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© 2012 Audio Duplicating Service
picture of Versadyne dupe line picture of Versadyne bin-loop duplicator
The bin loop is essentially a high speed tape player. A clear window is placed on the master between the beginning and end of the program to generate a cue tone. 
picture of Versadyne slave
Large pancakes of blank cassette tape are loaded onto the slaves (recorders) for duplication. The cue tone separates each program. 
picture of Concept designs cassette tape loader
The recorded pancakes are then threaded onto the loaders for despooling into C-0's (empty cassette shells). C-0's contain only a leader. This machine extracts and cuts the leader, splices the end of the program to one side, despools it to the beginning and splices both ends together. The cue tone signals it when to start and stop.
picture of cassette loader line
When the loaders are running full tilt it sounds like an air hockey tournament on steroids! Depending on length of program, these machines can load over 700 tapes per hour per machine. That's a lot of tapes!
picture of Apex off-set cassette printer
From the loaders the tapes then go to the cassette imprinter. This machine is dry offset. Ink is fed onto rollers which contact the printing plate. The plate then imprints a reverse image on the printing pad which contacts the cassette. The ink is cured by strong UV lights and off-loaded completely dry. This APEX printer can print up to 120 tapes per minute without sacrificing quality or detail.
picture of Emerald cassette tape packager picture of Emerald cassette tape packager
Once the tapes are imprinted (assuming there is artwork to be inserted) they move on over to the most rhythmic machine of the bunch, the J-card inserter. This machine will package close to 100 cassettes with J-cards and boxes per minute. It will also box cassettes sans J-card. The boxes are loaded onto a conveyer, the cassettes into a hopper and the J-cards into a separate hopper. All of the components come together and feed to a conveyer where they are offloaded and shrinkwrapped. That's it! Time to seal up the shipping boxes and get 'em outta here.
Bin loop duplication is pretty easy to understand. We take your master, convert it to a half-inch loop tape, and load it into a bin. The bin loop master plays at a speed of 64:1 or 32:1. Both speeds provide an excellent signal to noise ratio which means you hear more program and less noise. 32:1 CrO2 (chrome tape) is the highest quality.

Tape Making Process

How audio tapes are made

Manufacturing tapes