With 8 submenus each carrying several layered buttons, you're hitting the Blu‑ray Interactive Graphics (IG) limit of 16 MB per title. Encore rasterizes your menu graphics into the IG stream, and once that stream gets too heavy to multiplex, it throws the "Graphics buffer underflows" error, wrapped in the generic "File already exists" message. It isn't really a file conflict. It's your menu graphics exceeding the IG budget.
The good news is you don't need to remove any layers. You just need to reduce the file size of the graphics Encore is packing into that stream. Here's how to do that in Photoshop.
- Confirm each submenu PSD is 1920x1080 at 72 ppi. A higher resolution or DPI adds size without any visual benefit once Encore rasterizes it.
- Within each button group, merge the complex layers (text, icon, border, glow, and so on) into a single raster layer per button state. Fewer separate objects means less IG overhead.
- Export each graphic using File > Export > Save for Web. Set:
- Format: PNG‑8
- Colors: start at 128 to 256, then lower until you see visible banding
- Transparency: on, if needed
- Metadata: None
- Interlace: Off
PNG‑8 at 128 to 256 colors is usually indistinguishable from PNG‑24 for button graphics, but a fraction of the size. Reserve PNG‑24 for any graphics with gradients or subtle shading. - If several submenus share the same background or button style, reuse one PNG across them instead of near‑duplicate files. Where only the text differs, keep the artwork as one PNG and add the text as a separate text layer in Encore.
- Re‑import the optimized graphics and rebuild with all 8 submenus.
If the build still fails after optimizing everything, split the project into two titles, for example 4 submenus each. The 16 MB IG limit applies per title, so this effectively doubles your available space.
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