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DVD Replication & Packaging

Need DVD replication and retail packaging for independent or general film & video release? Or a bulk DVD replication run with basic sleeves for a magazine cover or showbag insert or individually addressed mailout? Or perhaps some copies of a corporate training video presentation?
If you require a project quote for DVD replication and packaging, we have dedicated sections in our instant quote and product gallery  Select a pack, choose your disc type and enter your project details to receive an immediate project estimate and artwork specifications via email.
Replicat offer an extensive range of retail quality DVD5, DVD9, DVD10 and mini DVD5 replication and packaging options to suit any NTSC or PAL DVD player and region. All Replicat discs are replicated (pressed) from a glass master, offset or screen printed, and supplied either in bulk or packaged.
We offer a range of professional retail packaging solutions and prepress advice to ensure that your products are visible on the retail shelf, or protected for short or long term transport and storage.

What is DVD Replication?

The DVD replication process involves a DVD replicator creating a glass master and stamper from your original disc, then injection moulding and printing the discs. In other words, we manufacture the discs from scratch. The minimum quantity for this service is 300 units per title.

The DVD replication process is very different from DVD duplication, which simply involves the burning or copying of content onto blank DVD +/- R or DVD +/- R DL media. A fuller description of the DVD manufacturing and printing processes are available in our technical library. We will always recommend that you press a replicated DVD for retail sale or use in a commercial environment due to the lower unit cost and more reliable playback. As DVD replicators and as our name suggests, Replicat, Australia, specialises in high volume disc replication.

A full description of the DVD replication and printing process, plus technical specifications for the various DVD formats and other information, is available in our technical reference library. The only thing you need to know however, is that if you can create a DVD-R master that plays correctly in a standard DVD player (not a computer, unless you are creating a software application or other DVD-ROM title), then we can create a replicated disc for you. Please be careful to check that you have set the correct TV standard (PAL or NTSC) and region code (usually open region) for your title. Maximum disc capacities are detailed in our quotations.

BD (Blu-Ray 25GB, 50GB) and UHD (Ultra High Definition 100GB) discs

Replicat can provide custom quotes for projects that have finished BD25 or BD50 masters ready to replicate. We can also quote for UHD (Ultra High Definition) 100GB discs through our affiliation with the only plant in the world that has fully automated UHD lines (not manual two pass lines). Please note that we cannot quote for BD and UHD disc projects unless clients have a finished master ready to replicate.

Our range of packaging for DVD includes:

Standard polypropylene DVD library cases with booklets (from 2 pages to 72 pages) and single or double sided outer sleeves. Cases are typically clear (for a double sided sleeve) or black, but we also offer a range of white and coloured cases for special projects. Please contact customer service for a list of available colours. We offer a wide range of multi disc DVD library case packs also – slimline (7mm spine double packs), standard and wide spine packs for 2 to 12 discs and multi disc blow-moulded and polypropylene story-book packs.

Tray-packs (digipacks, digipaks) with clear or black 188mmx133mm trays. These tray-packs (digipacks, digipaks) are available in 4, 6 or 8 panel designs with optional booklets and Australia’s largest range of booklet insertion options including horizontal pouch, diagonal pouch (first designed and produced by Replicat’s team), open and closed end pouches with a variety of concave, square thumb and long thumb cuts and specially orientated booklet gluing to either fold away from the pack or open up like a booklet. The DVD tray-packs (digipacks, digipaks) may be finished with a complete range of foils, laminates, recycled and standard coated or uncoated stock options, special inks and wraps. Replicat are Australia’s specialists in short-run complex DVD tray-pack (digipack, digipak) production.

Wallet packs, which allow all the flexibility of tray-packs (digipacks, digipaks) but without the plastic tray. A range of options are available for disc insertion into the wallets. Several panel sizes are available including retail 191x137mm panels and other panel sizes. If you have a custom wallet pack or tray-pack project, please contact customer service to discuss requirements and we will design a template to suit your project.

An extensive range of plastic and paper sleeves and protective polypropylene clamshell and standard mailer cases (flexible hard plastic e.g. DVD cases) and retail presentation polystyrene (hard clear plastic) standard, slimline and mini disc packs. And of course, you can still put a DVD into a CD case if you’d prefer.

Looking for a pack or sleeve that you can’t find here? If it exists, we can find it for you! Please contact our customer service team to discuss any packaging item that you would like to produce and we will source it.