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The Printing Process (Part 2): Printing Methods

Release time:

2016-04-20 10:00

The Printing Process (Part 2): Printing Methods

I. Classification of Printing Methods

1. The Four Major Printing Methods

Printing methods are classified according to the relative positions of the image and non-image areas on the printing plate:

(1) Letterpress printing (2) Offset printing (3) Rotogravure printing (4) Screen printing

2. Offset printing

Definition: In this printing method, the image and text areas on the printing plate are nearly flush with the non-image and non-text areas. Ink transfer is achieved by leveraging the principle that oil and water repel each other, allowing the ink to be transferred onto the substrate. It is the most commonly used printing technique and can be applied to print newspapers, packaging, posters, books, magazines, and more.

3. Gravure printing

Definition: Tiny recessed dots are engraved onto a metal roller to store ink, which is then transferred onto the substrate. This technique is suitable for high-end printing applications such as cigarette and liquor labels, postage stamps, coins, candy wrappers, and premium plastics.

4. Letterpress printing

Definition: Printing using a relief plate (a printing plate in which the image and text areas are raised). Commonly referred to as letterpress printing. It can be used for packaging paper, self-adhesive labels, paper cups, and more.

5. Screen printing

Definition: Also known as stencil printing and screen printing, this method involves forcing ink through the openings in a stencil.

6. According to the paper feeding method

(1) Flatbed printing: Also known as single-sheet printing, it is a printing method that uses flat sheets of paper.

(2) Web offset printing: Also known as rotary printing, this is a method of printing using roll-fed paper.

7. Whether the printing plate directly contacts the substrate

(1) Direct printing: In this method, the ink on the printing plate comes into direct contact with the substrate for printing, such as letterpress printing, gravure printing, and screen printing.

(2) Indirect printing: A printing method in which the ink from the printing plate is transferred onto the substrate via an intermediate rubber blanket.

8. According to whether a printing plate is used

(1) Plate printing: This refers to a printing method in which a pre-made printing plate is used to print onto the substrate, including letterpress printing, gravure printing, and screen printing.

(2) Plateless Printing: A printing method in which the printing plate directly prints onto the substrate via a computer-controlled print head (or printing head). Examples include digital printing.

9. Based on the principle of printing

(1) Physical printing

In the printed areas, the ink is entirely deposited and accumulated; in the non-printed areas, the surface is either recessed or raised, with a height difference from the printed areas that prevents it from picking up ink. Consequently, these non-printed areas remain blank, while the ink from the printed areas transfers onto the substrate solely through physical and mechanical action. Typically, letterpress printing, gravure printing, screen printing, and dry offset printing all fall under the category of physical printing (where the printing surface is either higher or lower than the non-printing surface).

(2) Chemical printing

The non-printing areas of the printing plate—those not intended for ink application—are unable to accept ink not because they are recessed, raised, or obstructed, but rather due to a chemical reaction that forms a thin film capable of absorbing water while repelling ink. Of course, the fact that the printing areas (the ink-receptive surfaces) absorb ink and repel water, whereas the non-printing areas absorb water and repel ink, and that water and oil mutually repel each other, is still a physical phenomenon. However, during the printing process, it is essential to continuously replenish this water-absorbing, ink-repelling film on the non-printing areas; thus, this type of printing is chemically based. Offset printing falls into this category. In offset printing,胶类 substances must be added to the fountain solution to ensure a constant supply of a mucilaginous layer rich in hydroxyl groups, thereby preventing the non-printing areas of the printing plate from being contaminated by oils.

10. Based on the number of printing colors

(1) Monochrome printing

Monochrome printing refers to printing using a single plate, which can be either black-and-white printing, color printing, or spot-color printing. Spot-color printing involves specially mixing a unique color required for the design as the base color and completing the print with just one plate.

(2) Color printing

Color printing is a method of reproducing images or text in color (in contrast to black-and-white printing, also known as monochrome printing). It involves numerous steps—or conversion processes—to produce high-quality color reproductions.

11. According to printing purpose

(1) Book and magazine printing: Previously, letterpress printing was commonly used. Now, it is gradually being replaced by offset printing.

(2) Advertising Printing: Most of the materials—including color images, pictorials, posters, and the like—are produced using offset printing; occasionally, letterpress, gravure, or screen printing is also employed.

(3) Printing of banknotes and other negotiable securities: Primarily using gravure printing, supplemented by letterpress and offset printing to fully achieve the desired results.

(4) Map printing: Offset lithography is the most suitable method. This is because maps typically cover large areas, require high precision, involve multiple colors, and are printed in relatively small quantities; moreover, the original manuscripts are often monochromatic.

