Vinylsizes & Productionprocess:
Here you get to know more about our vinyl sizes and the particular production steps of vinyl manufacturing OR
You easily order our image-DVD in a high-quality package and booklet. This film illustrates in an impressive way the several steps of the vinyl production an gives with the usage of great 3d animations the answer to the exciting question: "How does the music come into the groove?"
- 7" vinyl ca. 6 min*/side 45 rpm, 42g
- 10" vinyl ca. 6 min*/side 45 rpm, ca. 6-9 min*/side 33 rpm 110g
- 12" vinyl ca. 8 min*/side 45 rpm, ca. 9-20 min*/side 33 rpm 135g/170g
* this are just typical values, the final playtime per side accords to the delivered audiomaterial
The basic material is an aluminium disc covered with acetate lacquer or a high-grade steel disk with a special copper layer. (DMM-Technology = direct metal mastering) At this point the lacquer foil has no grooves (CU-Blank) and has to be put in the cutting machine for the transcription of the music information. In this step the "cutting head” is moved over the turning foil from the outside inward with variable speed. A ruby- or diamond-needle cuts, "forced” from the music, the well-known grooves into the vinyl.
Full Plating Process (Galvanisation)
During the galvanic process a metallic copy of the lacquer foil is made. For this step the surface of the foil has to be made electrically conductive. A thin silver layer is applied, this silvered foil is immersed in a galvano-plastic nickel bath. The foil works as the cathode and the nickel is used as anode. If now the electric power flows through the solution, the metallic nickel settles on the silvered surface of the foil. After achieving the desired thickness (ca. 0,23 mm), you have to remove the foil from the nickel layer. By doing this you receive the first Galvano, also called "father”. It is a negativ, that means, instead of grooves there are the corresponding elavations. Then the "father” is used for making another copy, called "mother”- this one is then used for making the "son”, which is convenient for the pressing. But these kind of stencils doesn’t have a long-lasting durability and so you can always get a new copy of "mother” and "father” and make a new pressing die (a "son”)
The pressing dies you’ve received during the Galvano are put in the upper and lower part of the pressing machine. There are always two dies: one for the front side and one for the backside of the vinyl. The granulate or powder is warmed up in an extruder machine and will be formed into a "cake”, then put between an open form and the labels. The form is closed under high pressure and the vinyls are pressed under the influence of steam and cooling. Now the outer edge of the vinyl is cut off and to stabilise the evenness, it is laid down. This pressing process is almost automatically and it takes about 20 seconds. There is already an optical control of the vinyls right before the pressing. To make sure that the pressing dies didn’t get damaged during this process, there has to be a frequently acoustic sample proofing