Hey, this is fascinating!
Sorry for bringing up old news but I'd like to hear more about this. I've never handled JNs and had no idea that they were embossed on one side.
Lee Asher has this video which clearly shows the extremely neat embossing on the BACK of the card.
http://www.leeasher.com/playground/articles/playing_cards_under_the_microscope.html
But what's this about a cotton roller 'painting on embossment' or something? I'm not sure what the standard embossing process is. I assumed it required a textured metal roller. I can't make sense of a fabric cotton roller unless it only textured the varnish rather than the card itself, as is usually the case. Was one side normal linen finish and one side cotton roller perhaps?
If anyone can clear up this surely it is Lee!
On the point of attempting a faithful reproduction, I imagine the main benefit of individually dip coating is to seal the edges of the cards which is achieved by Fournier for Lee Asher's 605's.
Please correct me if I am wrong, I'm not at all sure about this...I believe that USPC texture their card after varnishing (before cutting!), whereas Fournier, Cartamundi and many others varnish already textured card. Perhaps a significant contribution to the instant perfect fans of USPC produced decks?
I think that if someone was willing to pay, a one sided linen finish individually coated deck could be done. It might take the work of two manufacturers and probably cost a fortune for little benefit. It could be fun though!
Vintage cards weren't embossed by pressing a steel roller into the paper. The laminate applied to the card WAS the source of the embossing itself. The various cloth rollers used created the various textures - in fact, some finish names still in use today (Cambric, Linen, Linoid, Satin) were named after the fabrics used to create the embossing, and there was actual differences in the embossing. These days, they're all just "embossed" - the same regardless of the finish name, at least at USPC.
The embossing you see in cards now occurs before the coating is applied. The steel rollers have little closely-spaced "bumps" that press the embossing right into the paper. I think that technically means it's a debating process, rather than embossing, but I'm not a printer and keep forgetting which means pressed into the surface and which means raised above the surface. I'm pretty sure the embossing occurs before even printing - that it happens when the pasteboard is created by applying glue between two layers of paper and pressing them together under pressure. But I've also been told it occurs after printing. Never have I been told it takes place after the lamination - always before.
It would be impossible to re-create Jerry's Nugget playing cards in the United States. About six years ago, the Federal government enacted a law requiring playing card manufacturers to use more post-consumer recycled content in their paper as well as inks and laminates free of petroleum products. There's been rumors that certain banned toxic chemicals were used in making JN cards - well, they're no more toxic than what was in use before the new law. It was more about the manufacturing process no longer being in use.
I've always wondered how playing cards with single-side embossing would perform. I've yet to see a single card company experiment with the concept - to my knowledge, it was abandoned about the same time that cloth rollers for lamination were replaced.
Why are USPC cards superior to manufacturers like Cartamundi? I'm guessing that Cartamundi simply sources the cheapest materials it can find. Fournier makes their cards differently - in some ways better, in some ways perhaps not. They're sealed on the edges, making them washable if you're careful with them, but some don't like the slip for fanning and some cardistry moves, or at least on the Fournier 605s. They make a big variety of cards and I can't speak for all of them because I've only seen a fraction of them. I can say, interestingly enough, that the Bicycle Prestige decks are made by Fournier for USPC. I like them a lot, while others claim nearly all the major plastic decks on the market are better.