Exploring the Printing Techniques: Digital vs. Litho-Printing Plastic Cards

In a world filled with business cards, loyalty cards, and identification badges, the importance of creating a lasting impression cannot be overstated. When it comes to producing plastic cards, two primary printing methods dominate the field: digital printing and litho (offset) printing. 

Each method has its own advantages and disadvantages, and choosing the right one can significantly impact the quality, cost, and customisation of your plastic cards.

We’re here to ensure you understand the difference and know which printing solution you should choose based on your printing requirements. 

Card Monster: The Expert in Plastic Card Printing

Before delving into the differences between digital and litho-printing for plastic cards, it's essential to acknowledge Card Monster as a trusted expert in this field.

With a commitment to excellence and a reputation for producing high-quality cards, Card Monster ensures that every card is crafted with professionalism and precision. 

Our expertise spans various industries, making us the go-to choice for businesses and organisations seeking top-tier plastic card printing.

Now, let's dive into the key distinctions between digital and litho-printing when it comes to plastic cards.

Comparison table of litho and digital printing

Below we have a comparison table between litho and digital card printing. Based on your companies needs. You can choose which printing method is the best solution for you.

Of course if you would like some more advice on your printing needs, please feel free to contact us and one of our friendly staff members will be able to help walk you through the process and choose which method is best for your printing needs. 

	Litho Printing	Digital Printing
Industries	Suitable for large indsutries.	Suitable for small to medium industries.
Cost-effectiveness	High cost but more affordable with bulk printing.	Very affordable. Bulk printing is a great option too.
Quality / Colour accuracy	Pantone colour matching. Exact colour accuracy. Never pixilated. Very high-quality print.	Dots per inch printing. Meaning colours may not exactly match, still high-quality print.
Turnaround Time	Slower turnaround time due to plate creation process.	Fast turnaround time.
Customisation	Does not allow for variable data on cards. Plates are fixed once created.	Allows for variable data on cards. Making it more versatile.
Print runs	Large print runs. Can print large quantities.	Smaller print runs. Ideal for medium-small print jobs.
Consistency	Very consistent throughout long runs.	Not as consistent through long runs, errors may occur.

Digital Printing: Efficiency Meets Customisation

Digital printing is a versatile and efficient method for producing plastic cards. This technology transfers digital files directly to a printing press, eliminating the need for traditional printing plates. 

Digital printing is quite similar to a high-end colour laser printer like your HP or Samsung at your office. It applies a toner or ink directly onto the card using a printhead to distribute the colours.

All of the card printers we sell are digital printers. 

This is how the printer process works: An ID card printer works by feeding a blank plastic card under the print head. The card design is transferred onto the card's surface. This is down when the heated printhead meets the printer ribbon and binds the design onto the plastic card. The completed plastic card is released into the output tray.

Here are some key aspects to consider:

Customisation

Digital printing allows for customisation. Whether you need personalised names, unique QR codes, or variable data on each card, digital printing can accommodate these requirements seamlessly. 

Card Monster's digital printing capabilities allow for intricate designs and variable information, making each card unique.

So, if you have cards requiring variable data to be printed on them, digital printing is the way. 

Cost-Effectiveness

Digital printing is often the more cost-effective choice for small to medium print runs. 

The absence of printing plates reduces setup costs, making it ideal for businesses and organisations looking to print a limited quantity of cards without breaking the bank.

If you have a smaller print run and need your cards quickly, digital printing is the way to go.

Quick Turnaround

Time is often of the essence when you need plastic cards for events, promotions, or membership programs. 

Digital printing offers rapid turnaround times, making it suitable for last-minute orders. Card Monster's commitment to efficiency ensures that your cards are delivered on time with high-quality prints.

High-Quality Output

Despite being efficient and cost-effective, digital printing does not compromise on quality. 

Card Monster's digital printing technology produces sharp text, vibrant colors, and intricate details, ensuring that your plastic cards look professional and visually appealing.

Although digital printing allows you to produce vibrant cards with high quality colours. The colours may not be an exact match. That is why many customers prefer litho because the printing process matched their exact branding colours and sets them apart from their competition. 

