Printing processes.

Screen Printing

Setup: Uses basic screens and inks; low setup costs make it ideal for workshops.

Method: Ink is pushed through open areas in a mesh screen. A different screen is required for every color used.

Usage: Slow process with a high cost per unit. Best for small runs of posters, display boards, and T-shirts.

Flexographic Printing

Flexography uses flexible relief plates and fast-drying, water-based inks. It is common for packaging and continuous patterns.

Advantages:

Extremely high print speeds.

Perfectly suited for very long production runs.

Can print on a wide variety of substrates (plastics, films, paper).

Low cost of equipment, consumables, and maintenance.

Disadvantages:

The initial cost of printing plates is high (though they last a long time).

Setting up the job requires a large amount of substrate, leading to high initial waste.

Any changes to the print content are time-consuming and difficult.

Offset Lithographic Printing

A highly versatile process based on the principle that oil and water do not mix. It can handle up to 10 features (CMYK, metallics, varnishing, and double-sided printing).

Advantages:

Provides consistently high image quality.

Most cost-effective for high-volume runs (1,000+ units).

Printing plates are quick and easy to produce.

Plates have a long life because they only touch a soft "printing blanket" rather than the abrasive substrate.

Disadvantages:

Setup and running costs are too expensive for small quantities.

Digital Printing

Digital printing is the go-to for speed and efficiency, as it requires no physical plates.

Capabilities: Produces full-color, high-detail prints with the ability to change the design on every single page (front and back).

Mass Customisation: Ideal for "Print on Demand" (e.g., personalized names on bottles) because it uses fast-drying inks and requires zero setup time between different designs.

Usage: Popular for both low- and high-volume runs, especially promotional materials like flyers and business cards