Card Production & Ordering
Batch sizes, materials, add-on costs, proofs, and responsibilities when ordering co-brand plastic cards.
Overview
This page sets out the rules, design constraints, and responsibilities that apply when ordering physical plastic cards through Wirex and the card production supplier, TAG Systems.
Artwork must already meet Card Design Requirements and have passed Visa approval before production is scheduled.
Batch Sizes
The final unit price depends on batch size, selected materials, and custom design elements. Larger volumes reduce the unit cost.
| Available batch sizes |
|---|
| 3,000 |
| 5,000 |
| 10,000 |
| 25,000 |
| 50,000 and above, in steps of 25,000 |
Pricing Rules
| Rule | Detail |
|---|---|
| Quote validity | Prices provided by TAG Systems are valid for 3 days |
| Market fluctuations | Wirex is not responsible for price movements in raw materials or production costs |
| Final pricing | Confirmed only after the quantity is approved and TAG Systems issues a formal quotation or proforma invoice |
| VAT | Quotations usually exclude VAT. VAT is added at the proforma or final invoice stage, depending on supplier tax rules and entity jurisdiction |
| Mark-up | Wirex applies a mark-up to supplier costs in line with commercial terms |
Default Production Setup
The following configuration is the standard base cost:
| Element | Base configuration |
|---|---|
| Core | White PVC |
| Magnetic stripe | Standard black |
| Chip | Gold, included at no extra charge |
| Lamination | Full card lamination, glossy or matte at the partner's choice |
| Design enhancements | None |
Embossing, spot UV, specialty finishes, gradients, and custom materials are not included in the base cost.
Optional Add-Ons
Non-standard materials and finishes carry additional per-unit costs. The figures below are indicative, based on a 10,000-card batch, and subject to supplier confirmation.
| Custom element | Additional cost per card |
|---|---|
| Blue PVC core | £0.102 |
| Blue magnetic stripe | £0.020 |
| Silver chip | £0.035 |
| Matte lamination | £0.047 |
Selecting a white PVC core and the standard black magnetic stripe keeps the unit cost at the base level.
Design Customization Fee
Advanced custom design features — custom PVC colors, gradients, embossing, spot UV, holographic or specialty finishes — carry a flat design customization fee of USD 15,000. Additional per-unit production charges may also apply depending on the features selected.
Proofs
Manufacturing Proof (Included)
Every program receives a manufacturing proof in PDF format. The proof must be reviewed and approved by the partner before cards enter production.
Wet Proofs (Optional)
Wet proofs are physical samples. They are not mandatory; the decision rests with the partner.
| Scenario | Indicative cost |
|---|---|
| Wet proofs including the Visa logo and hologram — Visa submission required | ~£1,500 |
| Wet proofs without scheme branding | ~£1,200 |
Wet proofs are recommended for small batches using expensive materials and should be included in the statement of work in that case. They increase both cost and timelines.
Responsibilities
| Party | Responsible for |
|---|---|
| Co-brand partner | Design choices, approvals, decision on optional proofs, prepayment |
| Wirex | Scheme alignment, process coordination, supplier governance |
| TAG Systems | Production, pricing, proofs, manufacturing |
Before Ordering
- Card artwork approved by Visa through the BMAS process
- Batch size selected
- Materials and finishes confirmed, including any add-ons
- Formal quotation or proforma invoice received and accepted within its 3-day validity
- Manufacturing proof approved
- Decision taken on wet proofs
- 100% prepayment completed, including Wirex mark-up
Once cards are in stock, complete Pre-Launch Card Testing before ordering opens to end users.
Updated 3 days ago