The 1-PAS Advantage: From Blank Card to Complete Bundle in One Pass  

Every handoff in secure card production between personalization, inspection, serialization, and packaging multiplies risk. Manual transfers introduce errors, compliance gaps, and unplanned downtime, driving up costs and eroding customer trust.

From blank cards to bundled, ready-to-ship kits, the 1-PAS executes the entire process within one continuous machine cycle, ensuring unmatched efficiency, integrity, and compliance.

Current Industry Challenges in Secure Card Packaging & Production

Fragmented card manufacturing lines often look like relay races, where each station hands off to the next. But every transfer—whether manual or automated, introduces potential for misreads, misfeeds, or misplaced items. In high-volume environments, a millisecond-scale delay at one station can cascade into minutes of downtime, disrupting order fulfilment deadlines and eroding customer trust.

Compliance requirements from PCI DSS, GDPR, and other regulatory bodies demand airtight audit trails. Yet, when personalization, inspection, and packaging happen across separate machines, stitching together traceability records becomes a labor-intensive chore prone to human error. And manual intervention—whether for quality checks or cartoning, exposes teams to ergonomic strain and inconsistent quality outcomes.

To stay competitive, operations need not just speed, but synchronized precision: real-time inspection, tamper-evident security, and full serialization all without a single card ever leaving the automated flow.

What is the 1-PAS Card to Bundle System?

The 1-PAS (Personalization, Affixing, and Secure Packaging System) is the world’s first truly inline solution for high-volume secure card production. It seamlessly integrates card personalization, affixing, tamper-evident packaging, and pack-out, eliminating manual handoffs and consolidating multiple machines into a single, modular platform.

• Card Personalization: EMV and contactless chip encoding, magnetic-stripe, barcode/QR printing, PIN printing/data masking, RFID/NFC encoding, and edge-to-edge UV drop-on-demand printing at 600 DPI.
• Real-Time Inspection: Millisecond-interval vision verification of chip status, print fidelity, and carton integrity.
• Tamper-Evident Packaging: Automated folding-carton assembly with hybrid adhesive seal and continuous compression technology, producing 100% tamper-proof packages in just 0.5 seconds per seal.
• High-Speed Pack-Out: Kitting, labeling, stacking, and bundling into ready-to-ship kits without manual handoffs.

Governed by Pack-Smart’s Delta-X software, the 1-PAS provides real-time production data control and end-to-end reporting, mitigating quality risks and ensuring full compliance.

The 1-PAS Key Advantages

Speed & Throughput Without Compromise → Designed for industrial-grade operations, the 1-PAS processes up to 20,000 products per hour, with duplex personalization speeds up to 35,000 PPH. That performance drives dramatic reductions in cost per card and accelerates time-to-market for telecom kits, gift-card campaigns, loyalty programs, and financial credentials.

End-to-End Personalization & Encoding → 1-PAS executes every personalization function inline, with EMV and contactless chip encoding, magnetic-stripe and barcode printing, PIN printing and data masking, dynamic QR codes, RFID/NFC encoding, and high-resolution UV drop-on-demand printing at 600 DPI. Edge-to-edge variable imaging and personalized activation labels all flow through a single audit-ready cycle.

Integrated Vision Inspection & Defect Rejection → A millisecond-interval vision system validates chip status (dead/alive, UID match), print fidelity, and packaging integrity in real time. Defective items are automatically rejected and rerouted into an on-the-fly remake queue eliminating manual QC and ensuring 100% compliance with PCI DSS, GDPR, and other frameworks.

Full Serialization & Audit Trail Capabilities → Each card and package carries a unique serial ID, digitally documented and streamed live to ERP/MES/API systems. Operators can generate exportable audit reports on demand, turning multi-day audit prep into a matter of minutes.

Inline Tamper-Evident Packaging → Automated folding carton assembly with hybrid-adhesive seals and extended compression creates 100% tamper-proof packages. Cards are affixed, stacked, kitted, and bundled using recyclable, FSC-certified materials – no manual intervention required.

Modular Scalability → 1-PAS adapts as your business evolves. Plug-and-play modules enable RFID/NFC encoding, custom carton formats, and complex kitting configurations. Vision systems, software platforms, and data protocols upgrade seamlessly whether you’re scaling into healthcare ID programs, government credentials, or new retail formats without reinvesting in the core infrastructure.PlayWatch the 1-PAS in Action

Business ROI & Opportunity

Investing in 1-PAS yields rapid payback through multiple levers:

• Reduced Capital & Floor Space: Replaces standalone personalization, inspection, and packaging machines.
• Lower Labor & Training Costs: Streamlines operations to one operator plus minimal reloading staff.
• Minimized Scrap & Rework: Inline vision inspection catches defects early, slashing waste.
• Accelerated Time-to-Market: Consistent changeover times under 30 seconds let you respond instantly to SKU switches and rush orders.
• Audit Efficiency: Real-time data feeds and exportable reports cut record-keeping labor by up to 80%.

