Within the printing industry's CTP (computer-to-plate) technology ecosystem, thermal plates and process less plates are two core branches. These two technologies differ fundamentally in their imaging principles, process steps, performance and application scenarios. The choice of technology directly determines the efficiency, cost, and environmental performance of printing production.

The following is an in-depth comparison of the two across six core dimensions, highlighting their professional differences and technical features:

1. Core Imaging Principles and Plate Structure Differences

The imaging principle is the fundamental difference between the two types of printing plates, directly determining their subsequent process design and performance limits.

2. Comparison of Core Process Steps: "Multi-step Intervention" vs. "Zero Post-processing"

Process complexity is the most obvious difference between the two, directly impacting production efficiency and process stability.

1). Thermal Printing Plates: A "Four-Step Process Chain" (Must Rely on Post-Processing)

The image formation on thermal plates requires external process intervention, and the process cannot be simplified. The specific steps are as follows:

- Imaging:

The CTP device's infrared laser illuminates the plate's photosensitive layer, causing the resin in the heated area (the image) to decompose or soften, forming a "latent image";

- Developing:

The plate is fed into a developing machine. The developer (alkaline solution) dissolves the unexposed resin in the non-image area, leaving the resin in the image area;

- Washing:

Residual developer and dissolved materials are rinsed with clean water to prevent contamination of the ink during subsequent printing;

- Drying/Gumming:

The plate is dried to remove moisture. In some cases, a protective gum is applied to prevent oxidation or scratching. The final result is a press-ready printing plate.

2). Process-Less Plates: "One-Step Image Ready" (No Post-Processing)

Process less plates utilize the plate's own functionalities, eliminating all post-processing steps:

- Imaging:

The CTP device's laser (typically a violet laser with a wavelength of 405nm) illuminates the plate's functional layer, causing the photosensitive resin to polymerize. Simultaneously, the development inhibitor within the functional layer automatically activates, preventing polymerization in the non-imaged areas.

- Direct-to-Print:

After imaging, the printing plate can be sent directly to the press for loading and printing without developing or washing.

3. Key Performance Indicator Comparison (Professional Scenario Perspective)

4. Cost Structure Comparison: "Low Initial Cost + High Later" vs. "High Initial Cost + Low Later"

The cost difference between the two types of printing plates must be considered from a "full life cycle" perspective. Perspective analysis, not just plate price.

5. Application Scenarios and Technology Selection Recommendations

The technical characteristics of the two types of printing plates determine their applicable printing scenarios. There is no absolute superiority or inferiority; there are only differences in "scenarios."

1). Thermal Plates: Suitable for "long-run, high-precision, and multiple ink types" scenarios

- Core Application Areas:

Book and periodical printing (e.g., textbooks and bestsellers, with single-run runs exceeding 100,000 copies, requiring high press life and tonal stability);

Packaging printing (e.g., food packaging and gift boxes, requiring compatibility with UV inks and gold and silver inks, with high resolution requirements);

Commercial printing (e.g., high-end brochures and posters, requiring 1%-99% dot reproduction and color accuracy).

- Selection Logic:

When production primarily relies on "long-run" runs, demands extremely high print quality, and mature post-processing equipment and hazardous waste treatment systems are in place, thermal printing plates offer significant advantages in terms of cost-effectiveness and adaptability.

2). Process less Plates: Suitable for "Short Runs, Quick Turnaround, and Environmentally Friendly" Scenarios

- Core Application Areas:

Digital Quick Printing (e.g., corporate brochures and conference materials, with single-batch print runs of 500-5000 copies and requiring fast delivery);

Label Printing (e.g., pharmaceutical labels and electronic labels, with small print runs but frequent batches requiring frequent plate changes);

Regions with high environmental standards (e.g., the EU and first-tier cities in China, where hazardous waste emissions are restricted and "zero-pollution" production is required).

- Selection Logic:

When production primarily focuses on "short runs," requires "print-now-out" fast turnaround efficiency, or requires reducing environmental compliance costs, the advantages of process-free plates, with "no post-processing" and low labor costs, can significantly improve production efficiency.

6. Technology Development Trends: From "Replacement" to "Segmented Coexistence"

- Thermal Plates:

Technological iterations are focused on "high print run time + low energy consumption," such as the introduction of "ultra-thin photosensitive layer" plates (reducing laser energy requirements) and "long-lasting developer-compatible" plates (extending developer replacement cycles and reducing hazardous waste), further consolidating their advantages in long-run, high-precision applications.

- Process less Plates:

Technological breakthroughs are focused on "high resolution + long print run time," such as improving fine-dot adhesion through "nano-functional layer coating" technology (achieving dot reproduction below 1%) and employing "cross-linked resins" to enhance print run time (breaking the 200,000-print limit). These plates are gradually penetrating mid- and long-run applications.

In the future, the two types of printing plates will form a "segmented coexistence" landscape: thermal plates will dominate high-end, long-run printing, while process less plates will dominate short-run, quick-run, and environmentally friendly markets, rather than a single technology completely replacing the other.

The core difference can be summarized in one sentence: Thermal plates are a traditional technology that relies on external processes to create images and text, with advantages in long run lengths and high precision. Process less plates are an innovative technology that uses the plate itself to create images and text, with advantages in short run lengths, quick response, and environmental friendliness.

Selection Decision Tree:

If the print run is ≥100,000 prints and requires UV ink/high-precision dots, then choose thermal plates.

If the print run is ≤50,000 prints and requires delivery within 24 hours, and has high environmental requirements, then choose process less plates.

If the print run is 50,000-100,000 prints and has no clear environmental restrictions, then compare the total cost of thermal plates (plate + post-processing) with the total cost of process free plates (plate) and choose the lower one.