Small Scale Passport Datapage Production System
In response to demand for smaller volume passport datapage production Oasys has developed a semi-automatic finishing line to create “binding ready” polycarbonate datapages in smaller volumes
The system is compliant to ICAO and relevant international criteria and is used for pre-tender and smaller volume needs where autonomous production is required for security or national regulation reasons.
This allows smaller sovereign territories and security companies to participate in this area with a relatively modest investment and space requirement.
The system will output from a few hundred thousand Datapages per year up to ≈2M depending on configuration and shift patterns
Based on an industry standard format it provides for the following functions:
1.Punch : registered hole punch making accurate holes registered to the print, allowing accurate alignment of the layers.
2.Registration and layer assembly of up to 10 security layers forming the datapage structure
3.Facility for manual insertion and fixing of datapage hinges
4.Lamination of the assembled structure to form the secure mono block polycarbonate page
5.Automatic registered trimming and cutting of laminated datapage sheets into the “binding ready” double page format – ready to be combined with the paper pages and cover to form the final passport.
The system can process two main data page sheet formats:
4 up edge hinge – 4 Datapages to view with hinges on outside.
8 up back to back hinge – 8 Datapages to view with hinges inside the sheet.
Oasys can also provide impartial advice on specific datapage materials and options for different hinge solutions.
The system is comprised of the following elements:
4Up datapage format with hinges
8Up datapage format with hinges
Registration Punch
Registration hole punch – print registered holes are cut into each layer in accurate position relative to the print or other features
The OHP is a manually fed auto print registration hole punch for printed card / ID sheet layers prior to Collation. Registered holes and slots are punched into the individual card / ID sheet layers using printed sensor marks. This allows accurate manual collation by locating the holes over Collation pins on the OHC150 hand collator.
Individual card / ID sheets are presented manually to datum pins on the bed of the OHP200 and holes / slots punched in alignment to the print by registering against printed sensor marks. The registration holes then align accurately in X Y and Theta with the printing on each sheet.
As the printed sensor marks are in the same position ( relative to the printing ) on each sheet, the holes are consistently positioned, and the layers then accurately align at Collation when placed over the pins on the OHC150
The OHP200 can use printed marks for punch alignment and now options are available to register directly from RFID antenna, foils and holograms – subject to testing.
Collation / Hinge Insertion
OHC150 Manual assembly & welding station to assemble layers over pins, using pre-punched registration holes in each layer – provides complete flexibility – up to 10 layers – the layers are sonically welded in position to secure alignment
Collation includes the option to insert and weld hinges within the layer structure – these are sonically welded in position as part of the assembly process
The increasing complexity of some datapage structures and their need for higher yields and accuracy have made the Oasys Collator the machine of choice for professional ID Card manufactures across the industry.
Lamination
The Oasys OLA2-3 single stack lamination system – provides precision lamination for polycarbonate ID cards and passport datapages. A lamination tray and pin registration system ensures alignment of any tactile features laminated into the datapage ( eg MLI / CLI )
Oasys design, build and install a specialist range of Lamination machinery exclusively developed for the banking, ID & Security Industry. The result is a “no compromise” approach to the technology in achieving the optimum laminated quality – with the resulting benefits in productivity, quality, and yield.
Cutting
The ODG500 automatic print registration cutting system to convert the laminated sheets including trimming of hinge – taking the sheets, cutting all edges and outputting in a “binding ready” two up format.
The Oasys double cutting / guillotine system was developed 30 years ago to create accurate “datum” edges on laminated credit card sheets. Latterly the machine evolved to cut Passport Datapages and other ID documents – creating for example “binding ready” Passport Datapages
The system achieves and accuracy of within 150 microns using a precision transport and three axis registration to accurately cut sheets of ID Cards or Datapages into predetermined formats or sizes. The machine has evolved over the decades and achieves high availability “up time” and excellent quality & reliability.
OPTIONS & FINAL PRODUCT
As an alternative option and depending on budget, a lower volume output manual version of this machine process is also available.
The final product is as below a “binding ready” double datapage ready for further processing
KEY FACTORS
QUALITY CONSTRUCTION
All Oasys production machines are designed and built with quality in mind.From the frame construction to the use of the best custom configured sensors and the robust operational software.Oasys machines are often run 24/6 in the field and are built to enable this – 35 years of experience says that a higher build cost gives the customer a better performance and a faster return on investment.
FLEXIBLE OPERATION
The machines are designed to process all the major types of cards from Banking through Gift cards to high security ID. The machines will be configured to customer card sheet format and tooling made to match the materials and outputs required. Formats and configurations of build and processing can be altered automatically to predetermined settings with easy switching of tooling and load unload facilities.
SUPPORT AND SPARES
Internet based access to machines enables remote support to be provided – allowing diagnosis and intervention to resolve any issues quickly.
CONFIDENCE
As Specialists in a rapidly evolving industry Oasysprovides a machine that is able to process the latest in materials, components and construction.
Clients have the confidence that the Oasys technology is the best value for in technology, flexibility, and productivity money can buy.
