Offset vs. digital printing: an overview of the fundamentals and future prospects

In the printing industry, few topics are discussed as frequently as the question ‘offset or digital printing?’. It often seems as if offset and digital printing are locked in a battle for supremacy. But we can say this much in advance: in reality, both processes complement each other depending on the task and objective. To understand this, let's take a look at how the two printing technologies work, their strengths and their possible applications. Finally, we will consider the influence of current trends on development and what the future of the two technologies might look like.

Let's start with the older of the two printing processes. Offset printing is an indirect process. First, the motif is transferred to a plate, which is then used to print onto the printing material via a rubber blanket. This technique ensures consistently high-quality prints with rich colours, and can be used with a wide variety of materials – from thin paper to sturdy cardboard.

The strength of offset printing lies in its reproducibility: once set up, an offset machine consistently delivers high-quality results across thousands or even millions of copies. Offset printing is unparalleled, particularly when using special colours according to Pantone or HKS. The colour density and brilliance that can be achieved on various substrates make it indispensable for producing high-quality magazines, art catalogues, and premium packaging.

However, offset printing requires the production of printing plates, which involves preparation time and costs. These set-up costs must be amortised over the print run, which is why the economic advantages of offset printing only become apparent above a certain minimum quantity. Nevertheless, modern developments such as computer-to-plate (CtP) systems have significantly reduced setup times and streamlined the process.

With digital printing, this intermediate step is completely eliminated. Print data is transferred directly from a file to a substrate using either toner (electrophotography) or inkjet technology. This process is ideal for short set-up times, small print runs and flexible content. As no plates are required, variable data such as names, barcodes and QR codes can also be easily integrated.

Technological developments in digital printing are rapid. Modern inkjet systems now achieve print speeds and resolutions that were unthinkable just a few years ago. UV inkjet technology enables printing on materials that were previously unsuitable for digital printing. Water-based inks reduce environmental impact, and LED UV curing reduces energy consumption.

Another advantage is that errors in digital printing can be easily corrected. If an error is discovered in the file, production can be adjusted immediately, eliminating the need to recreate expensive plates. This flexibility makes digital printing ideal for agile production environments where requirements can change quickly.

Costs & print runs

As a general rule, digital printing is more cost-effective for print runs of up to around 500 copies. For larger print runs, however, offset printing is more cost-effective, as the fixed costs for plate production are spread over a greater number of copies. However, this depends to a large extent on the printing units themselves.

The boundary between the two processes is constantly shifting, though. Advances in digital printing, particularly inkjet systems, are making the process economically viable for medium print runs. At drupa 2024, machine manufacturers presented innovations that are redefining these break-even points. Some experts now estimate this threshold to be between 1,000 and 1,500 copies, depending on the format and complexity.

Another significant cost advantage of digital printing that is often overlooked is warehousing. Digital printing enables just-in-time production and print-on-demand. This means that companies do not have to produce large quantities in advance. This reduces storage costs, minimises the risk of obsolete materials, and improves cash flow.


Quality & colour fidelity

Offset printing is still considered the gold standard for colour consistency, particularly for special colours according to Pantone or HKS. The physical transfer of ink via the rubber blanket ensures a uniform ink layer thickness and brilliance, which is ideal for demanding applications such as art prints or premium catalogues.

However, digital printing is catching up fast. Modern inkjet systems offer excellent colours and a resolution that is perfectly adequate for most applications. Thanks to the development of extended colour gamuts, digital printing can now cover a wider spectrum than before using CMYK combinations. Some high-end digital printing systems already use seven or more colours to digitally simulate special colours.

At drupa 2024, leading manufacturers demonstrated how modern digital printing technologies are closing the gap with offset printing. Breakthroughs in printhead technology and ink formulations were particularly evident in inkjet technology. These innovations take colour fidelity and durability to a new level.


Speed & flexibility

Anyone requiring small print runs or customised content quickly will benefit from digital printing. Print-on-demand for books or personalised advertising materials would be virtually unthinkable without it. The ability to go from order to finished product in minutes is transforming business models in many industries.

Offset printing, on the other hand, is highly efficient for large print runs. Modern sheetfed offset presses can reach speeds of up to 18,000 sheets per hour, but web offset presses are even faster. Once set up, they can produce large quantities in a very short time.


Material diversity

Offset presses are compatible with a wide range of papers and cardboards, including special substrates such as metallic papers and textured or extra-thick cardboards. Mechanical transmission via the blanket ensures consistent ink transfer, even on challenging materials.

Digital printing systems have become considerably more flexible in recent years, but remain limited in some areas. Modern UV inkjet systems can now print on a wide variety of substrates, including smooth films, corrugated cardboard and textiles. A recent breakthrough has been the development of improved primer systems that enhance the adhesion of digital inks to challenging substrates. These developments are continuously expanding the range of applications for digital printing, making it a viable option for jobs that were previously exclusively the domain of offset printing.

Personalisation: the game changer in marketing

One clear advantage of digital printing is the ability to produce personalised prints. Each copy can be different, featuring names, codes or unique designs. This capability has fundamentally changed marketing. Variable data printing (VDP) enables printed products to be tailored to individual recipients, and this has been shown to lead to higher response rates.

Major brands are already using this technology for innovative marketing campaigns on products such as beverage cans and collectible packaging. Nowadays, we are seeing an increasing number of campaigns where entire designs are personalised based on customer preferences and geographical data from purchase history, not just names.

At drupa, machine manufacturers constantly demonstrate how they are increasing the speed and quality of such applications. This also enables personalised medium and large print runs to be produced. Modern workflow software can automatically generate thousands of individual designs from database entries. This makes the production of highly personalised campaigns economically viable.

The next step is real-time personalisation. QR codes and augmented reality elements on print products link the physical and digital worlds, enabling interactive, personalised customer experiences.


Hybrid solutions: the best of both worlds

Projects are increasingly combining offset printing for stable foundations with digital printing for variable content. This enables large quantities to be produced efficiently while retaining flexibility.

For example, a company might produce 100,000 catalogues using offset printing. However, the final few pages featuring regional offers are added digitally, meaning that each region receives its specific information without the need for 20 different offset print runs.

Hybrid printing presses make this possible by combining offset and digital printing modules in a single production line. Intelligent workflow software controls this integration, automatically deciding which pages are produced using which process.

Another hybrid scenario is offset printing with digital finishing. Basic prints are efficiently produced using offset, while high-quality effects such as metallic accents, raised embossing, and individual personalisation are added digitally. This combination enables the production of premium products at predictable costs.


Why the future belongs to both

Offset and digital printing are complementary technologies that optimally meet different needs. While offset printing continues to play a key role in quality and mass production, digital printing offers greater flexibility, personalisation and sustainability.

The future belongs to 'both/and', not 'either/or'. Companies that combine both processes intelligently are best placed to meet the growing demands of customers and markets. The boundaries between the two technologies are becoming increasingly blurred, with hybrid solutions becoming the norm.

Technological advances will further improve both processes. Digital printing is becoming faster and higher quality, as well as more economical for larger print runs. Meanwhile, offset printing is becoming more flexible, sustainable and efficient. These developments are making the printing industry more versatile and innovative than ever before.

For print service providers and their customers, this diversity means one thing above all else: more opportunities to implement creative ideas, optimise costs, and produce print products that precisely meet requirements, whether in small quantities or in large print runs.