Manufacturing Process of White PVC Core Sheet for Plastic Cards

1. Raw Material Preparation
PVC Resin: Base material providing thermoplastic properties.

Titanium Dioxide (TiO₂): Added for whiteness and opacity.

Additives:

Thermal stabilizers: Prevent degradation during processing.

Plasticizers: Improve flexibility and processability.

Lubricants: Enhance flow and surface finish.

Antistatic agents, brighteners, etc., as needed.

The materials are accurately weighed and mixed in high-speed mixers to ensure homogeneity.

2. Sheet Formation Process

Extrusion Method
The mixed raw material is fed into an extruder.

It is melted and plasticized under controlled temperatures (usually 160–190°C).

The melt is passed through a sheet die to form a flat sheet.

The sheet is then calibrated and cooled using chill rolls.

The final thickness is controlled (typically 0.20–0.80 mm).

3. Cooling and Trimming
The formed sheets are rapidly cooled to avoid deformation.

The edges are trimmed, and the sheets are cut to specific dimensions suitable for card lamination (e.g., 310 × 480 mm).

4. Surface Treatment (Optional)
Corona treatment or coating treatment may be applied to enhance ink adhesion for printing.

This is especially important for sheets used with offset, screen, or digital printing.

5. Application in Plastic Card Lamination
After sheet production, the white PVC core is typically used as the middle layer in plastic card lamination. The process involves:

Printing on overlay PVC sheets.

Stacking: Printed layers + white core sheet(s).

Hot lamination (130–150°C, 10–20 minutes).

Cooling, cutting, punching, and personalization (e.g., magnetic stripe, chip, barcode, etc.).