Offset printing is a common printing technique in which the inked image is transferred (or "offset") from a plate to a rubber blanket and then to the printing surface. When used in combination with the lithographic process, which is based on the repulsion of oil and water, the offset technique employs a flat (planographic) image carrier. Ink rollers transfer ink to the image areas of the image carrier, while a water roller applies a water-based film to the non-image areas.
The modern "web" process feeds a large reel of paper through a large press machine in several parts, typically for several meters, which then prints continuously as the paper is fed through.
Development of the offset press came in two versions: in 1875 by Robert Barclay of England for printing on tin and in 1904 by Ira Washington Rubel of the United States for printing on paper.[1] Rubel's contemporary in Continental Europe was Kašpar Hermann, the author of the offset machine prototype (1904), holder of a patent for an offset disc machine (two rubber transfer rollers facing each other) – rolling-press. In 1907, he successfully started printing in Germany on his Triumph sheetfed offset press.[2]
History
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Lithography was initially created to be an inexpensive method of reproducing artwork.[3][4] This printing process was limited to use on flat, porous surfaces because the printing plates were produced from limestone.[3] In fact the word "lithograph", which comes from Greek (λιθογραφία), means "an image from stone" or "written in stone".
The first rotary offset lithographic printing press was created in England and patented in 1875 by Robert Barclay.[3] This development combined mid-19th century transfer printing technologies and Richard March Hoe's 1843 rotary printing press—a press that used a metal cylinder instead of a flat stone.[3] The offset cylinder was covered with specially treated cardboard that transferred the printed image from the stone to the surface of the metal. Later, the cardboard covering of the offset cylinder was changed to rubber,[3] which is still the most commonly used material.
As the 19th century closed and photography became popular, many lithographic firms went out of business.[3] Photoengraving, a process that used halftone technology instead of illustration, became the primary aesthetic of the era. Many printers, including Ira Washington Rubel of New Jersey, were using the low-cost lithograph process to produce copies of photographs and books.[5] Rubel discovered in 1901—by forgetting to load a sheet—that printing from the rubber roller, instead of the metal, made the printed page clearer and sharper.[5] After further refinement, the Potter Press printing Company in New York produced a press in 1903.[5] By 1907 the Rubel offset press was in use in San Francisco.[6]
The Harris Automatic Press Company also created a similar press around the same time. Charles and Albert Harris modeled their press "on a rotary letter press machine".[7]
Newspaper publisher Staley T. McBrayer invented the Vanguard web offset press for newspaper printing, which he unveiled in 1954 in Fort Worth, Texas.[8]
Modern offset printing
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One of the important functions in the printing process is prepress production. This stage makes sure that all files are correctly processed in preparation for printing. This includes converting to the proper CMYK color model, finalizing the files, and creating plates for each color of the job to be run on the press.[9]
Offset lithography is one of the most common ways of creating printed materials. A few of its common applications include: newspapers, magazines, brochures, stationery, and books. Compared to other printing methods, offset printing is best suited for economically producing large volumes of high quality prints in a manner that requires little maintenance.[10] Many modern offset presses use computer-to-plate systems as opposed to the older computer-to-film work flows, which further increases their quality.
The 910-ton printing presses at the Las Vegas Review-Journal were the largest in the world when installed in 2000There are two types of offset printing: wet offset and waterless offset. Wet offset lithography uses a mix of wetting fluids (dampening solutions) to manage ink adhesion and to protect non-image areas. Waterless offset lithography employs a different method where a plate's non-image areas are protected via a layer of ink-repellent silicon. Waterless offset lithography is newer, invented in the 1960s by 3M. It was later sold and commercialized by Toray.[11]
Advantages of offset printing compared to other printing methods include:
Disadvantages of offset printing compared to other printing methods include:
Every printing technology has its own identifying marks, and offset printing is no exception. In text reproduction, the type edges are sharp and have clear outlines. The paper surrounding the ink dots is usually unprinted. The halftone dots can be hexagonal though there are different screening methods.[13]
Side view of the offset printing process. Multiple ink rollers are used to distribute and homogenize the ink.[14]Process variations
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Several variations of the printing process exist:
Blanket-to-blanket presses are also called perfecting or duplex presses because they print on both sides of the sheet at the same time.[16] There is no impression cylinder because the opposite blanket cylinders act as impression cylinders to each other during print production. This method is most used on offset presses designed for envelope printing. There are also two plate cylinders per colour on the press. Web and sheet-fed offset presses are similar in that many of them can also print on both sides of the paper in one pass, making it easier and faster to print duplex.
