Everything you need to know about Digital Printing

What is digital printing and how does it work

In this blog we will dive deep in to the advantages and disadvantages of Digital Printing, the equipment used, the cost and the specialized branch of large formats.

What is digital printing and how does it work?

Digital printing is a modern, versatile, and increasingly popular method of reproducing text and images on various surfaces, ranging from paper to fabric, plastic, and more. Unlike traditional printing techniques, such as offset printing for high volumes or screen printing, digital printing does not rely on plates or screens to transfer ink onto a substrate. Instead, it uses digital files as the source of the printed content.

At the heart of digital printing is a digital printer, which interprets digital files and directly applies ink or toner to the chosen medium. This technology has revolutionized the world of printing by offering greater flexibility, cost-effectiveness, and efficiency. It’s widely used in commercial printing, home and office settings, as well as for specialized applications like signage, labels, packaging, and even textile printing. The process involves several key steps:

key steps and equipment in digital printing
  1. File Preparation: Digital printing starts with creating or importing a digital file containing the design or content to be printed. This can be done using design software or by scanning a physical image.
  2. Printing: The digital file is sent to the printer, which uses inkjet or laser technology to apply the desired colors and patterns onto the chosen substrate. The printer precisely controls the placement of ink or toner to reproduce the design accurately.
  3. Finishing: After printing, the substrate may undergo additional processes such as cutting, binding, or laminating, depending on the final product’s requirements.

Pros and Cons of Digital Printing

When it comes to bringing your creative projects to life through print, the choice of printing process plays a crucial role in determining the quality, cost, and overall outcome of your vision. Among the various printing methods available, digital printing has gained popularity for its simplicity, speed, and cost-effectiveness. However, like any other printing technique, digital printing comes with its own set of advantages and disadvantages. In this article, we’ll dive into the pros and cons of digital printing to help you make an informed decision for your next printing project.

Advantages of Digital Printing

1. Short Print Runs: Digital printing stands out for its ability to produce shorter print runs economically. With minimal setup requirements, you can create a limited number of prints without breaking the bank.

2. Vibrant Color Options: Modern technology has enhanced the color capabilities of digital printing. It now comes close to replicating the rich and vibrant colors achieved by traditional offset printing. Your digital prints can be far from basic.

 3. Fast and Methodical Process:Unlike offset printing and other traditional methods that may demand days of preparation, digital printing is a swift process Digital printing’s rapid setup and execution translate to a shorter turnaround and will quickly bring your project to life.

 4. Flexible Paper Choices:The rise of digital printing has brought innovations in paper choices. You can now select from various options like gloss, matte, satin, and more, achieving results similar to offset printing.

 Disadvantages of Digital Printing

 1. Limited for Long Print Runs: While digital printing can handle longer print runs to some extent, it tends to become costlier than offset printing when dealing with high volumes.

 2. Toner-Based Color Limitations: Digital printing, despite its advances, may not always match the Pantone Matching System (PMS) colors. Instead, it may simulate PMS colors using CMYK values.

 3.Smaller Paper Sizes: Digital printers often accommodate smaller paper sizes, which could be limiting for certain projects. This constraint depends on the type of project you have in mind.

 4. Fading in Sunlight: Inks used in digital printing fade faster than other digital ink when exposed to direct sunlight.

Which type of machinery is used in Digital Printing?

Digital printing has transformed the world of printing and graphic design, and it relies on a range of machinery at various stages of the printing process to produce high-quality prints efficiently. In this article, we will explore the machinery used in different stages of digital printing, including a closer look at the importance of pile turners.

 Prepress Stage Machinery:

  •  Computer Workstations:The prepress stage begins with designers and artists creating digital files on computer workstations. These workstations are equipped with specialized software for designing and editing images, graphics, and layouts.
  •  Raster Image Processors (RIPs): A RIP is software or hardware that translates digital image files into a format that can be interpreted by the printing device. It processes complex color information and prepares the file for printing after the designers have created digital files.

Printing Stage Machinery:

  • Digital Printers: Digital printers are the heart of the printing stage. They come in various types, including inkjet and laser printers. These printers use digital data to apply ink or toner onto the printing substrate, producing the final image or text. Hp, Epson , Canon have a strong presence in the industrial digital printing market, and their products are often chosen for their reliability, print quality, and advanced features. It’s recommended to carefully evaluate the options available to find the best fit for your particular application.
  • Print Heads: Within digital printers, print heads are responsible for accurately depositing ink or toner onto the substrate. They contain tiny nozzles that dispense ink droplets precisely, ensuring high print quality.
  • Paper Feeders: Paper feeders are used to supply the printing substrate, whether it’s paper, fabric, or other materials, to the printer. They ensure a continuous and smooth feed of material through the printing process.
  • Dryers and Curing Units:Digital printing often requires drying or curing the ink or toner to ensure it adheres properly to the substrate. Dryers and curing units use heat or UV light to achieve this.
  • Pile Turners:Pile turners, also known as pile reversers, are critical machinery in the printing process, and they are used to handle the printed materials during or after the printing stage.
The role of pile turners in digital printing


The Role of Pile Turners in Digital Printing

Pile turners are essential in the printing process, especially in large-scale digital printing operations. Their primary function is to efficiently handle printed materials, ensuring quality and productivity. Pile turners offer several benefits:

 1. Paper Restacking: After printing, the output sheets or prints are often piled in large stacks. Pile turners help ensure that the printed materials are properly aligned and re-stacked in a uniform manner. Our pile turner allow for aligning of the load and centering onto the plastic pallet.

