Production Process

  • Premastering
    This is a process during which digital initial data is inspected and converted into a suitable format for CD/DVD replication (incl. stamper manufacturing).

    Premaster is usually called a master. Completed premaster, i.e. master, is usually delivered to the factory by the customer. Master can be on a physical carrier or as a disc image on ftp.
     
  • Testing
    During testing it shall be verified that the premaster delivered by the customer complies with the technical requirements and does not include digital recording errors.

    The conformity of the premaster and order formats shall be inspected. Masters are also tested on special testers so that each premaster shall be tested on the Eclipse tester comparing the conformity of the premaster with the technical requirements of the format. This shall guarantee that a disc replicated from a premaster shall work later on also in the respective players.
     
  • Mastering i.e. stamper production  (manufacturing of a matrix)
    Stamper, i.e. matrix, is prepared for production of industrial compact disc; this is disc’s data negative.

    We use Glass master technology -
    • A glass disc of 240 mm diameter and 6 mm thickness shall be covered with special light-sensitive (photoresistor) layer;
    • Premaster data is recorded onto the glass disc with a laser;
    • Covering the glass master with a nickel layer in vacuum. The so-called father-disc, i.e. positive, is obtained;
    • A mother-disc is manufactured from the father-disc; this is the negative of manufactured disc and used for manufacturing compact discs on the pressing line.
  • Pressing of discs
    Injection moulding method is used for industrial manufacturing of recorded compact discs. Stamper, i.e. matrix, is inserted to the pressing line’s mould. Heated and liquefied polycarbonate is sprayed under pressure to closed mould and polycarbonate takes the form of the matrix. The mould is chilled and a transparent recorded disc is obtained. DVD consists of two thin discs.
     
  • Metallization
    One side of the disc shall be covered in aluminium, so that the laser beam will not penetrate the disc and information on the disc could be read. CD consists of one disc, DVD of two thin discs.
     
  • Lacquering and gluing
    To protect information, CD shall be covered with a UV lacquer that shall automatically be dried on the production line.

    For DVDs, 2 thin discs shall be glued into one DVD with a special UV adhesive. Information on a DVD shall remain between the glued discs and additional protection is not necessary.
     
  • Optical test
    Both CD and DVD production line has a fully automated tester that inspects the quality of disc reflective surface. It will separate the discs below the standard from the discs that comply with standards.
     
  • Additional inspection of functionality and recording quality
    Before label printing, functionality of the manufactured discs is verified by "running" them in a respective player.
    At least 1-2 discs of each manufactured project are tested in the Datarius tester that verifies the quality of recording.
     
  • Printing
    Printing of a compact disc takes place according to the customer's order as either silk-screen printing (up to 5 colours) or offset printing (1+4+1 colours) technique.
     
  • Packaging
    Compact discs are packaged into packages chosen and ordered by the customer and wrapped into film if necessary. If necessary, we also produce the necessary cases and stickers so that the product shall be eye-catching. Finished products are packaged in to cardboard boxes. We label the boxes with respective order information and the address of the receiver.