Here I am talking in respect of printing terms on the product. Unlimited shapes and sizes made of products printing are mandatory it could be for branding on the product purpose, product packaging or to make easy for customer acknowledgment. There are different types of products available in the open market different stuff, different surfaces (even, uneven, 3d), print types (text, illustration & images), and different locations (inside, outside, on top and bottom) of products that need to be printed. Choose the best type of printing method for your product in terms of Printing Quality, Printability, Ink Adhesion, Ink Abrasion Longevity, etc.

The printing ink adhesion and abrasion depend on the product made of materials and used ink molecules to bond with. Each type of printing ink molecule, printing mechanism, and machine used is different.

I am going to dig out each type of printing done nowadays and with its principles, using ink quality. How beneficial a specific type of printing is for the environment, longevity, and why you should go for it. There is a big concern for the next generation environment and sustainable sources.

• Letterpress Printing
• Flexography Printing (Rotary Printing)
• Serigraphy Printing (Screen Printing-Flat & Round Printing)
• Electrostatic Printing (Photo State)
• Offset Printing (Sheet Feed & Web Offset)
• Rotogravure Printing
• Digital Printing (Laser, Inkjet, Toner Printing, Etching)
• Digital Sublimation Printing (3D Sublimation & Flat Sublimation)
• Hot Stamping (Digital & Traditional)
• Pad Printing
• Foil Printing
• 3D Printing
• Lenticular Printing
• Embroidery Printing

1. Letterpress Printing

The letterpress printing method has been used for a long period of time. Resources says that it was started in the late 14th century by John Gutenberg a german inventor before its invention in the printing era only can be stamped through a single alphabet on a wooden carved letter,

In this printing method, the principle is, that an alphabet is carved on metal and these alphabets are arranged to form a word and sentence. After applying ink to the carved letter face, with the help of a rubber roller, A letter is pressed against the paper by these arranged letters or sentences. Thus carved letters made impression on the paper. To make an ink impression proper ink roller plays a major role. More ink roller produces better ink saturation on the stuff. Ink roller payroll for applying evenly ink contrast on the object.

How does it work?

The inked letter is pressed against the substrate to produce a mark over the substrate. Each pressure impression produces one copy at a time, only one colour can be printed at a time. To add more color you required a new set of alphabet and was out properly ink roller and add a new colour.

Print can be produced only in sheet feed form (rectangle shape within limited thickness). There is a limitation of the thickness up to a max of 1mm and the surface must be plain.

To arrange the alphabet in the form of words and sentences called LETTER COMPOSITION

Ink Used:

It is also known as block printing. petroleum-based ink was used. it takes a few minutes to dry up. very concentrate ink has been used no need to add anything dryer. To keep ink safe from drying need to add a water layer over it. The concept behind it is as water does not mix with oil. To make ink dilute used petroleum oil as well as kerosene oil.

Product printed

Business Card, Envelopes, Letterhead, Plastic Files, etc. This method is applied to the Embossing and Debossing process.

Grievances

There was a limitation of print size, one time only one color can gets printed, There was a huge problem to change the font style of writing and composing a manual letter, and finally produced inferior quality printing and very low font sharpness, and longer time to make a more copy.

Printing Today

There is might be a printer who follows this method,

2. Flexography Printing

This type of printing can be applied only to flexible products likewise cotton fabric, plastic rolls, non-tearable paper, etc. Printing is done roll to roll materials then cut it into the size required.

Packaging products like packing tape, satin labels, and cotton label printing. Basically, to transfer data on the fabric a polymer material block is made for it to make a plate and the printing cost is very pocket friendly. It’s a low-cost printing method feasible for roll-based. Printing only can be done spot colour.

For transferring content data on fabric a polymer block (short-term used block) is used.

How Does it Work?

It works as well as stamping the fabric (polyester, satin, taffeta, cotton). These products are getting printed in a roll form, each colour needs a separate polymer block, and products are printed inline and in roll form. Ink applied on the stuff is low viscosity and high dry quality.

Ink Used

Textile printing ink, low viscosity ink, no harmful chemical involved. food grade ink used in.

Product Printed

Sash Roll Printing, Polyester Label, Taffeta Label, Cotton Printed Label, Plastic Tape Printing, Textile Label printing. Plastic Carry Bag.

