When it comes to choosing the right printing method for your project, understanding the difference between litho and digital printing is essential. Whether you’re printing business cards, brochures, flyers or large-scale posters, the method you choose can affect the cost, quality, turnaround time, and even the environmental impact of your job. Although both litho and digital printing have their advantages, they serve different purposes depending on your needs. In this blog, we’ll explore the key distinctions between lithographic and digital printing, the scenarios in which each is most effective, and how to decide which one is right for you.
Understanding Lithographic Printing
Lithographic printing, often referred to simply as “litho”, is a traditional printing technique that has been around for well over a century. The process is based on the principle that oil and water do not mix. In litho printing, an image is first etched onto a metal plate, typically aluminium. This plate is then coated with ink, which adheres only to the image area, while the non-image areas attract water and repel the ink. The inked image is transferred from the plate onto a rubber blanket, and finally onto the paper. This is why it is also known as offset printing – because the image is not transferred directly to the paper.
One of the defining features of litho printing is the setup process, which includes creating plates for each colour. This process takes time and preparation, but once it’s set up, the printer can produce large volumes quickly and efficiently. The quality is consistently high, with rich colour reproduction, sharp detail, and smooth gradients. Litho printing is particularly well-suited to medium to large print runs, where the cost of setup can be amortised over thousands of copies.
What Is Digital Printing?
Digital printing is a much more modern technique that emerged with the rise of digital technology in the late 20th century. Unlike litho printing, digital methods do not require physical plates. Instead, the artwork is sent directly to the printer via a digital file, typically a PDF. The image is printed onto the paper using either toner (in laser printers) or ink (in inkjet printers), similar to how a desktop printer works – though on a much larger and more sophisticated scale.
Because there is no need for plates, digital printing is ideal for short-run jobs or where time is of the essence. It allows for instant printing with minimal setup, making it perfect for personalised prints, test proofs, and on-demand printing. Digital presses are capable of producing surprisingly high-quality results, particularly in the latest generations of machines, although there are some differences in texture and colour richness compared to litho, especially on uncoated or specialty stocks.
Turnaround Time and Speed
One of the most significant differences between litho and digital printing is turnaround time. With digital printing, you can often receive your finished prints the same day or within 24 hours. Because there’s no plate-making or lengthy setup involved, you simply upload your artwork, proof it, and print. This makes digital printing especially useful for urgent jobs or last-minute print requirements, which is something many local businesses in Stevenage and beyond value highly.
Litho printing, on the other hand, requires more time due to the setup process. Plates must be made, the machine must be calibrated, and test sheets must be run before a full print job begins. Once it’s running, however, litho is faster in terms of producing large volumes. If you’re ordering thousands of leaflets or catalogues, litho will usually complete the run more efficiently, even if the initial setup takes longer.
Cost Considerations
Cost is always a key factor when deciding on a printing method, and the economics of litho and digital printing are quite different. With litho printing, there is a higher upfront cost due to plate creation and setup. However, the more copies you produce, the cheaper each unit becomes. This is because the setup cost is spread over the quantity printed. For high-volume print runs, litho can offer excellent value for money and unmatched per-unit cost savings.
Digital printing operates differently. Because there is virtually no setup involved, the cost per copy remains relatively constant regardless of volume. This means it’s more economical for short runs – say, under 500 copies – or for bespoke items like wedding invitations, one-off posters, or custom packaging samples. If you need 50 flyers for an event tomorrow, digital printing is undoubtedly the most cost-effective solution.
Print Quality and Colour Consistency
Both litho and digital printing can produce high-quality results, but there are some nuances to be aware of. Litho printing is known for its superior colour accuracy and consistency, especially for jobs involving large solid areas of colour or fine gradients. Litho presses can handle Pantone colour matching with precision, which is vital for branding consistency. The detail and sharpness achieved through litho are often preferred for high-end print work such as luxury brochures, art prints, or coffee table books.
