Organizations that use a centralized card issuance model often face extended periods of maintenance that hampers productivity. Additionally, the dependence on one large-volume printer credential issuance solves these problems and, with the advent of ruggedized, high-duty-cycle printers, can also boost card throughput while minimizing downtime. The latest solutions deliver high-capacity printing and encoding with the highest levels of image quality, reliability, security and privacy.

One example is HID Global’s FARGO HDP8500 Industrial Card Printer/Encoder, the industry’s highest capacity and most rugged and secure printing / encoding solution. Featuring the company’s fifth-generation High Definition Printing (HDP) technology, the new Industrial Series printer / encoder is designed for the extended-run, high-throughput and high-duty-cycle requirements of government ID card programs, laborious service bureaus conditions, universities and large enterprises. The printer/encoder includes an industry-high 400-card total input capacity, combined with features that ensure robust and reliable continuous operation. It also is the first to include a graphical touch screen user interface, which helps minimize operator intervention while maximizing card yield per shift.

A distributed system may be structured in one of three ways:

When deploying a high-duty-cycle distributed card issuance system, it is important to consider key system criteria including the flexibility of the print technology, as well as printer system reliability, system performance, operational convenience, and system scalability (see Fig. 2).

The flexibility of print technology determines how seamlessly printing and encoding elements can be integrated into a finished credential. Organizations should consider current and future needs for ID card composition, and the ability to accommodate potential variations in composition, material or thickness. There are also the ID card’s embedded electronic elements to consider, including contact and contactless smart chips or combination technologies. As for the print technology, retransfer or high definition printing (HDP) adds a protective layer to the card and its components (see Fig. 3). Because the HDP printhead avoids direct contact with the card surface and any embedded electronics, it also mitigates the risk of damaging the electronics. Furthermore, retransfer film conforms to ridges and indentations in the card surface, making it compatible with a wider array of card materials and thicknesses.

Printer system reliability is also critical. High-duty-cycle printing systems are exposed to contaminants, pollutants and debris that can reduce the quality of finished cards, resulting in lower yields from batch card printing operations, and premature wear on printer systems. It is necessary to choose ruggedized printers with such features as redundant card cleaning systems, heavy-duty positive air flow, internal filtration systems, rugged and tamper-resistant metal construction, temperature sensors to control print settings, and strong printer stepper motors to maintain card throughput. Other critical features include efficient card input gate systems to eliminate multiple card feed issues, enhanced high-duty-cycle material handling systems to prevent ribbon breaks and film errors, and finely-tuned consumables cartridges with precision rollers and aluminum spindle shafts for consistent print image production.

Next, organizations must consider system performance, which spans credentials issuance security, personalized card throughput, and the efficacy of the finished ID cards.  Printers should include a comprehensive set of security features including operator PIN number access and multi-locking entry points for secure printing, plus AES 256 bit data encryption and resin ribbon data-erase functionality. For improved security and efficacy, HDP technology can be used to create more durable credentials with clear visual evidence if tampering has been attempted. Specialty retransfer films also can be used to incorporate custom visual security elements that deter counterfeiting, and additional in-line card lamination may be applied over the retransfer film to further extend card life while visual security elements. Throughput can be improved with printing / encoding systems that perform multiple operations simultaneously, and feature dual input hoppers that enable one hopper to supply blank cards while the other is being refilled and eliminate manual hopper changes during multi-card production.  

The fourth system criterion is operational convenience. Advanced printers are engineered to simplify maintenance and speed the process of identifying and repairing problems. Key printer/encoder features that make this possible include: visible card feed mechanisms that provide unobstructed card access; a card personalization reject bin that automatically segregates mis-programmed cards; dual high-capacity input/output hoppers that reduce operator loading/unloading intervention; intuitive touch screen displays for system feedback and operator input; and in-line card flattening mechanisms to minimize and correct post-personalized warpage due to variations in card material construction.  Other key features include a sealed print mechanism to minimize the risk of card contamination, and dual pre- and post-personalization cleaning stations that ensure optimal quality of finished cards.

Finally, a high-duty-cycle distributed card issuance system should feature field-upgradeable modules that deliver the scalability to meet current or future credential needs. Modules should be available for such functions as ISO magnetic encoding, large capacity card input hoppers, dual-side printing, contact or contactless card encoding, ISO card flattening, single- or dual-sided lamination and laser engraving. As an organization grows and card issuance needs increase, it should also be possible to expand the network in defined increments simply by connecting additional printers. Conversely, if credentials issuance needs decrease over time, output can be trimmed by reducing the number of networked printers.

Today’s high-duty-cycle distributed card issuance systems offer a viable, effective alternative to centralized issuance for government agencies, card service bureaus, large universities and corporations. Properly deployed, they are easily scalable, they decrease operational and service costs, and they optimize credential output – whether each finished credential requires physical, electronic or visual personalization, or any combination of these elements. The latest solutions also offer features that significantly improve quality, security and privacy for card issuance operations of any size.