2. Aeration and De-Aeration: Pile turners use aeration and de-aeration processes to separate and align individual sheets in the stack. This minimizes the risk of double feeding or misaligned sheets during the subsequent finishing processes.

3. Preventing Curling: In digital printing, especially with high ink or toner coverage, the printed sheets may curl. Pile turners can reverse the curling effect, ensuring that the sheets are flat and ready for further processing, such as cutting or binding.

4. Enhancing Productivity: Pile turners streamline the handling of printed materials, reducing the time and effort required to manually handle large stacks of prints. This leads to improved productivity and a more efficient printing workflow.

5. Quality Assurance: Pile turners help maintain the quality and integrity of printed materials. They can prevent common issues such as ink smudging, double feeding, or misalignment that can occur when handling printed sheets manually.

The “Master Toppy” stationary Pile Turner can handle loads up to 3000kg. This machine streamlines the handling of printed materials, particularly in the context of high-speed digital printing operations. It not only saves time but also minimizes errors and waste. A stationary pile turner is a valuable investment that leads to increased efficiency, reduced labor costs, and improved print quality and higher safety. It is an essential tool for businesses seeking to optimize their digital printing operations. Master Toppy can be used as stand alone or in line with different levels of automation and with different optionals such as the Automatic Pallet Loader, Automatic Pallet Dispenser and Automatic Centering System.

Digital Printing for Large Formats

Large format printing is a specialized branch of digital printing that has become a game-changer in industries like advertising, signage, and interior design. What sets large format printing apart is its ability to deliver high-quality, attention-grabbing visuals. With the ability to produce oversized graphics with exceptional detail and vibrant colors, it’s a go-to choice for creating eye-catching displays and promotional materials. Here are some of the main features of digital printing for large formats:

  •  Large format digital printers are designed to handle much larger print sizes than standard desktop printers. They can produce prints ranging from 18 inches to several feet or even larger, depending on the specific printer model.
  •  The applications include: advertising, retail, construction, architecture, events, and fine art. It’s used for producing banners, signs, vehicle wraps, wall murals, trade show displays, architectural plans, and more.
  •  One of the advantages of large format digital printing is its ability to produce customized, one-of-a-kind prints to suit specific branding or design requirements.
  •  Large format printers are designed for efficiency and can produce prints quickly, making them suitable for time-sensitive projects.

Toppy Packaging manufatures an electrically powered mobile pile turner that  is ideal for the large formats of the graphic industry, as it can handle pallets of paper up to a maximum weight of 1800 kg, and with size from 70 x 100 cm up to large formats of 120 x 160 cm. “Maxi Toppy” in its flat legs and wide base version, is versatile and takes up very little space. The batteries are long lasting and it allows fot safe and efficient operations in small areas.

The reduced costs of Digital Printing

Digital printing eliminates the need for costly printing plates and allows for on-demand printing. This means that businesses can print only the quantity needed at a given time, reducing wastage and inventory costs. There are no prepress procedures, which cuts down on time and resources.

Additionally, digital printing offers unmatched flexibility. It enables variable data printing, making it easy to personalize each print with unique content or designs. This personalization can be a game-changer for direct marketing campaigns, as it increases engagement and response rates.

Moreover, digital printing provides quick turnaround times, allowing for rapid production and delivery. This speed is crucial for meeting tight deadlines and responding to fast-changing market demands.

Overall, the cost-efficiency, flexibility, and speed of digital printing make it a cost-effective choice for a wide range of applications, from business cards and brochures to labels and promotional materials. It empowers businesses to save money and resources while meeting the demands of a dynamic marketplace.



In conclusion, digital printing has ushered in a new era of printing, offering unparalleled advantages in terms of cost-effectiveness, flexibility, and speed. It has transformed the way businesses and individuals approach printing projects, allowing for on-demand, personalized, and efficient production. Whether it’s producing marketing materials, labels, or even fine art prints, digital printing’s versatility and convenience make it the go-to choice in today’s fast-paced world. As technology continues to advance, the possibilities in digital printing are only growing, promising even more exciting opportunities and innovations in the future. Embracing digital printing is not just a matter of staying competitive; it’s a gateway to unlocking creative potential and achieving printing excellence.

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