Varel vs Hawk: A Procurement Manager's Honest Take on Cost vs. Speed in Commercial Printing
Comparing Two Printing Vendors: Varel vs Hawk
When I took over purchasing in 2020, I inherited a roster of vendors that included both Varel and Hawk. For a mid-sized company like ours—processing 60-80 orders annually across 8 vendors—choosing between them for commercial printing wasn't just about price. It was about who could deliver without making me look bad to my VP when materials arrived late.
I've spent the last five years managing these relationships, and I've learned that the 'cheaper' option isn't always cheaper. Here's my breakdown of how they compare across the dimensions that actually matter to someone in my role.
Cost per Unit: The Obvious Difference
Let's start with what everyone looks at first. Based on publicly listed prices from major online printers (January 2025), here's what I found:
- Varel: Their base pricing for 500 business cards (14pt cardstock, double-sided, standard 5-7 day turnaround) comes in around $35-60. That's mid-range.
- Hawk: They're consistently in the budget tier—$20-35 for the same spec.
To be fair, Hawk's pricing is attractive. But here's what I learned the hard way: the 'budget vendor' choice looked smart until we saw the quality. Reprinting cost more than the original 'expensive' quote.
In Q3 2024, we tested 4 vendors and found pricing variations of 40% for identical specifications. That's a real number—I have the spreadsheets to prove it.
Lead Times and Reliability: The Real Cost
This is where things get interesting. I'm not a logistics expert, so I can't speak to carrier optimization. What I can tell you from a procurement perspective is how to evaluate vendor delivery promises.
Varel consistently hits their quoted lead times. In my experience, if they say 5-7 days, it's delivered in 5. Hawk, on the other hand, has a reputation for stretching that window. The 'expedited' option? That added 50% to the cost (which, honestly, felt excessive).
I still kick myself for one instance in 2022. We needed 1,000 flyers for a trade show. I went with Hawk to save $60. Ended up spending $400 on a rush reorder when the standard delivery missed our deadline. Net loss: $340, not counting the stress.
Granted, this doesn't happen every time with Hawk. But when it does, the cost far outweighs the initial savings.
Quality Consistency: The Hidden Variable
This gets into technical territory, which isn't my expertise. I'd recommend consulting with your design team. But from my perspective, there's a clear difference:
- Varel: Their output is consistent. The colors match the proofs, and the stock feels premium (think thicker cardstock, better coatings).
- Hawk: The quality varies by batch. We've had runs where the ink smudged (surprise, surprise) and others where it was perfectly fine.
The worst part? When a batch fails, it's not just the reprint cost. It's the time spent reapproving proofs, the internal complaints from the marketing team, and the awkward conversation with my boss about why we 'saved' money.
The 'Hidden Costs' Nobody Talks About
Setup fees in commercial printing typically include plate making ($15-50 per color for offset), digital setup ($0-25—many online printers have eliminated this), and die cutting ($50-200 depending on complexity). Custom Pantone colors add another $25-75 per color.
Varel includes most of these in their quoted prices. And their customer service—when I have a question about the setup, I get a clear answer. Hawk? Their pricing seems lower until you add everything up. Setup fees, revision charges, shipping—it adds up fast.
To be fair, Hawk's pricing is competitive for what they offer. But the hidden costs? I've seen them catch many people off guard.
When to Choose Which
Based on my five years of managing these relationships, here's my honest advice:
- Choose Varel when: You need consistency, you're ordering something that reflects on your brand (business cards, brochures), or the deadline is firm.
- Choose Hawk when: Budget is the only constraint, and you have buffer time for potential fixes—like internal documents or rough drafts.
I'm not saying Hawk is bad. They're a solid option for cost-sensitive projects. But for anything where quality or reliability matters? I've learned to pay a bit more upfront.
One of my biggest regrets: not building vendor relationships earlier. The goodwill I'm working with at Varel now took three years to develop. They know my preferences, they flag potential issues before they happen. That kind of relationship is hard to value on a spreadsheet.
Prices as of January 2025; verify current rates. Based on major online printer quotes and my personal experience across 200+ orders.