Hi Alan,
It sounds all too familiar, what you're describing.
I've recently posted an article on my site that discusses what is no doubt, a 'mini DVD pandemic' going on, and has been going on, out there with replicated titles, due to holes in replicators' quality control regimens. Here it is, if you're interested:
TFDVD Research Labs' Breakthrough DVD Check Disc Proofing
You can try going to your replicator and ask them to check for problems on a sampling of your run. The Eclipse report will show as passed, in these cases, however, so no help there. The replicator will also cite their faulty 'passed' bit-for-bit' compare tests to show their not at fault.
You'll have to depend on your clients' relating of all the customer complaints to help nudge the replicator to start physically testing a sampling of the run. They're not going to readily do this, however, as it can take a bunch of time.
Or, you could engage third party CATS physical testing of several of your discs yourself; but that's expensive (over $1,000) and still not guaranteed to move your replicator, I've found.
Of course, I offer a service that's guaranteed (sorry about the commercial). If it's your fault, we get it fixed, if it's the replicator's fault, they redo the run for free - or no charge.
As for your bit rate, as long as the video and all the audio streams in any VOB fall under 9.8 mbps, then a properly manufactured DVD will play in players just fine.
Take care,
Trai
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Trai Forrester
TFDVD Research Labs
DVD Verification, Proofing, Pre-Mastering
