We know access control! Numerous customization options include card sizes, inkjet or PVC, printed or blank, hole punches, and security features at the edge of innovation. We can do it all. Start designing today.
MATTE INKJET CARDS
Typically 28mil thick and resembling a credit card thickness, these inkjet cards are compatible with the SwiftColor printer. Adding RFID, depending on chip type, will push thickness to roughly 40mil.
This plastic formula accepts the toner inks much better than the glossy formula. Details, such as gradations and line work render closer to expectations. Color matching is easy and more consistent.
The one negative is that the matte stock cannot be pre-printed. This means that all of the static/redundant images must be printed at the same time as the variable. This is sometimes an issue with large scale events and needing to print the back of cards which requires feeding each card twice. You'll want to factor in the time to double feed matte cards if your event requires dual sided printing.
GLOSS INKJET CARDS
Typically between 26 to 30mil, these cards are built much like standard credit cards. Adding RFID to this stock/formula increased the thickness by roughly 10mils. Adding pre-printing to the card adds roughly 6mils. These are custom built to your event needs.
For years, the glossy inkjet stock was the most popular. Most all events require PMS matching and pre-printing so this continues to be a popular product. Litho printing is done on the base plastic with the clear inkjet material applied over. This allows you to print over or near the pre-printing and register data. Due to the layering, you can also incorporate embedded holograms, step and repeat invisible ink, etc.
If your event or custome requires an exact PMS match and/or pre-printed backs, this is the inkjet stock you need for the SwiftColor printer. Also, this material combination allows us to print digitally which means we can combine multiple images for volume (combo) pricing. This also allows us to run smaller amounts at a much lower cost.
PVC OVERSIZED CARDS
Built just the same as the CR-80 cards, this formula feels and acts just like cards in your wallet/purse. The oversized event cards stick to industry standards of 27 to 33mil with or without pre-printing. Adding RFID increases the thickness roughly 6-10mils.
This formula cannot be printed using inkjet or toner inks, only customized dye-sublimation, thermal or retransfer printers can be used. As these printers are custom and not readibly available online, the card stock and issuance process is considered very secure.
Like the glossy inkjet card stock, the oversized PVC cards can be printed litho or digital. The ability to digital print allows us to print various templates on one press run to combine volume (combo) for better pricing. Since these are laminated like normal credit cards, you have the option of adding pre-printing or numerous security features.
High end, durable, secure but costly.
ZC10L PVC OVERSIZED CARDS
Built just the same as the CR-80 cards, this formula feels and acts just like cards in your wallet/purse. The oversized event cards are thinner industry standards of 27 to 33mil with or without pre-printing. Typically the cards cannot be more than 22mil thick. Adding RFID in this thickness only creates problems as most 13.56MHz inlays are on their own, 17 mil thick leaving zero room to hide the antenna and IC bump. In most cases, only UHF is suggested and moved to an area of the card that is preprinted and not printed on within the ribbon transfer process.
This formula cannot be printed using inkjet or toner inks, only customized dye-sublimation ribbons sold by Zebra. Zebra, historically, does not sell ribbon unless you purchase card stock from them. This creates a very odd marketplace.We typically produce cards for customers that have excess ribbon inventory. As these printers are custom and not readibly available online, the card stock and issuance process is considered very secure.
Like the glossy inkjet card stock, the oversized PVC cards can be printed litho or digital. The ability to digital print allows us to print various templates on one press run to combine volume (combo) for better pricing. Since these are laminated like normal credit cards, you have the option of adding pre-printing or numerous security features.
High end, durable, secure but costly with a strange ribbon sale process.
RFID
Process is becoming more efficient with RFID. Kiosks can be set up to guide individuals through a sales or promotional experience. Tracking patterns and movement is critical in developing or refining the user experience.
Does the user have fun at your event? Do they feel like the messaging is unique and directed to them and their wants? These are a few of the benefits to incorporating RFID into your event credentials. No, not stickers or silly wristbands that can be handed off and used by many, RFID chips embedded into the card body. The chip data (often alpha/numeric) is assigned to a specific user and they are guided on their unique experience.
To the left you can see a SalesForce Dreamforce kiosk using a DSS event credential with RFID technology. This dual frequency card guided the guest through a series of challenges that explained products. Each guest was in complete control of direction and what they wanted to receive from the experience.
It's not as complicated as it seems. Start slow, work with a knowlegable brand consultant and explain what is desired. We'll take care of the card side.
Please note, most chips take 3 months to bring in. It's incredibly important to order well in advance.
FAQS
There are two we are fond of that operate completely different. If you are leaning toward inkjet, the best printer on the market is the SwiftColor SCC-4000D printer. If you want an event card that feels and looks more like a credit card, the Matica XL8300 is the industry leader. Steer clear from printers that hold ribbons hostage unless you buy from them. If you need an introduction to either supplier, just ask!
