Sony DADC User Manual

DVD MANUAL

V 99 E

Sony DADC

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1. From CD to DVD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1. Format and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2. DVD Types and Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3. Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. DVD-Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2. DVD-Video input media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. DVD-ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1. Data preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2. Formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3. Input media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Label Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.1. Printing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.2. Printing Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.3. Label Film Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.4. Film Specifications for Label Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.5. Standard Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.6. Colours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.7. Label Film Data via Electronic Storage Media . . . . . . . . . . . . . . . . . . . . 17

4.8. Label Film Data via Electronic Data Transfer . . . . . . . . . . . . . . . . . . . . . 18

4.9. Production of the Label Film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5. Disc Serialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6. Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.1. Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.2. Film Specifications for Production of Printwork and Stickers . . . . . . . . . 21

6.3. Specifications for Printwork and Stickers . . . . . . . . . . . . . . . . . . . . . . . 31

6.4. Packaging of Supplied Printwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7. Sony DADC The Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Introduction

The objective of this manual is to facilitate the correct preparation of
input components for DVD productions with Sony DADC. Similar
manuals are available for our other products including CD-Audio, CD­ROM, MiniDisc and PlayStation Disc. These manuals can also be
downloaded from our website at http://www.sonydadc.com.

Compliance with the specifications in this manual will avoid confusion
and reduce the requirements for modifications. Rework may
considerably extend the production, thus making it more expensive.
Therefore, we advise you to provide these specifications to the staff in
charge with the preparation work, in particular external video, sound,
graphics and other premastering studios.

As the final product will depend on the quality of the input components
supplied, the adherence to the manual specifications represents an
essential contribution to the total quality of the product and service that
we provide to you as a customer.

In general, all Sony DADC prices and schedules are valid based on the
assumption that the input components provided by the customer meet
the manual specifications. When components do not meet the outlined
specifications, these are either returned or improved based on the
customerÕs request. Additional expenses and charges apply. Prices for
DVDs and special Services (e.g. carrier, editing, film exposure, film
generation etc.) are provided in our current price list.

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DVD, which stands for Digital Versatile Disc, is the
next generation of optical disc storage technology.
It is essentially an optical disc that can hold video as
well as audio and computer data. This new optical
disc can reach a capacity of up to 26 times the
capacity of a CD-ROM and encompasses pre­recorded read only discs like DVD-Video, DVD-ROM,
DVD-Audio, SACD and recordable formats like
DVD-R, DVD-RAM, DVD+RW and DVD-R/W. For
movie applications, a DVD can store full length
movies in a high-quality digital video with surround
sound in several languages and a wide range of
interactivity as well as subtitles. Almost all DVD
players and DVD-ROM drives are equipped with an
additional laser diode or a special lens for playback
capability of existing Audio CDs and CD-ROMs.

Main Features

1.1. Format and Specifications

The DVD standard defines a disc that maintains the
overall dimensions of the current Compact Disc.
Therefore the backwards compatibility with existing
Audio CDs and CD-ROMs was easier to realise. The
table below demonstrates similarities and
differences of CD and DVD.

CD DVD

Disc diameter 120mm 120mm
Disc thickness 1.2mm 1.2mm
Disc structure single substrate two bonded

0.6mm substrates

Laser wavelength 780nm 650 / 635nm

Numerical aperture 0.5 0.6

Track pitch 1.µm 0.74µm
Shortest pit/land 0.83µm 0.4µm

length

Data layers 1 up to 4
Data capacity approx. 650 MB 4.7 GB - 17.1 GB

1. From CD to DVD

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The DVD family

A DVD consists of two halves, where each half disc
is 0.6 mm thick holding one or two layers of
information.

The total capacity of a single side, dual layer DVD is 8.5 GB,
which is 13 times the data capacity of today’s CD-ROMs.

DVD-5

DVD-9

1.2mm

0.6mm

substrate

substrate

movable Iens

single side
single layer

1.2mm

0.6mm

substrate

substrate

movable Iens

single side
dual layer

The total capacity of a single side, single layer DVD is 4.7 GB,
which is 7 times the data capacity of today’s CD-ROMs.

Disc Type

Capacity 12 cm

4.7 GB

8.5 GB

9.4 GB

17.1 GB

DVD-5 single sided, single layer
DVD-9 single sided, dual layer
DVD-10 double sided, single layer
DVD-18 double sided, dual layer

1.2. DVD Types and Formats

semi reflective
layer

The DVD format provides multiple configurations of
data layers. Each layer provides additional data
capacity.

reflective
layer

reflective
layer

The total capacity of a double side, single layer DVD is 9.4 GB,
which is 14 times the data capacity of today’s CD-ROMs.

Note: disc has to be reversed to playback upper side.

The total capacity of a double side, dual layer DVD is 17.1 GB,
which is 26 times the data capacity of today’s CD-ROMs.

Note: disc has to be reversed to playback upper side.

Availability of DVD-18 is to be confirmed by Sony DADC.

