What are offset printing methods, and how do they compare with flexo printing methods and digital printers? Learn about lithography, flexography, & digital printing. Here's everything you need to know.
As much as you desire functional products and visually appealing, well-branded packaging, the printing process is just as crucial. With advancements in technology, printing techniques have come a long way, offering a range of options suited to different budgets, volumes, and quality requirements.
This guide will introduce you to various printing techniques in packaging and how they can help make your custom boxes stand out. While there are several types of printing methods, lithography (offset printing), flexography, and digital printing are the three core techniques. Other methods include screen printing, rotogravure, and more.
Lithography (Offset Printing)
Lithography, also known as offset printing, is a popular method for high-quality, mass-production printing. In this process, ink is first applied to a metal plate, which then transfers the ink onto an offset plate and finally prints onto the substrate paper. If you are using the CMYK color system, four plates are required—one for each of the CMYK colors. Offset printing can also accommodate PMS colors and their combinations.
It is important to note that the cost of offset printing depends on the number of artwork designs rather than the number of structural designs. For instance, if you wanted 1000 boxes with two different designs, you'd be charged separately for each design due to the need for new plates and the plate-swapping process during printing. However, if you were to order 2000 boxes of a single design, the cost would be lower as no plate changes are necessary during production. To understand more about packaging costs and how to optimize your packaging budget, click here to learn more.
Offset Printer
Offset printing is widely favored for bulk production due to its ability to produce the highest quality prints with exceptional color accuracy, sharpness, and crispness. It is the go-to choice for many premium packaging solutions. However, in the United States, offset printing typically requires higher volume orders, often around 5000 units or more, to be cost-effective. For orders below this volume, digital printing is generally preferred due to its lower setup costs and flexibility for smaller runs.
At CustPrints, offset printing is our main method for creating excellent packaging at reasonable prices. Due to the high quality in sharpness and color, it allows us to produce packaging that is luxurious in appearance yet sustainable in nature.
Flexography
Flexography, or "Flexo," is a printing technique that is quite similar to offset printing but with a few key differences. In flexo, the ink is directly transferred from the plate onto the substrate, which could be paper, plastic, or other materials used for packaging. It works much like a stamp, where the plate acts as the stamp to apply the ink. As with offset printing, each plate can only handle one color, so for the CMYK color system, you'll need four plates.
Flexo is more cost-effective than offset printing, making it a better choice for large-volume orders. However, the trade-off is that the print quality tends to be lower, and it may not be ideal for intricate designs or projects that require multiple colors. Flexo is commonly used for printing on plastic pouches, food wrappers, and other flexible materials.
Digital printing methods
Digital printing is a popular choice for smaller-scale printing jobs, as it does not require plates like offset or flexo printing. Instead, it uses toners or cartridges to apply ink directly onto the substrate, making it a more straightforward and cost-effective method for low-volume orders. Commercial digital printers are typically used for runs of around 50 to 100 units, and they often use liquid ink for higher quality and precision.
One of the main benefits of digital printing is its ability to produce high-quality prints without the setup costs associated with other printing methods, which is why it's ideal for smaller quantities or custom designs. However, it may not be as cost-effective for larger volumes compared to offset or flexo printing.
Digital Printer
Digital printing is ideal for smaller orders and offers flexibility when it comes to multiple designs. Since there’s no need for physical plates, digital printers can quickly switch between different designs simply by changing the artwork on the computer, which significantly reduces setup time and costs. This flexibility allows manufacturers to charge per structure, rather than per design, meaning whether you order 5 different designs with 200 units each or 1,000 units of one design, the cost is likely to be similar.
Source: 99Designs
However, digital printing has some limitations. The cost of toners and cartridges can add up quickly, making it an expensive option for large-volume printing. Additionally, digital printers often struggle to support PMS colors, which are available in offset printing, and achieving a consistent, high-quality print can be challenging. Large color blocks may appear uneven, with potential mismatched tones or visible white lines.
Furthermore, digital printing can result in a blurry or pixelated outcome, which is more noticeable than the high-quality, sharp print produced by offset printing. While offset prints may show tiny dots under magnification, they maintain crisp clarity that digital prints often lack. The image comparison below illustrates the noticeable difference in sharpness between offset and digital printing, even without magnification.
Source: Akula Kreative
Screen printing and rotogravure
Screen printing and rotogravure are less commonly used compared to offset, flexography, and digital printing. Screen printing, also known as silkscreen printing, involves using a mesh screen with a stencil of the design. Ink is pressed through the mesh onto the substrate. While this process is relatively slow, it is one of the most affordable options for small-scale or custom prints.
If you have a low budget, need detailed designs for small volumes, and are okay with a more labor-intensive process, screen printing could be a good option. However, it has its drawbacks: it's not ideal for producing photo-quality images or intricate patterns due to its manual nature. Additionally, the labor-intensive process increases the likelihood of errors.
On the other hand, rotogravure, although less common, is suitable for large volumes and offers high-quality prints. However, it is typically used in applications like high-end packaging and is better suited for longer print runs due to the setup costs.
Source: Go Media
Rotogravure, or gravure printing, involves etching your design onto metal cylinders, which are then used to transfer ink onto the substrate. This method is one of the most expensive printing options, but it delivers exceptional print quality. It can easily accommodate both the CMYK color system and PMS colors, making it versatile for various designs. However, gravure printing is best suited for high-volume production and is less commonly used compared to offset printing due to its high setup costs.
Printing your packaging is a rewarding process, offering the opportunity to bring your designs to life. There is no "one size fits all" solution when it comes to printing methods, as each option has its own strengths and trade-offs. The best approach is to clearly define your requirements and choose the printing technique that aligns with your budget, design needs, and production volume.
Want to know more about our printing process and packaging offers? Reach out to us at contact@custprints.com!
Looking to produce packaging that is offset-printed? Get started by browsing our wide range of products or get configuring on our website today!
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