Damon Mcknight
Australia's banknotes are made from a type of plastic, or polymer, which makes them tough and durable. The process starts with plastic pellets, which are melted and blown into a bubble. The walls of the bubble are then pressed together and cooled to form laminated polymer film. Special inks are applied to make the film opaque, except for certain areas which are left free of ink to create the clear windows, before it is cut into sheets. Different-sized sheets are used for each denomination and the number of banknotes printed on a sheet varies. The sheets are then printed with background colours and patterns on both sides simultaneously. After this, intaglio printing is applied, which gives the notes texture and helps people authenticate them. Serial numbers are then added to the sheets, and a protective overcoating ink is applied. Finally, the sheets are cut into individual banknotes.
| Characteristics | Values |
|---|---|
| Currency | Australian Dollar |
| Banknote Material | Polymer (plastic) |
| Banknote Printer | Note Printing Australia Limited (NPA) |
| Banknote Security Features | Microprinting, raised print, clear windows, UV fluorescent features, shadow images, multi-coloured patterns |
| Coin Printer | Royal Australian Mint |
| Coin Production Process | Design, 3D modelling, engraving, striking blanks with dies, annealing, pickling, burnishing, pressing |
| Coin Types | Round, dodecagonal (50 cent coin) |
| Coin Production Cost | $0.20 for a $2 coin, $0.32 for a $100 note, $0.12 for a 5-cent piece |
| Annual Coin Production | 120-140 million coins per year |
| Digital Currency | Investigating a potential e-dollar |
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What You'll Learn
Australian banknotes are made from plastic pellets
The process of creating these banknotes begins with the melting of the plastic pellets and blowing them into a three-storey bubble. This film is then printed on with special inks to make it opaque, except for certain areas left free of ink to create clear windows. Different-sized sheets are used for different denominations, and the number of banknotes printed on a sheet varies. For example, a sheet of the new $5 banknotes has 54 polymer banknotes, while the $10, $20, $50, and $100 denominations have 45 banknotes on a sheet.
The first printing process involves printing the background colours and patterns onto both sides of the polymer sheets simultaneously. This is followed by the addition of other security features, such as microprinting, serial numbers, and a protective overcoating ink that contributes to the durability and cleanliness of the banknotes. One of the security features unique to Australian banknotes is the tactile feature, which consists of raised bumps on the long edges of the banknote next to the top-to-bottom window. This feature assists the vision-impaired community in identifying different denominations.
The use of polymer banknotes in Australia is a significant advancement in the country's currency, providing enhanced security and durability compared to traditional paper or cotton-based banknotes. The distinctive feel of the polymer banknotes also adds to their uniqueness and helps to prevent counterfeiting. While the process of creating these banknotes is intricate and involves multiple steps, the result is a secure, durable, and visually appealing form of currency for Australia.
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Coins are struck with up to 200 tonnes of pressure
The Royal Australian Mint is responsible for the production of Australia's coins. The minting process begins with an initial design brief, where product developers, coin designers, and engineers collaborate to create an image that will translate well onto a coin. Once the design is approved, a three-dimensional model is sculpted using traditional plaster modelling tools or 3D modelling software. The coin designer refines the model, ensuring that the final design can be manufactured to the highest quality.
After finalisation, the model is sent for the cutting of a master tool, and the manufacturing process begins. The coin design is cut directly into tool steel using a computer-controlled engraving machine, creating a reduction punch. This process can take up to 24 hours. The reduction punch contains a raised or relief impression of the complete coin design.
The reduction die is then placed in a hydraulic press, where the design is transferred onto a softened steel block using 100 to 400 tonnes of pressure in a process called hobbing. This results in a master die, with a negative impression of the coin design. The reduction die is then hardened, and during a multi-stage pressing procedure, a positive die is produced. This positive die is then used to produce the actual negative minting dies.
Blanks, the coin-shaped pieces cut from sheets of metal, are fed through the presses and struck on both sides simultaneously by dies. These dies can strike coins with up to 200 tonnes of pressure, producing up to 650 pieces per minute. The high pressure causes metal particles to spread and stretch, resulting in a sharper rim and the edge of the coin taking on any serration in the press' collar—this is how coins get their characteristic grooves.
Proof coins, on the other hand, are made in presses that strike with 180-360 tonnes of pressure. Each proof press is manually operated, and the blanks are struck 4-6 times each. These coins are specially minted for collectors and are usually sold in velvet presentation cases with certificates of authenticity.
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Banknotes have many security features
Australian banknotes are made from a type of plastic, or polymer, which makes them tough and durable. This material also makes it possible to include a range of security features that make them harder to counterfeit.
One of the security features of Australia's polymer banknotes is the raised print, which is created when ink is transferred to the sheets under great pressure using engraved metal plates. The serial numbers are then added using a letterpress printing process. A protective overcoating ink is applied last, contributing to the durability of the notes.