Grievances

There are a few unsolved defects in this printing method.

1. The only flexible material can be printed.
2. Flatbed and rigid material can’t be printed, High detail, as well as offset printing, can’t be printed.
3. The major problem of flexo printing is, that the plate is made of polymer that is flexible due to an equal press of the plate on the intended media excess the ink, kiss impression, and hin hole.

3. Serigraphy Printing (Screen Printing)

The first-time screen printing method was started in china for personalized t-shirt printing purposes. Later on, print demand for printing increased, and it was developed for commercial printing for various types of printing objects. Nowadays printing process can be applied to a long range of products made of paper, wood, plastic, metal, and no-metals.

How does it work?

This process is very long we can understand it in a few steps.

1. The first step is needed to make a wooden rectangle frame and stretch over the wooden frame with nylon or polyester fabrics tightened edge to edge.
2. The second step is getting a printout of the design on a transparent plastic sheet in black colour design.
3. The third step creation of stencil on the screen printing frame with the help of photo emulsion.
4. The fourth step is to set the screen printing frame on the press from one side with the clamp so that the opposite side can move up and down to the place and remove the printing object.
5. The fifth step is to place the printing object underneath the stencil screen frame and apply ink from the inside top to bottom frame with the help of a squeeze. of content to be printed,
6. The last and sixth steps let the product leave to dry up.

Ink Used

This printing application can be applied to various types of products made of, so there is a different type of ink that fit according to suitable stuff. A concentrated state of ink is used. Ink is made for different types of material to perform better in terms of eco-friendliness, ink adhesion, and longevity.

The ink used on paper is harmful to the body that is made of hazardous release gas during drying printing ink.

Textile printing ink for babywearing clothes is 100% eco-friendly.

Printing Product

T-shirt, Letterhead, Business Card, Envelope, Plastic and Wooden Flat Surface

Advantage

The best option for printing is a range of stuff like paper, rubber, cardboard, and metal nan metal. The best option for bulk printing products for the same copy. It’s static content printing.

Gravience

You can print one time in only one colour, Each colour printing required a new screen frame, and multicolor printing can’t print in-depth details. It required a basic setup cost for each print project. Variable data can’t be printed.

4. Electro-Photo state Printing

This type of printing is mostly done in offices through laser printers. The concept behind it is a toner-based-ink is applied as lenses come into contact with toner that attracts to the roller then the inked roller comes with paper contact and heat that melt the toner-based powder ink.

Ink Used

These toner-based are eco-friendly and used in home and office printers.

How does it work?

This type of printing can be applied only on paper or plastic thin layer that can bend easily passing through the roller. It works on the electron and proton attract and melt on the rolling stuff in the machines and fixed on it

Product Printed

Office Stationery, Plastic File, T-shirt, Wooden Product, Wedding Card, Advertising Sunpack, Glass and Non-metal Products even it is thick or thin.

Gravience

It is only for fewer selected items like paper and plastic sheets printing. the pinpoint off all sheets does not produce the same. Toner-based printing cost goes higher and no accurate pinpoint.

5. Offset Printing (Lithography Printing)

Offset printing started in the 19th century. This is the fastest and most quality printing method, in this process your printing content is burned on the metal plates then this content is transferred on the rotating rubber blanket and finally offset on the paper, the paper is passed between the rotating rubber cylinder paper pressure cylinder to make impression on the media.

Offset Printing Concept

First of all the data is burned on the aluminum metal sheet and then transferred to the rotating rubber blanket cylinder, During this action, a substrate is passed between the impression cylinder and the rotating inked rubber blanket. As soon as substrate contact with an inked rubber blanket, the rubber cylinder makes impression on the paper or any substrate.

5.1 Sheet Feed Offset

There are different Sheet feed offset printing done for the thick sheets as well as 60 gsm and above. The average printing speed, sheet per hour 7000-8000 per hour. These machines are made of horizontal shapes.l

5.2 Web Offset Printing

This printing application works better for lower gsm below 60 gsm, used for printing newspapers, bulk quantity flyers, and envelopes. The concept of printing is the same as per sheet feed offset printing machines but the differences are the only substrate is feed in the reel form. Most of all web offset printing is in verticle shape.

Product Printed

All types of newspapers, educational books, advertising, brochures, catalogs, commercial printing papers, etc.

