If you've ever ordered a batch of custom scratch cards and ended up with cards that scratch off unevenly, or worse, reveal the prize before they should, you know the frustration. I'm a quality/compliance manager at a printing company. I review every scratch card order before it reaches customers—roughly 15 to 20 orders per week. In 2025 alone, I've rejected about 12% of first deliveries due to inconsistent scratch-off coverage or registration issues.
This is a 6-step checklist I wish every buyer had before they placed their first order. It's based on reviewing hundreds of orders, from small promotional runs of 500 cards to global lottery ticket supplier contracts. Follow it, and you'll avoid the headaches I've seen too many times.
Step 1: Start with the Game Mechanics (Not the Design)
Most people start with 'what should it look like?' That's backward. Start with 'how does the game work?'
Here's what you need to define upfront:
Prize structure: What's the prize? A discount code, a free product, a cash value? Are there multiple prize tiers? How many winning cards vs. non-winning cards?
Redemption method: How does the user claim their prize? Is there a code under the scratch-off that they enter online? Or do they mail in the card? This affects the card's design and security.
Security requirements: Is this for a high-value promotion where fraud is a concern? Or is it a simple in-store giveaway? High-security scratch off anti counterfeiting printing solutions require specific features like unique serial numbers, UV inks, or layered scratch-off systems.
I rejected a batch of 10,000 cards last year because the client wanted a 'random' prize distribution but hadn't specified if the winning cards needed to be distributed randomly within the box or if they could be grouped. The vendor assumed grouped. The client needed random. That cost us a $4,000 reprint and delayed their launch by two weeks.
Specify this in writing. Don't assume the vendor knows your intent.
Step 2: Specify the Scratch-Off Material (Not All Are Equal)
People assume scratch-off material is scratch-off material. It's not. There are significant differences in opacity, durability, and feel.
OP-1 (Standard): Good for low-cost promotions. Scratches off easily but can be less opaque. If the cardstock is thin, the prize might be readable as a shadow. I've seen this happen with 14pt cardstock.
OP-2 (Premium): Higher opacity, more durable. Better for cards that will be handled multiple times or where security is a concern. This is what global lottery ticket suppliers typically use.
Custom scratch-off (Security grade): For anti-counterfeiting purposes. Usually includes layered color patterns or microtext that appears when scratched. Much harder to replicate.
From the outside, it looks like vendors just need to apply a layer of silver paint. The reality is cheaper scratch-off materials can crack, peel off in chunks, or leave residue. We ran a blind test with our marketing team: same card design, OP-1 vs. OP-2. 80% identified OP-2 as 'more professional' without knowing the difference. The cost increase was about $0.03 per card. On a 10,000-card run, that's $300 for measurably better perception.
Step 3: Nail Down the Cardstock and Finish
This is where many buyers make a mistake. They focus on the scratch-off layer and forget the cardstock matters just as much.
Cardstock thickness: Standard is 14pt to 16pt. For premium feel, go to 18pt or 20pt. Thicker stock also helps prevent the scratch-off from showing through the back.
Coating: Aqueous coating is standard. UV coating gives a glossier finish and better protection. For cards that will be handled a lot, consider a matte lamination to prevent wear on the scratch-off area.
Size: Standard is 2" x 3.5" (like a business card) or 3" x 5" (like a postcard). Custom sizes are possible but increase setup costs.
Setup fees for custom die-cut shapes can range from $75 to $200 (based on online printer quotes, January 2025; verify current rates). Standard rectangle shapes usually have no extra setup fee.
Step 4: Test the Scratch-Off Removal (Most People Skip This)
This is the step that's almost always ignored. And it's probably the most important one.
Ask the vendor for a physical proof. Not just a PDF mockup. A printed and scratch-coated sample. Scratch it yourself. Here's what to check:
Clean removal: Does the scratch-off come off completely, leaving no residue? Or does it leave a sticky film? If it's sticky on one card, it'll be sticky on all of them.
Opacity: After scratching, can you read the prize through any remaining film? If you can, the coverage isn't thick enough.
Edge retention: Does the scratch-off flake off at the edges before the user scratches it? This can happen if the material isn't well-adhered.
In Q1 2024, we received a batch of 5,000 cards where the scratch-off came off too easily—it flaked in transit. Normal tolerance is that scratch-off should require moderate pressure to remove. These practically fell off. The vendor claimed it was 'within industry standard.' We rejected the batch. They redid it at their cost. Now every contract includes a 'scratch-off adhesion specification.'
I should add: if you're doing a high-volume campaign, ask for a sample from the actual production run, not just a pre-production sample. Production tools can behave differently.
Step 5: Demand a Variable Data Proof (If Applicable)
If your scratch cards have unique codes, serial numbers, or prize values under the scratch-off, you need to verify that the variable data is correctly linked to the visible information.
Ask for a proof print of all the variations: For example, if you have 10 different prize tiers, ask for one card of each tier. Actually scratch them. Check that the prize code matches the visible label.
It's tempting to think you can just trust the data file. But mistakes happen. I caught an error last year where the data file had 2,000 'Grand Prize' winners instead of 200. The vendor's data processing had duplicated a row. That would have been a disaster.
For global lottery ticket suppliers and customized promotional cards, this is non-negotiable. Variable data errors can lead to significant financial loss and brand damage.
Step 6: Review the Pricing Model (Especially for Repeat Orders)
When comparing quotes for bulk scratch off card printing, look beyond the unit price. Here's what I've learned to ask before 'what's the price?':
Is setup included? Many vendors quote a low unit price but add a $100-$200 setup fee. For a small run, that can double the cost.
Are there per-color charges? If you have a 4-color process design, some vendors charge per color. Ask upfront.
How about reorder pricing? For global scratch card suppliers who might get repeat business, reorder pricing should be lower because the setup is already done. If the repeat price is the same as the first order, the vendor isn't passing on savings.
What's the shipping cost? This is a classic hidden cost. I've seen a $0.25 per card quote turn into $0.40 per card with shipping for small orders. Always get a total landed cost.
I get why people go with the cheapest quote upfront—budgets are real. But the vendor who lists all fees upfront, even if the total looks higher, usually costs less in the end. The hidden costs of a poor-quality reprint or a missed deadline are much higher.
Common Mistakes to Avoid
Ignoring the bleed area: Scratch cards need a proper bleed for printing. If your design doesn't extend past the cut line, you'll get white edges. I reject about 5% of first-time orders for this reason.
Not specifying the 'scratch-off area' shape: Most vendors default to a rectangle. If you want a circle, star, or custom shape, specify it clearly in the artwork.
Waiting until the last minute: Rush orders for scratch cards usually add a 25-50% premium (based on major online printer fee structures, 2025; verify current rates). Plan at least 2-3 weeks for the first order, including proofing and shipping.
Forgetting about storage: Scratch-off cards should be stored in a cool, dry place. Heat can activate the scratch-off material, and humidity can cause the cardstock to warp.
My experience is based on reviewing about 400 scratch card orders over the last 4 years, mostly for promotional and loyalty programs. If you're working with high-security lottery applications, your requirements will be significantly more strict—you'll need certified global lottery ticket suppliers with specific security protocols. But for most promotional campaigns, this checklist will save you from the common, expensive pitfalls.