The DVD family

DVD-10

DVD-18

1.2mm

0.6mm

substrate

substrate

movable Iens

1.2mm

0.6mm

substrate

substrate

movable Iens

semi reflective
layers

double side
single layer

double side
dual layer

4

reflective
layers

reflective
layers

Statistical process controls and in-line inspection
systems form a key part of our production process.
Full 100% checks by means of automatic test
systems of label print and read-out sides are imple­mented with the strictest error criteria.
A team of highly qualified staff as well as auxiliary
means such as optoelectronic test devices, an
electron microscope with X-ray spectroscopy, an
atomic force microscope and climatic chambers are
available for permanent process control and
improvement, for systematic error analyses as well
as for maintaining the durability of our products.

The processes and procedures are certified accor­ding to ISO-9002. This is an essential reason for the
fact that Sony DADC has qualified, after success­fully proving a 6-sigma quality, for ‘Ship to Stock’
Status to some of the largest international
computer manufacturers.

- Personal assistance by a member of
our Customer Service staff

- Authoring of DVD Video / Audio

- Premastering / formatting of DVD-ROM
( microUDF / ISO9660 Bridge format )

- Premastering / formatting
of all common DVD / CD formats

- On-line data transfer via 2Mbit ISDN

- Disc prototyping on CD-R / DVD-R

- Mastering of all DVD & CD formats

- DVD 5 / 9 / 10 disc production in short
turnaround times

- Screen and offset label printing on discs

- Support in artwork creation

- Disc serialisation

- Packaging / dispatching

- Drop shipment

We will be pleased to assist you in the solution of
your technical problems. If you are interested in an
electronic link for transmitting your master data and
other components to Sony DADC, we can offer our
know-how and our experience and will reserve
storage capacity for your data on our servers. If you
need further services, please inform our Customer
Service department so that we can assist you in the
realisation of your project.

1.3. Services

Our services comprise the following:

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Services

6

2. DVD-Video

2.1. General

DVD-Video is a new media for the distribution of
home videos. The digital nature of this new media
offers several new features to the consumer.
Amongst those features are:

● High video quality based on MPEG2 compression

and the ability to playback both aspect ratios of
4:3 and 16:9.

● A DVD-Video can hold up to 8 different audio

tracks (streams). Each track can be used for a
different language. It can also be utilised for high
quality stereo audio with a resolution of 16 bit
and 48 kHz, or for theatre quality surround
audio, like Dolby Digital AC-3.

● Up to 32 different streams of subtitles can be

placed on a DVD-Video, used as language
subtitles, as menu highlights or as instructions
for interactive functions.

● Digital copy protection via CSS and analogue

copy protection via Macrovision.

● Multibranching is another feature of DVD-

Video that simply offers the possibility to
playback one title with different parts of this
title, which can be interactively selected by the
viewer. In addition the multiangle option
allows a scene of a movie title to be viewed in
different angles.

● Every DVD-Video player implies a region code

corresponding to one of the six regions in the
world where it is sold. This regional coding
optionally enables playback of a DVD-Video title
only in certain regions.

● DVD-Video discs can be prepared with a

'Parental Lock' in order to restrict the playback
only by usage of a correct password.

2.2. Input media for DVD-Video

Sony DADC offers full authoring service for DVD­Video. For detailed information please refer to our
DVD-Video authoring manual or contact our
Customer Service department.

We also accept already authored DVD-Video titles.
As standard input media Sony DADC prefers a DLT
tape inlcuding DDP 2.0

DVD-Video

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DVD-ROM

The first step in formatting is the collection and
preparation of the input materials. You can submit
already formatted data as an image on tape or
leave the formatting of your data to us.
Unformatted data on storage media as well as
backup formats on tape or unformatted data
transmitted via ISDN first have to be converted into
a DVD-ROM compatible format. Please note that
these additional process steps take more time and
are more expensive. In order to arrange the data in
a desired sequence, please provide a detailed listing
of the file and directory structure of the final DVD­ROM.

If you submit a tape, please inform us whether
there is a DVD image or a backup format on this
tape. According to chapter 3.3. ( image on tape )
we are able to achieve shorter cycle times for your
orders and limit premastering costs as long as there
is an already formatted DVD image on tape.

When sending hard disks or exchange discs please
communicate the number of files and the data
quantity. Pack your data carrier carefully to avoid
damage during transportation. Moreover, we ask
you to mark your input carriers. Please be sure to
use adequate fibre pens which do not damage the
surface of the disc, particularly with CD-R.

3.1. Data preparation

Sony DADC formats data according to the UDF­Bridge ( UDF + ISO 9660 ) standard:

UDF-Bridge Format:

Is a new logical format for volume and file
structure on DVD-ROM discs to support the
interchange of information between a computer
system and dedicated DVD drives or players.
UDF-Bridge stands also for a combination between
the Universal Disc Format ( ISO/IEC 13346 ) and the
ISO 9660 standard.

