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Optical Disc Packaging |
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Disc duplication projects require disc labeling and some form of protective packaging. Sometimes disc duplication projects result in excessive printing, packaging or both. Budget resources spent on elaborate graphics or packaging is often unnecessary. However, it goes without saying that professional appearances and first impressions can be important. The primary objective for most commercial disc duplication projects is delivering content embedded on discs – using reliable and cost-effective methods. Packaged discs targeted at consumers or mass-merchandising necessitates eye-catching and noticeable graphics, that compels and lures shoppers to pick-up an item from a retail display. Decorative graphics may be tied with a strategic marketing theme, musician or new movie release. Retail packaging also necessitates plastic wrappers to help prevent intrusion and pilferage. Electronic security devices are sometimes embedded with retail disc packaging. But for most commercial disc duplication projects, functionality and simplicity often works best and accomplishes desired objectives. There are probably two-hundred different combinations to package optical discs. Selecting the method best suited for a particular project requires some advance considerations related to the target recipients, probable disc usage, methods employed to distribute discs and disc identification. Essentially, there are 7 standard methods used to package individual discs for duplication projects. These include:
Disc Sleeves Disc sleeves are produced from a variety of materials, including: paper, polypropylene, vinyl, Tyvek® and paperboard. Some sleeves have an adhesive backing for surface attachment to other materials. Disc sleeves can be transparent, semi-transparent or opaque. Normal colors are white, black and red – with white sleeves by far the most common. Sleeved discs can be integrated and included with other materials, shipped in bulk, handed-off to clients, internal personnel or colleagues. Polypropylene sleeves are sometimes used for industrial disc packaging applications where exposure to heat, moisture and chemical environments may occur. Vinyl “safety-sleeves” normally include a non-woven polyester fabric to help prevent dust and scratches on disc read-out surfaces. Some safety-sleeve designs include a separate pocket for insertion of a booklet, printed material or business card. Some software companies ship program discs using simple economical paper sleeves. Paper and Tyvek® disc sleeves are available with see-through windows, allowing visual confirmation of labeled discs without removal or handling. Other sleeve designs have “tamper-evident” seals or resealable flaps. In many cases, disc sleeves can offer the least expensive method to package optical discs for distribution.
Standard Jewel Cases Standard jewel cases have long been the packaging of choice for single audio discs from the early 1980’s – when CD’s began replacing vinyl LP records. Their transparent covers provide a canvas to display colorful printed inserts conducive to retail merchandising. Most jewel cases are constructed using a two-piece front & back hinged outer case. Individual trays are then inserted to accommodate one or more discs. The front cover has tabs for including a paper insert or booklet. The back of the case is often transparent for inclusion of a rear internal paper insert. Some jewel case designs combine a molded hinged disc-tray in one piece, serving as the rear outer case – with a clear plastic front. Although inexpensive, jewel case plastic is hard and brittle. Dropping one on a floor or desktop often results in snapping-off molded hinges or creating stress cracks that lengthen with use and time. Road-warriors that stuff jewel cases into computer notebook bags often experience damage. For many commercial disc duplication projects, jewel case packaging is no longer considered for distribution.
Polypropylene Jewel Cases Some cases incorporate one-piece molding using soft polypropylene to resemble a traditional jewel case design. They offer comparable functionality – but are far more durable - and can usually accommodate one or two discs. Tabs molded into the front cover allow for a paper insert. Due to the single mold construction – rear paper inserts are not possible. But another variation offers an external clear overlay that wraps around the outside of the case, allowing a paper insert to cover the front, back and spine, while still incorporating internal tabs for inclusion of a booklet.
DVD - Amaray Cases At the time feature-length movies were released on DVD, an alternative disc packaging dissimilar to jewel cases was desired. DVD or Amaray cases are available in multiple variations. One-disc and most two-disc versions are molded with one-piece construction. They’re made from soft polypropylene plastic and provide good durability. The standard color is black but additional color options include white, clear and dark gray. Color options are not available for all variations. Some cases accommodate up to eight discs, incorporating internal disc holders that function like pages in a book. Alternative designs can accommodate 2, 3 or 4 discs in a case – without internal page holders. DVD cases are molded with integrated snaps that prevent accidental or inadvertent opening when properly closed. Some case designs incorporate molded push-button release hubs to secure discs in place and provide easy removal – without having to “flex” disc media. Some DVD cases include molded tabs in the inside front cover for booklet or documentation insertion. DVD cases appropriate for disc duplication projects have a clear overlay that wraps around the outside of the case, allowing a paper insert to cover the front, back and spine. Some Amaray cases are designed with attributes suitable for disc archive applications. Cases will accommodate DVD as well as CD media.
Slim DVD Cases A case similar to the DVD case – but with a slimmer and lower-profile – is the Slim DVD case. Vertical and horizontal dimensions are the same as a regular DVD case, but they usually have only a quarter-inch thickness when snapped closed – about half the thickness of a standard DVD case. When compared to a standard DVD case storing a comparable discs quantity, the lower-profile case can increased bulk shipment densities and provide for larger shelf-storage capacity. Many of the same desirable attributes that exist in its thicker Amaray cousin – also apply to the Slim DVD case such as: one-piece molding, soft polypropylene plastic, integrated closing snaps and clear overlay that wraps around the outside of the case, allowing a paper insert to cover the front, back and spine. Some variations use molded push-button release hubs while others do not. Color choices are usually limited to black and clear. Due to its lower-profile, most cannot accomodate internal booklets. Slim DVD case options allow storage of one or two media discs. Some Slim DVD cases are suitable for disc archive applications.
Clamshell Cases Clamshell cases are inexpensive, versatile and rugged. They are used for CD or DVD distribution usually as an alternative to disc sleeves – when more robust disc packaging durability is desired. Cases are made from light-weight, break-resistant polypropylene. They are available in circular, rectangular and other geometries. Most clamshells are transparent allowing visibility of labeled discs – eliminating the need for additional print labeling expense. All variations incorporate a molded disc-positioning post and snap-closures to keep the case shut. Most are thin – around 3/16” thick – and are lighter than jewel cases allowing for lower shipping costs. Common clamshell case colors include clear, green and blue see-through colors. Some variations meet U.S. Postal Service regulations and can be mailed directly. Other versions have holes for storage in standard 3-ring binders. Clamshells accommodate one disc.
Disc-Hubs An easy and inexpensive method for securing discs to practically any item is with disc hubs. They adhere to paper, SBS board, plastic, cardboard, vinyl and other materials. Disc hubs are small and are typically made from vinyl or a thin foam material which is die-cut.
Custom Disc Packaging If discs distributed to recipients require packaging that conveys urgency, compels individuals to play disc content or establishes a unique tailored appearance, custom disc packaging may be an appropriate consideration. Custom designed collateral materials combined with discs can be used for marketing campaigns, information packets and other forms of relevant or high-profile materials. 919.552.5525
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