The two dominant printing technologies today are offset printing and print-on-demand (POD). As an editorial designer with over a decade of publishing experience, I analyze the pros and cons of each method to inform production choices.
Understanding Offset Printing
Offset printing has been the standard for high-volume book publishing for decades. It leverages a plate-based printing process, transferring inked images from plates to rubber blankets and finally paper.
This indirect printing method enables efficiently printing thousands of copies with consistency. While offset requires high upfront costs for plates and press time, the per-unit costs are very low for large quantities.
High print quality is achievable with offset. There is an expectation of professional results from offset printing in publishing. The consistency and scale suit long print runs of popular books.
The Emergence of Print-On-Demand
Print-on-demand (POD) uses digital printing presses to produce books as needed rather than printing a large run upfront. This eliminates warehousing costs and the risks of unsold inventory and waste.
POD has flourished with the rise of self-publishing and companies like Amazon creating global distribution channels. Digital printing quality has also improved vastly, now rivaling offset printing in many cases.
Short print runs are ideal for POD, making it cost-effective for niche titles and personal projects. Lead times are shorter and revisions simpler compared to offset printing's fixed plates.
Print Quality Considerations
POD struggles with consistency when printing large jobs due to fluctuations in temperature, humidity, and machine calibration. Results may vary across a long print run.
Offset's fixed plates enable very predictable, consistent output once initially dialed in correctly. Registration and alignment stay precise over the entire press run.
However, POD machines have improved vastly, now producing stellar results. Much POD work is indistinguishable from offset to the average reader. Very large POD jobs still risk more variability.
Cost and Waste Factors
For books above 1,000 copies, offset becomes the more affordable option based on economies of scale. The initial investment pays dividends across thousands of books.
POD involves no upfront costs, but per-unit pricing stays high for individual books printed as needed. Large inventories aren't produced.
If sales projections are uncertain, POD minimizes financial risk. Unsold books don't sit in warehouses. Offset printing surplus inventory can become waste without adequate demand.
Flexibility Compared
POD offers immense flexibility. Books can be revised and reprinted on-demand with ease. Self-publishers use POD to publish one book at a time with minimal hassle.
Meanwhile, offset printing locks in content once plates are made. Alterations require new plates and a new press run. The high setup costs deter frequent revisions.
As a result, POD is well-suited for books requiring regular updates. Educational, business, and reference titles benefit from POD's adaptability.
Turnaround Time
For 1,000+ books, offset printing initially has longer lead times - 4+ weeks for plates and scheduling press time. However, reprints take days without new prep work required.
POD books can print within a week as no setup is needed. But expanded distribution channels mean each book prints and ships individually, taking more time to fulfill large orders.
Rush offset jobs are costly but possible by paying premiums. POD relies on third-party shippers, making expedited delivery logistically difficult.
Summary
For high volume production, offset printing still delivers unparalleled results cost-effectively. But POD enables flexibility and accessibility ideal for personal, niche, and frequently-updated books.
Considering each method's strengths through the lens of specific projects allows publishers to strategically leverage these technologies. Their coexistence expands possibilities, letting creators bring more printed books to life.