Modern materials and technologies in bank card manufacturing: from eco-friendly PVC to innovative security elements. An overview of key features and industry trends
ASMO, an official representative of Beautiful Card Corp (BCC) in Armenia, specializes in bank card manufacturing using innovative technologies.
Modern Materials in Bank Card Manufacturing
Next-Generation Eco-Friendly PVC
Bank card manufacturing today utilizes several innovative types of PVC materials, each with unique characteristics and advantages.
Phthalate-Free PVC Compounds
In modern bank card production, environmental safety is paramount. Phthalate-free PVC compounds represent a new generation of plastics developed to meet the strictest environmental requirements. These materials fully comply with REACH regulations, contain no harmful plasticizers, and feature improved biodegradability characteristics. Importantly, the elimination of phthalates does not compromise the physical properties required for bank cards.
Recycled PVC Compositions
Following current environmental trends, we actively implement recycled PVC in our production. Modern technologies allow creating compositions containing up to 75% recycled material without quality loss. Each batch of such PVC undergoes special multi-stage purification, ensuring compliance with strict banking standards. All materials are ISO 14001 certified, confirming their environmental safety and high quality.
Bio-Oriented PVC
Bio-oriented PVC represents a special category – an innovative material produced using renewable resources. This type of PVC is characterized by a significantly reduced carbon footprint in both production and disposal. At the same time, bio-oriented PVC features improved strength characteristics and fully meets all requirements for bank card materials.
Characteristics of Modern PVC for Bank Cards
Regardless of the specific type, all PVC used in bank card manufacturing must meet strict technical requirements. The material ensures stable card operation across a wide temperature range from -40°C to +60°C, guaranteeing reliability in any climate conditions. High UV resistance prevents fading and material degradation during long-term use.
Special attention is paid to bending strength – modern materials withstand over 10,000 bending cycles without losing their properties. This is particularly important considering that bank cards are constantly subjected to mechanical stress during daily use. The material structure provides an excellent base for high-quality printing, allowing complex designs with high detail.
A crucial property is compatibility with EMV chips – the material must ensure reliable chip mounting and protection from mechanical damage. Additionally, modern PVC possesses optimal characteristics for embossing, allowing the creation of clear and durable relief elements on the card surface.
Modern PVC Processing Technologies
Multi-Layer Construction Lamination
The lamination process is a complex technological operation requiring precise control of multiple parameters. Modern equipment maintains optimal temperature ranges of 140-165°C, ensuring quality layer bonding without material deformation. Lamination pressure of 150-200 bar is evenly distributed across the card surface.
The lamination cycle time, typically 3-5 minutes, is carefully controlled, as even slight deviations can affect the final product quality. Special attention is paid to uniform material heating, using specialized temperature control and monitoring systems.
Printing Features
Bank card printing is carried out using specialized UV inks with enhanced resistance to abrasion and external factors. The technology involves multilayer image application, where each layer serves its function – from creating the background to applying security elements.
Deep printing technology is used for particularly complex elements, allowing the creation of microtext and finest lines with highest precision. Before image application, the card surface is treated with special primers that improve ink layer adhesion and ensure image durability.
Built-in Security
Modern bank cards feature a comprehensive built-in security system integrated directly into the card material structure. UV-luminescent additives form the basis of the security complex, becoming visible only under specific wavelength ultraviolet light. This allows quick authenticity verification using special equipment.
Special microparticles are embedded in the material structure, creating a unique “fingerprint” for each card. These particles are distributed using a random algorithm, making exact copying of their placement impossible. Additional security is provided by thermochromic additives that react to temperature changes by changing color.
Special security fibers embedded in the card material structure play a unique role in protection. These fibers, visible both under normal lighting and in the UV spectrum, create an additional layer of counterfeit protection.
Surface Protection
The external security level of bank cards is implemented through a complex of special elements applied to the card surface. Holographic elements play a central role in this system, creating dynamic images that change at different viewing angles. Modern holograms contain multiple security levels, from simple visual effects to hidden elements visible only under special lighting.
Microprinting consists of text or patterns executed with such high precision that they cannot be reproduced on standard printing equipment. These elements are visible only under significant magnification, making them an effective security measure.
Relief elements not only give the card an attractive appearance but also serve as additional security measures, as they are difficult to reproduce accurately. Metallized areas, created using special inks containing metal particles, create characteristic shine and can possess magnetic properties, allowing verification of their authenticity using special devices.
Prospective Developments and Innovations
The bank card manufacturing industry is in constant development. Current research focuses on creating next-generation materials that combine enhanced functionality with environmental safety. Special attention is paid to developing composite materials with improved strength and wear resistance characteristics while maintaining a thinner card profile. This allows creating thinner and more elegant cards while preserving all necessary security functions.
One of the most promising directions is the development of self-healing materials. This innovative technology allows the card surface to “heal” minor damage and scratches, significantly extending the card’s service life and maintaining its presentable appearance. Such materials contain special polymer components that activate upon microdefect appearance and restore surface integrity.
With the growing popularity of contactless payments, active research is being conducted in materials optimized for NFC technologies. New compositions are being developed that provide improved radio signal transmission and enhanced protection against electromagnetic interference. These materials also feature improved shielding characteristics, increasing the security of contactless payments.
Environmental research focuses on developing new types of biodegradable plastics. Modern technologies allow creating materials that maintain all necessary technical characteristics throughout the card’s service life while being capable of natural decomposition after disposal. This is particularly important in the context of global efforts to reduce environmental impact.
Comprehensive Quality Control System
Bank card production requires implementing a multi-level quality control system covering all stages of the production process. Each batch of materials entering production undergoes thorough testing for compliance with international standards and payment systems’ technical requirements.
Physical and mechanical testing includes comprehensive checks for tension, bending, and impact strength. Special attention is paid to testing compliance with ISO/IEC 7810 standard, which defines basic physical characteristics of bank cards. Materials are tested for resistance to various temperature conditions, humidity, and ultraviolet radiation.
Special test stands simulating real usage conditions are used to evaluate wear resistance. Cards undergo multiple cycles of mechanical stress, including bending, twisting, and exposure to abrasive materials. This ensures card functionality throughout its entire service life.
Environmental control is an integral part of the quality system. All materials undergo testing for compliance with international environmental standards, including testing for harmful substances and heavy metals absence. Special attention is paid to controlling emissions during production and material biodegradability indicators.
Conclusion
Through our partnership with Beautiful Card Corp (BCC) and direct supplies of components from leading manufacturers in Taiwan and the Republic of Korea, we guarantee the highest quality of each card produced. Our headquarters in Armenia coordinates all production processes and ensures prompt interaction with clients in the region. Strict adherence to all technological processes and the use of certified materials allows us to create bank cards meeting the highest international standards.
Contact us for detailed consultation on bank card manufacturing matters. We are always ready to offer optimal solutions for your bank card production needs.