The beating heart of any print operation – be it a huge commercial printing house or a nimble high-street shop – is not the machines, but the materials which run through them. Whatever the scale of your printing business, quality printing press supplies are the key to achieving the professional results your customers deserve.
Finding reliable printing press supplies is a critical aspect of any print shop’s operations. In a competitive industry, print shops must balance cost efficacy with the provision of high-quality products and services. Poor printing press supplies result in wasted substrates, increased down-time, and unhappy, time-wasting operators – with an inevitable blow to the bottom line. Conversely, high-quality printing press supplies enable the production of high-quality, consistent products while improving operational efficiencies.
This comprehensive guide provides an overview of the different types of printing press supplies, along with expert guidance on sourcing and managing the raw materials that keep your printing presses running profitably.
Understanding The Printing Press Supplies Ecosystem
Before beginning the process of sourcing, it is crucial to have an understanding of how printing press supplies fit into a working print shop environment. A print shop is an integrated mechanism – a delicate balance of consumables, machinery, and the environment they operate in.
The Critical Role Of Consumables
Consumable printing press supplies are the materials consumed and used up in the process of turning blank substrate into a finished printed product. These include things like inks, toners, fountain solutions, and printing blankets. Due to the fact that they are consumed in the process of production, consumable materials have a significant impact on a print shop’s COGS (Cost of Goods Sold).
In terms of cost, however, it is a mistake to look at the price of a consumable printing press supply in isolation. The true cost should be measured as the expense per job, bearing in mind the impact that a given printing press supply has on production efficiency and waste.
The Inter-Relationship Between Supplies And Machinery
Modern printing equipment requires very specific materials to achieve optimal performance. Some manufacturers of printing equipment will certify certain printing press supplies as suitable for use with their machinery.
While it is often possible to source cost-effective generic equivalents for many printing press supplies, there is always a risk involved in using non-certified materials, particularly for digital printing equipment. The sensitive printhead technology on digital presses can be irreparably damaged by the use of incorrect toners. Many offset lithographic printing presses, meanwhile, have less stringent requirements for their printing press supplies, though there are still recommended materials for offset inks and paper.
Essential Categories Of Printing Press Supplies
To better understand sourcing and management processes for printing press supplies, it is useful to break them down into discrete categories. Below are the core categories of materials used in print production, along with essential sourcing and management tips for each.
1. Inks, Toners, And Color Management Tools
This category encompasses the different types of inks used in the printing process, as well as tools and materials for managing and controlling color.
Offset Inks Versus Digital Inks/Toners
Traditional offset lithographic inks are primarily used in commercial printing, and are a paste-like substance that must be mixed with solvents. There are many different types of offset inks available – they vary according to the preferred setting or “drying” method, including oxidizing, heat-set, UV-curable, and more. It is important to choose the appropriate printing press supply based on the desired print media and production method. UV-LED offset inks are a recent innovation which enable faster production with lower energy consumption.
Digital printing equipment requires a different type of printing press supply, either in the form of liquid electroink (for HP Indigo printers) or dry powder toner (for Xerox, Konica Minolta, and similar printers). Printing shops using digital equipment should ideally source OEM (Original Equipment Manufacturer) printing press supplies, where possible, due to the sensitive nature of digital printing technology. That said, there are reliable third-party options available for older digital printing equipment.
Ink Kitchen And Spot Color Management
Many commercial printing shops have an “ink kitchen,” a dedicated space where customized mixed inks are produced for specific jobs. To create custom spot colors, it is necessary to have the right printing press supplies on hand, including base ink colors, scale, and mixing software. Having the ability to mix custom colors using an ink kitchen can be an important selling point, enabling the print shop to fulfill specialized Pantone Matching System (PMS) requests. It is crucial to source high-quality mixing materials so that consistent spot colors can be achieved.
Color Calibration Supplies
Beyond mixing inks to match the Pantone Matching System (PMS), color calibration and management is also a vital printing press supply for ensuring color consistency between proofs and the final print job. Color calibration and management printing press supplies include spectrophotometers, specialized calibration targets, and control strips.
2. Substrates, Papers, And Specialty Media
The substrate is the material that gets printed on – the “canvas” that makes up the printed item. The range of printing press supplies in this category is vast and varied.
The Importance Of Consistent Paper Stock
Of these, paper is the most common printing press supply. The importance of sourcing reliable and consistent paper cannot be overstated. It is always a good idea to work with a reliable supplier of this crucial printing press supply who can guarantee paper quality and delivery consistency.
It can be tempting to buy job-lot paper to reduce costs, but it is always a good idea to run test prints first to determine whether the paper is compatible with the press and produces the desired results.
The Difference Between Digital And Offset Paper
It is also crucial to understand the difference between digital printing paper and offset lithographic paper – using the wrong type of paper in a digital press can lead to paper jams and even damage to the printing equipment. Digital printing equipment (especially toner-based machines) requires paper that can withstand the high heat and pressure of the fusing rollers.
