Digital vs. Offset Press

 In today’s market, there is a lot of confusion about the changes in printing technology.  Digital presses have begun replacing offset presses in many print shops; however, many times the customer does not know what to choose or what exactly the difference is between the two.  Since making the wrong decision can result in hundreds of dollars difference in the price that customers pay, we at Ogden Blue thought we would help clarify the difference between the two and highlight the advantages of each.

What is Offset Printing?

Offset is the traditional “lithography” type printing that has been around for literally hundreds of years.  While the technology has changed over that period of time, the basic process remains the same.  In offset printing, the image is inked onto a plate and burnt in.  The image is then transferred to a rubber blanket then further to the actual printing surface.  The printing surface repels water, and the ink from rollers is transferred to the paper, while the non-inked areas attract water.  In this way the image is repeated over and over again as the surface of each “print” is inked again and again.  This is the traditional “copy” process.  Offset presses can either be “roll-fed” or “sheet-fed”.  Rolls of paper are typically cheaper per print than sheets.  Very skilled craftspeople are also required to ensure correct color matching in this process.

What is Digital Printing?

The digital process is much different, as the image is transferred directly from a computer to the print server or controller of the digital press.  Many different types of imaging engines are available, and the EFI Fiery Engine is probably one of the most common in commercial environments.  The images are usually saved as PDF files for most business printing then sent to the print controller.  The computer within the digital press translates the images to areas to be “imprinted” on the surface of the paper.  Most digital presses are sheet-fed.  This process saves a tremendous amount of time because the digital presses do not rely on the making of plates.  It is cheaper in low-quantity, because the process is simpler and the equipment does most of the work using computers.  Typically, graphic designers or print operators are used to set up the proper print parameters.

From Pinscreative.com, here are the advantages of each:

Advantages of Digital

• Shorter turnaround.
• Every print is the same. More accurate counts, less waste and fewer variations, due to not having to balance ink and water during press run.
• Cheaper low volume printing. While the unit cost of each piece may be higher than with offset printing, when setup costs are included digital printing provides lower per unit costs for smaller print runs.
• Variable Data Printing is a form of customizable digital printing. Using information from a database or external file, text and graphics can be changed on each piece without stopping or slowing down the press. For example, personalized letters can be printed with a different name and address on each letter. Variable data printing is used primarily for direct marketing, customer relationship development and advertising.

Advantages of Offset

• High image quality.
• Works on a wide range of printing surfaces including paper, wood, cloth, metal, leather, rough paper and plastic.
• The unit cost goes down as the quantity goes up.
• Quality and cost-effectiveness in high volume jobs. While today’s digital presses are close to the cost/benefit ratio of offset for high quality work, they are not yet able to compete with the volume an offset press can produce.
• Many modern offset presses use computer-to-plate systems as opposed to the older computer-to-film work flows, further increasing quality.

Use this checklist to decide which is right for you.

Quantity:  How many am I printing?  (Typically, offset printing, because the cost of setup is so much higher, will be more expensive until you hit 5,000 pieces 8.5X11.)

Printing Medium:  How heavy is the paper that I will be using?  Most digital presses are not equipped to handle the thicker papers (18pt. on up). 

Color:  How much color is needed?  1,2, and 4 color processes are available in digital or offset; however, digital offers better color matching and great flexibility in color choices.  We have printers at Ogden Blue that use up to 12 different colors.  This gives a high-grade of color matching. 

Resolution:  Offset actually gives the best resolution for production.  However, digital presses are hard to beat anymore.  It is difficult, without a loop, to tell the differences between them.  Ogden Blue uses a “true-color” and a true “1200X1200” resolution.  Poor resolution will actually make the product look grainy.  This is a topic for another blog post.

Turnaround:  How fast do I need it?  Digital is a much faster process, and is great for companies that need a fast turnaround on high-quality prints.  While keeping costs in line, digital also offers an unparalleled rapidity in production. 

Proofing:  Do I want to look at the “finished” product before it goes to print?  Digital presses also allow a “proof” which is an actual picture of the finished product produced in exactly the same manner as the printing process will be.  This means that a product can be fully proofed for color accuracy, resolution, and grammatical accuracy before the printed products are delivered.  Offset requires as much as $400 for a printed proof before going to press!

Customization and Flexibility:  Do I want to change a product per print?  Do I need addressing or customized marketing materials?  This is only possible to do on a digital press in one run.   Ogden Blue offers solutions in direct mail marketing, customizable marketing pieces, and many other customized pieces.