How to manufacture the Biodegradable plastic cards with BioSheet™ ? Is there any technical difference between Bio-based plastic cards making and normal PVC cards making? Do you need additional equipment by using BioSheet™?
PVC cards are normally produced by laminating solid plastic sheets together and then die cut with certain sizes. There are three processes in simple.
Unless for blank PVC cards making, the first stage is offset printing with typeset artwork on a single PVC sheet with thickness of about 150 μm (micrometer) Normally two PVC sheets for front and back artwork respectively.
The second step is to laminate in between 3 to 7 layers of PVC sheets using a combination of heat and pressure to form a final sheet, with printed PVC sheets on top and bottom side. The thickness of each PVC sheet is about 80 μm to 250 μm, the thickness of final sheet is about 760 μm to meet the CR80 card standard. There will be an extra step of Inlay making for RFID card which the final thickness is around 840 μm.
Die cutting is the last step to get each laminated PVC sheet into several expected shapes by different molds. For example to use the mold of CR80 size, you will get the PVC cards with standard credit card size of 86 x 54 x 0.76mm (2.13″ x 3.38″ x 30mil).
How PVC cards made and how those production equipment designed were based on the physical characteristics of PVC. BioSheet™ were designed also according to those characteristics with greener solution.