CD and DVD duplication has an inevitable environmental impact. Taking care in the choice of print method and packaging materials can go a long way to minimizing this.

The inherent environmental cost of producing DVDs and CDs is something that most people commissioning either CD duplication or CD replication may be aware of, though the full extent of this is often not recognised. It may be obvious that a DVD is made of plastic (polycarbonate to be precise) and that this must have some impact on the environment. In addition to this, DVDs have a reflective layer of aluminium which is sputtered on to the polycarbonate surface. A DVDR disc also has a layer of organic dye added (the recording layer). Organic in this context does not mean wholesome – it refers to the branch of chemistry that deals with these hazardous hydro carbons!

The process of printing (or decorating) the disc is one that arguably has the most potential for environmental cost. Whether it is DVDR duplication or DVD replication, the disc will require some printing so it can be identified (and to look good too!). The options for printing are varied but the most common for large volume runs are screen printing (sometimes referred to as silkscreen) and litho printing (more correctly referred to as offset). Both processes involve a great deal of waste and the flushing and disposal of environmentally damaging chemicals. Screen and offset printing start by exposing film of the artwork (involving the use of toxic chemicals and plastics) and the making of screens or plates. Screens have to be washed out after use resulting in more chemicals being flushed away. In addition screen and offset inks are inherently toxic and cause more hazardous waste to be dumped into the environment.
Finally before the job can be printed the printer needs to be run in to settle down, usually requiring up to 50 or 100 DVDs to be printed before the print is satisfactory.

In stark contrast to this, the latest generation of digital DVD printers require no plates, films or screens and no hazardous chemicals in the setup process. A DVD duplication job can be printed directly from the digital artwork with no setup. Although it is possible to print replicated DVDs this method is ideally suited to the on demand, low volume run size of DVD duplication. The machine prints the first disc exactly the same as all subsequent discs meaning that there is no disc wastage either.

If your next DVD production could benefit from lower environmental cost, and quicker turnaround and not to speak of the highest 4 colour print quality available you should look no further than digital printing. If you want your DVD duplication project to look as good or better than a replicated DVD found in shops then this is also the best option.

Environmentally friendly DVD packaging

It’s not a well known fact but 100% recycled Card uses more bleach in the whitening process during manufacture of the board than virgin pulp, so is actually more damaging to the environment. There is a better solution that truly environmentally conscious companies have been offering to its clients. A solution that is both better for the environment and actually cheaper.

The most eco friendly CD and DVD card wallets are 80% Recycled and 20% FSC (Forest Stewardship Council) sourced board. This uses less bleach to make the board, it’s also cheaper as the heavy bleaching process adds greatly to the cost. And because the 20% virgin pulp is FSC certified, it is guaranteed to be from a sustainable source.

This board can also be used to make other forms of CD and DVD packaging; valid options for clients that do not wish to use plastic packaging for their discs.

Lancing packs (a card wallet with an extra flap), and digipaks (2 or more panels with a tray) can also be made from the same board. Although a digipak does have a tray that is usually made of plastic to house the disc, it can easily be replaced with one made of corn starch for a completely eco friendly CD pack that will completely decompose.

With the addition of foam studs to attach the disc the creative options open up greatly – a disc can be stuck to any flat surface or incorporated, for example, into a book or a bespoke recycled card box.

Another popular misconception is that rough looking board is recycled, or somehow better for the environment. A card wallet can be made with the board reversed (i.e. the smooth surface turned to the inside) which reveals the rough textured board as the outside of the wallet. This gives an interesting texture to the board and can be used to great effect in the right CD and DVD packaging design, but is not necessarily an indicator of the provenance of the board. Once card has been processed it is virtually impossible to spot the difference between recycled, part recycled, virgin or FSC approved board.

Once you step outside the box (so to speak), it is possible to create exciting and eco-friendly packaging solutions for CD and DVD, while still keeping cost realistic. It is essential that you select a supplier with the experience and the sources for all the options available.

More information about DVD packaging and DVD duplication from 10th Planet Digital Media.