Vinyl is selling so well that it’s getting hard to distribute

There sits a Presto 6N record lathe — a 1940s-vintage machine the size of a microwave that makes records by cutting a groove into a blank vinyl platter. Unlike most standard records, which are pressed by the hundreds or thousands, each lathe-cut disc must be created individually.

“It’s incredibly laborious,” said Karl Hofstetter, the label’s founder. “If a song is three minutes long, it takes three minutes to make every one.” This ancient technology — scuffed and dinged, the lathe looks like something from a World War II submarine — is a key part of Joyful Noise’s strategy to survive the very surge of vinyl popularity the label has helped fuel. Left for dead with the advent of CDs in the 1980s, vinyl records are now the music industry’s most popular and highest-grossing physical format, with fans choosing it for collectibility, sound quality or simply the tactile experience of music in an age of digital ephemerality. After growing steadily for more than a decade, LP sales exploded during the pandemic.

In the first six months of this year, 17 million vinyl records were sold in the United States, generating $467 million in retail revenue, nearly double the amount from the same period in 2020, according to the Recording Industry Association of America. Sixteen million CDs were also sold in the first half of 2021, worth just $205 million. Physical recordings are now just a sliver of the overall music business — streaming is 84 percent of domestic revenue — but they can be a strong indication of fan loyalty, and stars like Taylor Swift and Olivia Rodrigo make vinyl an important part of their marketing. Yet there are worrying signs that the vinyl bonanza has exceeded the industrial capacity needed to sustain it. Production logjams and a reliance on balky, decades-old pressing machines have led to what executives say are unprecedented delays. A couple of years ago, a new record could be turned around in a few months; now it can take up to a year, wreaking havoc on artists’ release plans.

Kevin Morby, a singer-songwriter from Kansas City, Kan., said that his latest LP, “A Night at the Little Los Angeles,” barely arrived in time to sell on his fall tour. And he is one of the lucky ones. Artists from the Beach Boys to Tyler, the Creator have seen their vinyl held up recently. “It’s almost how I feel about playing live music,” Morby said in an interview. “I now count every show as a success. ‘Wow, we pulled it off — no one got Covid.’ Now I know what it’s like for the world to completely stop. So even if it’s going to be a little late I’m still grateful for that.” For Joyful Noise, the vinyl crunch has also presented a puzzling problem. Up to 500 V.I.P. customers pay the label $200 a year for special editions of every LP it makes. But the production hold-ups mean the label cannot predict which titles will be ready during 2022.

But the bigger issue may be simple supply and demand. Consumption of vinyl LPs has grown much faster than the industry’s ability to make records. The business relies on an aging infrastructure of pressing machines, most of which date to the 1970s or earlier and can be costly to maintain. New machines came along only in recent years, and can cost up to $300,000 each. There’s a backlog of orders for those, too.