During the sheet hot stamping process, security holograms are applied onto a single sheet. Important parameters for the implementation of the DOVID are pressure, time and temperature. A very high security level can be reached by laminating the hologram inside the document body so it cannot be removed.
The foil punching process is the preparation step for the production of inlays on sheet basis. Before the antenna can be inserted, holes are punched into the foils in one stroke with highest accuracy.
The inlay testing process step is highly important for quality assurance. The integrated transponders in the RFID pre-laminated, collated, laminated or inlay sheets are tested, ensuring that the complete output is fully functional.
Sheet collating is the preparation step for the lamination process. Several sheet layers e.g. the core layer, printed sheets, inlays or antennas are collated, aligned and welded by the welding system
Sheet lamination is a thermal welding process during which collated sheet sets are laminated with a specific temperature (depending on material) and pressure. To ensure a robust and stable result, the selected materials are connected non-detachably thus fulfilling all requirements regarding quality, lifetime and counterfeiting.
During this process step the unique Mühlbauer Hinge is milled into the holderpage (2-up) of a passport. The appearing Hinge is a thin and flexible, yet robust layer which is sewn into the passport with the paper set. Due to its soft transition it cannot be destroyed.
After the laminated sheets are separated from a pallet or trolley, they are aligned to print mark recognition sensors. The holderpages are punched from the sheets by a stamping tool and collected on a belt system. The unique hydraulic system is position and speed controlled guaranteeing highest accuracy and longest lifetime of tools.
The holderpage testing process step is highly important for quality assurance. Different tests of the holderpage are possible, amongst others for the testing of the printing quality and positions, output test of the chip modules etc.
The booklet production process contains the process steps collating and sewing of the inner set of booklets, lamination of the cover, embossing of the cover emblem, binding of the passport and finishing (cutting, folding and punching to finalize the booklet).
During pre-personalization the passport number is printed by letter press (impact) numbering, by inkjet as barcode or perforated through the inner pages. Optionally the integrated chip is encoded or a label is applied onto the back cover.
In order to achieve highest quality in the results, every process step of the production chain is continuously checked and controlled by quality assuring procedures. The testing depth and numbers of control samples are adjustable to the respective needs of the processes and the product specifications. Specific procedures, measurements and statistic process knowledge guarantee optimal results ensuring highest yields.