Will Blu-ray DVDs be too expensive?

Because Sony's Blu-ray disc technology appears to be the front-runner in the nasty fight to determine how the DVDs of the future are produced, movie studios and disc manufacturers are beginning to come to terms with the financial realities of the new format -- as well as some troubling uncertainties.

For more than a year now, a bitter public relations war has been waged between supporters of Blu-ray and a rival Toshiba-backed technology known as HD DVD. Both are high-capacity discs that will support the distribution of high-definition versions of movies, with much better picture quality than what's possible with today's technology.

Blu-ray appears to have the lead, with most major movie studios saying they'll release films in the format next year. That's led to new concerns about mass production of DVDs in the new format. Since it represents a major break with past DVD and CD techniques, some worry Blu-ray will be expensive to support -- at least in the short term -- and could jack up prices for consumers.

How much? No one can say for certain. But in at least one early test, according to a top manufacturing executive who asked to remain anonymous, a manufacturing line for HD DVD discs produced nearly twice as many usable discs as a similar line pumping out the Blu-ray format, over the same period of time. That translates into higher costs for Blu-ray producers. Moreover, component costs for Blu-ray can be nearly double HD DVD costs, because elements are still hard to find, the executive said.

That Blu-ray discs may start out pricey shouldn't be a shock. They face a classic curve for new technologies, which are initially expensive as manufacturers work with small numbers of orders and lean how to streamline the process. Sony also disputes those high-priced estimates.

"If there is a cost difference, that has yet to be determined," said Sony Pictures' Adrian Alperovich, the studio's executive vice president in charge of new business development. "There are manufacturers on both sides of the equation. If there is a difference in price either way, we think it will be minimal."

Alperovich argues that if there is a short-term price gap, the advantages of Blu-ray -- mainly more capacity and flexibility for things like gaming -- should outweigh that concern. But traditional engineering questions about Blu-ray have taken on a testier tone in this scrap.

Blu-ray's rival, the HD DVD format, relies on a reasonably well understood process. HD DVDs are constructed very similarly to existing DVDs, and the basic discs can be made with relatively minor modifications to existing DVD manufacturing lines.

Blu-ray discs, on the other hand, require completely different equipment. Most of the major disc replicators -- the companies that make DVDs and CDs -- now have a test line or two up and running, but hard data on production costs remains scant.

The format's backers at the Blu-ray Disc Association have repeatedly predicted that costs would come down quickly and be almost immediately competitive with those of HD DVD.

Yet one senior executive at a major disc replication facility said he has long been worried about Blu-ray costs.

"We feel that some of the Blu-ray backers' statements are setting unrealistic cost and price expectations for the content owners they are courting," said the executive, who asked to remain anonymous owing to a close working relationship with Blu-ray companies. "They're right at the zero point in terms of operational knowledge."