Digital vs Offset Printing

Digital vs Offset Printing for Packaging: Which One is Right for Your Business?

Printing

Technique

Efficiency

We live in an era where digital transformation is reshaping every industry, and packaging is no exception. Digital printing has been gaining popularity over traditional offset printing methods in recent years, offering numerous advantages. However, the decision of whether to invest in digital printing ultimately depends on your specific requirements.

In this article, we’ll delve into the key differences between digital and offset printing, explore their respective use cases, and help you determine which method is best suited for your packaging needs.

Understanding the basics

What is offset printing?

There is a reason why offset printing is called what it is. It is a traditional printing method that uses an indirect process to transfer ink onto a substrate. Ink for the image is transferred to a cylinder before being applied to the print surface, rather than directly. Each design requires a custom printing plate.

It’s a great option for large-volume production of the same designs.

What is digital printing?

Unlike offset, digital printing is a modern method that directly transfers images from digital files to the chosen medium.
It’s suitable for shorter runs, customizations, promotional offers, festive packaging, new product launches and frequent design changes.

Digital vs Offset Printing - Key Considerations

1. Set up time

Digital Printing Setup Time

Direct-to-plate technology: Digital printing machines use this technology to create the printing plates directly from digital files. This eliminates the need for intermediate steps like film or chemicals, significantly reducing setup time.
No physical plates: Since there are no physical plates involved, there’s no need for platemaking processes, which can be time-consuming.

Offset Printing Setup Time

Platemaking: Offset printing requires the creation of physical plates for each design. This process involves exposing a photosensitive plate to light, developing it, and mounting it on a printing press.
Multiple steps: The platemaking process can be time-consuming, especially for complex designs or large-scale production.

Verdict: Digital printing is ideal for speed and flexibility in production applications, frequent design changes, and personalized packaging. Offset printing on the other hand is better suited for large-volume production of the same design.

2.Minimum order quantity (MOQ)

Digital Printing MOQ

Lower MOQs: Digital printing is generally more flexible in terms of minimum order quantities. It can handle smaller runs efficiently, making it suitable for short-run production, prototypes, or limited-edition packaging.

On-demand printing: Digital printing allows for on-demand production, meaning you can print exactly what you need when you need it, eliminating the need for large stockpiles.

Offset Printing MOQ

Higher MOQs: Offset printing typically requires larger minimum order quantities due to the setup costs involved in platemaking.

Economies of scale: Offset printing becomes more cost-effective as the quantity increases due to the ability to spread setup costs across a larger number of units.

The ideal printing method depends on the quantity you need, the frequency of design changes, and the level of customization required. For example, digital printing is ideal for new product launches so you can start with a smaller quantity to test market response before committing to large-scale production or when you have multiple SKUs. However, if you need to produce a large quantity of packages over a long period with consistent designs, offset printing is more cost-effective.

3.Turnaround time

Digital Printing

Faster turnaround times: Digital printing typically offers much faster turnaround times compared to offset printing due to the elimination of platemaking processes during the setup time as discussed above which can significantly reduce the time taken per order.
Delivery time: Generally, takes only 5-15 days

Offset Printing

Longer turnaround times: Offset printing generally has longer turnaround times due to the platemaking process. Creating and preparing the printing plates can take several hours or even days.
Delivery time: Can take anywhere from a few days to several weeks

Verdict: The preferred printing method here would depend on your specific needs including the urgency and quantity required. Offset printing was designed for large-scale production, not a quick turn-around. For small runs, digital is the best choice in terms of turnaround time.

Conclusion

The choice between digital and offset printing ultimately depends on your specific packaging needs. Digital printing offers flexibility, speed, and customization, making it ideal for shorter runs, frequent design changes, and personalized packaging. On the other hand, offset printing excels in large-volume production with consistent designs and offers cost advantages for high quantities. By carefully considering factors such as setup time, minimum order quantity, and turnaround time, you can make an informed decision that aligns with your business goals and maximizes the efficiency of your packaging process.