3. Pressroom Chemistry, Coatings, And Cleaners
One of the most overlooked aspects of print production – and therefore of printing press supply sourcing and management – is pressroom chemistry. This category includes a range of specialized printing press supplies, from fountain solution additives to press washes and solvents.
Fountain Solution Additives
When using an offset lithographic printing press, the printing plate must remain damp to repel ink and ensure image sharpness. Fountain solutions are used to keep the plate damp and prevent ink from adhering to non-image areas. When sourcing fountain solution additives, it is essential to pay attention to the chemical balance (pH and conductivity) as incorrect levels can lead to scumming, stripping, and plate blinding. The choice of fountain solution printing press supply will also impact on the performance of the press and the quality of the final print.
Washes And Solvents
In addition to fountain solutions, printing presses require specialty washes and solvents to clean rollers and other press parts. When sourcing washing printing press supplies, it is essential to consider both performance (ability to remove ink and debris) and the health and safety impact on the workers – modern eco-friendly solvents tend to have a lower VOC (Volatile Organic Content) and are a safer option, though they may require different handling procedures.
Aqueous And UV Coatings
Many print shops apply aqueous or UV coatings to printed pieces as a finishing process, either inline on the press or on a separate coating machine. These printing press supplies serve to protect the printed surface, add visual appeal to the print job, and allow for special effects like gloss and matte finishes. When sourcing these specialized liquid printing press supplies, it is important to take into account viscosity, curing speed, and desired finish.
4. Pre-press Printing Supplies
Pre-press involves all the processes that take place before actual printing commences – this category of printing press supplies includes plates, film, and proofing media.
Offset Printing Plates
Whether you are using thermal plates, violet plates, or chemistry-free plates, one of the most crucial printing press supplies for a commercial printing shop is offset lithographic plates. When sourcing offset plates, it is important to take into account run-lengths (how many prints can be achieved before the plate needs to be replaced), resolution capabilities, and sensitivity (how easily the plate can be imaged). Chemistry-free plates are becoming increasingly popular, as they eliminate the need for chemical processing.
Proofing Media And Toners
Despite the rise of digital proofing, many print shops still utilize traditional proofing methods. This requires a range of specialized printing press supplies, including proofing papers for inkjet proofing, and proofing films for analog proofing. Due to the specialized nature of these proofing processes, the materials involved in them – particularly the specialized proofing inks and toners – must be sourced with particular care.
5. Finishing And Bindery Materials
Once the printing process has been completed, the printed piece must be finished and bound, turning it from a stack of printed sheets into a finished product. This category includes a range of different printing press supplies.
Lamination Films And Adhesives
There are many different laminating films, categorized by thickness (measured in microns or mils), finish (gloss, matte), and adhesive strength, with a range of options available for durability and resistance to scuffing. The choice of laminating film and adhesive printing press supplies will depend on the desired outcome – industrial-grade lamination such as self-adhesive vinyl films or high-performance banner materials will be required in some cases, whereas a thin pressure-sensitive film may be used in other finishing applications.
Perfect Binding Glues
To finish booklets and other bound items, most print shops will use some kind of stitcher or perfect binding glue. Depending on the requirements of the job, a print shop may need to source a range of different printing press supplies for stitching wire, hot-melt, and PUR bindings.
Tapes, Foils, And Die-Cutting Rule
Specialty finishing like foil stamping and die-cutting also require specific printing press supplies. High-quality stamping foil, double-sided mounting tape (for POP displays and signage), and steel die cutting rule are crucial to achieving a professional, high-quality finish.
Best Practices For Sourcing Printing Press Supplies: Vendor Management
Your ability to source and manage your print shop’s printing press supplies is only as good as the vendors that you work with.
What To Look For In A Supplier Of Printing Press Supplies
When looking for a supplier of printing press supplies it is essential not to fall prey to the temptation to buy the cheapest printing press supplies available. It is important to evaluate potential suppliers based on a number of different criteria:
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Consistency of quality
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Reliability of delivery
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Technical knowledge and support
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Range of products
Consistency of quality should be your primary concern when looking for a printing press supplies supplier. Ask for a Product Data Sheet (PDS) for the products you are considering, and look out for any variations between batches.
With regard to delivery reliability, ask suppliers about their on-time delivery performance. A good supplier should always strive to deliver the printing press supplies you have ordered when you expect them. If a printing press supply is late, it can cause serious disruptions to your print shop’s production schedule.
A good supplier should also have a thorough understanding of the printing process, and should be able to assist you in finding the right printing press supplies for your requirements.
It is also a good idea to look for suppliers who can fulfill a range of your printing press supply needs, rather than working with a number of different suppliers. Having fewer suppliers means streamlined management of your accounts payable, and can often lead to better pricing.
