We have had 550 years to find the best alternatives for print production and this has resulted in over 30 types of reproduction devices today.
I recently printed a page on a 15th century wooden press at the Plantin Moretus Museum in Antwerp. It was a one-page press, but the Museum has a number of two-page presses. These evolved after Gutenberg’s first version. Thus, a four-page signature was produced.
Most modern presses have a signature orientation of eight pages or more, and most digital printers are still at four pages. This is fine and dandy for books and other documents assembled by electronic collation, but may not be efficient for magazines, catalogues and other products.
Press sizes vary because of manufacturer. There is no one-size-fits-all when it comes to press sizes; some offset plate manufacturers have 18,000 SKUs for plate sizes, formats, and types. There are now more competing printing processes than at any other time in history. Each has a niche where it is still viable.
1. Letterpress
Still used for imprinting and even some corrugated printing, but on a limited scale.
2. Offset litho
The dominant process — excellent for moderate to longer runs of collateral/promotional, direct mail, books, catalogues, etc. It has several categories:
— wide web: for books, newspapers, catalogs, and magazines;
— narrow web: for books, direct mail, forms, and labels;
— large format sheet: for POP, signage, other display;
— 6- and 8-up sheet: for collateral, general commercial work;
— 4-up sheet: for collateral, general commercial work;
— 2-up sheet: for small commercial jobs.
3. Gravure
For very long runs of publications, packaging, and products. Gravure is losing ground to offset litho in publication printing, but does well in all forms of packaging and specialised products, like shower curtains and pool liners. It is almost all rollfed.
4. Flexo
For flexible packaging and some corrugated. It is mostly rollfed, with some sheetfed.
5. Screen
For signage, industrial, and fabric printing. Screen printing lays down a thicker density of ink on virtually any surface. It is primarily based on a sheet or other unit, like a T-shirt.
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