0.04	£0.03
Inlay sheet (4+4)	£0.20	£0.10	£0.08	£0.07	£0.06	£0.05
4 page booklet (4+1)	£0.11	£0.06	£0.05	£0.04	£0.04	£0.03
Other booklets	Please contact us for other booklet prices
Additional insertions (per move)	£0.04	£0.04	£0.04	£0.04	£0.04	£0.04
Wrapping	£0.02	£0.02	£0.02	£0.02	£0.02	£0.02
Super Jewel Box Packaging (more details here)
Super Jewel Box King (including insertion of disc, booklet and tray card)	£0.35	£0.35	£0.35	£0.35	£0.35	£0.35
Cases for more than 1 disc or other colours	Please contact us for other case prices
4 page booklet (4+1) and tray card (4+4)	£0.35	£0.16	£0.14	£0.12	£0.10	£0.08
Other booklet and tray card combinations	Please contact us for other booklet and tray card combinations
Additional insert (per move)	£0.04	£0.04	£0.04	£0.04	£0.04	£0.04
Shrinkwrap	£0.06	£0.06	£0.06	£0.06	£0.06	£0.06