For new publishers not familiar with magazine printing and the mammoth iron presses used in commercial print operations we hope this overview and photo tour helps to spark some creative ideas and/or questions for you to discuss as you plan and interact with your magazine printing vendor.

Print facility tours are not uncommon for new publishers. They most generally occur as part of your vendor evaluation process prior to you making your decision. Additional visits to the plant sometimes take place during actual production of key issues (such as the premiere or a special anniversary). These are referred to as “press checks”. These visits allow you to communicate your preferences in regard to the look of your magazine and establish a “face with a name” relationship with the pressman.

The Magazine Printing Process

Developed in 11^th Century China, Letterpress is the oldest form of printing still in use today. It has the reputation of being a mid to low quality process and is therefore primarily used on newspapers, labels, etc. The most common processes used today for magazine production are Heat-set Web Offset, Sheet-fed Offset and Roto Gravure.

Due to technological equipment advancements over the past decade, high quality is achievable with any of these common methods. The primary factor involved in determining the process that is best suited for your magazine is the number of copies you would like printed. Generally speaking, small quantities require a sheet-fed offset press, large quantities are better served on a Roto Gravure press. The heat-set Web Offset presses are most efficient for those that fall between.

The definition of “small” and “large” is subject to interpretation depending on the individual capability of your vendor. Quantities as small as 10,000 copies can be quality produced on Heat-set Web Offset Presses by some print companies.

In regard to Roto Gravure the typical range begins at 750,000+ circulation. It is the “endurance runner” of the processes. Unlike Offset, which uses a metal plate for image to paper transfer, Gravure uses a metal cylinder. The offset plates, which are less expensive than a gravure cylinder will wear out far faster. Not only are you billed for each plate used but quality may also be jeopardized as a plate begins wearing out. Therefore the breaking point between Offset and Gravure is largely influenced by price and quality. If you are close to this quantity have your vendor provide you with comparative quotes and ask them what they consider to be a comfortable quantity to make the transition based on their equipment.

Sheet-fed Offset Press Facts

• Best suited for small quantity magazines
• Image is transferred to paper using a metal printing plate and press blankets
• Prints on individual sheets of paper
• Wide selection of paper stocks available including colored and textured sheets
• Wide variety of page size options
• Wide variety of color combinations and coating options
• Ink dries via air
• Capable of producing a maximum of 16 standard pages at one time
• Average speed is 15,000 sheets per hour

• Best suited for large quantity magazines
• Image is transferred to paper using a metal cylinder
• Prints on a web of paper
• Wide variety of page size options
• Wide variety of delivery options
• Limited variety of color combinations and coating options
• Ink dries via heat
• Capable of producing up to 96+ pages at one time
• Average speed is 35,000 impressions per hour

• Best suited for medium quantity magazines
• Image is transferred to paper using a metal printing plate and press blankets
• Prints on a web of paper
• Wide variety of page size options
• Wide variety of delivery options
• Limited variety of color combinations and coating options
• Generally the most cost effective method (compared to Sheet-fed and Roto Gravure)
• Ink dries via heat
• Capable of producing up to 64 pages at one time
• Average speed is 50,000 impressions per hour
  

This following photos and magazine printing process overview are courtesy of Quebecor World in Riverside California.  The printing facility photos are from one of their retail press division - this specific facility is not a magazine printing and magazine finishing services facility. 

See Retail Press Photos Here

Courtesy of Quebecor World

Photos and the printing process overview are provided courtesy of Quebecor World. Quebecor World is one of the largest printing companies in the world. The Company philosophy is continually focusing on ideas, innovations, and efficiencies to produce value for their customers. Quebecor World provides sales representatives in all major regional markets to work directly with publishers for printing solutions and ideas. (Pictured left to right Camdon Johnson, Leslie Larson, George Decker.)