Credit Card Boxes.

With a removable adhesive specified for card carriers, which holds through automated sortation and then releases cleanly. Too strong an adhesive bends cards and leaves residue on the chip contacts, which generates complaints. Too weak and the card works loose in transit, which is a serious failure. General-purpose adhesive is the wrong answer in both directions, so we do not use it on this format.

No, the carrier uses an opaque security stock, and we add an internal security tint printed on the inside face. The pattern breaks up any read-through under bright light or backlighting. From outside the mailer carries no clue about its contents, which is the discretion the format relies on. A tamper-evident seal is an option where the programme wants the recipient to see the pack arrived untouched.

A printed carrier board with the card affixed to it, folded and placed inside an outer mailer. The board is rigid enough to keep the card flat through a postal run, and a window option is available where the programme wants the name visible for sorting. Both the carrier and the outer take full brand print, and the outer stays anonymous about what is inside.

Full CMYK brand artwork, with the activation instruction placed above the branding as the most prominent element. The recipient has one thing to do, and the layout leads them to it. A defined variable data zone carries the name and reference for personalisation at volume, planned into the artwork rather than retrofitted. Premium and metal-card programmes add matt lamination and a foil detail.

To mail thresholds first, then to the card. The standard carrier format is 3.8 × 2.4 × 0.4 inches, measured length by width by folded thickness. A few millimetres over a postal band can change the cost of every piece in a run of thousands, so we confirm the folded thickness with the card in place before tooling.

500 carriers. Card programmes are usually issued in the thousands, and the price steps down once the order passes 1,000 units. We run up to 100,000 carriers on a single order, with the variable data merged from your supplied file and checked against the card count.

Production takes 7 to 10 business days after the artwork and data are approved, with a 5 to 7 business day rush available. A sample takes 5 to 7 business days, and on this format we insist on one so the adhesive release and opacity can be checked with a real card. What the card box sample costs is credited back once the production order goes ahead.

Yes, it is built for it. Sortation equipment bends, squeezes and drops mail, so the carrier board is chosen to stay flat and the adhesive to hold under that rough handling. The outer mailer takes the scuffing. We test the pack through a mail run before approving a programme, rather than trusting the spec sheet.