Patent ID: 8096719

Claim:
A method for producing personalized cards on a continuous basis comprising: providing multiple supply rolls of card stock having a thickness of at least about 12 mils to an in-line printing system; corona treating the card stock in an in-line corona treating unit to provide a printable surface having a surface tension energy of at least about 38 dynes/cm; printing fixed data on individual card units of the card stock in a first printing unit of the in-line printing system; printing variable data on the card units of the cards stock in a second printing unit of the in-line printing system; applying a removable activation label to the variable data printed on the card units by an in-line label application unit; and die-cutting the card units in an in-line die-cutting unit to a predetermined size, wherein the first and second printing units are shaft driven printing units, and the card units are capable of being produced at a rate of at least 50,000 card units per hour.