What Does Automation Mean for Boutique Printing in the UK?
October 15, 2025
For boutique printers in the UK, automation is a strong way to simplify operations, lessen manual tasks, and ensure top quality. Using ...
Col-Tec Overseas
Plastic card collation is a specialist process. It makes sure printed cards are sorted correctly and ready for finishing, packaging, or dispatch. The final application might involve SIM cards, loyalty schemes, or secure banking materials. Yet, no matter what it is, it must arrange these items correctly for downstream accuracy and regulatory compliance.
A plastic card collator is a purpose-built machine that automates this step. It groups plastic cards, including ID cards, payment cards, and retail kits, into secure sets. These sets are prepared for lamination or fulfilment. These systems tackle the stiffness and static sensitivity of plastic substrates. They include features like suction-fed feeders, anti-static controls, knock-up alignment, and ultrasonic welding.
This article explains what a plastic card collator is, how it works, and its importance in production workflows.
Plastic card collators work by feeding, aligning, registering, securing, and transferring card sets across a production workflow. Each stage is controlled to ensure accurate set formation and minimise human error.
The typical five-stage process includes:
Adjustable suction feeders draw cards from pre-loaded stacks. They are calibrated to handle various card thicknesses and finishes. This preserves surface finishes while maintaining alignment accuracy from the outset.
Knock-up systems and pinpointed air-blow control push cards into position. Anti-static devices help neutralise surface charge, a key factor when handling synthetic materials such as PVC or PETG. The Bristish Plastics Federation states that these plastics are commonly used in card production due to their durability and print receptivity.
Each card is precisely registered in place using mechanical pins or air registration systems. This ensures uniformity in the set, especially when using variable data, barcodes, or chip components.
Where required, ultrasonic welding bonds the collated sets without the use of adhesives. This is important for applications where lamination happens afterwards. It helps keep the stack strong and stops slipping at high speeds.
The complete sets are sent to downstream equipment, such as laminators, wrappers, or mail insertion systems. These integration points can be tailored to your needs through our bespoke engineering services.
Each machine is built for long-term performance and system flexibility. For maintenance, spare parts, or diagnostics, Col-Tec offers a responsive service programme. Our trained engineers and scheduled support options are available across the UK and beyond.
Plastic card collators are vital for businesses that need to sequence products and fulfil orders quickly. These industries often deal with many card-based outputs. Usually, these businesses rely on accurate collation, personalisation, and packaging.
Common applications include:
Retailers creating loyalty or gift card packs often need to assemble cards with printed inserts or promotional items. Automation ensures that every set is assembled consistently and accurately. This supports both pre-packed promotional mailings and in-store display units.
SIM cards, activation labels, and customer information inserts must be collated before packaging. Variable data, barcodes, and different card formats rely on real-time registration. This helps maintain high accuracy during kit assembly.
Banks, insurers, and membership providers give out personalised cards. They also provide PIN carriers, terms of use, and other regulatory materials. Fulfilment processes must be accurate, secure, and fully traceable. This is vital when working with sensitive or regulated content.
Col-Tec’s machines are designed to accommodate a wide range of material weights, substrates, and production speeds. These systems are also compatible with inspection equipment and overprinting stations. Each system is designed for its specific use, like high-speed batch fulfilment or variable content collation.
For more industry-specific use cases, visit the Col-Tec blog.
Manual collation is often slow, inconsistent, and prone to human error. For operations managing high volumes or complex configurations, automation delivers significant performance benefits:
Collators are built to process thousands of items every hour. They keep consistency across various production formats. Each feeder and alignment part maintains steady output during extended production runs.
Automating collation frees personnel to focus on quality control and value-added tasks. It also reduces training overheads, as fewer operators are required to manage manual sorting or stacking.
Col-Tec collators work with lamination, wrapping, or mailing systems. This integration reduces material handling and accelerates turnaround times. Our bespoke engineering service helps create interfaces for current production lines.
In addition to our UK-based service team, we offer a lease rental option for operations wanting to lower upfront costs. This allows UK businesses to get demonstration or refurbished machines for 12 to 24 months.
Plastic card collation sits at the centre of efficient fulfilment. At Col-Tec, we specialise in engineering collators that integrate directly into production lines. We have more than 50 years of experience in suction-fed collation systems. We support high-volume manufacturers with UK-based service and global installation support.
For tailored advice or to arrange a demonstration, speak to our technical team today. We can help you explore your options. Our team can also provide specifications that ensure long-term production reliability. Ready to improve the speed, accuracy, and efficiency of your card fulfilment process?
Call +44 (0) 1425 627755 or contact Col-Tec to start the conversation.
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