What is Dry Offset Printing?
Dry offset printing, sometimes called waterless printing, is a unique hybrid of offset lithography and letterpress printing. This method is similar to traditional offset lithography but does not use a dampening solution to remove ink from non-image areas of the printing plate. Instead, those areas differ by the presence of a raised image photopolymer or other synthetic material displaying the image.
This method excels in high-speed printing applications, particularly on non-porous substrates such as plastics and metals, making it a go-to choice for decorating cylindrical objects like cans, tubes, and pails.
Zeller+Gmelin has been at the forefront of the dry offset printing industry, offering high-performance inks designed for precision and vibrancy across a wide range of applications
Understanding Dry Offset Printing
How Does it Work?
Dry offset printing uses a set of printing plates mounted on a rotating cylinder. These plates transfer ink to a rubber blanket, which then directly applies the ink to the substrate. Because there is no dampening process, dry offset relies on carefully engineered inks to achieve excellent adhesion and color fidelity.
How is it Different from Traditional Lithography?
While both processes utilize the basic principle of indirect ink transfer, hence the term “offset”, the absence of water in dry offset eliminates issues like emulsification and ink/water balance. This makes dry offset ideal for substrates that are water-sensitive or challenging to print on, such as plastics, foils, and metals.
Equipment Used in Dry Offset Printing
Dry offset printing requires specialized machinery designed for speed and precision. Key components include:
Printing Plate: Typically made of metal or polymer, these plates are durable and suited for high-volume printing.
Blanket Cylinders: Essential for transferring ink uniformly to the substrate.
Inking Systems: Advanced inking units ensure consistent application across colors, critical for multi-color jobs.
Substrate Handling Systems: Designed for smooth feeding of cylindrical or irregularly shaped items.
Zeller+Gmelin’s inks are formulated to perform seamlessly with leading dry offset equipment, ensuring reliability and quality in every print run.
Applications and Substrates
Dry offset printing is widely used in industries where durability, precision, and efficiency are paramount. Common applications include:
Packaging: Printed designs on tubes, containers, pails, and bottle caps.
Beverage Cans: Eye-catching designs on soda and beer cans.
Promotional Items: Branded pens, keychains, and more.
Plastic Cards: Custom printed cards such as credit cards and hotel keys.
The versatility of dry offset lies in its ability to handle challenging substrates with precision printing.
Advantages and Limitations of Dry Offset Printing
Advantages
• High-Speed Printing: Capable of handling large volumes with minimal downtime.
• Vibrant Colors: Achieves high-quality, sharp prints with excellent ink adhesion.
• Cost-Efficient: Suitable for mass production, reducing per-unit costs.
• Eco-Friendly Options: Recent advancements like Zeller+Gmelin’s EarthPrint™ inks provide sustainable solutions for plastic packaging, without compromising performance.
Limitations
• Setup Time: Initial setup requires precision and attention to detail, requiring more time that some other print methods.
• Specific Substrate Compatibility: While versatile, it may not be ideal for porous materials like paper or fabric.
EarthPrint™ Technology: Advancing Dry Offset Printing
Zeller+Gmelin’s EarthPrint™ technology represents a leap forward in sustainable printing for plastic products and packaging. These eco-friendly inks are designed to effectively wash off for full product recyclability, while delivering the vibrant, durable results that dry offset printing demands. Whether you’re decorating pails and containers or creating custom packaging, EarthPrint™ inks offer a balance of quality and responsibility.
View the EarthPrint™ Infographic and Blog for more information on de-inking properties and recyclability.
Are you ready to elevate your printing process with high-performance dry offset inks? Contact Zeller+Gmelin today to learn more about our range of solutions, including our innovative EarthPrint™ technology. Let us help you achieve unparalleled results in your next printing project.