This project profiles a high-complexity TCG production run involving mixed substrates and automated collation. The client required a “Retail-Ready” solution, necessitating strict color management to ensure brand consistency across the cards (Art Paper), booster packs (Foil Film), and display boxes (Folding Carton).

1. Card Manufacturing Specifications

Use these technical parameters as a baseline for your quote.

• Finished Size: 74mm x 105mm (Custom Die-Cut)
  • Manufacturer Note: This is a non-standard “Jumbo” size (larger than the standard 63x88mm Poker size). While it requires custom tooling, it offers superior visual impact for artwork-heavy games.
• Stock Material: 350gsm C2S Art Paper (Coated Two Sides)
  • Material Traits: Selected for its high stiffness and premium “snap.” Unlike standard Blue Core, 350gsm Art Paper offers the substantial, rigid tactile feel preferred for collectible cards.
• Surface Finish: Holographic Flash Film Lamination (Front) + Matte Varnish (Back)
  • Process: Holographic film is laminated pre-printing (or applied via cold foil) to distinguish “Rare” tier cards.
  • Playability: A specialized linen texture or smooth varnish is applied over the holographic film to prevent surface adhesion during shuffling.
  • Options: View our [Surface Finish Library] to explore available refractive patterns.

🏭 Factory Tip: For TCGs, we strongly recommend applying a “Slip Coating” to high-gloss or holographic cards. This reduces surface friction and prevents “blocking” (sticking) during gameplay.

Sealed Case

Booster Pack

2. Packaging & Kitting Solutions

We executed a comprehensive Booster Pack Assembly process for this project, utilizing our automated flow-wrapping lines.

• Primary Packaging (Booster Pack):
  • Material: Metalized PET/CPP (High barrier protection against moisture).
  • Seal Type: Fin-seal with crimped edges (Standard TCG format).
  • Collation: Automated Randomization. Our system ensures each pack contains exactly 11 cards with a guaranteed rarity distribution (e.g., 1 Rare, 3 Uncommon, 7 Common), eliminating manual error.
• Retail Display (Booster Box):
  • Structure: 350gsm C1S Folding Carton with Crash-lock Bottom.
  • Feature: Includes a perforated “Pop-up” header for immediate Point-of-Sale (POS) display.
• Master Shipper:
  • Spec: Double-wall Corrugated Case (B+E Flute) designed to prevent crushing during transit.

3. Components & Accessories

Complementing the core deck, this project also required the sourcing and assembly of peripheral items:

• Card Sleeves: PP (Polypropylene) material, acid-free, custom printed.
• Playmat: 2mm Neoprene rubber mat with edge-stitching for durability.
• Box Topper: Rigid Greyboard mounted card (promotional insert).

💡 Start Your Production

Reference This Configuration If your project requires 350gsm Heavy Stock or Automated Booster Collation, use this case study as your quality benchmark.