Plates
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Negative lithographic printing plateMaterials
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The plates used in offset printing are thin, flexible, and usually larger than the paper size to be printed. Two main materials are used:
Computer-to-plate (CTP) is a newer technology which replaced computer-to-film (CTF) technology, and that allows the imaging of metal or polyester plates without the use of film. By eliminating the stripping, compositing, and traditional plate making processes, CTP altered the printing industry, which led to reduced prepress times, lower costs of labor, and improved print quality.
Most CTP systems use thermal CTP or violet technologies. Both technologies have the same characteristics in terms of quality and plate durability (for longer runs). However, the violet CTP systems are often cheaper than thermal ones, and thermal CTP systems do not need to be operated under yellow light.
Thermal CTP involves the use of thermal lasers to expose or remove areas of coating while the plate is being imaged. This depends on whether the plate is negative, or positive working. These lasers are generally at a wavelength of 830 nm, but vary in their energy usage depending on whether they are used to expose or ablate material. Violet CTP lasers have a much shorter wavelength, 405 nm–410 nm. Violet CTP is "based on emulsion tuned to visible light exposure".[19]
Another process is the computer-to-conventional plate (CTCP) system in which conventional offset plates can be exposed, making it an economical option.
Sheet-fed offset
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Roland Favorit RF01 sheet-fed offset press Ryobi 4 color offset pressSheet-fed refers to individual sheets of paper or rolls being fed into a press via a suction bar that lifts and drops each sheet onto place. A lithographic ("litho" for short) press uses principles of lithography to apply ink to a printing plate, as explained previously. Sheet-fed litho is commonly used for printing of short-run magazines, brochures, letter headings, and general commercial (jobbing) printing. In sheet-fed offset, "the printing is carried out on single sheets of paper as they are fed to the press one at a time". Sheet-fed presses use mechanical registration to relate each sheet to one another to ensure that they are reproduced with the same imagery in the same position on every sheet running through the press.[20]
Offset duplicators
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In the United States, an offset press with paper size up to 12 in × 18 in (300 mm × 460 mm), is classified as a duplicator instead of a press. Offset duplicators are used for fast, good quality reproduction of one-color and two-color copies in sizes up to 12 in × 18 in (300 mm × 460 mm).[17] Popular models were made by A. B. Dick Company, Multilith, and the Chief and Davidson lines made by A.T.F.-Davidson. Offset duplicators are made for fast and quick printing jobs; printing up to 12,000 impressions per hour. They are able to print business forms, letterheads, labels, bulletins, postcards, envelopes, folders, reports, and sales literature.
Feeder system
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The feeder system is responsible for making sure paper runs through the press correctly. This is where the substrate is loaded and then the system is correctly set up to the certain specifications of the substrate to the press.[21]
Printing–inking system
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The Printing Unit consists of many different systems. The dampening system is used to apply dampening solution to the plates with water rollers. The inking system uses rollers to deliver ink to the plate and blanket cylinders to be transferred to the substrate. The plate cylinder is where the plates containing all of the imaging are mounted. Finally, the blanket and impression cylinders are used to transfer the image to the substrate running through the press.[22]
Delivery system
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The delivery system is the final destination in the printing process while the paper runs through the press. Once the paper reaches delivery, it is stacked for the ink to cure in a proper manner. This is the step in which sheets are inspected to make sure they have proper ink density and registration.
Slur
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Production or impact of double image in printing is known as slur.[23][verification needed]
Web-fed offset
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Web-fed refers to the use of rolls (or "webs") of paper supplied to the printing press.[24] Offset web printing is generally used for runs in excess of five or ten thousand impressions. Typical examples of web printing include newspapers, newspaper inserts or ads, magazines, direct mail, catalogs, and books. Web-fed presses are divided into two general classes: cold-set (or non-heat-set) and heat-set offset web presses, the difference being how the inks dry. Cold web offset printing dries through absorption into the paper, while heat-set utilizes drying lamps or heaters to cure or "set" the inks. Heat-set presses can print on both coated (slick) and uncoated papers, while cold-set presses are restricted to uncoated paper stock, such as newsprint. Some cold-set web presses can be fitted with heat dryers, or ultraviolet lamps (for use with UV-curing inks), thus enabling a newspaper press to print color pages heat-set and black & white pages cold-set.