3.2. Formatting

3. DVD-ROM

ISO 9660:

The ISO 9660 (level 1) file structure is limited to the
characters 'A - Z', '0 - 9' and. '_' (underscore) with
a maximum of 8 characters in length and 3
characters extension and a maximum of 8 directory
levels (including the root directory)
To avoid the restrictions of ISO 9660 level 1 and to
use longer file names Level 2/3 can also be used.
These levels restrict filenames to 30 characters and
directory names to 31 characters.

Joliet extension:

To meet the demand for Windows 95 file names
there was a extension designed called Joliet
format. This file system allows longer file and
directory names than ISO 9660 level 1 as well as
level 2/3, where file or directory Identifiers may be
up to 64 characters.

DVD-ROM images on tape

Sony DADC will accept ANSI labelled DVD-ROM
images either on DLT or SDX tape. We strongly
recommend that any tape compression is turned
off. The DVD Data Sector size can be 2048, 2054 or
2064 Bytes/Sector.
The DDP ( level 2.00 ) is either to be placed at the
front of the tape followed by the DVD Leadin-data
and the DVD Image or on a separate Floppy Disk.
The image is subjected to a logical incoming UDF­check and can be used for direct mastering.

3.3. Input media

Through the naming and file structure of UDF the
UDF file system is much more powerful than the file
structure of ISO 9660.
However, the UDF-Bridge combines both the UDF
and ISO 9660 formats, and therefore the file
structure has to meet the ISO-9660 designation
agreement.

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DVD-ROM, DVD-R (Recordable),
DVD-RAM, DVD+RW, DVD-R/W

An already replicated DVD-ROM is a preferred
input media because it can be used immediately for
direct mastering.
In order to determine the input media, please mark
your input carriers with a catalogue number.

CD-R (Recordable), CD-ROM

If you wish to put the data of a series of CD-ROM’s
on one single DVD-ROM or if you wish to transfer
data from a CD-ROM to a DVD-ROM we have to
generate a new DVD-ROM image.
In order to arrange the data in a desired sequence,
please provide a detailed listing of the file and
directory structure of the final DVD-ROM.

Electronic data transmission via ISDN

For shortest transport times of components to Sony
DADC, we offer a data link via an ISDN primary rate
interface directly to our servers. This data offers a
range up to 2 Mbit / second.

DVD-ROM

The data of a 650 Mbyte CD-ROM are then copied
in approx. 47 minutes to our servers. With previous
compression of your data the transmission is still
reduced further.
After receiving a compressed image we
automatically carry out a decompression and a
checksum control. The production of a glass master
is then carried out on-line. Upon request the system
transmits a short e-mail to the sender and
acknowledges errorfree transmission.

If you are interested in this kind of transmission for
your DVD-ROM data and order components please
get in touch with us. We will be pleased to assist
you in establishing an electronic connection with
us.

Apple Macintosh / DOS SCSI hard
disk

Please only send us SCSI hard disks with a
description of the file and directory structure of the
final DVD-ROM.

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Label Printing

4. LABEL PRINTING

The following pages contain important
specifications on the DVD printing and the
film material required.

Please transmit this information to your
graphics artist or designer.

4.1. Printing Processes

Sony DADC uses screen printing processes for
printing DVDs as well as offset printing processes.

The following types of print can be processed:

● line prints with up to 4 colours (3 colours for

DVD-10)

● half-tone prints

● duplex and triplex prints

● Four-colour prints

(picture disc: offset/screen printing)

For particular requirements with respect to printing
quality in four-colour print, we offer the High
Definition Picture Disc. This is to be recommended
particularly with applications including
photographs, faces, landscapes or designs which
are similar to photographs.

A specific offset process is used which facilitates a
resolution that is about double that of the screen
print.

4.2. Printing Areas

On the following pages the three possible printing
areas on a DVD label are illustrated (specifications
F, G and H).

Please mind that there may be colour deviations
between the print on the aluminium coated part
and the non-aluminium coated interior parts.
Therefore, we advise to preprint an entire white
base to minimise colour deviations with specifica­tions F, G, H.

4.3. Label Film Dimensions

Please ensure that your label films comply with the
required specifications F to H (see page 10 to 13).
Any necessary label film corrections are charged
according to our price list.

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Specification F - Label Print DVD 5 / DVD 9

15 mm

117 mm

120 mm

23 mm

Printing area on the DVD

Label Printing

11

Specification G - Label Print DVD 10 Side A and B

15 mm

38,5 mm

43,2 mm

120 mm

Printing area on the DVD

Label Printing

12

Specification H - Label Print DVD 10 Labelside A

15 mm

23 mm

43 mm

120 mm

Printing area on the DVD

Alternatively Sony DADC offers an extended
printing area for DVD 10. Please note that
Labelside A and Labelside B of specification H hold
different printing areas. This is required in order to
machine-read the barcode of the product.

Label Printing

13

Specification H - Label Print DVD 10 Labelside B

15 mm

23 mm

35 mm

120 mm

Printing area on the DVD

Label Printing