(5) Stationery printing—such as envelopes, letter paper, invitation cards, business cards, account books, exercise books, and the like—must be cost-effective and produced in large quantities; therefore, the quality tends to be relatively lower. For this reason, letterpress printing is often given priority.

(6) Packaging and Printing: From small items such as various types of alkaline, sweet, and vegetable snacks, candies, cookies, candied fruits, to larger items like corrugated cardboard boxes used for packaging and wallpaper used for interior decoration—most of these are printed using gravure photography.

(7) Special printing: such as bottle and can printing, hot stamping, embossing, flexible tubing printing, electronic printing, circuit board printing, label printing, ticket printing, and foil printing.

12. According to the printing plate

13. Based on the substrate material

II. The Most Commonly Used Industrial Printing Methods

1. Offset printing

Offset printing, also known as lithographic printing in the Guangdong and Hong Kong regions, is a type of planographic printing and represents the primary method of printing. Offset printing can accurately and clearly reproduce the colors, contrast, and tonal range of the original artwork with high precision, making it currently the most widely used method for printing on paper. It is suitable for posters, brochures, instruction manuals, newspapers, packaging, books, magazines, calendars, and other types of color-printed materials.

2. Flexographic Printing

Flexographic printing, a type of letterpress printing technology also known as aniline printing, uses rubber and flexible resin plates and employs water-soluble inks for printing. The original inks used were aniline dyes, which is why it was formerly referred to as aniline printing. This method is commonly used for printing plastic bags, labels, and corrugated cardboard. The fineness of printed halftones and lines has gradually approached that of offset printing.

3. Screen printing

As a printing technique with a wide range of applications, screen printing can be categorized according to the substrate material used: textile printing, plastic printing, metal printing, ceramic printing, glass printing, electronic product printing, lottery ticket screen printing, screen printing for illuminated advertising boards, screen printing for metal advertising signs, screen printing on stainless steel products, screen printing on light-reflecting materials, screen-printed electro-aluminum transfers, screen-printed prints and lacquerware screen printing, and more.

One of the intaglio printing techniques, screen printing uses particularly thick printing inks, making it ideal for producing prints with special effects. It is especially well-suited for small-run jobs that require high ink density. Moreover, this technique can be applied to three-dimensional surfaces such as square boxes, crates, round bottles, and cans. In addition to paper, it can also be used on fabrics, plastic materials, plywood, film, metal sheets, glass, and other substrates. Common new products include banners, streamers, T-shirts, corrugated cardboard boxes, soda bottles, and circuit boards. The flexibility of screen printing is unmatched by any other printing method.

4. Gravure printing

Suitable for printing high-quality, high-value documents, whether color or black-and-white images, gravure printing can achieve results that rival photographic quality. Due to the high cost of plate-making, large print runs are essential, making this method relatively less commonly used among general printing techniques. It is particularly well-suited for printing securities, stocks, gift certificates, commercial credit instruments, and stationery items.

III. Other Printing Methods

1. Transfer printing

A printing method in which the ink is first applied to a medium and then transferred from the medium onto the substrate.

2. Woodblock watermark

Also known as woodblock watermarking, this is a traditional printing technique in which a drawing is divided into several separate printing blocks, each of which is then printed using water-soluble pigments.

3. Lithography

Abbreviated as lithography. A flatbed printing process that uses stone as the printing plate.

4. Collotype printing

Also known as lithography on glass. A thick glass plate is coated with a photosensitive layer, and a negative image is used for exposure to create varying degrees of water absorption. Printing is based on the principle of oil-water repulsion.

5. Letterpress printing

That is, handwritten wax paper mimeograph.

6. Copper-zinc plate printing

Also known as letterpress printing. A printing method that uses copper or zinc plates as printing plates.

7. Resin plate printing

A printing method that uses resins, nylon, and other materials as printing plates.

8. Paper-based printing

Small-scale lithography using paper as the printing plate.

9. Light printing

Also known as the office printing system, this is a printing system that uses phototypesetting equipment, small offset presses, and small binding machinery.

“Light printing” is a relatively early concept referring to printing processes that involve very simple plate-making and printing techniques—for example, printing black-and-white text, which is typically accomplished using laser printers. As plate-making and printing technologies have advanced, grayscale and color printing with tonal gradations have become easy and cost-effective to achieve, and the category of “light printing” has largely faded away.

10. Online printing

The concept of online printing was introduced to China in 2005. It’s a solution that leverages the internet to provide printing services, enabling customers to obtain the printed materials they desire simply by using their personal computers.

Web-to-Print (WTP) is a term that first emerged in the late 1990s. It has gradually evolved into a convenient method for carrying out printing, driven by advancements in web technology and the growing popularity of online applications. WTP is not a printing method itself—it’s a printing solution.

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