An apparatus and methods for preventing engagement of stacked embossed cards is disclosed. The methods include the steps of embossing a sheet of cards in at least two unique embossment patterns, separating the cards from the sheet, and collating the cards using at least one conveyor such that no two adjacent cards have substantially the same embossment pattern. The apparatus includes an embossing press, a first conveyor, a stripping station, and a second conveyor.