Plastic playing cards are manufactured in a slightly different process than the paper (plastic coated) playing cards. You have to install the latest printing presses to print plastic sheets. You can see print process here: http://www.youtube.com/watch?v=cUBorxosoyk as you will see, you have to use the latest KBA 105 presses installed in our print production department. These presses allow you to print plastic sheets without any issues.
It is important to note that printing over plastic sheets has to be cured through infrared light. For example if you put a drop of water on paper it will dry up easily as paper will soak it in. In the same manner if you put a drop of water on a plastic sheet it will stay there as is even after hours as plastic is a substrate that will not allow liquid to soak up. Ink being semi liquid will have a tough time curing if it was to be put on a plastic sheet and not cured under special light. For this each printing press is equipped with inter deck systems having UV lights.
It’s a cold UV process whereby sheets run at a speed of 12000 impressions per hour and still get dried immediately. This is an expensive process of printing but the playing card manufacturers worldwide have kept the plastic playing cards price exuberantly high. There are some companies who use the best quality plastic sheets and still make plastic decks for under 2 dollars. This is the reason so many buyers want their custom playing cards on plastic instead of paper.
Also some companies have been making personalized playing cards on plastic sheets for long. Yes, the process is expensive but the production is huge and almost all steps of manufacturing are automatic. The sheets are printed automatically; the coating is done on automatically run plant. And the cutting collating process is fully automatic. This allows us to offer highly competitive prices to buyers looking for custom playing cards on plastic sheets
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