Conducting Audits Of Printing Press Supplies Vendors
It is a good idea to conduct regular supplier audits to ensure that your suppliers are continuing to meet your expectations. There is no need to conduct a full ISO-certified audit every time you meet with a supplier, but you should always have an open dialogue and ask yourself questions about the supplier’s performance, including:
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Have there been any recent quality or delivery issues?
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Is the supplier’s pricing policy satisfactory?
These supplier performance reviews should be conducted on a regular basis and should always take place in conjunction with an open and positive dialogue with the vendor.
The Debate: Bulk Buying Versus Just-In-Time Inventory For Printing Press Supplies
There are a number of advantages and disadvantages to both bulk buying and just-in-time (JIT) inventory purchasing.
The Advantages Of Bulk Buying Printing Press Supplies
Buying printing press supplies in bulk is a great way to reduce your costs. Suppliers are usually willing to offer volume discounts, and you also save money on shipping costs by reducing the number of shipments.
Having sufficient stocks of essential printing press supplies on-hand can also be a crucial risk management strategy. Having a reliable reserve of your most commonly used printing press supplies (such as papers and inks) means that you will always have materials available even if a supplier fails to deliver an order.
The Disadvantages Of Bulk Buying Printing Press Supplies
On the other hand, you must consider the opportunity cost of tying up your working capital in inventory. You will also need to find sufficient storage space for all your printing press supplies, particularly if you are buying large quantities of paper. Another potential downside of bulk purchasing is the risk of waste and obsolescence. Many printing press supplies have an expiration date, and buying stock that you cannot use within its expiration window can be extremely costly. This is particularly true of digital printing supplies like toners and inks, where new formulations can render old stock useless. It is crucial to have an accurate inventory management system in place to avoid waste and obsolescence.
Best Practices In Inventory Management For Print Shops
Now that we have outlined the fundamental principles of printing press supply sourcing, it is time to examine best practices in inventory management.
Storage And Handling Of Printing Press Supplies
Even the finest printing press supplies can be rendered useless through poor storage and handling.
The Importance Of Climate-Controlled Storage
Paper is a hygroscopic material – it naturally absorbs and expels moisture depending on the environmental conditions. Storing paper in an environment with unstable or fluctuating humidity can lead to curled or wavy sheets that are difficult to feed through a printing press.
Inks and other chemicals must also be stored in a stable environment with controlled temperature and humidity. Extreme temperatures can damage inks and coatings, rendering them unusable.
First-In/First-Out Inventory Rotation
It is vital to have a first-in/first-out (FIFO) inventory rotation system in place for all your printing press supplies, particularly those with limited shelf-life. Products like offset inks, digital toners, and chemicals all have a limited shelf-life and should be used before their expiry dates.
Future Trends In Print Production
The print production industry is in a constant state of evolution. As a print shop owner, it is always important to stay ahead of the curve and identify trends that will enable you to gain a competitive advantage.
The Rise Of Sustainable Printing Press Supplies
Sustainability is a growing concern for print buyers, and this trend shows no signs of slowing down. As a result, there has been a surge in demand for eco-friendly printing press supplies, including soy-based inks and recycled papers. To stay at the forefront of the print industry, print shops must embrace these new sustainable printing press supplies.
The Impact Of Smart Inventory Software On Print Shops
One of the biggest trends in print production is the advent of smart inventory software, which enables print shops to automate many of their inventory management processes. Some print MIS (Management Information System) programs offer integrated printing press supply management, enabling shops to track the consumption of specific inks, papers, and plates for each job. Once a job is completed, the relevant printing press supplies are automatically deducted from inventory. Once inventory reaches a predetermined reorder level, an automatic order can be sent to your preferred supplier. Some systems even utilize IoT (Internet of Things) technology embedded in your printing equipment to track ink and chemical consumption, completely automating the reorder process.
The Impact Of Advancements In Printing Technology On Printing Press Supplies
Advancements in printing technology are set to have a significant impact on the types of printing press supplies utilized by print shops. For example, nanographic printing technology makes use of water-based “NanoInk” pigments that are transferred to a heated printing blanket before being transferred to the desired print media. This innovative technology allows for the production of a durable printed image on any standard sheet of paper. Staying abreast of the latest developments in printing technology is crucial to ensuring that you are sourcing the most appropriate printing press supplies for your operations.
Conclusion
Sourcing printing press supplies is a critical element in the success of any print shop. By adopting a strategic and informed approach to sourcing and managing your printing press supplies, you can transform this essential function into a competitive advantage that delivers significant cost savings and boosts your shop’s profitability. Failing to prioritize this vital aspect of your print shop operations, however, can lead to significant financial losses and decreased print quality. By following the above-sourcing and inventory management tips, you can optimize your printing press supplies management process.