Digital printing has improved dramatically in recent years, with advancements in toner technology, inkjet resolution, and colour calibration. Today’s digital presses can produce vibrant, detailed prints that are suitable for most commercial applications. However, there may still be slight differences in colour accuracy when compared side by side with litho, particularly when printing on textured or specialty papers. Additionally, digital inks tend to sit on the surface of the paper, while litho inks absorb slightly into the stock, giving a subtly different finish.
Paper and Material Options
The type of paper or material you plan to print on can also influence your choice of printing method. Litho presses are generally more versatile when it comes to paper stocks, especially heavier weights or textured papers. They can also handle larger sheet sizes, making them suitable for posters, folded brochures, or multi-page documents that require trimming and binding.
Digital printing, while versatile in its own right, can be limited by the thickness and texture of paper it can run through the press. Certain textured papers or coated stocks may not print as well digitally, and large-format digital machines may be restricted in terms of sheet size. That said, digital printing does support a wide range of standard coated and uncoated papers, and many printers now carry digitally-optimised stocks designed specifically for best results with digital technology.
Personalisation and Variable Data Printing
One area where digital printing truly shines is personalisation. With digital presses, it is easy to change text, images, or other content from one sheet to the next without stopping the press. This is known as variable data printing (VDP), and it is widely used in direct mail campaigns, personalised letters, membership cards, and more. Each piece can be uniquely tailored to the recipient, which can significantly improve engagement and response rates.
Litho printing, by contrast, is not suitable for variable data or personalised jobs. Once the plates are created, every sheet will be identical unless the plates are changed and the machine reset – an expensive and time-consuming process. For this reason, litho is better suited to standardised print runs where every copy is the same.
Environmental Impact
Environmental considerations are increasingly important in the printing industry, and both litho and digital printing have their pros and cons in this area. Litho printing traditionally used more chemicals, water, and energy, especially in older presses. However, modern litho machines have become much more environmentally friendly, with innovations such as waterless printing, soy-based inks, and low-waste workflows. Many litho printers now use FSC-certified papers and offer carbon-neutral printing options.
Digital printing, while using less water and fewer chemicals, can have a higher carbon footprint per unit on large runs due to increased energy consumption. Toner and ink cartridges also create waste, although many digital printers have recycling schemes in place. From an eco-friendly perspective, short-run digital jobs are typically less wasteful, while larger litho runs, once set up, are more efficient. The key is choosing a printer who prioritises sustainability, regardless of method.
When to Choose Litho Printing
Litho printing is the best choice when you need to print in large quantities, require very specific colour matching, or want to use premium paper stocks. It is ideal for catalogues, magazines, corporate stationery, packaging, and high-end marketing materials. If brand colour consistency is crucial – for example, if you’re printing brochures and business cards across multiple campaigns – litho is likely to give you the consistency and quality control you need. It also remains the preferred choice for special finishes like spot UV, metallic inks, embossing, and die-cutting, which are more compatible with traditional print workflows.
When to Choose Digital Printing
Digital printing is perfect for short runs, urgent deadlines, and personalised materials. Whether you’re launching a local event in Stevenage and need same-day posters, or you’re sending out individualised postcards to your customer list, digital offers unbeatable speed and flexibility. It’s also ideal for testing new designs before committing to a full litho run. As technology continues to advance, digital presses are closing the gap in terms of quality and durability, making them suitable for an increasingly wide range of projects.
Final Thoughts
Both litho and digital printing have their place in modern print production, and the best choice often depends on the specific needs of your job. If you’re working with tight deadlines, small quantities, or require customisation, digital printing is likely your best option. If you need a large volume, high-quality colour accuracy, and premium finishes, litho may be the better route.
At XL Print in Stevenage, we offer both digital and litho printing services, providing expert guidance on which method suits your project best. Our team is always happy to advise, whether you’re printing a few leaflets for a local event or producing thousands of brochures for a national campaign. With decades of experience and a commitment to quality, we ensure that your print materials make the right impression – every time. Contact us today.