Advantage

The best option for bulk printing like newspapers, educational books, newsletters, company catalogs, brochures, etc.

Gravience

The basic setup cost for each printing project goes very high. Painful for a low-volume print.

6. Types of Digital Printing

Digital Printing in being a lifeline in 21 century. Started in 20 century last decade. Overall all types of printing required a basic setup cost it may be some methods are low and some high but digital printing does not at all.

There are various types of digital printing processes as well as Laser, Inkjet, Toner Base, Sublimation, UV printing, and Hot Stamping, These digital printing machines are made for different types of media rigid, roll, flat,

Digital Printing Concept

Data is created electronically and directly send to the attached computerized machines. There are different types of media ink, laserbeam, and toner. No need for any setup costs likewise in offset and screen printing. Easy to print variable data printing.

6.1 Laser Printing

This printing application is applied to metals, wood, leather, fabric, and plastics materials. It works on the upper layer of the object to 0.01 mm to 0.03 mm burned out and inside the upper layer, the colour starts peeping out. These laser beams are produced differently as well as their density. For low-density stuff, a fiber laser is used.

Product Printing

Plastic Gift Items, marking on metal plates, marking on the leather purse,

Advantage

No required to set up cost, 99.9% of content marking accuracy even if it is the text of any complex design.

Gravience

In this method, colour can’t be produced. It required thick stuff to laser mark.

6.2 UV printing

This printing is trending as well as my experience and public demand it will be trending in the coming up to 5-10 years. It is a fast printing method. Small designs can be printed in a sharp and detailed print. Easy to print variable data printing method. A wider range of printing products even it is made of plastic, paper, metal, and non-metals.

The biggest advantage is it can be applied to almost all types of stuff, any shape, and is ready to use instantly sooner than printing stop working. It has left behind printing methods such as pad and screen printing.

6.2. 1 DIGITAL UV Printing

It’s the digital form of printing, There are different types of media likewise sheet, roll to roll and cylindric. Each type of media required a separate type of printing machine. Flatbed UV printing machines come up to 8’x8′ that can print at a time this size.

6.2.1A Flatbed UV Printing

The Signage Industry and Gifting Business are getting very indulge. You can create a vibrant colour picture, text, and texture. Available Matte and Gloss ink quality. An additional advantage of white and transparent UV colour can create an extra embossing by overlap printing to create a wow factor. You can get to print up to 8’x8′ to fit a single sheet.

6.2.1B Roll to Roll UV printing

Flex Banner or Cloth fabric can be printed roll to roll up to any length. For a fadeproof flex banner of flex board, you can go for a Roll to Roll Flex Banner printing it lost coming 8-10 years long, where a solvent print lost in 2-3 years

6.2. 2 UV Coating

UV coating is a process that is operated manually, It works such as a screen printing method the difference is only in place of applying ink, No. 1 UV ink is used. 2. Each UV printing sheet is passed through LED UV light that makes UV cured. UV ink is not organic its non-organic component does not dry in the open air. This type so the coating is applied on the offset printed product catalog cover, brochure, and magazine titles.

As it does not require giving extra time to dry out

100% eco-friendly.

No colour fade and is very long-lasting.

No. odor, less ink consumed.

How does it work?

Very tiny droplets of ink make the smallest content much details printing quality and following UV light make it dry within a seconds. The ink used was abrasion-free and shining. UV printing machines come in flatbed and roll form.

Ink Used

Non-organic ink makes printing permanent. Not soluble in the water and long-lasting fade.

Advantages

Any type of print media that can be used may have different, shapes, sizes, and thicknesses.

Grievance

I think there is no grievance only gain. The best printing method of the decade 2010-2020.

6.3 Solvent Printing

The solvent printing method is done for flexible materials like canvas printing, and flex banners. Media is printed on the roll-to-roll form. Solvent printing is the cheapest printing form on the earth. The material used is also low cost which is why it is considered worldwide. The drawback is the hazardous printing methods. Highly advised to set up printing unit in the industrial area.

How does it work?

It’s an inkjet printing application and digital printing form, Printer is directly attached to the printer, most of all solvent printer comes with a 10.5″ wide printer and can produce a long you wish. Very low maintenance and high productions

Ink Used

The ink used is harmful to humans and the environment it releases a high volume of carbon during drying.

