This process comparison is where the three processes mentioned are used in wide format printing applications. It is for guidance purposes only but will give you a starting point when considering a process. PDS International Limited will be happy to discuss in much greater detail your requirement. The range of equipment available with the three processes is vast and you really need to get it right first time. Talk to us and experience the PDS DIFFERENCE.
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To view the Comparisons, clicke on the +/- next to the heading you are intrested in.
Digital Printing |
Large Format Litho |
Direct Screen Printing |
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Recognition factors |
Random dots thin ink film | Thin ink film line rulings 130 upwards | Thicker and more opaque, no clear or adhesive at edges |
Performance |
Up to 500 square metres per hour | Up to 18000 square metres per hour | Flat bed up to 900 per hour. Cylinder up to 4000 per hour |
Image size and limitations |
Can very large, up to 5 metres wide. Industrial printers up to 1500mm. Flatbeds 3 metres by 2 metres | 2000mm x1500mm Only up to 1.6mm thick | Screens can be made any size |
Resolution of detail |
Fine | Fine | Medium |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
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Large areas of solid colour |
OK but normally 4 colour process. Some systems can print line colour with dedicated ink supply | OK but normally 4 colour process | OK with good equipment and operator |
Opacity |
Fairly Good | Fairly Good | Good |
Colour match |
Uses process colour but suffers from colour drift on runs | Process colour but accurate with onboard colour management | Your responsibility in-house or ordered from outside supplier |
Registration of colours if multicoloured |
Registration is not a problem | No problem | Fair to good depending on equipment, tooling, operator and size stability of substrate from first to last print |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Part shape and limitations |
Flat. Uneven surfaces are possible but the image quality reduces as the distance from the head increases | Flat | Flat or single curve (cylinders) |
Arc limits on cylinder or a cylinder with draft or taper 10 or less |
N/A | N/A | Almost 3600, avoiding ink to screen contact on the wrap if it will be a problem |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Process wet ink or dry |
Wet. Solvent based, water based and UV Curing Inks | Wet | Wet - drying or curing required between and/or after final colour |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Inventory required |
Inks, cleaners, substrate to suit digital printing | Inks, fount solutions, cleaners, substrate | Screens of various meshes; inks to make custom colours for particular substrate chemistry; solvents, cleaners, retarders, squeegees; or order match colour inks as needed |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Health and Safety |
On solvent systems extraction is needed. UV needs shielding. Ensure Health and Safety Data Sheets are available for the inks | Normal Personal Protective Equipment will be fine | High levels of flammable solvents and inks require careful handling and storage. UV Curing inks must not come into contact with the skin. Dispose of with care; never into sewerage system. Guarding limited |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Learning-curve time frame for system start-up |
Days | Days/Weeks | Days to weeks |
New-operator learning-curve time frame |
Days to weeks | Days/Weeks | >Hours to days |
Set-up skill level |
Skilled | Skilled | Skilled |
Operator skill level |
Depends what responsibilities are. Either unskilled or skilled | Depends what responsibilities are. Either unskilled or skilled | Semi-skilled |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Part changeover, new part, and new design |
>Minutes | Minutes | Minutes to hours. Multi-colour inline machine 20 minutes for 4 all four colours |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Process variance causing defective "print" |
Changes in ambient conditions will affect performance. Blockage of heads an issue particularly with solvent systems | Temperature, humidity, fount solution condition, condition of rollers, ink condition. More sophisticated machines manage themselves | Ink viscosity somewhat critical |
Part variance causing defective "print" |
Substrate must be clean and at a stable temperature. Variation in thickness or position can cause catastrophic head damage | Cleanliness of substrate. Moisture content of substrate | Poor surface finish and such blemishes as sink marks (some defects) |
Digital Printing |
Large Format Litho |
Direct Screen Printing |
|
Cost of equipment |
Equipment cost depends on size depends on size. From £5,000.00 to £1.500,000.00 | Lots of money | Small to large area (100 sq. in.) not very cost sensitive but very cost sensitive to multicolour |
Cost of tooling |
N/A | N/A | N/A |
Part input/output equipment cost |
May need lamination or UV varnish that is screen or digitally printed | Feeders and stackers | Feeders and stackers |
Cost of inks, foil transfers |
Inks - expensive | Very cheap compared to digital | Inks - not very cost sensitive to size |
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Tel: +44 (0)1226 770772, Fax: +44 (0)1226 294797, Email: info@pdsinternational.com
