Key question
Which printing method suits the print run, colour and material?
Every printing technique has its strengths: offset is precise and cost-effective for large print runs, digital printing is flexible for small quantities, and screen printing provides opaque coverage on almost any material. The choice depends on the print run, the number of colours, the material, and the desired finish.
Learning objective: You can distinguish between the main printing processes and propose a suitable process for a printed product, providing reasoning.
The procedure follows the order.
4.1 / The Most Important Procedures
Four methods characterise standard practice.
These are the four methods you will encounter most frequently in practice:
01
Offset printing
Indirect planographic printing via a rubber blanket; sharp, colour-accurate, and cost-effective for medium to large print runs.
02
Digital printing
Plateless printing using toner or ink; ideal for short runs and personalisation.
03
Screen printing
Ink is pressed through a fine mesh; opaque on paper, fabric, glass, or wood.
04
Flexographic printing
Relief printing using flexible plates; standard for packaging, bags and labels.
Offset printing requires printing plates and set-up time; these fixed costs are only absorbed over larger print runs. Digital printing has virtually no fixed costs, but higher costs per unit. Screen printing and flexo are suitable for materials that are challenging for offset.
Fixed costs or unit costs: the print run is the deciding factor.
4.2 / Select by print run
Weigh up quantity, colours, and material.
As a rule of thumb, digital printing is worthwhile for up to a few hundred copies, and offset printing from around 500 to 1,000. This threshold varies depending on the format, page count and press. If you are unsure, request quotes for both methods.
Colours and materials also play a role: spot colours are straightforward in offset and screen printing, but are often only approximated in digital printing. Thick, textured, or dark materials frequently require screen printing or letterpress.
01
Edition
Small quantities digitally, large ones via offset; in between, compare quotes.
02
Colours
Spot colours and white help determine which process is suitable.
03
Material
Not every process prints cleanly on every material.
Print run, colour, material: always consider them together.
4.3 / Character in print
Some processes are themselves design.
In letterpress printing, ink is pressed onto paper from raised surfaces. When applied to thick cotton card, it creates a tactile impression. The process is ideal for small print runs with a limited number of spot colours.
Risograph printing is a stencil-based process using vegetable oil-based inks, applied colour by colour onto uncoated paper. Slight misregistrations and grainy textures are part of its charm. It is cost-effective for small print runs and popular for zines and posters.
The trace of the process may be seen.
Exercise
Identify procedure
Task: Identify the printing process of five printed items and give reasons for your assessment.
STEP 1
Examine every printed piece with a magnifying glass or a linen tester.
STEP 2
Pay attention to the grid, edges, ink layer and indentations in the paper.
STEP 3
Assign a procedure to each printed matter.
STEP 4
Suggest a procedure for the 'Kornfeld' bread bags and justify your choice.
Evaluation: Which features were clear, and where were you unsure?