Established in 1993 by directors
Rob Nicholls and Tim Holt


Plastic Card Services® was established in 1993 after directors Rob Nicholls and Tim Holt were made redundant from the DataCard Corporation as a result of the recession in the early 90s.  They saw an opportunity in the commercial card market and with them having over 20 years combined expertise in the field, felt it was a good time to launch their own company.

Plastic Card Services® opened for business in February 1993, at home in Wilmslow, Cheshire; where Rob and Tim were the only employees.  After investing in card personalisation and mailing equipment, an internal card bureau was implemented in 1995.

The manufacturer now has approximately 50 employees working from its purpose-built manufacturing campus within Tytherington Business Village in Macclesfield, Cheshire.  The company’s turnover for 2018 was £5.9 million and this is expected to grow to £8 million by 2022.  This has been boosted by the expansion of the manufacturing plant to take it to 30,000 sq ft, which has enabled our card production capacity to increase from 80 million to 160 million.

Despite a challenging year, the company has celebrated its 25th anniversary and continues to thrive with turnover having increased steadily year on year.

The key areas to the business are; card manufacturing, card personalisation and mailing, data processing, artwork and design as well as offering a secure warehouse facility for the storage and issue of stock into production as required.

Developing the business into new export markets has been a huge success story, particularly the Scandinavian market.  The work for Coop Danmark in Denmark earned Plastic Card Services® a Print & Design Award for best mailer.  Sales to Nordic countries continue to thrive including the production of over four million cards for Denmark’s largest health and beauty retail chain, Matas.

Investing in new products and technologies remains a business priority and as a result Plastic Card Services® have developed contactless shielding technology which can be used to protect the smart cards in your possession from unsolicited scanning as well as preventing card clash.  Plastic cards produced with degradable polymers are being adopted more widely both in the UK and in Europe as companies are given more specific environmental targets.

Equipment and technology

Card plant

KBA Genius 52 UV 5 colour waterless offset litho press with UV drying.
Screen CTP.
Koennigs Processor.
Svecia screen press with air tunnel and IR drying, UV drying and autopile.
Oasys auto collation system.
Oasys twin stack lamination system.
Oasys automatic card punch.
Oasys automatic progression punch (combined card and key-fob).
HP Indigo 5900 7 colour digital printing press.
Coltec fully automatic sheet-fed collator.
Buerkle Smartlam CHK 100/200 S laminator.MicroPOISE MK2 foiling machine.

Card personalisation bureau

Atlantic Zeiser DoD (with 720dpi and 360dpi black print heads and 720dpi white print head and plasma unit).
Smart 70 thermal printer with double sided dual print.
Smart 70 thermal printer with double sided flip unit and encoder x 6.NBS S18 thermal card printer and encoder x 3.
Zebra ZXP Series 7 dual sided thermal printer and encoder x 4.Magicard Rio Pro extended thermal printer and encoder x 2.
Datacard MX2000 twin drum embosser.
Datacard 7000 twin drum embosser.
CIM E1000 card embosser.
Oce varioprint 2110.
Canon ImagePRESS 1135.
GUK folder.
MBO folder (perf/score/cross fold etc).
Polar 78e Guillotine.Kirk Rudy pick and place unit with hot glue, Lake camera matching system, plow fold.
Kirk Rudy, stream feed with hot glue, Kirk Rudy camera matching system.
Kirk Rudy, stream feed with hot glue and inline HP inkjet printing system, Kirk Rudy camera matching system.
Bell + Howell C5 inserter with 5 additional stations x 2.
Kalmar C5 inserter with 4 additional stations.