Magnetic, signature and security stripes are applied onto overlay foils. The transfer is processed using reel-to-reel or reel-to-sheet. The magnetic stripes are stamped onto the overlay material, using their full width.
During the sheet hot stamping process, security holograms are applied onto a single sheet. Important parameters for the implementation of the DOVID are pressure, time and temperature. A very high security level can be reached by laminating the hologram inside the card body so it cannot be removed from the card.
The foil punching process is the preparation step for the production of inlays on sheet basis. Before the antenna can be inserted, holes are punched into the foils in one stroke with highest accuracy.
The inlay testing process step is highly important for quality assurance. The integrated transponders in the RFID pre-laminated, collated, laminated or inlay sheets are tested, ensuring that the complete output is fully functional.
Sheet collating is the preparation step for the lamination process. Several sheet layers e.g. the core layer, printed sheets, inlays or antennas are collated, aligned and welded by the welding system.
Sheet lamination is a thermal welding process during which collated sheet sets are laminated with a specific temperature (depending on material) and pressure. To ensure a robust and stable result, the selected materials are connected non-detachably thus fulfilling all requirements regarding quality, lifetime and counterfeiting.
After the laminated sheets are separated from a pallet or trolley, they are aligned to print mark recognition sensors. The cards are punched from the sheets with a stamp-matrix tool and collected in standard Mühlbauer magazines. The unique hydraulic system is position and speed controlled guaranteeing highest accuracy and longest lifetime of tools.
The process includes the inspection of surface (scratches), print (color deviation, position of elements in relation to card edge or other elements, etc.), UV-print, holograms and even complex inspections such as variable ink. Since the systems have been developed for ID card projects, all inspection technologies of state-of-the-art ID card machines are available, e.g. electrical testing of contactless cards. The process optionally includes the sorting of cards according to different criteria (bad card sorting, layout sorting, etc.).
During the card hot stamping process, a security foil (including holograms, signature panel, etc.) is applied onto a card using pressure, time and temperature. The foil can be applied to the front and / or back side of the card.
In order to achieve highest quality in the results, every process step of the production chain is continuously checked and controlled by quality assuring procedures. The testing depth and numbers of control samples are adjustable to the respective needs of the processes and the product specifications. Specific procedures, measurements and statistic process knowledge guarantee optimal results ensuring highest yields.