Most print buyers today default to digital print without giving much thought to the alternatives. Digital is fast, flexible, and works well for a wide range of jobs. But it’s not always the best choice, and for certain applications litho printing produces results that digital simply can’t match.
Understanding the difference helps you make a better decision for each project rather than defaulting to the same process every time.
How litho printing works
Lithographic printing uses a plate, typically made from aluminium, on which the image areas are treated to accept ink while the non-image areas repel it. The ink is transferred from the plate to a rubber blanket and then onto the substrate. Because the ink is applied directly in a thin, even layer, the colour reproduction is very precise and consistent.
Setting up a litho job involves making plates for each colour, which takes time and has a cost associated with it. That setup cost is why litho tends to be better suited to longer print runs, where the per-unit cost comes down as the quantity increases.
How digital printing works
Digital printing applies ink or toner directly from a digital file without the need for plates. There’s no setup cost in the traditional sense, which means short runs are economical. The trade-off is that colour consistency over large quantities can be harder to maintain, and some substrates don’t respond as well to digital print as they do to litho.
Where litho has the advantage
Colour accuracy and consistency are where litho genuinely outperforms digital. If you’re printing a large run of brochures and you need every copy to look identical, litho is more reliable. If you’re printing packaging where brand colours need to be precisely matched, litho gives you tighter control.
Litho also handles certain substrates better. Uncoated stocks, for example, tend to produce richer, more consistent results under litho than digital. And for very high volumes, the per-unit cost of litho is significantly lower than digital once the setup cost is spread across the run.
Where digital has the advantage
For short runs, variable data printing, or jobs that need to be turned around quickly, digital is the better choice. If you’re printing 250 brochures rather than 5,000, the economics work in digital’s favour. If each printed piece needs personalised content, like direct mail with individual names and addresses, digital handles that in a way litho can’t.
Digital is also more practical for proofing. You can print a single copy to check colour and layout before committing to a full run, which isn’t really possible with litho given the plate setup involved.
How to decide which is right for your job
The key questions are: what quantity do you need, how important is colour precision, and how quickly do you need it? For large quantities with consistent branding, litho is usually the better call. For smaller quantities, short deadlines, or variable content, digital works better.
For some jobs, a combination approach makes sense, using litho for the bulk of the run and digital for shorter personalised elements. A good print supplier will advise on which route makes most sense for a specific brief.
If you’re not sure which print process suits your next project, get in touch with the Birch team via the contact page. With over 40 years of experience across both litho and digital print, the team can recommend the right approach for your quantities, timelines, and quality requirements.
