Offset Printing: The Backbone of Commercial Printing

How Offset Printing Works (Quick Recap)

Offset printing has been a dominant method of commercial printing for nearly a century. It replaced the slower, less consistent processes of the 19th century and has rapidly improved and modernized in the decades since.

The process starts with a rubber roller that rotates against a custom-made cylindrical printing plate. The rubber roller picks up ink from the plate and transfers it onto the print substrate (paper, cardstock, etc.). Modern offset presses handle this process extremely efficiently, rapidly producing prints while minimizing the ink used per copy, resulting in an economical printing solution for all types of materials.

Benefits of Offset Printing

Modern offset printing is a precise and highly flexible technique, capable of printing everything from black-and-white text to elaborately embellished, high-resolution artwork. It offers superior color consistency over digital commercial printing, thanks in part to the invention of individual Pantone Matching System (PMS) inks. Offset presses can also accommodate a wide range of print substrates, inks, finishes, and coatings. So whatever you need printed for your project or business, from sturdy, fully customized luxury packaging to simple bulk mailers, offset can get the job done.

As for the cost benefits, the biggest advantage offset printing has over digital is its reduced ink usage. Though offset printing requires the creation of custom plates, which increases the initial cost vs. digital, its reduced ink per page means that the cost per copy decreases as the total number of copies increases. On the other hand, digital’s cost per copy remains flat. So the more copies you need printed, the more economical offset printing becomes, making it the hands-down winner when it comes to printing at scale.

Applications

Offset printing is used for just about any type of marketing collateral or print communication you can imagine. For example, in the healthcare industry, it’s used to print pharmaceutical packaging, brochures, medical device manuals, patient enrollment materials, and personalized confidential mail. At educational institutions, it’s used to print course catalogs, student handbooks, campus signage, custom diplomas, and branded stationery. Retailers use it to create POS/POP displays, custom mailer boxes, promotional mail, and product catalogs. The list goes on, but the point is clear - the potential applications for offset printing are virtually limitless. 

Offset vs. Digital 

We’ve already touched on digital as the key comparison to offset, because offset and digital are the two most versatile and prominent commercial printing methods in use today. They can achieve similar results, which sometimes makes deciding between the two methods tough. So, to conclude our summary of the offset printing process, here’s a quick comparison highlighting when each method might be a good fit.

• Print Quantity - The more sheets you need printed, the more likely it is that offset printing will save you money. The cut-off point varies depending on the project, but generally starts somewhere after the 500-copy mark.
• Color Accuracy - Both methods offer good color saturation and accuracy. However, when ultra-precise color reproduction is essential, such as with brand colors, offset printing with PMS inks is a better choice.
• Turn Around Time - Both methods produce prints very quickly. However, for smaller, extremely last-minute runs, digital will usually get the job done faster since it does not require any plate preparation.
• Materials and Finishes - Offset printing can accommodate a wider variety of paper types, coatings, and specialty finishes, making it a stronger choice for high-end and complex print jobs.

Even if there’s never seen anything like it before, at Wallace Carlson Printing, we can help you bring your wildest print dreams to life. With more than 90 years of print innovation experience, we’ve helped clients of all shapes and sizes push the boundaries of print marketing, communications, publications, and products. Contact our team today to get your project started!