Abstract: A method for producing personalized cards on a substantially continuous basis. The method includes providing multiple supply rolls of card stock having a thickness of at least about 12 mils. The card stock is corona treated in an in-line corona treating unit to provide a printable surface having a surface tension energy of at least about 38 dynes/cm. Fixed and variable data are printed on individual card units of the card stock in first and second printing units of the in-line printing system. A removable activation label may be applied by an in-line label application unit to the variable data. The card units are die cut in an in-line die-cutting unit to a predetermined size. The first and second printing units are shaft driven printing units and the card units are capable of producing card units at a rate of at least 50,000 card units per hour.