Kirk-Rudy | Print & Mail, Packaging and RFID Equipment Manufacturer

For years, offset printing has been the go-to solution for high-quality envelope production. But as customer demands shift toward faster turnarounds, shorter runs, and personalization, digital inkjet presses are gaining ground — especially for envelope printing.

So which is right for your business? Let’s break down the key differences between offset and inkjet envelope printing.

Speed & Setup Time

Offset Printing:
Requires setup time for plates, registration, and color calibration. Best suited for long runs where the upfront time investment is amortized over volume.
Inkjet Printing:
Minimal setup. No plates, no wash-up, and fewer manual adjustments. Ideal for on-demand printing, short runs, and jobs requiring quick turnaround.

✅ Winner for speed-to-production: Inkjet
✅ Winner for long runs: Offset

Print Quality & Color

Offset:
Produces sharp images and consistent solids. Great for brand-heavy jobs with large coverage areas and PMS color matching.
Inkjet:
Today’s inkjet systems (like Kirk-Rudy’s FireJet 4C) offer 1600 x 1600 dpi resolution, vibrant CMYK color, and impressive consistency — often rivaling offset quality on envelopes.

✅ Winner for color precision/PMS matching: Offset
✅ Winner for full-color flexibility and personalization: Inkjet

Cost Per Piece

Offset:
Lower per-piece cost on very large runs, but only after you cover the cost of plates, setup, and makeready waste.
Inkjet:
No plate cost, no makeready waste. More cost-effective for small to medium runs, especially those with variable data.

✅ Winner for short runs and dynamic content: Inkjet
✅ Winner for long-run static jobs: Offset

Personalization & Variable Data

Offset:
Not suitable for variable data unless paired with a separate inkjet addressing system.
Inkjet:
Built for variable data printing (VDP). Names, barcodes, images, and custom offers can change on-the-fly, piece by piece.

✅ Hands-down winner: Inkjet

Flexibility

Offset:
Typically tied to a fixed print format and slower to changeover between jobs or sizes.
Inkjet:
Capable of printing on a wide range of envelope sizes and materials. Better suited for mixed job batches, seasonal campaigns, and customized runs.

✅ Winner for adaptability: Inkjet

The Bottom Line

If you're printing millions of identical envelopes, offset is still a strong solution. But if your customers are asking for shorter runs, faster turnarounds, personalized content, and full-color flexibility, then inkjet — especially with equipment like the FireJet 4C — offers a smarter, more scalable path forward.

Looking to make the switch or add digital capabilities to your envelope production?
Let Kirk-Rudy help you compare options.