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.
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.
Large pancakes of blank cassette tape are loaded onto the slaves (recorders) for duplication. The cue tone separates each program.
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.
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!!
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.
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.