Printing Processes Explained: What Are They?

Printing Processes Explained: What Are They?

If you’ve ever wondered why one print job looks ultra crisp, another feels richly textured, and another is built for high-volume packaging or labeling, it comes down to the printing process.

This guide explains the most common printing processes used by professional print shops—offset lithography, digital printing, large-format printing, screen printing, flexography, and gravure—and gives you a clear way to choose the best option based on quality, quantity, turnaround time, and materials.

Quick Comparison: Which Printing Process Should You Use?

Use this as a fast starting point before diving into the details:

• Need the best value at higher quantities? → Offset printing

• Need fast turnaround or short runs? → Digital printing

• Need banners, posters, oversized graphics? → Large format printing

• Need bold ink on unusual materials (apparel, boards, specialty)? → Screen printing

• Need packaging or labels at production scale? → Flexography or Gravure

1) Offset Lithography Printing

Offset printing uses metal plates to transfer ink to a rubber blanket, which then transfers the image to the final surface. It’s a classic, proven process that’s still one of the best options for high-volume, consistent, professional-quality prints.

Best for:

• Brochures, catalogs, magazines

• Marketing collateral that requires consistent color

• Larger print runs

Why people choose offset:

• Excellent color consistency over long runs

• Efficient for higher quantities once setup is complete

• Works across a wide range of paper stocks and finished

2) Digital Printing

Digital printing transfers a print file directly from a computer to the printer—no plates required. It’s a top choice for short runs, variable data (personalization), and fast turnaround projects.

Best for:

• Short-run booklets, manuals, short-run marketing pieces

• Projects with multiple versions (names, SKUs, locations)

• Rush jobs and quick revisions

Why people choose digital:

• Faster setup and production

• Cost-effective for small quantities

• Easy to adjust or reprint without major setup

3) Large Format Digital Printing

Large format printing is a category of digital printing designed for oversized graphics that standard commercial printers can’t produce. It’s commonly used for posters, signage, banners, window graphics, event displays, and backdrops.

Best for:

• Posters, banners, signage, retail displays

• Step-and-repeat backdrops, photo walls, directional signage

• Trade show and event materials

Why people choose large format:

• High visibility and impact

• Flexible material options (vinyl, fabric, paper, more)

• Scales artwork up while maintaining professional output

4) Screen Printing

Screen printing uses a mesh screen and stencil process to push ink onto a surface. It’s known for bold, durable ink coverage and the ability to print on flat and non-flat items, depending on the setup.

Best for:

• Specialty print applications

• Materials where ink durability matters

• Projects that benefit from thicker ink coverage

Why people choose screen printing:

• Strong, saturated color

• Durable ink layer

• Works across a wide variety of materials

5) Flexography Printing

Flexography (“flexo”) uses flexible plates and is widely used in packaging and labeling. It’s built for speed and efficiency on many types of materials like paper, plastics, and films.

Best for:

• Labels

• Packaging materials

• High-volume production needs

Why people choose flexo:

• Extremely efficient for production printing

• Works on many non-paper substrates

• Common for packaging workflows

6) Gravure Printing

Gravure (rotogravure) engraves an image onto a cylinder, which transfers ink to the substrate at high speed. It’s typically used for very high-volume printing runs, such as magazines, newspapers, and packaging.

Best for:

• Large-volume publication printing

• Packaging and long-run production printing

Why people choose gravure:

• Built for speed at scale

• Excellent for extremely high-volume production

How to Choose the Right Printing Process

If you’re not sure what to pick, these decision points usually make it clear:

Choose Offset if:

• You’re printing a higher quantity and want consistent professional color

• You want cost efficiency as volume increases

• You’re printing catalogs, brochures, magazines, or high-run marketing pieces

Choose Digital if:

• You need fast turnaround or frequent revisions

• You’re printing short runs

• You need personalization or multiple versions

Choose Large Format if:

• Your graphics need to be oversized (posters, banners, signage, displays)

Choose Screen Printing if:

• You need bold, durable ink coverage on specialty materials

Choose Flexography or Gravure if:

• You’re producing labels/packaging at high volume

Getting Started: What We Need to Quote Your Project

To recommend the best printing method and provide an accurate quote, it helps to know:

• Finished size (and if it’s folded/bound)

• Quantity

• Color requirements (full color vs black and white)

• Paper/material type

• Finishing (lamination, coating, trimming, mounting)

• Deadline / delivery needs

Frequently Asked Questions About Printing Processes

What is the most common printing process for professional marketing materials?

Offset and digital printing are the most common for professional marketing materials. Offset is often better for higher quantities; digital is often better for fast turnaround and short runs.

What’s the difference between digital printing and offset printing?

Digital printing prints directly from a file without plates, making it faster for small runs and revisions. Offset uses plates and is more cost-efficient and consistent for larger quantities.

Which printing process is best for short runs?

Digital printing is typically best for short runs because it has minimal setup and supports fast production.

Which printing process is best for high-volume printing?

Offset, flexography, and gravure are common options for high-volume printing depending on the product type and materials.

What printing process should I use for posters and banners?

Large format digital printing is designed for posters, banners, signage, and oversized event graphics.

Is screen printing only for apparel?

No. Screen printing can be used for a wide range of materials and applications, including specialty surfaces and certain rigid substrates.

Can you help me choose the best printing process?

Yes. If you share your size, quantity, material, and deadline, a print specialist can recommend the best method and finishing options.

Does the printing process affect color accuracy?

Yes. Both digital and offset can produce excellent color, but the best choice depends on your specific needs, volume, and materials.