Why is CD replication more cost effective for large orders?

When providing quotes for orders the question is sometimes asked, why is CD replication more cost effective than duplication for large orders? The main answer is because replicated CD’s or DVD’s are mass produced from raw polycarbonate material and printed very economically using offset litho print. Some set up up costs are quite high but these costs are usually absorbed by the manufacturer or pressing plant.

Initial set up costs for CD replication include the creation of a DDP fileset, glass mastering, metalwork stampers and of course the print plates. All of this work is quite lengthy and expensive but on large runs of 1000 or more discs these costs become negligible compared to the unit cost per CD or DVD. Once the order is ready to run on the production lines the process is very fast and in-expensive.

In most cases a CD replication order will include litho print to the disc face and probably some kind of litho printed booklet or inlay. Again on larger orders the use of offset litho print keeps the overall cost of the job to a minimum. Litho print for 1000 or higher is far more cost effective than using digital print and of course much higher quality of print.

So in essence CD replication is a no brainer for larger orders of around 500 discs and above. Yes CD duplication can work out cheaper for very small runs but it always worth comparing prices between duplication and replication to work out if the option to replicate is financially more cost effective.

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