Digital printing is printed in dots per inch, and images that have not been vetorised may be pixilated because this is not the highest quality machine to use when printing cards.

However, if you have vectorised images on your design, the digital card printer will print accurate images and colours for your brand. 

Variety of Finishes

Digital printing can accommodate various finishes, including matte, gloss, and even spot UV. This versatility allows you to customise the look and feel of your plastic cards to match your brand's aesthetics.

This is great for customers who want to stand out from the competition. Please feel free to have a look at our custom design portfolio for more ideas on how to design your cards and what we offer. 

Litho (Offset) Printing: Precision and Consistency

Litho printing, also known as offset printing, is a traditional yet highly precise method for producing plastic cards. 

This technique involves the creation of metal plates for each colour in the design, ensuring consistent and accurate results. Litho printing ensures that you get the exact colours you want for your design. 

How does litho printing work? Metal plastes pull across ink rollers and then press against the plastic cards. This process is similar to the method used to recreate high-quality artwork prints. There is a smooth surface of the positive plate that embraces oil-based inks and repels water. The negative plate has a rough texture that absorbs water and repels oil. Rubber rollers then transfer the image from the plate to the plastic card.

Here's why litho printing stands out:

Colour Accuracy

Litho printing is renowned for its exceptional colour accuracy and consistency. If your brand relies on specific Pantone colors or requires exact color matching, litho printing is the way to go. 

Card Monster's litho printing methods ensure that your cards meet the most accurate colour schemes. Litho prints do not print in dots per inch and can closely match a vector image, as they're incredibly crisp, and never pixelated.

Litho printing is often the most expensive of the printing styles available, but it also has the highest-quality prints. It's expensive because, unlike digital printing (which works similar to an inkjet printer), a litho printing press applies one colour at a time. So, for a full-colour card, you would print all four colors on each side. That means eight colours to make the full print. If it's a clear card, it would be ten because of the need to apply a blocker to print clear cards. 

Therefore, if you need accurate coloured cards that stand out with the highest quality, then litho printing is the way!

Large Print Runs

Litho printing becomes cost-effective when printing plastic cards in large quantities. 

While the setup costs are higher due to the plate creation process, the per-unit cost decreases significantly with higher quantities. 

This makes litho printing the preferred choice for businesses and organisations that require bulk card printing.

So if you’re a business that requires bulk printing, litho is the best option.

Versatile Materials

Litho printing can handle a wide range of plastic materials, including specialty finishes and textures. 

Whether you want a sleek and glossy card or a textured, matte surface, Card Monster's litho printing expertise ensures that your material choice is accommodated.

Although you can print on different cards, you cannot print different information on your cards. Meaning that litho print does not allow for variable data printing. Because a set palte is created, you cannot print different information on your cards, you have to print multiple cards that are the same. 

Professional Finish

If you aim for a high-end, professional finish for your plastic cards, litho printing delivers.

The precision of the process results in sharp, detailed graphics and text, creating a polished appearance that leaves a lasting impression.

Consistency Across Large Runs

Litho printing shines with consistency. Whether you're printing thousands of membership cards or ID badges, each card will exhibit the same level of quality and colour accuracy.

You will never have to worry about your cards not matching or irregular print runs. 

Conclusion: Card Monster - Your Partner in Excellence

In the world of plastic card printing, the choice between digital and litho printing methods ultimately depends on the specific needs and priorities of your business.

Card Monster, with its expertise and commitment to quality, ensures that your plastic cards are produced at the highest standard, regardless of the chosen printing method.

If you prioritise customisation, rapid turnaround times, and cost-effectiveness for smaller print runs, Card Monster's digital printing capabilities is the best option.

On the other hand, if colour accuracy, consistency, and large print runs are your primary concerns, Card Monster's litho printing expertise is the best option.

Whichever path you choose, Card Monster remains your trusted partner in delivering professionally crafted plastic cards that make a memorable impression. 

With Card Monster, your plastic cards are more than just pieces of plastic; they are a testament to quality, precision, and excellence. Representing your business and brand in every way.