Offset has been the basis of printing for 150 years. We are analyzing how the technology works, when it is more profitable than numbers, and which print runs are offset.
What is offset printing?
Offset (from English off-set — transfer from one surface to another) is a technology in which ink from a printing plate is transferred first to a rubber cylinder, and from there to paper. It was invented in 1875 and has remained the basis of mass printing ever since.
How offset printing works
- Production of molds. A separate aluminum plate with the applied image is created for each color (usually CMYK — cyan, magenta, yellow, black).
- Humidification. Water and paint are applied to the mold at the same time. The printing zones absorb the ink, while the non—printing (hydrophilic) zones repel it by retaining water.
- Transfer to rubber. The paint is transferred from a metal mold to a rubber cylinder (offset cloth).
- Transfer to paper. The rubber is pressed against the sheet — an impression is obtained. This is the basic technique that gave the technology its name.
- Drying. The sheets are passed through IR or UV drying to fix the paint.
Advantages of offset printing
- Print runs from 500 pieces. The larger the print run, the cheaper each copy. For 10,000 business cards, offset is 2-3 times cheaper than digital.
- Color quality. Professional pantones are an exact match to corporate colors. Digital printing only gives an approximate hit.
- A wide range of papers. It works with all types of paper from 60 to 400 g/m2, including designer, textured, and metallized.
- Large formats. Printed sheets are up to 70×100 cm, and then cut into the desired format.
- Special paints. Fluorescent, metallized, with protective elements — all this is available only in offset.
Disadvantages of offset
- Expensive with small print runs. Mold making is a separate expense item. With a circulation of up to 500 pieces, this is unprofitable.
- Long-term preparation. 1-3 days to adjust the press, color tests, and adjustments.
- Personalization is not possible. All 10,000 sheets are the same. For personal business cards — only a number.
Offset vs Digital: what to choose
| Parameter | Offset | Number |
|---|---|---|
| Minimum print run | 500 pieces | 1 PC |
| Optimal circulation | from 1000 pieces | up to 500 pieces |
| Production time | 3-7 days | 1-2 days |
| Price per copy. at 100 pcs | high | low |
| Price per copy. at 5000 pcs | low | high |
| Personalization | no | yes |
| Color accuracy | Pantone | approximately |
| Paper selection | any | limited |
What is offset printing?
- Business cards with 1000+ copies
- Booklets and brochures 500+
- Books and magazines
- Packaging (boxes, labels)
- Quarterly and wall calendars
- Posters and posters
- Postal envelopes
- Strict reporting forms
Typical work process
In our printing house, the offset printing process takes place in several stages:
- Acceptance of the layout and verification of its suitability for offset
- Color test (Epson Stylus Pro) — you can see how the finished product will look
- CtP (Computer-to-Plate) Mold Manufacturing — Aluminum plates are laser-exposed directly from a digital file
- Press adjustment — adjustment of paper supply, colors, pressure
- Print run
- Drying and post-processing (cutting, folding, binding)
- Packaging and delivery to the customer
Conclusion
Offset printing is the choice for large print runs with high quality requirements. If you need 1000+ copies of the same print run, offset will give you better quality at a lower price. For small print runs and personalized items, choose digital printing.
Both technologies work at the Seventh Legion printing house in Yekaterinburg. We will select the best option for your order. You can calculate the cost using the calculators on the website or by calling +7 (343) 288-71-82.