Dating back to the Ultra XXL printer, the most common event card size is 3.456" x 5.5". This is often referred to as XXL. The size below this is 3.456" x 4.880" and referred to as XL. Every event card printer handles different sized cards. Changing card sizes is part of a good security program. Printers that can handle multiple sizes is a plus!
Yes, it depends on the card stock, versions and if there is any customization. For printed inkjet cards, the minimum order is 500. The same for gloss PVC cards. For blanks, if we have a smaller inventory quantity than 500 we are happy to sell at smaller quantities.
Set-up costs are spread over the quantity ordered so the larger the quantity, the lower the unit cost. Combining card templates/designs help to raise the quantity, however, the inks used on the cards must be similar or converted to CMYK.
First, you will want to look at the specifications of the printer you have to see what size(s) it can handle. We have roughly 30 different sizes that we can produce using expensive dies. Metal dies are critical to a consistent card size and smooth cut. Over the years we have invested in the tooling to produce both standard and unique sized event cards. To find out if we can produce the size you want, please contact us.
Our manufacturing plant has 3 printing presses. For litho printing (PMS color matching or CMYK for large runs) we have a 4-color and a 6-color. For small runs or multiple design templates, we have the option of printing digitally. In most cases, quantities over 10,000 are more efficient done litho. Digital does offer the ability to print variable information (names, numbering, barcodes, QR codes, etc.).
Yes. Based on the real run, the pricing differs. Unlike paper printing, plastic cards must be laminated in a hydraulic press that bonds the materials together. This lamination process squeezes the plastic layers, dots dance and the glossy finish is transferred down. Color changes during this process. Unfortunately, there is no shortcut for producing 1 card vs. a million. Pre-production proofs should always use the same processes and materials as the live run.
Your event cards will most likley use a lanyard. We stock multiple slot and round hole dies for your event cards. Please adjust artwork to accomodate these holes.
Counterfeiting is rampant in the event card industry due to the machinery and materials used. Protect your event, the user and facility by incorporating Level 1 and Level 2 features.
Standard card manufacturing is 3-4 weeks after proof approval, payment or PO. If you need product sooner, we do offer 5 business day or 10 business day rush pricing. The additional cost covers employee overtime as current queue remains and your order is expedited.
ABOUT US
Caulastics began as a sole proprietorship in 1960 under the name of Caulley's Creative Litho Service. The company incorporated as a standard private corporation in California in 1987, named Caulastics. Due to reorganization, the company changed names to Plastic Printing Professionals, Inc (P3) in April 2002. In February 2006, P3 was purchased by Document Security Systems, Inc. We now operate as a division of Document Security Systems, Inc. Legal name, Plastic Printing Professionals, Inc. dba, DSS Plastics Group. In 2020 our company was acquired by Bristol ID and our plant moved to Lima, NY. We now operate as a division of Bristol ID.
OUR SERVICES
Let us help you decide on what printer to select. High volume vs. low volume. Throughput vs print quality. Fixed size card vs ability to print multiple sizes. We will walk you through what printer is best!
We produce and help design over 10 million event cards every year. Adding security to your card is critical, not only for peace of mind and authentication but sometimes technology fails and it's critical to have a pass/fail component.
Our core compentency is card manufacturing. With 55 years of experience, you can trust us to match colors, layer correctly and demand high quality control. Every card is visually inspected one at a time.
Most orders come from event companies so we have a rich history of working with event teams. Let us know where your event is and we can suggest multiple companies!
ESTIMATING COSTS
Cards are typically priced by quantity, per version and colors per side. Often, cards are converted to CMYK so that they can be printed together for volume pricing. Small runs are done digitally, large runs litho. Depending on the printer used, we can recommend the right plastic formula.
01
Running multiple designs on one press sheet allows for less material, less plastic layering, less die cutting, etc. This is often called a "combo" run. The only downside to this concept is they must use similar colors. For small runs done digitally, this means CMYK. For large runs done litho, we can print a total of 6 common colors on all cards per combo.
02
Most event cards are printed in CMYK. This is susceptible to counterfeiting but allows us to run multiple versions on a single sheet. Why? Scanners import images in CMYK so printing in that method means the artwork can be reproduced easily. If you need to match a color, we use the Pantone Solid Coated color guide. Not all Pantone colors convert to CMYK so you'll want to check the conversion chart at the link below.
03
Need sequential numbering? If so, does the numbering print in color or black? If color, we will most likely print digitally. Barcodes, slot holes, security features and more. Understanding the full scope of the project, per card design will help us send the correct pricing, quickly. We know your time is valuable and you've most likely contacted us with little time to spare.
OUR SKILLS
Whether it is the Olympics or a Silicon Valley product launch, we lead the way in event card production. Come visit us while we produce your event credential. We are happy to walk you through card production and plant out timelines so we exceed your expectation.
For 55 years our brand has been the trusted source for event card production worldwide. You won't be disappointed, that's a promise.
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