A small panel with a lot of work to do
A scratch-off panel looks simple. You print a code or message, cover it with a silver layer, and someone rubs it away with a coin. But behind that small grey rectangle sit some real print problems. If the coating does not stick, it comes off in the post. If it sticks too well, it tears the printed code. If it is too thin, a person can read the code against a bright light without scratching anything, which is a serious problem if prizes or money are involved.
Scratch-off labels and scratch cards are used for retail promotions, gift vouchers, loyalty campaigns, product verification, and playful uses such as wedding date reveals or party games. This guide explains how the panels are made, how to choose between labels and printed coating, how to hide codes securely, and what to test before you commit a whole promotion.
Two ways of making a scratch panel
Printed scratch-off coating
For large runs, scratch-off ink is usually applied by screen or flexo printing over the area to be hidden. This allows very specific shapes, and the coating can include printed patterns or an overprinted design. It takes specialist materials and a machine set up for the job, which makes it a better fit for thousands of cards.
Scratch-off stickers
Scratch-off labels are thin stickers carrying the same kind of coating on a release-treated film. They are applied over a printed code by hand or machine, and they suit small runs, personalised invitations and anything you want to make in the office. They are the obvious option under a few hundred pieces. Keep in mind that a sticker can be peeled off and replaced by a determined person, and that hand application takes time.
| Factor | Printed coating | Scratch-off stickers |
|---|---|---|
| Best for | Larger runs, promotions, secure cards | Short runs, events, personal projects |
| Shapes | Custom, including large or unusual areas | Standard rectangles, circles, hearts, or die-cut custom |
| Security | Better, harder to remove and replace | Lower, more prone to tampering |
| Set-up | Needs a specialist printer | Can be applied by hand |
What makes a panel scratch cleanly
Scratching works because of a careful balance between layers. The surface beneath the coating has to hold on to the print, while letting the top coating go. If you skip this, it will fail in one of two ways: the silver will not come off, or the code will come off with it.
- A sealed surface. Printing on uncoated card lets the coating soak in and grip. Most scratch cards use a gloss laminate, a UV varnish, or a release varnish over the code, so that the coating sits on a smooth layer.
- Code that stays put. Toner and inkjet codes both need to resist rubbing. Test the particular combination you plan to use, as some codes smear when someone scratches with a coin.
- Enough opacity. The panel must hide the code when the card is held up to a bright light or tilted at an angle. Multiple passes, a dark blocking layer, or a pattern printed behind the code all help.
- Curing time. Coatings have to dry or cure completely. Rushed cards can stick together or transfer silver onto the next card in the pack.
If you are also weighing up materials for the rest of the card, our guide to durable label materials covers how different facestocks and laminates behave.
Hiding codes and running a fair promotion
Scratch cards used for promotions and vouchers usually carry unique codes, so this is a variable data job as well as a finishing one. The code list and how it is handled matters as much as the print. Our article on variable data printing explains how numbered and coded runs are set up.
- Generate codes properly. Use random codes from a good generator, and check for duplicates. Avoid sequential numbers, because a person with two cards can guess the others.
- Avoid confusing characters. Leave out 0 and O, and 1 and I, particularly on printed codes that people will type into a website.
- Keep the file secure. Limit who has the code list, and delete copies when the job is done. Decide who holds the master list for checking winners.
- Think about redemption. A website form should block repeat attempts, or a person can guess codes. Each code should become invalid after use.
- Plan for seeding. When only some cards win a prize, decide how the winners are distributed through the run, and keep a record of it. Winners should not all arrive in the same carton.
Rules and legal limits
Prize promotions and games of chance are regulated in many countries. In some places, a promotion that needs a purchase can fall under lottery or gambling rules, and you may need a permit, published terms or a free entry route. The details vary a great deal, so talk to a lawyer or your local regulator before you print. Also check that printed terms, closing dates and the number of prizes all match what you tell customers.
Designing the card around the panel
People need to see at a glance what to do. Make the panel large enough to scratch without effort, with enough room for the code. Most layouts need around 15 by 40 mm or so, depending on the length of the code and the type size. Other points to bear in mind:
- Put a short instruction beside it, such as "Scratch here with a coin to reveal your code".
- Keep key information, such as how to redeem and when the offer ends, away from the panel, so it does not get scraped.
- Use a clear typeface for the code itself, at a size large enough that nobody has to guess a character.
- Keep panels away from folds, which can crack the coating.
- Leave a little breathing room around the edge, since the panel can sit slightly off register.
Scratch-off on labels and packs
Scratch panels are also used on product packaging and labels, often for verification. A customer scratches a panel on the label and checks the code online to confirm the product is genuine. This needs a label stock and adhesive suited to the pack, and if your concern is counterfeiting, you might consider combining it with other features. See tamper-evident, holographic and security labels for the options. If these go through an applicator, the format matters too, which we cover in roll labels vs sheet labels.
What to test before printing the whole run
Ask for samples made using the final materials, and carry out these checks yourself. Testing is cheap compared with reprinting a promotion.
- Scratch test. Try a coin, a key, and a fingernail. Check the coating comes off cleanly, and that the code stays readable.
- Light test. Hold the card up to a bright lamp or phone torch, and try tilting it. If you can read the code, it needs more blocking.
- Rub test. Rub a card against another for a minute, or carry one in a pocket for a day. Panels shouldn't scratch themselves in transit.
- Stacking and heat test. Leave a wrapped stack in a warm place overnight, like a delivery van would be, and check for sticking or ghosting.
- Tamper test. Try to lift a sticker and put it back. If you can do it unnoticed, others can too.
- Redemption test. Enter a few sample codes on the live system. Try common typos.
Common mistakes
- Printing codes without a sealed surface. This is the classic cause of panels that refuse to scratch or take the code with them.
- Too little time in the schedule. Coating, curing and packing take longer than regular printed cards, so allow for that before a campaign date.
- No spare codes. Print a small number extra to cover spoilage. Keep track of which codes were used on spoiled cards, and deactivate them.
- Loose packing. Cards that rub in a carton can wear away their panels. Banding or shrink wrapping small bundles reduces the movement.
Producing scratch-off cards and labels with us
We work on specialist labels and printed cards where the materials matter as much as the design. Tell us what the panel has to hide, how many pieces you need and how they will be used, and we can advise on stickers or printed coating and the right base stock. We will arrange samples for testing before the main run wherever the job allows.
Visit our print quality and materials section, or contact us with your campaign date and quantity. If your promotion has codes and prizes, include your redemption plan too, so that we can think through the data handling together with the print side.
