An Insurance company needed an efficient solution for small batches of cards. These cards are typically damaged, lost and/or stolen insurance cards. Interruption of their central card issuance system for selected small reprints would slow their daily large scale production. A custom program was written to convert a Datacard Model 7000 data file to a format compatible to a smaller desktop printer. This custom solution allows the operator to select the files and the printer to run these smaller batches without needing to duplicate the records or reformat the information. This greatly decreased the margin of error and allowed the customer to maintain high-volume production flow while providing timely card replacements.