I'm going to tell you what most offset printers will not tell you, and it’s this: The offset printing process has many variables and the result is a constant fluctuation in quality. I have worked as a pressman in the offset printing industry and I can tell you this from first hand experience. The truth is that no two printed copies are alike in offset printing. That is why some offset printers will refer to each copy as a signature.
I'm going to share some variables with you that you must understand if you are going to hire someone to do your offset printing. It will help you to find a balance between your expectations and the ability of the offset printer to make money. Here are five points you should keep in mind.
1. There Will Be Ink Density and Color Variation
When the printing press starts (whether it’s sheetfed or web offset printing) the color and density of the ink will not be acceptable. This is normal. Here is an example of a printed baseball card that was obviously considered acceptable and allowed to go to the public.
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| The variation in both can be considered acceptable. |
The Pressman will as quickly as possible get the product to what's called saveable mode. This means that the quality is sufficiently acceptable in order to start saving your product. However what you may not be aware of is that it may not meet your standard of what is saveable. So here is what you need to do:
a. Clearly explain to your offset printer what is acceptable and what is not acceptable with color variation and density.
b. Tell your printer you would like to see the first saved copy that came off the printing press. There is nothing wrong with asking this.
c. Tell your offset printer that you would like a copy saved for you and time-stamped at intervals throughout the print run. You will need to trust their honesty on this one.
d. You may ask the printer to be present during the printing process. However keep in mind that this may cost you more money. (see point number 5).
2. Your Offset Printer Has to Make Money!
The offset printing industry is a very competitive business. The profit margin is often 3-5 percent. The biggest cost to an offset printer is the time and materials, most of which is paper. The object of the printer is to get a saveable copy as fast as possible and waste the least amount of material in the least amount of time. Your objective of course is to get the highest quality possible. You must allow your offset printer to save less than perfect quality. This is a reality you must accept.
TIP: some printers have adopted ISO 9000 standards. This basically means that there are certain parameters that they must abide by in order for their product to be acceptable to the industry standard. Ask your printer if they abide by the standard.
3. Offset Printers Must be Competitive
Offset printing presses vary in speed and quality. Technology is changing fast and newer printing presses can produce much higher quality in a much quicker fashion than older printing presses. Ask your offset printer what type of equipment they use and what equipment on the printing press helps monitor quality.
Some printers that have older printing equipment are tempted to save your product as it comes off the printing press even though the quality may be substandard. This is because they are trying to compete with other offset printers who's printing presses are new and produce very high quality quickly.
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| Modern offset printing press. |
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| An older offset press, still used in production. |
4. The Materials You Choose Have a Great Effect on Quality
Most likely your offset printer will allow you to choose the type of paper that is being used. However they will not allow you to select the type of ink that is used. They may allow you to choose colors, but they will not allow you to choose the brand of ink. This is fine. But bear in mind that the cheaper quality paper that you use, the cheaper your product will look.
TIP: Ask your printer for samples of various papers that they use. Notice the difference in quality between these printed products.
5. Ask Your Offset Printer for a “Press Check”
What this means is that your offset printer will allow you to be present during the print run. During that time you are expected to stay out of the way of those that are working. But you are allowed to monitor the quality that is coming off the press.
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| A viewing booth beside the offset press. One that you may be allowed to be at during a press check. |
If your offset printer allows you to do this, you should have some tools such as a loupe (such as this one here) and a sample of the standard they are trying to match (often referred to as a color key). During this press check, be observant. Take note of when the copies are made saveable at the end of the printing press. Ask for samples throughout the print run. Be kind and courteous to the pressmen, not critical.
In Conclusion
In summary we can say this. Because of the many variables in offset printing, not every copy will be the same. You need to be certain that your expectation meets the reality of what happens on the pressroom floor. Have an open, frank conversation with your offset printer about this. Doing so will eliminate misunderstandings when the final product is delivered to you.
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