Before I opened this thread, I thought you were going to do a run of custom Copag cards. That would have been epic.
Custom Copag cards? We'd probably need about $80,000 to $100,000 to do that. (That's not a joke. It would likely cost that to meet their MOQs.)
One of the issues with getting quality custom decks from big companies is the price and the minimum order quantity. If you are selective about what you want, you tell them the particular features you want. You'll find that with each feature, the MOQ increases. "In order to get that, you need to go up to 25,000. In order to get that, you'll need to go up to 30,000. Two colors? No, that's each color."
The other is price per deck. They'll be more than happy to make your custom decks during their downtime. They will price those decks at a premium above what their commercially available decks cost. That way, you are not using their equipment to make cards to compete against them in their market. In the end, you'll have cards every bit as nice as their retail decks, but they'll cost a lot more, and few people will be willing to pay the price for them.
The Gemaco brand is owned by GPI. Gemaco-branded products are still available, and if you hit up GPI for consumer product they will sometimes direct you to the Gemaco website.
I was surprised to read this, given GPI's attitude toward the home market.
Back when I searched for a producer for Key West cards, the guy from Gemaco USA was really very nice, and very open to making custom cards that would be top-notch. They quoted a price for the decks with casino tuck boxes, cellophane wrapped like cigarette packs with the pull tab, and even offered to package them with retail hanger tabs to sell in stores. I did not think their per-deck price was bad, considering their amazing quality. The issue for me was the MOQ, which would have made the order around $40,000.
That's a huge risk, considering everyone likes their particular brand and model of playing card. Without a big national retailer to distribute and sell those decks, I would never do it.