Together, these efficiencies shrink cost per unit, bolster margins, and free resources for strategic initiatives transforming secure card production from a cost center into a competitive advantage.

Who Benefits from 1-PAS?

1-PAS drives value across diverse industries and applications:

• Telecommunications: SIM-kit personalization, activation-card assembly, dual-factor packaging.
• Retail & Loyalty: Gift-card campaigns, membership-program credentials, promotional-package kitting.
• Financial Services: Credit, debit, and prepaid card issuance, reloadable-card packaging.
• Government & Healthcare: National ID cards, social-benefit cards, medical-record credentials.

Operations from high-security government programs to fast-paced retail gift campaigns benefit from the speed, traceability, and compliance that 1-PAS delivers all within the same unified workflow.

Sustainability & ESG Alignment

Sustainability isn’t an afterthought for the 1-PAS, it’s embedded at every stage. The platform uses low-waste production practices, recyclable FSC-certified cartons, and energy-optimized system controls. By minimizing material usage and supporting eco-conscious packaging, the 1-PAS helps organizations meet corporate ESG goals and comply with emerging global sustainability standards, all without sacrificing performance or speed

Specifications & Technical Highlights

• Throughput: Up to 20,000 PPH (standard), 35,000 PPH duplex personalization
• Print Resolution: 600 DPI drop-on-demand UV imaging (3.5 pL drop size)
• Affixing Accuracy: ±0.4 mm (± 0.5 mm edge-to-edge)
• Seal Time: 0.5 seconds per carton (continuous compression)
• Servo-Driven Reliability: Digital brushless servo motors for precision motion control
• Staffing: 1 operator + 2 reloading + 1–2 delivery assistants

Frequently Asked Questions

1. What distinguishes 1-PAS in the card-packaging industry? It’s the world’s first inline solution for secure open- and closed-loop card personalization, affixing, packaging, and pack-out handling 20,000 PPH with flexible workflows.
2. What are the main KPIs? Tamper-evident seal integrity, throughput up to 20,000 PPH (35,000 duplex), ±0.4 mm positioning accuracy, 600 DPI UV printing, and end-to-end reporting for full process visibility.
3. How does 1-PAS add value? By reducing operators, eliminating heat-seal setups, enabling quick changeovers, and delivering industry-leading print quality and package security.
4. What materials can it process? Open-loop cards (Visa, MasterCard), closed-loop gift cards (Amazon, iTunes), and specialty substrates from PVC to fiber based Renovo paper cards.
5. Can it integrate with existing lines? Yes. Its modular design allows plug-and-play integration with upstream feeders and downstream conveyors, plus software API connections.
6. What features stand out? Hybrid-adhesive tamper seals, on-the-fly rejected-card reissue, automatic bundle remakes, and real-time Delta-X data-matching and reporting.
7. What support does Pack-Smart provide? Comprehensive installation, training, technical support, and preventive maintenance to ensure maximum uptime and ROI.

Related Secure Card Systems

1-PAS leverages the broader Pack-Smart Inc. ecosystem:

• SC-500 Secure Card Packaging System: An inline solution that delivers high-speed tamper-evident sealing with continuous compression. When paired with 1-PAS, the SC-500 handles downstream carton assembly and pack-out at matching throughput rates.
• CP-250 Card Personalization System: A versatile standalone unit for magnetic-stripe, barcode/QR printing, and basic chip encoding. It can serve as an auxiliary personalization station upstream of 1-PAS or as a legacy module within hybrid workflows.
• EMV-250 High-Speed Chip Encoding System: Provides rapid, certified EMV and contactless chip personalization. Integrated in line with 1-PAS, the EMV-250 synchronizes chip encoding and data validation to maintain continuous, compliant flow.
• BA-250 High-Speed Pack-Out Fulfillment System: A fully automated solution for end-of-line wrapping, batching, bundling, and labeling, processing up to 2,000 bundles per hour. The BA-250 combines camera-based aggregation, weight verification, and an inline QA station to reject and remake defects on the fly. Each bundle, case, and pallet receives precise labels, while the Delta-X control system provides real-time traceability and advanced reporting, maximizing throughput and ensuring 100 % product integrity.

These systems, together with Delta-X vision inspection, and technologies like our SJ Series inkjet printers, High-speed Labellers, UV curing, ABM alignment and pick and place feeders, create a unified, scalable secure card packaging line managed via a single HMI interface.

Conclusion

The 1-PAS isn’t just another automation tool, it’s a strategic platform that transforms secure card production into a competitive advantage.

By unifying personalization, inspection, serialization, and packaging into one seamless pass, Pack-Smart Inc. delivers rapid ROI, future-proof scalability, and unwavering compliance.