Digital vs litho printing: which one is right for you?

When planning a print campaign – whether for brochures, direct mail, packaging or promotional materials – one of the most important decisions is how it gets printed. For many businesses, marketers and designers, that means choosing between digital and litho printing.

Both processes produce high-quality results, but they differ in areas such as cost, setup, turnaround and use cases. Knowing which option suits your project can save time, reduce postage costs and improve your final output.

In this article, we’ll explore:

The differences between digital and litho printing
The pros and cons of each approach
When to choose one over the other
Key considerations around cost, quality and sustainability

What is digital printing?

Digital printing is a modern method that involves transferring digital files directly onto paper or other materials using inkjet or laser technology. Unlike traditional techniques, there’s no need for physical plates – the image is sent straight from the computer to the printer.

The process works by applying toner (in laser printers) or liquid ink (in inkjet printers) directly onto the material. It’s a fast, flexible technique that’s well-suited to short print runs and personalised content.

Businesses often use digital printing for:

Direct mail campaigns with unique names or messages
Short-run brochures, flyers or business cards
Rapid turnaround projects with tight deadlines
Printing on demand without large upfront costs

Because there’s minimal setup, digital printing is often the go-to option when speed, flexibility and cost efficiency are top priorities.

What is litho printing?

Lithographic printing is a traditional method that uses printing plates and wet ink. It’s ideal for high-volume jobs where consistent, high-quality results are essential.

The process starts with creating metal plates – one for each colour – which are then mounted onto a press. Ink is applied to the plates, transferred to a rubber blanket and finally pressed onto the paper. This indirect transfer allows for smooth, detailed results.

Litho printing is typically used for:

Large print runs like catalogues, magazines and posters
Brand materials where colour consistency is critical
High-resolution imagery and fine detail
Jobs where unit cost needs to be reduced at scale

Although setup takes longer and costs more initially, litho printing becomes more economical as volume increases, making it a staple for commercial print jobs.

Key differences between digital and litho printing

While both digital and litho printing can produce excellent results, they’re suited to different needs. Here’s a quick comparison of the main factors:

Factor	Digital printing	Litho printing
Setup time	Minimal setup needed – print straight from file	Longer setup – plates and press preparation needed
Cost per unit	Higher per unit, better for small quantities	Lower per unit at high volumes
Print quality	Sharp, clean finish, but slightly less colour depth	Exceptional detail and smooth gradients
Colour matching	Good, but may vary slightly between batches	Precise Pantone matching and consistent colour
Turnaround time	Fast, so ideal for tight deadlines	Slower due to setup time
Personalisation options	Easy to customise each item (e.g. names on mail)	Less flexible, but can be overprinted at a later date

Understanding these differences can help you make a more informed choice, especially when you need to balance priorities like speed, quality and cost.

When should you use digital printing?

Digital printing is likely to be your best bet when you’re focusing on:

Small print runs: It’s ideal for quantities under 4,000 items, where litho setup might not be cost-efficient.
Fast turnaround: No plates or drying time means you can go from file to finished product quickly.
Personalised content: Digital printing is perfect for direct mail campaigns using variable data like names, addresses, tailored messages or unique QR codes.
Print on demand: Print exactly what you need, when you need it, meaning less waste and storage requirements.

If you’re launching a targeted mailing campaign or need marketing materials for a local event, digital printing gives you speed and flexibility without compromising on quality.

When is litho printing the better choice?

Litho printing really comes into its own when:

You need large volumes: The higher the quantity, the lower the cost per unit, making it ideal for bulk orders.
Colour accuracy is non-negotiable: Litho offers superior Pantone matching and consistency across thousands of prints.
High-resolution imagery is involved: If your design includes fine detail or subtle gradients, litho delivers a premium finish.
You’re producing branded materials: For items like corporate brochures, catalogues or stationery, litho ensures consistent professional quality.

When brand identity, image sharpness and long-term value are top priorities, litho printing is hard to beat.

Cost comparison: digital vs litho printing

When it comes to cost, the right printing method often depends on your run size and priorities.

Digital printing has low setup costs and is ideal for short runs. However, the cost per unit remains relatively high, meaning prices don’t drop much with higher quantities.
Litho printing involves significant setup costs (plates and press preparation, for example), but the cost per unit decreases as volume goes up. This makes it more economical for large-scale print jobs.

In short: digital is likely to prove more cost-effective for smaller quantities, but litho offers better long-term value for larger runs.

Considering factors like postage, storage and potential reprints can also help you assess true cost efficiency for your direct mail or marketing project.

Environmental considerations

Both digital and litho printing have environmental impacts, but the effects vary depending on the job.

Digital printing typically produces less waste and uses fewer chemicals, as there’s no need for plates or lengthy setup. It also allows for on-demand printing, which helps reduce overproduction and storage.

Litho printing, while more resource-intensive upfront, can be more efficient for large volumes. Many print providers – such as The Mailing People – follow practices such as only using FSC-certified paper to reduce their footprint.

Other sustainability factors include:

Energy use: Digital printers tend to consume more energy per unit for short runs.
Recyclability: Both methods can use recyclable materials, but you’ll need to check this with your supplier.
Waste reduction: Choosing the right method for your quantity helps minimise unused stock and materials.

Asking your print provider about the eco-friendly options they offer is always a good idea, regardless of the method you choose.

How to choose the right printing method for your project

If you’re not sure which option is right for your next print job, this checklist could be useful to guide your decision:

Quantity: Digital is suited to small runs: litho may serve you better for large volumes.
Budget: Digital keeps upfront costs low; litho is more cost-effective in bulk.
Timeline: Need it fast? Digital delivers quicker turnaround times.
Customisation: Personalised print (e.g. for direct mail) is easiest with digital.
Print quality: Litho excels at consistent colour and fine detail for premium materials.

Choosing the right method can save money, improve results and ensure your message lands exactly as intended – whether you’re printing brochures, mailers or packaging.If you need a quote or tailored advice about the right print solution for your next project, contact us.