Printed Product

Flex Banner, Standee, Flex Board, Vinyl

Advantage

The price per unit cost is the lowest compared to any type of digital printing method.

Gravience

Due to very harmful material release government has banned it legally. and warned to adopt cotton fabric. Most of all solvent printing material is done on plastic-made media like flex or PVC banners.

6.4 Hot Stamping

After the digital UV printing boom, This printing is now trending in the print industry before developing this technology hot stamping was processed through the traditional process that was to time taking. These types of applications are applied on the title page, invitation card, wedding card, and gift packing box to make it enticing to the customer

6.4.1 Digital Hot Stamping

It’s a fully computerized hot stamping process, A foil is a shiny and very thin layer that carries a heatproof plastic layer, foil is fused on stuff like paper, plastic, or any other stuff. It may be a multicolor holographic film. The concept of hot stamping is a UV is applied to the area where hot stamping is to be done. The sooner the UV was applied, followed the foil layer come into contact with it and stickered and forward to the UV light where a layer is overlapped.

6.4.2 Tradition UV Printing

Traditional UV is being done for a long period it needs to make a dye or block of the intended design. Putting a substrate between heated block and metal base, then pressure is applied on specific temperature over very thin layer is foil, the foil fixed on the substrate. This process is very cheap compared to digital hot stamping but it takes sufficient time to process.

6.5 Rotogravure Printing

Rotogravure printing is very accurate in terms of print quality, the concept of printing is based that content is engraved on a heavy metal calendar and then transferred to the media. This printing method work for flexible packing material printing chips pouch. Each colour printing required a separate calendar. The printing capacity of cylinder print is more than 100 thousand.

Inline printing process, cutting, packing at a time.

Product Printed

Pouch Packaging, high-quality label printing, rice pouch packaging, species packaging,

Grievance

The only flexible material can be printed like plastic film or foil, the basic cost is too high, quantity above 100 kg printing is the minimum order quantity.

7. Inkjet Printing

This printing method is more popular in the century 2021. This printing method work for all types of variation of media in thickness, rigid, flexible, even, and uneven surface.

Different types of media fit different types of printing ink and printing machines. printability of ink and durability is also a matter of quality of ink.

Printing concept ink transfer through a digital file sent to the computerized machine having thousands of thousand small holes on the printing head for individual colour droplets applied on the object and produce a high-quality print. No required min print quantity.

Smaller the ink droplet size, the better the print quality.

Printed Product

Flexible Product (cloth, banner, vinyl), Rigid (paper, wood, plastic) Metal (S.S, Aluminum) Non-Metal (Glass)

Most Advantage:

No required to expense basic setup cost, Instant printing procedure.

Gravience

Printing speed is very low compared to offset printing machines and gravure printing.

7. Sublimation Printing (Heat Transfer Printing Technologies)

It is a digital printing application. Can be printed either polyester or polyester-based objects like cloth, a polyester-coated coated mug, and metal bottles, etc. Area to printed on put into heat and press covering printed sublimation paper at a specific temperature for a defined time.

8. Pad Printing

Pad Printing works on the concept of the stamping process. most of all pad printing is done manually. each design required a dye cost come approx Rs. 500-1000. Each time can be printed only 1 pcs. It is applied only to small products. Novelty products, medical appliances, and crockeries are highly recommended.

Product Printed

Pen, crockery, medical device, cylindrical or 3d dimension base product

Gravience

Printing speed is very low, each time can be print only one colour.

9. Foil Printing

This printing method is applied for the aesthetic of the printing product. It works also on the concept of stamping just need to make a metal dye that is fixed on the metal base and keep the printing object down on the card base, just put a foil above the printing object and press it down. Foil colour is transferred in the shape of dye.

Product Printed

Foil Stamping on Brochure, Certificate, Catalogue etc.

Gravience

You need to make a dye even if you required a single pcs.

10. Laser Printing

This is the most popular method in 21 first century. This method work on the concept of the upper layer of product colour removed and the inside color of materials visual in the form of text or image.

Printed Product

Gifting pens, Mementoes, Metal-Based Plates, Metallic Utensils, Wooden Product Utensils etc.

Gravience

Products made of paper and plastic cant be engraved as they burned out.