Card & Carrier Assembly
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Precise, verified assembly
Attachment and assembly is where cards, carriers and security elements come together to form a finished, ready-to-use product. At this stage, accuracy and verification are critical, particularly where designs align across components, personal data is involved, or security features are required.
At Certus, attachment and assembly are carried out in our secure Skelmersdale facility, using controlled processes and camera verification to ensure every component is matched, positioned and finished correctly.
Our Capabilities
The way cards and carriers are assembled directly impacts presentation, security and fulfilment efficiency. Different programmes require different attachment and assembly approaches depending on the carrier design, number of cards and distribution method. By managing this process in-house, Certus ensures every pack is assembled accurately and consistently, ready for the next stage of production or fulfilment.
Verified Card Attachment & Design Alignment
Card attachment is managed with precision to ensure cards are positioned accurately on the carrier. This is particularly important where card artwork extends into the carrier design and alignment must be exact.
Camera verification is used during assembly to confirm correct positioning, ensuring that artwork across the card and carrier meets seamlessly and the finished product remains consistent across every unit.
Secure Sealing
During assembly, cards can be sealed inside carriers to provide secure, tamper-evident packaging. Secure Assure camera verification confirms correct glue application, ensuring seals are applied consistently and perform as intended.
These processes are commonly used for gift cards, prepaid cards and other programmes where security during distribution is essential.
Stickers, Seals & Promotional Elements
Assembly also supports the application of additional elements such as promotional stickers, security seals and information covers. This includes applying stickers over assembled cards and carriers for marketing campaigns, retail promotions or customer messaging.
Security seals and stickers can also be applied to protect personalised information once card personalisation is complete, helping safeguard sensitive data until the card reaches the end user.
Data Matching & Traceability
For personalised programmes where both the card and carrier contain individual data, camera verification and tracking systems are used throughout our Skelmerdale facility to ensure the correct card is matched to the correct carrier, which is especially important in membership and direct-to-customer programmes.
This verification process provides confidence that personalised components are assembled accurately and consistently, even at scale, reducing risk and supporting secure programme delivery.
Bundling & Preparation for Delivery
Once attachment and assembly are complete, finished items are bundled and prepared for delivery or mailing. This stage ensures products are protected, organised and ready to move seamlessly into the next stage of distribution.
Depending on programme requirements, items can be wrapped with paper seals printed with stock control information, plastic wrapped for protection, or packed into boxes for bulk delivery. For direct-to-recipient programmes, assembled items can also be placed into mailers and sealed, ready for onward mailing.
By preparing items correctly at this stage, we help ensure accuracy, protection and efficiency as products move into mailing and delivery.
Find out more
Tell us about your card and carrier programme and we’ll help you plan the right assembly and finishing process.