Web offset presses are beneficial in long run printing jobs, typically press runs that exceed 10,000 or 20,000 impressions. Speed is a determining factor when considering the completion time for press production; some web presses print at speeds of 3,000 feet (910 meters) per minute or faster. In addition to the benefits of speed and quick completion, some web presses have the inline ability to cut, perforate, and fold.
Heat-set web offset
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This subset of web offset printing uses inks which dry by evaporation in a dryer typically positioned just after the printing units; it is typically done on coated papers, where the ink stays largely on the surface, and gives a glossy high contrast print image after the drying. As the paper leaves the dryer too hot for the folding and cutting that are typically downstream procedures, a set of "chill rolls" positioned after the dryer lowers the paper temperature and sets the ink. The speed at which the ink dries is a function of dryer temperature and length of time the paper is exposed to this temperature. This type of printing is typically used for magazines, catalogs, inserts, and other medium-to-high volume, medium-to-high quality production runs.
Cold-set web offset
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This is also a subset of web offset printing, typically used for lower quality print output. It is typical of newspaper production. In this process, the ink dries by absorption into the underlying paper. A typical coldset configuration is often a series of vertically arranged print units and peripherals. As newspapers seek new markets, which often imply higher quality (more gloss, more contrast), they may add a heatset tower (with a dryer) or use UV (ultraviolet) based inks which "cure" on the surface by polymerization rather than by evaporation or absorption.
Sheet-fed presses offer several advantages. Because individual sheets are fed through, a large number of sheet sizes and format sizes can be run through the same press. In addition, waste sheets can be used for make-ready (which is the testing process to ensure a quality print run). This allows for lower cost preparation so that good paper is not wasted while setting up the press, for plates and inks. Waste sheets do bring some disadvantages as often there are dust and offset powder particles that transfer on to the blankets and plate cylinders, creating imperfections on the printed sheet. This method produces the highest quality images.
Web-fed presses, on the other hand, are much faster than sheet-fed presses, with speeds up to 80,000 cut-offs per hour (a cut-off is the paper that has been cut off a reel or web on the press; the length of each sheet is equal to the cylinder's circumference). The speed of web-fed presses makes them ideal for large runs such as newspapers, magazines, and comic books. However, web-fed presses have a fixed cut-off, unlike rotogravure or flexographic presses, which are variable.
Inks
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Offset printing uses inks that, compared to other printing methods, are highly viscous. Typical inks have a dynamic viscosity of 40–100 Pa·s.[25]
There are many types of paste inks available for utilization in offset lithographic printing and each have their own advantages and disadvantages. These include heat-set, cold-set, and energy-curable (or EC), such as ultraviolet- (or UV-) curable, and electron beam- (or EB-) curable. Heat-set inks are the most common variety and are "set" by applying heat and then rapid cooling to catalyze the curing process. They are used in magazines, catalogs, and inserts. Cold-set inks are set simply by absorption into non-coated stocks and are generally used for newspapers and books but are also found in insert printing and are the most economical option. Energy-curable inks are the highest-quality offset litho inks and are set by application of light energy. They require specialized equipment such as inter-station curing lamps, and are usually the most expensive type of offset litho ink.[citation needed]
In industry
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Offset lithography became the most popular form of commercial printing from the 1950s ("offset printing"). Substantial investment in the larger presses required for offset lithography was needed, and had an effect on the shape of the printing industry, leading to fewer, larger, printers. The change made a greatly increased use of colour printing possible, as this had previously been much more expensive. Subsequent improvements in plates, inks, and paper have further refined the technology of its superior production speed and plate durability. Today,[when?] lithography is the primary printing technology used in the U.S. and most often as offset lithography, which is "responsible for over half of all printing using printing plates".[27]
See also
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References
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Further reading
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There has been a longstanding debate over print on demand (POD) versus offset printing. What’s the difference? Is one truly better than the other? The answer, it depends.
