Carrier Production
Sector Titles
ABOUT
Precision carrier production
Carrier production is a specialist manufacturing discipline in its own right. Carriers must be printed accurately, converted precisely and finished to a high standard to ensure they perform correctly in retail, mailing and distribution environments.
All carrier production at Certus is handled at our specialist Colchester site, which has a long heritage in packaging and paper-based print. This experience underpins our approach to carrier manufacture, combining traditional packaging expertise with modern production techniques.
Confidence in Every Carrier
By producing carriers in-house and aligning them closely with card manufacture, we maintain control over colour, quality and tolerances, ensuring carriers are produced to exacting standards and are ready for secure assembly and fulfilment.
Stock Selection & Performance
Carrier performance starts with the right material choice. Different applications place different demands on strength, flexibility and finish, so selecting the correct stock is critical to how a carrier performs in use.
Our production equipment supports a wide range of paperboard stocks, from around 100 gsm to 450 gsm for more robust requirements.
At Certus, our specialists recommend stock based on functional needs such as supporting the weight of multiple cards, accommodating perforations, or enabling tamper-evident burst-to-open packaging.
Colour Accuracy
Carrier printing demands consistent colour reproduction and accurate registration across larger formats. Because we produce both the card and the carrier, we can test and verify colour matching across components before production begins, ensuring brand consistency across the complete card-and-carrier solution.
This approach reduces variation, prevents mismatch issues and ensures the finished product looks exactly as intended at the point of sale or delivery.
Screen Printing
Die cutting is used to create the physical shape and functional features of a carrier. Our in-house die-cutting facilities allow carriers to be produced with precision and repeatability, from standard retail formats to completely bespoke shapes.
This process is also used to create functional elements such as euro holes for retail hanging, barcode access panels, and perforations and tear lines, supporting secure handling and compatibility with retail and distribution environments.
Bespoke Folding, Creasing & Packaging
Once cut, carriers are formed through precision creasing and folding to create a finished, usable structure. This stage determines how the carrier opens, closes and supports the card or cards it contains.
Using controlled folding and creasing processes, we produce carriers ranging from simple presentation formats to more complex packaging, including gifting carriers and multi-card solutions where strength, usability and consistency are critical.
Distribution-Ready Carriers
Our experience working with major gift card and prepaid distribution channels means we produce carriers that are compatible with established distribution requirements, including platforms such as BHN, Epay and Incomm.
By understanding channel specifications and handling requirements, we ensure carriers are produced in a format suitable for onward distribution, helping programmes move smoothly through the supply chain.
Quality
Quality, Security & Compliance
Quality and consistency are embedded throughout carrier production at our specialist Colchester site. Controlled processes and experienced teams ensure carriers are produced accurately, finished to specification and prepared reliably for assembly and distribution.
Our production is underpinned by recognised quality and environmental management standards, supporting consistent output, traceability and accountability across every carrier programme.
Find out more
Tell us about your card carrier requirements and our team will help you choose the right format, materials and finishing options.