Digital vs Litho Printing: What’s The Difference?

Newbies to the world of professional printing will be forgiven for not knowing the difference between digital and litho printing, or even what the latter is at all. As technology continues to improve in the printing industry, there is an increase in options to choose from when it comes to printing your marketing materials. However, digital and litho printing are still the most popular options. 

In this article, we’ll discuss the differences between the two and consider the various pros and cons involved so that you can choose which option is right for your needs.  

What is digital printing? 

Digital printing is the process of printing digital media directly onto a substrate such as paper, heavy cardboard, plastic, fabric and synthetic substrates. With digital printing, there is no need for a traditional printing plate.

Digital printing uses either toner (equipment like Canon and Xerox copiers) or wet ink (high end Indigo Presses from HP) to print directly onto various papers and substrates. Additionally, inkjet technology has come through the ranks and is becoming a contender in the direct-to-paper printing market, however, costs currently prohibit inkjet from tackling large quantities. This is set to change in the long term though. 

Digital files, such as PDFs or desktop publishing files, can be sent directly to the printer. Because of advancements in digital printing technology, the finished product quality has improved dramatically. Some of the results of these technological advancements include: 

• Variable data printing, which allows the personalisation of various print jobs
• Web2Print, a web-based system that allows you to print on demand 
• Cost-effective short print runs
• Fast turnaround times

As mentioned above, digital printing is great for customisation, which means that if there is a spelling or grammar error or any changes are needed, the file can be easily modified for a reprint, making it a very flexible option.

Examples of digital printing?

Digital printing is extremely flexible and print files can be easily modified with this option. As such, it can be used for almost any printing job, especially if you require printing on various different types of substrates. This makes digital printing ideal for printing promotional items like foldable packaging items on thick cardboard or plastic.

What are the pros and cons of digital printing? 

The pros 

• It’s great for producing on-demand short-run print jobs in a cost-effective way.
• The set-up time is very short since traditional printing plates aren’t needed.
• It’s great for modifying print jobs to create personalised projects using variable data printing.
• With digital printing, you are able to print sample books for approval. This is a great way to secure sales and feedback before the actual job goes to print. If high end equipment is used, the quality is comparable to litho printing, giving the customer a realistic sample of the end product.

The cons

• Some digital printing is limited to four colour runs - cyan, magenta, yellow and black (CMYK). 
• A digital print job that is done using toner can result in cracking if the product is folded or creased. Using toner can also result in bubbling or not adhering to the medium properly.
• Longer runs can become very expensive with digital printing because there is a cost per impression that remains static (referred to as a “click”).
• Not all digital printers cannot produce light colours or white to be printed on dark surfaces. 
  
  
  

What is litho printing? 

In contrast to digital printing, lithographic, or litho printing uses wet ink. 

In this style of printing, an image is transferred to a printing plate through a laser engraving process, which is then covered in water and oil-based ink. Lithography thereby uses the natural resistance of water and oil to mix the ink. The water only adheres to the non-image area, while the ink adheres to the image on the plate. This creates clear highly accurate copies. A rubber roller is then rolled over the image, transferring the image to the roller.  The rubber roller then applies the finished image to the final print surface, which, in the case of litho printing, is usually paper. 

Litho printing is also known as “offset printing” for this reason. The image is offset from the printing plate, as opposed to being applied directly. 

Litho printing works with four colours - cyan, magenta, yellow and black (CMYK). Each colour is represented as a screen (dots) in varying sizes and at a particular angle to ensure that at the end, when all four colours are printed on top of each other, a perfect high quality image is created. These four varying angles form what is referred to in printing as a “rosette”. The four colours combine in these patterns to create millions of different colours. Litho is the highest form of printing available and is a true art form to admire.

Examples of litho printing?

Litho printing is the most popular method used in the production of books, newspapers, magazines, and other commercial materials due to its high speed in completing large print jobs, and its accuracy.

What are the pros and cons of litho printing?

The pros

• Once everything is set up, i.e. the plates have been made and the spare material is available, the cost per copy is generally cheaper than that of digital printing for longer printing runs. 
• Printing is not limited to four colour runs (CMYK), as is the case with digital printing, and special inks can be included to enhance the finished product.
• Litho printing is much better for large areas of a solid single colour as the colour comes out smoother and no pixels can be seen.  

The cons

• The turnaround time with litho printing is usually longer.
• Initially litho printing can be quite costly and time-consuming to set up. This is due to the time needed to make plates for each section and the make-ready time required on each section to get to industry standards before printing can start.
• Litho printing doesn’t allow for variation and customisation due to the ready-made plates that have to be used.

Choosing the correct printing method for your next job

Both digital and litho printing have their benefits and drawbacks, and choosing which one is right for your next printing job really depends on the type of project, your budget and the timeframe you have allocated for the project to be completed. Litho printing can create beautiful, highly nuanced pieces, while digital printing can produce personalised items using variable-data technology. 

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