Benefits of Print on Demand
Print on demand is just like it says: a book is printed when someone wants it. There is no inventory kept on hand. When someone makes a purchase from an online retailer or an author wants copies, that is when the book is printed in the quantity needed. There are several benefits to this type of printing.
1. Speed and Reduced Costs
As printing technologies have advanced, a more accessible method of printing has emerged. POD offers a wide array of authors a cheaper and faster method by printing directly from file to paper. This method offers a great reduction in the cost and labor required with traditional forms of publishing.
For small orders, a book can be printed and shipped to a consumer within a day or two of ordering. Thus, an author wanting copies of their book can get it printed in a couple of days to weeks, depending on the order.
This allows authors the ability to sell their book at a retailer without having to pay for any printing because the printing cost is built into the retail price. The author only has to pay for copies they print for themselves. Speed is the priority. In summary, the turnaround time is superior to offset printing. You can receive your books within 2-7 business days, rather than 3+ months.
2. Flexible Printing Options
The nice thing about POD is that an author can print in any quantity. There are no minimums or maximums. Larger quantities (750+) can take a little longer to print, most POD printers can print any quantity in a couple of days to weeks.
This allows authors the flexibility to order a couple of copies for friends or to order hundreds of copies for a speaking event. Flexible ordering can be helpful as events arise or demand changes.
3. Reduced Supply Chain Repercussions
Another benefit is that during times of tight paper supply, POD printers are not as affected by the supply chain. POD printers use a standard paper for their printing.
Because they are using a standard paper, it allows these printers to acquire the paper they need in the quantities that they need them. This helps to insulate them from the problems with the supply chain, supporting an author’s peace of mind. Standardization is key.
4. Ease of Revisions
Many authors discover that the process doesn’t end even after the first print run. In fact, authors, especially less seasoned authors, may wish to fix typos, update attributions, or make any other host of changes to their book.
If the changes are pressing, you will need to update your inventory. With digital printing, this is a relatively easy process. Instead of financing another 1,000 books via offset printing, you can simply make the updates as new batches of inventory are produced.
5. Inventory Storage
Since digital printing allows you to print only what you need at a time, you have significantly fewer copies to store. With offset printing, you will probably require a storage facility with sufficient climate control to store your copies. You may avoid this costly step if you need small batches of copies produced at a time.
Benefits of Offset Printing
The offset printing process is how books have been traditionally printed. This type of printing allows the author to print mass quantities at a high quality and a cheaper price. There are several benefits to printing in this manner.
1. Creative and Appealing Covers
First, the quality of traditional printing is the highest. The author can have many elements added to the cover. Raised lettering, foil, spot gloss, holographics, and more can be added to the cover to make it really stand out and catch the attention of a consumer.
These elements are only available through a traditional printer. Quality is a priority, not cost or speed.
2. Custom Ink
Offset printing allows the author greater choice when it comes to ink. Instead of the standard ink choices, they can choose from metallics or Pantone colors. Many people praise offset printing for better color quality and for printing “true-to-color.” However, paper choice also plays a role in how the color is perceived on the final product.
3. Bulk Printing
The price to print per book is low compared to POD. This is because they print large volumes at a time. The minimum to print is 1,000 copies. These large volumes allow the cost to print to stay low.
With offset printing, a book is made by first creating “plates” for each page. This results in increased labor and time. However, once the plates are made, the printing can be accomplished with speed and ease. This is why the cost is less per unit as greater quantities are produced.
This gives the author the opportunity to print books with the highest quality and lowest price. For authors that will use a thousand copies or more throughout the year, this allows them to maximize their margins.
Should I Choose POD or Offset Printing?
The choice between POD or offset printing is based on the needs of the author. If an author doesn’t need a lot of books, POD is better. If an author prefers quality and can use 1k copies throughout a year, then offset printing is better. However, there is one thing to keep in mind.
Bookstores prefer to work with authors that had an offset print run. This is because they want books that are readily available. The discounts from wholesalers are also better on offset print runs versus POD print runs. There are ways around it, which is why working with a distributor is important.
Get Expert Distribution Advice
At the end of the day, weigh the pros and cons of both options. There are benefits and drawbacks to each.
At Forbes Books, we offer a full-fledged distribution service to help you identify which option supports your needs the best. Learn more about how Forbes Books can help you publish your book and distribute it to top retailers by visiting our Book Distribution page.