The clear top-to-bottom window is another distinctive security feature. This window should be an integral part of the banknote and not an addition, and it contains several dynamic security features. When the banknote is tilted, a three-dimensional image with a colourful border can be seen, and the image will appear raised or recessed. For example, on the $50 banknote, a Black Swan can be seen moving its wings, and inside the building at the bottom of the window is a number 50 that changes direction. On the $5 banknote, an Eastern Spinebill moves its wings, and inside the Federation Pavilion, a number 5 changes direction.
Other security features include diamond-shaped patterns printed on each side of the banknote, which combine to form a seven-pointed star inside a circle when held up to the light. The shadow image of the Australian Coat of Arms can also be seen when the banknote is held up to the light. The serial numbers on the banknotes glow under ultraviolet light, and rectangular patches showing the value become visible on the $20, $50, and $100 banknotes, while a square patch appears on the $5 banknote. The polymer substrate also gives the banknotes a distinctive feel, and a genuine banknote should return to its original shape after being scrunched up.
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Banknotes are printed by Note Printing Australia Limited (NPA)
The NPA's main production building is a purpose-built, four-storey reinforced concrete structure. Here, Australian banknotes are printed on sheets of polymer substrate using various printing plates, processes, machines, and inks. This polymer substrate is what gives the banknotes their distinctive feel and durability.
The banknote printing process involves multiple steps, each adding layers of security features to make counterfeiting extremely difficult. Firstly, plastic pellets are melted and blown into a three-storey bubble to create the polymer substrate sheets. Then, the first printing process involves printing background colours and patterns onto both sides of the polymer sheets simultaneously. Special inks are applied to make certain areas opaque, while leaving other areas clear to create windows. Different-sized sheets are used for different denominations, and the number of banknotes printed per sheet varies accordingly.
After the initial printing, separate print runs are required for each side of the sheet, with ink transferred under high pressure using engraved metal plates. This results in raised print, another important security feature. Serial numbers are then added using a letterpress printing process, and a protective overcoating is applied using an offset printing press. This overcoating enhances the durability and longevity of the banknotes. Finally, a tactile feature, consisting of raised bumps along the long edges, is applied to assist the vision-impaired community in identifying denominations.
The entire process incorporates numerous advanced security features, making Australian banknotes highly secure. These features include microprinting, UV fluorescence, intaglio printing, multi-coloured fine-line patterns, and three-dimensional images. The use of polymer substrate, instead of traditional cotton or paper fibres, also adds to the security and durability of the banknotes.
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The Royal Australian Mint makes 120-140 million coins a year
The Royal Australian Mint is responsible for producing Australia's coins. The minting process begins with an initial design brief, where product developers, coin designers, and engineers collaborate to create an image that will translate well onto a coin. Once the design is approved, a three-dimensional model is sculpted using traditional plaster modelling tools or 3D modelling software. The coin designer refines the model, ensuring that the final design can be manufactured to the highest quality.
After finalisation, the model is sent for the cutting of a master tool, and the manufacturing process can begin. The coin design is cut directly into tool steel using a computer-controlled engraving machine, creating a reduction punch, which takes up to 24 hours. The reduction punch contains a positive, or raised, impression of the complete coin design.
Blanks, which are usually round, are fed through the presses and struck on both sides by dies. The dies can strike coins with up to 200 tonnes of pressure, producing up to 650 pieces per minute. The Royal Australian Mint can produce 120-140 million coins per year, with each coin press capable of making 20,000 coins per day. The Mint also produces special editions, such as "Olympic" and "Wiggles" coins, which are delivered as change through cash registers.
The Mint's output is under threat from reduced cash usage and soaring metal prices. For example, the rising cost of nickel after Russia's invasion of Ukraine has increased the cost of producing five-cent and 20-cent coins.
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Frequently asked questions
Australian banknotes are made from a type of plastic or polymer.
The process starts with a plastic film, which is melted, stretched, blown into a big bubble, and then squashed back down to form a film. White coatings are applied to both sides, leaving out areas for the clear window. Special inks are then applied to make the film opaque, except for the window area. After that, the intaglio print is applied, giving the note texture and helping with authentication. Finally, a protective overcoating is added to enhance durability and prevent the notes from getting dirty.
Australian banknotes have a range of special security features that make them difficult to counterfeit. These include microprinting, embossing, serial numbers, and other advanced embedded features.
Australia's banknotes are printed by Note Printing Australia Limited (NPA), a wholly-owned subsidiary of the Reserve Bank of Australia. NPA is located on a secure, high-tech site in Craigieburn, Victoria.
Worn and damaged banknotes are shredded, melted, and reformed into plastic beads, which can then be used to make other plastic products.
