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Print 101: Offset Lithography

Print 101: Offset Lithography

Print 101: Offset – Episode Summary

In this episode of The Print University, Ryan McAbee and Pat McGrew take viewers into the world of offset lithography—still the workhorse of the commercial printing industry. Often included in offset press training for new operators and printing press operator training courses, offset printing remains the go-to technology for high-volume, high-quality static print applications.

The hosts explain the mechanics: image areas on plates attract oil-based ink while non-image areas repel it with water. The image is first transferred to a rubber blanket and then offset onto the substrate. This process, known for sharp, consistent quality, relies on expert operators to maintain precise color registration and ink-water balance. The episode distinguishes between sheet-fed and web-fed systems, discusses B1 sheet sizes, perfecting units (4/4), and drying methods like heat-set and cold-set—concepts vital to bindery equipment training courses and color management training for new hires.

Offset’s flexibility shines through in its ability to handle paper, plastic, varnishes, and foils across a wide format range—from business cards to books to posters. Pat and Ryan also highlight workflow strategies like ganging jobs and using imposition to maximize press sheet real estate.

While offset excels in detail and durability, it struggles with short-run efficiency and variable data—areas better served by digital. Hybrid solutions with inline inkjet bridges that gap. Offset may be complex, but for thousands of identical, high-quality prints, it still delivers unmatched results.

You Will Learn:

  • How offset lithography works: plates, blankets, cylinders, and ink-water balance

  • Key components of sheet-fed vs. web-fed offset systems

  • Techniques like perfecting, ganging, imposition, and inline finishing

  • Applications ranging from business cards to booklets and posters

  • Equipment lifespan, automation trends, and hybrid press strategies

Who This Course Is For:

Production staff, press operators, estimators, prepress teams, and professionals undergoing offset press training for new operators or evaluating investments in hybrid workflows

Time to Watch:

Approx. 20 minutes